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Turbocharger FITTING INSTRUCTIONS MITSUBISHI PAJERO EXPRESS TRITON WITH 4D55 & 4D56 MOTOR

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Filed Under (Mitsubishi) by admin on 18-12-2010

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1. Remove exhaust manifolds and inlet manifold thoroughly cleaning old gasket from head. 2. Remove oil plug from rear of cylinder head using a 6 mm Allen headed socket and fit 1/4 BSP oil fitting No. 34 and oil pipe No. 35. 3. Remove oil filter and then whole oil filter casting. Clean old gasket from both surfaces and make a holding jig for aluminium casting so as to be able to drill out the oil return. Drill a 15 mm hole right through to return gallery and tap out to 3/8 BSP. Thoroughly blow clean of metal and fit 3/8 x 16 mm hose fitting No. 42 and oil return hose No. 40. Now refit to block using new gasket No. 39. 4. Fit new manifold gasket No. 7 and Denco Diesel exhaust manifold No. 6. Now fit turbo to manifold making sure to engage oil return fitting. Tighten turbo to manifold using lock nuts .9. (NOTE: Make sure all openings on turbo and motor have been covered to prevent foreign material entering.) 5. Fit oil pipe No. 35 to turbo and tighten fittings. 6. Fit inlet manifold No. 26 to motor and connect to turbo using No. 30 casting and item No. 28 and 29 clamps and hoses. Secure oil pipe with clamp and bolt. 7. Fit heat shield No. 17 to exhaust manifold No. 6 using bolts No. 18. 8. Fit air cleaner to turbo 4D 003 Casting No. 21 or 22 to turbo using items No. 24-25 clamps and hoses and connect to air cleaner using original hoses. 9. Fit exhaust dump pipe No. 43 to turbo using V Clamp No. 16. 10. Connect engine breather pipe to fitting No. 23. 11. Increase Max fuel on fuel injection pump by one sixth of a turn, or 2 segments of the clock inwards. 12. Fit 2 1/4 inch or 55mm exhaust system and straight through muffler (not supplied). 13. Start engine and allow it to idle for 5 minutes whilst checking for air and oil leaks. Set max. boost under load to 50 KPA by adjusting actuator rod. ALL DENCO DIESEL SYSTEMS RUN AT 60 KPA BOOST MAXIMUM AND A MAXIMUM OF 550°C UNDER POWER LOAD UNLESS OTHERWISE STATED. 14. Recheck for leaks.

Mazda MX5/Miata Turbo Kits

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Filed Under (Mazda) by admin on 17-10-2009

AVOTurboworld has been turbo charging motor vehicles for more than 30 years so it’s no surprise that we know exactly what it takes to make a high quality turbo kit for maximum performance and reliability. AVOTurboworld turbo kits use the highest quality components and manufacturing techniques available in the world. AVOTurboworld kits are designed for minimal installation time and ease of fitment. For example, to help expedite the fitment process, we pre-assemble the turbocharger with
the actuator assembly to the manifold and outlet casting

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1992 Volvo 740 Turbo Boost Pressure Test

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Filed Under (Volvo) by admin on 07-08-2010

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CAUTION: Excessive boost pressure can damage your engine. NOTE: First check all turbo related hoses and connections for good condition. Replace if needed. 1. Connect pressure gauge Volvo tool #5230 (or equivalent) between line to boost pressure gauge and intake manifold connection. 2. Run gauge into passenger compartment. 3. Start engine and run until it reaches operating temperature. 4. Drive vehicle in 3rd gear (2nd for A/T) at approx 1500 RPM. 5. Press accelerator pedal to the floor (but do not engage kick-down). 6. Apply brakes at approx. 3000 RPM while still holding the accelerator pedal in the full load position. Do not apply brakes for more than five seconds. Read boost pressure on gauge. Reading: 50 ±4 kPa (7.1 ±0.6 psi) If boost pressure is correct, turbo system operates correctly. Disconnect all testing equipment and reinstall hose. If boost pressure is incorrect, adjust wastegate valve (refer to ADJUSTMENT PROCEDURES ) and retest. 7. If valve adjustment does not fix the problem, check the following:

Turbo Systems Installation Instructions Acura Integra / Honda Civic

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Filed Under (Acura, Honda) by admin on 13-10-2009

Turbo Kit Installation Instructions No. 60108-rev.b
IMPORTANT, READ THIS FIRST: Study these instructions completely before proceeding. Engine and/or turbocharger damage may occur if any component within these instructions is improperly installed. Turbonetics, Inc. or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation. This complete turbocharger system can be installed using common tools and automotive procedures, but installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle. If in doubt, consult a knowledgeable turbo installer or Turbonetics tech support specialist with any questions

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2003-2006 Mitsubishi Lancer Evolution VIII & IX SHORT RAM INTAKE SYSTEM Installation Instructions

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Filed Under (Mitsubishi) by admin on 24-12-2010

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1) Getting started a) b) c) d) Make sure vehicle is parked on a level surface. Set parking brake. Disconnect negative battery terminal. If engine has run within the past two hours let it cool down. 2) Removing the stock air inlet system Push in and remove. Clip a) Push in clip on the center circle to remove. Remove both clips. Remove inlet duct to air box. b) Locate the 4 clips on each corner of the air box. Remove c) Unfasten the 4 clips that hold down the top to the air box. Remove top. 3 Loosen only. Remove d) Remove the filter element. Remove the bolts holding down the bottom portion of the air box. e) Loosen the hose clamp connected to the bottom portion of the air box. NOTE: Do not loosen the worm gear type hose clamp located on the charge pipe. Loosen and remove. Unplug. f) Disconnect the MAF sensor harness from the bottom portion of the air box. Carefully remove the bottom portion of the air box. The honeycombs in the MAF sensor are sensitive, take note not to damage during removal. g) Carefully remove the 4 bolts holding the MAF sensor to the bottom portion of the air box. Check the MAF sensor gasket for tears or cracks. Replace as necessary. h) Loosen the hose clamp connecting the blow off valve to the turbo inlet hose. Disconnect the blow off valve from the inlet hose. Remove hose clamp from the inlet hose. Loosen and remove. 4 Disconnect. Loosen hose clamp i) Loosen the hose clamp on the turbo inlet hose at the turbo. This double ring clamp is similar to the clamp in step f. j) Disconnect the crankcase breather tube at the turbo inlet hose. Remove k) Disconnect vacuum line from the boost solenoid to the turbo inlet hose. The vacuum line is located underneath the turbo inlet hose. Remove the turbo inlet hose.