2001 Ti TB45E auto to TD42T auto conversion

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..

http://i257.photobucket.com/albums/h...pscea0a227.jpg

http://i257.photobucket.com/albums/h...ps464aba85.jpg

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.

http://i257.photobucket.com/albums/h...ps3e2a1be9.jpg

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

http://i257.photobucket.com/albums/h...ps64204480.jpg

http://i257.photobucket.com/albums/h...ps8ac5a8c8.jpg

http://i257.photobucket.com/albums/h...psbd657d7b.jpg

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

http://i257.photobucket.com/albums/h...ps0acb11cb.jpg

http://i257.photobucket.com/albums/h...psfa671a5b.jpg


- 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.

http://i257.photobucket.com/albums/h...ps8429df48.jpg

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

http://i257.photobucket.com/albums/h...psa1b582f4.jpg

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.

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.

http://i257.photobucket.com/albums/h...psxfg6xfni.png

http://i257.photobucket.com/albums/h...ps9zcjwwvi.png

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..

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

Quote:

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Originally Posted by Pezzer

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

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

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

Sent from my SM-P600 using Tapatalk

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..

Quote:

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Originally Posted by 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..

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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.

Sent from my SM-P600 using Tapatalk

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.

http://i257.photobucket.com/albums/h...psz4mvqv4v.jpg

Couple of different angles..

http://i257.photobucket.com/albums/h...psjt9x6zjp.jpg

http://i257.photobucket.com/albums/h...psbcszzsc3.jpg

Quote:

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Originally Posted by 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.

http://i257.photobucket.com/albums/h...psz4mvqv4v.jpg

Couple of different angles..

http://i257.photobucket.com/albums/h...psjt9x6zjp.jpg

http://i257.photobucket.com/albums/h...psbcszzsc3.jpg

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

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

@Kallen, not sure I understand the question. You can see the PS reservoir in the last photo. Its position is almost exactly where it was on the TB45.

Quote:

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Originally Posted by jff45

@Kallen, not sure I understand the question. You can see the PS reservoir in the last photo. Its position is almost exactly where it was on the TB45.

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Yea wow. The genuine td42 the power steering and alternater are swapped to how you have it so the resivour is up at the top easy to get to and the alternater is tucked away under all the intake.

The reason I did it that way is because the TD alternator with vacuum pump won't fit without removing the TB45 A/C hoses.
You also have to modify the TB45 PS hoses & cooler lines if you use the PS pump on the right side where the TD has it.

I now have both my TB45 steering & A/C components exactly as they were on the TB45 engine. Didn't need to degas nor lose a drop of steering fluid. I just unbolted them and tied them to the side when I pulled the TB45 out.

I just had to weld up custom brackets for them.

Nice work mate how was the electrics not to bad or plug and play?

Electrics for a TD42T are pretty simple so it was easy to use existing wires in the engine bay.
A lot of the EFI wires are no longer required so you simply cut them out.

Very neat job all round. Question re the intake plennum. Is there a formula to work out required air volume held by the plennum?
Has been suggested too much or too little will effect turbo performance. GT 3540 seems overkill on td42. Keen to hear how it spools.

I don't have a GT35/40 on the TD42T. That turbo was for the TB45E project that didn't happen.
I'm currently fitting a Mamba 16G/6 in place of the HT18.

From memory, the recommendation is to lift the factory inlet manifold by 50mm

Edit: I see why the confusion re the XR6 turbo. I was referring to using the manifold on the TD but didn't word it precisely :)

Ok got the plennum bit,filed for future ref. The mamba 16g/6 any worthwhile advantages over gt 2860 ball bearing?

Quote:

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Originally Posted by Touses

Ok got the plennum bit,filed for future ref. The mamba 16g/6 any worthwhile advantages over gt 2860 ball bearing?

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Biggest advantage is that they've cast the turbine housing to bolt in place of the HT18. Big saving if you've bought an expensive cast dump.
The TD05H copies seem to be pretty popular for the TDs

Thanks for that lot am filing away info for my current rebuild.Cheers!