Turbo & Intercooler:

The first thing I always do with a new part I don't understand is tear it apart, clean it up and then "try" to put it back together. The turbo itself was pretty sound but the '86 Cougar it came from did have a few miles on it so I purchased a rebuild kit from a local shop that specializes in diesels. While it was apart, I also began my aluminum polishing mania! A few hours with a file, sandpaper and polishing compound and it cleaned up pretty good! I was hooked!

 

 

While on the cleaning binge, I also got my first taste of one of the Ford's turbo 2.3 weaknesses, cracked exhaust manifolds. Please, if your buying manifolds from the junkyard, bring a good wire brush and check to make sure it has no cracks (plus ask for a money back guarantee). Two more manifolds later, I finally found an un-cracked "E6" manifold.

While studying turbo-charging, I learned that with a blow-through system, I can use an intercooler to reduce the air temperature, reduce detonation and gain a bunch of horsepower in the deal. After searching wreckers unsuccessfully for months, I took the plunge and made my first Ebay purchase, an '88 Turbo Coupe intercooler. I also learned about boost controllers. The stainless flex hose going from the turbo and into the fender well. Is hooked up to a locking low-pressure regulator (black knob with red ring on left side of photo). With this set-up, pressure is diverted from the wastegate actuator and I should be able to dial in whatever boost pressure I want (or dare!). This is my version of the "Go Baby Go" button of "Gone in 60 Seconds" fame. The turbo inlet elbow in this photo will be replaced with a high-flow straight inlet I received as a gift (thanks again Craig!).

 

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