HOW TO: Boost Your Car

Thanks to Aasyranth on JBO for writing this!

General questions-

What is better, a turbocharger or supercharger?
----It totally depends on what you are going for. Some superchargers are known for excellent reliability (Eaton/Magnuson roots types have been known to last over 100,000 miles) but are limited in power potential. Turbochargers are will known for having vast potential and requiring a bit more TLC and maintenance than most superchargers. The fastest cars bearing J-body names are turbocharged, and the fastest cars on the J-body.org are turbocharged. But it's likely that the most reliable boosted cars are those running low levels of boost with the GM Supercharger kits. What are your goals and priorities?

How much boost can I run without sacrificing reliability?
----You do not run boost if you want to maintain maximum reliability. Normally aspirated cars are not designed to run boost in any way, shape, or form. Most people will tell you that you should be able to run 5 or 6 psi properly tuned for a very long time. Some people have gotten away with over 10 psi without breaking anything. But there is no magic breaking point number that we can hand you. All motors are different. They are mass produced with different flaws, and they are treated differently by the car's owners. The same applies even more so for transmissions.

Will XXXXXX turbocharger/supercharger work on my car?
----As stated above, normally aspirated cars are not designed to run turbo or superchargers. You will need a custom exhaust manifold for a turbo, and a custom intake manifold for a supercharger (there are rare exceptions, but custom work would still be required).

How much boost can I run using the stock fuel system?
----It is strongly recommended that you do not run any boost without an adjustable rising-rate fuel management unit at least (example- http://www.cartech.net/fmu2020.htm). It is recommended that you use a more dynamic form of fuel control, such as the Apexi S-AFC or the Greddy E-manage.


Turbocharger questions-

Where can I find a turbo kit?
----Please check the following websites before asking this question: speed-craft.com, itsturbo.net, exploitedracing.com, and cavalierconnecton.com.

Are there any cheaper ways to set up turbo on my car?
----Yes, but to save money, you must sacrifice time, quality, or a bit of both. If you decide to source the new parts yourself and fabricate everything needed, the quality will depend on the time and care that you put into it. Even more money can be saved by using a junkyard turbocharger off another car, but those turbos usually are in need of a rebuild. Some of those OEM turbos are somewhat difficult to fabricate manifolds for as well. Research the turbocharger carefully and make sure you can acquire everything else you'll need to make it work before you buy it.

At what boost level will I need to install an intercooler?
----It is generally accepted that you can run 5 or 6 psi without an intercooler. Keep in mind that it'll be safer if you use an intercooler even at low boost levels. The cooler air coming into the engine can yield more peak power as well, so it's a good idea all around. Most junkyard intercoolers will work just fine, but if you're planning on squeezing some major power out of your turbo, it'd be best for you to get an intercooler that is built for racing applications.

What size exhaust piping should I use with my turbocharger?
----You want the area after the turbocharger exhaust outlet to be under as little pressure as possible. 2.5 inch piping with a high flow muffler should be installed at the very minimum. 3 inch piping would be even better, and an exhaust cut out would be a great idea for racing. Any muffler shop that works with performance applications should be able to assist you.


Supercharger questions-

Where can I find a supercharger kit?
----RSMracing.com produces kits for the 2.2/2200, 2.4, and Ecotec motors. GM produces a supercharger kit for the 2000+ 2.4L engine. It can also be made to work with pre 2000 2.4 models by swapping to the 2000+ starter and installing a fuel management unit and/or a digital fuel control device (Apexi S-AFC, Greddy E-manage). The GM supercharger kit can be ordered from GMpartsdirect.com and Paceparts.com as well as the dealerships.

Is it possible to make a junkyard supercharger setup?
----Yes. Most junkyard superchargers will require a custom intake manifold to work. These manifolds tend to be more complicated and difficult to make than turbo manifolds, which is one of the reasons that custom turbo setups are more popular. Just like custom turbo setups, the quality will depend on the time and care you put into it.

Can I use an intercooler with a supercharger setup?
----Roots superchargers http://www.magnusonproducts.com must have the intercooling system integrated into the intake manifold. It would be a complicated and expensive fabrication. Centrifugal superchargers http://www.vortechsuperchargers.com run a pipe to get air to the throttle body, just like turbochargers do. They can use any intercooler that turbo cars use.

What size exhaust piping should I use with my supercharger?
----Treat a supercharged motor like any high-powered application as far as the exhaust is concerned. 2.5 inches should be appropriate for most supercharged street applications.

Hope this helps!

Thanks to -Jayson- for this write up!

Heres a few place ive seen that sell actual kits for cavaliers.

This TURBO kit is for the 2002-2005 Cavaliers and Sunfires with the Ecotec 2.2L Engine Only.
HAAS Performance Turbo Kits
http://haasperformance.com/turbokits.htm

This TURBO kit is for the 1995-2002 Cavalier/Sunfire with the 2.2L OHV and 2200 Engines.
http://www.exploitedracing.com/turbo22cavi.html

This TURBO kit is for the 1995 Cavalier with the 2.3L Engine
http://www.exploitedracing.com/turbo23cavi.html

This TURBO kit is for the 1996-2002 Cavalier/Sunfire with the 2.4L Engine.
http://www.exploitedracing.com/turbo24cavi.html

This SUPERCHARGER Kit is for the 2000-2002 Cavalier/Sunfire models with the 2.4L Engine ONLY
GM "Eaton M45" Supercharger Kit-Roots Type
http://www.paceperformance.com/index.asp?PageAction=VIEWPROD&ProdID=237

This SUPERCHARGER kit is for the 1995-2002 2.2L OHV and 2200 Engines only.
Vortech Supercharger
http://www.highrevmotorsports.com/catalog/product_info.php?cPath=27_40&products_id=71

This SUPERCHARGER kit is for the 1996-2002 2.4L DOHC Cavalier/Sunfire Engine.
Vortech Supercharger
http://www.highrevmotorsports.com/catalog/product_info.php?cPath=27_40&products_id=69

This SUPERCHARGER kit is for the 2002-2005 Cavalier/Sunfire with the 2.2L Ecotec Engine.
Vortech Supercharger
http://www.highrevmotorsports.com/catalog/product_info.php?cPath=27_40&products_id=70

what about electric superchargers?

[QUOTE=KustmAce]Thanks to -Jayson- for this write up!

This TURBO kit is for the 1995-2002 Cavalier/Sunfire with the 2.2L OHV and 2200 Engines.
http://www.exploitedracing.com/turbo22cavi.html

This TURBO kit is for the 1995 Cavalier with the 2.3L Engine
http://www.exploitedracing.com/turbo23cavi.html

This TURBO kit is for the 1996-2002 Cavalier/Sunfire with the 2.4L Engine.
http://www.exploitedracing.com/turbo24cavi.html


Brian from exploited racing stopped making kits for the cavalier.

what about electric superchargers?


No they dont work. most of them are just a modified bilge pump from a boat

you guys aren't going to boost your cars....fuck off

This is a good turbo write up, but its Integra specific. It has a lot of good info nonetheless....

http://www.beesandgoats.com/boostfaq/g2icturbo.html

that site is gold in the honda forums....hopefully it helps you guys too!

Good write up. Thanks for the link!

http://haasperformance.com/turbokits.htm is not a valid website.

try putting http://www.hahnracecraft.com/auto/index.htm there instead

guess what....

if anyone wants help for real...look me up on Honda-tech....same screen name

if you have time... instead of paying like 5 gagillion dollars for the kit off of a website.. either go to a junkyard or ebay (the online junkyard) and search for a stock volvo turbo... i run a stock volvo at 4-6 psi... up to 65 hp gain.... eclipse intercooler that is cracked.... intake, exhaust, and manifold.... all of this i payed under 400 for... maybe even under 300... but i made my own manifold because i know ppl.... even then it would still be under 400$.... oh and be careful, dont boost too much psi or you will throw a piston or rod.... on a cavalier i would say max boosting 8 or 9 psi, but i wouldnt recommend even that... oh and i forgot, make sure you get 450 fuel injectors or something larger than the stock because it definately wont hold the stock.... 98 cav 2.2L ls ....... look for something like a T25 greddy turbo because it has a built in wastegate, saves you 250$.... hope this helps, good luck.

:nono:

I dont quite remember where i read this but, is it true that if you supercharge your car it can increase your gas mileage?

generally no. it may make you more efficient per amount of gas used (potentially), but you will be using engine output power to push more air which will use more gas to keep the same air to feul ratio, and you'd be reving up faster. in the end you definately are using more gas per mile you put on your car.

using a turbo is potentially more efficient (i would say) because if you do it properly, you are taking power from your exaust fumes which would be already wasted energy anyway. but you'd still be pushing harder per cubic inch and burning more feul overall.

if you want to use less gas overall you should probably look into restricting your air flow into the car and letting your stock ECU calculate how much gas should be used for maximum feul efficieny. but i mean who wants to drive an underpowered car though AMIRITE?

what kind of rise rate would you go on a 02 sunfire 2.2l ohv running 6psi of boost? i see you can get anywhere from 4:1 to 14:1. any ideas?

Ok just for the fun of it, has anyone ever turboed a 2.2 tbi? I just wanted to ask because these blocks are damn near indistructable. Or can you bolt a different head onto a 90 2.2 block that will give me,it, more power, I DONT want to motor swap PERIOD. Also dont give me the these motors suck rutine. I've seen what these motors can do sprayed and blown and it would make you think twice about a ohc or a dohc motor being "the best motor for a cavy {4 cylinder} of course" At 100 bhp it seems these cars are just grocery getters but have you seen a 91 2.2 blow a way a 5.0 mustang with a 50 shot of nos or better yet a dodge magnum motor in a plymouth laser (yet it was hilarous to see) o by the way these cars were running completely fine and no one was two footing it. Or lagging behind these were strait up races and the "sleeper cavy" beat them both by a 1/2 second or more.

i didnt see anything on here about internals. wat will i need? is it ok to boost on the motor as is? not sure the stock compression ratio

and for anyone wondering.... this is for a 94 s-10 2.2L ;)