A Review Of Bolt-on Turbocharger Kits For The S13 Ka24de Engine

The Nissan 240SX, particularly the S13 chassis equipped with the KA24DE engine, remains a popular platform for automotive enthusiasts. While not renowned for its outright power from the factory, the KA24DE boasts a robust bottom end and ample potential for forced induction. One of the most common and relatively straightforward ways to significantly increase power is through the installation of a bolt-on turbocharger kit. This review dives deep into the world of bolt-on turbocharger kits for the S13 KA24DE engine, exploring the advantages, disadvantages, and key considerations when selecting the right kit for your needs.

Why Choose a Bolt-On Turbo Kit for Your KA24DE?

Before delving into specific kits, it's important to understand why enthusiasts opt for bolt-on turbocharger solutions. The primary advantage is the relative ease of installation compared to a custom turbo setup. Bolt-on kits are designed to utilize existing mounting points and minimize the need for extensive fabrication or modification. This makes them a viable option for weekend mechanics and those looking for a cost-effective power boost.

Here's a breakdown of the key benefits:

Simplified Installation: As the name suggests, these kits are designed to "bolt on" with minimal modification.
Cost-Effective: Often cheaper than building a custom turbo setup from scratch.
Complete Solution: Typically includes all necessary components such as the turbocharger, manifold, downpipe, intercooler, and associated hardware.
Increased Power: Significant horsepower and torque gains can be achieved with proper tuning.

However, it's crucial to acknowledge the potential drawbacks:

Fitment Issues: While designed to be bolt-on, some kits may require minor adjustments or modifications.
Component Quality: Not all kits are created equal; component quality can vary significantly between manufacturers.
Tuning Required: Proper engine management tuning is essential to ensure reliability and prevent engine damage.
Potential for Overboost: Without proper control, overboost can lead to serious engine issues.

Key Components of a KA24DE Bolt-On Turbo Kit

Understanding the components included in a typical KA24DE bolt-on turbo kit is crucial for making an informed decision. Here's a breakdown of the essential parts:

Turbocharger

The heart of the kit, the turbocharger is responsible for compressing air and forcing it into the engine, resulting in increased power. Turbo size and type are critical factors. Smaller turbos generally offer quicker spool-up and better low-end response, while larger turbos are capable of producing higher peak horsepower. Common turbocharger manufacturers include Garrett, Precision Turbo, and BorgWarner. Look for a turbocharger with a properly sized A/R (Area/Radius) ratio for your desired power goals and driving style.

Turbo Manifold

The turbo manifold connects the turbocharger to the engine's exhaust ports. It needs to be durable and efficiently direct exhaust gases to the turbine housing. Cast iron manifolds are common due to their heat resistance and affordability, while tubular manifolds offer improved flow but can be more prone to cracking. Consider a manifold with good flow characteristics and proper heat shielding.

Downpipe

The downpipe connects the turbocharger's exhaust outlet to the rest of the exhaust system. A larger diameter downpipe reduces backpressure and improves exhaust flow. Many kits include a downpipe with a catalytic converter, but some may require a custom exhaust system for optimal performance.

Intercooler

The intercooler cools the compressed air from the turbocharger before it enters the engine. This denser, cooler air charge results in increased power and reduced risk of detonation. Both front-mount intercoolers (FMIC) and side-mount intercoolers (SMIC) are available. FMICs generally offer better cooling efficiency but require more extensive modification.

Piping and Hoses

The kit will include piping and hoses to connect the turbocharger, intercooler, and intake manifold. These should be made of durable materials and properly sized to ensure adequate airflow. Silicone couplers are preferred over rubber due to their superior heat resistance.

Blow Off Valve (BOV) or Bypass Valve (BPV)

A BOV or BPV releases excess pressure in the intake system when the throttle is closed. This prevents compressor surge, which can damage the turbocharger. BOVs vent the excess pressure to the atmosphere, creating a distinctive sound, while BPVs recirculate the air back into the intake system. Consider the noise level and performance characteristics when choosing between a BOV and a BPV.

Fuel Injectors and Fuel Pump

To support the increased power output of a turbocharger, larger fuel injectors and a higher-flowing fuel pump are typically required. The stock fuel system is often insufficient to meet the demands of forced induction. Ensure the kit includes or recommends properly sized fuel injectors and a fuel pump that can deliver adequate fuel pressure.

Engine Management System (EMS)

One of the most crucial aspects of installing a bolt-on turbo kit for the S13 KA24DE engine is proper engine management. The stock ECU is not capable of handling the increased airflow and fuel requirements of a turbocharger. An aftermarket EMS, such as a standalone ECU or a piggyback controller, is essential for tuning the engine and ensuring reliable operation. Common EMS options include AEM, Haltech, and MegaSquirt. Professional tuning is highly recommended.

Popular Bolt-On Turbo Kit Options for the S13 KA24DE

While specific recommendations can vary based on budget and desired power levels, here are a few well-regarded options and considerations:

CXRacing Kits: Often considered an entry-level option, CXRacing kits offer a cost-effective way to get started with turbocharging. However, component quality can be inconsistent, and some modification may be required for optimal fitment. These kits are best suited for budget-conscious builders willing to do some extra work.
ISR Performance Kits: ISR Performance offers a range of turbo kits for the KA24DE, catering to different power goals. These kits generally feature higher-quality components than CXRacing kits and are designed for easier installation.
Custom Fabricated Kits: While not strictly "bolt-on," working with a reputable fabrication shop to build a custom turbo kit allows for maximum flexibility and control over component selection. This option is typically more expensive but can yield superior results.

Important Considerations When Choosing a Kit:

Power Goals: Determine your desired horsepower and torque figures. This will help you select a turbocharger and other components that are appropriately sized.
Budget: Bolt-on turbo kits range in price from a few hundred to several thousand dollars. Set a realistic budget and stick to it.
Installation Experience: Assess your mechanical skills and determine if you are comfortable installing the kit yourself or if you will need professional assistance.
Component Quality: Research the reputation of the manufacturer and the quality of the components included in the kit.
Tuning Options: Ensure that you have access to a qualified tuner who is familiar with the KA24DE engine and the chosen EMS.
Compatibility: Verify that the kit is compatible with your specific S13 model and any existing modifications you have made.

Installation Tips and Considerations

Installing a bolt-on turbocharger kit for the S13 KA24DE engine requires careful planning and execution. Here are a few tips to ensure a successful installation:

Thoroughly Research the Kit: Read online reviews, watch installation videos, and familiarize yourself with the components and procedures involved.
Gather Necessary Tools: Ensure that you have all the tools required for the installation, including sockets, wrenches, torque wrenches, and potentially specialized tools for removing stubborn bolts.
Follow the Instructions Carefully: Adhere to the manufacturer's instructions and pay attention to torque specifications.
Double-Check All Connections: Before starting the engine, carefully inspect all connections for leaks or loose fittings.
Use Quality Fluids: Use high-quality engine oil, coolant, and other fluids that are compatible with forced induction.
Break-In Period: Follow a proper break-in procedure for the new turbocharger and engine components.

Conclusion

A bolt-on turbocharger kit can dramatically transform the performance of your S13 KA24DE engine, offering a significant increase in horsepower and torque. However, it's essential to choose a kit that is appropriate for your budget, power goals, and installation capabilities. Careful research, proper installation, and professional tuning are crucial for ensuring reliability and maximizing the performance benefits. By carefully considering the factors outlined in this review, you can make an informed decision and unlock the full potential of your KA24DE.