Maximum Boost

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

Absolute pressure, 26
Absolute temperature, 51
Accelerator pump delivery, 104
Actuators, 176
Actuator signal, 147
Acura NSX
construction sequence for, 206
emissions testing of, 210
fasteners for, 207
fit and finish for, 206
fuel injection analysis for, 198-200
gaskets for, 207
installing turbo system on, 191, 196-210
intercooler efficiency in, 209-210
intercooling value for, 202
lower side of finished assembly, 208 (fig. 17-20)
material selection for, 206
performance testing for, 200
performance verification
for, 210
preinstallation test data
for, 198
testing of system in, 207-208
turbine section in, 209
turboselection for, 200-202
turbo system layout for, 202-205
verifying turbo compressor effi­ciency, 208-209
Aerocharger
complexity of, 186 (fig. 16-7) com­pressor flow maps, 201
(fig. 17-10, 17-11)
embossed stainless gasket with, 207
Mobil Oil SHC630 for, 230
oil-wick-lubricated bearings, 183 (fig. 16-2)
VATN, 184 (fig. 16-4)
AFR. See Air/fuel ratio
Aftermarket turbo kits
buying, 16-18
HKS Supra turbo, 17 (fig. 2-3)
ic fuel injection, 86, 87
idle, 175
and intercooler, 71-72
meter for, 165, 171 (fig. 14-8), 175 (fig. 15-3), 207
necessity for correct, 19
testing of, 171
tuning of, 207
in wastegate, 150
Air-mass/air flow sensor, 86, 175
Air sensors, 97
Air temperature sensor, 86
Air-to-water intercooler
air/air core in, 67 (fig. 5-34)
charge-air heat exchanger, 67-68
coolant, 68-69
front cooler, 69
front-mounted heat exchanger, 70 (fig. 5-37)
front water coolers, 66 (fig. 5-31)
layout of, 67 (fig. 5-33)
intercooler, 221-23
items to remove, 215
preliminary steps for, 215
testing of, 228-30
tools and equipment for, 214-15
turbine outlet pipe, 218-19
turbocharger, 219-21
VATN actuator signal lines, 225-26
Air/air intercooler
adequate air flow to,
64 (fig. 5-27)
bends and section changes in, 62-63
cooling air estimate, 56 (fig. 5-14)
core flow area measurement, 54 (fig. 5-12)
core flow direction with, 58
core sizing for, 55-56
core streamlining in, 56
core thickness of, 58, 59 (fig. 5-19)
direct air path in, 65 (fig. 5-29)
drag and air stream, 63 (fig. 5-25)
duct inlet area in, 57 (fig. 5-17)
ducts in, 56-58
end-cap designs in, 61 (fig. 5-23)
end tank design, 60-61
enlarging of, 60 (fig. 5-21)
extruded tube style core, 57 (fig. 5-15)
frontal area, 56
hoses and connections, 63-64
in-cap design, 61
intercooler tube tie bars, 63 (fig. 5-26)
internal baffling in, 60
(fig. 5-22)
internal flow area in, 54-55
internal flow area measurement, 55 (fig. 5-13)
nomenclature of core in, 54 (fig. 5-11)
out-cap design, 61
placement of, 64-65
plumbing, 64 (fig. 5-28)
proper dusting, 58 (fig. 5-18)
round-edged extruded-typecore, 57 (fig. 5-16)
staggered-core, 65
top and bottom cores, 59 (fig. 5-20)
in Toyota GTP, 65 (fig. 5-30)
tube intersections and flow, 62: (fig. 5-24)
tube sizes and shapes, 61-62
Air bearings, 183
Air corrector jet, 101
Air duct
in horizontally mounted intercooler, 50 (fig. 5-5)
Air filter box
aftermarket kit installation, 224-25
bottom case function, 224 (fig. 18-19)
Air filters
defining and positioning of, 194
lack of, 177
larger, 195 (fig. 17-6)
trouble with, 178
Airflow rate, 26
formula for, 27-28, 200
Air/fuel ratio meter, 165, 175 (fig. 15-3)
Horiba model, 171
(fig. 14-8), 207
Air/fuel ratios (AFR)
for aftermarket turbo
kits, 16
detonation and lean, 179
devices for maintaining, 19-20
and electronic fuel injection, 86, 87
idle, 175
and intercooler, 71-72
meter for, 165, 171 (fig. 14-8), 175 (fig. 15-3), 207
necessity for correct, 19
testing of, 171
tuning of, 207
in wastegate, 150
Air-mass/air flow sensor, 86, 175
Air sensors, 97
Air temperature sensor, 86
Air-to-water intercooler
air/air core in, 67 (fig. 5-34)
charge-air heat exchanger, 67-68
coolant, 68-69
front cooler, 69
front-mounted heat exchanger, 70 (fig. 5-37)
front water coolers, 66
(fig. 5-31)
layout of, 67 (fig. 5-33)
in Maserati bi-turbo, 66 (fig. 5-32) for Nissan V-6 sand car, 72 (fig. 5-40)
and racing boats, 69 (fig. 5-36)
reservoirs, 69
variation on, 68 (fig. 5-35)
water pumps, 68
Air valves, 87
Ambient heat and
detonation, 179
Antisurge valve, 105-106
float-bowl pressure relief, 106 (fig. 8-10)
installation example, 107 (fig. 8-11)
Area/radius (A/R) ratio
choosing of, 32-34
and closing ports, 183 (fig. 16-3)
definition of, 32 (fig. 3-11)
and discharge area, 33 (fig. 3-12)
effect of varying, 33 (fig. 3-13)
and turbine housings, 183-84
and turbine size, 29
Atmospheric engines
driveability limitations with, 8
torque curve for, 8 (fig. 1-8), 11
Atmospheric performance
camshafts, 163
Auxiliary fuel pumps, 215-16
clamp holding, 216 (fig. 18-3)
positioning of, 216 (fig. 18-2)
power wire for, 217 (fig. 18-5)
wiring of, 216-17

B

Back pressure, 2, 131, 142 and exhaust gas, 179
and tailpipe, 170, 176, 178
and turbos, 132 (fig. 11-2)
Baffle-style turbo mufflers, 137
Ball bearings
improvements in, 182
oil-wick-lubricated, 183 (fig, 16-2)
Banks, Gale
big-block Chevy twin, 191 (fig. 17-1)
Barometric sensor, 86
Bearings, 163
Bell, Corky
depicted, iv
Bellows
stainless steel, 139
Bleed orifice, 151-52
Blow-through carburetor
system
plenum signal source for, 148
Blow-through turbo applications, 102, 104-109, 110.
See also
Draw-through turbo applications
aftermarket BMW 2002, 105 (fig. 8-7)
controlling fuel pressure, 104
fuel pump requirements, 105
plenum design for, 109
plenum vent ports, 110 (fig. 8-15)
preparing of, 107-108
suitable carburetors for, 109
vacuum and pressure
distribution, 106-107
Blueprinting, 8
BMEP. See Brake mean effective pres­sure
BMW 2002, 19 (fig. 2-5)
Bogging, 178
Bolt fastener, 127
Boost
excessive pressure, 176
low or sluggish, 177-79
Boost controls, 188. See also Waste­gate
fooling the wastegate, 150-52
need for, 141
overboost protection, 153 (fig. 12-21)
override safety device, 152-53
Boost controls, cont'd
remote boost-change device, 151 (fig. 12-19)
and restrictor, 141-42
and vent valve, 142
wastegate actuator signal, 147-48
wastegate description and
selection, 142-44
wastegate design features, 148-50
wastegate integration, 144-46
Boost gauge
placement of, 228
signal line for, 228 (fig. 18-25)
Boost pressure, 11-12, 16, 147, 196
and blow-through carb
system, 107
and compression ratio, 156
and desired power, 155
and engine knock, 141
excessive, 176
and fuel pressure, 96
and ignition retard, 113, 116
and intercooler, 50, 53, 71, 72
loss across throttle plate, 169 (fig. 14-5)
maximum, 229, 230
and turbocharger improvements, 185, 186, 189
venting of, 142 (fig. 12-3)
Boost-pressure-powered fuel pressure regulator, 92
Boost-pressure-sensitive switch, 19
Boost threshold (or point), 36
and driveability, 9, 11-12
and turbo size, 23, 36
Borla stainless steel mufflers, 204 two-path, 205 (fig. 17-16)
Brake mean effective
pressure, 7
Brake specific fuel consumption, 94
BSFC. See Brake specific fuel con­sumption
Burning gas
and compressive load
(fig. 1-4)
Burn rate
of fuel, 114
Bypass, 42 (fig. 4-5)
Bypass valve, 106

C

California Air Resources Board, 182
guidelines from, 196
exemption orders from, 192
Camshafts, 163, 164
Capacitor discharge unit, 111
Carbon composites, 187
Carbureted manifold, 82
Maserati Bora EFI
conversion, 83 (fig. 6-17)
Carburetion
blow-through system, 102, 104-109, 110
blow-through system layout, 101 (fig. 8-2)
draw-through system, 101, 102, 103-104, 110
draw-through system layout, 101 (fig. 8-1)
early turbo example, 102 (fig. 8-3)
Lotus hardware for Esprit, 102 (fig, 8-4)
Mikuni PH44 carbo, 103 (fig. 8-5)
over carburetion layout, 104 (fig. 8-6)
setup types, 101-102
Cast aluminum hypereutectic pistons, 161, 162
Catalytic converter, 131, 189
positioning of, 134, 192
and wastegate discharge, 138
Ceramic
coatings, 163
lighter-weight, 187 (fig. 16-8)
long-term durability of, 187 (fig. 16-9)
turbines, 186
CFM. See Cubic feet per minute
Charge heat, 162
Chrome, 211
CIS. See Continuous injection system
Clearance volume, 156
Clocking, 35
Coked-up bearings, 35, 39 (fig. 4-1), 46
Cold plug, 111 (fig. 9-1), 112
Cold-start emissions tests, 199 (fig. 17-9)
Cold starting, 11
Cold start valves, 108
pressure balances across, 109 (fig. 8-14)
Combustion chamber
combination gauges for, 115 (fig. 9-5)
Electromotive ignition system, 112 (fig. 9-2)
electronic ignition retard, 113
events in, 111-16
and fuels, 114-15
and ignition systems, 116
and ignition timing, 112
knock sensor for, 113
and spark plugs, 111-12
voltage, 111
Combustion rate
of fuel, 114
Compression ratio
approximate boost-pressure varia­tion, 156 (fig. 13-2)
and boost-pressure allowables, 155 (fig. 13-1)
calculating change in, 156-57
changing, 157
defining, 157 (fig. 13-3)
and performance factors, 155
for turbocharged
engine, 64
Compressor
efficiency, 28-29, 37
protection while installing
turbo, 221
selecting size of, 26-29
and system performance, 24-25
Compressor bypass valves, 99, 104, 105-106
for Acura NSX, 205
float-bowl pressure relief, 106 (fig. 8-10)
and float/plenum pressure, 106 (fig. 8-9)
location of, 205 (fig. 17-17)
Compressor discharge temperature vs. pressure ratio, 29 (fig. 3-6)
Compressor efficiency, 28-29, 37
formula for, 201-202
Compressor inlets, 36, 223
Compressor inlet hoses, 178
Compressor inlet temperature, 166
gauge for measuring, 166
(fig. 14-2)
Compressor outlet, 147
pressure, 166
temperature, 167
Compressor retainer nut
tightening of, 177 (fig. 15-4)
trouble with, 177
Compressor surge, 20-21
Computer chips (EFI)
reprogramming of, 90
Connecting rod, 163
and burning gas pressure, 4 (fig. 1-4)
power and inertial loads, 3, 4 (fig. 1-5), 5
Conservative camshaft profiles, 8, 11-12
Continuous injection system, 85
Coolant temperature sensor, 86
Coolant temperature sensor
circuit, 89
Coolant-temperature-signal-change-based fuel system, 90 (fig. 7-4)
Copper-alloy locknuts, 127
Copper wire rings
in head gaskets, 159 (fig. 13-4)
Cruise
air/fuel ratio, 171
Cruise control actuator
relocation of, 226
Cruising, 11-12
Cubic feet per minute, 27
for four-stroke-cycle engines, 27 (fig. 3-5)
Cylinder block
preparing of, 158
Cylinder head
preparing of, 157-58

D

Dellorto carburetors, 109
Density change formula, 202
Density ratio, 27, 28
vs. pressure ratio, 26 (fig. 3-4)
Detonation
and aftermarket turbo
kits, 16
causes of, 178-79
and charge heat, 162
definition and destructiveness of, 179
and fuels, 114, 115, 178
and high compression
ratio, 164
piston and heat-
induced, 161
and pre-ignition, 112
and safety devices, 154
and temperature, 2, 179
testing aftermarket turbo kit, 229
Dial-a-boost, 151
Digital fuel injection, 98
Diode-readout mixture indicator, 171 (fig. 14-8)
Displacment volume, 156
Drain hose
routing of, 44-45
size of, 44
Draw-through carbureted system, 175
Draw-through throttle designs, 99
Draw-through turbo application, 101, 102, 103-104, 110
Drilled-cores
for glass-pack mufflers, 137 (fig. 11-15)
Driveability, 8-12, 13
Drivetrain, 13
Ductile iron, 119
Duct inlet, 57 (fig. 5-17)
Durability, 6

E

"Economy cam," 9
Efficiency
and power, 2
turbo compressor, 7
volumetric, 13
EFI. See Electronic fuel
injection
Electromotive, 98
engine-management system, 97 (fig. 7-20)
Electronic fuel injection (EFI)
adaptation in Acura Integra, 86 (fig. 7-2)
aftermarket systems, 97-98
calculating injector size, 94
extra injectors for, 92-94
and flowmeter integration, 99 (fig. 7-23)
four-barrel carbureted manifold conversion, 97 (fig. 7-19)
fuel injectors and pulse duration, 87-88
fuel pump requirements, 95-96
hardware for aftermarket, 98
modern engine management sys­tem, 85 (fig. 7-1)
modifying stock sytems of, 88-92
principle and sensors, 86-87
testing injectors, 94-95
Electronic ignition retard, 113
MSD ignition retard, 113 (fig. 9-3)
Embossed stainless gaskets, 207
Emissions laws, 181, 182
Emissions testing, 210
End-gas temperatures, 6
Engine
assembly balancing, 163
atmospheric, 8, 9
camshafts, 163
carbureted, 75
cfm for four-stroke-cycle, 27 (fig. 3-5)
Chevy/Ilmor Indy, 189 (fig. 16-11)
Cosworth V-8, 75 (fig. 6-1)
cylinder block preparation, 158
cylinder head preparation, 157-58, 164
developments in turbo charged, 189-90
fuel-injection equipped, 75
head clamp-up improvement, 160
head gasket improvement, 158-60
inspecting for turbo-induced dam­age, 173-74
Engine, cont'd
loads related to components, 2 (fig. 1-2)
modern management system for, 85 (fig. 7-1)
preparing of, 155-64
six cylinder inline, 127
torquing head fasteners, 160-61
turbo pistons, 161-63
wear and maintenance, 13
withstanding power output, 2-6
Exducer bore
and compressor power, 31 (fig. 3-10)
definition of, 31 (fig. 3-9)
and turbine size, 31
Exhaust gas temperature gauge, 211
Exhaust housing
trouble with, 176-77
Exhaust leaks, 177
Exhaust manifold, 117 (fig. 10-1)
adaptation of production, 124 (fig. 10-12)
in aftermarket turbo
system, 217-18
aluminum, 119
anti-reversion cone, 120 (fig. 10-4)
application of, 117
big-block Chevy design, 118 (fig. 10-2)
casting process, 124
cast iron, 118-19
compact design, 121 (fig. 10-6), 129 (fig. 10-19)
design criteria for, 117-19, 129
designing and building, 196
fasteners in, 127
four-into-one design, 121 (fig. 10-5)
gaskets in, 128-9, 130
Jim Feuling"s Quad 4, 122 (fig. 10-8)
log-style, 120 (fig. 10-3)
mild steel, 119
reversion in, 119
role of, 117
single-turbo V-8 exhaust plumbing, 128 (fig. 10-18)
single V-8 turbo design, 118 (fig. 10-2)
slim-profile nut for, 218 (fig. 18-7)
stainless steel, 118
styles of, 119-23
system air from above, 195 (fig. 17-7)
thermal characteristics of, 119
thermal expansion in, 126
tubing sizes, 120-24
turbo held to, 22, 218
(fig. 18-6)
twin turbo design, 118 (fig. 10-2)
V-8 casting, 118 (fig. 10-2)
V-12 custom header, 121 (fig. 10-7)
VW GTI design, 118 (fig. 10-2)
wastegate integration in, 124-25
Exhaust manifold pressure.
See Turbine inlet pressure
Exhaust systems, 131-40.
See also Tailpipes
for Acura NSX, 204-205
best for turbo, 131 (fig. 11-1)
catalytic converter position in, 134
design considerations for, 132-39
expansion joints, 134-35
fitting of exhaust tubing, 134 (fig. 11-6)
flanges for, 139
flow area and power, 133 (fig. 11-4)
front-wheel-drive requirements, 140
future improvements in, 189
hangers in, 135
mufflers, 136-38
oxygen sensor position in, 134
tailpipe tips, 139
wastegate integration, 138-39
Expansion joints, 134-35

F

Fasteners
for Acura NSX, 207
for exhaust manifold, 127
in exhaust system, 139
strengthening ribs between, 132 (fig. 11-3)
F-CON computer, 91 (fig. 7-6)
Feuling, Jim
Quad 4 system, 193 (fig. 17-3)
Flanges, 35
in exhaust system, 139
Flex joints
for four-wheel drive-vehicles, 140
Floats in blow-through carburetors, 107
Flow capacities, 105
Flow failures, 176
Flowmeter, 175
Flowmeter/filter case assembly, 224 (fig. 18-20)
Flow velocity in exhaust manifold, 129
Forged aluminum pistons, 161
Formula 1 race cars, 1
Fuel economy and volumetric efficiency, 13
Fuel enrichment
discussions of, 19, 20
Fuel enrichment switch, 20
Fuel flow
in carburetor, 101
Fuel injection analysis, 198-200
Fuel injection manifold
applications for, 75-76
injector location, 80
plenum, 79
progressive throttle
bodies, 82
and runners, 77-78
throttle bodies, 80-81
Fuel injectors. See also
Electronic fuel injection
and maximum pulse time, 88 (fig. 7-3)
and pulse duration, 87-88, 198, 199
Fuel lines, 87, 95
Fuel octane and detonation, 178
Fuel pressure increasing, 92
Fuel pressure check gauge, 227
placement of, 227 (fig. 18-24)
removal after testing, 230 (fig, 18-27)
Fuel pressure regulator, 87, 95, 104
aftermarket kit installation, 226-27
boost-pressure sensitive, 105 (fig. 8-8)
fuel and signal lines, 227 (fig. 18-23)
rising-rate, 226 (fig. 18-22)
signals origination for, 108 (fig. 8-12)
Fuel pumps, 87
and blow-through carburetion, 105 Bosch, 95 (fig. 7-15)
flow versus engine bhp, 96 (fig. 7-17)
flow versus fuel pressure, 95 (fig. 7-16)
in parallel, 96 (fig. 7-18)
requirements for, 95-96
Fuels
for aftermarket turbo kits, 230
combustion rate of, 114
burn rate of, 114
and combustion chamber, 114-15
Fuel system calibration, 8, 9, 11-12
Full-throttle air/fuel ratio, 171

G

Gaskets
for Acura NSX, 207
in blow-through carburetors, 108
in exhaust manifold, 128-9, 130
in exhaust system, 139
Glass-pack mufflers
types of cores for, 137 (fig. 11-15)

H

Haltech, 98
Australian EFI, 98
(fig. 7-21)
Hangers, 135
simple, 136 (fig. 11-11)
Head gaskets
with double O-ring, 160 (fig. 13-7)
improvement in, 158-60
strength of, 164
various wire rings for, 159 (fig. 13-4)
with O-ring, 159 (fig. 13-6)
without O-ring, 159 (fig. 13-5)
Heat-induced warpage, 126
and header, 126 (fig. 10-15)
Heat transfer area
in intercooler, 48-49
Higher-pressure fuel system, 217 (fig. 18-4)
HKS piggyback computer, 90 (fig. 7-5)
Hobbs, David, 179
Holley carburetors, 109
Horiba air/fuel ratio meter, 171
(fig. 14-8), 207
Hot plug, 111 (fig. 9-1), 112
Hot starting, 11

I

Ideal temperature rise, 28
Idle controls, 87
Idle jets, 101, 104
Ignition retard
aftermarket kit installation, 228
over-active, 178
Ignition timing and detonation, 178
Inertial loads, 2-3, 8, 12, 13
compressive, 2, 3
connecting-rod, 3 (fig. 1-3)
tensile, 2, 3
Injector pulse duration
lengthening of, 88-89
Injectors
additional, 92 (fig. 7-10)
add-on fuel supply, 93
(fig. 7-12)
calculating size of, 94
extra, 92-94
flow-test rig, 94 (fig. 7-14)
for inline-six Nissan
manifold, 93
staged secondaries, 93
(fig. 7-13)
standard, 80 (fig. 6-12)
testing of, 94-95
upstream, 80 (fig. 6-13)
Intake manifold
carbureted manifold, 82
Chevy Super Ram, 76 (fig. 6-3)
EFI manifold, 77 (fig. 6-5)
fuel injection manifold, 75-82
layout, 98
log-style, 76 (fig. 6-2)
measuring pressure in, 168-69, 170
Mitsubishi V-6 design, 83 (fig. 6-18)
plenum, 76 (fig. 6-2)
proper, 83
sourcing signal from, 147, 148
symmetrical vs. non-symmetrical, 77 (fig. 6-4)
Intake plenum signal source, 148
Intake runners, 77
design of, 77 (fig, 6-6)
intersection with plenum, 79 (fig. 6-10)
Integral wastegates, 37, 143, 144 (fig. 12-7), 146
(fig. 12-11), 146 (fig. 12-12), 153
modification for increased boost, 151 (fig. 12-18)
variation on, 147 (fig. 12-13)
Intercooler and intercooling, 51 (fig. 5-6). See also Air/air
intercooler; Air-to-water
intercooler
aftermarket kit installation, 221-23
air/air, 52 (fig. 5-8), 53, 72
airflow as installed, 222 (fig. 18-16)
air-to-water, 66-69, 72, 73
ambient temperature measurement, 168 (fig. 14-3)
in blow-through carb
systems, 110
boost and increase in, 72
(fig. 5-39)
calculating efficiency of, 52
(fig. 5-9)
calculating value of, 50-51
choosing type of, 53
configurations for, 72-73
definition and merits of, 71-72
Intercooler and intercooling, cont'd
design criteria for, 48-50
design of air/air, 53-64
and detonation, 179
and driveability, 9
efficiency of, 209-210
extruded-tube core of, 49 (fig. 5-4)
Ferrari Turbo GTO, 194 (fig. 17-5)
front-mounted, 48 (fig. 5-2)
interconnecting tube installation, 223 (fig. 18-17)
one-shot, 70
outlet conditions, 168
overview of, 47-48
plate-and-shell core of, 49 (fig. 5-4)
plate-style cores, 53 (fig. 5-10)
plumbing from, 204 (fig. 17-15)
Porsche, 194 (fig. 17-4)
positioning in aftermarket kit, 222 (fig. 18-15)
positioning of, 193, 204 (fig. 17-14)
staggered-core, 58, 65-66
tightening hose clamps, 223 (fig. 18-18)
tubes, 222-23
and turbo charger
development, 188
and turbo pistons, 162
value of, 202
water-based, 53 (fig. 5-9)
and water injector, 70, 73-74
water spray on, 70
in XKE Jaguar, 73 (fig. 5-41)
zero-resistance, 72
Intercooler efficiency, 52
and boost-pressure variation, 156 (fig. 13-2)
Interference-style
lockwashers, 127
Interheater, 65
Internal flow area
in intercooler, 49
Internal volume
in intercooler, 49-50
Inverted-sound-wave silencer, 189

J

J & S Electronic knock
sensors/indicators, 114

K

Knock-sensor-controlled ignition tim­ing, 115
Knock-sensor ignition retard, 113
active knock-detection
system, 114 (fig. 9-4)
Knock sensors, 113-14
failing, 178

L

Lag
and driveability, 9, 10-11
and two turbos, 34
for varying sized turbos, 11 (fig. 1-10), 23
Lambda systems, 20
Laptop computers
for aftermarket EFI, 98 (fig. 7-22)
Leakdown test
checkout, 174 (fig. 15-2)
described, 174
Lockwashers, 127
Loctite, 108, 222
Louvered-core
for glass-pack mufflers, 137 (fig. 11-15)
Lubrication, 39
and coked-up bearings, 40
and friction reduction, 161
and low-mounted turbos, 45
oil coolers, 42
oil drain system, 44
oil filters, 43
oil flow and pressure, 41
oil lines, 43-44
oil selection, 40
oil system aids, 45-46
types of, 40
and water-cooled bearing housings, 40

M

Main jets, 101, 104
Mandrel-bent tubes, 122, 206
Manifold absolute pressure sensor, 87
Manifold vacuum/pressure sensor, 87
MAP sensor. See Manifold absolute pressure sensor
Marine bilge pumps, 68
Mass flow EFI system, 86
Mazda Miata
installing aftermarket turbo system, 213-30
Performance Techniques design, 20 (fig. 2-6)
Metal-braid-protected lines, 43
Mikuni carburetors, 109
Mikuni PHH dual-throat sidedraft, 109
Mileage
and turbocharger, 13
Mineral-based oils, 42
Misfires, 175, 178
Mitsubishi 3000 GT, 15 (fig. 2-1)
Molysulfide, 112, 161
Motec air/fuel ratio meter, 171
Motorcraft two-barrel carburetors, 109
Mounting flanges, 150
Mufflers. See also Exhaust systems
Flow-master, 136 (fig. 11-13)
glass-pack, 137 (fig. 11-15)
parallel glass-pack, 137 (fig. 11-14)
positioning of, 196
styles, sizes, and number, 136-38
Super-Trap design, 136 (fig. 11-12)
and wastegates, 153

N

Never-Seize, 112, 217, 218, 221
Ni-Resist, 36
Nissan 300ZX Turbo, 23, 24
Nonsequential EFI systems, 87, 88, 89
Nozzle size (EFI)
increasing of, 90-92

O

Octane improvers, 115
Octane rating of fuel, 115
OEM. See Original Equipment Manu­facturer
Oil
for aftermarket turbo kits, 230
changes, 35, 39
coolers, 42-43
flow and pressure requirements, 41
mineral-based, 42
selecting, 40
synthetic, 42
Oil drain system, 44-45
inlet and outlet positions, 45 (fig. 4-8)
Oil feed-line installation, 43 (fig. 4-6)
Oil filters, 43
Oil lines, 43
and brace at frame, 44 (fig. 4-7)
Oil spray
on piston bottom, 162, 163
(fig. 13-11)
Oil sump, 44, 46 (fig. 4-10)
oil drain fitting for, 45 (fig. 4-9)
Oil system aids, 45-46
Oil temperature gauges, 43
One-shot intercoolers, 70
ice-chest heat exchanger for, 71 (fig. 5-30)
Original Equipment Manufacturer
turbo cars, 16, 39
and weak links, 16
Override safety devices, 152-53
Oxygen sensor, 87, 134, 171, 192

P

Peak pressure, 4, 5
Performance
and engine preparation, 155
verification, 210
Petty, Richard, 115
Pipe-thread fittings, 196
PLAN equation
and power gain, 7-8
and power output, 7 (fig. 1-7)
Plenum, 79
in blow-through turbo applications, 109
intersection with intake runner, 79 (fig. 6-10)
with multiple throttle plates, 76 (fig. 6-2)
for Porsche Indy engine, 79 (fig. 6-11)
entering throttle bodies, 147
vent ports, 110 (fig. 8-15)
Porsche 911 Turbo, 23, 24
Porsche TAG turbo engine, 1 (fig. 1-1)
Port sizes, 8, 9, 11-12
Power
and boost pressure range, 155
loss of, 176
and multiple turbos, 34-35
and turbo size, 23
Power loads, 3-6, 12
compressive, 2, 3
and crank angle, 5 (fig. 1-6)
Pre-ignition, 112.
See also Detonation
Pressure ranges, 105
Pressure ratio, 26, 28
vs. compressor density ratio, 26 (fig. 3-4)
vs. compressor discharge tempera­ture, 29 (fig. 3-6)
formula for, 165, 167
and heat, 166
Pressure-sensitive ignition
retard, 113
Primary scroll turbine-housing, 184
Progressive throttle bodies, 81, 82
linkage, 82 (fig. 6-15)
Neuspeed"s large VW, 82 (fig. 6-16)
Puddling, 103, 110
Pulse duration, 86
extending of, 89
of fuel injector, 87-88, 198, 199
Pulse signal interceptors, 90

Q

Quality control
for aftermarket turbo kits, 17

R

Real temperature rise, 28
Redline pulse duration, 89
Reformulated gasolines, 115
Relays, 87
Remote wastegate, 143, 144
(fig. 12-7), 153
Restrictors, 42, 42, 141-42
aftermarket kit installation, 225
and oil pressure reduction, 42 (fig. 4-4)
tailpipe, 141 (fig. 12-2)
Reversion, 142
Ring land area, 162
Rising-rate fuel pressure regulator, 91 (fig. 7-7, 7-8), 92 (fig. 7-9), 207 (fig. 17-19), 226 (fig, 18-22)
Rod bolts, 163
Runners
for fuel injection manifold, 77-78

S

Sandwich-type gaskets, 207
Scavenge pump, 45
Secondary scroll turbine
housing, 184
Sequential EFI systems, 87, 88, 89
Signal block, 206 (fig. 17-18)
Signal lines, 176
SK carburetors, 109
Soft spots, 135
Spark plugs, 111-12
Speed density EFI systems, 87
Split-inlet exhaust housing, 34 (fig. 3-14)
Squish volume, 157
Staggered-core intercooler, 58, 65-66
Stainless mechanical locknuts, 127
Stainless steel
braid lines, 43-44
in fastener bolts, 127
Steel wire rings
in head gaskets, 159 (fig. 13-4)
Straight-through glass-pack mufflers, 137
Stud fasteners, 127
Studs
compression and tensile stress, 161 (fig. 13-9)
heads held on by, 160 (fig. 13-8)
and tension, 160
Surge limit, 29
Swages
as flex joints, 135 (fig. 11-10)
for tailpipes, 135 (fig. 11-9)
Synthetic oils, 42

T

Tachometer circuit, 87
Tailpipes, 131
back pressure measurement for, 170
Borla, 140 (fig. 11-19)
for front-wheel-drive, 140
hangers for, 135
and joint reliability
problems, 140
restriction distribution, 170 (fig. 14-7)
restrictor for, 141 (fig. 12-2)
sizing of, 133
swaged joint for, 135 (fig. 11-9)
tips for, 139
trouble with, 176, 178
for wastegate, 138 (fig. 11-16), 146, 147, 153
Temperature. See also Intercooler and intercooling
absolute, 51
air pressure, altitude and, 28 (fig. 3-1)
and boost, 141
compressor inlet, 166-68
and detonation, 2, 179
end-gas, 6
and engine improvements, 190
in exhaust gas, 198
in exhaust manifold, 117, 122, 126, 128, 129
in exhaust system, 132, 134 (fig. 11-7), 135
formula for rise in, 52-53, 167
header bolts and, 126 (fig. 10-16)
ideal rise in, 28
measurement equipment, 165
measurement points, 169 (fig. 14-4)
and mep, 25 (fig. 3-3)
and piston damage, 161, 162
real rise in, 28
turbine bearing, 6
and turbo size, 25 (fig. 3-2)
warpage, 126 (fig. 10-15)
and wastegate, 149
water-and-non-water cooled bear­ings, 41 (fig. 4-3)
Testing
air filter flow loss, 165-66
air/fuel ratio, 171
ambient temperature in intercooler, 168
compressor inlet temperature, 166
compressor outlet conditions, 166-68
equipment and tools for, 165
intake manifold pressure, 168-69
intercooler outlet conditions, 168
tailpipe back pressure, 170
turbine inlet pressure, 169-70
Thermal controls
in aftermarket turbo kits, 17
Thermal efficiency
and intercoolers, 60, 61
Thermal expansion
of exhaust system, 134 (fig. 11-7)
and joint at transmission, 135 (fig. 11-8)
and pistons, 162
and wastegate vent tube, 138 (fig. 11-17)
Thermal loads, 12, 13
Thermal management, 6
Throttle bodies, 80-81
on Chevy small-block manifold, 81 (fig. 6-14)
connections to, 196
measuring pressure loss across, 169 (fig. 14-5)
Throttle position sensor, 87
Throttle response, 10, 155
Throttles, 147
Throttle shafts, 108
fuel leakage at, 108 (fig. 8-13)
Throttle valving, 98
Through-bolt fastener, 127
Through-bolts, 207
TIP. See Turbine inlet pressure
Toluene, 115
Tools and equipment
for turbo kit installation, 214-15
Torque, 8
and boost, 14
curves, 8 (fig. 1-8)
and friction, 160, 161
and smart wastegate controls, 188
turbo capability graph, 10
(fig. 1-9)
turbo size and low-speed, 23
Toyota GTP, 65 (fig. 5-30), 125
(fig. 10-14), 130 (fig. 10-20)
Transmission, 13
T6 heat-treated hypereutectic
alloys, 161, 162
Tube sizes
for exhaust systems, 132-33
Turbine
role of, 25
selecting size for, 29-34
speed and size of, 37
Turbine inlet pressure, 169-70, 209
measurement of, 170 (fig. 14-6)
Turbine outlet flange connections, 133 (fig. 11-5)
Turbine outlet pipe
in aftermarket turbo system, 218-19
positioning of, 219 (fig. 18-9)
preparation of, 218 (fig. 18-8)
Turbocharged engines
factory manufactured, 16
power from, 12
pricing of, 21
Turbocharged vehicles
aftermarket kit purchases for, 16-18
building own system for, 18
buying OEM, 16
methods for acquiring, 15
Turbochargers
aftermarket kit installation, 219-21
installation preparation, 219 (fig, 18-10)
interconnecting tube installation, 223 (fig. 18-17)
oil reservoir filling, 220 (fig. 18-12)
oil reservoir sealing, 220 (fig. 18-11)
Turbocharger systems, iv-v
and accidents, 173 (fig. 15-1)
Acura NSX installation, 196-210
aftermarket kit installation, 213-30
for BMW 535i, 197 (fig. 17-8)
big-block Chevy twin, 191 (fig. 17-1)
and boost production, 13
Callaway twin turbo Corvette, 18 (fig. 2-4)
Capri V-6 draw-through, 192 (fig. 17-2)
carbureted, 99
Chevy Camaro, 22 (fig. 22)
classic, 23 (fig. 3-1)
compressor efficiency verification, 208-209
compressor size in selecting, 26-29
defining actual, 196-210
defining theoretical, 191-196
desirable features in, 35-36
difficulty in installing, 210
driveability limitations of, 8-12, 13
emissions testing, 210
engine improvements for, 189-90
fuel injection analysis, 198-200
of future, 188 (fig. 16-10)
hardware for, 188-89
improvements in, 182-87
Indy car, v
intercooler efficiency, 209-210
intercooling value in, 202
layout decisions for, 202-205
layout of intercooled, 47 (fig. 5-1)
long-term durability of, 6
low boost response from, 177-79
lubrication of, 39-46
malfunction, 173 (fig. 15-1), 175-77
Mitsubishi 3000GT, 15
(fig. 2-1)
modern fuel-injected
system, v
multiple, 34-35
performance testing, 200
performance verification, 210
positioning components within, 193-96, 203
(fig. 17-12, 17-13)
and power gain, 7-8
power output of, 1-6
preinstallation test data, 198
pricing of, 21
selection guidelines for, 24-26
size selection, 186
small-block Chevy, 21 (fig. 2-7)
split inlet exhaust housing, 34 (fig. 3-14)
staged and staggered, 189
testing of, 165-71, 207-208
troubleshooting guide for, 180
trouble with, 173-80
turbine section, 209
turbine size in selecting, 29-34
turbo selection, 200-202
twin turbo big-block, iv
Turbocharging
developments in, 181-90
future in, 182, 188 (fig. 16-10)
VW 0-60 time, 181 (fig. 16-1)
Turbo compressor efficiency, 6
Turbo connections, 35-36
Turbonetics H-3 compressor, 30 (fig. 3-8)
Turbonetics 60-1 compressor, 30 (fig. 3-7)
Turbo performance camshafts, 163
overlap in, 164 (fig. 13-12)
Turbo pistons
heat removal from, 162-63
materials for, 161-62
mechanical design of, 162
ring lands on, 162 (fig. 13-10)
Turbo section clocking, 35
Turbo-to-tailpipe joint, 132
Turbulators, 55
Twin scroll turbine housing, 184
Twin turbos, 37
Two-level boost switch, 151

U

U. S. Environmental Protection Agen­cy, 196

V

Vacuum/boost gauge, 165, 209 (fig. 17-21), 211
Vacuum check valve, 228
Vacuum leaks, 175
Valve cover breather
hose routing to, 225
restrictor inside, 225 (fig. 18-21)
Valve gear, 163
Valve trains, 164 Vane position actuator
adding signal lines to, 219 (fig. 18-10)
Variable area turbine nozzle, 184, 185, 189
details of, 185 (fig. 16-5)
response time of, 185 (fig. 16-6)
success of, 186
turbo for, 197
Varicom VC200 acceleration comput­er, 200, 210
VATN. See Variable area turbine nozzle
VATN actuator signal lines
aftermarket kit installation, 225-26
VATN turbocharger, 153
Venturis, 104, 147
Volumetric efficiency, 13

W

Wall thickness
in exhaust manifolds, 122
Warranties
for aftermarket turbo kits, 17, 21-22
Wastegate, 142-43
actuator signal for, 147-48
and adapters, 143 (fig. 12-6)
adjustability of, 149
bleed angles into, 145 (fig. 12-10)
and boost control, 142 (fig. 12-4)
cracking pressure of, 149
design considerations for, 149
electronic/pneumatic controls for, 152
failures in, 176
flexible vent tubes, 148 (fig. 12-14)
fooling, 150-52
heat isolation in, 149
HKS, 143 (fig. 12-5)
HKS Electronic Valve Controller, 152 (fig. 12-20)
on Honda CRX, 139 (fig. 11-18)
importance of, 153
integration of, 138-39, 144-47, 153
mounting flange in, 150
safety devices for, 152-53, 154
selecting, 143-44
separate tailpipes for, 138 (fig. 11-16)
signal origination for, 108 (fig. 8-12)
signal source, 148 (fig. 12-15)
trouble with, 177-78
valves, 176
venting of, 145 (fig. 12-9)
vent tube, 138 (fig. 11-17)
Wastegate actuator
altering spring in, 150
Wastegate integration, 124
into exhaust manifold, 125 (fig. 10-13)
in Toyota GTP engine, 125 (fig. 10-14)
Water-based heat exchanger, 48 (fig. 5-3)
Water-cooled bearing sections, 35
Water-cooling jacket, 39
Water injectors, 70, 73-74
Water jackets, 103
with turbo bearing sections, 36 (fig. 3-15)
Weber carburetors, 109
Weld el manifold, 122
(fig. 10-9)
described, 122
as functioning art, 123
(fig. 10-10)
reducers selection chart, 124 (fig. 4-2)
selection chart 90-degree
elbows, 123 (tab. 10-1)
for triple-turbo Jaguar, 123 (fig. 10-11)

Z

Zero-resistance intercoolers, 72