Outer Limits 4x4 Board

Picked up my Denco turbo for my truck today

Just having a browse through the fitting instructions and cam across a few things that have me guessing...hopefully you guys can help me out.

1) It says that the oil return line is to be fitted to the rear engine side cover...this entails taking it off and welding the 3/4 pipe into the cover.

My truck already has a oil return plug in the sump itself...so can I extend the oil return line and plug into that???? Any adverse effects to doing this?

2) instruction number 7 says to "remove air cleaner top cover and disconnect hose from Venturi".

What on earth is the Venturi?

3) It says to cut 3 threads off the top manifold stud, 4th from front

Any reason why?

Now that you have finsihed laughing at my stoopid questions...I hope that you can answer them for me.

P.S I will be assisting in the fitting, but a majority of the work will be done by a diesel mech...the main reason for the Q's is curiousity.

When i set up my turbo i was supposed to weld a 3/4 fitting on to the sump to take the return for the turbo,i chose not to do this and tapped my oil return into the oil return for my alternator,this didnt allow my oil to drain fast enough so what was happening is it was banking up inside the turbo,in return giving me a very smokey engine,i rang mike vine who built the turbo for me and he told me this was very common if you dont weld that fitting back to the sump,this was on a 2.8 hilux though.

G_loomis wrote: 1) It says that the oil return line is to be fitted to the rear engine side cover...this entails taking it off and welding the 3/4 pipe into the cover.

My truck already has a oil return plug in the sump itself...so can I extend the oil return line and plug into that???? Any adverse effects to doing this?

Connecting to the sump should be OK, as long as the connection is above the normal oil level, and is sufficiently large diameter. But best to check with the manufacturer.

2) instruction number 7 says to "remove air cleaner top cover and disconnect hose from Venturi".

What on earth is the Venturi?

A venturi is a conical restrictor - the throat of a carby is a venturi. I wouldn't have thought there would be one on a diesel air cleaner - maybe they mean the cyclonig pre-cleaner???

3) It says to cut 3 threads off the top manifold stud, 4th from front

Probably because it would foul something if you dont???

ISUZUROVER wrote:

G_loomis wrote: 1) It says that the oil return line is to be fitted to the rear engine side cover...this entails taking it off and welding the 3/4 pipe into the cover.

My truck already has a oil return plug in the sump itself...so can I extend the oil return line and plug into that???? Any adverse effects to doing this?

Connecting to the sump should be OK, as long as the connection is above the normal oil level, and is sufficiently large diameter. But best to check with the manufacturer.

2) instruction number 7 says to "remove air cleaner top cover and disconnect hose from Venturi".

What on earth is the Venturi?

A venturi is a conical restrictor - the throat of a carby is a venturi. I wouldn't have thought there would be one on a diesel air cleaner - maybe they mean the cyclonig pre-cleaner???

3) It says to cut 3 threads off the top manifold stud, 4th from front

Probably because it would foul something if you dont???

Thanks ISUZUROVER...it all makes sence now. The 3rd answer you gave is what I was thinking, so something around that area must be a tight fit.

I had a look under the bonnet this morning, and the Venturi must be what the hose from the airbox connects to. It all seems to fit anyways.

I checked the exact location of the oil return that is tapped into the sump. Its only about 10mm below the top of sump...so it should be fine. The oil level at the moment is full, so I might just pull the plug off the return and see if oil spills...if there is no spill, well obviously the oil return is above normal oil level.

this is foir a 2H isnt it?

My air cleaner(2H) isnt cyclonic and doest have anything venturi like on it.

it does have a couple hoses attached to the top of it but this is to measure pressure difference which tells you wether or not your filter is too clogged.

G_loomis wrote:I checked the exact location of the oil return that is tapped into the sump. Its only about 10mm below the top of sump...so it should be fine. The oil level at the moment is full, so I might just pull the plug off the return and see if oil spills...if there is no spill, well obviously the oil return is above normal oil level.

What will happen while you're off-road? Steep slopes - climbing, descending, side slopes?

Rocker cover could be safer.

Shadow wrote:this is foir a 2H isnt it?

My air cleaner(2H) isnt cyclonic and doest have anything venturi like on it.

it does have a couple hoses attached to the top of it but this is to measure pressure difference which tells you wether or not your filter is too clogged.

A vacuum sensor may not like boost - this could be the issue.

Scott

-Scott- wrote:

G_loomis wrote:I checked the exact location of the oil return that is tapped into the sump. Its only about 10mm below the top of sump...so it should be fine. The oil level at the moment is full, so I might just pull the plug off the return and see if oil spills...if there is no spill, well obviously the oil return is above normal oil level.

What will happen while you're off-road? Steep slopes - climbing, descending, side slopes?

Rocker cover could be safer.

Shadow wrote:this is foir a 2H isnt it?

My air cleaner(2H) isnt cyclonic and doest have anything venturi like on it.

it does have a couple hoses attached to the top of it but this is to measure pressure difference which tells you wether or not your filter is too clogged.

A vacuum sensor may not like boost - this could be the issue.

Scott

rocker cover means it will have to push it up hill which could create the same problem as what bastard was having

they say plumb it into the side plates as this is well above the sump level obviously and drains very easily back into the sump. Its also a heck of alot easier to remove a sideplate than to remove the sump.

Plumbing it into the sump should be ok (they probably dont say put it there simply because its alot harder than using the sideplate, I suggest in other engines where sideplates arent there (other side of engine or overhead cam engines) they would specify it has to be plumbed into the sump.

-Scott- wrote:

G_loomis wrote:I checked the exact location of the oil return that is tapped into the sump. Its only about 10mm below the top of sump...so it should be fine. The oil level at the moment is full, so I might just pull the plug off the return and see if oil spills...if there is no spill, well obviously the oil return is above normal oil level.

What will happen while you're off-road? Steep slopes - climbing, descending, side slopes?

Rocker cover could be safer.

Shadow wrote:this is foir a 2H isnt it?

My air cleaner(2H) isnt cyclonic and doest have anything venturi like on it.

it does have a couple hoses attached to the top of it but this is to measure pressure difference which tells you wether or not your filter is too clogged.

A vacuum sensor may not like boost - this could be the issue.

Scott

Nah - the aircleaner is before the compressor, so there is no boost here. It's just a diaphragm with hoses into the housing pre- and post-filter to turn on a dash light once the difference is sufficient to activate the switch.

I reckon the rocker cover is too high for the oil return - you want it lower than the turbo. Won't the oil level in the sump be lower when the engine is running as some of the oil will be spread throughout the rest of the engine? I have an aftermarket turbo on my 2H and the return line also runs into a pipe welded onto the side of the sump near the top. I've had it on some steep slopes and never had a problem (at least not that I'm aware of).

As far as the 'venturi' goes on the 2H, could this be a reference to the throttle body? There's certainly no venturi in the aircleaner box.

juscruisin wrote: As far as the 'venturi' goes on the 2H, could this be a reference to the throttle body? There's certainly no venturi in the aircleaner box.

It specifically says take the top cover off the air cleaner assembly though.

Thats why i dont think they mean anything to do with the intake manifold etc.

Done a bit of research today...and this is what I discovered.

This is where the turbo outlet connects to when it refers to the Venturi. Apparantly this part is called the Venturi but the term is more commonly used with carbi driven motors.



This is the location of the sump plug oil return...The plug at the moment is slightly leaking, but I checked the actual stem itself and all is good. The plug is roughly central (front to back) of the sump.

G_loomis wrote:

How f^%%$#g lucky are you.

I had to pull the sump off mine.

udm wrote:

G_loomis wrote:

How f^%%$#g lucky are you.

I had to pull the sump off mine.

theres only one thing I can really say here....

I put my return in the sump as shown and have had no problems

In your little kit, you should find a small rubber cap to plug off the current crank case breather fitting in the venturi. It will look like the one you have on your oil return in your sump currently. Your crankcase breather line will be relocated to the non pressure cross over pipe that feeds the turbo.

As far as the oil return from the turbo goes, I did have mine in the side plate where the instructions specify. I can't however see a problem with the way you are going to do it.

And last but not least, you do need to cut a few threads off the 4th top manifold stud because it will be too long when you come to bolt the turbo manifold back up. It will foul against the manifold.

Hope that helps,
Aaron