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DYNO RUN
PICTURES
When we started on this project the engine modifications were relatively simple and as time progressed, they became more extensive.  Below, I have listed the modifications in phases.

 

Phase I

Consisted of minor modifications. When I purchased the car, the previous owner had installed a Ford Motorsport front mounted intercooler.  The intercooler was mounted between the radiator and the front grill.  We installed a Ford Motorsport roller cam kit.  The engine remained in this phase for about five year.  The photograph to the right shows the routing of the intercooler’s pipes.

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Phase II

This is were the bulk of the modifications came.  My father and I pulled the engine from the car to perform these modifications.  I will start out with a description of the short block.  We installed Crower sportsman connecting rods and new factory forged pistons. I have heard that they are good for 400 HP.  The crankshaft (rotating assembly) was balanced and secured with ARP main studs. 

Next we focused our attention on the cylinder head.  The head was machined to accept stainless steel - 1.89” intake and 1.59” exhaust valves.  To save some money, we cleaned up the ports ourselves.  The factory valve springs were then replaced with dual valve springs and the associated hardware.  The Motorsport cam was then reinstalled with an adjustable cam gear. The head was then secured to the block with ARP studs. 

On the intake side, I purchased a manifold (upper and lower) from a 1988 Turbo coupe at a local junkyard.  I heard that the 87-88 intakes flowed better than my 86’s.   The intake (upper and lower) was sent to Extrudehone for polishing.  Upon their return, the lower unit was port matched to the cylinder head.  To make the intake work, we needed to use the valve cover from the 88’ Turbo coupe (the new intake is shorter).  The factory throttle body was then reinstalled. To provide spark, a Crane Hi-6 ignition box and PS92 coil were installed. 

On the exhaust side, the factory cast iron manifold was scraped in favor of a tubular stainless steel header.  Attached to the header is a Stage III turbocharger from Turbonetics.   The turbo has a Super V compressor wheel and I believe a .63 exhaust housing.  The exhaust exists through a mandrel bent 3” down pipe and custom exhaust.  The charged air is chilled via a Spearco front mounted intercooler designed for the SVO Mustang.

 

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After Phase II was completed, we took the car to a chassis dyno to have it tested.  We made three runs and our best numbers were 258.9 rear wheel HP and 307.6 rear wheel pound feet of torque at 18 lbs of boost.   That works out to 298 HP and 354 pound feet of torque at the crankshaft. During the test, a wide band O2 sensor was used and detected a lean condition at maximum torque.  This lean condition lead to audible detonation and the factory computer pulled out timing in response.  The only fuel modifications that we had performed were the installation of 42 lb injectors and a Superchip to control them.  We suspected the factory fuel pump had reached its limits.

 

Phase III

This is the setup that is currently in the car.  The factory throttle body has been replaced with a 65mm unit.  The upper manifold has been port matched to the new throttle body.  A HKS blow of valve has been added to the Spearco intercooler to relieve pressure during shifts.

The 45 lb injectors have been replaced with a set of 55’s.  A 255 l/hr fuel pump and a Paxton adjustable regulator have been installed.  To control the injectors and spark the Factory computer has been removed and a programmable Speed Density system installed.  Please see the computer page for more information on the system.

Back in September I had Job Spetter Jr. at Turbo People tune the fuel injection system.  As of this posting, I have not had the opportunity to retest the car on the dyno.  Hopefully, I will get the opportunity this spring.

 

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Phase IV

March 28, 2003,  I received my Esslinger D-port aluminum cylinder head.  I had Esslinger set the head up with their solid lifter kit. In addition, they cleaned up the exhaust ports for me. I am now in the process of looking for a new cam.

Some other modification that have been performed during this phase include the swapping out the factory alternator for a 130amp 3G unit, relocation of the battery to the trunk, the installation of Esslinger's wide tooth pulley kit and the removal of the nonfunctioning air conditioning system.

Hopefully with these modification and some tuning I will get 400 HP out of the motor.

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Intake Side

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Exhaust Side

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Cleaned Up Exhaust Port.