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I got the ignition box kit from Australia, but I haven't counted the parts yet. The assembly will be later, perhaps in the xmas time.

The new radiotor comes from a Saab 9000 with an electric fan. The core size is  500 mm x 400 mm x 36 mm (about 20" x 16" x 1 3/8").

I bought a small Ford Transit Connect air to air intercooler from local dismantler Felke. The core size is: length in flow direction 13 3/8", width 5 5/16" and thickness 3" (340 mm x 135 mm x 75 mm).

I should make some kind of guide plates to direct the air flow to the radiator and the intercooler. A few holes in the front part of the bonnet would assist that nicely, too. I just don't have the heart to put holes in the bonnet yet.

The radioator and the intercooler are in their places. The intercooler seems to work all right. The ignition is in pos. N (max -6 deg) and there is knock only after 7 psi (1.5 bar) when accelerating off WOT. I took away the intake air temperature sensor. The water temperature is around 175 F (80 C) at cruise and the fan blows only shortly in idle.

The programmable ignition is still waiting for assembly and tunung. I should get the ignition right with it.

The first runs with the intercooler gave nice results. I put the kick-down off and the upshifts took place from first to second at 5000 rpm, from second to third and from third to fourth at 5700 rpm. The mixtures were mechanical lambda = 0.92 (AFR = 13.5) and electronic target lambda = 0.95 (AFR = 14.0). The air was a little wet and the temperature was 37 F (+3 C). The car's weight was approx. 2860 lbs (1300 kg). I used the cold start injector in the best run. The ignition was about 6 to 8 degrees retarded from maximum. Under the run the mixture varied from lambda 0.86 to 0.97 (AFR 12.6 to 14.3). The results are in the graph below in seconds and mh/h. The time was about 16.38@86.0 mph (138.4 km/h). The result is a good match for the four speed automatics in magazine tests: MB  280E (16.3 Autocar 9.12.1992), 190E-2,6 (16.5 Autocar 22.4.1987) or 300CE (16.6 Motor 24.10.1987). Before the turbo the best time was 18.42@77.5 mph (124.7 km/h) which means two seconds off so far and the first goal (a 15 second street car) is only 0.4 seconds away! The rear wheel power has changed from 101 hp to about 142 hp according to ET calculator so there might be around 160 hp at the flywheel.

More tests with different fuel mixtures. The weather was rainy and temperature was 37 F (+3 C). Mixtures: mechanical lambda = 0.92 (AFR 13.5) and electrical target lambda = 1.00 (AFR = 14.7). Kick-down and ignition as before. The best run was 16.32 @ 87.1 mph (140.1 km/h). The power with a weight of 2800 lbs (1270 kg) is approx. 144 hp. 0-62 mph (0-100 km/h) took 8.52 seconds. The mixtures were in the region lambda  = 0,84...0,93 (AFR 12.3...13.7)(mean value about  lambda 0.89 / AFR 13.1) except for the first gear, where the mixtures went too lean. Extra enrichment (cold start injector) seemed to help at launch but felt a little sticky in the third gear.

The mixtures are about right for the moment, next I will focus on the air flow to the cooling system and the programmable ignition.

The temperature has fallen to 23...14 F (-5...-10 C) and there has been some starting difficulties and heating inefficiency

The starting problems may be that the CIS-E won't get enough air when the turbo

Just found out the reason for the starting troubles. The cooling fluid started to flow through the engine as steam in the exhaust and there was smoke and bubbles in the cooling expansion tank which means the sylinder head gasket has blown.

The CIS-E fuel pressure regulator has a nipple for a hose to the intake vacuum. It propably lowers the fuel pressure at vacuum. I might use this to rise the fuel pressure at boost, must try it some time?