Huffin And Puffin - Jeep TJ Turbo Upgrade - Jp Magazine

Pete Trasborg Brand Manager, Jp

We are such big fans of turbochargers that you might be tired of hearing us talk about them. The fact is that a turbo can be a great way to build more power, and the inline Jeep engines are so overbuilt they can handle boost with no problems. Many people feel that a turbo automatically means lag, but with a properly sized turbo that just isn’t the case. We’ve driven turbocharged Jeeps before, have turbocharged our own Jeeps, and we’ve been pushing companies for years to bring out a reasonably priced turbo kit for the Jeep 4.0L.

huffin And Puffin Jeep Tj Turbo Upgrade jeep Burnout Photo 44685286

Well, we are happy to say that Gale Banks Engineering has listened and has come up with a remarkable turbo system with 50-state-legal status still pending as we go to press. With extensive experience in building turbo kits for bigger diesel-powered vehicles, we had high expectations for this kit and we weren’t disappointed. The kit is well designed and executed and features everything you need for installation. From the air intake kit to the bolt-on exhaust modifications, everything is here for you to get an average 45-percent bump in power. The kit fits ’991⁄2 to ’06 Wranglers. If your Jeep is a ’99 and you aren’t sure if this will work for you, the catalytic converters are key. If you’ve got two pre-catalytic converters, it will fit your Jeep.

But wait, there’s more! The basic kit sells for under $3,000 and can be installed in your driveway in less than a day. Compare that to $5,000 that most supercharger kits run that offer the same kind of power. We went to Gale Banks Engineering headquarters in Azusa, California, to get the exclusive on its new Wrangler turbo kit and hopped behind the wheel of the company’s ’06 TJ test mule.

We took the turbo Jeep over the same route we drove our ’01 Wrangler for an apples-to-apples comparison. Both Jeeps have 4.56 gears and 35-inch tires, but our ’01 has a manual transmission while the ’06 with the turbo has an automatic. On hills we had to shift into Fourth gear with the manual-equipped ’01, the automatic-equipped turbo Jeep often was able to climb the same hill in overdrive. Even with constant gas pedal input, boost would build, and the turbo Jeep was able to maintain speed up the hill, where we had to downshift and step on it harder with the non-turbo Jeep. It was a relatively cool day, but the turbo Jeep didn’t show any overheating tendencies, even with the stock radiator. The company tells us even in 100-degree weather, they haven’t had any problems with overheating.

JPMP 130600 BANK 013 HR Photo 45255278 We didn’t hear any detonation, and even with a soft top, the wastegate and blow-off valve were hard to hear, making it difficult to tell it even had a turbo from the outside. From the driver’s seat the turbo spools up quickly, and you feel it building boost. However, it drives so nicely that if it weren’t for the boost gauge the unsuspecting passenger would be hard-pressed to tell what was changed under the hood. PhotosView Slideshow A turbo builds boost exponentially as the engine speed rises and boost doesn’t stop rising. Obviously too much boost would blow your engine, so something needs to be done. It is called a wastegate, and at a set boost level it basically opens up and allows exhaust gas to bypass the turbine, keeping boost within the cylinders at a set level. For the basic kit, boost is set at 6 psi. An exploded view of the turbo allows you to see how it goes together. The wastegate diaphragm is much larger and more robust than others on the market and holds pressure better, which means the system builds boost faster. Banks calls it a Big Head wastegate, and it is the same one that the company uses on its bigger diesel turbo kits. The heart of the system is this cast bracket that holds the turbo and shifts the alternator up a bit for clearance. The turbo has a 46mm inlet diameter and a 58mm wheel diameter, and the bracket bolts to existing holes in the block using bolts included in the kit. The turbo comes out of the box already mounted to the bracket with the Big Head wastegate (A) and blow-off valve (B) already assembled. With these items integrated into the turbo housing, the final installation is very clean and factory-looking. The kit includes a new serpentine belt as well. When we arrived, Banks had a kit lying on a bench so we could manhandle the parts and check out all the components. The company had an engine on a cart nearby that it used for designing the kit. We took the opportunity to test-fit stuff to the engine to see how it went together. You can see here the 21⁄4-inch to 21⁄2-inch-diameter intake tube in grey powdercoat. It is attached using silicone sleeves over bead-rolled tubing ends and held in place with high-end clamps. You can also see the included 35 lb/hr injectors. The two included exhaust tubes are 21⁄2-inch-diameter 304 stainless steel, and you can see where it attaches in front of the oil pan, feeds into the turbo, and where it attaches back into your factory exhaust. It took us about 30 minutes to get this all bolted up to the test engine. Obviously it will take longer in a Jeep, but that time speaks well of how easy a full install should be. Speaking of exhaust, if you’ve had aftermarket exhausts that use clamps and slip fittings, you’ve likely had it fall apart on you on the trail. Well, Banks thought of that, too, with a double-slip joint. Your existing exhaust tube slides in the middle of this joint and is then retained by a stainless steel band clamp to make sure the exhaust isn’t going to come apart. In addition to all the necessary bolts and clamps, the kit even includes PTFE pipe sealant, thread-locking compound, and anti-seize. The instructions explain where everything needs to be used. Also included (but not shown here) is a 2-bar MAP sensor that plugs right into the factory wiring harness in the factory location to keep the computer from freaking out because of the boost. Here’s a sneak-peek inside the test mule. The kit requires 91-octane fuel to help prevent detonation, but a lot of real-world testing and tuning was done with a wide array of not-cheap test equipment. Banks has burned through many tanks of gas everywhere from sea level to some of the highest mountain passes in the Rockies—all to make sure that by the time you bolt the kit to your Jeep you won’t have any tuning issues. Speaking of tuning, the base kit includes an analog boost gauge and Banks AutoMind programmer pre-loaded with different tunes (left). The Banks iQ flash is optional and includes a Banks iQ touch-screen programmer and an AutoMind programming module. The iQ runs about $360, and for an extra fee you can also use the iQ as a turn-by-turn GPS unit. The optional hood scoop shown here is called a Super-Scoop and pulls cold air into the system from outside the engine compartment and can bump power. However, if you live where water crossings get up to the headlights, we’d advise against this one. Other options that should be available by the time you read this include an intercooler and/or water-methanol injection, both of which allow up to 10 psi of boost. You don’t need to buy it all at once, though; you can install the base kit and go for the add-ons down the road. Turbos need oil for lubrication and cooling, and this one is no different. This kit includes a “T” and fittings to tie into the oil pressure sending port to provide a feed line to the turbo. It also includes a weld-in 3⁄8-inch NPT bung for the return line into the oil pan. If you aren’t welding-capable, Banks offers new oil pans with the bung already welded in. For $3,000 this Jeep gained 66.1hp and 83.7 lb-ft at the rear wheels, which is better than some of the strokers we’ve installed. But that isn’t all—notice that the peak power now comes in lower in the RPM range, which really makes the added power more noticeable. Check out the gains between the curves to see a bit more of the entire picture.