What is the safest max boost level that can be run on standard internals?
MY96 wagon import with td05

 

Depends, but in my opinion 320/340 crank HP is running it close to the edge, on stock internals.If you just crank up the boost with a boost controller you can not go as high as with a full remap.

Also the stock injectors and pump will be the limiting factor before the engine internals, as the stock 380cc injectors (is it a WRX wagon, not an STI)will run @ 100 duty cycle at 310-320 crank HP assuming the stock pump still works like a new one (and it's safe to say it won't work like a new pump after 17 years)

 

But what would max boost level be at those figures? Psi/bar

 

It depends on the tune to be honest.
I've seen tunes that used a lot of boost for a certain HP number, and have seen tunes with the same power, but much less boost.

But I would err on the side of caution, and not go much above 1.3 bar (with a good tune, DO not use a boost controller and just crank up the boost) on a stock EJ20 with a 16G.
Especially with the small slant mount IC, as higher pressures cause a rapid rise in charge temperatures.
I ran my car on 1.5 bar with a Super16G, but the fueling and ignition were mapped to suit,also I had a FMIC.

 

When I got my Scooby, the guy had set it up in a stupid way. It was boosting to 24 psi. I took it back to standard but it had messed up the engine. Yet to find out what the damage is. Haven't got round to rebuilding it yet. Bought a spare Scooby for parts and rebuilt the engine in that and did a swap

 

16 psi is fairly shifty. That's what mine is chipped to at the mo. Uprated head gasket and forgotten what else but not far from standard. Not sure whether I should take it to 20psi

 

FMIC too

 

I would be careful given boost pressure advice,as no two engines run the same I would advise you get a mapping session and get it set up properly.the days of the bleed valve are long gone, switching the boost up and hoping for the best is not modifying.SJ.

 

Mapper will map it to a safe level, you don't need to know.

 

How will you be increasing boost pressure?