Fitting a turbo to a Toyota 3L 2.8D

[Brandon]

Hi, I am investigating adding a turbo to my 2.8 '91 Hilux to increase power for towing/4WD etc. I'm looking for reader feedback on their experences as I have read turbos shorten the life of engines but this will no doubt be attributed to the amount of increased power applied.
Also I have recvieved advise that Mitzubishi turbos are a sutiable match for the 3L diesel engine. Can anyone shed some light here?

[SupraLux]

The common way to do it is to find the CT-20 turbo and associated manifolds and piping from a blown 2.4TD surf and fit it. I believe the head needs work on the 2.8's to reduce compression or you shorten the engine life considerably, and one of the studs on the exhaust side needs to be moved - but this is all from memory as I have never done it.

I have driven a 2.8TD Hilux tho, and the difference is night and day - it was really nice to drive, had good power and it felt like it matched power with the 2.8TD Bighorn I had at the time, something that a non turbo one won't do. All up, I'd say do it - its well worth it.

As for shortening the life - why worry - if its done properly you should get heaps of life from it unless its on its way out anyway. Just get a diesel shop that knows what they are doing to do it - there is one in Kaiapoi near Chch thats done a few.

Steve

[Smurf]

Use the turbo and manifolds off a LN130 (not LN61) 2L-T. Not a 2L-TE though.
Grab the thermostat housing and all the pipe work going to and from the turbo, there are oil and water lines that you need, water lines run from thermostat housing.
Also get the metal heater hose lines that run down drivers side of motor above exhaust manifold it makes it easier to plump up water lines from turbo.
you will need to get a pipe welded into your sump for the oil drain from the turbo

you may also want to consider fitting the injector pump from the 2L-T(LN130 model truck not LN61)

[Steve_t647]

Most of the issues around the 2.8 turbo'd are due to heat and it does increase the heat! You should change your exhaust as even the 2LT exhaust is under spec, 2.5" and higher flow muffler should get the heat away.

You can buy a thicker than standard head gasket this does the same as the head work Steve suggested, I ran this no issues with the 2lt diesel turbo. You can use the 2lt manifold but you may want to clean it up internaly a bit as is doesn't flow well and the difference between one flowed and standard it is noticeable.

The fuel pump can be turned up or you can replace it with a 5l (3.0 NA Diesel pump) this is what I did it is pretty bang on fuel wise and allows more flow.

Long life towing you may also want to get an exhaust temp guage to see how hot it is getting a friend still with the 2.8 Turbo'd used it a lot and occasionaly shuts it down when the exhaust temp gets over 1250º to 1300º deg Fahrenheit before the turbo (the guage is Fahrenheit ) you are looking about 800 - 900 celcius pre turbo. This only happens for him towing uphill and is something a truck driver said they watch in their truck.

As far as drivability as Steve said it is Night and Day, it does use more diesel and is still not as good as a petrol but is comparable to the other turbo diesels out there. You still keep most of the torque (loose a little due to decompression) but have a lot better top end and more power through the whole rev range.

I still have a 2.8 diesel (I sold the turbo one) to have a play with lpg fumigation, but this I have not done yet it is similar to a NOS effect for diesels (longer burning stroke) but the heat may be an issue, and have a 2.2 Petrol one for a daily driver the 2.8 turbo was better towing and similar overtaking to the 2.2

[Brandon]

Thanks all, I have found a CT20 and intend on fitting soon.
Is it worth getting a copper spacer made up for the head gasket instead of the larger gasket option? If so what size?
Should I be concerned with turbo timers or intercoolers?

[Steve_t647]

Copper gaskets are good but you have to heat them until they go pink ( the copper goes pink) and fit it hot and fast! I would go the larger gasket I had copper in the race car due to the serious boost.

as for thickness roughly twice the std gasket.

[KiwiBacon]

Long life towing you may also want to get an exhaust temp guage to see how hot it is getting a friend still with the 2.8 Turbo'd used it a lot and occasionaly shuts it down when the exhaust temp gets over 1250º to 1300º deg Fahrenheit before the turbo (the guage is Fahrenheit ) you are looking about 800 - 900 celcius pre turbo. This only happens for him towing uphill and is something a truck driver said they watch in their truck.

1300F = 705 deg C.

The danger point for a healthy engine is 750 deg C pre turbo. If you've got a more fragile engine then reduce that temp as you see fit. An exhaust gas temp gauge (pyrometer) is a necessary tool when tuning a turbocharged diesel.
My one has saved my engine several times.

[Slider878]

Hey guys, im in the process of turbocharging my 2.8 diesel, i have a friend who has done it and he is happy as with it. He used a CT20 turbo, i was planin on jus doing the same thing but i accidently bought a CT12B turbo, (also from a surf) does anyone know if it will still work? its from a surf too so technically it should fit right? i got the manifold, turbo, gaskets, lines and everything, so i hope it does work! Also bout the head gasket, can i jus double up with 2 standard gaskets? or will i need to get someone to make one up for me? any help or ideas would be great guys!

[KiwiBacon]

Hey guys, im in the process of turbocharging my 2.8 diesel, i have a friend who has done it and he is happy as with it. He used a CT20 turbo, i was planin on jus doing the same thing but i accidently bought a CT12B turbo, (also from a surf) does anyone know if it will still work? its from a surf too so technically it should fit right? i got the manifold, turbo, gaskets, lines and everything, so i hope it does work! Also bout the head gasket, can i jus double up with 2 standard gaskets? or will i need to get someone to make one up for me? any help or ideas would be great guys!

The CT12B is the best turbo for your engine. Did you get the manifolds? They are fitted to the 1KZ-TE engines, I don't know if they'll bolt up to a 3L.

[tweake]

CT12 is better size wise but you will need either custom manifold or make an adaptor for the exhaust manifold to get it to fit.

usually the main reason the "turbo stuffs the motor" is they wind the fuel up with the standard pump.
the stock 3L (and 5L) pump do not have any boost compensator on them, so when you wind the fuel right up they over fuel when off boost and end up cracking heads/pistons.
you can get away with SMALL fuel increase. if you want a big increase then you need to fit a boost compensator or change the pump to one that has one (eg 2LT).

don't worry about compression with small fuel increase. however if you want decent power you really need to lower compession a bit (ie drop it down to 20:1).

no real need to connect the turbo water cooling (if turbo has it), but just watch you oil return. some use the alternator return and can get a problem where the oil backs up the exit pipe casue oil not to flow through the turbo quick enough.
no idea on how much oil the CT12 flows.

[KiwiBacon]

CT12 is better size wise but you will need either custom manifold or make an adaptor for the exhaust manifold to get it to fit.

So the 1KZ and the L series manifolds aren't interchangable or adaptable?

[tweake]

CT12 is better size wise but you will need either custom manifold or make an adaptor for the exhaust manifold to get it to fit.

So the 1KZ and the L series manifolds aren't interchangable or adaptable?

nope. there is a few guys on surf forum who have done ct12 coversions by making an adaptor to fit the ct12 turbo on the L series exhaust manifold. no doubt there is proberly a few write ups on doing it on the 3l motor on the hilux forums.
not sure if useing a surf manifold is better/worse than the 3l manifold. all depends on advaiable room.

[Slider878]

Oh ok, well its good to know that the turbo will be good, i got the mainfold, oil lines, hoses, metal gaskets, everything pretty much!
I wanna do it myself, i have some idea of how it all goes together, not sure wat u guys mean bout the fuel pump? is there a screw or somethin that will wind up how much fuel goes in? do i have to do it? ill be happy with jus some power increase, not that worried if i dont get the absolute max power out of it, i really dont wanna blow it up lol. So the manifold im gettin wont bolt onto my 3L head? thanx for the help guys, cant find any info anywhere on how to do it or wat i need to do!

[STUKLUX]

Just done mine 3 weeks ago,very worth wile project.I left the compression standard and run 10psi.The surf turbo(ct20) and manifold bolt straight on,I used a four way block that came with my oil temp gauge and put it in where the oil pressure sender is and ran the alternator feed off that,and used the alternator feed for the turbo.I had to weld a drain pipe into the sump as high as I could as I dont like the idea of running it into the very small alternator drain.Then used two T pieces to run the water lines into the heater hoses.To finish it off I made a 2 1/2" exhaust off the turbo to the back with one straight through muffler.And fitted a front mounted intercooler.Install a turbo timer and make sure you run a EGT gauge,I have been told not to let it go over 550c.Theres a screw with a 6mm head and a 12mm locking nut at the back of the fuel pump at the top,turn that IN 1/2 a turn and lock the nut again,test drive and watch your Exhaust Gas Temp.Turning the screw in gives more diesil,out less diesil(more diesil=more heat,more heat=cracked head).A long post I know but I hope this helps anyone doing this project.

[Slider878]

Hey guys! well ive got the turbo today, its in very good condition, my next step is to find out if anyone can tell me if they know where on the net i could find how to go about gettin the CT12B turbo to fit, its a low mount turbo by the looks and it needs to be a high mount to clear the oil filter. If anyone knows of a site where i could find where someone has done it would be awesome. thanx guys!

[Slider878]

Hey guys, i ended up gettin a hold of a CT20 turbo, now on the right track, n hope i can do it all myself, only thing im a little unsure about is, how did you guys go about putting the oil return line form the turbo into the sump? how do u tap a thread into the sump? or is it something an engineer needs to do? and is there any particular side it needs to go on? or jus the side that the turbo is on?

cheers boys!

[Steve_t647]

Yes you just tap a return to the sump, the better you do this the less leaks you will get it isn't massivley hot so a small gasket would be nice too. Did you get the turbo and manifold? if you did it is well worth taking the manifold in to get it cleaned up a bit, or if you have a dremel doing it yourself to help get the heat away from the head.

the 2.8 fuel pump when wound up to max can do about 6psi more than that and you need a biger pump, this is where the 5l (got it right this time) had the extra capacity, with the turbo you may want to change the oil you use to one that has a higer heat range.

[Slider878]

Hey, i just bought a set up that was apparently off of a surf, it came with a ct20, 2lt-e manifold, oil lines, and thats it, tho i already have a ct20 turbo, and this ct 20 is different! its a bit different shape and it onlt has an oil feed, no water feed on it, plus im thinking this wont work!!?? coz the 2lte manifold wont fit will it? i need a 2lt? dont i? dammit i didnt realise there was 2 different manifolds? help guys? will it still work???
cheers

:::Slider878:::

[tweake]

depends on what motor that other turbo is off. 2lt(2) is the same head as 2lt-e and manifolds will fit onto 2.8. 2lt had non-water cooled turbo. however 2lt(1) has different head and also had non water cooled turbo. i do not think the manifold will bolt up to 2.8. so if its off a 2lt(2) it should fit ok.

[loosenut]

Hey, i just bought a set up that was apparently off of a surf, it came with a ct20, 2lt-e manifold, oil lines, and thats it, tho i already have a ct20 turbo, and this ct 20 is different! its a bit different shape and it onlt has an oil feed, no water feed on it, plus im thinking this wont work!!?? coz the 2lte manifold wont fit will it? i need a 2lt? dont i? dammit i didnt realise there was 2 different manifolds? help guys? will it still work???
cheers

Had similar cock up with my conversion. Bought 2LT turbo and manifold of older 2LT (LN 61) for my 3L, they don't fit. Manifold wouldn't fit stud pattern and turbo not compatible with that manifold. Ended up buying turbo and manifold of 91 2LT. Much better!! Also attempted to use early 2LT (LN 61) sump as it had oil return already on it, used firstly instant gasket then tried proper gasket, in all cases kept blowing seals (they don't match up properly no matter what you try, the fact that it was happening saved my engine) so got local mechanic to braze fitting to 3L sump for return. No problems since. Make sure your radiator is up to task, I had to recore mine three days later but it was at that point 15 years old.

[loosenut]

Hey, i just bought a set up that was apparently off of a surf, it came with a ct20, 2lt-e manifold, oil lines, and thats it, tho i already have a ct20 turbo, and this ct 20 is different! its a bit different shape and it onlt has an oil feed, no water feed on it, plus im thinking this wont work!!?? coz the 2lte manifold wont fit will it? i need a 2lt? dont i? dammit i didnt realise there was 2 different manifolds? help guys? will it still work???
cheers

Using fuel pump off 2LT-E for sake of boost compensator and limiting tendency to smoke that seemed to occur with original 3L pump, along with the overheating issue when towing or on long uphills. What can I say it is a Hilux. Still tweaking it, smokes if revs drop and reckon 3L delivered a bit better power. My mechanic warned about using too new a turbo on older engines, boost to high. He was impressed that mine was running at 10 pound, what he recommended as absolute maximum.

[Smurf]

[quote="loosenutUsing fuel pump off 2LT-E for sake of boost compensator and limiting tendency to smoke that seemed to occur with original 3L pump, along with the overheating issue when towing or on long uphills. What can I say it is a Hilux. Still tweaking it, smokes if revs drop and reckon 3L delivered a bit better power. My mechanic warned about using too new a turbo on older engines, boost to high. He was impressed that mine was running at 10 pound, what he recommended as absolute maximum.[/quote]

Have since found out that it is easier to swap the top of the pumps over, leaving the 3L pump in place and just fitting the top plate with the boost compenstor from the 2LT

[tweake]

Using fuel pump off 2LT-E for sake of boost compensator and limiting tendency to smoke that seemed to occur with original 3L pump, along with the overheating issue when towing or on long uphills. What can I say it is a Hilux. Still tweaking it, smokes if revs drop and reckon 3L delivered a bit better power. My mechanic warned about using too new a turbo on older engines, boost to high. He was impressed that mine was running at 10 pound, what he recommended as absolute maximum.

2lt-e dosn't have boost comp. only 2lt did. 2lt-e is fly by wire, everything is electronic.

boost....certainly keep it down. CT20 is a fairly poor turbo imho and airflow at 10psi on the 2.8 is like 15psi on the 2.4. inlet temps skyrocket and with 3L's higher compression you certainly want to keep boost down. "hiflowing" the turbo is know to help majorly.

Have since found out that it is easier to swap the top of the pumps over, leaving the 3L pump in place and just fitting the top plate with the boost compenstor from the 2LT

pics please ! i'm sure there is a lot of people who would appreciate it greatly.

[Smurf]

Using fuel pump off 2LT-E for sake of boost compensator and limiting tendency to smoke that seemed to occur with original 3L pump, along with the overheating issue when towing or on long uphills. What can I say it is a Hilux. Still tweaking it, smokes if revs drop and reckon 3L delivered a bit better power. My mechanic warned about using too new a turbo on older engines, boost to high. He was impressed that mine was running at 10 pound, what he recommended as absolute maximum.

2lt-e dosn't have boost comp. only 2lt did. 2lt-e is fly by wire, everything is electronic.

boost....certainly keep it down. CT20 is a fairly poor turbo imho and airflow at 10psi on the 2.8 is like 15psi on the 2.4. inlet temps skyrocket and with 3L's higher compression you certainly want to keep boost down. "hiflowing" the turbo is know to help majorly.

Have since found out that it is easier to swap the top of the pumps over, leaving the 3L pump in place and just fitting the top plate with the boost compenstor from the 2LT

pics please ! i'm sure there is a lot of people who would appreciate it greatly.

Loosenut used a 2L-T pump not a 2L-TE, I know I was the mug that got to fit it.
Can't show you pics of pump swap sorry, but is reasonably straight forward, easier than swapping complete pump thats for sure, you can swap the tops without removing pump from engine

[Engineer]

once i overhaul my ct20 and put it back on my 2lte i was thinking of adding a needle valve to bleed of abit air to increase the boost pressure. does the efi compensate for the extra air? i would assume yes upto say maybe 1bar such as many jap cars do. however i am unsure car anyone confirm this?

i checked how much boost my turbo was running awhile back and it was only at 7psi. i was thinking boosting it to 12psi.

Cheers
Ryan

[loosenut]

Have since found out that it is easier to swap the top of the pumps over, leaving the 3L pump in place and just fitting the top plate with the boost compenstor from the 2LT[/quote]

pics please ! i'm sure there is a lot of people who would appreciate it greatly.[/quote]


Loosenut used a 2L-T pump not a 2L-TE, I know I was the mug that got to fit it.
Can't show you pics of pump swap sorry, but is reasonably straight forward, easier than swapping complete pump thats for sure, you can swap the tops without removing pump from engine[/quote]

Yeah, my bad, got to many different parts to try to remember now, thanks to encouragement.
Shame you didn't know when we did the pump.

[tweake]

Loosenut used a 2L-T pump not a 2L-TE, I know I was the mug that got to fit it.
Can't show you pics of pump swap sorry, but is reasonably straight forward, easier than swapping complete pump thats for sure, you can swap the tops without removing pump from engine

did you use standard pin (rod that controls the fueling thats connected to the boost comp, adjusted by the nut on top) ? modding the stock pin can produce good results.

2lt-e ....i think you can go up to 14psi before overboost kicks in.

[Engineer]

2lt-e ....i think you can go up to 14psi before overboost kicks in.

execellent, wasnt sure if it would have overboost couldnt see why it wouldnt but not rather not find out

Cheers

[Bulletproof]

Yes the top of all the pumps on the 2lt,3l and 5l are interchangeable.
I have a 5l with a 2lt top fitted and it works perfectly on the hilux with the supercharger.
You wont have any trouble with a turbo as long as you dont boost more than 8lbs and change the oil every 4500ks.

I do question whether a turbo causes extra heat.
I havn't seen any figures to prove it.
I run a dual air system on the hilux with supercharger.
All my driving is done on a pyrometer. The moment I turn the supercharger on, the exhaust temperature drops 150degrees celsius. This is the opposite of what everyone says should happen but because I have dual system know this for a fact.
I would like feedback on this.

Richard

[tweake]

All my driving is done on a pyrometer. The moment I turn the supercharger on, the exhaust temperature drops 150degrees celsius. This is the opposite of what everyone says should happen but because I have dual system know this for a fact.
I would like feedback on this.

Richard

not suprising. while your adding a bit more fuel in to turn the supercharger your shoving a lot more air thorough which will cool. you have a lot more air to heat up with similar amounts of fuel.