sammy198

This is the first build thread I have done (ever), so please bear with me as I make my way through this...

I have a 2001 2500 with 275rv injectors, Smarty, BHAF, and a Goerend built transmission. The tiny little hy35 makes for a smokey (and high EGT) truck, and I have wanted to change that for a long time. My Goal is much less smoke (especially off idle) and better airflow.


I have yet to find a full e2e write up of this swap, and there is no 'kit' to do it. I hope this thread will help others to understand what is needed to make it happen.

This post will outline the big things I bought to make it happen and I will update with posts of each of the major steps...

Fleece controller (can you even buy this thing anymore????) I got this in October 2013 and have been sitting on it:



Turbo: High tech turbo HE351VE with 63mm compressor





H#351VE 63MM compressor (and a preview of the manifold...




Sam

sammy198

One of the triggers to start the work now was a leaky (and very stopped up Radiator). It made sense to do the turbo work at the same time as I would have much more room to work.

So, I pulled the radiator.... and wow the breather issues these trucks have is no joke.

I wanted to put in the fleetguard oil seperator (cv50115) but it is discontinued and I can't find one anywhere . If you know where one is I will buy it at (almost) any price Otherwise I am going to vent it over the back of the motor. Cant have the new rad end up looking like the old one




So much oil... Will move breather as part of the project



Hard to see, but its cracked in the middle of this picture



So much room for activities...

sammy198

The HE351VE has a T4 flange and is too big to fit over the shock tower with the stock 2nd gen manifold so it must be replaced with a 6.7 manifold.

I got one off ebay and it was strange because it only has the rear EGR port

No matter the type of 6.7 manifold you get there are 3 things you need to address.
1. EGR ports: You need to get (or make) blockoff plates for a 6.7 EGR delete.
2. EGT gauge: I drilled and tapped a hole directly over the turbo flange. I feel this is the best location to get a true reading of the temps
3.Pressure port: Some people put the EGT gauge here. I didnt want to do that as it is around cylinder 3 and I want to measure off 6... So what do you do?!?

Weld it of course




The offending port. This must go!



Cut it off with a grinder



Drill it out so you have something to weld to. DO NOT DRILL ALL THE WAY THROUGH



Preheat it. I only have Mapp gas at the house, so this was a pretty crap preheat...



Weld it up (isn't flux core wire pretty)



Grind it smooth, Im not 100% happy with this weld but I think it should work fine for the pressure it will face. If it cracks or leaks i will get another manifold.



I took the time to flap disk the manifold to remove casting lines etc. I followed that up with a wire wheel to get the areas the flap disk wouldn't go.



Drilled and tapped EGT probe over the flange.

sammy198

Too many pictures it seems. This is the finished product.




Complete manifold (without blockoff plate installed)

sammy198

So, now it is time to remove the old turbo and manifold.

This is pretty straightforward so I will only put a few images for reference.



Remove exhaust and oil lines from turbo. I had to remove the rear flange as the downpipe bolts were very stuck.



Turbo off! next step is to cutoff and remove existing downpipe and deal with the transmission cooler....

sammy198

The transmission cooler is the next thing to be removed. It is sitting right where the new turbo needs to live so its got to go.

However, I am not bypassing it. I want to keep it as I believe it helps to manage the temp of the transmission (both helping to warm it up, and keep it from extreme overheating).

So, I will be relocating it to the front of the engine bay behind the bumper.





Remove transmission lines and catch fluid that drains. Cut, remove coolant lines. You can then unbolt the 4 mounting bolts.



Remove cooler. This is what you are left with.

sammy198

You are now caught up to where I stand today... I should be knocking out a lot this weekend so hopefully I will have a big update then.

Next steps are:
1. Remove un-needed hard coolant lines.
2. Figure out mounting of trans cooler
3. hang the new turbo and manifold
4. Deal with wiring of turbo controller.....

Let me know if you see anything I am going way off track on! I am always open to suggestions of better ways to make this work.

Sam

patdaly

Very nice build and documentation!

Keep up the good work.