Custom Turbo Kits.pdf

Custom Turbo Kits 101

These instructions are designed for an Integra, however, they can be used for a Civic with

too! The only difference are the way the pipes connect!

I've made custom turbo kits for a while now. Why waste $500 for Intake and Headers when

you can drop down another $500 and make your own CUSTOM TURBO KIT and push a lot

more horsepower, plus get the respect from people on the street when you whoop a 4.6 Liter

Mustang!

The great thing about building a custom turbo kit is that you can buy the parts peice by

peice at a time , rather then buying a whole kit and waste all your money at once and go

broke all at once!

Before we start on the installation, please inspect the picture that I've provided. Each part is

individually labeled by a number. The picture will also give you a jist of how a turbo system

works! I will go through each item one by one to show you how they work. Once you

understand how it works, then we will being building our custom turbo kit! And the thing is, all

turbo kits mainly consists of just "pipes". If you look at the pic, notice how SIMPLE a turbo kit

is! It's mainly just "pipes"!

So next time when you hear someone shedding out $3000-$3500 for a turbokit, laugh at their

face because they are throwing money out of their pockets. With the other $2000 that you

save, you can use that money to build your motor to handle 16+ PSI on the streets. Or use

that money for a new paint job or whatever you wish!

1. This is the wastegate. It is an external one that connects to the turbo manifold. The exhuast

gases from the turbo manifold blows into the turbo and keeps on blowing. The turbo keeps on

spinning and spinning and you get more and more boost! But you don't want too much boost

or else your engine will blow up! (Too much boost = too much power = pistons can't handle

this power = goodbye motor! ).

So how do we regulate the turbo so that it does not overspin? We have a wastegate. The

wastegate sees how much boost you have in your engine. If you have it set at 7 PSI, when

the wastegate sees 7 PSI, it will open up and send the exhaust gases AWAY from the turbo

so the turbo does not keep spinning!

Imagine you have a windmill and you blow on it. It will spin and spin and spin. However, if you

put a sponge in front of your mouth, the windmill will slow down. Thats exactly what the

wastegate does. It slows down the air flow from the exhaust.

2. Turbo manifold/Turbo Header. This is the 2nd most important thing of a turbo system. It

collects the exhaust gases from all 4 exhaust ports and reroutes those exhaust gases into

one "big port". To explain this a little bit easier, imagine you have four straws. Imagine four

people have a straw and they each blow on theirs. And then you put the ends of the straw

together, voila! More efficient! Same concept with the turbo manifold.

3. Turbo, the heart of the system. Also known as the "Air Pump". Now that you have those

exhaust gases from the exhaust ports, you shoot those exhaust gases into the exhaust

turbine, which spins the compressor turbine. To understand the turbo, imagine you had one of

those windmills. And you blow on it. The blade spins. Same concept with the turbo, except

you have exhuast gases blowing on it. And imagine you connect another windmill to it. If you

blow on one windmill, the other windmill will also spin. The one that you blew on, is equivalent

to the "exhause turbine" on the turbo. And the one that spins along is equivalent to the

"compressor turbine" on the turbo. The compressor turbine sucks in air and compresses it

and pumps air out of it down into Pipe #5 (Goto 5. )

The oil needs turbo to lubricate its bearings! Without oil, the turbo will overheat. Imagine you

have a bicycle wheel turning at 300 RPMS. The bearings inside will not overheat because the

friction from 300 RPMs (Revolutions per minute) is nothing compared to that of a turbo.

Turbos run up to 60,000 RPMs. If a bicycle wheel spun that fast, the bearings would overheat

from friction and stuff would melt fast! Now imagine you sprayed oil on those bearings while

its spinning at 60,000 RPMs. Much better because the heat is carried away by the oil and also

the oil lubricates the bearings and causes LESS friction which means LESS heat. Same

concept with the turbo. Turbos LIVE on oil!

4. Downpipe. Now that you have the exhuast gases blowing through the exhaust turbine,

where does it go? It goes into the exhaust system. And to do that, the downpipe connects to

the turbine side and then the other end of the downpipe makes a funny "U" turn and connects

to the cat convertor. Easy as that! If you get a bigger downpipe, your turbo will spool up

faster. However, if you decide to get a 3 inch downpipe, it will not clear your Air conditioner.

5. Now that the turbo is pushing air/Pumping out air, we need to "capture" this air and send it

to the throttle body/intake manifold for the motor to use this pressurized air. To use this useful

air, we have to send it through a bunch of pipes! This is a pipe and the air goes down, then

connects to pipe #6.

6. Pipe #6 is a U bend, it makes a U bend and then connects to the intercooler (#7)

7. When you compress air, it gets HOT! If you don't believe me, have you ever touched an air

pump after you pump your tires? Most of that heat is from the compressed air. And the other

is from friction.

So how do we cool this hot air? We send it through the intercooler, the radiator looking thing!

Intercoolers work almost like radiators except you send air through it. With the intercooler, it

will cool the air a LOT.

8. Now, after the air leaves the intercooler, it goes into pipe #8 and makes a U bend, the goes

into pipe #9.

9. The air from pipe #8 now enters this pipe and then the air goes into the intake manifold for

your engine to use this useful compressed air.

10. The blow off valve. This is the device that gives you the nice "PsssssssHHH!" sound when

you let go of the gas while under boost. Not just that, it lets your turbo live longer. Why is

that? Imagine you had a peice of straw. And pretend that you are a turbocharger. Blow

through the pipe. Easy right? Now imagine you cover the end of it. It is very hard to blow

right? By covering the end of the peice of straw, that is EXACTLY like closing the throttle plate

on the throttle body. Because when you let go of the gas, the throttle plate closes.

Now, imagine you had a mini blow off valve on the straw. So that everytime you put your

finger/cover the end of the straw, the blow off valve opens. So the air goes through there.

Now it's easier for you to blow! And since its easier, that must mean its easier on the

turbocharger! Which means longer lasting turbo!

11. FMU. FMU stands for Fuel Management Unit. You will definetly need this because it adds

more fuel into your cylinders when you boost. If you force more air into the cylinders via a

turbo, you must add more fuel! And how do we add more fuel? There are a couple of

methods. We can make the injectors shoot in more or we can increase the fuel pressure. For

now, lets ignore the first method. And focus on the second method because that's what we

will be using!

All B series motors are fuel injected and use a fuel rail. The fuel rail is always under pressure

so that when the injectors open, the fuel shoots into the cylinders! What we can do is,

increase the pressure so that it shoots more fuel into the cylinders. To make it easier to

understand, imagine you had a water hose with nothing attached to the end of it. Now,

imagine you squeeze the end of it, more water shoots out! Thats because you increased the

pressure.

The FMU does the same thing! It "squeezes" the fuel lines to increase fuel pressure.

Without an FMU, your motor will blow up for sure! All FMUs have ratings, such as 12:1 or 8:1.

What that means is, if its a 12:1, it will raise fuel pressure 12 PSI per 1 PSI of boost. So if you

boost 7 PSI, then it will raise the fuel pressure to 7 X 12 = 84 PSI. When the fuel pressure is

raised, more fuel is added into the cylinders. Easy concept.

Now you get how a turbo system works right? Lets review.

1. Exhaust gases from the turbo is blown into the turbo.

2. The turbo is like a pump, it uses the exhaust gases (free energy) to pump air.

3. This pumped air is then blown into some pipes that connect to the intake manifold which

forces the air into the cylinders.

4. This pumped air from the turbo is HOT, so we use an intercooler to cool down this air

slighty before it enters the engine.

5. The blow off valve is used to relieve pressure from the turbo when you let go of the throttle

when under boost.

Ok, one more thing! Lets look at another "turbo kit" picture:

All the parts that I crossed out, you do not need! Also, notice how SIMPLE a turbo kit is...it's

mainly just pipes that you can buy from your Auto store or Home depot! So now you know

what a turbo kit really is...it's really just pipes and a big fat hairy turbo!

1. Downpipe

2. Turbo Manifold

3. Turbo

4. Silicone hoses/Clamps

5. Intercooler

6. Various Pipes

7. Oil line for turbo and various fittings for check valves, oil return etc...

8. Blow off valve

9. Wastegate

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