TD04 Turbo

mr-ed_smt · February 25, 2016, 14:46

Can I ask where you got the manifold from (did you import it from MRW or is there a cheaper supplier? Does it have o2 sensor bungs at all?

Mark A · February 25, 2016, 17:45

I bought it off Mattperformance but originally its a Turbokits manifold. It has no O2 bungs, I'm planning create two bungs/ports in the down pipe.

Mark A · March 1, 2016, 23:04

Can anybody tell me where the oil take off is for the turbo, is it on the block?

mr-ed_smt · March 1, 2016, 23:10

You'll need to put a sandwich plate between the filter and block.

1979scotte · March 2, 2016, 06:57

Tte and Sp turbo kits drill the sump i believe but a sandwich plate is probably the easier option.
Allows installation of oil temp gauge too.

CrazySX · March 2, 2016, 07:16

Quote from: "1979scotte"Tte and Sp turbo kits drill the sump i believe but a sandwich plate is probably the easier option.
Allows installation of oil temp gauge too.

U have to drill the sump for the return. The sandwich plate will be the oil feed.

1979scotte · March 2, 2016, 08:33

DOH! Perhaps i was having a blonde moment.
I shall go and stand in the corner.

keljon · March 2, 2016, 10:33

Quote from: "Mark A"Can anybody tell me where the oil take off is for the turbo, is it on the block?

or a t-piece at the pressure sender take off

Mark A · March 2, 2016, 21:29

Quick update, rotated the turbo to the cool side is near the air filter

mr-ed_smt · March 2, 2016, 21:35

Looking good! How easy was it to clock the turbo and refit the actuator?
Is the turbo flange on that manifold "straight" or at an angle?

Mark A · March 2, 2016, 22:27

Yes the t25 mount is rotated slightly so the hot side is further away from the block. I need to check the clearance to the block and compressor housing.

Easy to clock once I'd bought some decent circlip pliers which have a rotating handle to open and close the pliers, only £20. Injectors, oil sandwich plate and exhaust tubing needs ordering tomorrow.

Mark A · March 8, 2016, 19:18

Slightly depressing day, started the turbo install today but slow progress.

Old manifold came off easy enough, ordered a new exhaust gasket but Toyota failed to deliver, so should be in tomorrow.

Test fitted the turbo and manifold but the clearance to the block is too tight so I've had to RE-clock it back to original orientation. During this procedure I seem to have damaged the compressor o ring, while cleaning it it snapped! I had a spare but taken from 100k turbo, so I'll need order another but hopefully I can continue the install. Tomorrow will hopefully be easier weather permitting.

Exhaust parts should arrive tomorrow.

Mr X · March 9, 2016, 10:03

Sorry to hear about the bad luck!
So you've had to turn it back around so the intake to the compressor housing is on the same side as the front of the engine (chain side)? That's a shame if that's the case it's going to make routing the pipework a PITA!
I take it that the cast iron manifold's shape wasn't quite designed for this turbo/orientation in mind?

CrazySX · March 9, 2016, 11:05

Quote from: "Mr X"Sorry to hear about the bad luck!
So you've had to turn it back around so the intake to the compressor housing is on the same side as the front of the engine (chain side)? That's a shame if that's the case it's going to make routing the pipework a PITA!
I take it that the cast iron manifold's shape wasn't quite designed for this turbo/orientation in mind?

I don't think its that bad, as the outlet will go into the IC anyway, its only the air filter that may prove to be a bit of a pain, but you could always run piping to the vent which i believe has some clearance for an air filter s;)

s;)

Mark A · March 9, 2016, 16:30

Managed about 2 hours on the car in between it spiss piss spiss ing down!

Much happier with the position of the turbo now, the exhaust side has more room but I might need to route the exhaust over the rear sub-frame, if this is the case I might lose the CHE exhaust and make some thing up.
The turbo intake is now positioned so the air filter sits behind the driver's side rear light and I'll make a cold air feed from the front side vent, over the wheel arch.
Drilled and drained the sump and on Friday should be ok to fit the oil return and the sandwich plate.
Ordered a JJC 90 degree angle to go from the throttle body to the PWR barrel inter-cooler and will just need to make up a MAF pipe, any ideas anybody?

Hoping to have most of the hard ware installed by Saturday not taken any picture yet but will do on Friday.

mr-ed_smt · March 9, 2016, 17:00

Elise parts do a lovely alu MAF adaptor pipe - its the best part of 60 quid though.

Out of interest - how badly did the compressor foul the block when the turbo was the other way round? Could you have moved it far enough away using one of these (blocking of the external waste gate port) m http://www.ebay.co.uk/itm/T25-to-T25-T2 ... Sws65TqGj4 m ?

Edit - heres the MAF adaptor pipe - not quite as expensive as I thought. m https://www.eliseparts.com/products/sho ... -air-feed/ m

Mark A · March 9, 2016, 17:10

Just bought a £35 alloy one off eBay.

The compressor housing was just catching the engine block drain but because of the manifold being twisted slightly the compressor intake was very close to bell housing, I felt it would restrict the flow. I would suggest using another manifold or make a simple log one.

Mark A · March 9, 2016, 17:12

If I had not bought the manifold already I would copy the Whiffybits one

CrazySX · March 9, 2016, 17:58

to where are you running your coolant feed and drain to the turbo?

Mark A · March 9, 2016, 18:57

I looked at TTE turbo install manual and plan to use the same hose, comes off the block just above the gearbox and bell-house. I've bought some P-clips to keep them away from anything hot.

Mr X · March 9, 2016, 19:41

Quote from: "Mark A"I looked at TTE turbo install manual and plan to use the same hose, comes off the block just above the gearbox and bell-house. I've bought some P-clips to keep them away from anything hot.

I take it that's the drain plug for the coolant in the block?

Quote from: "Mark A"If I had not bought the manifold already I would copy the Whiffybits one

It to me still seems a shame to have the compressor on the front side. Makes space tight for filter and chargecooler heat exchanger. I was going to say why not tig weld one up.. Would imagine the exhaust flow would be a bit more restricting over the cast one though.
Or how about getting a spacer made to put between the head and the exhaust manifold? Maybe out of 10mm steel or something just to bring it a bit more away from the block. Or wasn't it even kinda close to fitting ok?

mr-ed_smt · March 9, 2016, 22:15

Whifbitz will sell you their log manifold for £450(!!)

Mark A · March 9, 2016, 22:54

Anybody tried this type of BMC style filter? Auction site number 371508675774, thinking it might be a cheap option for me to the drivers side side intake?

Mark A · March 9, 2016, 22:56

I reckon you could make a turbo log manifold for a £100! I did see a guy on the mig welding forum making some great manifolds might worth tracking him down?

keljon · March 10, 2016, 10:45

got a link?

Quote from: "Mark A"Just bought a £35 alloy one off eBay.

The compressor housing was just catching the engine block drain but because of the manifold being twisted slightly the compressor intake was very close to bell housing, I felt it would restrict the flow. I would suggest using another manifold or make a simple log one.