FITTING INSTRUCTIONS

NISSAN NAVARA D22 WITH TD27

AND QD32 DIESEL ENGINES

As at 24 April 2008

1. Remove exhaust system, exhaust manifold and the entire air cleaner
system.

2. Remove oil plug from side of block on LHS in front of oil filter and
regulator assembly using 5mm Allen key. Remove larger plug just
below alternator on side of block to facilitate oil return.

3. Screw the 3/8 male hose tail into the large oil return hole in the block.
This thread is to be sealed with Loctite Hydraulic Sealant 569. Again
using Loctite 569 screw the small oil feed nipple into the 1/8 BSP hole
in the cylinder block.

4. Using new gaskets if necessary bolt the TurboDyn manifold and turbo
assembly on using original nuts and washers. Now bolt on exhaust
dump pipe and connect oil supply and oil return pipes.

5. Connect turbo air outlet to intake manifold using cast aluminium elbow
and turbo hoses and clamps supplied.

6. Bolt air cleaner bracket to inner guard with long end facing out towards
centre of wheel. Now fit air cleaner to bracket using original bolts, air
inlet to face towards rear of alternator. Measure original plastic
ducting, cut and fit to inner guard so as to connect to air cleaner inlet
using hose and clamps provided. Place actuator tube on flat section of
what is now the bottom of the air cleaner. Mark and drill a 25mm hole.
Now pop rivet from inside air cleaner and fit original rubber actuator
valve. Straighten out the 30mm wide bracket and bend on welded nut
end around 27mm from end to 90°.
The nut is to be on the inside of the bend. Now bolt to top air cleaner
mount with long end facing forward over the radiator support panel.
Bend over panel, cut and drill to enable it to be bolted to hole near
 washer bottle cap. Connect air cleaner to turbo using original
convoluted hose.

Note: small breather pipe to be connected to rocker cover breather

using extension tube and spacer supplied.

7. It will be necessary to readjust the position of the wiring around the

alternator region so it won’t rub on the air hose. Cable ties are
supplied for this purpose.

8. Fit flexible exhaust to dump pipe already fitted to turbo then fit long
pipe, expanded end forward then the muffler and lastly tail pipe.
Secure with clamps and hangers.

9. Fit pyrometer and boost gauge, start engine and check for air and oil
leaks. Adjust maximum boost to 60 KPA maximum under full power.
Note this may be done in 4th gear full power on dyno or road but allow
at least 1 minute under full power for full reading. Maximum
temperature 500°C under full load.
 WARNING TO ALL FITTING STATIONS
AS AT 1ST MAY 1996

INSTALLATION OF DIESEL TURBOCHARGER EMISSION CONTROL

SYSTEMS SHOULD NOT BE UNDERTAKEN UNLESS YOU HAVE A
BOOST GAUGE AND A PYROMETER.

ALL DENCO TURBO SYSTEMS RUN AT 60 KPA BOOST MAXIMUM AND

A MAXIMUM OF 500°C UNDER POWER LOAD UNLESS OTHERWISE
STATED.

REMEMBER: OVER FUELLING NOT ONLY CAUSES BLACK SMOKE IT

ALSO GENERATES EXCESS HEAT. EXCESS HEAT CAN ALSO BE
CAUSED BY AIR AND EXHAUST RESTRICTIONS SO CHECK ALL AIR
CLEANERS AND DUCTING TO THEM FOR RESTRICTIONS BEFORE
TESTING. EXHAUST BRAKES AND EXHAUST SYSTEMS SHOULD ALSO
BE CHECKED FOR CORRECT OPERATION AND RESTRICTION.

EXCESS HEAT CAUSES MANY PROBLEMS INCLUDING HIGH NOX

EMISSIONS, LAMINATION OF TURBINE HOUSING AND MANIFOLD, STUD
STRETCH AND PREMATURE ENGINE FAILURE.

DENCO DIESEL AND TURBO WILL NOT ACCEPT LIABILITY FOR ANY
PARTS RETURNED FOR WARRANTY THAT SHOW ANY OF THE ABOVE
SIGNS.

WARRANTY WILL NOT BE CONSIDERED IF REPAIRS ARE CARRIED OUT

WITHOUT TURBO DYNAMICS AUTHORISATION.

ALL KITS NOW HAVE DUMP PIPES WITH THE PROVISION FOR VDO
PYROMETERS.

REMEMBER: IF SET CORRECTLY OUR PRODUCT IS

ENVIRONMENTALLY FRIENDLY AND SAFER TO THE ENVIRONMENT
THAN PETROL ENGINES.
 NISSAN D22 PARTS LIST
NO QTY PART NO. BIN DESCRIPTION
1 1 313798 Turbocharger for QD32
313297 Turbocharger for TD27
2 1 TDMNISS004 Pulse manifold
3 4 TDM010 X18 Incanol studs 8mm
4 4 DNF X17 Locknuts 8mm
5 1 TDM020 F6 Heatshield for manifold
6 2 826.0650 X12 16 x 8mm bolts
7 2 826.7170 X11 S/S spring washers
8 1 TDM068 Aluminium Sleeve for turbo inducer
9 1 TDM060 X28 Oil out pipe
10 1 TDM104 F7 QD32, TD27 actuator bracket
11 2 SP3-0407 X7 ¼ hose x 7/16 x 24 UNS fitting
12 1 80-025 W7 80mm Purosil hose
13 1 MS8241 X2 ¼ goss hose clips
14 1 TDS1 Turbo back plate (TDM068)
15 3 826.0652 X14 25 x 8mm bolts
16 3 826.7170 X11 S/S spring washers
17 2 826.0650 X12 16 x 8mm bolts
18 1 6020-002 D19 3” V band clamp
19 4 DSF128 E14R Manifold gasket
20 1 670BLK-200 V2 2 ¼” X 2” Turbo hose
21 2 HSO32P HCB9 No 32 hose clamps
22 1 670BLK-250 V4 3” x 2 ½” turbo hose
23 2 HSO40P HCB9 No 40 hose clamps
24 1 TD32001 F10 Cast air out elbow
25 1 A64-02 T13 1/8 BSP plug
26 1 TDM053 F18 Air cleaner mounting bracket with
support bracket and 2 x 6mm
Nylok nuts
27 1 TDM379 Front air cleaner bracket
28 1 Deleted
29 Deleted
30 1 TDM069 F9 Vactuator tube
31 3 186752 F9 1/8 pop rivets
32 1 1365057 F7 3/8 bundy tube 2” long
33 1 FH1010 W4 9” of 3/8 breather tube
34 2 MH004P HCB3 No 4 hose clamps
35 4 CT200B X42 Cable Ties
36 1 HOS580 F8 Oil line
37 1 A7-0402 T11 ¼” x 1/8 BSP flare male union
38 1 TD80*270*16 W22 90° x 5/8 oil return hose
39 1 BP3-1006 C11R 5/8 x 3/8 BSP male connector
40 2 HSO10P HCB5 No 10 hose clamps
41 1 TDS1DP Cast dump pipe
42 3 TDM105 F6 Dump pipe heat shield
43 3 826.0650 X12 16 x 8mm bolts
44 3 826.7170 X11 S/S spring washers
45 1 DDNAV-2MB F4 Adaptor pipe
46 1 TDM378 F8 Engine pipe assembly with flex
47 1 DDNAV3.2- R4 Intermediate pipe
5MB
48 1 TR616CC250- 2 ½” muffler
GP
49 1 DDNAV3.2- R4 Tail pipe
6MB
50 3 C12 W11 Exhaust Clamp
51 1 TDM380 Exhaust Stay Bracket
52 1 TDM065 F14R Gear Box bracket
53 1 TDM066 F13 Straight rod centre hanger bracket
54 1 TDM067 F14F Rear bracket
55 1 Stickers, fitting instructions and warranty
forms
 NISSAN D22 PARTS LIST
NO QTY PART NO. BIN DESCRIPTION
1 1 313798 Turbocharger for QD32
313297 Turbocharger for TD27
2 1 TDMNISS004 Pulse manifold
3 4 TDM010 X18 Incanol studs 8mm
4 4 DNF X17 Locknuts 8mm
5 1 TDM020 F6 Heatshield for manifold
6 2 826.0650 X12 16 x 8mm bolts
7 2 826.7170 X11 S/S spring washers
8 1 TDM068 Aluminium Sleeve for
turbo inducer
9 1 TDM060 X28 Oil out pipe
10 1 TDM104 F7 QD32, TD27 actuator
bracket
11 2 SP3-0407 X7 ¼ hose x 7/16 x 24 UNS
fitting
12 1 80-025 W7 80mm Purosil hose
13 1 MS8241 X2 ¼ goss hose clips
14 1 TDS1 Turbo back plate
(TDM068)
15 3 826.0652 X14 25 x 8mm bolts
16 3 826.7170 X11 S/S spring washers
17 2 826.0650 X12 16 x 8mm bolts
18 1 6020-002 D19 3” V band clamp
19 4 DSF128 E14R Manifold gasket
20 1 670BLK-200 V2 2 ¼” X 2” Turbo hose
21 2 HSO32P HCB9 No 32 hose clamps
22 1 670BLK-250 V4 3” x 2 ½” turbo hose
23 2 HSO40P HCB9 No 40 hose clamps
24 1 TD32001 F10 Cast air out elbow
25 1 A64-02 T13 1/8 BSP plug
26 1 TDM053 F18 Air cleaner mounting
bracket with support
bracket and 2 x 6mm
Nylok nuts
27 1 TDM379 Front air cleaner bracket
28 Deleted
29 Deleted
30 1 TDM069 F9 Vactuator tube
31 3 186752 F9 1/8 pop rivets
32 1 1365057 F7 3/8 bundy tube 2” long
33 1 FH1010 W4 9” of 3/8 breather tube
34 2 MH004P HCB3 No 4 hose clamps
35 4 CT200B X42 Cable Ties
36 1 HOS580 F8 Oil line
37 1 A7-0402 T11 ¼” x 1/8 BSP flare male
union
38 1 TD80*270*16 W22 90° x 5/8 oil return hose
39 1 BP3-1006 C11R 5/8 x 3/8 BSP male
connector
40 2 HSO10P HCB5 No 10 hose clamps
41 1 TDS1DP Cast dump pipe
42 3 TDM105 F6 Dump pipe heat shield
43 3 826.0650 X12 16 x 8mm bolts
44 3 826.7170 X11 S/S spring washers
45 1 DDNAV-2MB F4 Adaptor pipe
46 1 TDM378 F8 Engine pipe assembly
with flex
47 1 DDNAV3.2- R4 Intermediate pipe
5MB
48 1 TR616CC250- 2 ½” muffler
GP
49 1 DDNAV3.2- R4 Tail pipe
6MB
50 3 C12 W11 Exhaust Clamp
51 1 TDM380 Exhaust Stay Bracket
52 1 TDM065 F14R Gear Box bracket
53 1 TDM066 F13 Straight rod centre hanger
bracket
54 1 TDM067 F14F Rear bracket
55 1 Stickers
56 1 Fitting Instructions
57 1 Warranty Forms
NISSAN NAVARA D22 WITH TD27 AND QD32 DIESEL ENGINES