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Discussion Starter · #1 · (Edited)
Ok, im going to try and jump start the turbo and supercharging info here so this will change over the next week as i acheive what I want from this thread. This is for info only. No discussion. If you have something to add, PM me and ill review it.

Also, you should read these books:
Maximum Boost - Corky Bell
Forced Induction Performance Tuning - A. Graham Bell


Here is info on the fuel rail and the subsequent discussion.

This is a list of turbo and supercharger compression maps that i have found over the course of my research into what turbo to buy.

Finally, this is information about our engines. I have referred to it several times in the course of my research including conversations with piston manufacturers and such

General:

Type In-line, Double Overhead Camshaft
Number of cylinder 4
2.0L Eng. [G4GC]
Bore 82mm (3.228 in.)
Stroke 93.5 mm (3.681 in.)
Total displacement 1975 cc
(120.52 cu.in.)
Compression ratio 10.1
Firing order 1-3-4-2
Idle R.P.M 700 ± 100
Ignition timing at
idling speed BTDC 8° ±5°/700rpm

Valve:

Timing-
Intake valve Opens (BTDC) 9°
Closes (ABDC) 43°
Exhaust valve Opens (BBDC) 50°
Closes (ATDC) 6°
Valve length:
Intake 114.34 mm (4.5016 in.)
Exhaust 116.8 mm (4.5984 in.)
Stem O.D.:
Intake 5.965-5.98 mm (0.2348-0.2354 in.)
Exhaust 5.950-5.965 mm (0.2343-0.2348 in.)
Face angle thickness of valve head (Margin):
Intake 1.15 mm (0.0452 in.) 0.8 mm (0.031 in.)
Exhaust 1.35 mm (0.0531 in.) 1.0 mm (0.039 in.)
Valve stem to valve guide clearance:
Intake 0.02-0.05 mm(0.0008-0.0019 in.)
0.10 mm(0.0039 in.)
Exhaust 0.035-0.065 mm(0.0014-0.0026 in.)
0.13 mm(0.0051 in.)
Valve guide:
Installed dimension O.D. Intake 46 mm (1.811 in.)
Exhaust 54.5 mm (2.146 in.)
Service oversize 0.05, 0.25, 0.50 mm
(0.002, 0.010, 0.020 in.) oversize
Valve seat:
Width of seat contact Intake 1.1-1.5 mm (0.043-0.059 in.)
Exhaust 1.3-1.7 mm (0.051-0.066 in.)
Seat angle 45
Oversize 0.3, 0.6 mm (0.012, 0.024 in.) oversize
Valve spring:
Free length 48.86 mm (1.9236 in.)
Load 18.3 kg / 39 mm
40.0 kg / 30.5 mm
Installed height 39 mm (1.5354 in.)
Squareness 1.5° or less
Valve clearance (cold) Intake 0.20 mm(0.0079 in.) 0.12-0.28mm
(0.0047-0.0110 in.)
Exhaust 0.28 mm(0.0110 in.) 0.20-0.36mm
(0.0079-0.0142 in.)

Cylinder block: (Iron)

Cylinder bore 82.00-82.03 mm(3.2283 - 3.2295 in.)
Out-of-round and taper
of cylinder bore Less than 0.01 mm(0.0004 in.)
Clearance with piston
(To set limits to new parts) 0.02 - 0.04 mm(0.0008 - 0.0016 in.)

Piston:
O.D.
(To set limits to new parts) 81.97 - 82.00 mm(3.2271 - 3.2283 in.)
Service oversize 0.25, 0.50, 0.75, 1.00 mm(0.010, 0.020, 0.030, 0.039 in.) oversize
Piston Ring:
Side clearance No. 1 0.04-0.08 mm (0.0015-0.0031 in.)
No. 2 0.003 -0.07 mm (0.0012-0.0027 in.)
End gap
No. 1 0.23-0.38 mm(0.0090-0.0149 in.)
No. 2 0.33-0.48 mm [2.0L](0.0130-0.0189 in.)
Oil ring side rail 0.20-0.60 mm (0.0078-0.0236 in.)

Connecting rod:
Bend 0.05 mm (0.0020 in.) or less
Twist 0.1 mm (0.004 in.) or less
Connecting rod big end
to crankshaft side clearance 0.100-0.250 mm(0.0039-0.0098 in.)

Connecting rod bearing:
Oil clearance
(To set limits to new parts) 0.024-0.044 mm (0.0009-0.0017 in.)
Undersize 0.25, 0.50, 0.75 mm (0.01, 0.20, 0.03 in.)

Camshaft:
Cam lobe height Intake 44.820 mm (1.7646 in.) 44.720 mm(1.7606 in.)
Exhaust 44.720 mm (1.7606 in.) 44.620 mm(1.7567 in.)
Joumal O.D. 28 mm (1.1023 in.)
Bearing oil clearance 0.02-0.061 mm(0.0008-0.0024 in.)
End play 0.1-0.2 mm (0.004-0.008 in.)

Crankshaft:
Pin O.D. 45 mm (1.77 in.)
Joumal O.D. 57 mm (2.244 in.)
Bend 0.03 mm (0.0012 in.) or less
Out-of-round, taper of
journal and pin 0.01 mm (0.0004 in.) or less
End play 0.06-0.260mm (0.0023-0.010 in.) 0.30 mm (0.0118 in.)
Undersize rework dimension
of pin 0.25 mm(0.010 in.) 44.725-44.740 mm(1.7608-1.7614 in.)
0.50 mm(0.020 in.) 44.475-44.490 mm(1.7509-1.7516 in.)
0.75 mm(0.030 in.) 44.225-44.240 mm(1.7411-1.7417 in.)
Undersize rework dimension
of journal 0.25 mm(0.010 in.) 56.727-56.742 mm(2.2333-2.2339 in.)
0.50 mm(0.020 in.) 56.477-56.492 mm(2.2235-2.2240 in.)
0.75 mm(0.030 in.) 56.227-56.242 mm(2.2136-2.2142 in.)

Cylinder head: (Aluminum)
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.06 mm (0.0024 in.)
Flatness of manifold
mounting surface Max. 0.15 mm (0.0059 in.) Max. 0.03 mm (0.0118 in.)
Oversize rework dimensions
of valve seat hole Intake 0.3 mm(0.012 in.) O.S. 33.300-33.325 mm(1.3110-1.3120 in.)
0.6 mm(0.024 in.) O.S. 33.600-33.625 mm(1.3228-1.3238 in.)
Exhaust 0.3 mm(0.012 in.) O.S. 28.800-28.821 mm(1.1338-1.1346 in.)
0.6 mm(0.024 in.) O.S. 29.100-29.121 mm(1.1456-1.1465 in.)
Oversize rework dimensions
of valve guide hole
(both intake and exhaust) 0.05 mm(0.002 in.) O.S. 11.05-11.068 mm(0.435-0.4357 in.)
0.25 mm(0.010 in.) O.S. 11.25-11.268 mm(0.443-0.4436 in.)
0.50 mm(0.020 in.) O.S. 11.50-11.518 mm(0.453-0.4535 in.)

Misc:

Flywheel Runout 0.1 mm (0.0039 in.) 0.13 mm (0.0051 in.)
Cooling method Water-cooled, pressurized, Forced circulation with electrical fan
Coolant Quantity 6 liter (6.3 U.S qts., 5.2 lmp. qts.)
Radiator Type Pressurized corrugated fin type
Radiator cap Main valve opening pressure 83-110 kpa(12-16 psi, 0.83-1.1kg/cm)
Vacuum valve opening
pressure - 7 kpa(-1.00 psi, -0.07 kg/cm) or less
Thermostat Type Wax pellet type with jiggle valve
Valve opening temperature 82°C(177°F)
Full-opening temperature 95°C(201°F)
Coolant pump Centrifugal type impeller
Drive beit Type V-ribbed belt
Engine coolant temperature
sensor Type Heat-sensitive thermistor type
Resistance 2.31-2.59KΩ at 20°C(68°F)
Oil pump:
Clearance between outer
circumference and
front case. 0.120-0.185mm(0.0047-0.0073 in.)
Front case tip clearance 0.025-0.069mm(0.0009-0.0027 in.)
Side clearance:
Inner gear 0.04-0.085 mm(0.0016-0.0033 in.)
Outer gear 0.04-0.09 mm(0.0016-0.0035 in.)
Engine oil pressure at idle
[Oil temperature is
90 to 100°C (194 to 215°F)] 166 KPa (1.7 kg/cm, 24.s psi)
Relief spring:
Free height 43.8 mm (1.724 in.)
Load 3.7kg at 40.1 mm(3.15 lb/1.578 in.)
Air cleaner:
Type Dry type
Element Unwoven cloth type
Exhaust pipe:
Muffler Expansion resonance type
Suspension system Rubber hangers

 
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