Safari Turbocharger Systems for 4WD diesel offroad vehicles

Safari Turbocharger System STHZJ100

Parts List
ITEM
PART NO
DESCRIPTION
QTY
EXHAUST SUB ASSEMBLY - STHZJ100 S1
1
000-104
STUD - M10 x 1.25 x 23.5mm (34mm O/L) - S/S
3
2
000-209
NUT - SELFLOC - 10mm x 1.25
3
3
000-303
WASHER - FLAT - 10mm
5
4
000-113
STUD - 8mm x 1.25 x 25mm (35mm O/L) - S/S
5
5
000-302
WASHER - FLAT - 8mm
5
6
000-211
NUT - SELFLOC - 8mm x 1.25
5
7
375-003-150
PIPE - TURBINE OUTLET
1
8
000-972
PLUG - HEX - 18mm x 1.5mm
1
9
000-316
WASHER - COPPER - 18/24mm
1
10
375-006-150
PIPE - FRONT INTERMEDIATE
1
11
000-013-500
CLAMP - EXHAUST - 73/79mm
1
12
330-411-000
GASKET - 2 BOLT FLANGE
1
13
000-054
BOLT - HEX - 10mm x 1.25 x 35mm
2
14
000-256
NUT - FLANGED - 10mm x 1.25mm
2
COMP. INLET SUB ASSEMBLY - STHZJ100 S2
15
375-122-400
HOSE - AIR CLEANER/TURBO
1
16
000-928
CLAMP - HOSE - 12mm x 70/90mm
2
17
375-994-400
HOSE - BREATHER - MOULDED - 5/8"
1
18
000-911-023
CLAMP - SPRING - NO. 23
2
19
000-911-027
CLAMP - SPRING - NO. 27
1
20
475-994-500
JOINER - HOSE - 5/8"
1
INLET MANIFOLD SUB ASSEMBLY - STHZJ100 S3
31
375-221-000
HOSE - COMPRESSOR DISCHARGE - SILICONE
1
32
000-926
CLAMP - HOSE - 12mm x 50/70mm
1
33
000-927
CLAMP - HOSE - 12mm x 60/80mm
1
34
330-972-200
PLUG - 18mm x 1.5 x 1/8" NPTF
1
35
000-316
WASHER - COPPER - 18/24mm
1
36
000-544
TEE-PIECE - 1/4" BARB RUN x 1/8" BSPT BRANCH
1
37
000-827-055
HOSE - RUBBER - 3mm ID x 550mm
1
38
000-585
ADAPTOR - 90° - 1/8" NPT x 1/4" BARB
1
TURBOCHARGER SUB ASSEMBLY - STHZJ100 S4
41
330-061-063
TURBINE HOUSING - 1HZ/TD06
1
42
330-471-000
RING - SEALING - EXHAUST
1
43
000-956
PLUG - 1/8" NPT - EGT PORT
1
44
000-063-765
CHRA - TD06 - 18G
1
45
000-062-600
COMPRESSOR HOUSING - TD06 - 18G
1
46
000-454-C
CLAMP - TURBINE HOUSING RETAINING
1
47
000-453-C
CIRCLIP - COMP. HOUSING RETAINING
1
48
000-068-900
BRACKET - ACTUATOR
1
49
000-011
BOLT - HEX - 8mm x 1.25 x 16mm - S/S
2
50
000-305
WASHER - STAR - 8mm
2
51
000-302
WASHER - FLAT - 8mm
2
52
000-970-765
SPACER - ACTUATOR MOUNTING
2
53
000-301
WASHER - FLAT - 6mm
2
54
000-204
NUT - NYLOC - 6mm x 1.0
2
55
000-066-765
ACTUATOR/ROD ASSEMBLY
1
56
000-963
CLIP - 'C' - 4.5mm
1
57
000-808-070
HOSE - 1/4" ID x 700mm
1
58
000-917
CLAMP - HOSE - SPRING 1/4"
2
59
330-011-999
BRACKET - TURBO SUPPORT
1
60
000-1056-000
BOLT - 12mm x 1.25 x 25mm
2
61
000-308
WASHER - SPRING - 12mm
2
62
000-331
WASHER - FLAT - 12mm
2
63
000-106
STUD - 10mm x 1.5/1.25 x 27mm (42mm O/L) - S/S
1
64
000-303
WASHER - FLAT - 10mm
1
65
000-209
NUT - SELFLOC - 10mm x 1.25
1
LUBRICATION SUB ASSEMBLY - STHZJ100 S5
71
000-961
ADAPTOR - OIL SUPPLY
1
72
375-962-000
HOSE ASSEMBLY - OIL SUPPLY - 1/4" ID x 1060mm
1
73
000-011
BOLT - HEX - 8mm x 1.25 x 16mm
1
74
000-302
WASHER - FLAT - 8mm
1
75
000-305
WASHER - STAR - 8mm
1
76
000-981
CLAMP - HOSE SUPPORT - 8/20mm
2
77
000-987-178
CABLE TIE - NYLON - 4.8mm x 178mm
3
78
000-601-500
ADAPTOR - ST. - 7/16" JIC x 10mm x 1.25
1
79
000-312
WASHER - COPPER - 10mm x 16mm
1
80
375-969-200
DRAIN - OIL - UPPER
1
81
000-449
GASKET - OIL DRAIN
1
82
000-002-400
BOLT - HEX - 6.0mm x 16mm - SELFLOC
2
83
330-836-000
HOSE - OIL DRAIN (TAPPED) - MOULDED - 5/8"
1
84
375-836-000
HOSE - OIL DRAIN (PUNCHED) - MOULDED - 5/8"
1
85
000-911-023
CLAMP - SPRING - NO. 23
2
86
000-514
DRAIN - OIL - LOWER
1
87
330-034-000
BRACKET - OIL SUPPLY SUPPORT
1
88
000-943
CLAMP - HOSE SUPPORT - 8/12mm
3
89
000-021
BOLT - HEX - 5mm x 0.8 x 12mm
2
90
000-320
WASHER - FLAT - 5mm
4
91
000-982
CLAMP - HOSE SUPPORT - 12/15mm
1
92
000-023
BOLT - HEX - 5mm x 0.8 x 20mm
1
93
000-221
NUT - NYLOC - 5mm x 0.8
1
Installation Guide
1 Special Tools
  • Metric and Imperial Wrench & Socket Sets
  • 3/8" BSPF Thread Tap
  • M18x1.5 Thread Tap
  • Engine Sump Spike (Engine Oil Pan Oil Drain Option)
  • Right Angle Drill (Engine Block Oil Drain Option)
  • Reduced Shank Drills (15mm Dia) (Engine Block Oil Drain Option)
  • M12 x 1.25 Thread Tap (early model engine block turbo support)
  • 8mm & 10mm Stud Installers
  • Fast Setting Adhesive (5mn Araldite)
  • High Temperature RTV Silicon Sealant (Permatex Ultra Copper or equivalent)
  • Hydraulic Sealant (Loctite 569 or equivalent)
  • 7mm Flexible Shaft Hose Clamp Driver
2 Disconnect the negative (-ve) battery terminal.

Remove the following in accordance with the factory service manual:

  • Air Cleaner Lid
  • Intake hose and resonator assembly
  • PCV breather hose
  • Intake Duct
3 Remove the rocker cover.

Push on the PCV baffle tabs to close the gap to 10mm as shown.

Reinstall the rocker cover.
4 Remove the exhaust engine pipe.

Remove and discard the engine pipe support bracket.

NOTE: The nuts retaining the engine pipe to the exhaust manifold may be seized and require attention (penetrating lubricant or heat) to avoid breaking the exhaust manifold outlet flange studs.
5 Remove the PCV tube from the intake duct

Tap the hole square to the boss in the duct with a M18x1.5 thread tap.

Non EGR: Install the 18mm plug (Item 34), copper washer (Item 35). Apply hydraulic thread sealer to the 90 deg adaptor (Item 38) and install into the plug (Item 34). Note orientation.

With EGR: Install the 18mm plug (Item 34), copper washer (Item 35). Apply hydraulic thread sealer to the Tee piece (Item 36) and install into the plug (Item 34). Note orientation.

6 Remove the three studs shown from the exhaust manifold

Install three new M10x1.25x23.5mm stainless steel studs (Item 1).
7 Install the actuator mounting spacers (Item 52) to the wastegate actuator/rod assembly (Item 55) and then install the wastegate actuator assembly to the actuator mounting bracket (Item 48) with the actuator vent hole orientated as shown.

Retain with 6mm washers (Item 53) and 6mm Nyloc nuts (Item 54).

Install the wastegate assembly to the turbocharger compressor housing. Retain with 8mm bolts (Item 49), apply hydraulic sealant to bolt threads, 8mm star washer (Item 50) and 8mm flat washer (Item 51).

Ensure that the wastegate actuator rod is in the centre of the actuator mounting bracket hole when the end of the rod is positioned upon the wastegate swing valve crank arm.
8 Close the wastegate swing valve and adjust the wastegate actuator rod length to achieve a 1/2 hole diameter preload as shown.

Install the circlip (Item 56) to the wastegate swing valve crank arm.

  • More Pre-Load (Shorten Rod) = Higher Boost
  • Less Pre-Load (Lengthen Rod) = Lower Boost
9 Install the five 8mm studs (Item 4) to the turbine outlet flange.

Install the 10mm stainless steel stud (Item 63) to the turbine housing.

Install the turbocharger upper oil drain (Item 80) and gasket (Item 81). Retain with two 6mm selfloc bolts (Item 82).

NOTE: DO NOT use any silicon sealing compound on the oil drain gasket surfaces.
10 Install the 7/16" straight adaptor (Item 78) and 10mm copper washer (Item 79).

Install the EGT port plug (Item 43) (If not already factory fitted).

Apply a small amount of high temperature sealant to both faces of the exhaust gasket (Item 42). Install the exhaust gasket (Item 42) to the turbine housing inlet flange.
11 Install the turbocharger assembly to the studs (Item 1) on the exhaust manifold.

Retain with washers (Item 3) and 10mm selfloc nuts (Item 2).
12 Install the 18mm copper washer (Item 9) and 18mm hex plug (Item 8) to the turbine outlet pipe (Item 7).
13 Apply a bead of High Temperature RTV Silicon Sealant to the turbo outlet flange as shown.
14

Install the turbine outlet pipe (Item 7) to the turbocharger outlet and retain with 8mm flat washers (Item 5) and 8mm Selfloc nuts (Item 6).

Install the exhaust clamp (Item 11) over the end of the turbine outlet pipe (Item 7) and install the front intermediate pipe (Item 10) into the turbine outlet pipe.

Install the 2-bolt flange gasket (Item 12) between the exhaust pipe and the front intermediate pipe (Item 7) and retain with 10mm x 35mm bolts (Item 3), 10mm flat washers (Item 13) and 10mm flanged nuts (Item 14).
Turbocharger Oil Drain - Option A - Drain into Engine Oil Pan
15a Mark the position of the lower oil drain hole which is:

From the rear, between the 4th and 5th oil pan retaining bolts and 20mm down from the oil pan mounting flange as shown.
16a

Use a sump spike to punch a hole into the oil pan.

Apply grease to the 3/8" BSPF tap and tap hole. Note that the grease is used to prevent swarf from entering the engine oil pan.

Clean the tapped area of the oil pan and apply 5 minute Araldite or similar fast setting adhesive to the threads of the lower oil drain (Item 86) and install into the engine oil pan.

Turbocharger Oil Drain - Option B - Drain into Engine Block
15b NOTE: Apply a generous amount of grease to each drill bit to prevent swarf from entering the engine.

Drill a pilot hole squarely into the engine block assembly in the position shown.

Use progressively larger diameter drills to drill to 15mm.

Thread the hole with a 3/8" BSPF thread tap.

Apply hydraulic sealant to the threads on the lower oil drain (Item 86) and install the lower oil drain (Item 86) into the engine block.

17 Install No 23 spring hose clamps (Item 85) to each end of the oil drain hose and install the oil drain hose

Option A - Item 84 (shown)

Option B - Item 83 (not shown)

between the turbocharger upper drain (Item 80) and the lower drain (Item 86).

Move the spring hose clamps (Item 85) to secure the oil drain hose.
18 Install the turbocharger support bracket (Item 59) to the engine block and retain loosely with 12mm x 25mm bolts (Item 60), 12mm spring washer (Item 61) and 12mm flat washer (Item 62). NOTE Do not tighten bolts yet.

Retain the turbocharger support bracket to the turbocharger with a 10mm flat washer (Item 64) and 10mm selfloc nut (Item 65) to the 10mm stud (Item 63) previously installed on the turbocharger.

Align the turbocharger support bracket (Item 59) and tighten all mounting hardware evenly.

NOTE: Some engine blocks do not have tapped holes in place. If so, hold the turbocharger support bracket in place and mark the position of each hole on the bosses cast into the block. Drill and tap to M12x1.25 at a depth of 20mm maximum.

19 WARNING: Ensure that the battery is disconnected.

Pull the rubber boot back from starter motor lead shown and loosen the terminal nut.

Rotate the lead 45 deg away from the engine block and re-tighten the terminal nut. Refit the rubber boot.
20 Unplug the oil pressure sender wire from the oil pressure sender unit and remove the oil pressure sender unit from the engine block.

Apply hydraulic sealant to the threads of the oil supply adaptor (Item 71) and install the adaptor into the engine block. Note orientation of hole shown.

Apply hydraulic sealant to the threads of the oil pressure sender unit and install the oil pressure sender unit to the adaptor (Item 71).

Reconnect the oil pressure sender wire to the oil pressure sender unit.
21 Install the 90 deg fitting end of turbocharger oil supply hose (Item 72) to the oil sender unit adaptor (Item 71).

Install the straight fitting end of the turbocharger oil supply hose (Item 72) to the turbocharger oil supply adaptor (Item 78) installed previously. Note: Use two wrenches - one wrench to stop the hose from turning whilst tightening the straight fitting with the other wrench.
22 Install the intake duct back onto the engine.
23 Install a spring hose clamp (Item 58) to each end of the 1/4" wastegate actuator hose (Item 57) and install the hose to the wastegate actuator port (Item 55).

Install the other end of the 1/4" wastegate actuator hose (Item 57) to the

Non EGR: 90 deg adaptor (Item 38) installed previously.

With EGR: Tee piece (Item 36) installed previously.

Support the 1/4" wastegate actuator hose along the turbocharger oil supply hose (Item 72) with the three cable ties (Item 77).
24 Non EGR: Install the oil supply hose support bracket (Item 87) to the intake manifold with a 8x16mm bolt (Item 73), 8mm star washer (Item 75) and 8mm flat washer (Item 74).

Install the two 8/12mm hose support clamps (Item 88) to the oil supply hose (Item 72) and fasten to the oil supply hose support bracket (Item 87) with two 5x12mm hex bolts (Item 89) and 5mm washers (Item 90).

Install one 12/15mm hose support clamp (Item 91) to the 1/4" wastegate actuator hose (Item 57) next to the 90 deg adaptor (Item 37) installed previously

Install a 8/12mm hose support clamp (Item 88) to the oil supply hose (Item 72) and fasten the two clamps together with a 5x20mm bolt (Item 92), two 5mm flat washers (Item 90) and a 5mm nyloc nut (Item 93).
24-EGR Install a 8/20mm hose support clamp (Item 76) to the oil supply hose (Item 72) and fasten to the intake manifold with a 8x16mm bolt (Item 73), 8mm star washer (Item 75) and 8mm flat washer (Item 74).

Install a 8/20mm hose support clamp (Item 76) to the oil supply hose (Item 72) and fasten to the EGR pipe stud shown and retain with the standard fastener.
25 Install a 60/80mm hose clamp (Item 33) to the large diameter end of the silicon compressor discharge hose (Item 31) and install a 50/70mm hose clamp (Item 32) to the smaller end.

Install the silicon compressor discharge hose (Item 31) between the turbocharger compressor outlet and intake duct inlet.

Ensure that the hose clamps are perfectly square on the silicon hose before tightening.
26 Install a 70/90mm hose clamp (Item 16) to each end of the turbocharger entry hose (Item 15) and install the hose to the turbocharger compressor entry.

Install the air cleaner lid to the air cleaner and the turbocharger entry hose (Item 15). Tighten the turbocharger entry hose clamps (Item 16).

Install a 5/8" joiner (Item 20) to the PCV breather port of the air cleaner lid and retain with a No 27 spring hose clamp (Item 19).

Install a No 23 spring hose clamp (Item 18) to each end of the PCV breather hose (Item 17) and install the hose between the PCV port on the rocker cover and the joiner (Item 20).
27 With EGR: Remove the rubber hood from the top of the altitude compensator on the diesel injector pump.

File the top of the port until the central hole has enlarged to 2mm diameter.

Remove the vacuum hose from the rear of the injector pump and the solenoid at other end.

Install the rubber hood removed previously from the top of the pump to where the vacuum hose was originally fitted.

Install the 3mm vacuum hose (Item 37) to the port on the top of the altitude compensator, route as shown and connect to the tee piece (Item 36).
28 Completion of Installation:
  • Check All Fluid levels.
  • Check for Exhaust Leaks.
  • Check for Fluid Leaks.
  • Ensure all Hoses have adequate clearance to surrounding area. (trim hoses if required)

TUNING: See specifications below. Click here for tuning procedure.

Tuning Specifications below are a guide only. Local conditions and vehicle specifications may demand alteration of the values below.

Boost Level: 10-12psi @ 3000RPM full load/full throttle measured at intake manifold or crossover duct.

  • More Wastegate Actuator Pre-Load (Shorten Rod) = Higher Boost
  • Less Wastegate Actuator Pre-Load (Lengthen Rod) = Lower Boost

Max Exhaust Gas Temperature:

Full load/full throttle at 3500RPM - 4000RPM after 1min at full load/full throttle

  • Measured in the EGT Port (in the turbocharger inlet - Preferred position) = 650 deg C
  • Measured in the engine pipe (after turbocharger - Not Preferred position) = 500 deg C

Air Fuel Ratio (AFR)

  • 1000RPM = 15.5:1 - 16.0:1 at full load/full throttle
  • 3000RPM = 20.0:1 - 20.5:1 at full load/full throttle

NOTE: Higher AFR ratio numbers result in cooler and more reliable engine operation.

  • To lower AFR number (increase fuel delivery rate) turn main fuel screw clockwise.
  • To increase AFR number (decrease fuel delivery rate) turn main fuel screw anti-clockwise

Maximum Speed Governor

  • 4200RPM - 4300RPM at full load/full throttle in 2nd gear

NOTES
Sump Spike configuration - Used in Turbocharger Oil Drain - Option A