OK, so I finally found a good deal on a turbo to try. The swap looks pretty easy, but I know there are always quirks to any job. I've done brake jobs in 30 minutes and then had them take half the day. So what are the little unseen things to watch out for and how long did it take you. I have access to pretty much every tool I could need. So, how long and what are your tips.
Thanks
By the way, it is already mounted to an ATS manifold. Will it come out and go in that way?

 

Just be sure to take the drain tube off of the old turbo and itstall it on the new one BEFORE you put the new ex. manifold on.

If you have everything you need right there it shouldn't take very long.

intake
exhaust
intercooler pipe
pull oil drain out of the block
take oil feed line off
take cover off of ex manifold
12 bolts yank the whole thing out

Then... go backwards

 

if i read your post right you are replacing the manifold too? if so the heater lines under the exhaust manifold always give me problems where it bolts to the stud towards the back of the manifold, other then that it simple if you go in through the wheel well, it is 8-10 8mm screws and the whole wheel well comes out, take the tire off and you have room for days. have fun, 1-3 hours of work

 

Another thing I did... After you get it bolted up. Crank it without letting it start until oil runs out of the oil drain. Then stick it in the block.

 

I did take the inner fender and wheel off as well. Made it much easier...

I forgot about the heater line. I just cut it.

If you have a helper to hold the manifold up it while you start the bolts it helps alot!

 

Thanks guys
Sounds like the wheel and inner fender are a good tip. So Luken, would you agree it can be done in 3 hours? I thought it looks like 2-3, but I was just making sure it didn't take like 7-8 for some reason I might have missed.

 

You should be able to swing it in 2-3 no problem... If you run into anything just post up and someone will have the answer

 

Hey I just did mine 99% of the way.

Make sure you have everything before you start.

You will need the oil drain tube gasket and since mine was an 03 I needed a new assembly.

I also needed to get two bolts and nuts because the new turbo might not accept studs.

I tried to do it by myeslf and it was pretty difficult if you dont rempve the manafold and do it on the bench. I tried to remove the inner fender well but it woldnt come out so I just left it alone.

Trust me its easier to take the exhaust manafold out and install the turbo on the bench and then reinstall. Like said before install the oil return line before and try to get someone to help you install the heavy setup.

The hose on the turbo out was a little short so I had to move the clamps to get the extra 1.5" it needed. I hope its OK

I really wish there was a FAQ on turbo installs because my truck has been down for 4 days because I didnt have everything I needed I searched but none of this was mentioned.

Also tighten up all your boost hose clamps since you might blow them off with all the more boost you will have.

Goodluck and make sure to remove the battery and dissconect the driverside.

 

[IMG][/IMG]

 

omaha, keep us posted on how that new turbo works out.

 

I plan to start a thread once I get it installed to let everyone know what I think of it. I just hope I can get it done sometime soon. It fits in my garage with the 315s but I have very few tools. My dad has every tool known to man, but it won't go in his garage. So I have to do this in his driveway but right now its very cold in Omaha Nebraska. It also gets dark at 5:30 now. I hope it gets warm for a few days again in the next couple of weeks. I would hate to have to wait until spring.

 

I tried taking the fender well cover out before and it was absolutely useless...didnt help me one bit.

 

The only thing it really helped me with was being able to have my dad hold it up while I was on top starting the bolts.

When I was putting it back together the last time I got on top and held the manifold up with one hand and started the bolts with the other. I agree that it's pretty much useless....

 

I came through the top when I put mine on. Omaha PM me and see if we can work something out. I am about an hour south of you and I could give you a hand if you need it.

 

Hey Sloverado
I haven't been on for a couple days. Where do you live, Neb.City, Auburn? My dad should be able to lend me a hand when I can get time to do it, but thanks a bunch for the offer. I would like to go for a ride in your truck sometime since we aren't too far from each other.