2001 Ti TB45E auto to TD42T auto conversion

[jff45]

I'm starting this thread now although my TB45E is still running at the moment. I can update it as I progress and it avoids having to do it all once it's finished.

A big thanks to those who have taken the time to share their experiences with their TD42 conversions.

The original project was to turbo the TB45E engine but I finally had to accept that, if I wanted to pull a fair sized caravan around Australia, the fuel bill was going to be horrendous.
This won't be a rapid conversion. I'm 70 years old and I'm doing it by myself. I have the advantage of being retired and having a fairly well-equipped shed.

This is the vehicle I started with..





I was already well advanced with my turbo project but I'm confident that a lot of what I've done can be used with this conversion.

- I fitted a TD42 airbox with cobra head and 3" outlet.



- I made a cradle for my Ebay intercooler with Davies Craig fan







- I bought a $115 Ebay "Navara style" scoop, painted it with rattle cans and fitted it to the bonnet






- I bought this log manifold for the GT3540 turbo that I'm now fitting to the TD42T. It brings the turbo further forward and allows much more room at the rear for the dump.
One of the issues with the Ti model is the A/C lines for the rear evaporator. With a standard TD42T turbo manifold, the dump hits these pipes. My manifold avoids this issue.



Also made a heatshield for it from a small sheet of stainless from Bunnings. Just need to modify it slightly for the TD42



A lot of the braided teflon fittings I had already purchased for the GT3540 can now be used on the HT18.
I'm keeping the HT18 and simply adding a 3" exhaust. Will be going with Scotts Rods, I think, I can drive there and pick it up.

[jff45]

This is the engine I bought from a wreckers here in Brisbane. It's an imported TD42T so factory turbo. It has the advantage of being from an auto vehicle so it has the elusive flexplate and the TPS on the pump. Being factory turbo it also has the boost

compensated pump.





It's 24v so all accessories on it are throw-aways. I've already fitted new 12v glow plugs and a 12v fuel cutoff solenoid.
I currently have it on an engine stand (they're heavy buggers) so it's easier to work on. I'm preparing pics of that shortly..

[Pezzer]

Ok JFF45 whats happened to the rest of the info mate....all great so far.

[jff45]

Ok JFF45 whats happened to the rest of the info mate....all great so far.

The main thread is on the other forum. Much too busy to maintain 2 threads..alas..

[mudski]

Im still bloody impressed with your intercooler and mounting. Old mate bloodyaussie should really look at this.

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[jff45]

There's really nothing complicated in the way I did it. I used the fan to dictate the width between the 2 rails and the fixing to the firewall is very simple.

You should drop in on your way to Fraser..

[mudski]

There's really nothing complicated in the way I did it. I used the fan to dictate the width between the 2 rails and the fixing to the firewall is very simple.

You should drop in on your way to Fraser..

Its been changed to Moreton now. I wanted to go to Fraser but the boss didn't want to go another 3 or so hours. Even though its a 3 day drive from home...
Be good to catch up for a beer if your not too far. We will be based at Hope Island for our time.

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[jff45]

This is the engine bay now with the TD42T in place of the TB45E..

I have the alternator mounted on the right side with the PS pump on the left in the same positions as they were on the TB45. I had to run the oil pressure & return for the alternator vacuum pump on the right side as well.



Couple of different angles..

[BigRAWesty]

This is the engine bay now with the TD42T in place of the TB45E..

I have the alternator mounted on the right side with the PS pump on the left in the same positions as they were on the TB45. I had to run the oil pressure & return for the alternator vacuum pump on the right side as well.



Couple of different angles..

Very neat mate. How hard is the power steering to fill down the bottom?

[Winnie]

Super neat mate! Awesome work can't wait to see the rest of it.