1980 Ford carbureted turbo 2.3L engine buildup
This page provides a visual tour of a complete engine buildup of a Turbo Ford 2.3L engine which was available in select models of the Mustang and Capri. Unlike later fuel injected types, this engine uses a standard 2.3L carburetor in a draw-though configuration. A header pipe comes from the exhaust manifold underneath the engine and then back up to the turbo and the turbo outlet pipe exits down and back over to the right side near the starter which makes the engine bay complicated. Power output is lower than fuel injected types since a carb is used and the inefficient turbo placement.
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Engine assembly essay
The first slides show the engine parts as they came from the factory still in the original box. Also included is the shop manual in three languages. Thankfully the engine kit included all needed items including the oil filter, spark plugs and cables, all wiring and fuel line. Assembly lube was the only item that needed to be obtained. The next slides show the engine block with crankshaft, completed reciprocating assemblies and main bearing caps as well as the oil pump. When the crankshaft was installed for a test fit, it was discovered there some some interference so it was removed and casting flash when the crankshaft was created was removed. It was then reinstalled in place and the main bearing caps lubed and torqued into place. The next pics show the completed recirprocating assembly and then also showing the oil pump installed. Now that the basic block is completed, attention was now turned towards the starter. Being preassembled, nothing had to be done other than route the wires correctly and bolting it into place after installing the oil pan and the mounting the engine to the 4 speed bellhousing. The engine can be viewed from all directions in the next slides that follow. The distributor and its wiring were then assembled. Spark plug wire stock was provided to allow for custom spark plug cable lengths. It was cut and fitted into place and spark plug boots and the plugs themselves put into place. Finally, the engine stand was assembled and the engine hoisted into place which makes further construction much easier. Additional pics show detail on all sides. The rotating assembly turns smoothly with no problems. The next slides show the cylinder head assembly. The valves and keepers were installed, and then finally the camshaft and followers. Remember to apply a liberal coating of assembly lube to all rotating parts in the cylinder head as that is one of the last areas to get oil pressure. Once the head was completed, it was carefully set on the engine block and torqued into place. Once completed, the camshaft timing can be set. Installing the timing belt can be (and was) tedious as sometimes one of the toothed pulleys can move. After installing the timing belt, rotate the engine several times to make sure the timing marks still line up. Once verified, the timing belt cover was installed and the water pump fitted followed by the crankshaft and water pump pulleys. Next up is the alternator bracket followed by the alternator itself. The air injection pump gets installed on the other side and once complete, the accessory drive belts are put on and finally the water pump fan. The next two slides show the intake manifold/turbo assembly. Note the coloured turbine wheels. The distributor cap is put on followed by the carburetor installed on the intake manifold. The manifold itself is then fitted to the engine. The exhaust manifold is bolted to the head, then the spark plugs and wires are installed. Firing order is 1-3-4-2. Final items are the exhaust pipe from the manifold to turbo, and then the one from the turbo outlet. Air cleaner, dipstick and fuel pump lines are the last things to get put on. This engine also has a non turbo mechanical fuel injection system with a header that will be featured later along with a custom valve cover which will be installed at a later time.
The engine has not been started yet. Everything's been verified and checked over twice so it should crank up without a problem. Future plans will be to compare power output between the turbo and fuel injection types.
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page created 05may03
