Turbo 15B 80/40 (1 Viewer)

[frankenyota]

So my new Holset HX30 Super arrived with the exhaust and intake housing fittings. This thing is a beast, now to get the engine in its new home so l can build the rest of the manifold. Also drilled out the block to 16mm instead of 13mm for better flow, this was recommended by someone with more experience than me. Need to source some fittings still for the drain.

 

[frankenyota]

Still looking for an automatic trans and bellhousing to suit but it’s looking like l will stick with the H151 with the BIg4 adapter. A440 full hydraulic trans is hard to find and the bellhousing looks to be available from amayama but costs $1,200.
Here’s a picture of the H15# gearbox with the dyna bellhousing fitted with the adapter.

 

[frankenyota]

I have to get a gear stick as my spare gearbox didn’t come with one. Going for a VDJ79 gear stick, a mate gave me his old 80 series full time transfer case and A442 auto which he inherited when he bought his last property. It had to make the 6hr journey back home via another good friend. Transfercase oil looks clean so might have had a good win. Looking to go a part time kit for the transfer and will add a marks part time centre. Already have some aisan hubs for the 80 front end with bearings, birfs and rebuild kits for the hubs.

 

[frankenyota]

So thought it was time to slot this thing in and see where the turbo will mount up and see what clearance problems it will have.
Been told that the 15B mounts up to the 80 chassis mounts and the plan was to reuse them in the new position. I have been given some 1HZ mounts from a HZJ75 but once the engine was positioned it appeared that the angle of the engine brackets was at 50 degrees and the chassis mounts at 40 degrees. One broken engine mount later l decided that l would check the original chassis mounts from the dyna. They were at the 50 degree angle as well, and swapped the 1HZ mounts to the old dyna ones for mock up. Don’t think l will ever buy non geniune engine mounts after these new looking mounts came apart

 

[frankenyota]

Here’s the 1HZ mounts. Glad l didn’t pay for these. New late model 1FZ mounts is what I’ll use, geniune of course.

 

[frankenyota]

Here’s some pictures of the mount angles. Everyone loves pictures
Original 80 chassis mounts showing 40 degree angle

Bolted up to the Dyna mounts showing a big gap against the chassis due to angle difference

Original Dyna chassis mount, checking the mounting angles

Dyna engine mounts on the block showing 50 degrees which is the same as the chassis.

 

[frankenyota]

Cut and shut the engine mounts to the correct angle. Finalised the manifold turbo position and welded the flange on. Test fitted the turbo to see how it sits and clears, looks bloody sexy Can’t wait to get the adapter and have all this sitting in the engine bay.
Outlets are 3” on the turbo and engine so inter cooler and piping will be the same.

 

[Dougal]

So my new Holset HX30 Super arrived with the exhaust and intake housing fittings. This thing is a beast, now to get the engine in its new home so l can build the rest of the manifold. Also drilled out the block to 16mm instead of 13mm for better flow, this was recommended by someone with more experience than me. Need to source some fittings still for the drain.







View attachment 3917764

The turbo looks like it's had something broken out of the intake. It goes from a machined aluminium face to a lumpy fracture surface.

 

[frankenyota]

The turbo looks like it's had something broken out of the intake. It goes from a machined aluminium face to a lumpy fracture surface.

I did notice that surface but assumed that was normal
Might ask the question of the supplier.
Update
Supplier response was no problem, just machining on the basis of a normal blank. No worries, thanks.
Seems rough but must be the normal?

 

[frankenyota]

I have been researching and working out the best feed and drain hose combo for the Holset. Looking to get the Gryphon hose kit. It comes with custom length hoses to suit your application, oil feed fitting is 2mm restricted and seems like a complete kit with good quality parts. I optioned in the extra AN drain fitting to mount at the factory block return that l drilled. HX30 is good for max of 72psi oil pressure apparently, Not sure what the spec oil pressure are for a 15B.
Sin4x4 recommend drilling out the feed to 5mm.
Oil drain should be 3/4” hose or AN12 recommended by Benzforce.

 

[frankenyota]

Been playing with some designs to mount the gearbox crossmember. Instead of removing the factory chassis mounts and rewelding new brackets with new mounting holes in the chassis rail l decided to do an offset style mount to the one pictured. This way it keeps the factory mounting points and allows it to pick up the mount approx 130mm further back. Will use 6mm plate to make new ends.
This is a design l will copy.

 

[frankenyota]

I found this in the Holset manual for oil pressure requirements:

1. The orientation of turbine housing, bearing housing and compressor cover is fixed according to application. During installation, do not attempt to rotate these components. Inclined turbocharger installation is not recommended. If an installed angle is necessary, oil inlet centreline must be +/- 10 degrees from vertical and rotor centreline +/- 5 degrees from horizontal.
2. Holset permits oil return pipes to decline at an overall angle of not less than 30 degrees below horizontal. All turbocharger applications require a pipe of internal diameter greater than 19 mm which has integrated connectors. To ensure oil returns into the engine under all operating conditions, the return connection
   into the engine sump must not be submerged and the outlet flange of the turbocharger must be 50 mm above the maximum oil level of the engine sump pan. Crankcase pressure should be limited ideally to 0.8 kPa (0.12 lbf/in2) but 1.4 kPa (0.20 lbf/in2) can be accepted by reference to Holset.
3. Oil pressure of 150 kPa (20 lbf/in2) must show at the oil inlet within 3 - 4 seconds of engine firing to prevent damage to turbocharger bearing system. A flexible supply pipe is recommended.
4. The minimum oil pressure when the engine is on load must be 210 kPa (30 lbf/in2). Maximum permissible operating pressure is 500 kPa (72 lbf/in2) although 600 kPa (88 lbf/in2) is permitted during cold start up. Under idling conditions pressure should not fall below 70 kPa (10 lbf/in2).
5. Recommended oil flows for the turbochargers are 2 litre/min at idle and 3 litre/min above maximum torque speed.