INSIDE THE ECOBOOST 2.0L ENGINE

Full-Race Fusion FReak-O-Boost

This article documents the transformation of our 2014 Fusion SEMA project from “EcoBoost’ to “FReakoBoost”! Working with our team of top-shelf aftermarket partners, Full-Race developed a 2014 Fusion 2.0L themed as a daily-driver tuner vehicle that is fun to drive with excellent fuel economy and handling. We are increasing horsepower and torque by installing a high-performance Full-Race 2.0L EcoBoost EFR turbo kit with BorgWarner EFR6258 turbocharger and using Cobb AccessPort for tuning

EcoBoost (Before)

FReak-O-Boost (After): SEE US AT SEMA

Working with our team of top-shelf aftermarket partners, Full-Race developed a 2014 Fusion 2.0L themed as a daily-driver tuner vehicle that is fun to drive with excellent fuel economy and handling. We are increasing horsepower and torque by installing a high-performance Full-Race 2.0L EcoBoost EFR turbo kit with BorgWarner EFR6258 turbocharger and using Cobb AccessPort for tuning.

Full-Race EFR Turbo Kit for the 2L Ecoboost

The Full-Race BorgWarner EFR Turbo Kit Consists of:

Full-Race EFR Turbo Manifold
Full-Race EFR 3” V-Band Downpipe
Full-Race Cold Air Intake
Full-Race Charge Piping Kit (mandrel bent 2.5” aluminum)
Full-Race Charge-Air-Cooler (optional)
Full-Race Oil Cooler (optional)
Full-Race ATF Cooler (highly recommended)
BorgWarner EFR Turbocharger

Installing this high performance BorgWarner EFR turbo and plumbing the lines is remarkably simple, because BorgWarner’s K03 is the OE turbo:

Here are some photos showing the lines and how they are plumbed for the new turbo:

6F35 Transmission Cooler

In order to safely put this increased HP down to the pavement, we must keep the transmission’s ATF fluid cool. Amazingly Ford equipped the 6F35 transmission with a thermostat controlled flow valve – so it only cools the fluid once it’s reached operating temp.

As a side benefit, installing a transmission cooler like this allows us to run a true CAI (cold-air intake):

2 Liter Ecoboost Oil Cooler

We also want to keep the engine oil cool for high boost runs. The larger 2L ecoboost vehicles like escape and explorer have a built in oil cooler, but the fusion has none. This is a good thing since we would delete it anyway and convert to a thermostat controlled air-to-oil Bar and plate heat exchanger:

Exterior: Paint and Body by Slickshot

While we deliver exhilarating performance to our kids, family and other passengers, we also need to look the part. Ford did a great job making the Fusion look great, stock – so we had to work carefully to avoid changing any of the clean body lines that make the car flow

Working with Sean McDermott @ Slick-Shot Paint in Phoenix, AZ he applied BASF lightning-silver paint and semi-matte clear to achieve the look we wanted. Slickshot had all the glass out of the car, exterior torn down painted and ready for our tight-schedule in record time.

We chose to use a carbon fiber front splitter. APR makes a great looking and functional front splitter that compliments the Fusion/Mondeo body lines and front bumper nicely:

Rims, Tires and Suspension

Traction and grip improvements come from MRR 19×9.5” +42 GF06 wheels wrapped in Toyo 255/35/19 tires and KSport coilover suspension and Big Brake kit. We made certain to match the OD but did not want any increase in rotational weight:

Electrical

To ensure we have more than enough electrical capacity, we’re using an Odyssey Extreme Racing Battery ER30 with tin-plated brass M6 stud terminals. This compact powerhousew weighs just 20 lbs and rated to 450 cold cranking amps with a whopping 950 pulse cranking amps, for 5 seconds, or 60 minutes of reserve capacity.