Added intercooler to '86

Topic: Added intercooler to '86 - Now won't run (Read 1192 times) previous topic - next topic

Added intercooler to '86 - Now won't run

July 29, 2006, 08:06:55 PM

Hey folks,

The setup:
I had an intercooler setup from an '87-'88 car and decided to install it today.
I started by rotating the compressor housing so its outlet was aiming straight up (for the intercooler inlet). There was enough room to cut off the first 1.5" on the charge tube and grind it smooth. I did not have to grind the off of the compressor housing.
I routed the vacuum lines in a similar fashion from stock and used Ford intercooler couplers. Everything seems to match up and fit well. I was even able to use the stock setup for the oil separator lines to the compressor inlet.

The problem:
The car will no longer run. It starts and goes into its idle mode, then dies after 1-2 seconds. It will run if you keep your foot on the throttle and hover it at 2,000 RPM or higher. However, it poops itself as soon as you let off.
My first idea was a vacuum leak, but I've tried everything. I tried swapping lines, plugging lines, etc. I even had the battery unhooked and checked all of the fuses...
I'm at my end. I spent some time on the phone with Shawn, but we just can't figure this thing out.
Does anybody have any idea what could be wrong? I've checked everything several times.

Added intercooler to '86 - Now won't run

Reply #1 – July 29, 2006, 09:18:56 PM

I'm gona call you...

Added intercooler to '86 - Now won't run

Reply #2 – July 30, 2006, 12:21:24 AM

boost leak is my only guess.

Added intercooler to '86 - Now won't run

Reply #3 – July 30, 2006, 01:17:12 AM

Yep Boost leak is what is sounds like to me.

Added intercooler to '86 - Now won't run

Reply #4 – July 30, 2006, 02:05:28 AM

Something with the VAM? Meh. I don't know shiznit about turbo cars. I had one for a whopping 4 months.

Added intercooler to '86 - Now won't run

Reply #5 – July 30, 2006, 10:13:42 AM

Check all the intake hoses for cracks. I had the hose between the intercooler and turbo get a small crack in it. It would run but idled very bad. Then when I would get on it I would here a PSST at about 5psi kinda like a BOV. changed the hose and all was well. I tell you take the hoses off and roll them between on a hard surface while pushing down on them to see if there are any cracks. It might not be visible with it on the car or under vac.

Added intercooler to '86 - Now won't run

Reply #6 – July 30, 2006, 01:04:53 PM

Hey Zach, I don't know if that car had cruise control or not but if so did you hook it up, and if not did you plug that fitting in the front of the IC?

Oh yeah, dumb question but, your IAC didn't come unplugged or something did it?

Added intercooler to '86 - Now won't run

Reply #7 – July 30, 2006, 04:41:54 PM

The car has cruise. I used the vacuum line from the firewall on one intercooler fitting, and I used the line from the compressor inlet on the other fitting. The IAC appears to be just fine.
There are no dumb questions.

Well, I took it all apart today and inspected everything. The intercooler hoses looked fine to me, and the intercooler doesn't seem to have a leak. It's in very good condition.
I removed the stock airbox and installed a K&N cone filter just before the VAM.
I noticed that when I rotated the compressor housing, the inlet was pointing down; this led to stress on the VAM-to-compressor hose. I decided to remove the AC compressor (which was dead anyway) to free up some space.
I put everything back together and the car runs fine! There must have been a "weak link" somewhere after the VAM, just as you guys suggested.
There is one thing, however:
The car feels like it didn't gain anything. There is no increase in power. Once I hit 10+ PSI of boost, there is a loud hissing sound from the front of the car.
I can't tell if it's the K&N filter or if it has another leak somewhere, which only leaks under boost.
At least I can drive the car again. :)

Added intercooler to '86 - Now won't run

Reply #8 – July 30, 2006, 07:15:49 PM

With the K&n you should hear the turbo spool up. Kinda like the way you here the whine of the turbo on a diesel. That hissing sound could be a boost leak. go over to turbo ford and search boost leak. they have a nice setup to test yours. It may not leak under vac but under boost it could expand the hose and expose a crack. By the way did you get the hood also. If not you aren't doing any good with the intercooler. No air flowing over the core won't cool down the air charge. With it right over the exhust it is heating the air, if you don't have the hood get some PVC tube and mount it in front of the radiator. besides the intercooler is only gonna do you good when you are crusing at 45mph or above. unless it is a front mount and air is going over really good.

Added intercooler to '86 - Now won't run

Reply #9 – July 30, 2006, 09:39:06 PM

Boost leak. I had one I could NOT track down about a month ago, took all my pipes and everything off, and by chance I happened to glance at the coupler on the turbo outlet before I put it back together and it had a big split right down the side of it.

However your issue might just be that you don't have your clamps down tight enough, make sure you crank em down pretty good.