2006 Ford Mustang GT Turbonetics CARB Legal Turbo System
On The Dyno
After installing Turbonetics' CARB-legal, S197 turbocharger system on an '06 Mustang GT (stock engine, five-speed transmission), we definitely were anxious to see exactly what type of "clean" rear-wheel power and torque the huffer makes. For smog purposes and to provide general safety margins against detonation when California's 91-octane fuel (minimum octane permitted for the turbo system) is used, the company's tuning is a lot more conservative than non-smog-legal and custom calibrations we've worked with for power adders. However, although custom dyno tunes tend to be slightly leaner on the fuel side and have more timing advance, the plug-and-play PCM change that Turbonetics created is on the money overall, as both horsepower and especially torque levels show more-than-considerable gains with the bolt-on system.
Before dyno testing, Turbonetics'...
Before dyno testing, Turbonetics' "smog-legal" calibration is loaded into the 'Stang's PCM via a DiabloSport Predator handheld flash tuner, which is included with each kit. The plug-and-play tune is the result of more than a year of development by engineers at Turbonetics. They were challenged with improving power and torque on an '05-'09 Mustang GT's stock pump-gas (91-octane), Three-Valve, 4.6-liter engine without increasing combustion or evaporative emissions; more than 150 different parameters had to be adjusted to make the system operate properly.
The '05-'09 S197s, many of which are which are now beyond their warranty periods, have become attractive candidates for modification. Moreover, California performance enthusiasts have shied away from adding turbo systems on their Ponies for fear of incurring the wrath of CARB. Turbonetics has put an end to the apprehension, as this turbo system gives stock 'Stangs the ability to run with the big dogs and pass state emissions inspections with flying colors.
Upon completion of the installation,...
Upon completion of the installation, this is the decal that is affixed to an S197's radiator cover, letting state smog inspectors and all others know that your Mustang's boost is backed by the board. Turbonetics' V-6 Mustang turbo system (PN 15184) also has been given CARB's approval, and feeds six-popper Ponies enough oats to make rear-wheel steam that rivals their V-8 brothers power, in bone-stock trim.
These are our project 'Stang's...
These are our project 'Stang's OEM catalytic converters, which remain intact and unmodified with this CARB-legal turbo system. Despite the performance gains that come with removing these pieces and replacing them with H- or X-shaped crossover tubing, tampering with or removing cats is a huge no-no in any state. Without the converters, the Turbonetics Mustang system wouldn't stand a chance at being validated by CARB.
The only cutting is done on...
The only cutting is done on the 'Stang's factory H-pipe tubing 21/2 inches back from the welds on each cat. With the exhaust section removed,....
....Ricardo installs the turbo...
....Ricardo installs the turbo system's Y-pipe, which routes exhaust gas to the up-pipe and into the compressor housing on the turbocharger.
Positioning the downpipe is...
Positioning the downpipe is a trial-and-error affair, as the 3-inch tube must be wrangled spot-on through a tight passageway between the engine and chassis. Notice the lip incorporated in the end of the pipe. Turbonetics includes a V-band clamp with the kit, which is used to secure the tube to the turbo's exhaust housing.
This wastegate tubing tucks...
This wastegate tubing tucks closely below the passenger-side A-arm and into the turbo system's exhaust tube. All of the stainless-steel/hot-side and aluminum/cold-side plumbing in Turbonetic's system is fully TIG welded. The system is designed with completely slip-fit pipes that are secured with 2.5-inch band clamps.
Two brackets are affixed to...
Two brackets are affixed to the transmission and clamped on each side of the Y-pipe tubing, and help keep the tubing structure rigid and free of vibration against the Mustang's chassis.
This is the under-car view...
This is the under-car view of the completed myriad of the turbo kit's hot and cold tubing. A single Y-style tube channels exhaust from the downpipe and out to the tailpipes and mufflers. While fitment is good, the plumbing does require some finessing to install. It is strongly advised that you keep the clamps loose until all clearances and the final fitment are confirmed when installing this system.
Turbonetics' external Evolution...
Turbonetics' external Evolution wastegate is outfitted with a spring that regulates boost at a maximum 9 psi. In the event boost falls a bit shy of the number upon initial startup and testing, the 'gate can be adjusted by loosening the jam nut and turning the Allen screw clockwise in small increments to raise boost pressure.
Turbocharged air is cooled...
Turbocharged air is cooled with a four-core, front-mount, air-to-air intercooler. The Spearco unit is huge (measuring 3 1/2x12 inches), but it bolts in cleanly behind the front bumper support using brackets that are included with the turbo system.
In addition to the bigger...
In addition to the bigger fuel injectors, an MSD fuel-pump controller is provided to ensure air/fuel remains on the rich side when boost climbs. The controller is pre-programmed by Turbonetics, so installation is as simple as mounting, wiring, and providing a boost signal for it to function.
A small amount of bench assembly...
A small amount of bench assembly is required before mounting the turbocharger. Ricardo adds the included fittings for oil and coolant lines, and then places the turbocharger on a stainless-steel gasket that sits on its mounting plate....
....Mock fitting the turbo...
....Mock fitting the turbo is mandatory, as the compressor housing must be clocked for proper discharge-to-intercooler tubing alignment.
CARB mandates using the factory's...
CARB mandates using the factory's airbox for the turbocharger system, for the hydrocarbon absorption mat below its lid. However, the stock paper air-filter element is replaced with this drop-in, high-flow piece. A clean, leak-free airbox-to-turbocharger connection is made with a silicon coupling hose that also comes with the kit.
Tubing and such make for a...
Tubing and such make for a crowded area at the front of the engine bay, and thus requires relocating an S197's coolant reservoir. A clean aluminum replacement canister comes with the Turbonetics package. The reservoir gets its footing from bands that secure the power-steering-fluid container on the driver side of the engine compartment.
Once the turbo is final-mounted...
Once the turbo is final-mounted and all of the tubing and clamps are confirmed secure and tight, this is how an S197's engine bay looks with Turbonetics' CARB-legal turbo system installed. This 60mm system can be upgraded to 78mm and support more than 700 rear-wheel horses. But, of course, a stout engine with forged internals is required, and that upgrade technically is not approved by the board.