D series turbo kit

Types of D Series Turbo Kit

A D series turbo kit is a collection of components designed to add a turbocharger to a Honda D-series engine. The D-series engine family consists of in-line 4-cylinder piston engines, with the D13B and D14B series being the most common base engines in most countries. The D-series engines are popular among car enthusiasts and tuners because they are cheap and easy to maintain. Adding a turbo to a D-series engine can improve engine performance, increase horsepower, and improve torque delivery.

There are several types of D-series turbo kits, including:

• Universal turbo kits: These are generic turbo kits not designed for a specific vehicle make or model. Universal turbo kits contain basic components, such as a turbocharger, manifold, wastegate, blow-off valve, intercooler piping, and oil lines. Buyers may need to purchase additional components, such as an ECU controller, piping, and downpipe, to ensure the universal D-series turbo kit fits their application.
• Intercooled turbo kits: Most D-series turbo kits come with an intercooler. The intercooler cools the compressed air coming from the turbo before sending it to the intake manifold. By cooling the compressed air, the intercooler increases the density of the air, allowing the engine to extract more oxygen. This results in a significant increase in horsepower and engine performance.
• Oil-cooled turbo kits: A D-series turbo can be cooled using oil. When the engine is running, the oil flows through the turbocharger, lubricating and cooling the internal components. The oil then returns to the oil pan after exiting the turbocharger. Oil-cooled turbo kits use high-quality heat-resistant hoses to transfer oil to and from the turbo. These hoses may have multiple layers for added strength and durability.
• Water-cooled turbo kits: Water-cooled D-series turbo kits use water to cool the turbocharger. The water-cooled system is similar to a radiator. When the engine is running, water flows through the turbocharger to cool the internal components. The water then exits the turbocharger and is heated before returning. The water-cooled D-series turbo kit allows the turbo to maintain optimal operating temperatures, increasing efficiency and reducing turbo lag.
• Twin-turbo kits: Twin-turbo D-series engines are powerful and can handle high load applications. The twin-turbo kit contains two turbochargers, which can be beneficial when increasing the torque and horsepower of larger engines. The twin-turbo kit is ideal for performance upgrades.

Specification and maintenance of D series turbo kits

The D series turbo kit specification varies depending on the type. Below are some common specifications:

• Turbocharger:

  Compressor wheel: The inlets of the compressor wheel range from 38 to 60 mm, while the outlets (exits) measure 48 to 70 mm.

  Turbine wheel: The turbine wheel has 6 to 10 blades, with each blade measuring about 8 to 15 mm in height.

  AR ratio: The aspect ratio of the housing is between 0.35 and 0.7.

• Wastegate:

  Type: The wastegate can be internal or external, depending on the d series turbo manifold.

  Diameter: The wastegate valve is between 20 and 50 mm in diameter.

• Intercooler:

  Core size: The intercooler's core is 250 mm wide, 150 mm tall, and 500 mm long.

  Flow rate: It has a flow rate of 500 liters per minute.

• Oil feed and return lines:

  Material: The oil lines are made of stainless steel or high-quality rubber.

  Diameter: The oil feed line has a diameter of 4 to 6 mm, while the return line measures 10 to 12 mm.

• Flanges:

  Material: The flanges are made of mild steel, stainless steel, or aluminum.

  Thickness: Each flange has a thickness of 5 to 10 mm.

• Blow-off valve:

  Type: The valve can be vent-to-atmosphere or plumb-back.

  Diameter: The valve has a diameter of 25 to 50 mm.

Maintaining a D series turbo kit is important to improve its lifespan and performance. Below is the maintenance procedure:

• Oil and filter change:

  The oil and filter should be changed every 5,000 kilometers or as recommended. This is important to prevent contaminants from reaching the turbo. Also, ensure the oil is the right grade to lubricate the turbo properly.

• Cool down:

  The car owner should allow the engine to idle for 2 to 5 minutes before turning off the ignition. This is because the turbo spins very fast when the engine runs. Stopping the engine suddenly will prevent the turbo from cooling down, which can cause damage.

• Inspect the turbo:

  The turbo should be inspected every 10,000 km for any signs of wear. A professional mechanic should check the D series turbo kit for leaks, damage, or excessive play in the turbo shaft.

• Boost levels:

  Car owners should avoid overloading the boost. This puts excess strain on the turbo. If the vehicle has a boost controller, ensure the settings are within the manufacturer's recommended limits.

• Replace the wastegate:

  The wastegate should be replaced after 100,000 km or when it starts to show signs of wear. A faulty wastegate can cause the turbo to overboost or underboost, affecting engine performance.

• Replace the blow-off valve:

  The blow-off valve should be changed after 100,000 km or when it becomes faulty. A damaged blow-off valve can lead to compressor surge, which can damage the turbo.

• Keep air filters clean:

  The air filters should be inspected every 5,000 km. Clean or replace them to prevent dirt and debris from entering the turbo, which can reduce its efficiency.

• Use quality fuel:

  Car owners should use fuel with the octane rating recommended by the vehicle manufacturer. Avoid using fuel with lower octane ratings, as it can cause knock and strain the turbo.

How to Choose D Series Turbo Kit

Here's a comprehensive guide on how to select D series turbo kits:

• Understand the Engine

  Get complete details about the car's D-series engine. This includes knowing the engine's exact specifications and its power output, and which D17 turbo kit options are compatible with the engine.

• Turbocharger Size

  Learning about the turbocharger's size and its A/R ratio is also important. Larger turbochargers might be more efficient, but they will also have a higher lag time before reaching peak power. Smaller turbochargers have less lag time but may not produce enough power at high RPMs.

• Kit Quality

  Research the reputation of the D-series turbo kit manufacturer. Look for reviews from others who have used the same kit. A well-made kit from a trusted company is less likely to cause problems.

• Intercooler

  The intercooler cools the air from the turbo before it goes into the engine. A bigger intercooler can help the engine make more power and run cooler. But, making the intercooler too big can slow down the airflow. Find the right-sized intercooler for the turbo kit.

• Fuel System

  The fuel pump, fuel injectors, and fuel lines need to be upgraded to provide more fuel to the engine when using a turbo. Make sure all parts of the fuel system will work together and deliver enough fuel for the power goals.

• Tuning

  The engine needs to be tuned properly for it to run well with the new turbo. A tune is required to adjust settings for the turbo to work correctly. Find someone with a good reputation to tune the engine using a tuning device.

• Exhaust

  The exhaust system should have a larger diameter pipes to allow better airflow. A new downpipe is also needed to connect the turbo to the exhaust. The downpipe replaces the pipe from the exhaust manifold to where the exhaust system starts.

• Warranty and Support

  Check what warranty or customer support is provided with the turbo kit. A good warranty shows the company stands behind the quality of the parts. Helpful support can assist if any issues arise during installation or tuning.

• Budget

  Determine the budget for the turbo kit and associated components. Consider the long-term benefits of increased performance and potential fuel efficiency gains. Balance initial costs with expected returns.

• Legal Compliance

  Research local laws and regulations regarding emissions and noise levels. Ensure that the chosen turbo kit and supporting components comply with legal standards to avoid potential fines or penalties.

How to DIY and Replace D Series Turbo Kit

Installing a D series turbo kit can be complicated, but once the necessary steps are followed, it will be a success. Before the process, ensure that the D-series turbocharged kit is complete and contains all the parts that will make the installation easy. See some of the parts in the D-series turbo kit above.

The tools needed for the installation are:

• Socket set
• Wrench set
• Torx bit set
• Hacksaw (for exhaust manifold)
• Dremel (for exhaust manifold)
• Drill
• Tap

Follow the steps below to install a D-series turbo kit successfully:

• Prepare the Vehicle

  Disconnect the battery and drain the engine oil and coolant. Then, read the manufacturer's manual and know how to disassemble and reassemble the parts that will be removed. This may include the intake manifold, exhaust manifold, downpipe, etc., to make room for the turbocharger.

• Assemble the Turbocharger

  Follow the manufacturer's manual to assemble the turbocharger. Connect the turbine and compressor housing and install the wastegate and blow-off valve.

• Install the Turbocharger

  Put the turbocharger onto the exhaust manifold and tighten the bolts. Connect the oil feed and return lines and the cooling lines between the turbo and the engine. Install the downpipe and exhaust pipes and ensure there are no leaks.

• Connect the Intake

  Connect the intake pipe from the turbocharger's compressor outlet to the intercooler (if available) and then to the engine's intake manifold. Install the blow-off valve on the intake pipe. Connect the vacuum line to the blow-off valve.

• Install the Wastegate

  Mount the wastegate onto the exhaust manifold or downpipe. Connect a vacuum line from the wastegate actuator to the engine's intake manifold.

• Connect the Engine Management System

  Install the engine management system according to the manufacturer's instructions. Connect the system to the engine's OBD-II port. Follow the manufacturer's instructions to tune the engine for the new turbo setup.

• Reassemble and Test

  Reassemble any parts that were removed during disassembly. Reconnect the battery and fill the engine with oil and coolant. Start the engine and check for any leaks or unusual noises. Take the car for a test drive and monitor the engine's performance and behavior.

Q and A

Q1: Are single-turbo or twin-turbo setups more common in D-series turbo kits?

A1: In D-series turbo kits, single-turbo setups are more common. They are simpler to install and maintain while providing ample power for most tuning needs.

Q2: Can a D-series turbo kit be installed on a non-Honda vehicle?

A2: D-series turbo kits are designed specifically for Honda's D-series engines. However, similar turbo kits are available for other engine types. Always check compatibility before installation.

Q3: Do D-series turbo kits require high-octane fuel?

A3: While high-octane fuel is not always mandatory with D-series turbo kits, it is often recommended. It can help prevent engine knock and optimize performance under boost.

Q4: How often should the turbocharger in a D-series turbo kit be replaced?

A4: Turbochargers do not need replacement at a specific mileage. However, signs of decreased performance or physical damage may necessitate a turbo replacement. Regular checks can ensure optimal performance.

Q5: Can the D-series turbo kit fit all D-series engines?

A5: No, the D-series turbo kit cannot fit all D-series engines. The kit is designed to fit specific engines within the D-series family, such as the D15B and D16Z6. Check the kit specifications to confirm compatibility.