Cosworth

The Octagon

44 St James Mill Road

Northampton

NN5 5RA

United Kingdom

T: +44 (0)1604 598300

Author: Matthew Feasey

Terms and Conditions

© Copyright Cosworth Ltd

Toyota GT86 / FRS / Subaru BRZ Stage 1.0 Tuning Kit Fitting Instructions

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Kit contents:

Free flow Air filter

Low running temperature coolant thermostat (starts opening @ 76°)

Revised Calibration

Associated ECU licence with purchase

Cosworth memory stick loaded with calibration data and technical information

Car badge

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Contents

1. Getting started - EcuTek ............................................................................................................................... 4

1.1. Map switching and RaceRom Features ...................................................................................................... 6

1.2. Throttle calibration .................................................................................................................................... 7

2. Exhaust System Fitting....................................................................................Error! Bookmark not defined.

3. Thermostat fitting......................................................................................................................................... 8

4. Air filter Installation ...................................................................................................................................... 9

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1. Getting started - EcuTek

Notes for ECUtek installer:

1st visit the EcuTek website (http://www.ecutek.com/Home.aspx) to download the latest version of the ECU interface

software (ECUtek ProECU) onto your laptop.

This must be downloaded from their site and it’s recommended to periodically update this software at least once per month.

Before fitting any parts the 1st thing to do is install the software onto your laptop and connect to the car.

Within the help files on ProECU Refer to the PDF file; ProEcu Programming Overview

Then before fitting any new parts, load in the new calibration /ROM file from those that are saved onto the Cosworth USB

stick or that has been emailed to you

© Copyright Cosworth Ltd 5

Depending on your market and transmission type that you have purchased it will be one of the following calibrations:

Market Manual

Transmission

Auto

Transmission

Original

ROM ID

Cosworth

Cal Part no.

Euro & Aus ZA1JA01G 20046948

Euro & Aus ZA1JA01I 20046949

USA ZA1JB01C 20046950

USA ZA1JB01D 20046951

Japan ZA1JA02A 20046952

Japan ZA1JA02B 20046953

Gulf ZA1JA01J 20046954

Gulf ZA1JA01K 20046955

General ZA1JA01E 20046956

General ZA1JA00F 20046957

You must select the appropriate market and transmission type for your car for the calibration to be matched.

It is not possible to flash a USA car with a Gulf ROM as the software will not allow it

It is also not possible to flash a manual car with an automatic ROM.

The Standard ROM file name you queried earlier should match one of the ones above.

Once the calibration is loaded start and run the engine to check the installation, it should idle normally.

DO NOT DRIVE THE CAR YET

As the Cosworth calibration requires the fitment of the mechanical parts in order to be safe to use, driving the car on the

calibration without these parts fitted will put the engine into detonation, have problems with fuel mixture and possibly

damage your engine.

Having established the engine starts and runs on the new cal only then fit the new parts.

Please note that the calibration is locked out to prevent viewing / editing of the values in the various maps.

You are of course free to create your own map but you will have to start from scratch and will miss out on the time and

expertise Cosworth has put into the calibration.

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1.1. Map switching and Race-Rom Features

Using the cruise control switch the following 4 modes of operation are available, with the engine running pull the cruise

control stalk toward you and hold it until the rev counter becomes stationary and points to 1(1000rpm / mode 1)

Then to switch maps release the stalk and nudge it up as if you were increasing speed on the cruise function, the needle

should move to 2 ( mode 2) again for mode 3 and so on.

The map switching can be done at any time while driving except when cruise control is enabled.

The mode switching function is configured as follows:

Mode 1 - Default mode upon engine restart

Calibrated for 95RON Un-leaded gasoline (91 in USA)

No Racerom special features enabled

Mode 2

Calibrated for 98 RON Unleaded gasoline (93 in USA)

Rev limit increased to 7600Rpm in gears 1-3, 7500Rpm in 4th and 7400Rpm in 5th & 6th

Mode 3

As mode 2 with flat foot shifting function enabled and auto blip on gear down shifts enabled, flat foot shift will hold the

engine revs back during a gearshift, providing your foot is hard on the accelerator the strategy is enabled when you press the

clutch.

Auto blip will blip the throttle on a down shift when the brake pedal is pressed and the clutch pedal is pressed and providing

that the vehicle speed is above 35 kph (22mph).

Mode 4

As mode 3 with launch control enabled.

Launch control is enabled when the vehicle is stationary and the clutch pedal is depressed and the accelerator pedal is fully

depressed. To prevent it conflicting with the traction control, the TC button must be pressed before initiating the launch.

For automatic transmissions there is no auto blip, flat foot shift or launch control enabled, but the alternative fuel and

ignition maps and gear rev limits are enabled.

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1.2. Throttle calibration

Once the ECU has been re-flashed the throttle pedal control needs re-calibrating, this will happen normally as the car is

driven over the next 20-30 miles, however you can greatly speed this process up by following this procedure:

1) Switch on ignition but do not start engine

2) Press and hold throttle down to the stop for a count of 10 seconds

3) Release pedal and repeat step 2 twice

4) Switch off ignition - done

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2. Thermostat fitting

With the engine under-shield removed the thermostat is accessed from under the engine you remove this housing

Figure 1 - Thermostat housing

All bolts are accessible even with the standard manifold in place; the new thermostat is a like for like replacement. You will

lose some coolant during this process so be prepared to have to replace it and then bleed the engine from the high point tap

on the heater hoses at the back of the engine bay.

Typically one heat up / cool down cycle is required to remove all the air from the system and allow the coolant overflow /

siphon tank to work and set the correct level.

Double check coolant levels before giving the engine any hard work.

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3. Air filter Installation

Fitting the air filter is a like for like replacement of the standard part

Figure 2 - Fitting Cosworth Filter - note pleat direction

Figure 3 - Air filter corner note matching radius

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Figure 4 - Filter in place