This is section explains some of the most important details of the setup
for a single or twin turbo Sn95: routing all the pipes, headers, and where
to locate the Turbo units.
The SN95 has a small engine bay, where the Ford designers
had to put not only the engine but all those accessories and smog equipment.
On the drivers front side, we have the A/C and Steering
pump, which leaves us with a small space above and between them to route
the exhaust into the turbo. The passenger side has the Smog pump, smog
lines and some A/C lines.
Also on the drivers side there's the POWER BOX which has
some engine relays and fuses that power some important devices such as
the EEC, fuel pump and some important equipment.
This box, if exposed to heat, can melt and probably cause some electrical
failure or worse.
So, where do we start?
The first step involves moving your battery to the trunk,
its a fairly easy thing to do. You can buy a complete kit at several places
such as Summit Racing.
We suggest to choose the easiest (not necessarily fastest)
path, and by that we mean, move and reroute everything that could be a
possible restriction to a another place inside the engine.
The Power
box can be moved above the Brake Booster, for that you will need to REWIRE
everything and route the wiring inside the fender well. THIS IS NO EASY
task, but we think it can be done in a couple of days. We suggest that
you get a shop manual with wiring diagrams if you want
to do this. You can also use heat shields/insulators to protect the power
box and it's harness.
For single and Twin setup there are some differences and
Pro's /Con's on the installation.
A Twin turbo setup requires modified headers
on both sides, then reconnect the exhaust back to the H pipe. Also on
a twin setup you will need a BLOW THROUGH Maf, such as the one sold by
Pro-Flow (Pro-M). More piping is also required for the intercooler(s).
For a SINGLE setup, you will only need to modify or custom
make one header, the other stays stock.
If you place the turbo on the passenger side, then the drivers
side header remains stock, but you will need to cut the drivers
side H pipe (reduce the length). The driver's side equal length header
goes to a x-over pipe under the motor and then into the turbo manifold
on the pass side.
SINGLE TURBO SETUP:
If you followed the previous articles, by now you might
have chosen one setup or the other, and if you are going single
then keep reading, else skip this section and go to the Twin setup.
This is a partial list of parts you will need:
Turbo T04B: Garret / Turbonetics
or similar turbo
Stock header (drivers side)
Header kit (Hedman) or modified header to make the turbo manifold
Intercooler(s)
Steel Pipes and bends of different diameters, mostly 2.5" and 3"
Assortment of 2.5" and 3" hoses and heavy duty clamps
High temperature RTV sealant and gasket maker
Header to H pipe flanges, header flanges, header gaskets, exhaust to
turbo flange, turbo to exhaust flange, exhaust clamps.
Braided line for oil line(s)
Wastegate (if not included in Turbo)
Braided line for coolant lines (depending on turbo)
Boost gauge
High capacity Fuel pump, Injectors (30 recommended), FMU or custom chip
The drivers side header is connected to a crossover pipe,
which goes from the drivers side header, behind and underneath the motor
(in between motor and tranny), and then comes back up connecting with
the passenger side turbo manifold. That turbo manifold, connected with
the drivers side header, feeds air forward into the turbo's compressor
housing, and then out to a 2.5" downpipe. After the downpipe you
will use a 2.5" Y-pipe which splits off into the catback exhaust.
For the Twin setup you would would need smaller Turbo's
such as T3 units, luckily there are lots of cars that came factory with
this kind of units:Chryslers, Saabs, Mitsus..etc, try too look for ones
with factory wastegates and NON LIQUID cooled ones, they are easier to
setup.
Turbo's T3s: Garret
/ Turbonetics or similar size turbo's
Header kit (Hedman) or modified header to make the turbo manifolds
Intercooler(s)
Steel Pipes and bends of different diameters, mostly 2.5" and 3"
Assortment of 2.5" and 3" hoses and heavy duty clamps
High temperature RTV sealant and gasket maker
Header to H pipe flanges, header flanges, header gaskets, exhaust to
turbo flange, turbo to exhaust flange, exhaust clamps.
Braided line for oil line(s)
Wastegates (if not included in Turbo)
Braided line for coolant lines (depending on turbo)
Boost gauge
High capacity Fuel pump, Injectors (30 recommended), FMU or custom chip
Now to hook it up all together there are some considerations,
the twin setup takes more space than a single one, so you will have to
relocate some stuff like the battery, a/c lines etc. Make sure you do
this before any attempt to make the setup.
There are 2 main approaches for the twin setup, both with
pro's and con's, the "simplest" is to use modified factory headers
swapped LR-RL, where the turbo's will be placed on the battery and stock
air box locations.
The second ones involves a bit more work to make the turbo
manifolds. You can also use the LR-RL approach but in this case the TURBOS
sit UNDER them, this is the approach INCON followed.
The exhaust gases will go directly into the turbo's inlet
and directly form the turbo exhaust outlet into the H pipe. This setup
requires less relocation and lots less piping. It is also less restrictive.
Turbo T04B: Garret / Turbonetics
or similar turbo
Turbo's T3s: Garret
/ Turbonetics or similar size turbo's