Turbocharger installation

Good afternoon and thanks for visiting.

Gaining performance from your engine can range from a little extra to the "immense" as you put it. There is an old adage when dealing with speed and performance. "Speed is a function of money, how fast do you want to go?"

Adding a turbocharger is nice way to get added performance especially if you wish to also retain some ability to be economical. But the addition of a turbo is not something that can be taken lightly and requires a lot of thought.

Depending on the amount of boost you want to add for the HP gain, the compression ratio of the engine may need to be modified (changing pistons to a lower ratio), adding a better head gasket or metallic o-ring type seals to the cylinders (machining required).

The volumetric efficiency and displacement of the engine must be taken into consideration along with the performance map of the turbo compressor. There are two phenomenon that you wish to avoid when using a turbo. Surge, and stall. These will occur if the turbocharger is not correctly sized for your engine.

To gain the large power you are referring to will require a lot more work than just bolting on a turbo. You will need to look at the exhaust system, camshaft, port polish, pistons, rings, possible changing to stronger connecting rods, ECU reprogramming, re engineering of the induction system and possibly upgrading the fuel injectors if they cannot handle the duty cycle of the extra fuel required by the extra mass of air induced by the boost pressure.

Still interested?
Jon

Is this a standard (normally aspirated) 2.0L or is this a turbo car already?

Jon

Okay then,

This will be a pretty large project then but starting off, based on the displacement and some assumptions made about the stock engine, I did some rough calculations. You would need to move about 750 CFM of air @ 6000 RPM to make 500 Hp. Shopping around, and I like Garrett by the way. ;) You would need a turbo that will work with a pressure ratio of 2.6 : 1 and maintain it best isentropic efficiency while moving 51 Lbm (pound mass of air)/minute.

Than being said, Take a look at the compressor map attached. The Garrett T-61 seems to be right sized for what you have and what you want to do. You see that the this turbo will be smack in the middle of the 76% efficiency zone.

For this I was assuming a 0.8 Volumetric Efficiency (Vol Eff) for the engine which is pretty conservative.

Main things you have to shop:
Exhaust system (may have to make some custom parts)
Turbo mounting flange (for exhaust)
Inter-cooler plus mounting kit
Intake piping and boots
Blow-off valve

You should find a reputable machine shop near you and talk to them about what you want to do. They can make recommendations on cylinder head modifications, cams, valves etc.
They should also be able to recommend what pistons to use given the amount of boost you will be running, recommendations on connecting rods and crankshaft as well as recommendation son what should be done to the block deck and or gasket substitution.

You will also need to look for someone who makes or modifies engine controllers that can re-do your fuel mapping to account for the extra charge air you will have. That is what I can think of off the top of my head.

Let me know if you have any other questions.
Jon