DIY - TB45E turbo install

As I mentioned at the start of this thread, I'm running an auto trans with this project and I added a Davies Craig cooler for the trans fluid.
This involved relocating one half of the power steering cooler from the right to the left side and I thought it might be of interest to others how cheaply this can be done.

For those using a manual box, this might also be a handy mod if they want to mount a radiator for a W2A IC.

This is the standard layout on a TB45E..

http://i257.photobucket.com/albums/h...psb0d9b171.jpg

..and this is what we want to achieve:

http://i257.photobucket.com/albums/h...ps2e238350.jpg

http://i257.photobucket.com/albums/h...ps1078f431.jpg


These are aluminium tubes and I have nothing to weld them.. and they are probably too thin for the average amateur to attempt to weld anyway.

As luck would have it, the tubes are just the right size for these 1/2 brass plumbing elbows with the nylon olives..

http://i257.photobucket.com/albums/h...ps5fdcb5fc.jpg


You just need to be able to silver solder a short length of copper tube with 2 copper elbows to join this part here:

http://i257.photobucket.com/albums/h...ps96839e2f.jpg


I decided to retain the original trans cooler and connect it in series with the new Davies Craig. I had to move the original ~25mm forward.

http://i257.photobucket.com/albums/h...psc901ae86.jpg


This is the finished mod. I've been running it now for over 6 months and not the slightest sign of an issue.
There's very little pressure there anyway.
From memory, cost of the brass elbows for this mod was <$15..

http://i257.photobucket.com/albums/h...ps472eb17b.jpg


This is the cooler I used. Bought from Ebay.

http://i257.photobucket.com/albums/h...ps6ed270c3.jpg


The highest temp reading I've seen since is 80C. Before the extra cooler I could get it to ~105C so a turbo installation definitely needs this mod.
Standard temp on the highway with the TC locked is between 60 & 70C which is almost a little too cool.

I'm also planning on removing the cooling pipes that run through the radiator.
There has been more than one report of failure of these pipes resulting in mixing of trans fluid and coolant in both the trans and the engine.

This is a pic I received from a friend in WA who has also done a TB45E turbo install.
He started with the AXT turbo kit.

This is just to show his Frozen Boost water to air IC installation. He also chose the Millweld airbox.
Nice but both options were outside my budget :)

http://i257.photobucket.com/albums/h...ps3ea1e26e.jpg

What are the millweld boxes like in terms or flow capability?

Quote:

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Originally Posted by Dales300exc

What are the millweld boxes like in terms or flow capability?

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No idea. That's a pic from a friend..

I know of another TB45E turbo install in Melbourne who swapped his Millweld out for the big PatrolDocta that has the snorkel coming through the bonnet and says it goes better..

Yes thats good enough for me then. Ill not put it in the decision list haha.

Back on track though, your work looks superb and very well thought out. I like it very much!

great work mate, a low boost turbo makes a big improvement to the nissan tb engines, im running 4psi into my tb42e using an axt kit and with out intercooling and a restrictive exhaust it made 100rwkw on 33"s about 25% more than a na motor would. the power/torque also comes on so much earlier and is much more useable

Just thought I'd add some pics of fittings on the turbo. I initially used an adapter for the oil feed with the 1mm restrictor (as shown a bit earlier) but I was never really happy with the number of connectors needed to guide the feed line in.

This is what I mean - there's the adapter/restrictor then a F to F -4AN elbow (couldn't find F to M) then a M to M union to be able to fit the elbow from the feed line.

http://i257.photobucket.com/albums/h...pse9eb509a.png


Then I found this the other day.. a banjo fitting with the 1mm restrictor in the banjo bolt and a -4AN inlet.
This is also a much lower profile and allows a lot better access to one of the T3 flange nuts. With the previous connectors, I had to clock the turbo a couple of degrees more to make sure I could get a socket onto the flange nut.

http://i257.photobucket.com/albums/h...psc698ad07.jpg

http://i257.photobucket.com/albums/h...ps0f942a75.jpg


Here's a pic of how all the fittings should be as seen from the block side. The oil feed is much neater now. The water cooling will be also be banjo fittings with -6AN cones (also from Kinugawa) and the oil drain is -10AN.

http://i257.photobucket.com/albums/h...ps7897ce8f.jpg


I've seen installations where rubber hoses have been used for both the water cooling and the oil drain but the teflon braided hoses and fittings are not a lot more expensive if you source them from Ebay and make them yourself.
They certainly look a lot better..

Did you finish the project or not yet?
Just keen for an update mate.
Haha

Quote:

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Originally Posted by Dampies

Did you finish the project or not yet?
Just keen for an update mate.
Haha

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No, not yet.. I got involved in removing some big trees that were too close to the house and we decided to keep all the wood so I've bought a used log splitter that I've had to work on and it's all given me a fair bit of chainsaw work to do.
I'm having to use the Patrol to cart top branches to the dump with my trailer.

I'll need to put it off the road for a good week because I also have a front seal to do as well.
Also have to make my own exhaust from turbo to cat.

I'll update with pics as soon as I get back into it..

Cant wait to see that thing roll.

It probably won't be up and running before the New Year.

I've now decided to rebuild my spare trans with a Q45 rebuild kit (extra friction & drive plates) and a Nomad valve body so I'll have a trans that will take the extra grunt.

I've seen a few of these 4.5 and 4.8 turbo's in action
you'll certainly silence a few Hoon rice burners lol
No Badges we dont need no stinkin badges BBWWHHhhhhaaaaaa

Hmm, I have my 69th birthday coming up in a couple of weeks.
At this point in my life, silencing hoon ricers is not real high on the agenda.. :)

As the old saying goes; do it once, do it right!

Quote:

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Originally Posted by scottmeister

As the old saying goes; do it once, do it right!

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I'll take this opportunity to acknowledge all the invaluable assistance you've given me while I've been doing this build..

Wonderful work !!!:bowdown:

Quote:

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Originally Posted by Nicki & Chris

Wonderful work !!!:bowdown:

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Merci Christophe! J'essaie de faire du travail Suisse :)
T'as vu l'ecusson de Genève sur le pare-choc avant?

Quote:

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Originally Posted by jff45

Merci Christophe! J'essaie de faire du travail Suisse :)
T'as vu l'ecusson de Genève sur le pare-choc avant?

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Maintenant oui !!! Je confirme l'horlogerie Suisse a trouvé son maître en mécanique :clapping:
En Février,nous faisons la côte Ouest, c'est dommage, je serai bien passé voir cette horloge ...

Now yes !!! I'll confirm watchmaking Switzerland found his master in mechanical ...
I'll be come to see this clock.

do you have a picture of your airbox setup and afm location please mate

Quote:

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Originally Posted by dakka1

do you have a picture of your airbox setup and afm location please mate

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If you go back and read the thread from the start, it's in post #1..

Hi. .

Can you please add a photo how you plumed the fuel pressure regulator up please. I can only see on the above photos how its fitted. I want to do it but dont know the correct way.

Thank you.

Quote:

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Originally Posted by Dampies

Hi. .

Can you please add a photo how you plumed the fuel pressure regulator up please. I can only see on the above photos how its fitted. I want to do it but dont know the correct way.

Thank you.

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It's simply plumbed into the return hose of the original regulator i.e. the original regulator is still in place.
I did braze up an adaptor to replace the regulator using an old regulator that I cut the flange off but haven't fitted it yet.

Here's a pic I took this morning..

Anymore progress here??

Quote:

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Originally Posted by tallman

Anymore progress here??

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I finally decided to go with the turbo diesel option..

Quote:

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Originally Posted by jff45

I finally decided to go with the turbo diesel option..

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With so many diesel turbo options Which combo have you decided on Nissan 4.2 TD????
Chev or Dura-max?

Quote:

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Originally Posted by threedogs

With so many diesel turbo options Which combo have you decided on Nissan 4.2 TD????
Chev or Dura-max?

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See my signature.. :)

Do you still have all your 4.5 turbo stuff?
And if you do, do you maybe wanna sell it?
Cheers

Quote:

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Originally Posted by Dampies

Do you still have all your 4.5 turbo stuff?
And if you do, do you maybe wanna sell it?
Cheers

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I plan on using the manifold, the intercooler (cheap off Ebay anyway) and the cradle I welded up for the intercooler for the TD42 engine if it fits. All the rest will be for sale but I haven't had time to take pics of it all together.
The Xede is still wired into the ECU but that's easy to disconnect.

A quick list off the top of my head:
The GT3540 turbo which is clocked for a 45 degree low mount manifold (pics are in this thread) and has 3" dump for that angle.
New billet Kinugawa wastegate actuator set at 0.3 bar. Have spare original spring, can't remember pressure..
All new GT35 specific oil & water fittings, including Garrett oil restrictor for oil feed, for braided teflon hoses.
Homemade IC pipe from IC to throttle body including the silicone elbow(as shown also in this thread)
BOV & pipe to turbo inlet
Adjustable fuel pressure regulator with fittings - has spare diaphragm.
Knock indicator.
Innovate MTX-L wideband gauge complete with wiring and sensor
Chiptorque Xede piggyback ECU currently loaded with TB45E timing profile. Tuning software is free for the Xede. I can supply a copy and am happy to help with any questions.

I might have forgotten a couple of things like silicone bends, etc. If they don't fit my TD42 installation, I'll throw them in.

Edit: See, I did forget something. I also have 6 x 370cc RB25 injectors. They have been cleaned and I've fitted new pintle caps.
Also have 2 new T piece adapters to plumb the water cooling into the heater hoses.
Have a new Bosch inline fuel pump as well..
There's also the adapter I made to move the IACV valve to make room for the IC above the throttle body.

As I decided not to continue with this project, I have most of the turbo install gear for sale.

This is a bit of a repeat of the previous post..

Garrett GT35/40 (3582R) turbo from a BA XR6. Sold to me as having done 80,000 kms but obviously can't be proved.
It has a new Kinugawa wastgate actuator with 0.3 bar spring. It is clocked for a 45* low mount manifold and the 3" dump was made for that angle.
It has all stainless water & oil fittings for -AN unions including 2 oil restrictors.
New dump pipe gasket & inline oil strainer.
I have a video of this turbo being spun up with compressed air.

Chiptorque Xede piggyback processor. I have been using this with my TB45E engine. It has the timing profile for TB45E installed and has the wiring added for switching dual tuning maps. I also added an external red/green LED to indicate status.
It currently has a tuning map for TB45E with extractors & 2.5" exhaust.
I have all wiring & connection instructions and the Xmap tuning software is free.

Innovate Motorsports MTX-L wideband gauge & sensor. Will need a weld-in bung for the sensor.

6 x NIssan Skyline RB25 DET 370cc injectors. They have been cleaned and I've fitted new pintle caps.

Adjustable rising rate fuel pressure regulator with pressure gauge. With spare new membrane.

New Bosch inline electric fuel pump.

Electronic knock detection device. Has bright visual indication if knock occurs. Has 5v output option. New, never used. Connects to original TB knock sensor.

BOV (blow off valve) with 25mm hose connections.

I have the custom intake pipe I made with silicone elbow for the TB throttle body but it would only be useful if using the same Ebay intercooler as shown in this thread.

Most of what I've listed here will be in the pics in this thread.

$1000 for the lot. That's the price of a new Xede today..

All the above turbo gear has now been sold.

Good read , sort of a shame it never eventuated.
Any teething probs with the TD4.2? cooling?

Cheers, 3D. It didn't eventuate because I had to give myself a reality check. Driving a turbo'ed 4.5 around the country with a couple of tons on the back would have resulted in a horrendous fuel bill.

The TD42T goes really well with the auto. It's a much more "unhurried" feeling driving it compared to the 4.5 which had to be given a bit more boot to get up in the revs before it would start to pull properly.

No heating issues at all. Big Ebay alloy radiator with new genuine water pump. Put in a new Tridon 77* thermostat and 50% Nulon coolant. Doesn't get over 80 city or highway.
I've only done 150 kms with it and haven't seen the fuel gauge move yet.

Need to get it tuned now.

with that oil line into the sump all the shops Ive seen do it, use a big centre punch Whack then use a 3/4 tap and tap a thread.
Never had a problem but a bit rough imo

Quote:

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Originally Posted by threedogs

with that oil line into the sump all the shops Ive seen do it, use a big centre punch Whack then use a 3/4 tap and tap a thread.
Never had a problem but a bit rough imo

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What was this in reply to? I don't have any hole punched into the sump, it's a TD42T factory turbo with the oil return cast in the block.