Turbo Technics Capri
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1. Technics design expertise has produced a technically advanced pulse separation configuration using a single turbo In conjunction with the carefully matched Garrett T3 turbocharger excellent low speed response is achieved with minimal turbo lag The resulting engine not only gives exhilarating performance but does so in a totally fuss free manner with no perceptible transition to boost conditions Economy is virtually unaffected and an effective intercooler in conjunction with a carefully integrated system ensures a very high degree of reliability for which Turbo Technics have established a trend setting reputation The kit uses the standard compression ratio and runs with standard transmission and consists of a T3 turbocharger manifold intercooler vacuum capsule fuel enrichment air cone block oil feed and return pipes cross pipe and a down pipe from the turbo as well as all the pipe work and clips to plumb everything in The only part not included from the original kit is the complete exhaust system see figure 13 in drawings The Turbo system can be fitted in a few days by any competent DIY er and does not need to be carried out by specialists However it is important that the engine is in good mechanical condition before the kit is installed especially if it has covered high mileage Engine Power Output Maximum power 200BHP 149Kw 5 500rpm Maximum torque 247 Lbf Ft 320Nm 3 800rpm Typical Performance Figures2. 1 1 5 with the engine thoroughly warmed Idle speed 900 rpm ENGINE OIL The use of synthetic or semi synthetic oil is recommended for turbocharged engines Turbo Technics approves the use of Shell Gemini in the Capri Turbo FURTHER SERVICE NOTES ENGINE F9 The engine is unmodified except for the distributor advance capsule TURBOCHARGER No servicing is required for the turbocharger In the event of a turbocharger failure it must be removed complete and replaced by a factory reconditioned unit Only the pressure controlling wastegate actuator can be replaced as a service item Do not attempt to dismantle the turbocharger as this will almost certainly cause damage BOOST PRESSURE CHECK Connect a suitable pressure gauge to the Inlet plenum at the multi connection offtake Run the vehicle on the road in 3rd gear at 3 000 rev min using full throttle Hold steady speed for a few seconds by braking with the left foot and read the boost pressure Repeat at 1 750 rev min Pressures should be 1 750 rom 3 000 rpm F9 0 25 bars 3 6 Ibf in min 0 40 0 45 bars 5 8 6 5 Ibf in ACTUATOR REPLACEMENT Check the actuator for free movement and diaphragm integrity by pressurising up to but not beyond the working pressure There should be no leakage To replace an actuator fit the new unit and adjust the screwed rod end so that it must be pulled out approximately 2mm to fit over the pin on the arm Road test as described above and adjust the
3. Capri 200BHP 0 60 MPH 6 5 seconds 0 100 MPH 14 8 seconds Max speed 143 MPH on the standard final drive The cost of the kit is 2500 VAT Your order will be taken with a 20 deposit CAPRI 2 81 TURBO Service Bulletin INTRODUCTION The special edition Capri 2 81 Turbo follows the same turbo system layout as employed previously by Turbo Technics on this model and is similar to that used on the XR4i XR4x4 and Granada models The turbo system is based on the use of a single Garrett AiResearch T3 turbocharger mounted on the left side with an air air intercooler cooling the charge air prior to entering the engine The basic engine remains standard Harder suspension location bushes are employed at key points together with upgraded front brake pads 4 pot front callipers and ventilated discs are available as an optional extra MODELS COVERED Turbo system types F9 Turbo Technics 200 BHP service details identical to f26 ROUTINE SERVICING service intervals 6 000 miles or 6 months 12 000 mile or 12 month service as Ford requirements plus blow off the exterior of the intercooler with an air line Check all pipes for tightness 6 000 mile or 6 months service as Ford requirements plus change spark plugs SPARK PLUG TYPE NGK BCP6ES gap 0 75mm IGNITION TIMING 12 B T D C 900 rpm vacuum disconnected NOTE On no account should the engine be run under load with the vacuum pipe disconnected IDLE CO SETTING
4. The Background toa Thriving Young Company Tha bl a di toa rod sala Aa tee ede peta of ting cents A Wide Range of Conversions ISTE Eo Deno x DEI M i Teckia hus erabtsh d mei sl marka btala iP Lb demit Ee comi aS loa Perr riw Bl a E modes laor uar on Thai Braces Es x lar baa gps vas Lies hl beady B scita her ramps o thy pab s fe Car manilactirerz alke realy ei ens hp le Tabo Tocina ita And dd roll cal De cd ee perra hy ebria mv ard arcana he bes AA Tibe Techn ars ww Milly paid nar ete partos s Alen a Hara nne dendoped Fonda bats incisie urba charqse Kirat For niak Frisii LC Caer EICH raw Grarawia ar d oy raras e Capa wann amabi porra alos arm mopped in ra bore da sisi bd al he open era anderen all Sar COPA Turisi arion in becoming EREE O pafi a es coy dra kah dall de tiraire oll Porh rabia TCETIO CR eed carne on ae n rides cra and Tar Freie ars tepeippod ta Cee Pra afl mad mi of Farbe cae Paro repr hare Veces Des ppc rien iha LE danita fairer Gin kn Las mimaa Tore Sie alert Turbo Vara ae Da Fia Eis rai This kit is identical to the famous kits we produced in the 80 s and 90 s which when fitted to the new Capri s would make 200bhp Producing power at high speed is relatively easy but the aim of the development programme was to build an engine which would also produce a high level of torque from very low speed The key to achieving this is the exhaust manifold and Turbo
5. The turbo system can be fitted in a few days at either Turbo Technics Northampton or Aldershot facilities and whilst careful servicing is required this does not need to be carried out by specialists Warranty for a period of 12 months an all Turbo Technics components is included Engine Power Output Typical Performance Figures Maximum Power 0 60 mph 6 5 seconds 200 bhp 149Kw 5 500 rom 0 100 mph 14 8 seconds Maximum Torque Maximum Speed 143 mph 247lbs ft 320Nm O 3 800 rpm Technical Specifications Turbocharger Turbo Technics assembled Garrett T3 with integral wastegate pressure control The turbo is mounted on the nearside with a link pipe carrying gas across from the off side manifold Exhaust Manifold Multi branch manifold designed for pulse separation cast in high nickel iron Air Supply Air supply is through the standard filter to the compressor then cooled by a front mounted intercooler before passing to the standard inlet manifold Fuel System The standard injection system is retained with minor modification 11 Ignition The standard high energy electronic ignition is retained with a modified characteristic incorporating a vacuum advance pressure retard capsule Wide heat range spark plugs are employed with silicone high tension leads Lubrication An oil supply is taken from the main engine feed via Aeroquip pipe to the turbo returning to the sump Cooling The standard radiator is
6. eck cam timing 6 0 Oil pull over Check compressor inlet and rocker cover vents for excessive oil flow HIGH FUEL CONSUMPTION 1 0 Check part throttle CO CO at high idle 2 000 3 000 rpm should drop to below 0 50 This with the vehicle stationary On rolling road test steady CO readings should be less than 196 at off boost conditions 2 0 Check ignition timing Particularly check the function of the vacuum advance capsule 3 0 Check engine conditions HIGH OIL CONSUMPTION 1 0 Oil smoke on full power excessive ring wear damaged pistons damaged bores 2 0 Oil smoke on over run poor valve guide condition damaged stem seals 3 0 Oil smoke at idle damaged turbo seals 4 0 engine oil leaks damaged pistons bores blocked breather Parts List 6 BMiosos Bott 8 NMOSP Nut J O 9 12861 J Exhaust cross pipe left bank Exhaust cross pipe right bank as pair 11 Clamp flange Ford originalpart Brakes Standard Calliper 6244 Brake pads Mintex Brakes 4 Pot Calliper Brake pad Brake disc Calliper assembly left side Calliper assembly right side Spacer washer 2 per side Brake pipe 4 00000 Breather System Diagram Breather System operation On Boost Valve 6060 closes Engine breathes via valve A053 to air metering unit and hence to engine On Over Run Valve A053 closes Engine breathes via by pass through valve 6060 to plenu
7. m chamber Note 3 8 hose from plenum chamber to valve 6060 must be secured with clips Valve A053 is tie wrapped to the brake pipes on the bulkhead Detailed below are the Miofiltre Valve and Fuel Enrichment Profile Block 10 CAPRI V6 2 81 TURBO The exclusive performance system developed by Turbo Technics From the same stable as the well renowned XR3i the V6 turbo system employs the same design principles and engineering expertise to produce a superbly balanced performance Producing power at high speed is relatively easy but the aim of the development programme was to build an engine which would also produce a high level of torque from very low speed The key to achieving this is the exhaust manifold and Turbo Technics design expertise has produced a technically advanced pulse separation configuration using a single turbo In conjunction with the carefully matched Garrett T3 turbocharger excellent low speed response is achieved with minimum turbo lag The resulting engine not only gives an already good vehicle exhilarating performance but does so in a totally fuss free manner with no perceptible transition to boost conditions Economy is virtually unaffected and intercooling coupled with a carefully integrated system ensures a very high degree of reliability for which Turbo Technics have established a trendsetting reputation The 200 bhp turbo engine uses standard compression ratio and runs with standard transmission
8. pressure as necessary shorten the rod 1 turn at a time maximum to increase boost and lengthen to reduce Lock the nut and refit the E clip FUEL SYSTEM The fuel system is standard except that a profile block is fitted to the air metering cone However the system is balanced to give matched flows from each injector Injectors must always be kept in their respective positions and if any component of the system is changed a flow check must be made With the air flap at full lift the flow from each injector must be within 200 220 c c min IGNITION SYSTEM The ignition system is standard except 1 A vacuum advance pressure retard capsule is fitted to the distributor Retard should be 8 10 C A at 0 40 bars pressure at all speeds Free movement of the base plate should be checked 2 An over boost pressure switch is fitted in the inlet plenum to interrupt the ignition feed in the event of turbocharger control system failure 3 Silicone ignition leads are fitted EXHAUST SYSTEM The standard exhaust system is retained for the main run including the two main expansion boxes cut 520mm in front of these boxes and a 2 section front pipe and Y piece connects FAULT DIAGNOSIS SYMPTOMS AND POSSIBLE CAUSE LOW POWER 1 0 Check vehicle servicing Particularly check spark plugs filters valve clearances 2 0 Check boost pressure 2 1 Low pressure at 1 750 rom air leak exhaust leak intake blockage throttle not opening weak mixtu
9. re on load damaged turbo turbo wastegate not closing 2 2 Correct pressure at 1 750 rpm but low pressure at 3 000 rpm wastegate actuator incorrectly set 3 0 Check ignition timing With vacuum disconnected Idle timing should be 12 B T D C Timing at 3 000 rpm should be 17 21 B T D C 4 0 Check fuel air mixture Check injector flows as above Check full throttle CO on a rolling road should be 3 5 between 3 000 rpm and 5 000 rpm 5 0 Check engine condition Normal condition check as described in the Ford service manual MISFIRING 1 0 Check vehicle servicing Check spark plugs type and condition Check H T leads continuity and insulation Check H T firing voltages 2 0 Check turbo boost at 3 000 rpm Over boosting will cause intermittent cutting of the ignition supply DETONATION 1 0 Check fuel 96 RON octane 4 star minimum NO LUBRICATING ADDITIVES 2 0 Check ignition timing With vacuum disconnected Idle timing should be 12 B T D C Timing at 3 000 rpm should be 17 21 B T D C Check for smooth advance action 3 0 Check ignition timing retard 0 40 bars pressure on the distributor capsule should give 8 10 C A retard Check for smooth action 4 0 Check for over boosting Boost pressure at 3 000 rpm too high incorrect actuator setting leaking actuator pressure pipe perforated actuator diaphragm sticking wastegate 5 0 Incorrect valve function Check valve seat condition Check valve clearances Ch
10. retained Service Apart from different spark plugs and ignition timing servicing is unaltered 12
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