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Project: 300 (diesel hp...) nearly done!

136539 Views 129 Replies 35 Participants Last post by  Johannissan
17
It's been awfully quiet around here on the modded Navara front....
My long postponed upgrade of a diesel d40 is nearly finished as of today, in fact, the truck started up nicely yesterday....
Now it's on to roadtuning and a dynorun in a week or so, and I'm bringing along a bonestock diesel d40 for a quasi baseline.
Here are some pics (crappy, sorry!) of the build.
My truck:



Main fuelling mods:
-DTE injector plug-in, 28 maps for upping dutycycles;
-Monster Industries/DMS FPC (fuel pressure controller);

-Throttle controller;


And now for the hardware upgrade:
-Tial/Garrett GT2860RS;


-equal length stainless custom tubular manifold;

-Tial MVS watercooled external wastegate with atmospheric dump;


-Bar/plate intercooler upgrade, 21x10x3" core, and alu boost pipes (in hindsight a 20x12x3"core, 27" end to end would have been even easier);

-Turbosmart diesel BOV and controller;
-Carter 100gph liftpump;

-Larger Blitz intake to replace K&N Apollo II while retaining my cold air intake setup:



Overall hardware setup has been repositioned for optimised efficiency: IC piping is now short and straight, turbo sits higher and more to the front:




In a week or so I'll post some dyno results (as well as a cleaned enginebay..) The goal: at least 250hp atw.....or a nice even 300 flywheel hp or thereabouts...
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That is some great work.
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Only the bare aluminum of the new IC gives away what has changed under the hood:

It could almost pass for OEM, couldn't it?

My new office (pre IC boostgauge, Greddy boostcontroller showing post IC boost, scangauge, EGT):


Some teething issues (which is to be expected):
-some exhaust vibrations;
-boostgauge sticks a bit;
-some steady chattering above 15psi, will recheck BOV and wastegate.

First instance I stretched her legs just a bit:
About half throttle: from 2500rpm and onward boost shot up to 23psi in an instant (boostcontrol is off), before i had the chance to lift....sounds/feels very promising....
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That is just way too cool!!!! Subscribed!
Thats very nice!

Got a link to the wing and the gilled fenders? those are the tits!
SWEEEET. This is gona be cool.
Thanks for that read it was cool!

I found the Wing at the end, thanks!

But my other question was more so the entire front fender you have it GILLED. I did read you seperated the intake from the engine compartment. So is it safe to assume that its a factory fender and you gilled it yourself for more airflow?

There are simmilar ones for my honda that i can purchace, i just thought yours would be as well.
But my other question was more so the entire front fender you have it GILLED. I did read you seperated the intake from the engine compartment. So is it safe to assume that its a factory fender and you gilled it yourself for more airflow?
Yes, the gills were cut and beaten by hand out of the original metal fender. I did buy an ABS plastic intake of the same shape initially, and I intended to have that cut and bonded in, but the guys at my bodyshop were sure that they could reproduce the same shape by hand out of the fender's original sheetmetal.

They were right....

Isolating the intake from the hot enginebay air is just a simple plate with rubber ring snug around the filter's suction bellmouth (assuming that you'd use an enclosed filter intake such as the K&N Apollo or Blitz Sonic).
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Update: got some roadtuning in yesterday and things are sorting themselves out, slowly but surely. Base boost is at a stable 22.5psi without use of the electronic boostcontrol as of yet, and the BOV and it's solenoid controller work like a charm. At 20+psi, it goes off like a shotgun...

Went up to 75mph a few times, up to 75%-80% throttle, 22.5psi, max EGT reached: 1000F. Slight wheelspin as it shifts from 2nd to 3rd....Midrange is simply devastating, but I still need to finetune low end response a bit, partly with boostcontrol, partly through fuelling adjustments.

The chattering I mentioned earlier is not the BOV, nor surge under load, nor the wastegate, it's the exhaustpulses from that atmospheric dump with minimuffler!
Update:
I put the ecu in learning mode this morning and almost immediately, lowend response has picked up quite a lot. A droning sound through the cabin at 2000rpm is now largely gone. I was previously thinking about swapping the .86 TIAL turbine housing for a .64 because of the sluggish low end (although this is still in the premilinary stages of tuning), but the reset has done wonders for the low end.

So, at this time I still feel that the .86 turbine housing is the way to go on the Nav, keeping in mind I still haven't touched the Greddy Profec boostcontroller's spool up assist options.

Now, I know that the ecu reset has been touted as a panacea for everything from bad mileage to measles, but this is really the first time in all those years I've experienced such a dramatic and immediate effect with the "pedal shuffle"...

I think this has mostly to do with the effect of the Carter 100gph lift pump on the injection pump's load and fuel temperature. Both will have an effect on injection timing (advance) to some degree.
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This is too sweet. Sounds like you have a good handle on what you're doing. I just had a great idea. You should ship me your motor, wire harness, and ECU when your done. That way I could have a diesel over here. Share the love. No??? 8)
This is too sweet. Sounds like you have a good handle on what you're doing. I just had a great idea. You should ship me your motor, wire harness, and ECU when your done. That way I could have a diesel over here. Share the love. No??? 8)
No problems my friend!

In return I only expect the mailman to bring me a VK56 complete with tranny...:)

Wait a minute, I actually hope to better the VK's power (certainly the torque curve...) with my tiny little 2.5l oil burnin' fourbanger....:nana:
dude your project is amazing! major props and i love the sleeperish look. great idea and cant wait to see how u end up once every bit of tuning is done.
Amazin'

Awesome work on the Navara man....I would absolutely love a midsize or half ton diesel here in the states with some potential of big hp and monster torque. I have been sitting on plans of sticking a Cummins 4bt into my YJ. I don't think we will see a midsize(frontier,taco, ranger) diesel here because it might take away form the more expensive full size segment. There is always talk but nothing happens. Get some pics of that beast blowing some black smoke.
good to see its going ahead nicely.

the carter holding up ok? not to noisy?
good to see its going ahead nicely.

the carter holding up ok? not to noisy?
It's doing OK, the sound is largely drowned out by my 3" straight through exhaust..From the drivers seat it sounds exactly like driving around with a little fishtank on the backseat....
What's nice is how the engine starts on the very first swing of the crank, every time!

I'm having the electrical connections plastic coated as we speak.

By the way, do you think deadheading the pump for 35-40seconds for something like a ecu reset is a problem (my bypass is with a manual shut-off, rather than a checkvalve), or is it safer to put in a on-off toggle switch for such purposes?
Lucky Navaras and their diesel options!
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