6.0L INTERCEPTOR

A Power Stroke equipped, 12-Second Crown Vic

For most of us, it’s natural to do a double-take when we spot an old cop car. But folks who come across Matthew Barnett’s retired police cruiser aren’t just momentarily preoccupied with its physical appearance—they’re perplexed by what they hear. “People definitely swivel-neck when you drive by,” he told us. “I’ve had some pretty good looks.”

Like so many others, Barnett picked up his retired CVPI dirt cheap, and thanks to its superb highway manners he made it his daily commuter. However, he then fell into a deal on an ’05 Ford Shuttle Bus and the wheels started turning. Having been a huge fan of the Duramax Camaro and Cummins Charger projects from One of Won Customs, Barnett pondered the idea of building his own diesel-powered car—a 6.0L-powered Crown Vic. “I thought to myself, somebody should put a Power Stroke in a Ford car,” he says. In the spring of 2017 he decided to go for it.

Shuttle Bus 6.0L

Easing the integration process, the 5R110 TorqShift remained attached to the 6.0L throughout the swap. But before the combo was lowered into the Crown Vic’s engine bay, the 6.0L’s heads were pulled, checked out, and ARP studs added. A new oil cooler was also added for peace of mind. Then, with the front end of the car completely apart, the engine and transmission were positioned in place while Barnett built a pair of motor mounts and a transmission cross member using pieces from both the shuttle bus and the sedan.

Small Sacrifices

Despite the tight squeeze, Barnett tells us the conversion was surprisingly smooth. A few tweaks at the firewall, a tab removal on the transmission and a few sensor relocations were the extent of the most time-consuming tasks. However, due to space limitations, Barnett was forced to abandon the intercooler and make use of the car’s original cooling system (radiator, coolant reservoir, fan and fan module).

People definitely swivel-neck when you drive by.
—Matthew Barnett

Painless Wiring

As far as the wiring was concerned, Barnett didn’t overthink it. The car’s original wiring for controlling the windows and all the functions on the dash was retained, while the harnesses necessary for the 6.0L, 5R110 and Econoline gauge cluster to work flawlessly came off the bus. Both Ford ignition systems are tied together so that each one powers up simultaneously at key-on.

Basic Mods

Once again keeping things as straightforward as possible, Barnett opted for the intake, tuner, exhaust approach to adding power (for now). The factory Garrett VGT is fed air via an intake he fabricated, and it produces more than 30 psi worth of boost thanks to custom tuning from Innovative Diesel. An SCT Livewire TS+ allows Barnett to keep tabs on boost, transmission, coolant and engine oil temp, FICM voltage, ICP and various other key vitals. For exhaust, a custom-formed 3-inch system begins where the factory downpipe ends and culminates with a polished stainless turn-down tip out back.

12-Second Sedan

Even though the 6.0L more than doubled the car’s power output, Barnett’s original intention for his Crown Vic hasn’t changed—he still plans to use it as his summertime commuter. With the smooth-riding four-door capable of achieving 20 mpg, it’s hard to argue with that. And with the 5,000-pound sedan also capable of running mid-12s, it’s hard not to want to be behind the wheel. If you encounter Matthew Barnett’s unique creation out on the highway, be sure to move over. He’ll be cruising in the fast lane.

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Specifications

2007 Ford Crown Victoria (Police Interceptor, a.k.a. “CVPI”)

Owner: Matthew Barnett
Hometown: Princeton, Idaho
Odometer: 146,000 miles (car), 78,000 miles (engine/transmission)
Engine: 6.0L Power Stroke with ARP head studs, Crown Victoria cooling system
Air: OEM Garrett VGT and 3-inch downpipe, custom fabricated air intake
Fuel: Stock injectors and lift pump
Oil: Factory high-pressure oil pump
Exhaust: Custom-bent 3-inch system with MBRP turn-down tip
Tuning: Innovative Diesel via SCT Livewire TS+
Transmission: Factory five-speed 5R110 TorqShift automatic
Horsepower: 450 rwhp (est.)
Torque: 850 lb-ft (est.)
Tires: Road Control Touring A/S, 235/65R17
Wheels: Factory steel, 17×7.5
Axles/Suspension: Stock 8.8-inch rear, 3-inch coil spring spacers

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FREQUENTLY ASKED QUESTIONS

What is the price range for specific turbo models for the 6.0L Powerstroke engine?

Price Range for 6.0L Powerstroke Turbo Models

If you’re in the market for turbo upgrades compatible with the 6.0L Powerstroke engine (2003-2007), the options vary greatly in terms of features and pricing. Below, you’ll find a general guide to help you navigate through the available choices:

Turbo Chargers

• Stock Replacement Turbos: Prices start around $934. These are ideal for those who want to maintain factory specs while replacing worn-out parts.
• Dual Ball Bearing Turbos: If you’re interested in optimized performance, these models start at approximately $2,506. They offer greater durability and efficiency compared to standard models.

Injector Options

• 155cc to 205cc Injectors: Priced between $166 and $330. These are suitable for enhancing fuel delivery and achieving better power output.

Compressor Wheels

• Upgraded Compressor Wheels: Typically cost $250. These components can enhance the turbo’s airflow and boost capability.

Turbo Rebuild Kits

• Basic Rebuild Kits: A budget-friendly option from $69. Essential for maintaining turbo performance over time.
• Enhanced Rebuild Kits: Priced around $99, these include additional components for high-stress applications.

Intercoolers and Additional Upgrades

• Intercoolers: Available at roughly $790. They are crucial for cooling the compressed air and improving engine efficiency.
• Fuel Return Kits and Other Enhancements: Prices start at around $585, offering additional performance adjustments.

The price range for these upgrades reflects the variation in performance, reliability, and enhanced capabilities offered by each product. Whether you’re looking for a simple replacement or a high-performance upgrade, understanding these options will help you make an informed decision tailored to your vehicle’s needs.

 

What are the price ranges for 6.0L Powerstroke engine parts?

Price Ranges for 6.0L Powerstroke Engine Parts

When it comes to replacing or upgrading parts for a 6.0L Powerstroke engine, costs can vary widely depending on the specific component and quality. Here are some general price ranges you can expect:

• Budget Options: You can find basic replacement parts starting around $180. These are typically more affordable and suit simple repairs or anyone working with a tight budget.
• Mid-Range Components: For better reliability and quality, expect to spend between $1,000 and $9,500. This range covers a wide variety of parts, from turbochargers to fuel injectors.
• Premium Parts: High-performance or brand-name parts can range from $14,000 to $19,000. These options are ideal for those looking to enhance engine performance or ensure long-term durability.

It’s crucial to compare the offerings from various suppliers and consider the specifics of your vehicle’s needs when selecting parts. Additionally, investing in higher-quality components can often save money in the long run by reducing the need for frequent replacements.

 

Which manufacturers produce parts for the 6.0L Powerstroke engine?

When exploring parts for the 6.0L Powerstroke engine, you’ll find a variety of manufacturers offering specialized components. Here’s a breakdown of some key manufacturers and the parts they produce:

Performance Upgrades & Accessories

• Gen-Y Hitch and Icon provide essential towing and lifting accessories for enhanced vehicle performance.
• Fabtech and Banks Power offer a range of lift kits and performance enhancements.
• For those focusing on air filters and intakes, S&B and AFE are notable brands.

Exhaust & Turbo Systems

• Mishimoto and MBRP offer high-quality exhaust systems designed for improved flow and reduced backpressure.
• BD Diesel and KC Turbo specialize in turbocharger solutions, ensuring optimal power output.

Lighting & Electrical Components

• Oracle Lighting and KC Hilites are leaders in advanced lighting solutions, offering sophisticated LED systems.
• Strictly Diesel provides essential electrical upgrades for improved performance and reliability.

Fuel & Injection Systems

• Fass Fuel Systems and AirDog deliver advanced fuel system components, ensuring clean and efficient fuel delivery.
• Industrial Injection focuses on injection systems designed to maximize engine performance.

Suspension & Steering

• Bilstein and King Shocks excel in suspension components, providing durability and comfort.
• Fox also offers premium shocks that enhance off-road capability and ride smoothness.

Engine Internals & Fasteners

• Mahle and Gibson supply robust engine components ensuring reliability and longevity.
• Gator Fasteners offer essential fastening systems for secure engine assembly.

These manufacturers contribute to a comprehensive selection of parts that cater to various needs—be it performance enhancements, durability improvements, or aesthetic upgrades for the 6.0L Powerstroke engine.

 

How can products be displayed in terms of quantity per page for 6.0L Powerstroke engine parts?

When browsing for 6.0L Powerstroke engine parts, you have the flexibility to customize how products are displayed on your screen. This feature allows for a more tailored shopping experience, ensuring you can view the right number of items easily and efficiently. Here’s how you can adjust the number of products you see per page:

Display Options:

1. Compact View: Opt for displaying just 8 items per page. This option is perfect for focusing on detailed comparisons between fewer products at a time.
2. Moderate View: Choose to see 16 items on each page for a balanced browsing experience. This middle ground allows you to explore a wider selection without losing attention to detail.
3. Expanded View: If you prefer a more extensive overview, you can display 24 items per page, making it easier to scan through more options quickly.
4. Wide View: For those who want to maximize their browsing session, displaying 32 items per page offers a broad view of available parts.
5. Full View: The option to display up to 48 items on a single page is ideal for those who prefer an exhaustive list and have higher screen space.

By adjusting these settings, you can ensure a seamless and efficient search experience, tailored to your specific needs and preferences, whether you’re comparing turbochargers, injectors, or other vital components for your 6.0L Powerstroke engine.

 

What types of engine upgrades and rebuild kits are available for the 6.0L Powerstroke engine?

Basic Mods

Once again keeping things as straightforward as possible, Barnett opted for the intake, tuner, exhaust approach to adding power (for now). The factory Garrett VGT is fed air via an intake he fabricated, and it produces more than 30 psi worth of boost thanks to custom tuning from Innovative Diesel. An SCT Livewire TS+ allows Barnett to keep tabs on boost, transmission, coolant and engine oil temp, FICM voltage, ICP, and various other key vitals. For exhaust, a custom-formed 3-inch system begins where the factory downpipe ends and culminates with a polished stainless turn-down tip out back.

To protect his investment in a fresh oil cooler, Barnett installed a coolant filtration system from Sinister Diesel. Bypass filtering engine coolant through a 27-micron WIX filter keeps larger particles of casting sand and sediment from entering and eventually plugging up the oil cooler.

Comprehensive Engine Upgrades

For those looking to explore the full spectrum of enhancements available for the 6.0L Powerstroke engine, a variety of injectors, turbos, and rebuild kits are on the market:

• Injectors:
  • Premium Stage 4 205cc injectors for those seeking maximum performance.
  • Basic reman 155cc injectors with a 30% nozzle upgrade for balanced power and efficiency.
• Turbo Options:
  • Stock replacement turbos offer reliable performance, while dual ball bearing turbos like the Jetfire series provide enhanced response and durability for more demanding applications.
• Compressor Wheels and Rebuild Kits:
  • Upgraded billet compressor wheels, such as the S372 and S369 models, are perfect for those looking to increase airflow and boost capabilities.
  • Turbo rebuild kits, including both 360 and 270 options, ensure continued performance and longevity of your turbo setup.
• Additional Enhancements:
  • Intercoolers specifically designed for the 6.0L Powerstroke enhance cooling efficiency.
  • Regulated fuel return kits help maintain optimal fuel pressure, supporting better engine performance.

By combining Barnett’s personalized modifications with an array of available upgrades, enthusiasts can tailor their 6.0L Powerstroke to meet specific performance goals, whether it’s for everyday driving or pushing the limits on the track.

 

What are the different types of engine components offered for the 6.0L Powerstroke?

Robbed out of an ’05 Ford Shuttle Bus, the 6.0L Power Stroke under the cowl hood of Matthew Barnett’s ’07 Crown Vic was treated to a set of ARP head studs and a new oil cooler prior to being shoehorned into place. With space at a premium, Barnett was forced to retain the sedan’s original cooling system, along with foregoing the use of an intercooler. All told, the engine swap and retention of the 5R110 TorqShift added roughly 800 pounds to the car’s bottom line.

Beyond just the intriguing swap, the 6.0L Powerstroke offers a wide array of components that cater to various performance needs. Here’s a glimpse into the diverse types of parts available for enthusiasts and professionals alike:

• Lighting: Enhance visibility with an extensive selection of lighting options.
• Air Intake Systems & Filters: Boost engine performance with high-flow intakes and efficient filters.
• Exhaust Systems & Components: Upgrade to improve exhaust flow and sound.
• Turbo Parts & Accessories: Optimize turbo performance with specialized parts.
• Cooling Systems: Maintain optimal engine temperatures even under stress.
• Fuel Systems: Ensure consistent fuel delivery with robust system components.
• Intercoolers: Maximize air density and power output.
• Fuel Injectors: Precision injectors for improved combustion efficiency.
• Transmission: Components designed to handle increased power outputs.
• Exterior: Customization options to match aesthetics with performance.
• Charging & Starting: Reliable options for maintaining electrical integrity.
• Chips, Modules & Programmers: Tailor engine management for desired performance.
• Suspension & Chassis: Enhance handling to complement engine upgrades.
• Fluids & Filters: Keep everything running smoothly with essential fluids and filters.
• Emissions Equipment: Stay compliant with emissions standards.
• Axle & Driveline: Strengthen drivetrain components for durability.
• Digital Monitors: Keep tabs on engine vitals with precision monitoring.

This extensive selection of components not only supports the kind of ambitious projects like Barnett’s but also caters to a wide range of upgrade and maintenance needs for the 6.0L Powerstroke. Whether you’re looking to enhance performance, reliability, or both, these parts provide the foundation for a more powerful and efficient engine.

 

What are the lesser-known or less commonly discussed components available for the 6.0L Powerstroke?

Beyond the standard offerings, there are digital monitors, steering components, emissions equipment, and axle and driveline parts available, though these categories contain fewer products compared to others like lighting and air intake systems.

 

How many products are available in each category for the 6.0L Powerstroke?

The availability varies by category, with lighting options at 107, air intake systems at 94, exhaust systems at 88, turbo parts at 50, engine components at 44, and cooling systems at 38, among others.

 

What types of products or components are available for the 6.0L Powerstroke?

A wide array of products is available, including lighting, air intake systems, exhaust systems, turbo parts, engine components, cooling systems, fuel systems, and intercoolers. Other offerings include fuel injectors, transmissions, exterior components, charging and starting systems, chips, modules, and programmers.

 

What are the specific turbo parts and accessories available for the 6.0L Powerstroke engine?

At full tilt, the original 78,000-mile Garrett VGT builds 32 psi of boost. A fabricated air intake feeds the compressor inlet, while a high-temp silicone hot-side tube sends boost directly toward the intake elbow. One benefit of the engine being void of an intercooler is the fact that no pressure drop (i.e., boost loss) occurs, and better off-idle responsiveness is on tap.

For those looking to upgrade or replace components on their 6.0L Powerstroke engine, a variety of turbo parts and accessories are available to enhance performance and efficiency:

Turbo Components and Upgrades

• Injectors: Options range from individual premium stage injectors to remanufactured models with various nozzle sizes, catering to different power requirements.
• Turbochargers: From stock replacements to high-performance dual ball bearing models, there’s a solution for every need. These turbos promise improved boost and reliability.
• Compressor Wheels and Rebuild Kits: Upgraded billet compressor wheels and complete turbo rebuild kits are available, offering enhanced durability and performance.

Additional Accessories

• Intercoolers: For those seeking improved cooling efficiency, upgraded intercoolers are designed to maximize air density and engine performance.
• Fuel Return Kits: These kits help maintain consistent fuel pressure, crucial for optimal engine performance.

Performance Packages

• Complete Kits: Comprehensive packages, including non-VGT and VGT setups, provide everything needed for a robust upgrade.
• Heavy-Duty Options: From enhanced oil filtration systems to heavy-duty pushrods, these components are designed for those pushing their engines to the limit.

These options ensure that whether you’re maintaining stock performance or aiming for high-performance upgrades, there are products available to meet your needs. With the right components, the 6.0L Powerstroke can achieve exceptional power and reliability, tailored to any driving style or requirement.

 

What types of products are available for the 6.0L Powerstroke engine?

Once again keeping things as straightforward as possible, Barnett opted for the intake, tuner, exhaust approach to adding power (for now). The factory Garrett VGT is fed air via an intake he fabricated, and it produces more than 30 psi worth of boost thanks to custom tuning from Innovative Diesel. An SCT Livewire TS+ allows Barnett to keep tabs on boost, transmission, coolant and engine oil temp, FICM voltage, ICP, and various other key vitals. For exhaust, a custom-formed 3-inch system begins where the factory downpipe ends and culminates with a polished stainless turn-down tip out back.

Beyond Barnett’s strategic modifications, the 6.0L Powerstroke engine offers a plethora of product types for enthusiasts looking to enhance or maintain their vehicle’s performance. Here’s a breakdown of what’s available:

• Lighting Systems: Enhance visibility and style with a variety of options.
• Air Intake Systems & Filters: Improve airflow and engine efficiency.
• Exhaust Systems & Components: Optimize exhaust flow for better performance.
• Turbo Parts & Accessories: Boost power and responsiveness.
• Engine Components: Keep your engine running smoothly and reliably.
• Cooling Systems: Essential for maintaining optimal operating temperatures.
• Fuel Systems & Injectors: Ensure efficient fuel delivery and power.
• Intercoolers: Enhance turbo efficiency by cooling compressed air.
• Transmission Parts: Upgrade for better power transfer and durability.
• Exterior Accessories: Customize your vehicle’s look and functionality.
• Charging & Starting Systems: Reliable power from start to finish.
• Chips, Modules & Programmers: Fine-tune performance and efficiency.
• Suspension & Chassis: Improve handling and ride quality.
• Fluids & Filters: Maintain cleanliness and efficiency in all systems.
• Emissions Equipment: Stay compliant with regulations.
• Axle & Driveline Components: Enhance traction and power distribution.
• Digital Monitors: Keep an eye on vital statistics with precision.
• Steering Enhancements: Improve control and handling.

With such a wide array of options, owners can tailor their 6.0L Powerstroke to meet their specific needs, whether they’re seeking more power, better efficiency, or simply maintaining their vehicle’s performance. This diversity in product offerings ensures that every aspect of the engine and vehicle can be optimized to the owner’s preference.

 

What are some less common product categories for the 6.0L Powerstroke?

Some of the less common categories include digital monitors, steering components, and axle and driveline products, which have fewer options compared to more popular categories.

 

How many products are available in each category?

The product availability varies by category, with lighting having over 100 items, air intake systems and filters around 94, exhaust systems approximately 88, and other categories like turbo parts and engine components having fewer options.

 

What categories of products are available for the 6.0L Powerstroke engine?

There are various categories, including lighting, air intake systems and filters, exhaust systems and components, turbo parts and accessories, engine components, cooling systems, and more.

 

What are the goals and expectations of tuning a Crown Vic with a turbo system?

Goals and Expectations of Tuning a Crown Vic with a Turbo System

Tuning a Crown Victoria with a turbo system is all about transforming a standard vehicle into a high-performance machine. When undertaking such a project, there are several key goals and expectations:

1. Enhancing Horsepower and Torque

The main objective is to significantly increase the car’s horsepower and torque. For example, initial modifications might push the vehicle’s horsepower from 200 to over 350. This gain demonstrates the potential for raw power increases that a well-designed turbo system can deliver.

2. Optimizing Fuel Delivery and Efficiency

To support the turbo, the fuel system needs careful upgrading. This involves adding components like return-style systems and high-performance fuel injectors, ensuring that the engine receives ample fuel under various driving conditions. Proper tuning aims to maintain efficient fuel consumption while maximizing power output.

3. Ensuring Engine Reliability and Safety

It’s crucial to make sure that increased power doesn’t come at the expense of engine health. This involves setting optimal fueling and timing parameters to prevent issues such as knocking or detonation. Expectations include reliable performance under stress, thanks to adjustments that ensure safe temperature and pressure levels.

4. Testing and Fine-Tuning

Once the turbo and fuel upgrades are installed, thorough testing on a dynamometer is essential. The goal is to validate power gains and refine the vehicle’s performance profile. Collecting data on partial and full pulls helps in adjusting the setup to squeeze more power safely and efficiently.

5. Performance Validation through Real-World Conditions

The final expectation is that the vehicle will perform impressively not just in testing scenarios but also in real-world conditions. This involves street testing to ensure the enhancements translate into better acceleration, handling, and overall drive experience.

6. Exploration of Further Upgrades

After a successful tuning session, there can be room for additional modifications. The desire to push boundaries might lead to considering other enhancements, like more advanced turbo setups or engine replacements, to see just how far the Crown Vic can be transformed.

In summary, tuning a Crown Victoria with a turbo system is about maximizing performance, ensuring reliability, and achieving extraordinary driving dynamics. The combination of horsepower boosts, fuel optimization, and extensive testing creates a vehicle that’s not only more powerful but also more thrilling to drive.

 

How does the tuning process work for optimizing a turbocharged engine?

Optimizing a Turbocharged Engine: The Tuning Process Explained

When it comes to tuning a turbocharged engine, the process is methodical and crucial for maximizing performance safely. Here’s how it unfolds:

1. Initial Setup and Baseline Testing
   • The process begins by loading a startup tune into the engine’s control system. This baseline program allows the tuner to check if the engine runs smoothly at lower power levels.
2. Dynamometer (Dyno) Testing
   • The engine is placed on a dynamometer to simulate real-world conditions. Initial tests focus on part-throttle scenarios to ensure the engine behaves well without excessive load. At this stage, the goal is to verify that the engine’s air-fuel mixture is correct and stable.
3. Wide Open Throttle Calibration
   • After confirming that things look good at part-throttle, it’s time to test the engine at wide open throttle (WOT). Typically, this involves gradually increasing engine speed, starting from around 2,500 RPM up to 5,000 RPM or higher, depending on the setup.
4. Monitoring and Adjustments
   • Throughout the WOT testing phase, crucial parameters like fueling and ignition timing are closely monitored. The aim is to detect issues such as engine knock (pre-detonation), which can be detrimental to the engine’s health if not addressed promptly.
5. Power Optimization
   • Once safe operation is confirmed, finer adjustments are made to squeeze out more power. This may involve tweaking boost levels, fuel maps, and timing advances to enhance performance while maintaining reliability.

During the entire process, sophisticated tuning software and equipment are essential to accurately measure output and engine parameters, ensuring the turbocharged engine delivers optimum performance without compromising safety.

 

How do exhaust and fuel modifications contribute to increased horsepower in a Crown Vic?

How Exhaust and Fuel Modifications Increase Horsepower in a Crown Vic

When it comes to unlocking the full potential of a 2008 Ford Crown Victoria P71 Police Interceptor, the right combination of exhaust and fuel modifications can significantly elevate horsepower. By implementing these modifications effectively, you can nearly double the engine’s output, transforming it from a standard 200HP to an impressive 368HP.

Exhaust System Enhancements

1. Improved Exhaust Flow: Upgrading to a high-performance exhaust system reduces back pressure, allowing exhaust gases to exit the engine more efficiently. This improved flow enables the engine to breathe better, freeing up additional horsepower.
2. Turbocharging: Adding a small tailpipe turbo is a game-changer. A turbocharger compresses the air entering the engine, increasing the oxygen available for combustion. This results in more power being generated during each engine cycle.

Fuel System Upgrades

1. Fuel Injector Modifications: Enhanced fuel injectors deliver more fuel to the combustion chamber, complementing the increased air supply from the turbocharger. This ensures optimal fuel-to-air mixture for maximum power output.
2. Fuel Pump Adjustments: A more powerful fuel pump can support the higher fuel demands created by the engine modifications, maintaining consistent fuel pressure and flow.

The Result? Power and Performance

After these exhaust and fuel system modifications, the Crown Vic experiences a remarkable increase in horsepower. The interplay between the turbocharged air intake and the fuel system upgrades ensures that the engine runs efficiently and powerfully, making it ready for any high-speed pursuit.

Whether you’re a car enthusiast or a professional looking to enhance vehicle performance, understanding how these modifications work together provides valuable insights into achieving significant horsepower gains.

 

How does dyno testing help in evaluating the performance of a turbocharged vehicle?

How Dyno Testing Evaluates Turbocharged Vehicle Performance

When assessing the performance enhancements from a turbocharger, dyno testing plays a crucial role. This sophisticated testing provides detailed insights into how effectively a turbocharged vehicle utilizes forced induction for increased power output.

Understanding Turbochargers

Turbochargers function by harnessing exhaust gases to increase the volume of air entering the engine. This process begins with the exhaust flow activating a turbine wheel. Simultaneously, on the opposite end, an aluminum impeller wheel draws in and compresses fresh air. Both wheels are fixed on a precision-engineered shaft capable of spinning at speeds exceeding 100,000 RPM. The result is an impressive boost in intake pressure, potentially elevating engine performance significantly.

The Role of the Dyno

A dynamometer, or dyno for short, is an essential tool in quantifying this performance boost. By measuring the power output at various stages of tuning, a dyno test reveals how modifications translate into horsepower gains. During testing, sensors capture the engine’s output in real-time as the turbocharger’s increased air pressure feeds the engine. The data extracted highlights the incremental gains in horsepower, helping pinpoint exactly how much additional power the turbo is delivering—often a substantial increase, like 160 horsepower, from even modest boosts.

Benefits of Dyno Testing

• Precision Measurements:Dynos offer precise measurements of horsepower, torque, and overall engine efficiency.
• Optimization Guidance:The data aids in fine-tuning the turbo system and engine settings for maximal performance.
• Performance Validation:Real-time numbers validate the effectiveness of turbocharging modifications, ensuring they meet performance expectations.

In conclusion, dyno testing serves as an indispensable approach to evaluating how well a turbocharger enhances a vehicle’s performance, offering empirical evidence of power gains and guiding further optimization efforts.

 

What is the purpose of a scavenge pump in a turbo system?

What is the Role of a Scavenge Pump in a Turbo System?

A scavenge pump plays a critical role in certain turbocharger systems, particularly those with unique configurations. Here’s how it functions:

• Oil Return Assistance:For turbochargers mounted at a distance from the engine or positioned lower than the engine, gravity alone isn’t sufficient to move oil back to the engine’s oil pan. This is where the scavenge pump steps in, providing the necessary pressure to return the oil efficiently.
• Prevention of Oil Accumulation:Without a scavenge pump, oil could accumulate in the turbo’s housing, potentially leading to oil leaks and turbocharger damage. The pump ensures that oil is consistently and effectively removed, maintaining optimal performance.
• Maintaining Engine Health:By facilitating proper oil circulation, a scavenge pump helps keep the turbo system and engine running smoothly, preventing overheating and excessive wear.

In essence, a scavenge pump is essential for maintaining the performance and longevity of a turbocharger system, especially in setups where gravitational oil return is not feasible.

 

How do you route plumbing for a turbocharger installation?

How to Route Plumbing for a Turbocharger Installation

Installing a turbocharger in a vehicle involves a detailed process of routing plumbing, which is crucial for optimal performance. Here’s a step-by-step guide to help you through it:

1. Understand the Turbo Components

• Hot Side: This involves the exhaust that powers the turbo.
• Cold Side: Fresh air is compressed and sent to the engine.

2. Connect the Exhaust to the Turbine

First, direct the exhaust from the engine into the turbine. This will spin the turbocharger blades and generate the necessary boost pressure. Be sure to mount the turbo securely to handle the force.

3. Pathway for Fresh Air

Next, connect the turbocharger’s compressor housing to the engine intake. This often involves routing a series of tubes from the front of the vehicle to the engine.

• Tip: Utilize straight runs of tubing with minimal bends to ensure efficient airflow.

4. Building a Custom Y-Pipe (If Needed)

If you’re working with a V-configuration engine, you’ll need to merge the exhaust from both banks:

1. Start with two 45-degree pipe bends.
2. Cut and join them to form a Y-shape.
3. Connect these to a single pipe leading to the turbo.

5. Mounting the Turbo

Once you’ve laid out your piping, mount the turbo. Ensure that the cold charge pipe and exhaust lines are optimally placed to eliminate space constraints.

6. Set Up the Oiling System

Turbochargers require a steady supply of oil to function:

• Oil Feed Line: Provides pressurized oil from the engine to the turbo.
• Oil Return Line: Sends oil back to the engine.

If your turbo is mounted below the oil level, install a pump to return oil efficiently.

7. Final Assembly

Complete the setup by securing all connections and welding where necessary. This ensures that there are no leaks and that the system is robust enough to handle the pressures involved.

By following these steps, you can successfully route the plumbing required for a turbocharger installation, optimizing both airflow and engine performance.

 

What is the process of installing and setting up a turbo on a Crown Vic?

At full tilt, the original 78,000-mile Garrett VGT builds 32 psi of boost. A fabricated air intake feeds the compressor inlet, while a high-temp silicone hot-side tube sends boost directly toward the intake elbow. One benefit of the engine being void of an intercooler is the fact that no pressure drop (i.e., boost loss) occurs, and better off-idle responsiveness is on tap.

Turbo Installation Process

The journey begins with strategically positioning the turbo where the driver’s side muffler used to be. This clever placement not only maximizes space but also maintains a low-profile look under the hood. The exhaust was meticulously cut off behind the catalytic converters, making room for the turbo mount.

Plumbing and Piping

With the turbo in place, the next step involves routing the exhaust and cold charge pipes. The exhaust connects into the turbine, spinning the turbocharger, while fresh air from the compressor housing is directed to the engine. This setup eliminates the need for an intercooler, maintaining boost levels without any pressure loss.

Custom Fabrication

For a streamlined exhaust flow, a custom Y-pipe was fabricated from 45-degree bends, which channels exhaust from both banks into a single two-and-a-half-inch pipe. This DIY approach keeps costs down and ensures a perfect fit for the system.

Oil System Setup

Turbos require a steady supply of pressurized oil. Here, a scavenge pump was mounted to the frame to assist in returning oil to the engine, crucial for remote or low-mounted turbos. This ensures the turbo is adequately lubricated, preventing any potential damage from oil starvation.

Monitoring and Performance

To keep tabs on the turbo and overall engine health, an SCT Livewire TS+ monitors key vitals such as boost, transmission, coolant and engine oil temperature, and more. This real-time data is essential for fine-tuning performance and ensuring everything runs smoothly.

For exhaust, a custom-formed 3-inch system begins where the factory downpipe ends and culminates with a polished stainless turn-down tip out back.

Final Adjustments and Goals

The project wraps up with the installation of a wastegate and the necessary wiring for the scavenge pump. With an upgraded fuel system, including a new pump and larger injectors, the goal is to achieve a robust 400 horsepower at the wheels. The combination of custom tuning and strategic upgrades promises a significant boost in performance.

To protect his investment in a fresh oil cooler, a coolant filtration system was installed, bypassing engine coolant through a 27-micron WIX filter. This prevents larger particles from clogging the oil cooler, safeguarding the engine’s longevity.

By maintaining a balance between customization and practicality, this setup not only enhances performance but also ensures reliability and durability, making it a compelling upgrade for any enthusiast.

 

How can you almost double the horsepower of a 2008 Ford Crown Victoria Police Interceptor?

Even though the 6.0L more than doubled the car’s power output, Barnett’s original intention for his Crown Vic hasn’t changed—he still plans to use it as his summertime commuter. With the smooth-riding four-door capable of achieving 20 mpg, it’s hard to argue with that. And with the 5,000-pound sedan also capable of running mid-12s, it’s hard not to want to be behind the wheel. If you encounter Matthew Barnett’s unique creation out on the highway, be sure to move over. He’ll be cruising in the fast lane.

But how exactly did this transformation come to life? The key to unlocking such impressive power lies in several strategic modifications. A small tailpipe turbo was added, along with carefully calibrated exhaust and fuel system enhancements. These changes not only boosted the horsepower from a modest 200HP to an exhilarating 368HP but also maintained the vehicle’s drivability and fuel efficiency.

Steps to Boosting Power:

1. Turbo Installation: A compact turbocharger was fitted to the tailpipe, a critical component in increasing air intake and boosting power.
2. Exhaust Modifications: Upgrades to the exhaust system allowed for better airflow and performance.
3. Fuel System Enhancements: Adjustments were made to fuel delivery, ensuring the engine could support the increased power output without compromising efficiency.

These enhancements ensure that while the Crown Vic is ready for high-speed pursuits, it still serves as a practical and enjoyable ride for everyday use. Whether you’re a car enthusiast or someone seeking a unique, powerful commuter, this transformation showcases the potential of innovative automotive engineering.

 

How does a turbocharger function to increase engine power?

At full tilt, the original 78,000-mile Garrett VGT builds 32 psi of boost. A fabricated air intake feeds the compressor inlet, while a high-temp silicone hot-side tube sends boost directly toward the intake elbow. One benefit of the engine being void of an intercooler is the fact that no pressure drop (i.e., boost loss) occurs, and better off-idle responsiveness is on tap.

To understand how this process amplifies engine power, it’s essential to grasp the fundamentals of turbocharger operation. Turbochargers are forced induction devices that utilize exhaust energy to push more air into the engine. Here’s how it works:

• Exhaust Flow: Exhaust gases from the engine’s header drive the blades of a turbine wheel.
• Turbine Action: This turbine wheel, in turn, spins an aluminum impeller wheel on the opposite side.
• Air Compression: The impeller draws in and compresses fresh air, allowing more oxygen into the combustion chamber.

These wheels are mounted on a precision shaft that can rotate at speeds exceeding 100,000 RPM. The increased air density in the engine enables it to burn more fuel, resulting in more power output. High-performance turbos can ramp up intake pressure by as much as 50 pounds, significantly boosting engine performance.

By combining these technical elements with the specific setup of the Garrett VGT, you get an efficient system that maximizes power without the downsides of pressure loss, thanks to the absence of an intercooler. This synergy of components ensures optimal engine responsiveness and power delivery.

 

What are some considerations when installing a turbocharger on a Crown Vic?

Robbed out of an ’05 Ford Shuttle Bus, the 6.0L Power Stroke under the cowl hood of Matthew Barnett’s ’07 Crown Vic was treated to a set of ARP head studs and a new oil cooler prior to being shoehorned into place. With space at a premium, Barnett was forced to retain the sedan’s original cooling system, along with foregoing the use of an intercooler. All told, the engine swap and retention of the 5R110 TorqShift added roughly 800 pounds to the car’s bottom line.

Turbocharging Considerations

When it comes to turbocharging a vehicle like the Crown Vic, there are several key factors to keep in mind:

• Space Constraints: The limited space under the hood meant creative solutions were necessary. The charge pipe was ingeniously routed to help cool the air naturally as it travels, effectively compensating for the lack of an intercooler.
• Exhaust Dynamics: The turbocharger capitalizes on exhaust energy, with exhaust flow driving a turbine wheel. This setup efficiently crams more air into the engine, enhancing performance.
• Precision Mechanics: Inside the turbo, both turbine and impeller wheels are mounted on a shaft that can spin at incredible speeds, often exceeding 100,000 rpm. This precision requires careful installation and balancing to avoid potential issues.
• Expertise and Guidance: With the complexities involved, seeking advice from seasoned turbo installers is invaluable. Their insights can ensure that both the hot and cold sides are routed optimally, preventing performance bottlenecks.

The blend of these considerations with the robust Power Stroke engine provides the Crown Vic with a unique balance of power and innovation.

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