How to Build Your Own GSR Turbo Kit
It's no secret that turbocharging is the ultimate way to increase an engine's horsepower. Even inexpensive, low-boost kits can add 60 or more horsepower to your Integra GSR when set up properly. As the Integra has been a popular application in the "tuner car" culture for over a decade, there are numerous options available if you're looking to turbocharge, including full kits from various aftermarket manufacturers. However, if you want to turbocharge your GSR on a budget, building your own turbo kit may be the route to go.
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Things You'll Need
- Turbocharger
- Intake
- Oil lines
- Coolant lines
- Intercooler w/ piping
- Blow-off valve
- exhaust manifold
- Wastegate
- Downpipe
- Engine management system
Instructions
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1
Decide which turbocharger you want to use for your setup. A popular choice for the Integra GSR is the 14b turbo used in the first generation Mitsubishi Eclipse and Eagle Talon vehicles. The 14b is one of the cheapest and most frequently used turbos. Other popular choices are the T-25 turbo found in the second generation Eclipse and Talon, as well as various Nissan turbos, such as the T3 that came stock on the Nissan Z31 300ZX. Search local car enthusiast forums as well as public classifieds, such as found at Honda-Tech.com and Hondaswap.com, to locate one of these turbochargers.
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2
Gather supporting parts for your turbocharger. For intake, there are many "universal" air filters that can be used--simply measure your turbo's intake and find a filter with an equal diameter. Most stock turbos are made with internal wastegates, but these are sometimes removed, requiring the use of an aftermarket external wastegate. If you don't want to purchase an external, insure your turbocharger has its internal wastegate intact. For oil/coolant lines, various rubber hosing and T-fittings will be required. These can be purchased at most local auto parts dealers and custom fitted to your setup--refer to Honda enthusiast websites for helpful routing diagrams.
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3
Purchase an intercooler and piping kit. Air charged by the turbocharger is substantially heated; thus an intercooler system is needed to cool the air before it enters the engine. Used units from the stock turbo applications listed in Step 1 can often be found in enthusiast classifieds; however, these will require custom piping. As the price of fabricating custom pipes is often more expensive than purchasing aftermarket kits, it's best to locate an intercooler system that includes piping custom-made for the Integra, such as a secondhand custom kit or those made by numerous aftermarket companies. A blow-off valve attaches to the intercooler piping just before the intake manifold and lets out excess turbocharged air when the throttle is lifted. Stock units from the Mitsubishi and Nissan applications listed in Step 1 can be fitted, and various universal aftermarket units are also available.
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4
Piece together your kit's exhaust system. A turbo exhaust manifold is needed to attach the turbo to the engine. These can be custom machined from the stock manifolds of many turbo vehicles, such as those listed in Step 1. Alternatively, there are many aftermarket options available that will bolt directly on. Many manifolds can accept a wide range of turbochargers, and furthermore can be easily fabricated by a custom exhaust shop to bolt to whichever turbo you choose. The pipe that connects the manifold to the rest of the exhaust is a downpipe. These can be cheaply fabricated at an exhaust shop as well, or alternatively purchased aftermarket from most of the same manufacturers that produce exhaust manifolds. There are various diameters available for different applications. For a basic custom-built turbo setup on the GSR, a 3-inch diameter is a good choice.
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5
Tune your newly turbocharged engine via an engine management system. This is paramount, both in maximizing horsepower and in creating a smooth-running, reliable setup. There are increasing numbers of open source options for tuning engines, such as PGMFI. Alternatively, there are numerous aftermarket companies that produce piggyback and stand-alone ECU systems. Whichever option you choose, it's best to have ECU modifications professionally installed and tuned by a performance shop, as doing so requires extensive knowledge of tuning and engine parameters, as well as electronics. A dyno tune is preferable, as it allows all engine parameters to be monitored and refined, thus producing the most power from your GSR, while allowing it to run more reliably.
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Tips & Warnings
The more time and patience you have, the better selections and deals you'll be able to find when searching for used parts for your turbo kit.
Upgrading the clutch to a heavier aftermarket kit is recommended, as the stock unit is more likely to slip with increased power and aggressive driving.
The substantial horsepower added via turbocharging will increase stress on the engine, thus lowering reliability.
Check current state laws regarding emissions, as engine and exhaust modifications will not allow your car to be street legal in some states.
