TD42 Turbo Conversion Project

[Michael]

Gents!!
Been a while since I have posted anything and it is totally my fault. But I humbly apologize for not being active on the forum and will ease my way back into posting more of what we are busy with.

So without more delay, let's get right to it. One of my clients (who wants to remain anonymous) asked me to do a thread about his build.
Some background on the vehicle...... Its a factory stock standard GU TD42 and has been maintained really really well. Its always nice to start with a vehicle that has not been modified in a negative way or been butchered. This one is really nice!

The objective!
We will be doing a moderate power turbo conversion with the following:
Turbo Pistons
Arashi TD05 turbo
Top mount turbo manifold
3" exhaust system with silencer
High flow PC stainless air box
Front mount intercooler with custom boost and intake pipe
All pipes including air box will be powder coated black
10mm boost compensated fuel pump.

With all this we should bump up the factory 50kw on the wheels to a healthy 110kw on the wheels and the torque will move up from around 200Nm to around 400Nm+
This is figures on the wheels so its about 40kw more and 70Nm more on the engine.

Whatch this space and feel free to comment or ask questions as we go. This is a live thread as we progress!

[jakeslouw]

I thought the conrods also differ?

[Michael]

Step 1 we remove the head, drop the sump and remove the conrods with pistons so that we can replace them with the proper turbo spec pistons.
Just a pic of the engine bay with the head off

[Michael]

While the head is off and we have some space, it's the ideal time to assemble the air box and install it on its correct location

[Michael]

I thought the conrods also differ?

Jakes, there is no real difference between the turbo and non turbo conrods. It does have a different part number, but nothing you can see with the naked eye.
In terms of strength, we have pushed the non turbo conrods as hard as we can with no failures, so we actually never change them to the turbo ones.

[Michael]

This is how your engine's sleeves should look after 300,000km+ and this is why it is no surprise to see a TD42 go past 1,000,000km. You can actually still see the factory hone marks.
We have just cleaned the carbo off on the top section of the sleeve. There is zero wear on this engine.....

[Michael]

Last post for the day.
We always check the cooling system and inspect the water pump.
In this case we will be changing the water pump (just because its not expensive) and the fan blade (because it has started to crack, but will show this in the next post).
In the photo you can see very slight wear on the timing cover. To be honest I am not sure what causes this other than cavitation. The vehicle has no corrosion in the water system and was driving with coolant from day 1.
The wear is nothing to be worried about and the engine will not receive a new timing cover.

[ruankruger333]

This is a passion topic for sure, with plenty of questions that will follow.

Keep up the good work.

[SJC]

[jakeslouw]

In your experience, what causes the plethora off snapped cranks that the TD42 has been ear marked with in Australia?

Tell us more. Never heard of this