1hz turbo install matts adaptor with pics

[crunk81us]

Ok so I took some photo's of my install and figured i might post them up here for all to see.

Firstly I removed the airbox and all pipes



then the exhaust and studs from manifold



Removed the oil filter and drip tray for access to the oil pressure sender



installed t-piece and stainless braided hose



installed the adaptor with a genuine toyota flange gasket (which i forgot to take a photo of by itself, matt would u like to put one up?) and mounted the turbo using stainless steel gasket and hi temp goo. Connected oil line with banjo bolt and restrictor



I had trouble finding pipes to go from the 2 inch turbo to the 2 3/4 inch intake. I used a 2 - 2 1/2 adaptor bend, put a piece of 2.5 inch exhaust pipe inside the 2 1/2 inch end then slid a 2 3/4 inch straight join over the top of the silicon 2 1/2 inch pipe and clamped it down. the 2 inch end wasn't long enough so i lengthened it with and extra piece of 2 inch exhaust pipe and rubber hose. (i plan on installing an intercooler soon so this setup is fairly temporary.)
also temporary is the 3 inch bend with a pod filter (4 inch snorkel coming).





Still working on the water (see other thread) http://www.outerlimits4x4.com/viewtopic ... 8&t=215491" onclick="window.open(this.href);return false;

Also haven't fitted boost guage/pyro/dump/wastegate.

Haven't touched fuel yet, waiting on all of the above. Goes better already lots of power from 1800ish and really on song at 2500 (does cool donuts in 2nd )

did have a scare as i had oil in my compressor outlet and engine intake. But the owner before me did not have the oil restrictor in place which i think might have blown some oil past the seals. I cleaned it and took it for another 10 min drive and no more oil.. phew

Will post more as i go..

[98lux]

looks good, Where is the hose to the rocker cover??

[crunk81us]

Had to disconnect it from intake otherwise it would pressurise the motor. it needs a hose to run from it to the intake side of turbo.. or it's own filter.

[crunk81us]

link to safari install guide.. It recommends adjusting the gap in the pcv baffles to 10mm.. why?

http://www.safarisnorkel.com/turbo/guid ... guide.html" onclick="window.open(this.href);return false;

[80's_delirious]

closing up the tabs on the PCV baffle is an attempt to control the amount of oil that gets blown out through the breather. Oil mist from the PCV accumulates in the intake piping and makes a mess in an intercooler if fitted. Turboed engine can have more blow-by so more likely to have oil mist blowing through the PCV.

I dont think changing the tabs made much difference to mine?

[crunk81us]

ahh ok.. i'll do that if i get excessive blow by..

[98lux]

I am putting a small catch can on mine, someone else is getting about 20ml out of the can when he does the 5000k oil change.

[98lux]

Here is what i was told when i installed the turbo on mine.

"Looks good, but just watch as your inlet system post turbo starts to gunk up from the EGR valve and the increased oil mist in the crankcase ventilation feeding into your engine upstream of the turbo.

About 20,000km it will be considerably there. Have a think about fitting an oil catch can to eliminate most tof the crankcase oil mist.

Where your crankcase ventilation fits into the inlet up stream of the turbo, does it have a angled exit for the c/c air or is it straight into the inlet pipe..?.. often the straight in is afffected by the drawn air to the turbo from the air cleaner, and ...over assists .. in the transfer of crankcase vapours.....and can increase oil consumption thru this. "

[crunk81us]

was thinking of putting a plain old filter on the egr breather (like what u do with an old holden red motor) for the time being.. then maybe plumb in a catch can later.

[Z()LTAN]

I dont run a catch can.

Just run your pcv hose from the motor up to the fire wall then down to your airbox. My theory is that the oil will cling to the walls of the hose, and run back into the rocker cover.
Seems to work, with 25psi i dont have any oil in my intake still. I just wipe out a very small amount of oil from the bottom of my airbox when i clean the filter.

[98lux]

I dont run a catch can.

Just run your pcv hose from the motor up to the fire wall then down to your airbox. My theory is that the oil will cling to the walls of the hose, and run back into the rocker cover.Seems to work, with 25psi i dont have any oil in my intake still. I just wipe out a very small amount of oil from the bottom of my airbox when i clean the filter.

So your theory does not work For the amount of efort to run the hose up the fire wall and back down to the airbox would be the same as running a home made $4.50 catch can.

And this install is on a daily driver not a weekend warrior.

[crunk81us]

ok so i got the boost gauge installed and hooked up the wastegate..

took it for a spin, boosts so quick in the lower gears (short test road) i cant accurately say what revs=psi but i would guess 15psi by 1700 and 20-25psi from 2200 right thru to redline.

I don't want this much boost...

adjusted the wastegate now getting about 12psi from 1500 thru to 15psi @ 2800, then up to just under 20 psi @ redline.

Still too much..

I don't know what the wastegate is supposed to open at but it is difficult to move by hand..

Any suggestions on what rating wastegate actuator i need?

I would like to keep it below 12psi at full noise.

EDIT: Faulty boost gauge...

[Z()LTAN]

12 psi waste gate should do the trick then

[hulsty]

what turbo and specs is it? sounds like it boosts well!

[crunk81us]

what turbo and specs is it? sounds like it boosts well!

its a garrett gt2860rs

[crunk81us]

12 psi waste gate should do the trick then

Ok was unsure because i read somewhere that the actual boost can be higher than the rating of the actuator.. like if i put in a 12psi actuator i might see 15psi ??

[ledgend80]

you will only get 15psi with a 12psi actuator if the actuator is not adjusted correctly

[crunk81us]

ok thanks will post how i go..

[a1 mech]

How does the factory exhaust manifold go compared to a 1HD turbo manifold flow wise when being adapted for a turbo?

[crunk81us]

i think the biggest restriction is the turbo.. I'm not sure but i don't think there is a whole lot of difference between the two.

[drr]

ok so i got the boost gauge installed and hooked up the wastegate..

took it for a spin, boosts so quick in the lower gears (short test road) i cant accurately say what revs=psi but i would guess 15psi by 1700 and 20-25psi from 2200 right thru to redline.

I don't want this much boost...

adjusted the wastegate now getting about 12psi from 1500 thru to 15psi @ 2800, then up to just under 20 psi @ redline.

Still too much..

I don't know what the wastegate is supposed to open at but it is difficult to move by hand..

Any suggestions on what rating wastegate actuator i need?

I would like to keep it below 12psi at full noise.

Sounds like the wastegate can't keep up with the level of exhaust flow, it may be damaged or just too small. You may need a bigger external wastegate on it.
Is it easy to operate the wastegate valve without the actuator connected? How did you adjust it? Did you use a bleed type valve or did you lengthen the actuator rod? Lengthening the rod will only delay spool up and full boost, not reduce max boost level.

[crunk81us]

ok so i got the boost gauge installed and hooked up the wastegate..

took it for a spin, boosts so quick in the lower gears (short test road) i cant accurately say what revs=psi but i would guess 15psi by 1700 and 20-25psi from 2200 right thru to redline.

I don't want this much boost...

adjusted the wastegate now getting about 12psi from 1500 thru to 15psi @ 2800, then up to just under 20 psi @ redline.

Still too much..

I don't know what the wastegate is supposed to open at but it is difficult to move by hand..

Any suggestions on what rating wastegate actuator i need?

I would like to keep it below 12psi at full noise.

Sounds like the wastegate can't keep up with the level of exhaust flow, it may be damaged or just too small. You may need a bigger external wastegate on it.
Is it easy to operate the wastegate valve without the actuator connected? How did you adjust it? Did you use a bleed type valve or did you lengthen the actuator rod? Lengthening the rod will only delay spool up and full boost, not reduce max boost level.

I lengthened the rod.. It moves freely by hand. have a mate dropping off a handful of actuators (works at a scrap metal yard and just got a huge pile of turbo bits..) also getting the good boost gauge tomorrow. I think the cheapy is reading high.

[drr]

Yeah, lengthening the rod isn't the correct way to do it, but it gets done so often. The reduction in boost you see at lower revs from doing that is just like wastegate 'creep'. Best way to do it is find an actuator with a lower boost threshold than you want and use a decent bleed type boost controller. They're cheap and work well enough, the 'turbotech' branded ones are supposed to be pretty good at holding boost steady.

[crunk81us]

Yeah, lengthening the rod isn't the correct way to do it, but it gets done so often. The reduction in boost you see at lower revs from doing that is just like wastegate 'creep'. Best way to do it is find an actuator with a lower boost threshold than you want and use a decent bleed type boost controller. They're cheap and work well enough, the 'turbotech' branded ones are supposed to be pretty good at holding boost steady.

Yeh I figured that it was letting it thru.. it took longer to wind up. Hoping to get a handful of free actuators soon. will try them..

[matt.mcinnes]

Looks like every thing fitted nicely, sorry I don't have a pic of the Genuine 1HZ gasket for the exhaust.

Regards Matt

[crunk81us]

Looks like every thing fitted nicely, sorry I don't have a pic of the Genuine 1HZ gasket for the exhaust.

Regards Matt

I meant (put the brackets in the wrong spot )the adaptor..

Yes it fit very nice! wastegate actuator on standard bracket with at least 1/2 inch gap to block! Had trouble finding allen head bolts the right length, so cut 2 inch ones down to fit..

[matt.mcinnes]

Had to have a few more made

[biegetroopy]

nice adaptors matt ,my troopys is still going after the conversion to turbo power and your adaptor is working a treat, cheers mick