The installation of the BNR (BankNerf Racing) 60mm Turbo on the Elantra N is a significant upgrade that can transform your vehicle’s performance. This detailed guide expands on the basic steps, providing deeper insights, safety precautions, and additional technical details to ensure a successful installation. Whether you are a seasoned enthusiast or a first-time turbo swapper, following these instructions carefully will help you achieve optimal results.

Tools and Materials Needed

Before beginning, gather all necessary tools and materials. Having everything at hand reduces downtime and prevents interruptions. Below is a comprehensive list:

  • BNR 60mm Turbo Kit – Ensure it includes the turbocharger assembly, gaskets, oil and coolant lines, and all necessary hardware.
  • Socket set – Metric sockets from 8mm to 19mm, including deep sockets and extensions.
  • Torque wrench – A beam or click-type wrench with a range of 10–80 ft-lb.
  • Screwdrivers – Both flathead and Phillips head, various sizes.
  • Wrenches – Combination wrenches (10mm, 12mm, 14mm) and a flex-head ratcheting wrench for tight spaces.
  • Oil and coolant – High-quality synthetic 5W-30 oil and Hyundai-approved coolant for refill after installation.
  • Hoses and clamps – New silicone hoses and constant‑tension T‑bolt clamps for intake and charge piping.
  • Gasket maker – High-temperature RTV silicone (copper or black) for sealing mating surfaces.
  • Safety gear – Gloves, safety glasses, and a jack/stands if you need to access the undercarriage.
  • Miscellaneous – Shop rags, penetrating oil (for stubborn bolts), a drain pan, and a flashlight or work light.

Preparation

Proper preparation is critical to a smooth install. Park the Elantra N on a level surface and allow the engine to cool completely – working on a hot turbo can cause burns and damage components. Disconnect the negative battery terminal to prevent accidental electrical shorts. If you plan to work underneath, safely lift the car with jack stands on designated lift points. Remove the engine cover and any under-engine splash shields that block access to the turbo.

Drain the engine oil and coolant to avoid spills when disconnecting lines. Place drain pans under the oil pan and radiator drain valve. It is also a good idea to label or photograph hose and wiring routing before disassembly to simplify reassembly.

Step 1: Remove the Existing Turbo

Removing the factory turbo requires patience, especially because of limited space in the engine bay. Follow these sub‑steps:

  • Remove the intake duct – Loosen the clamps at the air box and turbo inlet. Wiggle the duct free and set it aside.
  • Disconnect the wastegate actuator – Unplug the electrical connector and remove the actuator rod from the wastegate lever (note the clip orientation).
  • Disconnect electrical connectors – These include the mass airflow sensor, oxygen sensors (if mounted near the turbo), and any boost control solenoid wiring.
  • Unbolt the turbo from the exhaust manifold – Use penetrating oil on the flange bolts. A combination of a ratcheting wrench and a breaker bar may be needed. There are typically four to six bolts holding the turbo to the manifold.
  • Detach the downpipe – Unbolt the downpipe from the turbo outlet and from the catalytic converter support bracket. Be prepared for a little rust or carbon buildup.
  • Remove oil and coolant lines – Place rags underneath to catch drips. Disconnect the feed and return lines from the turbo by loosening banjo bolts or tube nuts.
  • Remove the turbo assembly – Carefully lift the turbo out of the engine bay, maneuvering around the valve cover and frame rails. Inspect the manifold and downpipe for cracks or gasket remnants.

Tip: Remove the heat shield over the turbo/ manifold first – it is often held by a few small bolts.

Step 2: Prepare the New Turbo

Before installing the BNR 60mm turbo, inspect it thoroughly. Check the compressor and turbine wheels for any damage from shipping. Rotate the shaft by hand – it should spin freely with minimal axial play. Clean the mating surfaces on the exhaust manifold and downpipe with a wire brush or sandpaper to remove old gasket material and carbon deposits.

  • Apply a thin bead of high‑temperature RTV gasket maker to both sides of the new gasket (if using a reusable gasket, skip RTV).
  • Mount the wastegate actuator to the new turbo’s compressor housing if not pre‑installed. Connect the push rod to the wastegate arm and secure the clip.
  • Prime the turbo with oil – Before final installation, pour a small amount of clean engine oil into the oil inlet port. Rotate the shaft manually to coat the bearing. This prevents dry start wear.
  • Attach the oil drain tube – Ensure it is oriented to gravity‑drain properly (check clearance with the engine block).
  • Install coolant fittings – Use new crush washers and tighten banjo bolts to the manufacturer’s torque spec (typically 25–30 ft‑lb).

Step 3: Install the BNR 60mm Turbo

With the new turbo prepped, carefully lower it into position. This step requires muscle and patience – you may need to tilt the turbo to clear the valve cover.

  • Position the turbo onto the exhaust manifold – Align the studs or bolt holes. Use new manifold‑to‑turbo gaskets. Hand‑tighten bolts first, then torque in a star pattern to the spec provided by BNR (typically 35–40 ft‑lb).
  • Connect the downpipe – Use a new downpipe gasket. Tighten the downpipe bolts to the turbo outlet (30-35 ft‑lb). Reattach the support bracket to the transmission bellhousing nearby.
  • Reconnect the oil and coolant lines – For feed lines, use new crush washers. For the drain line, ensure it routes above the oil pan and is not kinked. Torque banjo bolts to 25 ft‑lb.
  • Reattach the wastegate actuator – Plug in the electrical connector and ensure the actuator rod is properly seated on the wastegate lever.
  • Attach the intake duct – Slide the silicone hose over the turbo inlet and tighten the T‑bolt clamp. Connect the other end to the air box or aftermarket intake system.
  • Reconnect any remaining electrical sensors – MAF, O2 sensors, boost solenoid. Double‑check all connectors for secure fit.
  • Refill engine oil and coolant – Add fresh oil (approx. 5.5 quarts with filter change) and top off the coolant reservoir. Run the engine for 30 seconds to circulate fluids, then recheck levels.

Important: Do not start the engine yet if you have not completed Step 4 (leak check). You should prime the system first by cranking the engine with the fuel pump fuse disconnected for 10–15 seconds to build oil pressure without firing.

Step 4: Reconnect the Battery and Check for Leaks

After reassembly, reconnect the negative battery terminal. This is the moment of truth – but do not drive yet. Perform a thorough leak check:

  • Prime the oil system – Remove the fuel pump relay (in the fusebox) and crank the engine for 10–15 seconds. This circulates oil through the turbo bearing before the engine starts.
  • Start the engine – Let it idle for at least five minutes. Listen for unusual rattling or hissing sounds. Watch the oil pressure gauge (if equipped) – it should reach normal pressure quickly.
  • Inspect all connections – Feel around oil feed lines, drain tube, coolant hoses, intake and charge pipes for any wetness or smell of burning oil. Use a mirror to see behind the turbo.
  • Check oil and coolant levels – Turn off the engine, wait a few minutes, then check dipstick and coolant reservoir. Top off as needed.
  • Check for exhaust leaks – With the engine warm, listen for a ticking or puffing sound at the turbo‑manifold joint and downpipe connection.

If you spot any leaks, tighten the offending fitting or replace the gasket. Do not skip this step – a small oil leak can become a fire hazard.

Step 5: Test Drive and Tuning Considerations

Once leaks are addressed, it is time for a cautious test drive. The BNR 60mm turbo is significantly larger than the stock unit, so boost response will change. Follow these guidelines:

  • Take a short, low‑boost drive – Stay below 3000 RPM for the first 10 miles to allow the rings and seals to seat properly.
  • Gradually increase load – After the initial break‑in, do a few moderate pulls (4000‑5000 RPM). Listen for detonation or surge. The car may need a custom tune – do not run high boost without proper fueling adjustments.
  • Monitor critical parameters – If you have an OBD2 scanner or aftermarket gauge, watch boost pressure, intake air temperature, and air‑fuel ratio. The BNR 60mm can flow enough air to exceed stock injector capacity; a tune is highly recommended.
  • Check everything again after the test drive – Re‑torque turbo bolts, downpipe nuts, and oil line fittings once the parts have gone through a heat cycle.

For additional tuning resources, consult professional tuners experienced with the Theta‑II engine platform. You can also refer to the BNR website for specific calibration files if you use their piggyback or ECU flash.

Performance Expectations and Upgrades

The BNR 60mm turbo typically supports 350‑400 wheel horsepower on pump gas with proper supporting modifications (injectors, intercooler, exhaust). The spool characteristics differ from stock – expect boost onset around 3000‑3200 RPM with full boost by 4000 RPM. The power band shifts higher, but the larger turbine reduces backpressure, allowing the engine to rev more freely.

To maximize gains, consider upgrading the intercooler and charge pipes to reduce intake temperatures, and install a high‑flow downpipe and cat‑back exhaust to relieve the exhaust side. A cold‑air intake is also recommended to feed the larger compressor.

Common Pitfalls and Troubleshooting

  • Oil leaks at the drain line – The stock drain tube may not align perfectly; you may need a flexible or custom drain line. Ensure the drain is above the oil pan return port.
  • Boost creep – The larger turbine can overboost if the wastegate is not properly ported or if the actuator is weak. BNR often provides a boost controller recommendation – follow it.
  • Oil feed restrictor – Ball‑bearing turbos require an oil restrictor in the feed line to prevent excessive oil pressure damaging the seals. Verify with BNR if your kit includes one.
  • Clearance issues – The 60mm compressor housing may contact the engine torque mount or radiator fan shroud. You may need to slightly reposition the mount or trim the shroud.

Conclusion

Installing the BNR 60mm Turbo on the Elantra N is a rewarding project that unlocks substantial power gains. By following this expanded step‑by‑step guide – and investing time in careful preparation, leak checking, and proper tuning – you can enjoy a reliable, high‑performance upgrade that transforms your driving experience. Always prioritize safety and consult professional help if you encounter obstacles beyond your skill level. Happy boosting!