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Td04 actuator problem
steve-hv8 - 14/9/16 at 06:51 PM

evening everyone
I trial fitted my td04 turbo today after getting my manifold from blackcat
And have found that the actuator is fouling on the bonnet as it's too high
Turbo was clocked and a plate was made so the actuator still lines up right but iS way to high
My son said just cut a hole in the bonnet and have it showing
What would be my options with moving the actuator
[URL=http://s1240.photobucket.com/user/steve-h1/media/Mobile%20Uploads/20160914_181252.jpg.html][/URL

CosKev3 - 14/9/16 at 07:10 PM

Can you get a longer shaft on the actuator so you can bring the diaphragm part of the actuator forward and lower it slightly in front of the compressor housing?

Other options would be a smaller actuator? Or go for a external wastegate

CNHSS1 - 14/9/16 at 08:51 PM

Either extend and kink the actuator arm or use a dinky actuator. External waste gate is a good option in some ways but adds complication and potential failure points (heavy ext gate and need for screamer pipe or separate waste gate exh)

ash_hammond - 15/9/16 at 11:01 AM

I assume you are using a manifold which is designed to go in an MX5 which has loads room in that position. I had the same issue and decided to have a one off manifold built. My turbo now hangs down the side of the engine. I also installed a vent into the side panel to help give me some more wiggle room and get the air out. Also you might want to think about heat protection if your turbo is close to the body work.

You can see mine hanging down here.

https://www.youtube.com/watch?v=feE778O9dG0

steve-hv8 - 15/9/16 at 07:16 PM

Was having a think about this today while I sat there staring at it and thought
What about if I turned the actuator over
And on a quick trial fit it may look like it will be low enough to clear the bonnet
After work tomorrow I'm going to get straight on it so I'll post a pic when I'm done

madteg - 15/9/16 at 07:29 PM

You could turn the outlet from the manifold down so it points 45deg down. The compressor housing and where the down pipe fits can be spun to where you want them. Just have to re-drill the dowel hole, obviously the drain has to point down. This will keep it all under the bonnet

steve-hv8 - 16/9/16 at 03:22 PM

Here's what I'm thinking of doing, just need to make a bracket to suit

steve-hv8 - 16/9/16 at 03:22 PM

Here's what I'm thinking of doing, just need to make a bracket to suit

ash_hammond - 16/9/16 at 04:07 PM

For the sake of a bit of steel, I would give it a go, looks like a good compromise.


Hook an airline up once its done to test the actuator is still working.

ash_hammond - 16/9/16 at 04:12 PM

The water outlet below the turbo, i turned my 180 degrees to face forward. Makes coolant plumbing easier.

steve-hv8 - 16/9/16 at 04:26 PM

But what did you do with the other smaller pipe coming from the outlet?

ash_hammond - 16/9/16 at 05:45 PM

quote:
Originally posted by steve-hv8
But what did you do with the other smaller pipe coming from the outlet?


The long metal one? This is the return for the heater matrix in the mx5, it just pulls out as it's an interferal fit. As we don't have an heater, I pulled it out and welding in a small hose tail. This is then connected to one of the water unions on the turbo. The outlet at the back of the engine that is normally the feed for the heater matrix is used to connect up to the other water union on the turbo, It needs a reducer as the union on the engine is 12mm and the turbo is 6mm IIRC. The turbo effectively replaces the heater matrix. Mines run like this all summer and never over heated.

luke2152 - 17/9/16 at 06:11 AM

I extended wastegate lever to other side of pivot and then mounted actuator on back of engine near cam sensor. Needs very long linkage but works ok.

http://s1288.photobucket.com/user/luke_2152/media/20141223_135705_zps21374204.jpg.html?sort=2&o=62