DIY - TB45E turbo install

[04OFF]

There isn't any real risk if you think about it. A well greased drill bit retains a lot of the aluminium shavings. Anything that might fall in has to get through the oil pickup screen which is designed to only allow stuff through that can go through the pump. Finally, it has to get past the oil filter before it can get into the working parts.

I guess my concern would be ,Id have thought alloy shavings could float on oil, then perhaps the big end/crank could dip the oil and pick this up, probly overthinking things, but ive always removed sumps on other turbo installs, to fit the oil return.

Anyway, John i don't wan't to start spamming up a exellent build thread, so if its still all working then sweet, lets leave it at that.

[jff45]

I don't see it as spamming at all. I appreciate your interest, even more so now that you've mentioned you've done turbo installs yourself.

I've never done this sort of thing before so I'm a complete novice. These threads are for sharing ideas and I welcome any and all comments especially if someone sees something that I've done blatantly wrong.

[jff45]

Intercooler:

This has been the most challenging and rewarding phase of the excercise so far.
My research convinced me that there was nothing more important than keeping intake air temps down so that meant fitting the biggest IC I could. It had to be top mount because of the winch and auto trans coolers not allowing for front mount fitting.
This in turn meant I had to use a low mount manifold to leave enough room on top.

As this is a budget install, no point in throwing big money at it. Ebay is my friend so I got this:



I knew it was going to be close to the bonnet and I didn't want it to shake with the engine. I also wanted a fan underneath it so I decided the best way was to make a cradle that fixed it to the bodywork.
The cradle would also serve to better mount the fan rather than bolt the fan directly to/through the IC.

Here are some pics of my first attempts using too many silicone elbows which would have meant too many hose clamps and the whole thing a bit too thick where it fits to the throttle body.








So I decided it would be more practical (and look better) if I fabricated as much of the intake piping as possible from exhaust pipe. This would allow me to mount the BOV a bit closer to where it crosses over to the pre-turbo air intake.
I had bought a whole bunch of different sizes and bends of 2.5", 2.75" & 3" mandrel bent 1.6mm pipes from Ebay.
I did the fine grinding to get angle right with an old belt sander I haven't used in years.





Added the air feed pipe for the IACV and welded an 8mm nut on for the temp sensor for the fan switch.



Added the 25mm pipe for the BOV.




This is where it's at at the moment





This the fan I chose. It's a Davies Craig 12"



Here's the fan fitted into the IC cradle.




More to come...

[jff45]

Intercooler continued..

In order to fit that size IC over the throttle body, you have to move the IACV because the connector plug sits too high.

My thanks once again to JoseM from Panama for this idea. It was his TB45E turbo build pics that showed me that a 76mm thick IC could be fitted over the throttle body.

I made this adapter from some 3mm plate and a short length of 25mm square tube. This allowed me to have the IACV down behind the inlet manifold.
I brazed up some copper pipe & elbows to be able to use the original air feed pipe in the meantime. Also, the wires need to be lengthened.


It's actually light grey but the iPad camera turned it blue..







Here's a pic of the fan mounting bolts. 6mm welded to the frame with nuts and washers fitted first.




This is the clearance under the fan. You'll need to use elbows on the PCV outlets to maintain the clearance.




Small detail on the IC.. I added 20 x 25 x 1.6mm aluminium angle front and rear with pop rivets to have a flat surface for the sealing foam.




Bonnet scoop next..

[jff45]

Bonnet scoop..

I would have preferred not to do this but with a top mount air-to-air IC you don't have much choice.

This is the Ebay 'Navara style' fibreglass jobbie for $115. Not the real cheapie plastic one nor the higher end $300 - $400 article.
It covers the IC pretty well.




I painted it with rattle cans (we're talking budget install here, remember..)





I took the bonnet off to cut it and fit it. It's very slightly off-colour depending on the angle and sunlight but in real life you don't really notice it.. and it is a 13 year old vehicle after all..






More to come...

[Alitis007]

Me too! I've already fitted a 1mm restrictor (Kinugawa only supplied it with -4AN) as recommended on the Garrett website for the GT35R. I'm running -4AN for the oil feed because it was the only size in line filter (strainer) I could find and the 1/8 BSPT to -4AN adapter for the oil feed outlet on the block was also easy to find.

The -3 feed line was recommended to me by another workshop and also recommended by the local Garrett dealer aswell after i enquired about it while i was installing a TO4Z On my toy but saying that i didn't run an inline filter. Those fittings are readily available at speed shops like Rocket and VPW and even hose and fittings specialists like Enzed and Pirtex

[04OFF]

I don't see it as spamming at all. I appreciate your interest, even more so now that you've mentioned you've done turbo installs yourself.

I've never done this sort of thing before so I'm a complete novice. These threads are for sharing ideas and I welcome any and all comments especially if someone sees something that I've done blatantly wrong.

Ive only done Turbos on old holden motors 186 and 202s, plus helped with my bro in laws Turbo VW drag car, the only Nissan stuff has been RB30s, had nothing to with Turbo TB45s (even tho i own a TB45) im afraid.

With the progression of pics etc, Im assuming you may have already finished this install ?, if so, this makes it even better for any readers, as you already "know it works".


Scoop looks mint !

FYI, I used the same cheapo intercooler you have, except mine was 150mm wider across the face (600), the engine made over 500hp (eng) so don't let anyone tell you it won't work.

[jff45]

The -3 feed line was recommended to me by another workshop and also recommended by the local Garrett dealer aswell after i enquired about it while i was installing a TO4Z On my toy but saying that i didn't run an inline filter. Those fittings are readily available at speed shops like Rocket and VPW and even hose and fittings specialists like Enzed and Pirtex

Cheers, I've already bought all the fittings and braided teflon hose.
Using -4 for the oil, -6 for the water and -10 for the oil return.

[jff45]

No the install isn't finished yet. Everything is ready now for me to remove the extractors and bolt the turbo on then make the exhaust.
I've been caught up with home-owner chores and stuff and I want to do some N/A logs of timing with AFRs for comparisons.
Also want to log what the MAP sensor is reading up to 100 kpa.
I'm hoping turbo will be fitted in the next month but I wanted to get the thread underway before it became too daunting a task..

[04OFF]

Sweet, look forward to the rest of your posts then

Test & Tune at Willowbank before and after, will give you a great idea on how much more "overtaking" speed you will develop.