Toyota mtdi truck, stage 2

[410]

I've been holding off posting this until I actually had some real progress to talk about, but this evening I actually starting the install.  I have been driving my toyota 4wd pickup for over a year now with my mtdi.  I was running a k14 turbo with no intercooler.  This setup has worked quite well with very little turbo lag.  Performance in the summer has been less than perfect though because of the lack of intercooler.  I just finished installing a front mount intercooler and a gt1749va turbo off of a 2005 passat 130pd.  Everything is done except the final exhaust hookup.  I have a lot of adjusting of my mechanical vane control and that's pretty much it.  I'll get some pics up as soon as I get a chance but for now I just want to get driving this thing again as my daily driver.

[410]

More progress; It took no time to adjust the vane control and got the exhaust reconnected.  Man what a difference!  It pulls much harder than it did before the new turbo and intercooler.  I took it fairly easy on the first test drives but I got a chance to really load it up today.

Here's where the bad news starts.  I was revving at about 1800rpm no load in fourth and I floored it.  When the boost kicked in, which is almost instantly, it revved up to 2500 rpm instantly.  I then backed out of the throttle a bit and the revs dropped back down to about 2100 rpm.  My stock clutch cannot hold my new found power.  Looking back a year, I should have spent a little more time researching clutches and bought something that can handle the torque.  I found a company called marlin crawler which specializes in toyota's and they offer basically a clutch for every application at great prices.  The price I paid for my stock clutch would have covered the cost of their super heavy duty clutch.  Live and learn I guess.

I hope to get pics tomorrow so I can share my vnt control setup and all the parts I made to make this work.  I was able to get some numbers, boost was peaking at about 23psi, 24 max and settling at around 22.  Peak exhaust pressure was about 35 psi and dropping very quickly to less than 30 once the boost can started to open up the vanes a bit.  I'm really happy with those numbers.

[rbremiller]

This is very exciting; I want to do this setup in the future. I'd like to see how you engineered your linkage(s). Keep us updated please.

[410]

I didn't get a chance to do pics today since I was too busy working on the pump, but I thought I would try and describe my vnt control. 

Basically it consists of 2 levers.  The first lever pivot is mounted solid to a bracket on the turbo.  The boost can is connected to the one end of this lever and the other end is the pivot for the second lever.  This second lever is connected to the vane control and throttle. 

Basically, it uses the same principle as libbybapa's setup by moving the pivot of the lever with the boost can.  I found that adding the extra lever to move the pivot got rid of a lot of slop in the system.  I keep promising pics and they are coming, as soon as I can get my stuff together!

[410]

Lets try that again.

[410]

Holy cow it worked!  

This picture shows the connection to the injection pump.  The spring shock is to prevent the wastegate from locking the injection pump to wide open throttle.  The pump lever can return to idle at anytime.  The shaft that connects the shock to the rod that runs to the turbo is supported by two small ball bearings.
 
I built my own wastegate and modified the aaz intake inlet by welding up the sealing surface and porting out the inside of the inlet.  I found that the inlet was the most restrictive part of the intake.  I made my own flange to match the larger opening and used a 90 degree 2.25" silicone bend to finish it off.  It's all 2.25" piping.

[745 turbogreasel]

Your hardware looks  serious
Too bad about the clutch.... is it stock for Toyota?

If you hit {enter} before and after pasting the IMG code, the pics wont wander all over the screen.
I'm looking forward to an engine bay overview shot

[410]

The clutch was identical to what the truck came with from the factory.  Aisin or something like that.  And it was new.  I ordered a super heavyduty clutch from marlin crawler on Monday so it might be here Friday, but probably Monday.  According to them the stock pressure plate has 900 lb of clamping force and the one I ordered has 1600 lb of clamping force.  Cheap too at $200. 

I apparently didn't take a pic of the whole engine bay so I'll see what I can do today.  Thanks for the tip on hitting enter before and after adding links.  I'm just starting to get the hang of this computer!

[blackdogvan]

If this linkage works as good as it looks, works as well as it appears to be built well then I think 410 might be the new king of the mechanical VNT control. On boost throw length adjustment looks great.  Very nice adaptation of the original concept (ahem... ).

[Wingaman]

Really nice, just wonder why a spark plug coil is there on the first pic ?

[410]

Good eye on the ignition coil.  Its only purpose now is to operate my tach.  I could've bought a dakota signal amplifier but this method was free.  If you look closer you'll notice that the coil wire goes right to ground.

The hose curling around the air intake is the high pressure power steering hose.  It's in its most comfortable position at the moment. 

The boost is just a little too high for me right now so I plan on extending the bottom of the wastegate housing and adding a threaded rod to adjust the compression of the spring inside.  I'd like to be at 22 psi tops and I'm just a pinch over at 24 psi.

[rallydiesel]

Could you post some more pics of the vnt controller? Specifically the pump top pivot and the attached to the vane control lever right at the turbo? Very nice build by the way. 

[410]

Thanks for all the comments guys.  This vnt setup has been a work in progress for over six months now.  I've made countless different levers and rods trying to find something that works.  Most of the adjustments on my current setup were just to give me room for the initial setup and will now stay in those positions.  I'll try and get more pics today.

[410]

Here's the connection to the turbo, nothing exciting to see here.  I used the stock retaining clip on my fabricated aluminum rod.

And here's the bracket bolted to the top of the injection pump.  The top lever isn't splined or keyed, just clamped so it can be in placed in any position.  The bracket has two small bearings to support the shaft which I made out of a bolt and machined the threads off the end.

My next challenge like I mentioned in my previous post is making my wastegate adjustable.

I plan on making a new bottom piece that's about a half an inch deeper.  I machined a 'tophat' which will support the bottom of the spring in the wastgate that can be adjusted by a bolt that threads into the new housing.  Here's a pic of the 'tophat' with a 3/8" fine threaded bolt.

[rallydiesel]

I love it!