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4th July 2011, 09:16 PM
#1
Fitting a genuine Nissan turbo to a N/A TD42
This thread is designed as a guide for those who are thinking about fitting a genuine Nissan turbo kit from a GU TD42T Patrol to a naturally aspirated TD42 GQ or GU.
I have done this conversion myself a few years ago on my first GU, a '99 model wagon, so I speak from experience. Unfortunately I did not take any photo's or keep notes, I was not involved in Patrol forums at the time.
This thread relates to the early GU TD42T kits that had the water cooled turbo, later GU's did not have water cooled turbo's.
The parts you need in the kit
*Turbo and flange gasket
*Exhaust manifold and preferably heat shields as well
*Alloy turbo inlet pipe
*Alloy turbo outlet pipe and hose and hose clamps
*Alloy cross over pipe (sits over the rocker cover) and hose and hose clamps
*Alloy inlet manifold adaptor and gasket
*Air filter housing
*Plastic inlet ducting and hose clamps
*Oil and coolant feed and drain pipes
Missing from this pic are the inlet manifold adaptor and exhaust manifold, and hoses that connect the alloy turbo outlet pipe and cross over pipe.
Shown assembled.
Other parts you will need
*Full exhaust system
*Other bits that I can't think of right now but will add later!
Tony
Last edited by YNOT; 5th July 2011 at 07:24 AM.
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4th July 2011 09:16 PM
# ADS
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4th July 2011, 09:28 PM
#2
Removing the old unnecessary parts
*Remove the air filter assembly including ducting and pre filter if fitted.
*Remove the alloy air fliter adaptor from the inlet manifold.
*Remove the air filter housing mounting brackets from the inlet manifold and rocker cover.
*Remove the exhaust manifold and complete exhaust system.
Tony
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4th July 2011, 09:58 PM
#3
Fitting the good bits
EXHAUST MANIFOLD
Assuming the exhaust manifold studs are in good condition (best practice would be to replace the studs and flange gaskets, I reused both) give the the studs a light smear of copper coat anti seize and bolt the new exhaust manifold in place. At this stage leave the heat shields off.
Notes; GU exhaust manifold will bolt straight up to any TD42 head.
TURBO
Loosely bolt the turbo to the exhaust manifold (again best practice is to fit a new gasket) with 2 nuts.
Things get a bit more complicated here but are still well within the abillities most with basic mechanical knowledge and competence on the tools.
Turbo oil feed
Most naturally aspirated TD42 engine blocks were not drilled and tapped for the oil feed required to feed the turbo. The oil feed line on TD42T taps into a drilling on the front LHS of the engine block, if you fit the turbo onto the manifold with the oil feed pipe attached you should be able to see roughly where that drilling should be. If the drilling is there just remove the blanking plug and fit the banjo bolt with copper washers.
If like me you were not that lucky then you will need to get a custom braided hose made up. I purchased and fitted a T-piece under the oil pressure sender unit on the RHS of the block and ran the braided hose around the front of the engine securing it to the oil pipe that feeds oil to the vacuum pump (red arrow in photo shows the pipe - Photo from "Modded GU"). I used a piece of string to measure what length of hose I needed and got my local hydraulic hose supplier to adapt the right length of hose to the original but now shortened turbo oil feed pipe.
Tony
Last edited by YNOT; 5th July 2011 at 07:31 AM.
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4th July 2011, 10:11 PM
#4
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4th July 2011, 10:15 PM
#5
Once you get this far most of the hard work is done. You can now properly fit the turbo to the exhaust manifold and fit the heat shields. The inlet ducting from the turbo to the inlet manifold can now be fitted and secured.
Air filter
The air box from either a TD42T or a ZD30 can be used, the base of the airboxes (filter housings) is the same and will fit neatly in the front left corner of the engine bay, but you may need to drill one or two holes for the mounting bolts.
If you have the TD42T air box and ducting as shown in the first post then you can just bolt it all together. The plastic ducting will have a fitting that the PCV hose can connect to, though you may need to source a length of oil resistant hose.
The photo above shows where the PCV hose attaches to the inlet ducting if you have a TD42T airbox and ducting. This is a very rare GQ Safari Autech with factory fitted TD42T.
My kit didn't come with an airbox or plastic ducting so I found a ZD30 airbox with airflow meter housing still attached(some say the ZD30 airbox lid has better air flow) and made my intake ducting from parts I purchased at QLD diesel spares. From memory I needed a 3" 45 degree rubber elbow (to fit onto the air flow meter housing), a 3" to 2.5" steel reducer which I painted black, then a 2.5" 90 degree rubber elbow to connect the reducer to the alloy turbo inlet pipe.
That still left me with nowhere to attach the PCV hose. To get around that I utilized the now unused airflow meter sensor hole. I made a blanking plate to cover the hole and had a fitting welded to it for the hose to attach to, it required a 90 degree fitting.
The photo above shows the position of the AFM sensor that I replaced with a blanking plate and adaptor for the PCV hose. Unfortunately I did not take ANY engine photo's of my TD42 after I turbo'd it.
Tony
Last edited by YNOT; 5th July 2011 at 10:08 PM.
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4th July 2011, 10:16 PM
#6
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4th July 2011, 10:17 PM
#7
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4th July 2011, 10:21 PM
#8
Obviously this thread is a work in progress, I'm putting in as much detail as I can remember and finding and modifying photo's as I go which all takes time.
Tony
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4th July 2011, 10:21 PM
#9
If you're putting together a turbo kit and either can't find a TD42T/ZD30 airbox or want something a bit better, consider one of these;
Made and sold by Patroldocta (http://www.patroldocta.com.au/custom_engineering.html) and selling for $415.
Tony
Last edited by YNOT; 15th July 2011 at 09:42 PM.
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4th July 2011, 10:25 PM
#10
Administrator
Thanks a million Tony. This will be a huge help for me mate and I can add photos later on too. If you need more posts added then delete this one. I'll read this properly tomorrow!!!
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