Step-by-step Guide to a 4g63 Turbo Upgrade: from Stock to 550+ Hp with Borgwarner Efr Series

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Upgrading your 4G63 engine to achieve 550+ horsepower is an exciting project that can significantly enhance your vehicle’s performance. This guide will take you through the step-by-step process of upgrading your turbocharger to a BorgWarner EFR series, ensuring you get the most out of your engine.

Understanding the 4G63 Engine

The 4G63 engine is a turbocharged inline-four engine produced by Mitsubishi. It is known for its robust design and tuning potential, making it a popular choice among car enthusiasts. Before diving into the turbo upgrade, it’s essential to understand its components and capabilities.

  • Engine Block: The foundation of the 4G63, designed to handle increased power.
  • Cylinder Head: Features a DOHC design for efficient airflow.
  • Stock Turbocharger: Typically limited to around 300-400 hp.

Choosing the Right BorgWarner EFR Turbo

The BorgWarner EFR series offers several options for turbo upgrades. Selecting the right turbo depends on your goals and engine setup. Here are some popular options:

  • BorgWarner EFR 7670: Great for a balance of response and power.
  • BorgWarner EFR 8374: Ideal for high horsepower builds, capable of exceeding 600 hp.
  • BorgWarner EFR 9180: Best for extreme performance, designed for serious racers.

Essential Parts and Tools Needed

Before starting the upgrade, gather all necessary parts and tools to ensure a smooth installation process. Here’s a list of what you will need:

  • BorgWarner EFR Turbocharger
  • Turbo manifold
  • Wastegate
  • Boost controller
  • Intercooler and piping
  • Fuel injectors (1000cc recommended)
  • Fuel pump (high-flow)
  • ECU tuning software
  • Basic hand tools (sockets, wrenches, etc.)
  • Torque wrench

Step-by-Step Installation Process

Step 1: Prepare Your Workspace

Ensure your workspace is clean and organized. Gather all tools and parts, and have a good lighting setup to help you see all components clearly.

Step 2: Remove the Stock Turbo

Start by removing the stock turbocharger. Follow these steps:

  • Disconnect the battery to prevent electrical issues.
  • Remove the intake and exhaust piping connected to the stock turbo.
  • Unbolt the turbo from the manifold and carefully remove it from the engine bay.

Step 3: Install the New Turbo Manifold

Once the stock turbo is removed, it’s time to install the new turbo manifold. Make sure to:

  • Align the manifold with the engine block and secure it with bolts.
  • Use a torque wrench to tighten the bolts to the manufacturer’s specifications.

Step 4: Mount the BorgWarner EFR Turbo

With the manifold in place, you can now mount the BorgWarner EFR turbo:

  • Position the turbo onto the manifold.
  • Secure it with the appropriate bolts and gaskets.
  • Connect the wastegate to the turbo as per the manufacturer’s instructions.

Step 5: Install the Intercooler and Piping

The intercooler is crucial for reducing intake temperatures. Follow these steps:

  • Mount the intercooler in the front of the vehicle.
  • Connect the piping from the turbo to the intercooler and from the intercooler to the intake manifold.

Step 6: Upgrade Fuel System

To support the increased power, upgrading the fuel system is essential:

  • Replace stock fuel injectors with 1000cc injectors.
  • Install a high-flow fuel pump to ensure adequate fuel delivery.

Step 7: ECU Tuning

After all hardware is installed, tuning the ECU is necessary for optimal performance:

  • Connect your ECU tuning software to the vehicle.
  • Adjust fuel maps and boost levels according to the new turbo setup.
  • Test the vehicle to ensure all systems are functioning correctly.

Testing and Fine-Tuning

Once the installation is complete, it’s time for testing. Make sure to:

  • Perform a dyno test to measure horsepower and torque.
  • Monitor air-fuel ratios and boost levels during testing.
  • Make any necessary adjustments to the ECU for optimal performance.

Conclusion

Upgrading your 4G63 engine with a BorgWarner EFR turbocharger is a rewarding experience that can lead to impressive power gains. By following this step-by-step guide, you can achieve 550+ horsepower and enjoy the thrill of enhanced performance. Remember to always prioritize safety and ensure all components are installed correctly for the best results.