Irace86.2.0's KPower Turbo K24 Swap

[Irace86.2.0]

Let the fun begin. This is a preemptive thread, so don't get too excited. I haven't even bought the motor, nor is the swap kit released, but I have started buying parts. I am hoping this thread will act as a mild tutorial on what to do. Here is the original thread on KPower Industries' 86 swap and the link to their blog/website:

https://www.ft86club.com/forums/showthread.php?t=143987
https://kpower.industries/blogs/news...ft86-swap-faqs

Here are a few websites that might also be utilized for the swap or for turbo or NA performance products:

https://www.tf-works.com
https://k-tuned.3dcartstores.com
https://4pistonracing.com

Workshop manual:

http://redliners.ru/manuals/Acura%20TSX.zip

The plan is to sell my Harrop Supercharger, which I can't do that until I get the water pipes and replacement harness from Harrop. I also have a DT Flex-Fuel kit, DT 4bar map sensor, DW700cc injectors, stock ECU, ECUTEK cable/dongle, CARB tune, custom tunes, Ace 150 header, 95mm/85mm/75mm pulleys and associated belts with extra belts, Verus forged clutch fork, Verus billet pivot, and a whole bunch of stock items. I'm hoping to sell these to help fund the next phase.

These are the parts I will need, and I will add to this list:

OEM Components
--K24A2 RBB JDM engine from a 2003-2008 Acura TSX (Purchased)
--K20 water pump and housing (Purchased)
--K24 USDM accessories (Purchased)
--Water plug 90001-PM3-003 + washer 90401-PR4-000 for turbo water return (Purchased)
--RSX Type S oil pump kit (Purchased)
--50 degree VTC gear (Purchased)
--EP3 K-Tuned Pulley (Purchased)
--Refresh components like spark plugs, oil and filter, thermostat, gaskets/seals, etc (Purchased)
--***ARP K series manual flywheel bolts (Purchased)***19mm head will not fit***
--OEM K series manual flywheel bolts (Purchased)
--Stock FA20D throttle body (Retained)
--Stock 86 ECU (Retained)
--Stock clutch, clutch fork, pivot, TOB (Retained)


KPower Swap Kit
--Haltech Elite 1500 with base maps configured for wiring harness (Purchased)
--Kpower Engine wiring harness and sensors (Purchased)
--KPower Engine mounts (Purchased)
--KPower Oil pan (Purchased)
--KPower Intake Manifold (Purchased)
--KPower TB adapter (Purchased)
--KPower Transmission mounts (Purchased)
--Kpower Transmission adaptor w/ block off plate (Purchased)
--Kpower Aluminum flywheel (Purchased)
--Kpower Shifter relocation (Purchased)
--Kpower Shifter arm (Purchased)
--Kpower Aluminum driveshaft (Purchased)
--Kpower Fuel rail (Purchased)
--Kpower Rear/Upper coolant housing/neck (Purchased)
--Kpower Heater pipes (Purchased)
--Kpower AC kit (Purchased)
--Hybrid Racing thermostat plug (Purchased)
--Kpower water pipe adapters (Purchased)
--Kpower silicone water pipes (unavailable)
--Gates 23383 upper radiator hose (Purchased)
--Dayco 71718 lower radiator hose (Purchased)
--1.5” to 1.25” adapter x2 (Purchased)
--Kpower hydraulic released bearing (unavailable)


Turbo Kit
--Garrett G25-660 replica by Pulsar (purchased)
--Turbo blanket (purchased)
--Tial 44mm wastegate replica by Pulsar (purchased)
--Turbosmart 50mm BOV replica by Pulsar (purchased)
--Black Market Fab RWD Turbo Manifold (purchased)
--BlackMarketFab Downpipe/recirculation tube 50% (purchased)
--Custom downpipe to stock frontpipe (Purchased)
--Oil return T25 flange to -10AN male end (purchased)
--2NRS Oil return bung for timing chain tensioner cover (purchased)
--Greddy oil cooler sandwich plate w/ PT adapter and plug for sensors and oil feed (purchased)
--TracTuff -6AN water pump/block adapter (Purchased)
--AN lines (Purchased)
--Silicone vacuum hoses (Purchased)
--Morimoto S-Line Intercooler Black (Purchased)
—IC pipes and couplers (Purchased)
--ID1050x injectors and adapters (Purchased)
--Haltech Flex Fuel sensor (Purchased)
--Haltech EBC (Purchased)
--Skunk2 4bar Map Sensor (Purchased)

Tuning through TunedByShawn and dynoed locally.

I plan to weld the rest of the downpipe myself. I also plan to weld the IC and intake pipe myself. I was thinking of doing a drop-in style K&N filter into the stock intake box and run the IC to that, but I will have to see what I decide to do.

I would get the K24A2 already, except I need to clear out some of the garage, and I also need to wait longer. North West JDM Motors in Sac has a 90 day startup warranty, so there is no point in getting the engine until preorders are released, which hopefully will be next month. RSX oil pumps are backordered like everywhere, so I will need to order the oil pump right away. KPower is only selling the ones they have to customers who have purchased a swap kit, so if I purchase it when the preorders drop then I should get it when the kit releases in the next month.

With regard to the Pulsar Garrett replica: I considered going turbo later, but that means tuning the car NA and then eventually selling the header (if I could) and retuning the car. This is a waste of money. While I would like to buy original components, I paid just over a grand for the turbo, wastegate and BOV, and that saved me easily over two grand. There are cheaper replicas, but these ones are one of the more quality replicas that exist, where they balance everything and have higher machining. With that said, I'm sure it is not to Garrett's standards, and I believe it will have a mild steel and not a stainless steel turbine housing, which is fine. Solidsnake11 had a replica G42 (if I remember correctly), and he made great power. My goals are 350-400whp for now on low boost with fast spool and good top end, and I bet this turbo will do great.

[Irace86.2.0]

www.2nrs.com/products/vented-tensioner-cover

Here is a picture of the stock tensioner location and the product.





The -AN adapter above seems to be a straight -10 ORB (said, dash ten o-ring boss) to a -10AN fitting. There are many fittings someone could run. The one they are using would require at minimum for their hose to terminate in a 90 degree -10AN, so two fittings total. Most often the simplest setup is the cheapest and introduces the least opportunities for failure. The simplest setup would be to have a return hose end fitting that is a 90 degree -10AN ORB fitting like below, but it might not be the swivel variety, so this could clock the fitting in the wrong direction. The advantage is one less piece to buy and one less failure point, but that is debatable because the adapter could be more complex internally or be more expensive than two fittings. Also, someone people might buy hose assembled with standard female -AN ends, so secondary adapters are necessary.



https://www.anhosefittings.com/90-de...g-fitting.html

Someone could also terminate the hose with a -10AN hose to banjo and run a bolt that is a -10AN ORB like below.



I like this fitting too. It can be clocked 360 degrees, and it seems like it could flow well and smoothly--draining well.


https://www.anhosefittings.com/an-90...b-adapter.html

Occasionally, the simplest option is a more complex or rarer option, so it is more expensive than running a standard female -AN end to a more standard -AN adapter. I bring this up because -AN fittings and adapters and lines can quickly add up. $15 here, $25 there and x10 and lines and someone could be looking at $500 in hoses and fittings. Maybe there is money to be saved in taking some time in planning out routing, and also, it will look cleaner and have less chance of failure.

Also, some places can custom assemble everything with the fittings of your choice, so you can buy the simplest setup to the custom length of your choosing. This is preferential, so there isn't extra length of hose, and it can be preferential for those who don't want to make their own lines or buy extra feet of hose and be left with waste.

Assembling hose and applying shrink wrap is not hard at all, but buying these already assembled isn't much more expensive:

https://www.anhosefittings.com/10an-...-assembly.html

[Irace86.2.0]

I found these two videos, which go through the process of installing the VTC gear and RSX oil pump. He goes through the process in the most thorough way, and he includes the torque specs on all the bolts. There are many videos on the market, but I thought this was the best with a few minor exceptions in technique.

[jflogerzi]

subbed

[Sam86]

What were your impressions of the Harrop SC before it went bang? I live local to Harrops HQ and planned to get the kit in the future, stay stock but aim for no more than 290-300 wheel on the 85mm. If you could do it again would you still go SC or would you turbo it

Also how significantly did the SC contribute to your mileage in addition to e85 only? I’m full e85 NA but considering going back to 98 with the kit as I’m filling up every 5-7 days with mostly sedate driving

[Irace86.2.0]

Originally Posted by Sam86

What were your impressions of the Harrop SC before it went bang? I live local to Harrops HQ and planned to get the kit in the future, stay stock but aim for no more than 290-300 wheel on the 85mm. If you could do it again would you still go SC or would you turbo it

Also how significantly did the SC contribute to your mileage in addition to e85 only? I’m full e85 NA but considering going back to 98 with the kit as I’m filling up every 5-7 days with mostly sedate driving

It was an excellent SC. The only thing that needs refinement is that the Harrop and Edelbrock SC suffer from resonant vibrations in the runners at certain rpms that lead to fluctuations in the MAP sensor reading, which in turn causes fueling to fluctuate slightly. This can be tuned out or someone could do a remote MAP sensor, but it isn't a deal breaker of a problem.

The SC is very good in the power delivery. It is instant and linear and the power band is very broad, so it feels like just like a higher displacement engine. If you want a NA feeling 3.5-5L V6-V8 then it is a good supercharger to add. I really liked it--a lot more than I anticipated. It rewards revving out the engine.

A turbo isn't better; it's different. Having owned turbo cars before, there is a little more surge of torque and drama. In fact, the stock FA20 provides a VTEC like surge of torque out of the torque dip in a similar way, but in a small way.

I liked the SC, and a big part of why I went with a supercharger was the OEM look and CARB tune. Now, the latter issue isn't an issue, but for me, the Harrop SC is still the best FI package for the FA20.

For the K24, I would either go high revving, high output NA, or I would go turbo. SC could be good, but from an engine bay aesthetic and balance perspective, the SC just doesn't fit.

[Irace86.2.0]

This is a great reference thread:

https://www.clubrsx.com/threads/k20-...cation.728152/

Sensor Location and part#s for K20/24

Pictures in order below
X: A/C compressor
Y: Water Pump
Z: Auto Tensioner Pulley
1: Auto Tensioner
2: A/C compressor harness
3: Passenger side engine mounting bracketX:
4: Charge harness
5: Intake manifold
6: Thermostat housing
7: Engine harness to Charge harness connectors
8: Engine harness to Charge harness connectors
9: Battery ground
10: Clutch Slave Cylinder
11: Starter bendix
12: Starter
13: Power Harness for Alternator
14: ******* bolt hole
15: Knock Sensor (it is just behind the manifold support on the block)
16: IAC (idle air controller)
17: TB heater line
18: TPS
19: engine harness
20: Brake Booster Vacuum line
21: engine harness
22: IAT, wire and connector
23: Shifter assembly
24: Shifter Cables connection
25: Front transmission mount bolt (not used in swap)
26: Front transmission mount bolt (not used in swap)
27: Front transmission mount bolt (not used in swap)
28: EVAP solenoid
29: EVAP Test Port
30: Valve Cover breather heating assembly
31: Throttle body (opening for air intake)
32: Coolant line (feed/return?)
33: Bolt
34: Driver's-side transmission mount bolt
35: Transmission Vent
36: Reverse switch
37: Coolant Outlet
38: AAV & line (Air Assist Valve)
39: Fuel line
40: Fuel Pulse Damper
41: Fuel rail
42: Fuel injector wiring loom
43: Injector #1
44: Injector #2
45: Injector #3
46: Injector #4
47: Engine oil filler cap
48: Engine oil dipstick

[Irace86.2.0]

A: Coolant outlet /inlet to heater
B: Vehicle Speed Sensor, or VSS
C: Clutch line
D: Tranny ground
E: Main engine harness
F: Oil Filter
G: Coolant drain bolt
H: Oil pressure sender
I: Crank Position Sensor
J: Part of Oil Cooler
K: Another part of Oil Cooler
L: Crank pulley
M: Vtec Solenoid
N: VTEC oil pressure sensor
O: brake booster line
P: Evap control valve hardline.
Q: VTC oil control solenoid valve
R: Vin plate
S: Exhaust manifold heat shield
T: Header
U: Charge harness
V: Tranny bracket

[Irace86.2.0]

H: Oil pressure sender
I: Crank Position Sensor
J: Part of Oil Cooler
K: Another part of Oil Cooler
L: Crank pulley
M: VTEC Solenoid
N: VTEC oil pressure sensor
Q: VTC oil control solenoid valve
W: Alternator
X: A/C compressor
Y: Water Pump
Z: Auto Tensioner Pulley
1: Auto Tensioner
2: A/C compressor harness
3: Passenger side engine mounting bracket
4: Belt tensioner cover

[Irace86.2.0]

Sensors/Valve Assemblys:

-Knock Sensor
Accord 04-07 Knock Sensor P/N: - 30530-PPL-A01
Civic 03-05 Knock Sensor P/N: - 30530-PPL-A01
CRV 03-07 Knock Sensor P/N: - 30530-PPL-A01
Element 03-07 Knock Sensor P/n: - 30530-PPL-A01
TSX 04-07 Knock Sensor P/N: - 30530-PPL-A01
RSX 02-06 Knock Sensor P/N: - 30530-PPL-A01
RSX-S 02-06 Knock Sensor P/N: - 30530-PRB-A01
Civic Si 06-07 Knock Sensor P/N: - 30530-PRC-003

-Crank Position Sensor
Accord 03-07 Crank Position Sensor P/N: - 37500-RAA-A01
Element 03-07 Crank Position Sensor P/N: - 37500-RAA-A01
TSX 04-07 Crank Position Sensor P/N: - 37500-RAA-A01
CRV 02-07 Crank Position Sensor P/N: - 37500-PNB-003
Civic 03-07 Crank Position Sensor P/N: - 37500-PNB-003
RSX-S 02-06 Crank Position Sensor P/N: - 37500-PNB-003
RSX 02-06 Crank Position Sensor P/N: - 37500-PNB-003
Civic Si 06-07 Crank Position Sensor P/N: - 37500-PNB-003

-Camshaft TDC sensor
Civic 02-07 Camshaft TDC Sensor P/N: - 37510-PNB-003
RSX 02-06 Camshaft TDC Sensor P/N: - 37510-PNB-003
RSX-S 02-06 Camshaft TDC Sensor P/N: - 37510-PNB-003
CRV 03-06 Camshaft TDC Sensor P/N: - 37510-PNB-003
CRV 07 ONLY Camshaft TDC Sensor P/N: - 37510-PNB-003 <-Exhaust- // 37510-RAA-A01 <-Intake-
Accord 03-07 Camshaft TDC Sensor P/N: - 37510-PNB-003 <-Exhaust- // 37510-RAA-A01 <-Intake-
Element 03-07 Camshaft TDC Sensor P/N: - 37510-PNB-003 <-Exhaust- // 37510-RAA-A01 <-Intake-
TSX 04-07 Camshaft TDC Sensor P/N: - 37510-PNB-003 <-Exhaust- // 37510-RAA-A01 <-Intake-
Civic Si 06-07 Camshaft TDC Sensor P/N: - 37510-PNB-003 <-Exhaust- // 37510-RAA-A01 <-Intake-

-MAP Sensor
Accord 03-04 MAP Sensor P/N: - 37830-PGK-A01
CRV 02-04 MAP Sensor P/N: - 37830-PGK-A01
Civic 01-05 MAP Sensor P/N: - 37830-PGK-A01
RSX 02-04 MAP Sensor P/N: - 37830-PGK-A01
RSX-S 02-04 MAP Sensor P/N: - 37830-PGK-A01
RSX 02-04 MAP Sensor P/N: - 37830-PGK-A01
TSX 04-07 MAP Sensor P/N: - 37830-PGK-A01
Civic Si 06-07 MAP Sensor P/N: - 37830-PNC-003

-Water Temp. Sensor
Accord 03-07 Water Temp. Sensor P/N: - 37870-PNA-003
CRV 02-06 Water Temp. Sensor P/N: - 37870-PNA-003
Civic 03-07 Water Temp. Sensor P/N: - 37870-PNA-003
Element 03-07 Water Temp. Sensor P/N: - 37870-PNA-003
RSX 02-06 Water Temp. Sensor P/N: - 37870-PNA-003
RSX-S 02-06 Water Temp. Sensor P/N: - 37870-PNA-003
TSX 04-07 Water Temp. Sensor P/N: - 37870-PNA-003
Civic Si 06-07 Water Temp. Sensor P/N: - 37870-PNA-003

-VTC Spool valve assembly
Accord 03-05 VTC Spool Assembly P/N: - 15810-RAA-A01
CRV 03-05 VTC Spool Assembly P/N: - 15810-RAA-A01
Civic 03-05 VTC Spool Assembly P/N: - 15810-RAA-A01
Element 03-05 VTC Spool Assembly P/N: - 15810-RAA-A01
RSX 02-06 VTC Spool Assembly P/N: - 15810-RAA-A01
RSX-S 02-06 VTC Spool Assembly P/N: - 15810-PRB-A01
TSX 04-05 VTC Spool Assembly P/N: - 15810-PRB-A01
Civic Si 06-07 VTC Spool Assembly P/N: - 15810-PRB-A03

-VTC Oil Control Valve Assembly
Accord 03-07 VTC Oil Control Assembly P/N: - 15830-RAA-A01
Element 03-07 VTC Oil Control Assembly P/N: - 15830-RAA-A01
CRV 03-05 VTC Oil Control Assembly P/N: - 15830-PNC-003
Civic 03-05 VTC Oil Control Assembly P/N: - 15830-PNC-003
RSX-S 02-04 VTC Oil Control Assembly P/N: - 15830-PNC-003
RSX 02-04 VTC Oil Control Assembly P/N: - 15830-PNC-003
TSX 04-07 VTC Oil Control Assembly P/N: - 15830-RBB-003 (same as 05-06 RSX-S)
Civic Si 06-07 VTC Oil Control Assembly P/N: - 15830-RBB-003

-Timing Chain Tensioner
02-07 CRV - 14510-PNA-003 (K24A1 and K24Z1)
03-05 Civic Si - 14510-PNA-003 (K20A3)
03-07 Accord - 14510-PNA-003 (K24A4 and K24A8)
02-06 RSX Base - 14510-PNA-003 (K20A3)
03-07 Element - 14510-RAA-A01 (K24A4)
02-06 RSX-S - 14510-PRB-A01 (K20A2 and K20Z1)
04-07 TSX - 14510-PRB-A01 (K24A2)
06-07 Civic Si - 14510-PRB-A01 (K20Z3)
07 Acura RDX - 14510-RWC-A01 (K23A1, Turbo)

Another good page with pictures and part numbers:

https://hive.blog/honda/@cptcaveman/...apped-ep3-blog

[Brz-123]

Originally Posted by Irace86.2.0

It was an excellent SC. The only thing that needs refinement is that the Harrop and Edelbrock SC suffer from resonant vibrations in the runners at certain rpms that lead to fluctuations in the MAP sensor reading, which in turn causes fueling to fluctuate slightly. This can be tuned out or someone could do a remote MAP sensor, but it isn't a deal breaker of a problem.



The SC is very good in the power delivery. It is instant and linear and the power band is very broad, so it feels like just like a higher displacement engine. If you want a NA feeling 3.5-5L V6-V8 then it is a good supercharger to add. I really liked it--a lot more than I anticipated. It rewards revving out the engine.



A turbo isn't better; it's different. Having owned turbo cars before, there is a little more surge of torque and drama. In fact, the stock FA20 provides a VTEC like surge of torque out of the torque dip in a similar way, but in a small way.



I liked the SC, and a big part of why I went with a supercharger was the OEM look and CARB tune. Now, the latter issue isn't an issue, but for me, the Harrop SC is still the best FI package for the FA20.



For the K24, I would either go high revving, high output NA, or I would go turbo. SC could be good, but from an engine bay aesthetic and balance perspective, the SC just doesn't fit.

Interesting you mention about the runner vibrations. Is that for all PD SCs aka Cosworth too? And can the driver feel it when driving?

Sent from my SM-G781B using Tapatalk

[Irace86.2.0]

Originally Posted by Brz-123

Interesting you mention about the runner vibrations. Is that for all PD SCs aka Cosworth too? And can the driver feel it when driving?

Sent from my SM-G781B using Tapatalk

Please refer to these links. Anytime someone is using scaling based on the MAP instead of the MAF on a PD supercharger with the MAP sensor in the runners, this will likely be the outcome, as resonance in the runners can often create oscillations in the signals, which can be felt as breakup or less power. The solution is the D-Box, ECUTEK filtering, or doing a remote MAP sensor:

https://www.ft86club.com/forums/show...onance&page=72

https://www.ft86club.com/forums/show...nance&page=240

https://www.ft86club.com/forums/show...ce#post3335754

[DIY]

I know you've already bought it but honestly I think a g25-660 is going to be too small for a K24.

[Irace86.2.0]

Originally Posted by DIY

I know you've already bought it but honestly I think a g25-660 is going to be too small for a K24.

Garrett's website says 350-660 crank horsepower on a 1.4-3.0L, and all I want is 350-400whp for now. The spool should be as good as a GTX28 or faster with a top end of a larger GTX30 or smaller GTX35.

KPower on a stock K24Z3 (probably had RSX oil pump and 50 degree VTC) made 470whp and 385wtq with E85 at 12psi. Admittedly, I don't know what A/R they had, but I'm not worried. I'm actually more concerned I'll be making too much power because this turbo is too efficient and powerful.

https://chromjuwelen.com/items/item/...70-whp-on-dyno



Here is a 2.5L EJ making 397whp and 345wtq at 7k rpms using the G25-660 0.72 a/r. It doesn't look like the turbo is close to maxing out or outside of its efficiency at 20psi, and it doesn't seem to be dropping off at all.

https://forums.nasioc.com/forums/sho....php?t=2910464



Here is a K24 with the G25-660 with a 0.92 a/r making 421whp/303wtq on 93 and 477whp/330wtq on E70.

https://www.s2ki.com/forums/s2000-fo...1180669/page3/


I spent hours reading through all of this thread, and after reading all the results from different cars and different displacements and different turbos, I realized the G25-660 will offer the fastest spool with the best top end at the horsepower I'm aiming for. I'm not looking to throw down big numbers. That could come in the future with a built motor, a different trans and a different turbo.

https://www.vwvortex.com/threads/che...think.3980360/