Rockets Wagon

I had already removed the old POS turbo and the wagon has been sitting there eagerly awaiting this install. First up I noticed 2 unpluged coolant ports in the turbo, 1 on each side.

http://i1083.photobucket.com/albums/...pswe2lcbl4.jpg

These are from the turbos previous life, are not required on the TD42Ti and are just left exactly like this.

Tme to lift it in and begin bolting it up, next problem, the outlet pipe hits the exhaust manifold and won't let the turbo bolt up.

http://i1083.photobucket.com/albums/...psccgynwjs.jpg

So I loosen the centre clamp and rotate the front of the turbo so it clears the manifold, also allows the actuator to work freely and straight. Now to do the nuts up, what a PITA, the front two are easy, the back inside one is not too bad but the front inide one is there to test your patients.

http://i1083.photobucket.com/albums/...pst2wed4pv.jpg

Next up was to bolt up the exhaust, at first I didn't think it was going to line up, but it did, mostly. TIP. Put the bolts in the dump pipe first as it's difficult (impossible) to get the inside bolt in from the top once everything is in position.

http://i1083.photobucket.com/albums/...psgg4dvk9f.jpg

Now for the oil line. I screwed the adaptor into the block first then added the line to the turbo, another PIA job. I ground down a 9/16 spanner to do it. Added some of Caltex's finest Dello 400 to the oil line then screwed the other end into the block. Added the EGT probe and job done.

http://i1083.photobucket.com/albums/...ps96e4i6sq.jpg

Now it's time to start adding the intake pipework. Man these things were NOT designed for 4" intakes, anyway trial fitted it and it kinda fits. I will need to mod the heat shield as well.

http://i1083.photobucket.com/albums/...ps5ryclpaj.jpg

http://i1083.photobucket.com/albums/...ps2iknjba4.jpg

So looking forward to firing this thing up again and diving it.

I'm sorry but the price your paying for that regardless of its transport damage receiving a product with that damage is a bit sad. Especially when you are approaching 3k for it.

The red actuator mate how does the grind job on it look?

Quote:

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Originally Posted by Rocket55

Time for an update. Finally after 3 months my UFI gear has turned up, hoping it's worth the wait as it hasn't really been a smooth process getting to here, but anyway lets put that behind us and concentrate on going forward.

first up, new style 18g turbo

http://i1083.photobucket.com/albums/...psmpbmi9sc.jpg

Followed by a 250hp 12mm pump (nice clear pic through the plastic bag ....)

http://i1083.photobucket.com/albums/...psvuuisk96.jpg

Some new squirters

http://i1083.photobucket.com/albums/...psogs2wwld.jpg

and a UFI clutch to hold it all together

http://i1083.photobucket.com/albums/...psvf1tbz1u.jpg

Just waiting on the flywheel now which will look something like this

http://i1083.photobucket.com/albums/...ps3qwzmcy4.jpg

It was definitely a shame the turbo had some slight damage to it on the front lip

http://i1083.photobucket.com/albums/...pswgoy7vo2.jpg

Probably occured during transport and UFI could definitely package them better, especially after such the long wait. All impressive looking gear though. Anyway, quickly tidied up the front lip and went about installing the turbo.

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That looks like it has taken a huge hit, personally I would sand/grind whatever, any traces of a square sharp edges and burrs


Edit, thats if you dont get another one

Quote:

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Originally Posted by nissannewby

I'm sorry but the price your paying for that regardless of its transport damage receiving a product with that damage is a bit sad. Especially when you are approaching 3k for it.

The red actuator mate how does the grind job on it look?

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It certainly pissed me off and I did expect better from them, the packaging was quite frankly under done. Just wrapped in a few layers of bubble wrap and chucked in a big cardboard box with the pump, which was similarly wrapped. But to be honest, it doesn't affect it's performance, you can't see it and I just don't have the time or patients waiting another couple of weeks to frieght it back and forthe to WA to get fixed. I need the car working by a certain date and that will be with or without some of this gear in. When i ordered I was told 3-4 weeks max, which gave me about 15 weeks contigency in time before I really needed the car and here I am in week 13 insrtalling this stuff during the night... Didn't notice anything untoward with the red actuator.

Quote:

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Originally Posted by Ben-e-boy

That looks like it has taken a huge hit, personally I would sand/grind whatever, any traces of a square sharp edges and burrs


Edit, thats if you dont get another one

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I did remove all the raised and rough edges and smoothed it out.

I think I had a conversation with you about this didnt I :p

They do work well mate. It will be a huge step up from where you were especially once you get that pump on. Just come for a trip to qld and ill throw the pump on lol.

Yes you did.

I would happily come for a drive up your way if I had the time. There's a guy just under an hour south of where I am that has a serious diesel injection business and is venturing into the world of Patrols. I know him through one of the other forums I'm on. He can change the pump for me pretty economically and when I told him what it is and has, he was happy to run it up on his dyno for nics, no doubt an opportuity to compare his in house developments, so could be a win win.

Ok, the Rocket mobile is running again.

Installed the heat shield over the exhaust mainifold, it need a tweek here and there to suit the new turbo and pipework. I wasn't completely happy with the way the intake pipe work was sitting, it was too close ie: touching the exhaust manifold, not good. After a few google searches I notoce most run the wiring loom under the intake pipe, I did this and all good, fits much better now.

http://i1083.photobucket.com/albums/...psifoqu1vx.jpg

Preceeded to test fit up the rest of the pipe work and intercooler

http://i1083.photobucket.com/albums/...psztef539q.jpg

The cooler then came off and I Sikaflexed at 50 deg C thermo swithch to the back of the cooler which the fan will run through

http://i1083.photobucket.com/albums/...psqzkayzzo.jpg

Next step was to replace the injectors, set about getting them out. Those little rubber brackets are a royal PITA, then I managed to get the spill tube off in 1 piece, Big win for the novice.

http://i1083.photobucket.com/albums/...psumn8kpow.jpg

Then the injectors out, No. 1 injector with the wire on it required a special tool, so off to Supercheap I go, pick up a 22mm deep socket and preceeded to chop it up, worked a treat.

http://i1083.photobucket.com/albums/...psrazcd1m3.jpg

Out with the old, then spent the best part of the next 45 minutes knealing on the radiator support panel, rocker cover and EGR valve trying to fish out those bloody injector washers, luckily none of them were stuck so it was just a bit fiddley. I was using a little screwdriver that I bent the tip over on. Thinking how the bloody hell am I going to get the new washers in the right way up, then it dawned on me. A set of external circlip pliers. Just hold the washers from the inside, put them in the hole and let them go, soo easy, got them all in in about 2 mins if that. Definite tip for getting the old ones out.

New injectors in.

http://i1083.photobucket.com/albums/...psbibgytxm.jpg

All the fuel lines in, including a new spill tube.

http://i1083.photobucket.com/albums/...psdgezdtu9.jpg

Intercooler back on and batteries in, then ready to start it.

http://i1083.photobucket.com/albums/...psesaydklq.jpg

Please tell me you bled the lines before refitting the intercooler?

Didn't need to bleed it at all, it fired up straight away and idled like a gem, never sounded so good or smooth since I've had it.