OK, when you search for "TURBO" on Zuwharrie most people find very little info or pic's and most of the posts are people asking "how do I do it" or "who has done it". This lack of info and pic's is not really helping those people seriously interested in turbocharging their Samurai, Sidekick, or Tracker and we are going to change that. Here is what I have been calling my "junkyard" turbo setup as it was swapped in as fast as I could (took about 4-5 hours) to run it in a Tough Truck event a few months ago:
The motor has approximately 30,000 miles on it and is a JDM (Japanese import motor) and has a 1995 intake manifold and accessories, wiring and computer to control it.
The first pic was before I added the larger air filter up and away from water and mud and in this pic you can see the intake running over to the pass side fenderwell. The wiring to the mass-air sensor had to be extended and the 2 1/4" exhaust tubing was used to connect the turbo inlet to the mass-air then just a coupler to the air intake.....and yes that is a Ford Super Duty after market center cap with a K & N filter installed on it....works good!
This is a SAAB turbo with a custom made turbo exhaust manifold & SAAB intercooler. The piping is economical and easy to bend exhaust tubing with radiator hose and silicone couplers.
The blow-off valve (BOV) is a cheap one off eGay (will be upgraded soon) and the insulation is a basic header wrap material to help insulate the intake piping directly above the manifold from the heat.
The fuel pump is the stock 1.6 16 valve model out of a Tracker tank installed in the Samurai tank and the blue circular thing is a Rising Rate Fuel Pressure Regulator (RRFPR) that increases the fuel pressure as the boost increases so that it supplys enough fuel. A SAFC air/fuel controller is in the near future for it to help optimize the power and make it run even better.
Nothing has really been cleaned up on the motor as I have been experimenting with vacuum line sources and the RRFPR as well as a few other things. The mud is from the last Mud Bog at Gravedigger's and TurboZuki got 1st place in the 4 & 6 Cylinder classes (look under "Off-Road Pic's and Video" for some cool action shots and video's).
The Samurai is completely street friendly and still gets 20+ MPG, but I choose to run the higher octane fuel with the turbo. None of the low-end torque/power has been lost and there is almost no noticeable turbo lag at all. The Turbo isn not even noticeable for daily driving unless you punch it to pass someone or really accelerate from a stop light. I have had it up to 100 MPH and it was still accelerating! I'd like to take it somewhere to test the maximum speed without fear of a wreckless driving ticket! So far other than the cost and time involved in swapping on a turbo I cannot say there are many negatives to this swap, but no matter what it has to be tuned properly otherwise you will create problems for yourself. It is FASTER THAN ANY OTHER SAMURAI I HAVE EVER DRIVEN! Power estimate is well over 150 HP and I will take it to the dyno when I have time....sometime after GonZookin.
GOT QUESTIONS? I am sure I didn't cover everything..... Ask away and maybe we will end up with a "Turbo FAQ" or at least some decent info in a searchable thread.
Sean (Addicted to TURBO's!) DeVinneyAFTERMARKET4X4@cox.net