I have a '90 model ford aerostar van with a high mileage 3.0 in it currently. As the engine bay is too small for an easy 5.0 swap I'd like to turbocharge it. I am well aware that the engine will not take the boost but I plan on purchasing a bare block and building it up with forged pistons, rods, etc. so it wont grenade on me. I understand how a turbo system works, I am just curious as to whether this seems like a feasable project or not. I have not seen any 3.0s with turbos and I'm wondering if I would have to replace the manifolds or if I could just T them together and run them to the turbo. Oil lines for the turbo would also be a concern because I wouldnt know where on the block to tap in. I am aware that the fuel system and ignition wouldnt be up to the task so I plan on building a megasquirt fuel injection computer and converting to MSD ignition. Any ideas or tips are greatly appreciated.

 

I would say just about any turbo project is feasable. You might be able to flip your exhaust manifolds upside down and run them into a T before the turbo. Or you can build your own manifolds from weld els. You can get your oil feed from the oil pressure sending unit, just use a T or Y there. Cut a hole in the oil pan and weld or JB weld a fitting in there for the oil drain and you are in business. It would be interesting to see a turbo charged van.


Marlon

 

Egads... someone else with the insane idea. I've been watching the rear mounted turbo system stuff, and that looks like the best bet, given our less than spacious engine bays. Wouldn't take a huge turbo either to make big gains, plus we have PLENTY of room under the van.

 

I have had a remote mounted turbo on my truck before I stuck it under the hood. I can tell you from first hand experience they do work and work well. I had some oiling issues to work out on mine, and since my truck is a 4X4 I opted to change to an underhood setup. I am using the same turbo as before and I can't tell much of a performance difference between remote and under hood. Going remote is much eaiser IMHO than fabbing manifolds.

Marlon

 

Ahhh... oiling! That's the one thing I don't know a thing about on a turbo system. How did you get oil back to the turbo?

 

For the oil feed line to the turbo you can tap into the engine oiling system at the oil pressure sending unit usually. Normally the turbo is mounted above the engine oil level, so gravity takes care of getting the oil back into the oil pan. But on a remote mount, or any low mounted turbo, you need a oil scavenge pump to get the oil back to the oil pan, or valve cover.


Marlon

 

BTW, I've noticed that Whipple has a supercharger for some late model 3.0 liter Rangers. Big hp increase. This fundamentally is the same engine as the Aerostar. I'm not sure if there would be room for the supercharger or not -- it's not very high profile but neither is there an enormous amount of space available.

Might be possible to swap a late-model Ranger engine and transmission in, and use the supercharger kit.

 

I'm not familiar enough with Aerostar Vans to know this... are they FWD or RWD? If they are RWD, there is absolutely nothing stopping you from removing all the sheet metal on the nose, and the dashboard, and hacking a much larger space, welding the structure for strength, to shove in what you like.

A friend of mine shoved a 460 into a 91 Ford Explorer 4-door, and the hood closed. It was ridiculously tight, but it fit

 

They are RWD.

 

RWD? awesome. Plasma cutter time

 

Yeah I just need to get me a daily driver first b4 I retire the aerostar. after that I'm thinking 351 and T56...with a blower of course.

 

The 5.4L has a supercharger on it. You might find one of those in a Mustang that you could jam in your Aerostar. Check this one out:
Ford Racing Performance Parts []

 

Why not just find a donor with a 4.0 and upgrade to that? Call me silly.