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Discussion Starter · #1 ·
Here's some pictures of a turbo installation for a customer's 855D. It's still a work in progress, so nothing fancy here.

First attempt was with a Mitsubishi TD03-07G, which didn't work at all. It just would not spool no matter what. So we switched the turbo to a smaller IHI unit which works a treat. With the original intake tubing and air filter we managed to get 0,5bar (7psi) very easily. Seems that the original filter restricts the airflow pretty much, so we removed that and the tubing altogether and replaced them with a cone air filter mounted straight to the turbocharger inlet. This gave us 0,8bar (11psi) of boost and plenty of grunt.

After thorough test driving I'm pretty sure we almost doubled the amount of horsepower, but this wasn't enough(!) for the customer. So we'll be upping the boost and fuel even more, maybe somewhere in the area of 1,2bar(17psi). The exhaust needs redesigning and at the moment I'm trying to find a suitable intercooler. This should see us reaching easily over 50hp mark. I'm hoping to get the Gator to a dyno after all the modifications are finished to see how much difference they make.

The CVT needs some attention too. Even with more power the Gator still feels sluggish. With minor modifications we've already got the top speed up to 60kph(37mph), but it's seriously lacking acceleration. The top speed is good as it is, so next we'll try to find a way to make it accelerate more quickly. Any suggestions, hints and tips are welcome!

Needless to say, I am not a native english speaker, so I hope you all can manage with the imperfections in my writings.

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Discussion Starter · #2 ·
Time for update.

We took the fuel injector pump to a specialist who managed to increase the output 15%. After some difficulties with the timing the pump was installed back on and black smoke was pouring again. :)

This time the maximum boost under load got up to 1,1bar (16psi). Any more might blow up the engine pretty soon. The engine ran very hot so we installed an intercooler where the original air filter used to be. Intercooler is from Fiat Brava 1.9 diesel and is the smallest cooler we could find. Windshield washer fluid container needed relocationing so we made a new bracket for that, as well as for the intercooler. The fan is from a chinese Linhai ATV. There is still room for another one so maybe we'll be adding one later.

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Tubing was a little difficult as there's not very much room in the engine bay, but after some fiddling and fettling the tubing was in.

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how much hp and torque is that monster pushing with 16 psi?!!
 

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Discussion Starter · #4 ·
how much hp and torque is that monster pushing with 16 psi?!!
We have no idea about the exact power output at this point, but it sure has plenty! :D I'm guessing somewhere around 50 to 70 hp. I will post a video soon to show the pretty much improved towing capabilities.

The CVT belt is a big question mark now, we don't know how much torque that can cope with.
 

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Nice job!

I'm glad you mentioned about the cooling issue you ran into as I was about to ask. I've souped-up Cummins engines and first ran into TIT (turbine inlet temperature, exhaust gas) temperature limits first. Turning the engine faster to keep the exhaust gas cooler took care of that. Then the next problem was engine temperature. Who knew that burning a lot more fuel would create more heat :D .
 
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