Cosworth Tips and Tricks

Cam Sprocket Exchange Program

Order from the Author

$60.00 Post Paid

View the Table of Contents Vol. I

View the Table of Contents Vol. II

View the comments of others

    Many years ago, when I learned of the Yahoo Cosworthvegas message board started by Chris Wheaton, I was intrigued. Something for us Cosworth Vega nuts on the Internet!

    Awesome.

    So I kept going to the board, daily, just to see what was going on and, after a short while, to participate. It was great. I learned the answers to questions that I had long wondered about. I re-learned information that I had once known and forgotten. I discovered information that I had written down somewhere, but had forgotten just where. I was glad. Now all of this information could be found in one place, and would be preserved.

    Soon the number of messages grew to 500, then 1000, then 2000, with no end in sight. At about 3000 messages I found that I was having a hard time finding information that I remembered being posted. You see, the titles of the posts often have little or nothing to do with some or all of the information in the post. People have gone off on a different thread and not changed the title, people have also included several topics under a single title.

    At this point it was Gerry Cross to the rescue. He gave me a CD-ROM with an archived compilation of all the messages to date. I soon discovered that this message file, while useful, left something to be desired. I might search on one word and not find anything, because the poster used another word. This wasn't the "Final Answer".

    Asking for information on the board wasn't the perfect answer either. If I need a piece of Cosworth information, I generally need it immediately. But sometimes it takes days and even weeks to get a response on the message board.

    Something better was definitely needed.

    I decided to take matters into my own hands. I decided to to compile not just the messages--I decided to compile the information in the various messages under the "correct" headings.

    I decided to read each message, and pull out the information in it and place it under an appropriate heading. If a message had four topics, then the relevant information would be split out under four separate headings. I wanted/needed the information to be easy to find. So I went back to the beginning and started cutting and pasting the information from the messages into a Word document on my computer. Initially I just typed the headings at the beginning of the text. But quickly I found that I was spending a lot of time scrolling through the document to find the appropriate place for the next nugget of information. This quickly became an impossible procedure as the document grew, so I created hyperlinks at the beginning of the document so I could click on a heading and be transported into the document itself to the appropriate spot. This worked well for a long while, but then I discovered that Word's Table of Contents generator would do the same thing and put the page numbers with the headings as well. Even better! The task was not as simple as just cutting and pasting under the appropriate headings. No, there was much more involved. I decided early on to correct misspellings, to correct bad grammar, to clarify fuzzy writing, and to correct improper punctuation, including the adding of an extra space at the end of each sentence.

    It was an enormous amount of work. I also organized the postings, putting questions or comments and answers or replies together. I tried to make it highly readable. Then I had to decide on the format. The size and style of the headings, the spacing between headings and headings and paragraphs, and the pagination.

    More time and effort.

    But in the end, I had a "book" with a table of contents over 7 pages long, a "text" of 344 pages, and 51 "chapters", many composed of numerous sub-parts. In the end I succeeded in preserving in a readily accessible format a wealth of knowledge about the Cosworth Vega automobile.

Cosworth Tips and Tricks Knowledge Base I

 

An Edited Compendium of Cosworth Vega

Information and Knowledge

From the Yahoo Cosworthvegas Message Board

 

Copyright 2001 by Mark A. Rock

Compiled through message 6331

Hit Counter

 

TABLE OF CONTENTS

TIPS AND TRICKS KNOWLEDGE BASE I

 

ACCESSORIES

Air Deflector
Console
Dobi
Fender Flares
Front Valence
Hatch Hutch (Tent)
Mirror Inside
Mirror Outside Passenger
Spoilers

ALTERNATOR
Alternator Bushings
Alternator Belt

BODY PARTS
Battery Tray
Doors
Fenders
Fiberglass
Front End Sheetmetal
Gas Cap
Hatch
Hatch Struts
Hood
Hood Blanket
Trim

BRAKES
Buick
Corvette
Fluid
Handbrake
Monza
Pads
Proportioning Valve
Rotors

BUILD SHEETS
CAR SHOW
CLUTCH
Assembly
Cable
Disk
Flywheel
Pressure Plate

COOLING SYSTEM
Capacity
Coolant
Radiator Cap
Thermostat

CVOA
DECALS
DIFFERENTIAL
ELECTRONIC FUEL INJECTION COMPONENTS
Air Solenoid Valve
Air Temperature Sensor
Coolant Temperature Sensor
ECU (Computer)
Fast Idle Valve
Fuel Injectors
Fuel Pressure Regulator
MAP Sensor
Wiring Harness

ENGINE POWER/BUILDUP
Overview
2.3 Liter Engine
Crankshaft
Performance Testimonials
Jim Reardon
Bearings
Block
Heavy Duty Block
Cam Carrier
Cam Carrier Oil Leaks
Cam Cover
Camshafts
Crane Cams
Short Track
Specifications
Compression Ratio
Cylinders
Distributor
Deck Height
Dipstick
Dyno Results
Doug Wallingford’s Engine Specifications for baseline run:
Doug Wallingford’s Modifications for last run:
Doug Wallingford’s Dyno Results Graphed:
Exhaust Theory
Fuel
Head
Horsepower
Nitrous
Oil Pan
Windage Tray
O-Rings
Pistons
Rings
Rods
Sleeves
Tin
Water Pump
Valves
Weight

ELECTRICAL
Fuses Underhood

ENGINE SWAPS
EXHAUST
Catalytic Converters
Crossover Pipe
Header
Mufflers
Noise
Pipes
Pulse Air Tubes
Tailpipes

FILTERS (FUEL AND AIR)
Air Filter (EFI)
Air Filter (Webers)
Fuel Filter

FUEL PUMPS
High-Pressure
In-Tank

GAS TANK
GAUGES
Clock
Fuel Gauge
Fuel Pressure Gauge
Oil Pressure Light
Speedometer
Tachometer
Accuracy
Doesn’t Work
Spastic Tach
Substitutes
Temperature Gauge

GASKETS & SEALS
Gaskets
Cam Cover Gasket
Cam Carrier Gasket
Differential Gasket
Head Gasket
Intake Gaskets
Oil Pan Gasket
Water Pump Gasket
Seals
Axle Seals
Camshaft Seals
Crankshaft Seal
Rear Main Seal
Valve Stem Seals
Sealant
Weatherstrip
Doors
Hatch
Swingout
Window Felt

HISTORY
HOSES, BELTS & LINES
Hoses
Heater
Fuel
Coolant
Belts
Lines

HOW TO:
Blown Head Gasket Diagnosis
Clean Aluminum Block
Clutch Fork Spring
Coolant Light
Connect an External Tach
Damper Pulley R & I
Emissions Test Preparations
Engine Removal
Fuel System Maintenance
Headliner Installation
Heli-Coil
Hood Removal
Intake Manifold Bolt
Refinish Timing Cover
Parking Brake Cable
Pulse Air Tube Removal
R&R Gas Tank
Shim Lifters
Tilt Steering Column
Timing Cover Removal
Transmission Removal
Transmission Swap
Un-Store a Cosworth

HYPERLINKS
IGNITION
Coil
Distributor
Module
Pole Piece
Advance Springs
MSD
Spark Plugs
Wires

INSURANCE
INTERIOR
Carpet
Dash Bezel
Dashboard
Dash Plaque
Door Panels
Lens Cover for Gauges
Painting Vinyl
Pedals
Rear Panels
Seats
Visor

LEAKS
Fuel Leak
Oil Leaks
Camshaft Leaks
Right Side of Engine
Distributor Drive Housing

LIGHTS
Headlights
Tail Lights

LUG NUTS
MISCELLANEOUS
AC
Car and Driver Rally Car
Comparison of 75 and 76 Cosworths
Engine Noise
Metrics
Quad-4 EFI
Vert-a-pac
Why?
Copper Motor Mount Washers

MODEL
MOUNTS
HP Fuel Pump Mounts
Motor Mounts
Transmission mount

OIL
Differential Oil
Engine Oil
Filter
Transmission Oil

PAINT
Body
Dash Paint
Engine Paint
Powdercoating
Stripes
Wheels

PCV VALVE
PERFORMANCE
PROBLEMS/SOLUTIONS
Backfire
Brake Pedal Goes to Floor
Cam Timing
Clutch Won’t Release
Clutch Adjustment
Clutch Noise
Clutch Safety Switch
Cold No-Start Condition
Combustion Chamber Damage
Erratic Idle
Fast (3500 rpm) Idle
Fuel Gauge Not Working
Fuel Smell with Full Tank
Gearless 5-Speed
Hard Starting
Generally
Hard Starting, Runs Rich
HP Fuel Pump
HP Pump Runs Constantly
HP Pump Whines
In Tank Hose Disintegration
Known Problems
Lack of Torque
Lack of Power Over 3000 RPM
Lack of Power Over 4000 RPM
Low Idle When Hot
Miss in #4
Off Idle Stumble
Pulse Air Tube Fittings Seized
Poor Oil Pressure
Runs Rich
Runs Rough at 2000 RPM
Rusted Rear Control Arm Mounts
Shifter Loose
Shock Bolt Clip Broken
Speedometer Cable Melted
Stalls Out When Hot
Starter Doesn’t Turn
Tach Not Working
Timing Belt Jumped Tooth
Vibration Between 55 and 65
Weak Spark
Yahoo Messages Unavailability

RADIATOR
Radiator Fan

RESTORATION
Dash Bezel
Inspection Marks
PAIR Non-Chrome Fittings
Reproduction Parts
Repop Dash Bezel
Repop Front Timing Cover
Repop Rear Spoiler
Repop Stainless Valves
Restorationitis

SHIFTER
SPEAKERS
STARTER
STEERING
SUN ROOF
SUSPENSION
Alignment
Anti-Roll Bar
Bushings
Panhard Bar
Suspension Bushings
Torque Arm Bushing
Performance Suspension
Part Numbers
Shock Absorbers
Spindles
Springs

THROTTLE BODY
TIRES
TOOLS
Cam Belt Tensioning
Camshaft Rotator
Garage Lift
Hand Tools
Must Have Tools
Tappet Bucket Hold Down
Tappet Bucket Holding Tool

TRAILERING
TRANSMISSIONS
Alternatives
Automatic
4-speed
5-speed

TRIVIA
TRUNNIONS
TURBOCHARGING
TWIN CAM TIMES PORTFOLIO
VALVETRAIN
Belt and Gear Removal
Noise
Shims and Lash
Valve Guides
Valve Seals
Valve Springs

VIN
WEBERS
Safety

WEB PAGES
WHEELS
Aftermarket/Special
Five Lug
Racing
Stock

GOOD COSWORTH WIFE RULES
Male View
Female View-(aka "Lessons I have Learned")

WINDSHIELD
FOR SALE
Autos
Parts

1974 COSWORTH
Silver Cosworth

1977 COSWORTH

What the Cosworth World is saying about:

Cosworth Tips and Tricks Knowledge Base I

KUDOS

Received the book in good order earlier this week. You have done a great job of organizing a jumble of information to a useable form. Thanks for the effort. Roy Linenberger


WOW. I know that was a lot of entry work. At least cut-n-paste. Steve Larson


Mark: Got the Compilation, read it, and started looking for build sheets. So far no luck in the '76. The seat back yielded only a partial. Great book. I recommend it to anyone. It is amazing how much information is out there, and I'm glad someone is preserving that info. Thanks. Shawn Parsons


It is very good and worth the money. Should note that "all messages are not accurate" and should be read in context. Mike Rupert


For those of you who did not attend the Louisville Roundup, Mark Rock edited and organized 6300+ Cosworth Vega message board postings in a bound edition for sale. Mark did an outstanding job compiling and editing the information. The information is indexed and has 344 pages of in-depth information. NO one has taken the steps to do a project like this since Duke Williams produced the Twin Cam Times. I am asking Mark via this post to post his e-mail address for all those who may be interested in obtaining a copy of the book. I think we all should thank Mark for his great effort and look forward to possible updates as time goes on. Dan Newman


FYI Guy's. The first edition of Mark Rock's Cosworth Vega Tips and Tricks is 351 pages of condensed, INDEXED and bound information. Cost of copying alone is probably about $50.00 per copy. Just my opinion. Later Ya'll. Tim


I have seen Marks Tips and Tricks it is an excellent document of 6000 plus yahoo post in a convenient 344 page book you can access information on any posted subject on yahoo in the first 6000 plus post. I dare anyone to find all information regarding any subject listed in Mark's book here in yahoo in less than one week. Duke, the TCT is an excellent document. But you should get Mark's Tips and Tricks and read it before you knock it. It is not an easy task to compile all those posts. For my own use I have started a Cosworth group which has post going to automatically the back posts. If I were able to transfer them over at 100 posts per day (about 2 hours), it would take 60 days. I don't know about anyone else but I do not have that kind of time each and every day. BTW access to the group is restricted in fairness to Mark. Art


My dad and I bought the "techs and tricks", and let me tell you, my dad and I have used it already. My dad does not regularly check this site, but I do, and both of us have learned something from it. This tool, which is just as important as a 5/16 inch socket for the battery, is needed. If you have any questions, this "TOOL" will help solve it. Whether answering your question outright, or getting you in contact with those who have had your same problem, this device has helped bring many a Cosworth, including mine, to driveability, let alone, show status. I applaud Mark for his time consuming efforts. John J. Cowall


Mark, just thought I'd drop you a note. The book came in good condition, and I think it is great. Just brushed through it but it looks to be well planned out. When and if I ever have a problem I am sure it will be very useful. Thanks again. Jeff Lanz, CV # 1786 

The Tips and Tricks book is a lifesaver, best reference. Shawn


Your "knowledge base" book arrived in my mailbox, Thursday afternoon, in good shape. The Tyvek envelope held up quite well.

Be advised, however, that I haven't been able to complete my first pass from cover to cover because I keep getting bogged down, reading all the posts for each topic that catches my eye. (Even found a few of my rare posts included among the threads.)

Mark, this was clearly a phenomenal undertaking on your part - not just to compile, but to edit out "meaningless" posts and to organize it all into such a logical order. (The gold cover and black binding are a nice aesthetic touch, too.)

When I started visiting the Yahoo! online club, I began cutting and pasting posts on topics that had merit relative to #0372 and my quest for maintaining it in authentic cosmetic and operating condition. Yet, that was a bit tedious to do in such a piecemeal fashion (each visit), and after all that time, I had only amassed about 15 pages - at 12-point type. Also, since I visit the online club on a rather irregular basis (too many other irons in the fire), I always worried that I might miss a post because of the way that Yahoo! manages the message threads.

While some may think that they can always check back through the online "history," the sheer number of posts there now makes that nearly impossible. (Never mind the fact that several users have shown themselves to be too lazy to even try.)

Also, some take for granted that those posts will be online for posterity. Little do they realize how fragile the reality of cyberspace can be. While Yahoo may go on "ad infinitum," that doesn't mean the online info couldn't fall victim to anything from a ruthless act of cyber-terrorism to a simple housekeeping decision made in the name of that scarce natural resource known as "hosting space."

So, this compendium was truly a worthwhile undertaking. You should take the extra step and pay the filing fee to have the copyright formally registered (which means a copy will be kept on file in the Library of Congress). 

With future volumes, collecting these posts would essentially create a full-bodied encyclopedia of knowledge for CV owners.

(Now, if I can ever lay my hands on a copy of the TCT Portfolio...)

Brian Harpst
CV-0372


Mark: Buying your book was the best $60.00 that I have ever spent. I have been having numerous problems with the CV lately and your book came in the mail just in time to help me out. It is a nice reference book and I use it quite often. In fact, I may have to order another one due to mine is getting greasy fingerprints all over it. It is nice that you have the foresight and knowledge to undertake such a task of this magnitude. I am going to write a letter to the President of the CVOA and have you nominated for the Robert A. Maloy Award. When part II comes out please let me know because I will purchase that also. One more thing, when will this becomes a movie, who will play my part? Take care. Mark "Fred" Blomquist 02/09/02

Mark, I returned from a business trip to find Tips and Tricks waiting for me. I have had a chance to look through it and it is very well organized and easy to find information. Thanks for a marvelous reference guide which will prove invaluable in getting my CV back on the road. John Ottosen, 8/25/02

I think your book will be very helpful with my cars. It contains a lot of information which is probably not available anywhere else in an organized form. Dave Stewart 08/09/02


I have read through it cover to cover. I think it is great, learned a lot about Cosworths. Dan Isaacs, 9/18/2002


Mark, just got the package today, it's great. (Cannot imagine the time necessary to put it together, though.) Have a good one. Troy 12/02

Mark: I received your book in excellent condition. Having just had time to thumb through it, it looks like a monumental effort on your part!! I will get back to you at a later date after I've had time to look through it. Many thanks, Carl Baccari, 01/31/03


I received the book on Thursday. It was in great shape. I have scanned through it. I believe it is going to be a lot of help to me for finding places to get parts and will keep me from going through some of the bad experiences others have already gone through. Thanks for all your work in compiling this for us. Chris Chasteen 2/22/03


Hi Mark: I've barely scratched the surface of Tips and Tricks 1, but so far it has been absolutely fascinating, as well as informative. You definitely deserve some kind of award for compiling and organizing the huge volume of information that is contained in this book. Carl Baccari, 2.28/03


What the Cosworth World is saying about:

Cosworth Tips and Tricks Knowledge Base II

KUDOS

I don’t spend much time in the Yahoo Cosworth messages because I find them hard to follow (sequence wise), so I need someone like you to summarize them for me. Dan Isaacs, 2/27/03


Hi Mark: … As for your second book on the Cosworth, my head went numb when I reviewed the subjects covered! Yes, I am very interested in obtaining a copy of this book. I will send you a money order this weekend to cover the cost. Carl Baccari, 2/28/03


 

TABLE OF CONTENTS

TIPS AND TRICKS KNOWLEDGE BASE II

 


 


TABLE OF CONTENTS.. i
ACCESSORIES
  
A/C.. 1

   Addco Sway Bars. 1
   Diamond Xenon Lights. 1
   Hatch Hutch. 2
   Luggage Rack.. 2
   Oil Pressure Gauge. 2
   Radio. 3
   Roll Bar. 4
   Tent-Go Camp. 4
ALTERNATOR.. 4
   Belt 5
   Bracket Bushings. 5
BODY PARTS.. 5
   Air Dam, Lower, Front 5
   Air Deflector (aka “chin spoiler”) 7
   Battery Trays. 8
   Bumpers. 9
   Decals/Labels. 9
      Cargo Hatch. 9
   Drip Rail Molding. 9
   Hatch. 10
   Hatchback Lift Supports. 10
   Hood. 10
   License Plate Bracket 10
   Locks. 10
   Stripes. 11
      Fender Logo. 11
   Spoiler. 13
   Swingouts. 13
   Valence Panel, Front 13
   Window Felts. 14
BRAKES.. 15
   1975-1976 Comparisons. 15
   Master Cylinder. 15
   Monza Conversion. 16
   Pad Break-In. 16
   Pads. 18
   Performance Brakes. 18
   Power Blocks. 18
   Power Brakes. 18
   Rear Brake Conversions. 19
      1976 Rear Brakes Onto a 1975. 19
      Rear Disc Brakes. 19
      S-10 Conversion. 22
CABLES.. 22
   Clutch Cables. 22
   Hood Latch Release Cable. 23
COOLING SYSTEM... 24
   Coolant Debate (Cont’d) 24
   Fan. 26
   Low Coolant Sensor. 27
   Pressure Cap. 27
   Radiator. 27
   Thermostat 27
CVOA.. 28
   Autocross Rules/Classifications. 28
   Concours Rules/Classifications. 29
   Tires & Trophies. 29
DIFFERENTIAL.. 32
   Axles. 32
   Gearing. 32
   Posi 33
EFI COMPONENTS.. 34
   CTS.. 35
   ECU.. 35
   FIV (Fast Idle Valve) 35
   Fuel Injectors. 36
   Fuel Pressure Regulator. 38
   MAP Sensor. 39
   Pulse Air. 40
   Sticker Numbers. 40
      EFI# 0295. 40
   Temperature Sensors. 40
      Generally. 40
   TPS.. 41
ENGINE/POWER/BUILDUP/COMPONENTS.. 41
   Alloy. 41
   Blocks: Stock & Cosworth. 43
      Origins. 43
      Interchangeability. 43
      Splitting Problems. 43
   Cam Carrier. 44
   Camshafts. 46
   Camshaft Sprockets. 53
   Coatings. 72
   Cold Air Induction. 72
   Combustion Chamber Volume. 72
   Compression Ratio. 73
   Computer Simulation Programs. 78
   Connecting Rods. 78
   Coolant Corrosion (Electrolytic) 81
   Cost to Build. 83
   Deck.. 83
   Dimensions of Engine. 83
   Dipstick.. 84
   Dyno Results. 84
   Firing Order. 87
   Flywheel 87
   Friction. 87
   Head. 88
      Head Milling. 88
      Ported Head. 88
      Price. 88
   Gasoline. 88
   Gooseneck.. 89
   Horsepower. 90
      Horsepower Quest 90
   Hutton Motors. 94
   Index Sparkplugs. 95
   Intake Manifold, Hutton. 96
   Oiling System.. 96
      Oil Pan. 97
      Oil Pump. 98
   Overview.. 98
   Paint 100
   PCV Valve. 100
   Pistons. 100
   Availability. 100
   High Compression Pistons. 101
   Piston Clearances. 101
   Piston Coatings. 101
   Identification. 102
   Rev Limits. 103
   Rings. 103
   Software. 104
   Specifications. 104
   Sprint Car Motor. 105
   Studs. 106
   Supercharging. 106
   Timing. 107
   Torque. 107
   To sleeve, or not to sleeve?. 107
   Valves. 113
   Valve Guides. 114
   Valve Seals. 115
   Water Pump. 115
EXHAUST.. 115
   Catalytic Converter. 115
   Component Clearances—75. 118
   Crossover Pipe. 119
   Dual Exhaust 119
   Header. 120
   Muffler. 120
   Replacement Proposals. 121
   75 Muffler. 125
   Temperature of Exhaust 126
FILTERS.. 126
   Air Filter. 126
   Fuel Filter. 127
   Oil Filter. 128
FUEL.. 129
FUEL PUMPS.. 129
   Fuel Pressure. 129
   High-pressure Pump. 130
   High Pressure Pump Mounts. 131
   In-Tank Pump. 131
FUEL TANK.. 132
   Sending Unit 133
GASKETS.. 134
   Bottom End Gaskets. 134
   Cam Carrier Gasket 134
   Head Gasket 134
   Oil Pump Gasket 137
   Teflon Gaskets. 137
   Thermostat/Housing Gasket 138
   Water Pump Gasket 138
   Weber Gaskets. 139
   Upper End Gaskets. 139
HEADER.. 139
HEATER.. 140
   Heater Core. 140
HISTORY.. 140
HME. 141
HOSES.. 141
   Fuel Hoses. 141
   Heater Hose. 142
   Radiator Hose. 142
   Radiator Hose Clamps. 142
HOW TO: 143
   Adjust Valve Lash. 143
   Autocross. 145
   Build a Fuel Injector Tester. 145
   Build an RC Cosworth. 146
   CC a Cylinder Head. 146
   Check for Sleeved Block.. 147
   Check for Power to HP Pump. 148
   Cleanly Remove Oil Filter. 148
   Cosworth Power a Fiero. 149
   Drain a Fuel Tank.. 149
   Evaluate and Buy a Cosworth. 150
   Find TDC.. 153
   Get that Show Car Shine. 154
   Improve Braking Performance. 155
   Index Spark Plugs. 155
   Install an Automatic Transmission. 156
   Install an Oil Restrictor. 156
   Install a 4-bbl. 156
   Install a 5-Speed. 157
   Install Cam Cover and Carrier Gaskets. 157
   Install Carpeting. 158
   Install Head Gasket 158
   Install Most Gaskets. 158
   Install Oil Pan Gaskets. 159
   Install Quarter Windows. 159
   Install Quarter Window Trim.. 159
   Install Timing Belt 159
   Keep Tires from Dry Rotting. 160
   Order Parts from a Chevy Dealer. 160
   Pass California Smog Test 161
   Polish EFI Pieces. 162
   Rear Subframe Trailing arm Mounts. 163
   Reduce Interior Noise. 163
   Remove Alternator Bolt Spacer. 164
   Remove Crankcase Vent Tube. 164
   Remove FIV.. 165
   Remove Fuel Tank.. 165
   Remove Grille (Header) Panel 165
   Remove Harmonic Balancer. 166
   Remove Hood. 166
   Remove Map Sensor Cover. 166
   Remove Timing Cover. 167
   Set Timing. 167
   Ship an Engine and Transmission. 167
   Verify Timing Mark on Damper Pulley. 168
   Wake a Long Stored Cosworth. 168
HURST SHIFTER.. 169
IGNITION.. 170
   HEI 170
   Coil 170
   Distributor advance. 171
   Distributor Grease. 171
   Ignition Module. 172
   Spark Plugs. 172
   Vacuum Advance Can. 172
   Wires (Ignition Impulse Harness) 173
   Wires (Sparkplug) 173
INSTRUMENTS.. 173
   Coolant Temperature Gauge Sending Unit 173
   Fuel Gauge. 174
   Speedometer. 175
INTERIOR.. 175
   Arm Rests. 175
   Carpet 175
   Dash Bezel 176
   Dash Pad. 176
   Dash Plaque. 177
   Glove Box. 177
   Light 177
   Knob/Latch. 178
   Shifter Knob. 178
KUSTOM KOSWORTHS.. 179
LISTS.. 179
   Checklists for Roundup. 179
      Air. 179
      Cosworth Tool Box. 179
      Main Tool Box. 180
      Appearance Items. 181
      Lubricants. 181
      Parts. 181
      Personal 182
      Barb’s List 182
   Brakes Checklist for Trips. 183
   Tires Checklist 183
   Wheels Checklist 183
   Fluid levels Checklist 183
   Vision Checklist 183
LUGNUTS.. 184
MAARS.. 184
MISCELLANEOUS.. 185
   Capitalism and Cosworth Vegas. 185
   Comparison of 75 and 76 Cosworths. 186
   Cutaway Motor. 186
   Dash Numbers. 187
   Dave’s Vega Village. 188
   Enjoyable Entertainment 188
   How Many Are Left?. 191
   IECO.. 193
   Kudos. 193
   New Year’s Resolution. 193
   NOS Definition. 194
   Once I was lost, now I am found…... 195
   Opinion Poll 195
   Purity and (In)Tolerance. 197
   Self-Deprecation. 200
   Sire to the Quad 4. 201
   Speedometer Cable Heat Shield. 201
   Top Speed. 202
   Trivia. 203
   Way Out Questions. 203
   When is a Cosworth not a Cosworth?. 203
OIL.. 209
PAIR SYSTEM... 211
   Vacuum.. 211
   Pulse Air Tubes. 211
PARKING BRAKE. 212
PROBLEMS/SOLUTIONS.. 212
   Alternator Light 212
   Backfiring in #2474. 212
   Blown Engines. 215
      Ron’s Engine. 215
      Chris’ Engine. 215
   Brakes—No Pedal Pressure. 215
   Brakes (Rear on a ’75) Lock Up. 217
   Broken C-Clips in Rear Axle. 220
   Cam Carrier Threads Stripped. 220
   Clock Doesn’t Work.. 221
   Camshaft Sprocket Bolts Shear. 221
   Clanking in Oil Pan. 224
   Dash Lights. 224
   Dead Cylinder. 225
   Detonation. 226
   Erratic Idle. 227
   Excessive Oil Consumption. 228
   Failed Emissions Testing--Chris. 229
   Failed Emissions Testing—Wendell 229
   Farradio. 231
   Flooding on Cranking. 231
   Fuel Injector Delivery Uneven. 232
   Fuel System Problems. 233
   Fuel Tank Collapse. 233
   Funny Things Going On #0880. 234
   Hard, Slow Cranking. 234
   Heater Blows Hot in Summer. 234
   Hesitation Upon Acceleration. 235
   High Idle. 235
   High Idle, Quits Once Hot 240
   Hot Steering Column and Ignition Key. 240
   JB Reardon. 243
   John J. Cowall, Jr. 246
   Ken’s #0259. 247
   Lacks Power Off Idle  Al 249
   Lacks Power Over 6000 RPM... 254
   Lacks Power, Throttle Response, Idle. 258
   Leaking Oil Filler Cap. 258
   Low Vacuum at Idle. 259
   Melted Speedometer Cable. 259
   Missing Ignition Timing Tab. 259
   No Fuel in #0126. 259
   No Fuel in #2474. 260
   No Fuel in Manifold. 260
   No Power to Fuel Pumps. 261
   No Spark in #2474. 263
   Oil Leaks. 264
   Oil Leaks from Loosening Cam Carrier Bolts. 266
   Oil Pressure Line Rupture. 267
   Oil Pushes Up Vent Tube. 268
   Paint Maintenance and Repair. 268
   Popping Sound at Rear Over Slow Bumps. 269
   Rattle at Front of Engine. 269
   Rattle Underneath Car. 270
   Rear Window Defrost Relay Repair. 270
   Rough Idle (Webers) 271
   Runs on 1 or 2 Cylinders. 271
   Steve. 271
   Ish. 272
   #0307. 273
   Runs Rich. 274
   Runs Rich at Idle. 277
   Runs Rich, Won’t Idle. 278
   Runs Rough When Cold. 279
   Seat Belt Light 279
   Selling a Cosworth. 279
   Senior Moments. 280
   Sheared Cam Sprocket Bolts. 280
   Short Legs. 281
   Severe Lack of Power. 281
   Spastic Tach. 282
   Spax Shocks Squeak.. 283
   Spitting at Highway RPM... 283
   Stalls Upon Starting. 283
   Stalls When Hot 284
   Starter Cranks Slowly. 289
   Starter Hesitation. 289
   Sticky Steering Wheel 290
   Stiff Clutch Pedal 290
   Stripe Adhesive Removal 291
   Ted’s #0152. 291
   Tik, tik, tik.. 293
   Timing Jumps Around. 294
   Torque Arm Counterweight 294
   Tune Up Part Numbers. 294
   Valve Guide Anomaly. 294
   Voltmeter Not Working. 295
   Window Trim Glue. 295
   Won’t Start--#0441. 295
PUBLICATIONS.. 296
   Assembly Instruction Manual (AIM) 296
   Broadcast (aka Build) Sheets. 296
   Cosworths in Print 297
   Cosworths in the Movies. 297
   GM Restoration Package. 298
   Owner’s Manual 299
   Magazine Articles. 299
   NADA Price Guide. 299
   Service Manual 302
   Shop Manual 302
   Tips and Tricks Knowledge Base I 302
   Twin Cam Times Portfolio. 302
   Webers. 303
REAR END.. 303
   Gears. 304
REGISTRATION.. 304
RESTORATION.. 305
   Air Deflector. 305
   Battery Tray Area. 305
   Brake Lines. 306
   Bumpers. 306
   Cam Cover. 306
   Carpeting. 307
   Clock.. 310
   Dash Bezel 311
   Dash Bezel Refinishing. 313
   Dash Pads. 314
   Door Hinge Bushings. 315
   Drip Rail Molding. 315
   Dye for Interior Plastic and Vinyl 315
   EFI Air Cleaner. 316
   Electro-Clear Tag. 316
   French Locks. 317
   Fuel Filler Neck.. 317
   Hood Pads. 318
   Lug Nuts. 318
   Oil Filler Cap. 318
   Radiator. 318
   Rear Window Defogger Wires. 319
   Rear Valence. 321
   Seat Belt Guides. 321
   Spark Plug Wiring. 321
   Spax Shocks. 322
   Speedometer Cable. 322
   Stripes/Decals. 322
   Sway Bars. 322
   Timing Belt 322
   Weber Carb Refinishing. 322
   Wheel Restoration. 323
SEALS.. 331
   Camshaft Seals. 331
   Fuel Injector Seals. 331
   Rear Main Seal 331
   Transmission Input Shaft Seal 332
   Transmission Shift Lever Seals. 332
   Valve Seals. 333
SPARK PLUGS.. 333
STARTER.. 333
STEERING.. 334
   Rebuild Kit 334
   Steering Box Monza. 334
   Steering Box, Quick.. 335
STEERING WHEEL.. 335
SUPERCHARGING.. 335
SUSPENSION AND HANDLING.. 338
   Overviews. 338
   Duke’s Overview.. 338
   Gerald’s Overview.. 339
   Terminology. 340
   Alignment 341
   Bushings. 343
   Center of Gravity. 343
   Geometry, Rear. 343
   Overall Opinions/Recommendations of Gerald Storvik.. 344
   Panhard Bar. 346
   Ride Height 346
   Shock Absorbers. 346
   Springs. 347
   Sway Bars. 351
TECHNICAL TOPICS.. 353
   Calculations. 353
   Desktop Dyno 2000. 353
   Oversquare. 353
TIRES.. 354
   Autocross. 354
   Replacement Street 358
   OEM (Originals) 362
   Vibration above 55. 362
TOOLS, SPECIALTY.. 362
   Cam Belt Tensioning Tool 362
TRANSMISSIONS.. 363
   4-Speed. 363
   5-Speed. 364
   Swaps. 370
UNDERCOATING.. 372
URBAN LEGENDS.. 373
   Lordstown Hi-jinks. 373
VIN.. 375
   Block Stampings. 378
   Body Locations. 378
   EFI Stickers. 379
   Fender tags. 379
   Tonawanda Number. 380
   Colors. 380
   Registry. 381
WATER PUMP.. 383
WEBERS.. 383
   Adjustment of Weber Carbs. 385
   Idle Mixture Screws. 385
   Air Filters. 386
   Air Horns. 386
   Books on Webers. 387
   Fuel Pressure. 390
   Rebuild Kits. 390
   Vacuum Taps. 391
   Welding Webers. 391
WEIGHT.. 391
WHEELS.. 392
WIRING.. 395
   Alternator. 395
   Fuel Injector. 395
   Primary Ignition Harness. 395
   Spark Plug. 395
XP-898. 396
NOTES.. 396