Turbo-Glide installation on 1982 BJ42

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Turbo-Glide Turbocharger Installation on 1982 BJ42

Well, after almost two years I decided it was time to turbo my truck. After weighing a kit vs. DIY, I chose a Turbo-Glide kit. The ordering process was simple. John at TG always responded to emails promptly and answered all questions regarding their kit. So, after ordering the kit, I wired the money and a few days later - I had the kit. They ship FedEx, so you get it in 2-3 days - Impressive.

OK, so with that as the back drop - here is the kit: as you can see, it has the fittings that swap right into the oil lines at the filter - very simple design. The only aspect that I don't like is that on 1982 and older models, you have to cut down the length of the "arm" on the air cleaner lid and weld on their 90degree arm to make the tight turn to the turbo intake. So, I'm looking for a post-82 lid (they have a shorter arm): https://forum.ih8mud.com/diesel-jdm-parts/372835-post-82-3b-air-cleaner-top-lid.html

Other than that, the kit is nice. FYI the cost out the door with shipping was $2730AUD as of February 2010 (roughly $2500USD). I know I could have saved some money by gathering my own DIY kit, but I don't have the time or patience for that. As they say: you can have it cheap, fast or good - pick two and it won't be the other.
TG4.webp
 
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Removed the air cleaner for better access to the exhaust manifold. Wiper fluid reservoir removed on a different project. Exhaust manifold wasn't bad BUT FOR the lower left bolt - that thing was a beast to get out. I soaked everything in liquid wrench.

Since part of the problem was access and the ability to get any leverage on the bolt, I also removed the exhaust pipe @ the manifold... and since one nut (back one, without much room to get a wrench/socket) was stubborn, I sawzall-ed the pipe so I could get clear access underneath it. I'm getting all new exhaust, so easier to cut it out than work around it.
TG2.webp
 
So, finally got the manifold off, what a PITA. I was pleased that I won this battle - so I had to show my 3B who is boss...
TG3.webp
TG7.webp
 
Since my side cover looks like it leaks and I happened to have a new cork gasket, I removed the old gasket with a razor (had baked onto the engine and cover) and slapped some high-temp RTV on there with the gasket and cleaned up the oil a bit. I don't know if the oil-spewing 3B will now keep the side of the engine clean (doubt it), but I'll give it a try.

Then I installed the TG-supplied oil/return line fittings - very easy job. :banana:

Attached the lines to said fittings and began putting in the studs to which the turbo/manifold bolts.
TG6.webp
TG5.webp
 
:doh: I thought you were adding and auto trans when I read the title
 
Lookin good bj,I would love to go for a ride when your done,I am itching to do the same to my 3b.Let me know if you need anything,tools,shop,...welder...spare 3b!!
 
OK, so the beat goes on. Here is the boost and pyro fittings all snugged into place. I tapped the crossover tube for boost and pre turbo for pyro. Drilled both with an 11/32 bit (after breaking one on the TG manifold - thing is a tank, see below...grrrrr) and threading with a 1/8 NPT tap.

After doing the pyro tap on a fixed exhaust manifold the first time around, I REALLY recommend removing the manifold - makes it 10x easier. Luckily for me, I was installing TG's new manifold, so the removal of the old one was a necessary evil.

I put my pyro pre turbo, and am gonna bank on the sensor not breaking off into turbo = FUBAR. I made sure all shavings and debris were removed from manifold.

FYI, I use and recommend the digital EGT from auberins.com, Temperature control solutions for home and industry - they are simple and work well, Amaurer and KllyJansen and use them (among other people) and haven't heard of any problems. The company ships lightning fast and offer excellent customer support...

Pics:
TG8.webp
TG93.webp
TG91.webp
 
My dog didn't think any of this was at all exciting...he wanted to hang out in the bed of my truck and catch up on some sleep.
TG9.webp
 
So, this is where I'm at. Manifold is on. I'll post up more as I go. Hopefully, these pics are useful to somebody jumping into this.

I see one problem: anybody have an idea as to how I can not fry my throttle cable? The way it fits, it touches the turbo unit - not good, that thing is gonna get toasty under load.

TG's pics seem to show a tin-foil-wrapped contraption (not kidding) on the part that passes over turbo. I've gotta figure something out.
TG92.webp
 
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Lookin good bj,I would love to go for a ride when your done,I am itching to do the same to my 3b.Let me know if you need anything,tools,shop,...welder...spare 3b!!

Thanks for the offer Brian, appreciate the assistance. I will definitely come by the shop once I get it all back together, no problem at all. Might take you up on the welding, I may have to use the shorter elbow supplied in the kit if I cannot find a "short" replacement...
 
Did you decide where to place the boost hose? also, do not, forget to use collar on the two hose at the throttle body.
 
Subscribed.

BJ42Gringo, keep the pics coming. That's what we like to see!

I'm pulling my BJ42 out of storage next weekend (have to protect it from the salt). A turbo is in the back of my mind for later this year.

My guess is you paid about a $1000 premium for the Turbo Glide kit. But what you get for that (in my very uninformed opinion) is a commercially proven system with all the bits to make it go together quickly. There must be hundreds of these in use so hopefully the bugs have been worked out by now.

Good luck!
 
Probably won't get to any more of this until tomorrow evening, but I'll keep the pics coming and post up some video when it's all done. I also have an H55 coming from Lynchmob and plan on an OME suspension upgrade....so, plenty of projects and pics to come.

Final piece of the puzzle is finding a 83 or later air cleaner top or finding a suitable aftermarket alternative. From most of the posts I've read, the K&N style "cone" gets no love. I'd really prefer not to hack up and weld my 82 unit - really want to find a short-arm version... the search continues.
 
OK, so the beat goes on. Here is the boost and pyro fittings all snugged into place. I tapped the crossover tube for boost and pre turbo for pyro. Drilled both with an 11/32 bit (after breaking one on the TG manifold - thing is a tank, see below...grrrrr) and threading with a 1/8 NPT tap.

After doing the pyro tap on a fixed exhaust manifold the first time around, I REALLY recommend removing the manifold - makes it 10x easier. Luckily for me, I was installing TG's new manifold, so the removal of the old one was a necessary evil.

I put my pyro pre turbo, and am gonna bank on the sensor not breaking off into turbo = FUBAR. I made sure all shavings and debris were removed from manifold.




FYI, I use and recommend the digital EGT from auberins.com, Temperature control solutions for home and industry - they are simple and work well, Amaurer and KllyJansen and use them (among other people) and haven't heard of any problems. The company ships lightning fast and offer excellent customer support...

Pics:

Cheap drill bits suck, ti coated equals chinese crap bits...:popcorn:


~Rob
 
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Cheap drill bits suck, ti coated equals chinese crap bits...:popcorn:

It was a DeWalt bit... I thought it would be of decent quality. On the bright side of things, this project gave me an excuse to buy a really nice drill - my 18v cordless wasn't doing the job.

The bit went into the metal pretty well, but then at the end, it literally "snapped" off. I had to work it back out with a pair of pliers. I think I'll take it back to OSH and ask for my $8 back...what BS.
 
My dog didn't think any of this was at all exciting...he wanted to hang out in the bed of my truck and catch up on some sleep.


Now that is one handsome looking dog, had a few rotties.

Coool to see him with a full tale.

~Rob
 
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It was a DeWalt bit... I thought it would be of decent quality. On the bright side of things, this project gave me an excuse to buy a really nice drill - my 18v cordless wasn't doing the job.

The bit went into the metal pretty well, but then at the end, it literally "snapped" off. I had to work it back out with a pair of pliers. I think I'll take it back to OSH and ask for my $8 back...what BS.



Yep, Dewalt means nothing, they are chinese also.

High end bits are well worth the money, I purchased a set four years ago, never broke one yet...:beer:

~Rob
 
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