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My Story on Twin Turbo
This is my story why I
created this Twin Turbo Kit. I have been searching on
the internet for the past two years trying to find out more
about performance parts and bolt-on kit for the Lexus V8
engine. However, no such luck. There have been
few cases that the Lexus V8 (1UZFE) being turbocharged, but
as of right now, I have not seen any Lexus LS400 having twin
turbo. Please correct me if I am wrong.
I have been driving and
playing around with Mustangs for years. Currently I
own a 98 Mustang Cobra with forged internal with a 15 psi
supercharged. I love to drive the convertible SVT
Cobra. .
Anyhow, after I got married
and with little child on the way; I need a 4 door sedan.
I always like the luxury of Lexus since it was first
introduced in the early 90's. Well, I decided to
purchase a 1990 LS400. I like the 1990 year because it
was the first luxury car from Japan. Secondly, the
LS400 is and was the best of the best from Japan.
After driving the car for
few months, I looked around for performance upgrade.
As we all know, there isn't much performance parts for the
flagship. However, plenty of performance parts for
other Lexus lines. After months of reading on
www.turbomustangs.com,
www.supraforums.com and
www.clublexus.com I finally
have enough gut to start a project this magnitude.
Before my project started, I have a lot of people on the net
have doubts and discourage this project. Even the
friend who gave me two ball bearing turbos also discouraged
me. I told them, if it is easy, it would not be
challenging anymore. If it is easy, everyone would
have done it. If it is easy, it would be very boring.
With my determination, I kept on asking questions, I kept on
reading and kept on searching for knowledge of forced
induction and the overly engineered 1UZFE engine.
The information on the Lexus
V8 engine is so limited due to lack of interest in
performance after market parts. Therefore, I have to
do my own Research and Development (R&D). Calling
different dealers (Toyota and Lexus) and asking questions
about interchangeable parts and modifications.
Unfortunately, neither Toyota or Lexus technician would know
the answer. Being the first always have it drawbacks
and rewards.
Beside being an active
member of the above forums, I have purchased few books about
turbocharging. Maximum Boost was best turbo book I
have ever read. It gives very specific details and
examples. I would strongly recommend this book to
everyone who is thinking about starting a turbo project.
My project officially
started in late September of 2002. I was given two
ball bearing turbos from Joey of Spark Motorsports
www.sparkracing.com In Rowland Heights California
(now in La Puente, California. If you need 2JZ-GTE
swap into you SC300/400, please give Joey a call and tell
him that I send you. He will take care of you and your
car at a great price.) These turbos are imported from
Thailand and which was imported from Japan off the Nissan
Skyline VG30DET. I
was told that the turbos had about 25k miles on it.
The bearing spin free with no play. The T3 turbos are
both oil and water cooled with integrated wastegate.
While on the internet, I
also have found that the Lexus LS400 engine is a very strong
V8. The LS400 engine (1UZFE) has been documented to
produce over 2,700 horse power. That is with built
internal with 50 psi of boost. Beside the Australian
making monstrous power, Turbonetics also use similar motor
to break the 200 mph mark in 1/4 mile. Meanwhile, a
Japanese high performance company called HKS also use the
similar motor to produce mega horse power in their drag car.
However, beside being strong, the 1UZFE engine also
demonstrated to be very durable. The average life span
of the engine had been widely reported to hit at around 400k
miles. Few instances the car had reached 600k miles.
For insurance purposes, I know I have a good strong
foundation to start.
Currently, my LS has 150k
miles and its running stronger than ever before. At
150k, most car would require a re-build or a new engine.
Secondly, replacing a complete used engine from Japan is
very affordable. I have seen used 1UZFE drive train
(engine and transmission) for about $300 U.S. dollars from
wrecked cars. The question is "why is it so cheap?"
My answer would be because the engine is so strong, its does
not break and no one really need it. Therefore, the
demand for the well engineered engine is very low.
With the potential of making
more horse power than Twin Turbo Supra (MKIV 1993-1998)
engine, I can predict that many Supra owners would use this
engine in the future for drag racing. Currently, a
built Supra TT is maxing out around 1000 rwhp. Besides
being a V8, stroking and boring is being explore by racing
companies.
When I talk about power
adders, you must compare the price you pay and the horse
power you gain. For example, some people stroke their
4.0 DOHC to a higher displacement, but at what cost?
How about 152 rwhp for around $5,500? Which is about
$36 per rwhp. Some people spend over $5,500 and only
get around 20-25 rwhp that would be around $250 per rwhp.
I really do not think its worth it.
Since I had much fun and
headache with my Twin Turbo Lexus LS400 project. My
next project is to fabricate a single turbo kit for the
first generation Lexus SC400 by using T74 Q-Trim. This
turbo is good for 800 rwhp. With that amount of HP, it
should scare some most Vipers, Vets and Porsche owners.
The SC400 has the same drive train as the LS400.
Remember, replacement for displacement is BOOST!
TURBO:
The turbos are
from Nissan Skyline VG30DET. They are imported from
Japan via Thailand. The turbos have about 25k miles on
it. The turbos are carefully exam for shaft play and
spin. The VG30DET turbos are made by Garrett for
Nissan. These turbos are the usual upgrade of choice
for the Skyline RB25DET. The T3s are ceramic bearing
with both oil and water cooled capability. However,
these turbos will max out at around 640 bhp. For this
system and the location of the turbos, the turbos are 100%
air cooled. Therefore, water cooled is not necessary.
These turbos spool up very quick. I get 8 psi at
around 3100 rpm, which is excellent for street use.
Not too low and not too high. Due to the original
application was not intended to my car, I have to make some
custom flanges in order to fit them under the car.
Upgrade turbos head unit (T3) are available to 900 rwhp.
Low mount turbos will not allow you to lowered your ride.
OIL:
The oil system is unique
to low mount turbos. Due the location and height, oil
return is unlike traditional method. The oil is
obtained from the engine oil pressure gauge by using a T
adapter along with a restrictor orifice bypass to control
the oil flow to the turbos. The turbos are drain to a
8-AN stainless steel braided line, immediately the oil is be
pick up by a Tilton self primed differential oil pump.
After the hot oil being drawn out of the turbos, it quickly
pump the oil back to the oil pan. The rate of the
inlet and outlet must be precisely accurate, otherwise your
turbo will smoke or run dry. All the line being used
are capable to withstand high temperature and pressure.
All the connections are use Army/Navy (AN) standard
fittings. With high temperature area, steel fittings
are used. Low temperature area, aluminum fittings use
for weight saving reasons.
The hardest part of this low turbo mount
system is the oil. Too much oil or oil pressures going
to the turbos will cause the turbo to smoke. Not
enough oil, the turbo seals will break. Either way is
not good news. Therefore, precise tuning of the oil
flow is very important. After I destroyed 3 good
condition turbos I finally realize that the proper oil flow
is very important. The oil being pump out of the
turbos must be faster than the oil coming into the turbos,
but not by much. This oil system utilized oil from the
crank pressure. As the engine rev at higher rpm, so
does the oil pressure. The increase of oil pressure
will have higher oil flow. Currently, the system is
tune to around 3000 rpm. For optimal oil cooler and
lubrication, a small oil sump will be very useful.
I have a custom oil sump made with 1" thick
at one and 2" at the other end with two 8-AN inlet and one
8-AN outlet. The oil sump is mounted between the two
turbos and the Tilton oil pump pulls the oil out from the
sump to the oil pan. The oil sump is made specifically
for low mount turbo/turbos. The sump solved all my oil
problem. I also have a small opening on top of the oil
sump for ventilation.
AIR INLET:
The air inlet from
the turbos are unique in its own rights. The inlet air
is travel under the car and jointing two 2" mandrel bend
tubes into one 3" tube. The 3" mandrel tube then lope
up between the radiator and the engine. During this
path, some intercooling is obtain. However, an
intercooler can be place under the car. The compressor
inlet of fresh air is place under the car. It uses two
2.5" opening K&N high performance, low resistance air
filter. However, due to the low mount of these air
filters, it is highly recommended to having a custom tube
made up into the suspension area. Recently, I have a
local muffler shop made me two custom turbo inlet extension.
These extensions are great with heavy rain. However,
with those 2.25" extension tubes, I noticed a slight
restriction on the intake side. During summer time, I
will remove the extension tubes to achieve better flow.
INTAKE:
The intake uses a
combinations of products. For example, Turbonetics
short radius aluminum cast elbow is being used. Due to
the tight space in the V8 engine bay, tight radius elbow is
a favorable choice. The intake is connected with high
quality silicon hoses by Hosetechniques along with heavy
duty T-Bolt clamps. All pipes have flare ends for
strong connection. A Blow Off Valve (BOV) is being
used. I choose Greddy Type S because is very quite.
Due to the location and the routing of the intake pipe, the
fan cover need to be slightly modify. Running my turbo
LS400 without a fan cover will cause excessive heat.
You can modify the OEM fan safety cover or get an
aftermarket electric fan. 16" electric fan is highly
recommended.
INTERCOOLING:
Traditionally, a
front or side mount air to air intercooler would be used.
Due the limitation of the Lexus LS400. A small front
mount intercooler was impossible. Therefore, I used a
Methanol/Water injection system was used. The system
was purchased via
www.snowperformance.net. The methanol and water work as
a median to cool the charged air through a boost sensitive
activation. Currently, its set to be activated at 7
psi. For stage I, I am running 8 psi. Since I
purchased this kit from above link, I have modified this kit
heavily for safety sake. I replaced all cheap Home
Depot plastic line to Stainless Steel Braided Lines and I
also replaced those Push-In connectors to aluminum -AN
fittings. I also completely replace the cheap plastic
bottle with Jaz Fuel Cell. All connection are via
metal/aluminum fittings.
I will increase boost to 9-11 psi in the
near future with further fuel system upgrade.
Secondly, due to the location of the turbos, water cooling
is not necessary. Since my turbos are air cooled, I
have no change in my engine temperature. The engine
temperature is the same even with twin turbo. Due to
the cool running turbos, turbo timer for cooling turbos down
after ignition shutdown is not require. However, an
air to air intercooler can be place under the car or some
where by the fender. After few days of assessment, I
realized the horizontal and front mount would be very labor
some and practical.
First, horizontal mount would have a ground
clearance problem and front mount will be labor some due to
the OEM AC fans and few other mounts. I have been
reading about side mount turbos. The top two
candidates of OEM intercooler would be Saab Turbo
Intercooler or Eclipse 1st generation intercooler.
As for update on intercooling. I
purchased a 3" x 6" x 31" intercooler which be mounted under
the bumper.
IGNITION:
The ignition and timing
retardation will be control by MSD DIS 4. This unit is
capable increasing ignition at the same it also control
timing. Besides MSD DIS-4, Unichip can also control
timing too. Currently, I am running complete stock
ignition.
FUEL:
Upgrade in-take fuel is a
must if more power is desired. A High Pressure Walbro
255 L/H in-fuel pump is being used along with Aeromotive
adjustable fuel pressure regulator (AFPR). If higher
horse power is needed, 440 cc top feed injectors are highly
recommended. Currently my stock fuel pressure is set
to 39 psi. For Stage I (8 psi) stock fuel system is
sufficient with a rising fuel pressure regulator to support
up to 325 rwhp. For great horse power, larger
injectors will be require. 400 rwhp would require
440cc and 500 rwhp would require 550cc. With larger
injectors like 550cc a stand alone is highly recommended to
control the large injectors during idle. I have been
looking at an Australian product call Wolf 3D Version 4.
This stand alone computer is very affordable comparing to
the rest of the stand alone computer on the market today.
The Wolf 3D is about $700 U.S. Dollars. Any sponsor
out there? I need one.
CONTROL:
Currently, An Apexi Super
AFC is being used as a piggy back computer along with OEM
ECU. An Unichip is also a highly favorable choice.
After playing around with my system, I finally realized with
8 psi, a piggyback is not necessary. A basic
adjustable rising fuel pressure regulator will do the job.
Piggyback computer is necessary when bigger injectors are
installed. Between 8-15 psi piggy back would work.
More than 15 psi, a stand alone computer is high recommended
or a combination of piggyback with rising fuel pressure
regulator. Here is my recommendation:
<8 psi - Rising Fuel Pressure Regulator with
stock fuel system
8-15 psi - 440 cc with piggyback computer
>15 psi - Stand alone computer or a
combination of RFPR and piggyback computer
However, I would recommended a stand alone
computer for higher boost. The worst thing about boost
engine is ill tuned.
PERFORMANCE:
Currently, car is
dynoed at 324.5 rwhp and 324.7 rwtq at 8 psi without
intercooler. I am sure that I can push it to 350 rwhp
with more tuning and an intercooler. The stock 90
LS400 was dynoed at 172 rwhp. That is about 152 rwhp
increase. That is about 20 rwhp per pound of boost.
The car pulls very hard after 3000 rpm to redline. The
dyno result on 01-30-03 was using stock fuel system.
Please see dyno result
http://www.lextreme.com/Dyno.htm I can not wait to
see Stage II with estimated 500 rwhp. I would like to
take this sleeper to the track and find out what this beast
can do in 0-60, 1/4 mile and so on. I would not be
surprise to see low to mid 13 seconds with proper traction
and driving skills. Currently, my spare engine is
being build by a 36 years of experience engine builder.
He was one of the original engine builder for the legendary
Carol Shelby in the 60's. The new engine is getting
custom JE Dish pistons with over bored .020" along with
O-ring head and groove block and ARP head studs and few
other boost friendly goodies.
COPY RIGHTS:
There is no copy rights to this system. If you have
some mechanical knowledge and skills, please feel free to
copy my kit. You are welcome to ask any questions
regarding this kit. Secondly, I have received many
emails regarding in the production of this kit. As I
have responded to all emails, I will only produce this kit
if there is a large order. Large order means 10-15
pre-paid kits at a time.
INSTALLATION:
If the kit ever see the light of production, this kit
will be truly Bolts-On with few minor modifications to the
exhaust and oil system. I estimated the complete kit will
take around 5-8 hours to complete. It will be direct
copy of my kit.
Twin Turbo Stage II
Stage I Parts
Installation Instruction
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| These are 3" resonator help quite exhaust
noise. These are high flow resonators.
They are louder than stock |
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| These are two 12" long 3" diameter straight
resonators. My car have total of 4
resonators. |
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| High quality hoses and T-bolt clamps are
being used. The intake pipe will be chrome
soon. |
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| This is the turbo inlet flange along with
braided stainless steel line. This is no longer
use. Its being replace with 2" pipe |
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| The picture shows two 3" straight pipe
before the primary resonators were installed. |
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| This is the secondary resonator: its 18"
long with 3" diameter. |
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| This picture show both primary and secondary
resonators installed with protected spray. |
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| In this setup, the car idle much smoother
like OEM. MAF gets smooth air flow. |
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| This is the driver side turbo. Notice the
blue silicon hose for filter connection. |
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| This is the passenger side turbo along with
oil drainage line. |
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| Close up on driver side turbo. |
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| The down pipes (DP) are 3" mandrel bend
steel pipe. |
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| Side view of right turbo along with 2"
mandrel bend tubes. |
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| Close up left turbo. These turbos
spool up very quick. 8 psi at around 2600
rpm. |
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| Thermotec heat wrap and tie. |
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| Rear view of left turbo along with
Turbonetics actuator. |
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| The is the first oil drain path. Later it
was changed to center T-Drain. |
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| This is a tight turn of the left turbo.
Notice the protective wrap and straps. |
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| Oil drain line of the right turbo and
actuator. |
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| The turbo outlet is connected to the braided
line. All connections use heavy duty T-Bolt
clamps. |
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| Oil drain line from turbos to the oil pump. |
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| Other view of drainage line along with
thermal wraps. |
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| This is OEM Nissan Skyline actuator. The
bracket fit perfectly. The right turbo actuator
was just bolt-on. Stock actuators for 8
psi.. |
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| You are seeing the oil needle restrictor
along with T-connection. |
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| Crank oil pressure is being to supply oil to
the turbos. |
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| Excellent view on the AN fitting. |
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| Side view of the driver side turbo with K&N
filter. |
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| Two 2" mandrel bend pipes are joint in a 3"
Y-pipe. Very clean setup. |
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| Top view of the custom intake along with two
inlet braided line and blow off valve. |
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| The OEM air filter is where the
methanol/water injection is located. |
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| A clear picture of Greddy Type S BOV.
Its not loud. |
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| Rear view of stainless steel MagnaFlow
muffler. The Magnaflow muffler has both 3" inlet
and outlet. |
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| Beautiful picture of the Y-pipe. |
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| This system is none intercooled, but the
pipping will provide some intercooling effect. |
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| These are custom adapter that connect to the
OEM headers and turbos. |
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| This is the driver side turbo with 3" down
pipe and thermal wrap. |
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| Picture of the two DP along with Greddy BOV |
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| That is my superchaged 15 psi with built
motor and 6 speed. |
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| This is a short radius cast aluminum elbow
from Turbonetics. Pipes are connected with heavy
duty T-Bolts clamps. |
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| Alcohol/Water injection system |
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| Side view of the intake along with the
removal of fan protector. |
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| More pictures on inlet pipe going up into
the throttle body. |
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| This is my gauge pod. I am using my glove
compartment to hide all the gauges. SLEEPER! |
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| Rear view of dual mufflers. This is how it
looks like from a M5, CK55 AMG and Jag driver. |
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| Left rear view of Magnaflow and 3.25"
stainless steel tip. |
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| Right muffler. Polished finish |
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| Adjustable needle valve to help oil
restriction |
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| New location of Tilton Differential oil
pump. This mounting location help to reduce
vibration. |
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| This is the return oil to the oil pan via a
braided line 8-AN |
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| Close up of Tilton oil pump and lines |
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| This is the new oil lines. Two to the turbos
and one bypass back to the oil pan. |
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| New drainage path, notice protective sleeve. |
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| General under car view of oil pump and
lines. The heart of the oil system is the
pump. |
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| Oil drain line from turbo |
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WARNING: THIS APPLICATION IS ONLY FOR OFF ROAD USE.
ITS NOT LEGAL FOR PUBLIC HIGHWAY AND ITS NOT SMOG LEGAL.
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