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Above: Custom-fitted a used front-mounted Intercooler, permitting
(planned) maximum of 16 -18 PSI Boost -- by Omni Cool (a
California-based company that is no longer in business) -- see custom mount installation
photos
here. While this intercooler is a approximately the same 300 to 350
CFM capacity as
a stock MoPar cooler, its efficiency is enhanced by constant fan-forced
airflow and by the addition of an ERL Aquamist 1S Injection system (see below).
Dual (inlet and outlet) temperature gauges are
installed to monitor intercooler efficiency. |
Above:
Added a used FoMoCo front-mounted Oil
Cooler (p/n
EOAE-6K761-AB) with sandwich (thermostatic) block adaptor (p/n EOAE-6881-AA).
AN-10 fittings and .625-inch oil lines. Unit was originally fitted on
mid-70's Ford 460 Police Interceptors. This cooler is also front-mounted (between
the radiator and grill on the passenger side) and is
installed to lower oil temps in towing and severe stop-and-go city driving
or towing conditions. |
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A Design
Engineering, Inc's Versa-Shield
protects Bosch Starter motor. |
DEI's Cool
Tube aluminized-fiberglass, split-loom provides 500 F thermal and
physical protection for various lines running near heat sources. The
standard '89-90 Turbo minivan firewall heat shield was considered, but not
installed. |
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The entire "piggyback" radiator/condensor assembly is slightly offset (with special stand off
spacers); longer on the driver's
side to accommodate needed space for front-mounted intercooler and oil cooler lines.
In 1993, the 2.5L-4's shared the same crossflow radiator and fan assembly
with the various V6's.
Unlike earlier 89-90 Turbo vans, which featured
"side-by-side" radiator & A/C condenser with separate fans,
the stacked or piggyback arrangement utilizes a larger diameter two-speed
fan with the full-width A/C condenser residing in front of the radiator. The
intercooler and oil cooler are both placed forward of the A/C condenser/radiator/fan
assembly. See installation photos. |
Water-injection
from ERL Aquamist
features High Pressure (6-bar) Injection pump (Type: System 1S).
Inspired by the turbocharged,
WWII fighter plane, P-47).
Presently the Aquamist is adjusted to fire at 8 PSI via its pressure-actuated switch. Injector
pump is fed from stock windshield washer
reservoir, with the supplied stainless steel, 100-micron water filter. Note:
This idea is
hardly new. The 1962
Oldsmobile Jetfire Turbo V-8 used water/alcohol injection so that it
could retain the high compression ratio of the naturally aspirated version.
I installed
the high-pressure Aquamist
1S installation kit consisting of: pump, relay & fuse, and adjustable
(Hobbs-type) boost-pressure switch on the firewall on the passenger
side. |
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| The 0.6mm x 4mm Injector nozzle is tapped into the intercooler return pipe,
just ahead of the throttle body. Intercooler inlet (Charge Air) temp sensor is visible to left of Aquamist injector
nozzle. View
Aquamist 1S parts list.
The injection of any liquid will cool the intake charge due to the
heat it absorbs as it evaporates. The most convenient liquid to inject for
this purpose is usually more gasoline, which is why most turbo engines suck
so much fuel during hard driving.
The next most convenient liquid is
windshield-washer fluid. The reservoir already exists, and the liquid
doesn't freeze. The idea here is to reduce the
temperature of the intake charge air during turbo boost so that the fuel mixture
need not be enriched and can remain at the stoichiometric ratio that permits
efficient operation of the catalytic converter.
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Above is a Chrysler diagram showing the effects of
Anti-Detonation sensing
(ECM timing reduction or "pull-back") due to lower octane fuel. A Chrysler
DRB II scanner is used to monitor knock sensor signal output.
The
Aquamist water-injection system's main function is to completely suppress detonation
caused by high temperature and pressure developed within the combustion
chamber when the effective compression ratio has been taken beyond the
pre-ignition point by turbo charging. It does this by spraying through a
high-pressure magnetic piston pump, a finely atomized mist of water and
alcohol through the throttle body, causing the (turbo) charged intake air
temperature to drop, significantly (usually 50 to 100 deg F) decreasing the possibility of detonation.
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With
water-injection, the result is low emissions
(production of oxides of nitrogen) even during full-throttle driving. And combustion chambers, valves and spark plugs stay
cleaner. In typical driving, the reservoir is refilled at every fuel
stop with distilled water (which reduces the potential for mineral deposit clogging).
When the fluid runs out, a low-fluid indicator sensor mounted within the
windshield washer reservoir, signals the dual boost control system to dial
back the boost to avoid destructive detonation.
I swapped a
used minivan reservoir with the low-level indicator sensor and added a gauge cluster
bulb, as wiring and plugs were already present within the existing
under-hood harness. |
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