Hey guys, im looking for some help here. i have a 1994 1.6l 16v Sidekick JLX with a 5 speed. Its pretty much stock now other than 30's and larger exhaust. I would like a little more power and since I know nothing about turbos this seems like the way to go! I did some reading and it can be done fairly cheap (good thing) and it seems fairly easy as well. Since I know nothing about turbo installs Im going to be asking for a lot of help. I did bid on a Garrett T25 turbo on ebay, I should win it in a few hours. I know Ill have to fab up my own turbo manifold, I can kinda weld so that shouldnt be too bad. Ill need a megasquirt for the fuel managment. A BOV since its 5 speed. What am I missing?

Some specific questions...

1) I read that a lot of people have the 8v version, how is the 16v different when doing a turbo? what is the max boost on a totally stock 16v engine?

2) The stock fuel pump can handle the boost, its the injectors that can not, right? Can the stock pump handle the max boost the engine can handle? What PSI does the pump start to fail at?

3) Intercooler, what do you get one from? I have one from a new Neon SRT-4 but I think my younger brother is planning on using it for some project of his.

4)The turbo manifold, do I need one? or can I just use the stock manifold and hook the turbo on the bottom of it?

5) Most all the posts I found were from like 2005, I saw that the MegaSquirt has been changed and updated since then. How does this affect things? Ive never heard of MS before this forum so I do not know how it works, how it has changed, or what specific parts I need to buy. From what I understand you buy the components and solder them together yourself. This is not a problem for me, Ive done a lot of electronics work.

5) Most all the posts I found were from like 2005, I saw that the MegaSquirt has been changed and updated since then. How does this affect things? Ive never heard of MS before this forum so I do not know how it works, how it has changed, or what specific parts I need to buy. From what I understand you buy the components and solder them together yourself. This is not a problem for me, Ive done a lot of electronics work.

If you're competent with electronics you may well be able to retune your stock ECU. Do you know which processor is in your ECU?

This has been done before, and a write up about it, with photos posted in the "HOW TO" section. All of your questions are answered there. Check it out. BTW, I've done a 16v turbo and am still running it after 3 years now. Do yourself a favor and do it right the first time, don't cheap out on components, and build it for relibility.
 Just to answer your questions quickly:
1. The 16v engine is better suited to turbocharging because of the multi port fuel injection. Max safe boost on a stock engine is 5/6 lbs.
2. The injectors should be fine, I run bigger ones, but others have used the stock ones providing they're in good shape. You might want to add a manual fuel pressure regulator to up the pressure a bit.
3. If you don't have air conditioning, or don't plan to use it, the whole job will be much easier. You can easily fit a air to air cooler in front of the radiator without the ac condenser in the way, and the manifold for the turbo will be much easier to build as well without the ac compresser installed. Air to liquid intercooling is much more consistant, but a more complicated install.
4. YES, you do need a turbo manifold. Don't cheap out, build a good one. If you can "kinda weld" better off letting someone who knows what there doing weld it up. Use at least steel weld el's, better yet stainless steel for longevity and better heat retention.
5. You don't need a Mega Squirt with the 16v engine, the stock ecu ccan compensate up to about 5/6 lbs of boost.
6. Good luck and happy boosting.

Quote from: AmDD on March 30, 2010, 08:42:14 AM

5) Most all the posts I found were from like 2005, I saw that the MegaSquirt has been changed and updated since then. How does this affect things? Ive never heard of MS before this forum so I do not know how it works, how it has changed, or what specific parts I need to buy. From what I understand you buy the components and solder them together yourself. This is not a problem for me, Ive done a lot of electronics work.

If you're competent with electronics you may well be able to retune your stock ECU. Do you know which processor is in your ECU?

I havnt a clue what processor I have. If its written in plain english for me to follow, I dont see why I couldnt retune it... As long as I have a guide.

Post up a pic of the PCB and I'll tell you if its feasible.

Post up a pic of the PCB and I'll tell you if its feasible.

ok, I went out to snap a pic and realized I have no clue where the PCB is located. Searching google tells me it is under the dash on the drivers side. is this the same PCB your talking about?

I'm going to be honest here,  it sounds like you're mechanically handy, but dont know what you're doing well enough to be messing with turbocharging.   no offense, but if you're going to do this, I'd have a professional do it so it wont go BOOM when you turn the key the first time.

as far as internals,  Personally, I"m happiest if an engine exceeds the minimum requrements, rather than JUST meets them.   then you've got potential for a long term dependability thing. 

I'm going to be honest here,  it sounds like you're mechanically handy, but dont know what you're doing well enough to be messing with turbocharging.   no offense, but if you're going to do this, I'd have a professional do it so it wont go BOOM when you turn the key the first time.

as far as internals,  Personally, I"m happiest if an engine exceeds the minimum requrements, rather than JUST meets them.   then you've got potential for a long term dependability thing. 

No harm, no foul. I understand that and I admit I do not know what Im doing but I want to learn and I learn best when I do something myself. This is not my daily driver, i have a fully bagged s10 that I drive all summer, I picked up this suzuki used a few years ago for about $1000 to run just as a winter beater. I have no real money in the thing and if it does blow up Im not out too much, which is why I decided to turbo it rather than my truck.

Im not just some kid trying to make a sports car out of a sidekick for as cheap as possible. I enjoy working on cars and building things, I like a challenge. I want to do this to learn about turbos. I do appreciate your honesty, and thank you for wording it how you did rather than "your a moron and have no business under the hood of a car!" or something like that.

Post up a pic of the PCB and I'll tell you if its feasible.

Is this what your looking for? The silver box?

Im not just some kid trying to make a sports car out of a sidekick for as cheap as possible. I enjoy working on cars and building things, I like a challenge. I want to do this to learn about turbos. I do appreciate your honesty, and thank you for wording it how you did rather than "your a moron and have no business under the hood of a car!" or something like that.

you get credit for asking the right stuff, which you are.   whats the best way to learn? there really is only one way.  experience is the way you're gonna find out what will/will not work.   

I had an S10 for a few months.  I dont want o start a chevy argument, cause I got NOTHING good to say about the last 3 my family has owned, so I'll just keep my mouth shut. 

Its all about gettin dirty, learnin and havin a bit of fun in the process isnt it?   so keep at it, learn what works for your situation, share what you learn and maybe it'll help someone else someday.