SG1's GU

[SG1]

Hi, thought I better start our build thread as the mods are slowly coming along.

We recently bought a 02 GU SIII ST ZD30 Auto Patrol wagon, it came with a few extras, like rear cargo barrier, Uniden 40ch UHF, Nissan winch compatible roo bar, Narva driving lights, Haynes reese electric brakes, new 265/75/16 BFG A/T, a 3/4 steel roof rack which I recently removed, 2 spare tyres, dual batterys, snorkel.

The Patrol has 222 tho on it with the engine being replaced by Nissan (crate engine) 68 tho ago.

The mods list to come.

3 inch exhaust
dawes and needle valve
pillar pod with egt and boost gauges
dominator winch
full aluminium roof rack
2' lift (undecided on brand)
2.5m awning
rear draws
blocking plate
provent 200 catch can
rear reverse lights
rear reverse camera
tail light mod
glow plug timer

So a lot to do and have started on some of it but a couple of pics first.

[SG1]

So first mod was the provent 200 catch can, took a bit to organize it to fit as there is abs lines to contend with, so bought a bracket from Bunnings and re mounted the brake vacuum booster to beside the dual battery and mounted the pro vent where the vac booster was, was about the only place I could find to make it fit and still be serviceable.

[SG1]

Next on the to do list was the exhaust system, after much thought we decided on the Redback Extreme 3' system, managed to price match and the service we received from Mark at A1 Exhaust was in our experience second to none, the after sales and during sales service was fantastic with nothing a problem and everything done extremely timely with the products sent directly to our door at a great price, remember to price match

One of the reasons we settled on the redback system was, it fitted into our budget, the 10mm four bolt flanges, its own custom mounting brackets, the extended warranty, and Australia wide service if needed, seemed to tick all the boxes.

What I will say is the system is quality, there is no doubt, first up we ordered from the turbo back with hi-flo cat, comes with egt bung and O2 bung, two extra sets of gaskets and extra set of lockable nuts for serving in the future, and only a resonator instead of muffler which turned out to be a mistake on my behalf as there was a bit to much noise for our liking, sent a text to mark at A1 Exhausts about it Saturday night, not a problem and a new muffler was organised and delivered to our door on Tuesday, simply bolted it in and now sounds very nice tho not loud.

Doing the exhaust system on my back in the driveway was a pretty big job, had the old system of in 1.5 hrs, no problems but then to putting the new redback system on turned into a bit of a slog even though there was instructions and pictures to follow it still had to be done in a certain order, it fitted perfectly and no knocking.

Pictures tell a thousand words so pictures to follow, glad we chose the system as the mounting bracket are a lot more heavy duty than factory, also noticed on the factory Nissan system that just below the Cat had cracked almost all the way through and was only just hanging in there, also the mount for exhaust on gearbox had started to crack through as well.

[SG1]

So next came the dreaded Heat Shield, after reading on here about it and the numerous frustration of others I was pleasantly surprised when I got it unbolted and out of the engine bay in about 15 minutes, putting it back in was another story tho..

Given I now had a EGT probe to think about, I decided to cut the heat shield in half, still kicking myself for doing it and straight away was not happy with it, so a trip to the wreckers and managed to pick another one up.

Bit more thought and decided to trim the "fat" of the new heat shield and with a hole saw make an area for EGT probe to fit in, was starting to curse my self as had it fitted but decided to take it out to drill the hole for the EGT probe, another 15 minutes later and wondering what I was doing wrong then a little twist the right way and in it slotted, bolted it up and put the probe in, was pretty happy about it and the misses was finally as had been putting it off, did drive it without the heat shield on for a small trip and checked the amount of heat coming of the turbo was intense, the difference from having it fitted to not temperature wise is incredible.

[SG1]

So of with the old intercooler and on with new, had to be done prior to fitting the dawes and needle valve and boost gauge as it was leaking and oiled up, probably the easiest mod to do to date.

Only bought a cheaper replacement but fully welded instead of crimped, works well.

Old intercooler

[SG1]

Installed the EGT and Boost gauges, Auto Meter Sport Comp.

Had a little issue with the EGT gauge as when first turning the key it would calibrate but then go straight to 900c, a bit closer look and at the back of the gauge the yellow wire had come out of the plastic clip upon inserting into gauge and was loose, so pulled it out then went hmm which hole did it go back in...anyway bent the retaining clips back so it wouldn come loose again and put it back in and got the hole for it, working no probs now.

Found on the forum how to wire up the light for it, and the lights for the gauges now dim with the dimmer dial, which I thought was a nice touch.

Took the Patrol for a test drive and it is a little scary seeing the boost bounce all over the place and the EGT's rise when boost drops of, Dawes and Needle Valve will be going in very soon..

Some pics of the install and used a Quick Fit Boost Adapter for the gauge.

Some pics.

[SG1]

Have since fitted the dawes and needle valve, appears to be working from what I have read to be right, took a bit and even uninstalled it for a week just to get a better idea of what the vehicle is doing without it. Think I'm happy but would of loved a pro in this area to look at it and test for me to ensure it was right.

Also bought a new alloy full length roof rack and installed it yesterday, got it at a good price and the weight difference between it and the 3/4 steel rack we had is huge, now me and the misses can take the roof rack off easy but before with steel rack was flat out with two blokes, really needed 3 or 4 to do it safely.

Will load pics up soon.

[Bob]

Great write up mate thanks

[Bacho86]

Hey thanks for the write up SG1 - where'd you source the gauges from and how much they set you back if you don't me asking?

Cheers

[SG1]

Hey thanks for the write up SG1 - where'd you source the gauges from and how much they set you back if you don't me asking?

Cheers

Hi, I got both gauges from Autobarn, done a bit of research and looked at prices via ebay ect, bit of haggling and the boost gauge was $99 and the EGT gauge $250, they ordered them in and a couple days later got a call to come and pick them up. Was pretty happy with the service and nothing was a problem for them.

[threedogs]

Noticed someone fitted 04 mags and tail lights,
Gotta love the white GU I say

[SG1]

Have been wondering about the rims but wasn't sure, also interesting you mentioned the tail lights as planning on getting them working or replacing them with the wiring already to go as there empty except for the reverse light left hand side and then on the right in the indicator which has a globe and ciggy lighter to plug in to the back, figured someone wired this up so as to offer some lighting at night at rear of vehicle.

Ended up getting a ferrets twin mount light bracket and put it on, got a couple of lights ready to install for it but been hanging back on installing them while I figure out the wiring and where I'm going to bring it in from the outside, prob do the drill through bolt thing but still undecided, was also looking at where the washer fluid comes out for rear window washer as a possibility.

[SG1]

Couple of pics of the new Aluminium roof rack, got it of ebay new and delivered from killa concepts http://www.ebay.com.au/itm/301270423988?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649, happy with the service and got it a bit cheaper by dealing with them direct , was a pretty easy install and measured the distance between the feet of the old roof rack, 1300mm, and only had a couple of small adjustments once it was on, the better half helped me assemble and lift it up on the roof no probs.

[SG1]

Been messing around with dawes needle valve setup for sometime now, only been managing 14psi max with okay EGT's and good fuel economy, been thinking on how to improve this so decided to buy the HPD maf housing and installed it today, can easy get 18psi now with no limp, and could go higher but will hold it there for now, noticed the power range changed slightly with the install and power is more from 2000 rpm onwards and feels like a slight power band when accelerating from there on wards while revving easier.

So may of lost a bit of low down torque on engine but the Automatic transmission seems to compensate it fairly well, EGT;s are well down on hill runs under throttle and only got it to max 400c where on same hill used to be 450c plus under moderate to hard acceleration, cruising at 100k's EGTS are down about 20c but do need to test this some more.

I really think the next bit to all this is winding my VNT grub screw down a bit to, as even before putting on the maf housing noticed my boost would jump up and then back then go up to where it would its boost, will try anyway, also think a chip may help with low down torque but gotta find the money for one..maybe one day.

[SG1]

Installed the HPD MAF housing the other day, noticed a drop in performance in mid range power but was able to up the boost significantly and lower EGT's, so installed the HPD Air Box Lid today and hoping that will also help, time will tell, it will be matched up to DP chip and dyno run as part of the service so I'm expecting some better power gains and possibly fuel economy(hopefully).

I was surprised to learn that around 400c-450c was ideal for EGT's as it allowed proper diesel burn or so I was told by HPD, interesting really as always thought if you lowered your EGT's it would help in prolonging the life of the engine and give better results and or economy, makes me wonder chasing the lower EGT's in our vehicles is really that effective and we take a knock in performance in doing so, anyway still going down this path and can always go back if needed, will update when I know more and how the vehicle is performing.

544295442854427

[threedogs]

looking good . surprised by the EGT comment like you.
What are your EGTs at 100 if yours is an Auto,
IMO it will be different to a manual as revs are higher in a manual
Do you think the maf housing is worth while

[SG1]

Hi threedogs, I think it may be worth it if your getting high egt's, lacking boost or want to run higher boost and getting limp mode but there is a few things early that I have found and think a chip would really compliment it which is what HPD advised.

Have done a few configurations and tested each time with resetting the ecu(disconnecting battery) Early testing returned,

Just with the HPD maf housing, was able to run high boost with out limp mode (18.5 psi was the highest I tried and could possibly go higher but decided to turn it down to a conservative 16psi) and noticed a considerable drop in EGT's upon accelerating and hill climb(have a testing hill and use the same roads), seemed to lack some power down low in the rev range but once boost came on accelerated nicely, sometimes felt I had to push it a bit between 8o-100km and found maybe slight loss of power when hitting hill and maintaining throttle position, accelerate harder and would gain speed up same hill which was an improvement over original maf housing, no limp mode and egts lower 380-400c on hill climb, possibly due to higher boost levels.

HPD Airbox lid and original MAF housing, Limp mode was back with a vengeance, even turning boost down to 13 psi still resulted in limp mode, egt's were a lot higher, hill climb was 480-490c egt's, power felt better down lower in the rpm range and accelerated better and easier although egt's were higher.

HPD MAF housing and HPD Airbox lid, similar results to the HPD maf housing findings but with a little more power, almost like a power band once it reached 10psi from standing start and accelerated nicely, still felt had to push it a bit from 80-100kmh, egt's were lower than with standard MAF housing and no limp, put boost back up to 16psi, hill run returned 380-390c egts.

Prior to fitting my EGT's at 100km would be from 340-365c pending weather, after fitting HPD products egt's at 100km are down 320-345c, still early days of testing but is the results of todays testing. Reason for fitting is vehicle could easily reach high egt's on hills, head winds, high temp days and or extra load carrying kids and or camping gear.

Still very drivable and possibly accelerates better under 'harder' acceleration tho upon normal driving conditions does feel that there is a loss of power down low and between 80-100km but a good chip or tuneable one may remedy this. Feels as if it revs more freely and seems to go better in the higher rev range.

[SG1]

Replaced the Rear non working tail lights with working ones, wired it up, had to run a reverse wire, tail light wire and also ran an earth wire from the passenger side, was the misses idea as she had noticed it awhile back that only the reverse light on the passenger side worked, if it makes her feel better why not, secretly was on my to do list..

5470954708

[threedogs]

I didnt fit indicators in the body lights just reverse and stop/brake.
I think you EGTs are a tad high still, on the HWY flat road my EGTS are 260-300c
will reach 425c pushed up hill, Do you have a tigged intercooler?.
My missus said the same thing " you only have one light working" shheeesh women lol

[SG1]

Yes have a tigged intercooler, was a cheapish in comparison ebay special, kinda wished I had saved a bit longer and put the dollars towards a premium intercooler, as have noticed some heat soak (think that is what it is) when exploring the tracks in 4wd slowely ishly. Car goes in next week for install of DP chip and they will be looking at the dawes and needle valve settings while there and adjust if need be, will be interesting to see what comes of it and is not costing anything extra for the install and before and after dyno runs.

[threedogs]

great ,,dyno will sort it out

[SG1]

Had some interesting emails with DP Chip regarding the HPD Maf housing and HPD airbox lid with there chips, it all but confirmed my findings to date, they said it is there recommended modifications to these vehicles along with the main modifications being exhaust and tigged intercooler with some form of boost controller. They can send there chip pre programmed to run with the HPD mods as they have tested and have the programmes there for mine and similar vehicles with these mods.

They also mentioned that they to found a loss of power by a couple of kw down low in the rpm range on the dyno when running without a chip but when the vehicle reached 2500 rpm or more there was no loss, which is similar to what I have been experiencing, as soon as it gets up there in the rpm range the vehicle really humms along but to be honest is not ideal and generally drive it down lower in the rev range most times.

Solution is fitting the DP chip and having it programmed to the modifications, doing a dyno run with air fuel meter in exhaust and not exceeding 16/1max mix with more give than take, same as was suggested by HPD somewhere around the 18-19/1 would be about right pending what you want from your vehicle, this helped me understand the modifications can and should be beneficial by allowing you to get the correct fuel air ratio for your vehicle and avoid the over fuelling problems the Di patrol has, while controlling the boost and lowering EGT's.

DP Chip should be fitted up Monday, have adjusted dawes valve to reach 18psi and adjusted needle valve to suit and vehicle responded well with lower EGT's.

[SG1]

Had the DP chip installed today and dyno run done before and after, result from fitting DP chip was a 20kw gain at the wheels with a conservative setting on there dyno, from the short test runs there is a very noticeable difference down low in the rpm with more torque and easier acceleration, the vehicle also held gear easier in the auto and felt as if the shifts were smoother, looking forward to more longer drives with a good 300k trip coming up this week.

So far happy but is early days and a lot more driving is needed.

[mullet_hunter]

Nice build up/Solid feedback... got my hpd gear on order.. will be doing pretty much same mods as u..

[SG1]

Thanks, I will be sending the DP chip back in a couple of weeks to be re programmed to my vehicle, even tho it runs fine and a lot better with the chip installed I figure might as well get it spot on since it only cost freight for it to be done. Hope the write up helps anyone else who goes this path or similar.

[SG1]

Finally got around to sending the DP Chip back with Modifications listed to vehicle, also mentioned about cruise control and small surging type affect at different settings at different speeds ect, not really noticeable but I noticed it so thought I would mention it to them. DP chip came back today re adjusted to suit my vehicle and mods, the difference is really noticeable and the installers put it back on the dyno (for free) to check and it showed there as well with considerable gains, 15-34kw through rev range jump in performance.

It came back with instructions to take of the grey wire, what ever that was for but think it may of been the TPS for the chip and installers looked after that, no more surging affect that I have noticed and much more smoother delivery of power.

All up very happy with my purchase of DP chip and that DP re tuned chip at no cost to me to my vehicle, also the installers here at 4wd Centre have been great with 2 runs on dyno and installation of chip at no charge, just the cost of the chip.

[Paule]

Awesome write up mate. Interesting that they can re tune your chip for the hpd gear. Is the mob that fitted and dynotuned you rig in Melbourne?

[SG1]

Is the mob that fitted and dynotuned you rig in Melbourne?

Thanks Paule, No they are a couple of hours east of Melbourne in Latrobe Valley, Traralgon.

[threedogs]

Good stuff I think there is a small pot inside the chip you can adjust
I love my DP chip and will see how it goes after I change my intake.
Dont think Mudski had any issues with his HPD install

[mudski]

Good stuff I think there is a small pot inside the chip you can adjust
I love my DP chip and will see how it goes after I change my intake.
Dont think Mudski had any issues with his HPD install
Nah none with mine. Ive been toying with the idea of getting the DP reprogrammed. But it all depends on the cost. How far do i go too? Im just starting to get the funds built up for the TD build.
I got most of the parts for the new intake pipe, gonna order new squirters soon too.
Good to see the op is happy with his results. Will always put a smile on ones face when things work out.

[threedogs]

With so many doing the HPD maf housing mod it might be worth sending Scott at DP chip an email?