If everything goes to crap at 10# of boost then I would lean more towards the ignition module/coil pack.
You mean the car's been running that badly since it came from the dealership over a year ago??? What have you been doing since?
I thought the same at first but he says in the original post that he's already swap tested these with known good parts. Might double check this.
It's been a year, doubt if they would do anything. And would I even want them to!
Well, you screwed up. You should have taken it back right away when you noticed the intcooler fan problem. Your right they probably won't do anything, so thats water under the bridge now.
The car has not run right since the timing chain replacement back in January of 2003!
I hate to say it but with all the things you've already checked and the fact that you can't keep an intercooler fan on the thing, I would have to check and see if they did the timing chain install correctly and everything was buttoned up right. Figure out whats destroying those intercooler fans and go from there. Good Luck.