Hey guys.
A bunch of you have helped me a ton picking out the right turbo, figuring out the injection system and providing a general wealth of diesel knowledge I needed to swap out my blown up 2LT and drop in a 5L with an upgraded turbo. Just want to share my progress so far and hopefully put some pictures and info out there that will help others in the future.
To start with, heres a link to some back-reading on how I chose the TD04L-13t. Many thanks to @gerg and @dare for helping with the math on that thread and @GTSSportCoupe for being a general L-series wizard.
Best turbo/ turbo specs for turboed 5l?
And heres my parts list:
TD04L-13t off of a Subaru Wrx. (Used on ebay, with supposedly 15k miles) ($200ish)
SPA turbo exhaust manifold #TMTY01 for Toyota 3l or 5l engines and t25 flanged turbos ($280ish)
Custom adapter flange for TD04L flange to t25 flange, 5/8" thick (6 bucks in material, 15 hours on my friends mill).
Custom downpipe flange. ($6 1/4" plate and $30 3" Summit Racing mandrel U-bend)
Ebay special intercooler (leftover from 2lt build)
2.5 inch aluminizied exhaust for charge pipes and intake (leftovers from 2LT exhaust build)
Silicone elbows: 2x 2"-2.5" reducer 90s, 2x 2.5" 45s, 2x 2.5" 90s, 1x 2"-2.5" straight reducer. (7-15 each)
1/4x4x4 aluminum plate for intake neck adapter. (leftover from 2lt build)
Xenon brand rear quarter window scoop off an 05-11 Ford mustang. (100ish, leftover from 2LT)
Oil feed line for turbo (30ish)
5/8 Npt barb and 1/2 npt steel bung. 15ish
K&N air filter (spare parts bin)
A bunch of new coolant and oil hose.
Lots of assorted hoseclamps, nuts and bolts and beer.
Heres the truck. The hoodscoop feeds my weird intercooler. See pictures below.
Heres the top view of the engine so you can see the final product:
Heres the adapter plate to affix a TD04L-13t to the t25 manifold. You could make one at home on a drill press, but I just happen to have a friend with a CNC mill in his garage. Cutting 5/8 steel on a mill is slow work though and after completing my first adapter, we accidentally counterbored the wrong side of the plate. Measure twice! This one is after I finished porting it out to fit the exhaust manifold (which was not particularly rectangular, as the t25 should be)
Moved the oil pressure sending unit to the back end of the engine near the bellhousing and used its hole to tap an oil source for the turbo (stainless line). For some reason the heat shield mounting hole closest to the header outlet was drilled all the way though. Decided to drill it out and tap to 1/8npt for my EGT probe.
Heres the downpipe:
I took a 3" mandrel U-bend and cut it in half. But closer to one leg so that the cross section of the cut created an oval-ed end. Then I pinched it down to the width of the turbo outlet with a vice and flared it out out lengthwise with some vice grips and ended up with a roughly 2.75x4.5 inch dump opening.
I tapped an oil return into the oil pan. Others have tapped the return into the alternator oil return, but have had bad results trying to push that much oil through a small hole. This one is a 5/8 barb and should flow plenty of oil.
When I clocked the turbo I had to put the compressor housing at a bit of a funky angle. A 45 would have been nice, but would have necessitated a bracket to keep the wastegate aligned. Easier to find reducer elbows in 90 degree angles anyway.
As it is the wastegate location required a BFH mod. Admittedly, I could have been a bit less agressive with the hammer...
Heres a photo showing the clearance I had around the dump pipe
Intercooler charge pipes routed under the master cylinder. These used to go over the top on the 2lt build, which worked fine with the 4cyl MC but couldnt fit a v6 MC which Im upgrading to now that my truck will be moving a little faster. The stock intake neck from my 2lt was rotated to point straight towards the left fender using a 1/4 inch aluminum plate
I will post up some updates as I make more progress. My to do list includes finishing the 3" mandrel bent exhaust, adding the boost compensator from my 2lt injection pump to the 5l injection pump, and tuning the pump to match the new turbo. Still deciding on whether I care about my A/C enough to re-install it and re-route the A/C lines.
Anyway, hopefully this info helps somebody down the road
A bunch of you have helped me a ton picking out the right turbo, figuring out the injection system and providing a general wealth of diesel knowledge I needed to swap out my blown up 2LT and drop in a 5L with an upgraded turbo. Just want to share my progress so far and hopefully put some pictures and info out there that will help others in the future.
To start with, heres a link to some back-reading on how I chose the TD04L-13t. Many thanks to @gerg and @dare for helping with the math on that thread and @GTSSportCoupe for being a general L-series wizard.
Best turbo/ turbo specs for turboed 5l?
And heres my parts list:
TD04L-13t off of a Subaru Wrx. (Used on ebay, with supposedly 15k miles) ($200ish)
SPA turbo exhaust manifold #TMTY01 for Toyota 3l or 5l engines and t25 flanged turbos ($280ish)
Custom adapter flange for TD04L flange to t25 flange, 5/8" thick (6 bucks in material, 15 hours on my friends mill).
Custom downpipe flange. ($6 1/4" plate and $30 3" Summit Racing mandrel U-bend)
Ebay special intercooler (leftover from 2lt build)
2.5 inch aluminizied exhaust for charge pipes and intake (leftovers from 2LT exhaust build)
Silicone elbows: 2x 2"-2.5" reducer 90s, 2x 2.5" 45s, 2x 2.5" 90s, 1x 2"-2.5" straight reducer. (7-15 each)
1/4x4x4 aluminum plate for intake neck adapter. (leftover from 2lt build)
Xenon brand rear quarter window scoop off an 05-11 Ford mustang. (100ish, leftover from 2LT)
Oil feed line for turbo (30ish)
5/8 Npt barb and 1/2 npt steel bung. 15ish
K&N air filter (spare parts bin)
A bunch of new coolant and oil hose.
Lots of assorted hoseclamps, nuts and bolts and beer.
Heres the truck. The hoodscoop feeds my weird intercooler. See pictures below.
Heres the top view of the engine so you can see the final product:
Heres the adapter plate to affix a TD04L-13t to the t25 manifold. You could make one at home on a drill press, but I just happen to have a friend with a CNC mill in his garage. Cutting 5/8 steel on a mill is slow work though and after completing my first adapter, we accidentally counterbored the wrong side of the plate. Measure twice! This one is after I finished porting it out to fit the exhaust manifold (which was not particularly rectangular, as the t25 should be)
Moved the oil pressure sending unit to the back end of the engine near the bellhousing and used its hole to tap an oil source for the turbo (stainless line). For some reason the heat shield mounting hole closest to the header outlet was drilled all the way though. Decided to drill it out and tap to 1/8npt for my EGT probe.
Heres the downpipe:
I took a 3" mandrel U-bend and cut it in half. But closer to one leg so that the cross section of the cut created an oval-ed end. Then I pinched it down to the width of the turbo outlet with a vice and flared it out out lengthwise with some vice grips and ended up with a roughly 2.75x4.5 inch dump opening.
I tapped an oil return into the oil pan. Others have tapped the return into the alternator oil return, but have had bad results trying to push that much oil through a small hole. This one is a 5/8 barb and should flow plenty of oil.
When I clocked the turbo I had to put the compressor housing at a bit of a funky angle. A 45 would have been nice, but would have necessitated a bracket to keep the wastegate aligned. Easier to find reducer elbows in 90 degree angles anyway.
As it is the wastegate location required a BFH mod. Admittedly, I could have been a bit less agressive with the hammer...
Heres a photo showing the clearance I had around the dump pipe
Intercooler charge pipes routed under the master cylinder. These used to go over the top on the 2lt build, which worked fine with the 4cyl MC but couldnt fit a v6 MC which Im upgrading to now that my truck will be moving a little faster. The stock intake neck from my 2lt was rotated to point straight towards the left fender using a 1/4 inch aluminum plate
I will post up some updates as I make more progress. My to do list includes finishing the 3" mandrel bent exhaust, adding the boost compensator from my 2lt injection pump to the 5l injection pump, and tuning the pump to match the new turbo. Still deciding on whether I care about my A/C enough to re-install it and re-route the A/C lines.
Anyway, hopefully this info helps somebody down the road