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SET UP GUIDE

¡BOOST SETTING STOCK CONDITION
1.0`1.1‡s/cm² (14.2`15.6psi) On Boost Controller
TUNED ENGINE 1.6‡s/cm² (22.8psi) On Boost Controller

The M7960 when boosted at around 1.6 kg /cm² (22.8psi) can deliever 400ps on 100 Octane pump gas (As tested in Japan). Please note that the maximum output depends on the state of the car. If the engine internals are completely stock, then the max power it can handle is 330ps. Have the car running in 4th or 5th gear when you're making changes to the boost setting. As when it is changed whilst in lower gear, the higher load in lower gear will result in the wrong boost settings. (It's not unusual to see on some occasions when the rpm reaches its peak and the boost drops).
 
¡ACTUATOR STOCK CONDITION Not Required
{Pre-set at 0.9‡s/cm² (12.8psi)}
TUNED ENGINE

The actuator has been pre-set at our factory, so there is no need for any additional adjustments.
But it is best to have a boost controller installed to make the required adjustments on the day
when driving conditions demand certain performance conditions.
 
¡TARGET POWER STOCK CONDITION
330PS
TUNED ENGINE 400PS

A significant impact on performance will show when upgrading the Camshafts, Suction Intake,
Exhaust Manifolds, Outlet Pipe, Catalyzer and Muffler System. With stock Cams, exhaust manifold,
outlet, boost of 1.0`1.1 kg / cm² (14.2`15.6 psi) can get about 350ps. If all of the above is upgraded
to the TOMEI items, with set Boost of 1.6 kg / cm² (22.8psi): 400ps is possible.
 
¡PISTON
STOCK CONDITION
Stock
TUNED ENGINE
Forged Piston

The stock Pistons in the G4KF are capable to cope with up to 330ps. However, with a drop in pressure
or engine compression, this increases the unwanted stress levels in the stock Pistons. So
upgrading to Forged Pistons are highly recommended.
 
¡CONNECTING RODS
STOCK CONDITION
Stock
TUNED ENGINE Conrods Recommended:
H-Beam Conrod

The stock G4KF conrods are fine for up to 330ps, however that depends on the state of the engine as well.
 
¡CAMSHAFTS STOCK CONDITION TOMEI PONCAM Best Suited
TUNED ENGINE

The standard camshafts cannot provide enough performance flow & pressure, so this limits your chances of
utilizing larger turbines. But once you upgrade your camshafts, you'll be able to run larger turbines with ease.
 
¡HEAD GASKET
STOCK CONDITION
Stock
TUNED ENGINE Upgrade Recommended:
METAL HEAD GASKET

Higher combustion pressures and boosts increase. When the G4KF boost is set with the stock head
gasket. It is highly recommended to upgrade the Head Gasket for increased sealing which will
enhance performance when running higher boost. When changing the thickness of the Head Gasket,
your compression ratio will change. You'll have to check all variables, Combustion chamber
volume, and block and head surface amount and so on to get the the correct compression ratio.
 
¡INJECTORS
STOCK CONDITION 550cc
TUNED ENGINE 650cc Or Higher

To work out the injector sizes you need you use this formula,
Target Horsepower x 5.9 ÷ No. of Cylinders = the cc flow amount per cylinder required.
Take into account that you will run up to 80%~90% of the injector's capacity.
 
¡FUEL PUMP
STOCK CONDITION 240L/h Or Higher
(Fuel Pressure 3kg/cm²)
Recommended: TOMEI 255L/h (Fuel Pressure 3kg/cm²)
TUNED ENGINE

To work out the fuel pump size you need you use this formula,
Injectors Capacity x No. of Cylinders x 0.06 = Fuel Pump flow rate required.
Then consider that the fuel pump should be used at 80-90% capacity when making your choice.
 
¡AIR CLEANER STOCK CONDITION High Flow Type
TUNED ENGINE

Choose the right high flow air filter to suit your power target.
 
¡AIR FLOW SENSOR (MAF) STOCK CONDITION
Stock Air Flow Meter or Without
TUNED ENGINE


 
¡SUCTION PIPE
STOCK CONDITION
Stock bolt on replacement, or standard.
TUNED ENGINE STRAIGHT PIPE

When running at higher boost, the stock suction pipe is not strong enough, so deformation occurs.
You can improve the intake efficiency by upgrading it. However, when taking advantage of the
straight airflow method, idling will become rougher and it will be easier to stall the engine.
 
¡INTERCOOLER STOCK CONDITION
Stock Replacement Upgrade, or stock.
TUNED ENGINE
Large capacity, high flow type.

Pressurized air from the Turbine is compressed and sent to the engine. This process forces the air temperature to increase with heat. So when it does, the air density drops and combustion efficiency becomes poor, resulting to performance loss. The intercoolers job is then to extract the heat from the forced air via the fins in the intercooler. This again helps compress the air again, and the denser colder air will improve combustion efficiency to optimize performance. The Hyundai Genesis stock intercooler is too small, so when you start to tune the engine, you'll
have to pay attention to the intake temperature conditions when using the stock intercooler.
 
¡BLOW OFF VALVE
  (Recirculation Type)
STOCK CONDITION
Recommended:
Strenghtened Type (Recirculation)
TUNED ENGINE

When the throttle is suddenly closed, the forced air from the Turbine will have no where to go. This restricted flow places a heavy burden on the turbo and other parts. So the Blow Off Valve is fitted somewhere between the turbo and the throttle to prevent this problem by giving an option of an escape route to vent the excess pressure. This saves the turbo from any possible problems. The stock BOV was never designed to handle high boost applications, so it will struggle to do it's job properly when the limits are exceeded. This puts the turbo at risk of failure and response drops. This is why we recommend to upgrade the BOV to a stronger type.Additionally, when the BOV is a vent to atmosphere type, this can cause other problems with the flowing into the engine. ECU not being able to read correct air volume that is flowing through it. As the volume of air still passes through the air flow meter but not all of if goes to the engine. In this case the air to fuel mixture will be incorrect. So we recommend the recirculation type design.
 
¡EXHAUST MANIFOLD STOCK CONDITION
Stock
TUNED ENGINE
Large capacity, high flow type.

By upgrading your camshafts, you can increase the exhaust pressure, this in turn will help spool larger turbines efficiently once the exhaust manifold has also been changed. All together will aid with the performance increase. Then your larger Turbine will be able to come on boost faster.
 
¡TURBINE OUTLET STOCK CONDITION
Stock
TUNED ENGINE
Large Capacity High Flow Φ76.3mm Diameter.

The stock outlet pipes will hinder the gas flow efficiency. At higher engine speeds (RPM), these narrower outlet pipes will choke the Turbine exhaust gas flow, causing the boost to be unstable. With the larger outlet pipe, exhaust gas flow will be more efficient, boost will stabilize and the efficiency of the Turbo will increase.
 
¡FRONT PIPE STOCK CONDITION
Recommended:
Pipe Diameter φ76.3 or Similar
TUNED ENGINE

By using a similar sized pipe with the outlet pipe diameter, exhaust gas flow will be smoother,
better mid range pick-up and more power in higher RPM range.
 
¡CATALYTIC CONVERTER STOCK CONDITION
Recommended:
Metal Catalytic Converter
TUNED ENGINE

By upgrading to a sports metal catalytic converter, you can get the high flow performance needed
whilst still meeting the most of the current smog emissions standards.
 
¡MUFFLER STOCK CONDITION
Recommended:
Pipe Size φ80-90 or Similar
TUNED ENGINE

By using a larger high flowing turbo outlet pipe, more performance gains are possible. Most noticable in
the upper engine speed range.
 
¡COMPUTER STOCK CONDITION
Custom Tune Required
Recommended: HALTECH PRO PLUG-IN HYUNDAI
TUNED ENGINE

An aftermarket ECU is required to optimize the setup of your engine with the new setup.
 
¡SPARK PLUGS STOCK CONDITION
UPGRADE REQUIRED
Recommended: 8~9 Heat Range
TUNED ENGINE

With the increase of horse power, the increase in combustion temperatures and this will be a risk of
the plugs from melting. The recommended plug heat range of 8-9 is suitable.
 


Copyright (C) 2006 TOMEI POWERD,Inc. All Rights Reserved.
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