While this 60mm T-40655 ceramic...
While this 60mm T-40655 ceramic ball-bearing turbocharger is one of the highlights in Turbonetics' new single-turbo system for '05-'09 Mustang GTs (PN 15168-1; $7,599), the fact that this bolt-on upgrade is 100 percent legal for use in all 50 states is the much bigger deal.
We've extolled the virtues and pitfalls of adding power adders to '79-'10 Mustangs for what honestly seems like an infinite number of times. Our work with nitrous, blowers, and turbo systems always includes giving you specifics on the amount of rear-wheel horsepower and torque they help generate. However, anti-pollution standards established by the California Air Resources Board put Cali enthusiasts in a tough spot, as installing one of the Big Three power adders could put them at odds with the authorities. Officially, CARB's "smog laws," as the regulations are known throughout the world of high performance, are "designed to protect the environment and public health, and provide safe, clean air to all Californians by reducing emissions of air contaminants through the fair, consistent, and comprehensive enforcement of air pollution laws, and by providing training and compliance assistance," according to the organization's website (www.arb.ca.gov).
Most products designed to enhance an engine's performance require significant changes in fuel volume and timing advance that could cause engines to produce and emit carbon-dioxide levels greater than the CARB's accepted maximums for cars or trucks, based on their engine size. These limits create a catch-22 for enthusiasts craving performance, mainly because non-CARB-approved engine parts make bigger steam than smog-legal parts, and the board is extremely uptight about the amount of CO2 vehicles emit (during an emissions test). CARB's tough tests focus primarily on a fuel-injected engine's "cold-start" emissions output, which usually is predi-cated by the engine's basic running condition and emissions control equipment, as well as the calibration in the PCM.
Our '06 test Pony's bone-stock,...
Our '06 test Pony's bone-stock, 4.6-liter Three-Valve engine laid down a paltry 272.94 horses and 298.16 lb-ft of torque at the rear wheels in baseline tests. Turbonetics' 9-psi system should bring those numbers up considerably. We'll see when we get this baby on GTR High Performance's Dynojet chassis dyno.
Earning a coveted EO authorization number is a long and expensive process that most aftermarket companies don't pursue. From a dollars-and-cents perspective, the returns from sold products just don't justify the overall investment for making parts to meet the board's restrictive standards and still perform in the same manner as non-compliant hardware.
The hard reality is in order to be profitable, aftermarket performance-parts manufacturers must build for the masses in the entire U.S. and beyond, not exclusively for Mustang fans in the Golden State. And at the end of the day, improving a Pony's performance is what we're all about, and it's one of the main reasons why non-CARB-legal products are predominately featured in our tech reports.
As you know, making big steam usually is our primary goal during these types of exercises. Honestly, CARB's clean-burn attitude is the least of our concern. However, this doesn't mean we have absolutely no compassion for 'Stangbangers in California or any other state with tough smog laws. However, we're interested in working with new, cool CARB-approved hardware for late-model Mustangs. Faithful readers on the West Coast know such opportunities have been few and far between for many years. So when we received word that a turbocharger setup for late-model 'Stangs had received CARB's blessing, we knew right away that installing one and giving you all the intelligence was mandatory!
Ricardo Topete of GTR High...
Ricardo Topete of GTR High Performance in Rancho Cucamonga, California, performed the installation for us, which starts with securing the Mustang on a twin-post hoist, removing the battery completely, and then taking off the Pony's front bumper cover.
The actual hardware in Turbonetics' '05-'09 Mustang GT turbo system (PN 15168-1; $7,599) really isn't "new," per se. The fact that this bolt-on boost kit is the first of its kind to be approved by CARB makes it worth covering.
We found a perfect candidate for testing in a stock, five-speed, '06 Mustang GT that GTR High Performance regularly services. Installing the turbo system is quite involved (the kit's detailed manual is nearly 100 pages long); it isn't a recommended DIY install unless you have a twin-post hoist and complete shop facilities at home. GTR co-owner Ricardo Topete handled the wrenchwork and dyno testing for us.
While we can't show every step of the bolt-on process, these photos and captions depict some of the CARB-legal turbo system's key features, important facets of its installation, and our dyno results. One thing we really like about this kit is that all of its brackets attach to existing factory positions (holes, studs, and so on), so there's no drilling or elaborate fabricating required, and all of an S197's original accessory equipment, including air conditioning, is unfazed by the turbo system.
Removing the coolant reservoir...
Removing the coolant reservoir also is required. Ricardo uses a clean five-gallon pail to recover the antifreeze, as it will be reused once the turbo system is completely installed. The radiator brackets also are redrilled to relocate the radiator 3/4 inch forward for additional clearance.
The PCM is briefly removed...
The PCM is briefly removed to facilitate tucking the main engine harness into a pocket of space along the inside of the passenger-side fender. Having the wires out of the way eases positioning the turbo kit's 3-inch downpipe a bit. An air-conditioning line also is bent below the radiator at this time, for sufficient up-pipe clearance.
fuel_injectors.jpg)
We mentioned fuel volume being...
fuel_injectors.jpg)
We mentioned fuel volume being an integral part of performance/engine upgrades for late-model, EFI Mustangs. Turbonetics provides new 39-lb/hr fuel injectors with each kit, a set of eight Autolite HT0 (colder heat-range) spark plugs, and the all-important PCM calibration (uploaded via a DiabloSport Predator handheld flash tuner prior to hitting the dyno) that keeps combustion and evaporative emissions within CARB's accepted parameters, despite higher fuel flow.
Turbochargers included in...
Turbochargers included in most Mustang systems are both lubricated and cooled only by engine oil. Turbonetics takes one step further and adds additional water cooling for its S197 system. Hoses (CARB requires replacement hoses to have SAE J30R9 "zero permeability" rating) and these two AN -6 T adapters are incorporated into the factory heater plumbing to transfer coolant into and out of the turbo housing.
On the oil side, yes, punching...
On the oil side, yes, punching a hole in the pan (for a drainback line) is required. A punch and 3/8-inch NPT tapping tool are included. Note the use of thick grease on the tap, which helps keep metal shavings out of the oil pan when threads are being cut.
Since the downpipe (the turbo's...
Since the downpipe (the turbo's main hot-side tube) runs next to and below the passenger side of the engine, all wiring in those areas (starter, crank sensor, and so on) must be relocated or protected with tubing wrap. Wrapping wires and tubes is a tedious process, but it prevents damage to wiring due to extreme heat from the exhaust.