Turbo certification

[42south]

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

[coxsy]

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 ,

[42south]

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.

[coxsy]

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,

[42south]

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.

[coxsy]

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,

[42south]

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

[coxsy]

Get exhaust gas Temp gauge fitted too 600 + not a good idea on hill pull

[42south]

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

[BlakeNZ]

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]

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

[42south]

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

[mudtroll]

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

[42south]

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?

[coxsy]

One should be on there , standard ,

One the by, selling my safari had it twenty years, costing more , time for it to go

[42south]

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.

[42south]

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

[coxsy]

Towingnin fifth gear not recommended considered as weak gear

[42south]

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

[42south]

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