Turbo certification

42south
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Turbo certification

Postby 42south » Tue Jul 13, 2021 7:24 pm

Hi Guys
Im having a DTS turbo kit and 3 " exhaust fitted to my GQ TD 42.
Could anyone give me an idea of whats required to get this certified?
regards
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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coxsy
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Re: Turbo certification

Postby coxsy » Wed Jul 14, 2021 9:09 pm

Put shroud around turbo , fuel lines are close to turbo ,
sintered metallic pads on front discs, brakes in general serviced.
You should be good to go after that ,
Put I would go whole hog and fit intercooler at same time , get it all done lift tyres drop boxes what ever ,
89 safari, pto winch, 33x15 simexs. sliders,75mm lift . turbo intercoolered

42south
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Re: Turbo certification

Postby 42south » Sat Jul 17, 2021 4:30 pm

Thanks Coxsy,
I was wondering about a drive shaft safety loop for the rear driveshaft, it seems to be mentioned in the LVVTA literature.
Also whats the test for the brakes, 100km to stop several times?
I cant find any reference to the heat shield, is there any document that lists all the requirements?
Thanks for your help.
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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coxsy
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Re: Turbo certification

Postby coxsy » Sat Jul 17, 2021 4:57 pm

Oooo good point on driveshaft hoop , not sure if heat shield is in specs , but top mount turbo an dump pipe close to the lines .
Yes they take it to 100 kph hit the brakes till stopped then another two times , acid test,
89 safari, pto winch, 33x15 simexs. sliders,75mm lift . turbo intercoolered

42south
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Re: Turbo certification

Postby 42south » Sat Jul 17, 2021 9:24 pm

Hi
Found the answer on the driveshaft safety loop. Latest amendment March 2021, only required if power is increased by 50% or more. So turbo on its own ok at 41%, but with intercooler 53%, according to DTS website.
Cheers
This is a Mitsubishi TD05h bottom mount turbo.
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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coxsy
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Re: Turbo certification

Postby coxsy » Sun Jul 18, 2021 3:27 pm

Yes,just looked at the kit not cheap is it.
Got my set up from some guy up north no support $1800 .
But it works ,
Lower mount free from all fuel lines cool,
89 safari, pto winch, 33x15 simexs. sliders,75mm lift . turbo intercoolered

42south
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Re: Turbo certification

Postby 42south » Mon Jul 19, 2021 9:10 pm

Thanks for your input Coxsy
I am really looking forward to hitting the road with the caravan this summer. It will be nice to be able to do a reasonable job on the hills. Last year going over Arthur's pass I was in 1st gear, and really slow, quite embarrassing when there's no where to pull over and let others pass.
cheers
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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coxsy
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Re: Turbo certification

Postby coxsy » Thu Jul 22, 2021 6:54 pm

Get exhaust gas Temp gauge fitted too 600 + not a good idea on hill pull
89 safari, pto winch, 33x15 simexs. sliders,75mm lift . turbo intercoolered

42south
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Re: Turbo certification

Postby 42south » Tue Jul 27, 2021 5:05 pm

Thanks coxsy
Yes Ive bitten the bullet and purchased one of those expensive, but nice, Redarc combination Boost/EGT gauges. Ive seen mention not to go over 550 C but you feel 600c is the limit? Ill go conservative and use 550c.
By the way I do have a decode of the wires coming out of the 24v12v factory converter. Im using it to powre the redarc gauge I just need to know how to post it.
Cheers
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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Re: Turbo certification

Postby BlakeNZ » Fri Jul 30, 2021 12:31 pm

Remember Exhaust gas temps are relative to where the sensor is mounted (ie before or after the turbo), so make sure you compare apples with apples. So 650-700 degrees pre turbo is not always the end of the world. Also depends how long you hold your foot down too... :)

42south
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Re: Turbo certification

Postby 42south » Sun Aug 01, 2021 8:54 pm

Thanks Blake
The DTS dump pipe has the sensor after the Turbo.
As far as driving goes, I'm conservative with the gas, I want this truck to last, and not let me down in the middle of nowhere. Nothing to prove, just want to make the driving experience a bit easier, be nice to be able to keep up with the traffic, when towing.
cheers
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

42south
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Re: Turbo certification

Postby 42south » Tue Sep 21, 2021 9:08 pm

Hey guys
Were nearly there, lockdown took its toll, but the lads at Southland fuel injection have finally got it done.
As a matter of interest for anyone considering the DTS turbo kit, there were problems with the exhaust manifold fitting, had to have some milling done. Another issue was the poor quality exhaust gasket supplied, got a genuine nissan one in the end. Not sure about the exhaust studs either, ordered genuine nissan ones instead. The studs all came out no problems, thank goodness. Got rid of all that exhaust gas reticulation pipework as well, nice.
Fitting of the 3 inch exhaust is hampered by the winch PTO shaft, a bit of squeezing of the pipe required.
Just the fitting of the boost/EGT gauge and then some real world road testing. The DTS dump pipe does have a fitting for the EGT probe.
Last issue will be getting certification. It should be no problem as the power increase is around 40%, which is under the 50% mark which triggers drive shaft hoop requirement.
However the $ 800 dollar cost does sting a bit.
cheers
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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Re: Turbo certification

Postby mudtroll » Tue Oct 05, 2021 7:26 am

Watch out for how close the exhaust is to the clutch slave cylinder & lines, probably best to carry a spare slave cylinder.

42south
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Re: Turbo certification

Postby 42south » Sun Oct 10, 2021 6:50 pm

thanks for the heads up on the clutch slave issue.
I'll take a close look at how they fitted it soon. Is it possible to heat shield the slave cylinder?
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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coxsy
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Re: Turbo certification

Postby coxsy » Mon Oct 11, 2021 5:02 pm

One should be on there , standard ,

One the by, selling my safari had it twenty years, costing more , time for it to go
89 safari, pto winch, 33x15 simexs. sliders,75mm lift . turbo intercoolered

42south
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Re: Turbo certification

Postby 42south » Sat Oct 23, 2021 10:27 am

Well she's all done, just certification to go.
replaced all brake hoses, pads, discs, master, balance valve. Should be good for the brake fade test, the mechanic reckons she's spot on.
The fuel has been turned up 1/4 turn with no excessive smoke issues. Id be interested to hear if others have put more fuel in, and what was the result?
The certifier has insisted on a driveshaft hoop, even though the manual does not require it. As he is the only one nearby, im just going to do it.
There is still good clearance to the clutch slave cylinder, with the new 3" exhaust, but to make certain, we are going to fit another heat shield at this location.
Once I do a test with my caravan behind, I'll post some boost and temperature figures.
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

42south
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Posts: 47
Joined: Sat Apr 16, 2011 9:13 pm
Location: Ohope Bay of Plenty

Re: Turbo certification

Postby 42south » Wed Nov 17, 2021 6:09 pm

Hi guys
Some initial results

Some real world figures on the turbo

Truck with 2 people. Level road
100k/hr 3 lbs. temp below 300

Truck with 2 people plus 1.5 tonne caravan
Level road
100k/hr 5lbs. Temp 380

Slight uphill
100k. 10lbs. 450
Very quick drop once you back off the accelerator.

Steeper hills with caravan, pushing into Norwester, 10-12 lbs. up to 550deg if I let revs drop below 2000 in 5th. Changing down to 4th and revs around 2200, temps fall back to around 500.
So lesson is to change down a bit earlier, and keep those revs up.

Cost of exercise. Gst inclusive
Turbo and fitting etc $6200
3inch stainless exhaust. $1500
Certification. $ 800
Total. $8500

So not a cheap exercise, but it has transformed the truck as a tow vehicle. The alternative would be to trade in the truck on a 4wd Ute, a $20,000 exercise. The real decider was that my wife loves this little truck, trusts it on tracks and water crossings, no more to say really!

Cheers
Mark
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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coxsy
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Re: Turbo certification

Postby coxsy » Wed Nov 17, 2021 7:32 pm

Towingnin fifth gear not recommended considered as weak gear
89 safari, pto winch, 33x15 simexs. sliders,75mm lift . turbo intercoolered

42south
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Re: Turbo certification

Postby 42south » Thu Nov 18, 2021 7:23 am

Thanks Coxsy
I was completely unaware of that problem. The only gearbox issue I have, at the moment, is a sticky / hard change between 1st to 2nd first thing in the morning until she warms up.

I used to own a Toyota Prado, and the owners manual did recommend not to tow in 5th gear.

Cheers
Mark
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

42south
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Posts: 47
Joined: Sat Apr 16, 2011 9:13 pm
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Re: Turbo certification

Postby 42south » Sun Nov 21, 2021 8:34 pm

The final word
Diesel mileage. around town. 12l/100k

Mix 50% town 50%towing caravan. 15l/100km

Edit just done 270 km trip towing caravan, mostly rolling country, some hills. Fuel consumption was 15.8 lt/100k
1991 SWB GQY60 TD42 safari.
DTS turbo kit.

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