I've been searching the forums for the last week and haven't found what I'm looking for. I seem to have more questions now than when I started! ;-)

I have a 2002 E450 box truck that we use as our service/tow vehicle for our race team. It is always loaded and usually towing.

I'd like to do at least two things to it initially:

1.) Install an intercooler. I have not been able to locate a kit to fit the van body. I've seen pictures of an ATS kit for older PSD trucks, but not for vans. Has anyone intercooled their van? We can fab our own system if we have to. If anyone has pictures of what they've done, please share!

2.) Install a larger diameter exhaust. Reading in the diesel sections, someone commented that the turbo exhaust housing is actually different on the vans. Does this mean that the downpipe flange is different from a truck turbo? I'm trying to find an exhaust system, "I can just bolt on," but can't get anyone to confirm whether or not their system will fit.

3.) Other mods. I'm interested in doing anything that will help the engine run more efficiently and live a longer life. If there are mods that I could/should do while doing the exhaust and intercooler projects, I want to research those and line those up so I can do it all at once.

I've read about the compressor wheel swap, EGR disconnect, and some other mods, but it's really difficult to make sense of what I SHOULD do. I don't see where anyone makes a cold air intake for the Econoline platform?

Any suggestions/help is greatly appreciated.

Cheers! John

 

As I understand it, the exhaust is the limiting factor on diesel performance in the van body. The engine is really shoe-horned in there and they can't use the same exhaust manifolds used in pickups (more free-flowing) because of clearance issues. Since the exhaust is restricted, the entire engine is detuned somewhat to match...

 

Thanks for the reply packlet. My understanding is the same. There's a discussion elsewhere that the turbo in the van does not have a wastegate. There is also information that the compressor housing is a slightly different size.

Anyway, my goal is to intercool the truck and get some sort of larger exhaust on there. I was hoping that someone else had already figured this all out! ;-)

Cheers! John

http://www.lastditchracing.net