turbo build underway

[widetrack212]

Well after 2 days of trying to pull the engine it's finally out.. I've purchased a "junk" Chinese knockoff t3/t4 turbo waste-gate opens at 7psi, a 0-30 psi boost controller, pyrometer and probe, a .65 oil restrictor since the "junk" turbos don't have good seal and don't handle oil pressure very well. Now I know I'm going out on a limb that might bust off while I'm at the top of the tree since I'm going to put a knockoff turbo on, but I know of a shop that will rebuild the turbo with garrett components and to garrett specs for $300. I'm not sure how to do the manifold for the turbo I'll have to see when it gets here. My main concerns are torquing the head bolts down a little more and trying to oil cool the pistons. If anyone has the specs to torque the headbolts down it would be nice to know. As for oil cooling the pistons I'm not sure as to where to get the oil supply from or what size nozzles to use. If I can oil cool the pistons I'm considering turning up the injection pump and for normal driving running the 7psi, then when I want to screw around or something 12-15 psi. I know these engines aren't power houses but I'm kinda seeing what it'll do without blowing it up..   Hopefully I don't:-/ 
Thanks,
Max 

[widetrack212]

Also might be adding a intercooler and water injection

[phillip.brannon]

you wont want to go over 5psi of boost....read through the forums...lots of turbo information on here

[montana]

Head bolt torque specs are 80-85 ft-lbs.

[widetrack212]

I've read through the posts and I haven't seen much besides melting pistons said when it comes to boosting these engines over 5psi, now wouldn't oil cooling the pistons get rid of that problem for the most part? Thanks for the specs Montana.

[wayne83]

Ive been running mine at 8psi for the last 20k. No problems as of yet. Driving down the highway at 67 to 70mph it runs between 5 to 8psi, and i have driven like that for 3 hours none stop multiple times. Egts before i intercooled it were getting up to almost 1400, after the intercooler the highest i have seen it get is 1280 and that was pushing it hard, on average going up hills it will hit about 1140 and hold there until it gets to the top then will start to drop again.

[widetrack212]

What all do you have done to your engine? What brand or what did you get your intercooler off of? I'm looking curious where did you get the oil supply for your turbo from? I haven't really looked at the engine for oil supply and stuff yet since I just got it out. Any and all info is appreciated. 

[wayne83]

Oil supply i teed off the oil pressure sensor port and the return i welded a 5/8 elbow into the oil pan just below where the pan mounts to engine so its for sure above the oil line. I have absoultly nothing done to engine. The turbo is off a newer 2.3 turbo diesel ranger. Intercooler is just a cheap ebay kit

[widetrack212]

Might be a dumb question but is the oil pressure sensor port where the line runs out of the filter housing with a hose over to some round thing mounted on the frame of the truck?

[fatguppy]

The 4.182 (same family as the 4.135: series 200) came with piston oil squirters, but was not turbocharged. The 4.182 oil pump is physically larger than the 4.135 though, might need that to supply the extra oil to the squirters.
You might be able to tap into the engine oil galley and install the squirters.

[widetrack212]

would that oil pump mount up without modification? Are the oil pumps for the 4.182 engine's still available? I'm sure they're not cheap if they are...

[widetrack212]

This weekend I will be pulling the head off of the engine, I will be figuring out the CC's of the combustion chambers and valve reliefs in the pistons to figure out compression ratio, then I can figure out how much to take off of the pistons to lower the compression ratio. Desirably around 17 or 18:1. Once that is figured out then we'll determine if we can take that much off the pistons without weakening the strength. If it weakens them to much she'll be getting new rings and will have to abandon the compound turbo idea, and will just have to live with the T3/T4 for now with stock compression ratio. Not sure yet but will probably have to cut the pistons 20 - 40 thousandths. If anyone knows the piston design on these such as if they're anodized on the tops like a 6.5 piston (since aluminum melts around 1400* they did this to the tops to strengthen them and help them handle heat) what they're made ect.. Anything known about the pistons would help! Will keep updated as progress is made.

[widetrack212]

Just pulled the head off and it doesn't look good. need head possibly and an injection pump.. If someone wants a good transmission and a parts truck it might be for sale soon. Need to think.

[widetrack212]

Figured out what had happened, Looks like the build shall continue. Pistons are out. Now the decompressing part... Looks like 35-45 thous will have to be taken off. 45 thou would put the compression ratio at 17.02:1... Anyone have ideas for a small turbo for the compound setup?

[widetrack212]

Figured out what the problem was, The intake valve was open on one cylinder when we washed the engine before taking it apart to de-grease it. The build shall go one! Hopefully can run up to the machine shop Wednesday to have the pistons cut. Probably will buy another China knockoff turbo as the pressurized turbo (smaller one) for the compound system. I'm looking at a GT2252 turbo A/R .51... So it'll be a GT2252 over a t3/t4. Should perform pretty good. I guess we'll find out! Pistons and combustion chambers will be Ceramic coated for handling the heat, really hope it has power and holds together.. If it does probably next year it'll be getting the injection pump re worked for more fuel then more boost. I think I'm gonna build a girdle to hold everything together in the bottom end.   For now 13-17psi boost.. With more fuel if the pump gets re worked, Maybe 30-35psi. Shouldn't hurt it since it'll be decompressed to 17:1. 

Attachments: