I want to turbo my '91 XT 6, I'm looking to get at least 100 more horsepower out of it(145 to 240some). What are my options, what are your thoughts?

we need more info than "i want to turbo it" - everyone just about "wants to turbo my car".   you want to retain the engine, replace the engine with something else, are you doing the work, are you okay with custom wiring and splicing together new hardware....?

 

Engine swap - this will all require wiring work, ECU, custom wire cutting, splicing, installing.  it's not plug and play.

EJ turbo swap

EG33 (230 hp)

EZ30 (212 hp) swap

 

all three of those have been done by members of subaruxt.com (they're all members here but they frequent subaruxt.com far more).

 

there are some folks on here that will do the wiring harness prep for you.

Sorry for being vague, is my first time treading these waters.

 

I have access to(a friend would sell to me) an EJ 255 to swap in, but I'm exploring keeping its current engine and putting some sort of turbo charger on it. I will be doing it my self, well with the help of experienced friends. As for the wire harness, I am comfortable in that area.

EJ255 will require all custom work/parts:
wiring - cut and label everything, have FSM's or pinouts for each wiring harness

bellhousing adapter (SJR used to sell them, probably still does) or search for threads on how to make your own, it's been discussed.

exhaust - turbo won't clear the crossmeber

 

***But otherwise the EJ engines bolt in place rather easily fitment wise.  physically they fit rather easily with minor concerns (bellhousing being the onloy major one).

 

the ER27 is a really bad candidate for a turbo.  weak heads and more.

have to go really light boost if you're just going to turbo an NA block, which won't get you to 230 hp anyway

otherwise you'll need:
turbo pistons (so probably a full or partial rebuild)

custom exhaust and crossmember tweaking again

 

the following is cost driven:
fuel management - the stock ECU is weak $$$$$$$$$$$

or compromise with an SPFI injector and RRFPR rising rate fuel pressure regulator (inexpensive)

 

if you're wondering what an ER27 is capable of you could look at what EA82T's are cabable of and multiply it by 1.5 - it's very close.

EA82/EA82T's have the same pistons, pistons rings, bores, sleeves, bearings, valves, valve springs, HLAs...basically the same engine they just slapped two more cylinders on it to get an H6.

 

so if you find old EA82 info, data, dyno charts - look at what they did and multiply by 1.5 to see what hp numbers are possible.

 

but take note those have turbo pistons and they eat headgaskets...and blocks, and bearings for lunch....

Edited November 17, 201312 yr by grossgary

subaruxt.com is an XT6 specific forum with lots of XT and XT6 members and information.

we have the Subaru FSM's available over there as well.