My 1995 GTR project thread.

[cortexx]

Stardate 22:6:2011

Well last night i decided to get the turbos bolted up and into the engine bay. not so many pictures this time because i really had to concentrate on getting all the lines hooked up properly rather than friggin around with the camera every 5 minutes.

Started with the rear turbo , hooked up the water feed line to the block , hooked up the oil feed line to the block and immediately didnt like the angle that the oil line was bent at so i removed the rear facing 90deg bend on the banjo bolt on the block and fitted the line so it fits fluch against the block directly inline with the banjo fitting. One less fitting to worry about leakage lol .

At this stage the main line from the rear to the front turbo was installed to the rear turbo housing and i slid on the silicon and glass heat shield the full length of this line. This is the only line that needs this because it runs in close proximity to the hot side of the front turbo housing.

Leaving the turbo resting on the front drive shaft I installed the rear header using stainless gaskets , and a brand new set of oval locking nuts with new washers . One this was done i raised the turbo and carefully bolted it to the exhaust flange using the "old" exhaust manifold bolts so i didnt have to use the lock tabs (which i hate) , in the awkward space.

The front turbo was lowered in front and the line secured that feeds the water from the rear to the front turbo , oil line feed on the front turbo is very long and goes down and back up under the engine mounting to the oil feed line on the block. This time i used the 90 deg bend and it's very easy to install and secure this from under the car. Front turbo water return line was pulled up and secured to the main banjo housing above the turbos.

Bolted on the front header and pulled up the front turbo (not so much wiggle room in the front) and bolted it to the header. I used lock tabs on regular nuts on the front 4 bolt flange because they are incredibly easy to get to. At this point the turbos are in place and need only the oil return hoses and support brackets fitted underneath to finish.

This is where we get to the greddy suction kit that is supposed to be a straight bolt on.

Well using original factory turbos it probably is a straight bolt on but the tomei turbos ? no frikkin way!

The front S-shaped pipe that bolt up to the front turbo impeller housing does not bolt up because the tomei wastegate actuators are about 3/4 inch further forwards and much larger so it fouls. After a bit of measuring , 2 cans of kilkennys and some pondering i figured a 5/8 inch flange extension will bring the front suction pipe forward enough that it will all fit together .

I roughly matched all the greddy piping to the horrendous pictures in the manual and thought there were pieces missing. I rooted through the box of old piping and realized that the greddy kit does not replace all parts , i have to use 4 old pieces to install which was a bit of a disappointment but still.

I took one of the impeller housing gaskets to a local machine shop today and they will make me a billet aluminum extension which should be read for next week

I threw the old castings that have to be recycled into my sand cabinet and sand blasted the crap out of them with walnut shells to bring them up to snuff , remove the old gaskets and make the aluminium look a little less ugly , washed them in the wash tank and they look ok now.

Looking at the pipework I also realise that the vac tube take off for the boost control is not on the greddy pipe so i am going to reduce the size of the pipe that is supposed to feed the PCV system and use that to feed it. Cant imagine why they would omit this .

Here are a few pics of the turbos in place , more pics when i have the greddy kit fitted and the filters on etc






Because I coated the headers and dump pipes with the ceramic coatings im hoping i wont need the heat shields , we'll see how that goes.

The 2 turbo brackets that holds them underneath to the block need modding a bit because the turbos are bigger and the holes dont line up.

Everything assembled extremely easily , nothing was hard to put together with engine in the car.

[Rides]

Good job man! Car is looking good!

[93VSpec]

I see why you went to the Tomei complete kit. All of those custom fittings look awesome and sure seem to have made the prep work a piece of cake. Looking forward to seeing the full install.

[bellis_GTR]

Let me know if you ever need a hand! London isn't to far.

[cortexx]

we go to long point a couple of times a year , i live about 20 minutes away , about 10 minutes from turkey point

[bellis_GTR]

Wow mate nice update. Im in love with those tubbies <3

Are you ever in Long point? We should meet there some time!

[Ignitecgy]

Can't wait to see what these are capable of compared to similar sized turbos. Nice job BTW.

[DJ]

Looks like a very nice kit!Good job

[cortexx]

Now I know most of the guys on these forums don't need to be told this - but i'll introduce this concept to the noob mechanics here because experience has told me that this next step is one of the easiest upgrades you can do to any engine , and it WILL pay dividends down the road .

A well kept secret yes it's ANTISIEZE paste !

Thats right , spread a bit of this shite on every thread you assemble and tearing it all down in 2 years will be as easy as breaking up legos . BTW if your fingers , tools and workbench are not smeared in this , you didn't use enough. The stuff im using is rated for 1800deg farenheight . should be good for my install !



so after about 10 minutes , a tin of antisieze , 2 wrenches and a couple of nuts to seat the studs this is what i had :-



and then 10 minutes later I had them both studded and ready for lines



front turbo first to be worked on , this is the oil drain orifice



the kit comes with nice new shiney pieces to bolt to the oil drain holes with new gaskets and bolts that i used ANTISIEZE on:-



And after about another 20 minutes of effing around with the parts , comparing the diagrams to the parts list , i had one turbo fitted with its stainless lines



The quality of the fittings is amazing , their design and utilization has been well thought out by tomei and is probably one of the easiest things to assemble so far on my car. Everything has a logical placement , everything fits impeccibly , and the stainless lines make earls lines look like glam rock garden hose ! A few other aftermarket tuning companies could learn a few lessons here!



TIme to test fit the dump pipes to the turbos using new gaskets ( the tomei expreme kit came with nissan gaskets btw) , cleaned up the old nuts and used them and fitted the new stainless studs on the downpipe flange with ....... you got it , lots of effing ANTISIEZE !



by the way this is the method used for tightening up studs , i remember back in the day during my mechanic apprentiship that i was given a very similar job to do , i was told to use the 2 nut method but being young , dumb and full of (wow its getting late - ill cut to the chase), i just tightened the nut down to the unthreaded part of the stud figuring id tighten it using 1 nut , of course i then couldn't get the nut off without undoing the stud again, then i couldn't get the nut off the stud anyways and wrecked the stud trying.

Moral is , use two friggin nuts .



Time to install the dumps using the supplied nissan gaskets that came with the dump pipe kit :-



after another half an hour we have a couple of fully assembled turbo units ready to install and alot less parts littering my work space :-



I must once again appologise for stating the obvious and mundane points , but noobs stand to learn more by this the the rest of us...

... tune in next time to see another exciting episode of WTF is cortexx doing to his skyline -

[cortexx]

The water fitting it ditched completely and replaced by a single 90deg bend coming out and pointing 45 degrees to the front of the car.

This kit is designed to delete the dual coolant feeds (1 to each turbo cartridge) , and replace them with a single feed to the back turbo that then feeds into the front turbo and onto the thermostat housing . I still have reservations about this but wtf , if it's good for tomei lets roll it out like that !

here is the new fitting :-



here it is on the block :-



next mod is the water line coupler that is situated just above the exhaust manifolds about 1/2 way down the length of the engine , because there are no longer 2 feeds going to it , you get a blank to block off the rear feed and a new fitting to convert the other inlet for the stainless line as you see here :-





it's important to make sure all fittings are secure as getting to them to fix a leak from a loose fitting once the car has been assembled is akin to feeding your testicles to a sausage machine !

Well lets have a look at the turbo units themselves , they look pretty , shame they wont really be visible after all the other crap has been installed. Not that it really matters what they look like , as long as they do their job well..

[cschepp]

Wow looks great man. Lots of good stiff on this build. I'm enjoying this

[cortexx]

Well thanks for the comments

Stardate 20:06:2011

cortexx's log: Better get the frig on with this thing if it's ever going to make it back out of the workshop and to skymeet ..... turbo kit hmmm.

so after several cups of tea i decided it was time to assemble all the little parts ready for the install of the tomei turbos ... the parts came in various bags but as i found out after studying the list of parts number - not in a any particular order.

these are the bags of small parts as they come out of the box :-



after trying to match the parts up with the diagrams and prts list i decided i'd just start assembling them step by step.

The instructions are not the easiest to follow and it's easy to make mistakes , simply because all the lines are a very slightly different size , and each one has it's place. Im going to be very specific with some steps because the instructions are not !

We first remove the old oil and water fittings from the engine block on the passenger side :-





It's funny , i had a nightmare about removing these fittings a few nights back , ever broken a banjo bolt off in a block before ? I have and it's a twat to remove so i heated them a bit to make sure i didn't create chaos here.

into the wash tank with the parts for a soak while i figure out what i needed to keep and what i could throw :-



the oil fitting on the block is reused including its banjo bolt , the kit supplies new copper seal rings for refitting to the block , make sure you use them . The new stainless fittings in the kit are assembled into this fitting BEFORE replacing it on the block because you cannot do up the fittings while it's attached ( i tried , didnt work ) .

when fully assembled and back in place it looks like this :-

[aN4rk1]

Well i cheat .

I have a business that has 2 service vehicles and those parts are for a H3T and a RAV4 on paper

Can similar parts for a Silver R32 be also for those two service vehicles?!?!?! PRETTY PLEASE!

Seriously though, R33's are usualy my thing but damn man yours makes me question myself sometimes.

[Sharkus29]

No joke, this is the nicest R33 i have ever seen, and the build is unbelievable! Great work man cant wait to see it finished!

[cortexx]

do i bring my gtr or my lawn tractor ?