Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on June 16, 1988.
As of Monday, December 17th, 2018 this Executive Order has not been overturned or superceeded.

Approved Parts

Part NumberModelsModification
Model 6.9L/7.3L1983-1987 model year Ford Motor Company vehicles powered by a 6.9L Navistar International heavy-duty diesel engine and 1988 model-year Ford Motor Company vehicles powered by a 7.3L Navistar International heavy-duty diesel engine.Modifications to the OEM emission-related parts due to the installation of the turbocharger include replacement of air cleaner assembly and replacement of the OEM exhaust system with a 3" diameter exhaust system.

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-180
  • Executive Order 180 / D180
  • ARB # D-180
  • Executive Order No: D-180
  • C.A.R.B. No. D-180
  • Resolution D-180
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-180 PDF

D-180 Document:



                                   .                        (Page 1 of 2)
                              State of California
                              AIR RESOURCES BOARD

                              EXECUTIVE ORDER D—180
                 Relating to Exemptions under Section 27156
                            of the Vehicle Code



                               THE TURBO SHOP
                     TURBOCHARGER KIT MODEL §.9£/7.3L


Pursuant to the authority vested in the Air Resources Board by Seciion 27156
of the Vehicle Code; and

Pursuant to the authority vested in the undersigned by Sections 39515 and
39516 of the Health and Safety Code and Executive Order G—45—5;

IT IS ORDERED AND RESOLYED:    That the installation of the add—on
turbocharger kit mode! 6.9L/7.3L manufactured by The Turbo Shop using an
Allled Signal Turbocharger mode! No. TO4B with an A/R ratic of 1.0 has been
found not to reduce the effectiveness.of required motor vehicle poliution
control devices and, therefore, is exempt from the prohibitions of Section
27156 of the Vehicle Code for installation of 1983 through 1987 model—year
Ford Motor Company vehicles powered by a 8.9L Navistar International heavy—
Auty diese! engine and 1988 model—year Ford Motor Company vehicles powered
w; a 7.3L Navistar international heavy—duty diese! engine.

Modifications to the OEM emission—related parts due to the installation of
the turbocharger include replacement of air cleaner assembly and
replacement of the OEM exhaust system with a 3" diameter exhaust system.

This Executive Order is valld provided that instailation instructions for
this device will not recommend tuning the vehicle to specifications
different from those listed by the vehicle manufacturer.

Changes made to the design or operating conditions of   the device,   as
exempted by the Air Resources Board, that adversely affect the performance
of a vehicle‘s poliution control system shall invalidate this Executive
Order .

Marketing of this device using an identification other than that shown in
this Executive Order or marketing of this device for an application other
than those |isted in this Executive Order shall be prohibited unless prior
approval is obtained from the Air Resources Board.  Exemption of a kit shall
not be construed as an exemption to sel!, offer for sale, or advertise any
component of a kit as an individual device.
                                                                               m


THE TURBO SHOP                                      EXECUTIVE ORDER D—180
TURBOCHARGER KIT MODEL 6.9L/7.3L                    (Page 2 of 2)




This Executive Order does not constlitute any opinion as to the effect that
the use of this device may have on any warranty elther expressed or implled
by the vehlcle manufacturer.

TH1IS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATION, ACCREDITATION,
APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE AIR RESQOURCES BOARD OF ANY
CLAIMS OF THE APPLICANT CONCERNING ANTI—POLLUTION BENEFITS OR ANY ALLEGED
BENEFITS OF THE TURBO SHOP TURBOCHARGER KIiT MODEL 6.9L/7.3L.

No claim of any kind, such as fiApproved by Air Resources Board" may be made.
with respect to the action taken herein in any advertising or other oral or
written communication.

Section 17500 of the Business and Professions Code makes untrue or
misleading advertising unlawful, and Section 17534 makes violation
punishable as a misdemeanor.                              —

Section 43644 of the Health and Safety Code provides as follows:

     "43644.   (a)   No person shall   install, seill, offer for sale, or
     advertise, or, except in an application to the state board for
     certification of a device, represent, any device as a motor
    _vehlcle pollution control device for use on any used motor
     vehicle unless that device has been certified by the state board.
     No person shall sell, offer for sale, advertise, or represent any
     motor vehicle poliution control device as a certified device
     which, in fact, is not a certified device.  Any violation of this
     subdivision is a misdemeanor."

Any apparent violation of the conditions of this Executive Order will be
submitted to the Attorney General of California for such action as he deems
advisable.                                    .
                                             y EP
Executed at El Monte, California, this           day of June 1988



                                           ////}/J/a/ ,{//%‘/
                                          K. D. Drachand, Chief
                                          Mobile Source Division


                    State of California
                    AIR RESOURCES BOARD




    EVALUATION OF THE TURBO SHOP ADD—ON TURBOCHARGER KIT
  MODEL 6.9L/7.3L FOR INSTALLATION IN 1983—1987 MODEL—YEAR
     FORD MOTOR COMPANY VEKICLES POWERED BY A 6.9 L1TER
    NAVISTAR INTERNATIONAL HEAVY—DUTY DIESEL ENGINE AND
   1988 MODEL—YEAR FORD MOTOR COMPANY VEHICLES POWERED BY
A 7.3 LITER NAVISTAR INTERNATIONAL HEAVY—DUTY DIESEL ENGINE




                        June, 1988


                                                           June,   1988




            EVALUATION OF THE TURBO SHOP ADD—ON TURBOCHARGER KIT
          MODEL 6.9L/7.3L FOR INSTALLATION IN 1983—1987 MODEL—YEAR
             FORD MOTOR COMPANY VEHICLES POWERED BY A 6.9 LITER
            NAVISTAR INTERNATIONAL HEAVY—DUTY DIESEL ENGINE AND
           1988 MODEL—YEAR FORD MOTOR COMPANY VEKICLES POWERED BY
        A 7.3 LITER NAVISTAR INTERNATIONAL HEAVY—DUTY DIESEL ENGINE




                                     by

                           Mobile Source Division

                            State of California
                            AIR RESOURCES BOARD
                            9528 Telstar Avenue
                            El Monte, CA 91731


(This report has been reviewed by the staff of the California Air Resources
Board and approved for publication.  Approval does not signify that the
contents necessarily reflect the views and policies of the Air Resources
Board, nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.)


                                     SUMMARY



           The Turbo Shop has applied for exemption from the prohibitions    in

Vehicle Code Section 27156 for their add—on turbocharger kit Mode! 6.9L/7.3L

designed for 1983—1987 Ford Motor Company vehicles which are powered by the

Navistar    International 6.9 liter heavy—duty diese! engine and 1988 model—

year Ford Motor Company vehicles powered by a 7.3 liter Navistar

International heavy—duty diesel engine.

           The Turbo Shop has submitted a completed application and all   the

re&ulred information as well as comparative exhaust emissions data which

shows that their kit does not have a significant adverse effect on the

emissions from the vehicles described above.     Testing performed at the

Haagen—Smit Laboratory cénfirmed the results of the tests performed by the

Turbo Shop.

           The staff recommends that the Turbo Shop be granted an exemption for

their add—on turbocharger kit and that Executive Order D—180 be    issued.


                                                CONTENTS




                                                           Page Number

SUMMARY                                                         1

CONTENTS                                                       1i

1.          NTRODUCT                                            1

DT.                 N      LON                                  1

111.        RECOMMENDAT I        ON                             1

IV.         TURBOCHARGER KIT DESCRIPTION                        2

v.          TURBOCHARGER KIT EVALUATION                         3

VvI.            1          1ON                                  5



 PPEND 1C   I

APPENDIX A              Installation Instructions               6

APPENDIX B               identification Labe!                  13

APPENDIX C              Test Program                           14


               EVALUATION OF THE TURBO SHOP ADD—ON TURBOCHARGER KIT
             MODEL 6.9L/7.3L FOR INSTALLATION IN 1983—1987 MODEL—YEAR
                FORD MOTOR COMPANY VEHICLES POWERED BY A 6.9 LITER
               NAVISTAR INTERNATIONAL HEAVY—DUTY DIESEL ENGINE AND
              1988 MODEL—YEAR FORD MOTOR COMPANY VEHICLES POWERED BY
           A 7.3 LITER NAVISTAR INTERNATIONAL HEAVY—DUTY DIESEL ENGINE

[.          NTRODUCT I ON

           The Turbo Shop of 940 West Manchester,   Inglewood, California 90301,

has applied for exemption from the prohibitions of Vehlicle Code Section

27156 for their add—on turbocharger kit Model! No. 6.9L/7.3L for 1983—1987

Ford Motor Company vehicles powered by the 6.9 liter Navistar      International

heavy—duty diese! éngine and 1988 model—year Ford Motor Company vehicles

powered by a 7.3L Navistar    International heavy—duty engine.

           The Turbo Shop has submitted a completed application, all    the

necessary information and comparative exhaust emissions data.       Also,

confirmatory testing was performed at the Haagen—Smit Laboratory.

11.           CLUS   I

           Based on the submitted information and the comparative exhaust

emissions tests performed on a 1987 Ford F—250 heavy—duty diesel       truck at

the ARB and Olson Engineering Inc., the staff concludes that the

Installation of the Turbo Shop turbocharger kit Mode! 6.9L/7.3L will          not

have a significant adverse effect on the exhaust emissions from the vehicles

for which the exemption has been requested.

1M .       RECOMMENDAT IONS

           The staff recommends that the Turbo Shop be granted an exemption for

its turbocharger kit for use on 1983—1987 Ford Motor Company heavy—duty

vehicles powered by the 6.9 liter Navistar    International   heavy—duty diese!

engine and 1988 model—year Ford Motor Company vehicles powered by a 7.3L

Navistar    International heavy—duty engine, and that Executive Order D—180 be

issued.


IV.         TURBOCHARGER KIT DESCRIPTION

            The purpose of the Turbo Shop turbocharger system is to increase the

power output of the engine by     increasing the volumetric efficiency of      it by

compressing the     intake charge to pressures above that of the atmosphere.

This   increased pressure allows a greater charge density to enter the

combustion chamber providing more oxygen for combustion.         The maximum fue!

delivery is slightly increased (1/4 of a turn)        in order to maintain proper

air—fuel!    ratios with the increased air flow from the turbocharger when      it   is

providing positive manifold pressure (boost).

            The major components of the system include a 1.0 A/R ratio

Allied Signal Mode! No. TO4B turbocharger, custom intake adaptors, 3"

diameter exhaust tubing, air cleaner assembly, brackets, hoses and the

hardware necessary to complete the      installation.    The OEM exhaust system is

replaced by a 3" diameter exhaust system.

            Maximum positive manifold pressure is limited to 10 psig by the size

of the turbine and the compressor.         The maximum engine speed   is regulated by

the OEM fuel!    injection governor.   Therefore, by controlling max Imum engine

spseed, maximum turbline speed and corresponding boost pressures are also

controlled.

            Modification to the OEM emission—related parts due to the

Installation of the turbocharger kit        include replacement of the air cleaner

assembly and replacement of the OEM exhaust system with a 3" diameter

exhaust system.     The positive crankease ventlilation (PCV) vaive is relocated

to allow the turbocharger     installation.    No other OEM emission controls are

removed or disconnected when the turbocharger kit        is installed.


           Installation instructions,       included in every kit, show the kit

installer how to properly        install   the turbocharger system and adjust the

maximum fue!    delivery properly (see Appendix A).       A prototype identification

label    is shown   in Appendix B.

v.          URBQCHARGER KJT EVALUATION

          Evaluation of the Turbo Shop turbocharger kit        included analysis of

all submitted information to confirm that          it meets the requirements for the

exemption, a comparison of the submitted exhaust emissions data, and a

comparison of the confirmatory emissions data generated at the Haagen—Smit

Laboratory.

          The test vehicle was a 1987 Ford F—250 pick—up truck with an

afitomatic transmission.         The Turbo Shop had requested in writing that the

1988 Ford heavy—duty diesel vehicles be          Included in the exemption.   Based on

the fact that the 1988 7.3L Navistar          international heavy—duty diese! engine

Is a replacement engine for the 1987 6.9L engine and both engines have

similar designs and the 7.3L engine design complies with the carryover

criteria as outlined in EPA‘s Advisory Circulars 17F and 20B, the 1988 7.3L

engine    is included In the exemption.

          The Turbo Shop performed comparative exhaust emissions tests at

Olson Enginsering,      inc.,   in Huntington Beach, California, on a 1987 Ford

F—250.    The test program used was the "Test Program for Add—on Turbocharger

Kits for Heavy—Duty Engines" (see Appendix C).          The results of these tests

are shown    in Table 1.


                                    Table 1

                      Comparative Emissions Testing of
              The Turbo Shop Turbocharger at Olson Engineer ing

                                                    1     in   m
     _Mods             I     tion       _HC_       _CQ_            _NOx
     Idle           Base! ine           254        702             2428
                    Device              295        675             1110
                    Change %            +16    _   ~4              ~—54

     20 MPH         Base l ine          281        530             3478
                    Device              236        350             2312
                    Change %            —16        —33             —34

     30 MPH         Base l ins          217        392             2823
                    Device              239        408             2050
                    Change %            +10        +4              —27

     40 MPH         Baseli ine          292        558             2715
                    Device              320        522             2521
                    Change              +9         —6              —7

     50 MPH         Base| ine           491        852             2464
                    Device              579        834             2217
                    Change %            +18        —2              —10




Confirmatory testing was performed at the Haagen—Smit Laboratory and the

results are shown   in Table 2.


                                          Table 2

                          Comparative Emissions Testing of
               The Turbo Shop Turbocharger Kit on a 1987 Ford Vehicle
                         With 6.9L Heavy—Duty Diese! Engine

                                                           Results
       Mode        Cconfiguration             HCCpom)       CO%         NOx (ppm)}

      [die              Base! ine             24.10        0.02         435.50
                        Device                16.80        0.01         332.50
                        Change %               —30          —50           —26

      20 MPH            Base! Ine             21 .20       0.01         795 .50
                        Device                18.90        0.01         617.50
                        Change %               ~11         0.0            —22

      30 MPH            Base| Ine             21.50        0.01         762 .50
                        Device                25.50        0.02         743.00
                        Change %                  +19      +100           —3

      40 MPH            Base!ine              35.15        0.02        1116.0
                        Device                33.90        0.03         863.0
                        Change %                  —4       +50           —23

      50 MPH            Base | ine            62.55        0.04        1222.50
                        Device                44.90        0.03         896 .00
                        Change %                  —28      —25           —27

      55 MPH            Base| ine             74.75        0 .04       1192.50
                        Device                61.60        0.05         878 .00
                        Change %                  ~18      +25           ~26

VI.      1        LON

       The steady—state test results at Olson Engingering,              Inc., and the ARB

indicate that emissions at some test points are increased.               The Olson

Engineering test results show Iincreases in HC emissions and the results of

the confirmatory testing show increases            in HC and CO emissions with the

turbocharger     installed.      Although these    increases seem to be significant   in

percentage, they are not significant         in magnitude.       Based on that, the staff

believes that the       installation of the Turbo Shop 6.9L/7.3L turbocharger kit

will not have significant adverse effects on the exhaust emissions from the

vehicles for which exemption is requested.


                                       *A1IN434Y3 Gamoi170¢4 INY u3M 39
  LSMW SNOILONXILSNI ‘GI7¥AN 38 OL ALNYVHHYM MO4 "ALNWHHYM ANY MIINN
  dg3¥43Add 38 L0N qOnom Ss1I¥4§30 0. 3n0 J¥NIIYI OfHNL ‘3¥N71974 OSYNL
     3SN#3 Q7N0D0 WBLSAS JMYLNI 3HL 30 LSNWVHX3 3HL NI SIHSZT ANY
                  *37815504 MIAMINIHM CNSWWODFM SI 3MOW ‘six4¥4 iSn?H
   —x3 lDH WOl4 HONI (1) 3N0 10 WNWINIW ¥ 7179 ONIIIIX *SY3M4 TIVIIL
—I1M43 WOMJ AYVMY ONIMIM QNW S4SOH 31L M0 IILNOMIYX *19Y4WYG 3SNYD AVW
L9HL $4909 dNYHS INH    S1X¥I   ONINOW   ‘IY¥3H LSNWHX3 WOHJ AUMY WSHL
ONI4I3X ‘ONIXIM    NY $4S0H 77# 40 ONILNOM IML OL NO LLNMZLLY A¥A
                                                                  *AMG
dNY NY37D 38 ILSNW 3111907 HLIM QS°ZND3S 39 OL SOU3MHL ANY ‘ONILLII
  10 NOLLYTMIYILSNI  ONIMMG   440 3WO0D LONM T7IM 3491 OS ‘savaxHL 3H4
 ONII¥L NIJHM SQOW3WHL OML LS%MIId WOSJI 048 34¥1 G4NOH "SNOILIOINNOD
dYIXHL   IJJdId 7179 NQ  349L   NOTIIL M0      LNUTIYVIS GVIMHL 3Sn
                                                  iM3W9P V A8 ATUNO 03
—L¥0dd08 370IHIN 4 NO MYOM ANY W&YO—443@4 MTATN ‘LHSI3M S370IHIM 3MA
 d70H OL ALIOYIY3 3IVNS30Y HLIM Sd4WVH X0 SQNVIS XINP Ad QJINOIINS
   38 LSNW LI ‘s733HM SLI 440 d3§$I¥¥ 398 OL SI 2749!H3A 3H. N3HMm
                                                       *NO LLPTHIKLSNI 3JHL
MOY4 AMYSSTHIOIN 38 717IM S100L LYHM INIWHTLTG ‘39¥4W90 H3H1D X0 $M974
   dNY SMIIN 404 §30¥4¥NS8 QINIHOYW 7179 X499HQ ‘ONIddIHS WOXJ 399W#0
 MOF4 SLNINOAIWOQ 779 1L334SNIL ‘*ONITIONYH INY ONIJIINHS ONIXNI O3431N3
IANFH A¥W L9HL THIMSLYW NOIIHOJ ANMZ 404 SLNTNOWOQ 70¥ 103I4SNI
      30604360606 06 30 30303630363696 303096.96 963636 36 36.96 2696.36063636 36363636 9636363636 6363636 36263636 3636 364036 069036
                    NO LLYTMIYILSNI ONIINYIS 3304398 SNOILONHLSNI 777 GVIH
                                                               LNYLHOAWI
                                                                                                                                   w owe e ce owe




    we ue ue se k
        30303030302036 3636363006363636.363636ol 06 3696 3636363630309636 5606 3636.3630363036 963630 96963696 3636 36 360636363636
                           SNOILOINXHLSNI MJNSXL dNNMNDId OHI/IMOd C*226°?P
                                                         2bI0—SIZ(EIZ)
                                                     10804
                                                    *417493 ‘4dom379N1
                                                    MFLS3HONYM °M Ofé
                                                       40HS OSXML IHL
                            Y XICNHAdY


                                                   APPENDIX A(CONTINUED)



                       * INSTALLATION PROCEDURE *


1.    Locate   the exhaust  cpyrometer gauge and  gauge  mounting
bracket. Install bracket and qauge in suitable place in drivers
compartment per manufactures instructions. Drill and tap the dri—
verside  exhaust  manifold between the 3rd and 4th exhaust  ports
for   the gauge probe. After       the gauge has been connected start              the
engine   and allow to    idle    for   several   minutes.    This will     blow any
chips  from  the drilling and taping of the manifold out  of  the
manifold, stop engine and disconnect the negative battery cables
at both batteries. (This is for safety only)

2.    Remove air cleaner assembly.

3.   Remove      right rear engine       lifting bracket and         bolts,      save
bolts.

4.   Remove positive crankcase ventilator valve from rear of                      in—
take manifold, save as it will be used later.

     NOTE: On 1987 and later wehicles it will be nessary to move
the glowplug control relay on the back of the engine. Locate the
"T" shaped bracket and mount it between the third and fourth in}—
ector on the passengerside of the engine on the intake manifold.
Mount the relay to the bracket on the center mounting holes. The
outer hales are to tie the wireloom too. You will have to cut one
wire and extend it to move the wirelcoom.

5.    Remove oil     sender from rear of         the engine.

&.    If vehicle is equipped with acoustic shield on the firewall
it  must   be   removed from the area between the left  and  right
heads.

7.    Locate   the   lip where   the   firewall     is   attached   to   the   floor—
pan in the transmission tunnel. Bend this lip toward the rear of
vehicle and upward as far as possible. See fig. #1 for location
of the area to be bent. It may be necessary to slightly reshape the
hbeatshield on  the passengerside floorboard for  proper   exhaust
pipe clearance. Use the exhaust pipes to check for clearance.

8.    Install oil— sender adapter fittings where oil sender was re—
moved from,     first the 1/4" street elbow then the 1/24" street tee
facing    the   center outlet up.  Next install the oil line fitting
in the rear outlet with the line connection     facing   upward. Next
install the oil sender into the center outlet of the tee. When
the    assembly   is complete it should face rearward   and   slightly
toward the passengerside of the vehicle.



                                          —/—


                                                                   APPENDIX A (CONTINUED)




?.    Install turbe oll pressure line to the  oil line fitting in—
stalled in   the previous step,  using  the  straight end   of the
hose.   Positian  the  hose so that the free end faces toward. the
front of the vehicle, tighten the line.

10.  Clean hole in rear of intake manifold where positive crank—
case ventilator was removed. Install rubber plug supplied with
Kit into the hole and tighten. DO NOT OVER TIGHTEN!

11.  Relocate the vacuum block   on—the firewall above                                the passen—
gerside valve cover 2" to the left and 2" upward from                                 the original
location.

12.   Reroute the vacuum hose that goes to the powerbrake unit thru
the retaining hangers located on the top of the firewall.

13.      Vehicles        equipped with automatic                   transmission must         rebend
the    steel    vacuum      line   at    the    rear   of    the   engine    to run   along      the
top  edge        of     the passengerside valvecover next                      to     the     intake
manifold.

14.   Locate   the 3" exhaust pipe and round 4 bolt flange.  Slide
the flange onto the pipe with the beveled edge first. Install the
pipe   and flange into the vehicle behind the  passengerside   head
toward  bottom of vehicle.    It maybe necessary to rotate the pipe
on  the   way between the engine and firewall.    Check   for    proper
clearance   around  the pipe,    pay attention to the   area  of    the
firewall that was bent back. There must be a minimum of                                   1/4"   be—
tween the pipe and firewall.

15.  Locate the 1/2 " long spacers, 37§—146 x 3 174" bolts and
the  turbo mounting    pipe. —Install 3/§8—146 bolts into holes   on
the bracket on pipe. Install pipe into vehicle from behind intake
manifold downward toward driverside of vehicle.     Using the   1/2"
long spacers mount the pipe to intake manifold where lifting bra—
cket was removed. DOQ NOT TIGHTEN BOLTS.

16.  Raise wehicte and remove stock   exhaust system.                               Cut     the head
pipes and remove the exhaust flanges.

17.. Locate the new head pipes, Z 1/4" muffler clamp, 2 1/2" muf—
fler  clamp  and  a flange removed from  the  stock  head  pipes.
Install the flange onto the new head pipe and slide pipe into the
slip    joint    on   the    other      pipe.    Install       assembly      into     the   vehicle
using     the    two.muffler clamps and the stock nuts from the exhaust
manifolds.        The       head     pipes must        fit    into    the   slipjoint       on    the
turbo mount pipe before bolting to the exhaust  manifolds.  Check
for clearance around all pipes and tighten all connections as well
the two botts holding turbo mount   pipe to the intake  manifold.
There must be a minimum clearance of 378" between turbo mount pipe
and the firewall where it was bent!

                                                   —8—


                                                                      APPENDIX A (CONTINUED])



 18.     Vehicles with            automatic          transmission must                remove       the    dipstick
 tube and replace it with a new tube.(sold separately) Install per
 instructions  sold with tube.   You may rebend the stock tube  so
 that  it  clears  the  exhaust  pipe   and comes  up  behind  the
 passengerside            head.

 19.     Locate      turbocharger,             oil    drain pipe,          oil    drain bushing,                oil
 drain    gasket         and four       (4)    3/8—14 x       1"    header       bolts.          Lossen       the
 twelve (12} bolts in the center of turbocharger. Remove the plug
 from oil drain in turbocharger. Install oil drain pipe to turbo—
 charger  with  gasket and two (2) header bolts.  Slide oil  drain
 bushing  on end of drain pipe.  Install assembly onto  the  turbo
 mount   pipe with          two    (2)       header    bolts making sure                   oil    drain       pipe
 fits into tube in the walley of the engine where positive crank—
 case ventilator was removed. Tighten two <2) of the bolts halding
 the center of the turbocharger to the exhaust housing. Set the
 discharge hat onto the intake manifold and align the compressor
 housing outlet with the hat inlet, tighten two (2) of the boits
 holding the compressor housing to the turbocharger. Remove the
 turbocharger assembly from pipe and tighten the remaining bolts
 per manufactures instructions. See fig. #2

 20.     Reroute           the    injector       return       hose,        throttle             cable,        cruise
 control      cable         and        wiring        loom.—at       the     rear           of     the     intake
manifold.          It     will     be    necessary          to cut    the    tape       holding          the        oi1l
sender   wire into the loom.  Pull wire out of the loom and    route
along passengerside valvecover to rear of engine and onto sender.
Using  the   ties provided tie the cables and wire loom  to   the
mounting    lugs where   the  positive  crankcase  ventilator   was
mounted.           Now    tie    the    injector       return       hose    to    the wire              loom,        be
 careful      not        to pull       the    ties to tight and pinch                      line     off!         See
 fig. #3

 21.   Lacate   heatshield,  eight (8) header   bolts,     turbocharger
 flange qgasket, turbocharger assembly, 2" dia. silicone hose, #32
 hose  clampe,   bolts  from engine lift bracket,    1724 to  —4°  hose
 fitting,   discharge  hat  and safety wire.   Install the    —4   hose
 fitting      into         the    turbocharger          facing       the    —4 connection                to     the
 rear when     installed on              the vehicle.              Clean    intake manifold                     where
 air   cleaner      used to mount              and run       a bead of       silicone             around mani—
 fold.       Install        discharge hat using bolt and washer from lifting
 bracket. and silicone                 to seal       bolt    and washer          in    place.       Install          2"
 silicone hose and hose clamps to the                              inlet of hat.                 Coat    the        end
 of    the   oil     drain       pipe with       silicone          and slide          oil       drain     bushing
 on.   Coat  the            end  of the oil drain bushing with   silicone   and
 install    turbo           assembly into the vehicle with  four   <4)  header
 balts and gasket.                Connect       the    turbo discharge                to    the    discharge           hat
  with hose and clamps. Tighten the clamps and hat hold down bott.
  Take safety wire and connect one end to the button on the rear of
, heatshield.   Place   heatsh ield  in   position on   turbo   and
 secure with safety wire. Attach oil supply line to turbo fitting.
 With  four  (4) remaining header bolts attach 3"   exhaust  pipe,
 check for proper clearsance and tighten.                  —



                                                        _9


                                                     APPENDIX &A (CONTINUED)




22.  Locate air cleaner housing, turbe connecting tube, 3" sili—
cone  hose,  #48 hose clamps,  positive crankcase ventilator   and
bolits and S§/16 —18 x           324 bolts with washerse.            Using 5714 bolts and
washers mount the air cleaner housing to the discharge hat. Put
silicone   sealer on the threads and under the washers before in—
stalling. Install the turbo connecting tube using the 3" silicone
hose and #48 hose clamps. Mount the positive crankcase ventilator
to   the turbo connecting tube using original bolts,  washers and
seal .

23. Locate the oil fill adapter, oil vent tube, 1" rubber hose &
clamps. Remove o—ring and plastic washer from the positive crank—
case   ventilator  and— install  Othe 1" rubber hose. Mount the oil
fill adapter to   the front of the   injector  pump cover. On early
model engines this will be between the oil fill tube and cover on
late     model      engines       there   is Just     a flat       plate      to remove     on    the
cover. Install the oil  vent  tube into the adapter with silicane
sealer and the other end into  the rubber hose on the ventilator.
Tighten clamps on hose.

24.  Install air cleaner               into air cleaner cover and attach                     to air
cleaner housing.

25.  Do a finial inspection of your installation making sure all
connections are tight and properly position. Alli hoses and lines
are away from hot exhaust and turbocharger. Use extra heat blank—
et  to  shield anything that cannot be moved or is close   to  hot
parts.

24.   Reconnect negative battery cables and start vehicle. DO NOT
REV    ENGINE,  ALLOW TO IDLE FOR &A FEW MINUTES. During  this   time
check    all   connections for leaks and proper operation of   gauges
installed. Stop engine and repair as necesseary.


                                  EXHAUST SYSTEM

        We   have      designed        an exhaust system to               give      you     maximum
‘performance with          the   turbo system.       The    next    best      possible      exhaust
system would          be     a 3"     exhaust with a          quality         low   restriction
muffler .

                                          CAUT ION

        Excessive          backpressure        will        result        in      high       exhaust
temperature.         Under       no   conditions should            the    exhaust         temp.     rise
above    1190 deg.     F.    serious engine damage may occur!




                                             —10—


                                                           APPENDIX & (CONTINUED)




                             INJECTOR PUMP ADJUSTMENT


        To    obtain maximum performance                  from your           turbe system       it    is
necessary  to make an injector pump adjustment.  This   adjustment
increases the total amount of fuel delivery to the  engine.   This
with  the  increased supply of air provided by  the   turbocharger
will give you power gains of as much as 40%.

        Cleanliness is the most important thing to remember when                                      the
pump     is  being adjusted.  Do not allow any foreign  material                                       to
enter    the injector pump during this adjustment.

        First place a drippan under                  the vehicle under the flywheel
inspection           cover         area    too   catch      the        fuel     released         during
adjustments.  Locate  the  cover  on  othe passengerside  of  the
injector pump, it is secured by two screws. Using a 1/4" wrench
losgen the lower screw and remove the upper. This will allow you
to   rotate     the      cover     and gasket       out    of    the way for          access    to    the
adjusting   screw,.  Rotate the engine in a clockwise direction   by
HAND ONLY until the    allen  head  screw   appears inside the pump.
Center  the    screw  in the opening before trying   too adijust it,
using a      light       and mirror will         make     see    the    screw much       easier.

        Using        a     5732"      allen      wrench         adjust        the      screw     inward
¢clockwise when looking at the screw) will increase fuel flow and
increase exhaust temp.    ,— outward (counterclockwise> to decrease
fuel flow and lower exhaust temp.    . Under no circumstance should
the  screw    be rotated inward more than 1/3 of a turn  from   it‘s
original    setting.  WE RECOMMEND AN INCREASE OF i/4 TURN  INWARD.
THIS   I1§S THE  ONLY SETTING LEGAL IN THE    STATE OF  CALIFORNIA.
Increases of more than 1/4 of a turn up to 1/3 turn are for HIGH
PERFORMANCE USE ONLY.

        Exhaust           temperature must not exceed 1150 degree   fahrenheit
as      shown on          the pyrometer furnished with   this  kit.   If  this
temperature          approaches under            heavy     uphil1       load reduce        epeed      and
use a lower gear.  If vehicle continually reaches this temperature
a reduction in the injector pump setting is necessary!


                                    THINGS TO REMEMBER

        1.   Keep    air    cleaner       element    clean.       When    the       element    becomes
dirty remove from holder and clean per manufactures instructions.
A dirty air cleaner will cause excessive oil consumption and high
exhaust temperatures.

        2.   Change oil       and filter every 2500 miles.

        3.    Before       shutting engine          off make       sure       exhaust     temperature



                                                    11—


                                                  APPENDIX & (CONTINUED)


is below 300 degrees fahrenheit.




       4.   When    etarting your engine do not rev          the engine!     Allow
the   engine   to   idle   and warm up   before   driving.

     Foilowing  these easy directicons will give you many                  trouble
free miles of enjoyment from your turbo system.




                                         ~12—


                                             APPENDIX B
KXEEEKEKIKIKKERKELRELREERELLEKILEKLERERLE¥
*      THE TURBG SHOP &£.9/7.3 L. #
*      MODEL # To4R                      *
*   _/ "CARB E.0. No B— .                *
                                  —13— _


                                                   APPENDIX C




Test Program for Add—On Turbocharger Kits for Heavy—Duty Engines

Testing will consist of back—to—back chassis dynamometer tests. Baseline
{unmodified configuration) emission results will be compared to
turbocharged {modiffed configuration) emission results on the same
vehicle.

A.    STEADY STATE TESTS

      1)      (Idle

      2)      20, 30, 40, 50 and 55 mph at 1XRL.

      Prior to measuring exhaust emission at any steady state test point,
      the vehicle‘s engine temperature shall be stabilized. This is
      satisfied when engine oil temperature is stabilized as monitored
      and indicated by a temperature recorder.

      If a steady state point is unattainable in the baseline
      configuration, then the last point at a specified horsepower should
      be WOT and the speed should be recorded. The test in the
      turbocharged configuration will be performed at the same speeds and
      horsepower as the baseline configuration. >

      Any steady state may be deleted if 1) the steady state exceeds or
      can be expected to exceed the engine redline or 2) steady state
      conditions might cause serious damage to vehicle components or
      dynamomter, ‘or create a hazard for test personnel.

      STEADY STATE DATA REQUIREMENTS

      1)      CO concentration

      2)      C072 concentration
          )   HC concentration
     to




          )   NOx concentration
     oo




          )   engine rom
     on




      6)      engine oil temperature

      MISCELLANEOUS

      1)      The same fuel will be used for both the unmodified and modified
              configurations unless the turbocharger manufacturer‘s written
              instructions specify a different fuel for the turbocharged
              configuration.

                                           ~14—


                                   APPENDIX C (CONTINUED)


Tire pressure in the drive wheels will be the maximum indicated
on the tire sidewall.

Test vehicles from secondary manufacturers may be tested
without a body shell if 1) the cab is intact, 2) the vehicle is
legally driveable on the street, 3) the frontal area is
identical to the built—up vehicle, 4) the chassis is loaded to
a weight simulating loaded vehicle weight. Loaded vehicle
weight is defined as the manufacturer‘s estimated weight of the
vehicle in operational status with all standard equipment, the
weight fuel at nominal tank capacity, and the weight of
optional equipment.     j




                        «15—



Document Created: 2005-09-01 12:41:52
Document Modified: 2005-09-01 12:41:52

| Previous E.O. D-179 | Next E.O. D-180-1 | Next E.O. D-181