I've decided to turbo my 3.6 H engine!

[davidchj45]

Few may consider this a bad or insane option but after lots of reading and a good mechanical knowledge of what kills engines I decided to just go for it and see how I get on.

I was really frustrated with the lack of power which equals poor driving enjoyment in hilly area where I live so knew I needed to make a change.

After a lot of chasing the holy grail of a 12ht and resisting the major changes required of a 1hdt transplant, plus, in the hope this doesn't destroy my H! It's a bolt on kit so back convertible for originality if I ever wish to do so, I've ordered a Whistle and Soot turbo kit, airbox and cab dump exhaust kit, along with an intercooler kit from Legendary 4x4s in USA who I've had a good bit of dialogue with about this upgrade.

whistle and soot seem to have a great reputation for quality in Australia and the dialogue I've have seems to be if you're sensible with boost its no worse that caning it in 1st flat out.

Turbo kit is a low boost unit but reputed to deliver 30% improvement so that should keep those 1st gear flat out runs at minimum!

I'll be fitting a EGT monitor and for what it's worth a rev counter as part of upgrade. Already have more accurate oil pressure, temp and water temp gauges installed.

I may also add an oil cooler on turbo oil return line but still reading on keeping oil flow resistance to a minimum through the turbo unit.

First check was a compression test and a number of different runs all show consistent good compression.

Second gauge of condition of engine is the beating it gets keeping up with the hilly terrain of North Wales and Clwydian Mountain range. Water temp never worries nor oil temp or pressure and engine bay is always clean and free from signs of oil leaks due to strain of hill driving.

So decided to give it a try, worst case it kills it and I'm on look out for a 2H, rebuild it and I just need different exhaust manifold from W&S, rest of kit same, or if a 12HT comes up I've an interesting desk ornament in the form of an Arashi turbo charger!

Kit has been delivered today and looks very exciting.

Must say the quality and detail of kit with plenty of instructions included on all fronts is reassuring.

First job of oil change has been done ready for new era! Took advice and went for TEXACO DELO 400 RDS SAE 10W40 HEAVY DUTY ENGINE OIL

Next job is to commence stripping down old rad, exhaust etc.... ready for new kit to go on.

Once I've laid all the new kit out I'll start with the photos as we all know they are the best part of posts like this!

David

 

[Ben Stratford]

Sounds exciting David. Looking forward to how it progresses and the end result.
Agree with the doubt about the oil cooler in the return line, I would worry about the potential back pressure but have no experience to draw on. Lots of gauges would be a recommendation. Hopefully you won’t need a cooler. Good luck!

 

[Grimbo]

I've never seen an oil cooler routing from a Turbo return and would avoid it . Every single factory turbo engine I've seen has a big free flow return from the turbo....any pressure in the return is likely to make the turbo oil seals leak . Don't mess with the turbo oil return .
If it needs an engine oil cooler just fit one of the sandwich plate ones that bolt onto the existing oil filter mounting and either route engine oil to a front mounted cooler or have an element in them and just need a water feed and return ( space dependent on which type you use )
Wouldn't worry about engine longevity....if the basic engine is in good shape then you will be fine . Low boost turbo won't stress it .
I had a 1988 Hilux with the 2.4 engine that had an aftermarket turbo fitted from nearly new ....it did 130K before I sold it and never had an issue , it actually ran smoother after the turbo started to boost . We had the waste gate wound right up and it would occasionally blow the rubber pipe off the inlet manifold but it never burnt a drop of oil .

 

[davidchj45]

Thanks for advice/encouraging input gents, appreciated.
All packages have been opened up and a quick review of plan of attack done!
Might as well swap out rad top and bottom hoses while doing this all so be on the hunt for them in UK after this post.
Must say the kit from Whistle and Soot is very good and comprehensive with very clear instructions provided as is intercooler kit from Legendary 4x4s in USA.
Ordered my EGT monitor now I now what thead my bung on dump pipe is.
Fist job is to clear out a space inn log store to back pick up into so I'm undercover before I start strip out.

Few photos of kit attached.

 

[Ben Stratford]

Is the dump pipe the best place for an EGT sensor? The piston temperature is the concern I believe so the dump pipe will have a relationship with piston temperature but quite a bit cooler.
So establishing the relationship is key to avoid any damage. How would you know what the offset is though?
Which gauge did you go for?

 

[davidchj45]

It's just the easiest place to fit one, the dump had the bung ready waiting for it. It's quite early on in the flow so will be a good guide, if not as accurate as a in cylinder reading.
Used mainline sensors as theirs are very accurate and wanted the digital ready out rather than a dial.
I can build my own margin in from what gauge reads to what is going on in cylinder.
It's more just for me to know when things are getting a bit too hot for my liking and to ease off.

 

[felix2566]

If you have the exhaust manifold off, would be much better to fit your EG sensor into that. The turbine will take out a fair bit of energy.
The readings you get wont be easily comparable to others as, mostly the sensor is pre not post turbo.

Great project and look forward to seeing it progress!

 

[davidchj45]

Hi Felix

Where would the sensor go? would I need to get the manifold drilled and a npt nut welded on?

David

 

[guruvetim]

Hi Felix

Where would the sensor go? would I need to get the manifold drilled and a npt nut welded on?

David

I have the EGT sensor for my 100 series drilled into the manifold

 

[felix2566]

Close to the entry into the turbo.
most egt kits will come with an NPT threaded bung, they are cone shaped so as you screw it in it naturally gets tighter.

You will have to drill and tap the correct sized hole

You could alternatively get a bung welded in, but is not easy to do on a cast iron manifold, assuming you dont have a tubular steel one?

 

[davidchj45]

I'll check when back workshop if it's cast. The kit does come with nut, just though easier to use one already on dump pipe!!

 

[davidchj45]

It's not cast its welded tube sections so that should be easy enough to drill and weld npt nut too, thanks for tip

 

[felix2566]

Good news!

 

[davidchj45]

So finally made a start!

Had to clear my log store to be able to get HJ in there to work on so all winters logs are cut split and stacked.

First stage done and it reiterates how willing this vehicle is to be worked on.

Air filter housing off, exhaust manifold off and not one siezed or snapped stud (guarantee that would be a different story if it was my lotus!). One thing I did spot is it's been running without manifold gaskets so that might explain the easy nuts as it's obviously been off before.

Hardest part of today's quick 1 hour stint was wriggling the full length exhaust out as its in 1 piece, that was fiddly.

Hoping to get a full go at it next week but couldn't resist when I found myself with a spare hour.

So far so good.

David

 

[davidchj45]

Little bit more progress today.

Old rad out, block and heater give a good flush through to clear and crappy water.

Great feature this fold down front grill assembly

Whistle plenty of room, for the sake of £30 I've added a hall sensor rev counter.

Assembled new rad, intercooler and bracket from Legendary 4x4s.

Offered up for fit and just want to nudge their fixing holes over slightly, that way rad will sit dead centre on front grill. Ideally it would go a couple inches more as fan behind isn't sitting fully central on rad but bit of messing around with the cowl and it will fit, also any further over and bottom outlet from rad might foul engine timing chain cover.

I might have a look at the original rad to see if that would fit with intercooler and stack bracket and get a new toyota rad for perfect fit yet.

Hopefully I'll get a bit more time on Monday to meddle.

 

[davidchj45]

Making good progress here.

Rad and intercooler fitted.
EGT nut welded to manifold for on the spot readings!
Sump off, new oil pump fitted, turbo oil drain welded on.
Sump back on, letting rtv set before torque up and refill.
Manifold on, turbo on, dump section of exhaust on.

Left to do is cab dump exhaust bits, air filter box and piping to turbo and from this to intercooler.

 

[felix2566]

Nice progress, bet your happy with how its looking