I got the HTB2 and HT intercooler yesterday. The i/c went in easy. Now it's time for the turbo. Instructions say some people take off exhaust manifold to make it easier. Any tips would be appreciated.

 

I pulled the exhaust manifold and seems like that is much easy than just trying to pull the turbo. https://www.dieseltruckresource.com/...=turbo+install
Here is a thread with a few opinions about the install.

 

I would pull the exhaust manifold trying to get to the bolt on the back side is a bear!!!.... Just be careful when you pull the manifold the gaskets can go every direction and for reference there if four for each cylinder....

 

Every response on the other thread said remove it also, so that'll be it. Thanks, can I reuse the 24 exhaust gaskets that I'll pick up off the ground?

 

I have heard that there are several gaskets for each cylinder, but when I pulled mine I only had 6 total gaskets, or 1 per cylinder. Is there a different number of gaskets for the 03-04 trucks as compared to the 04.5 and up trucks?

 

Cometic has come out with a new Exaust mani gasket that is a 3-piece gasket that is all riveted together for three cylinders. I used this for the last turbo install I did and it was a breeze. I'll see if I can't get the Link

 

HERE YA GO IT WILL MAKE PUTING THE MANIFOLD/TURBO COMBO ON THE HEAD A BREEZE: http://www.competitiondiesel.com/for...616#post270616

 

You have to take the ex. man. off but what ever you do, don't bolt the turbo to it! You need to bolt the drain tube up first, the bolt closest to the engine is a real son of a gun. Have to slip your hand in between the turbo and engine and use index and middle finger to grab a few threads while a guy is underneath with a magnet to hold it. Get a gear wrench and cut it in half. Only tool you can use to tighten that particular bolt. Also, you have to cut the ex. system hangars and slide the system back 2" or so. I did it, and took me two days because HT didn't mention anything about the ex. system mod.

 

Forgot to mention, being the turbo is back a bit, you'll have just enough boost tube poking inside the hoses, maybe a 1/2" either side.

 

make sure you oil the turbo before you start the truck, too

 

i bolted the turbo to the manifold before i put it in, there was no way the else for me to do it, the wastegate was hitting something and would not go down low enough to get the studs into the flange. i got under the truck and my buddy was under the hood and went in pretty easily that way. and BTW i had 2 gaskets for each cylinder. the oil drain tube was a little tricky this way, but i got it to go into the pan after playing with it a little.

 

Yah, read my comedy of errors thread on my Silver 62 install.... can be a real pain

 

I had all the same issues with the install and pulling the manifold will save many, many cuss words. That back bolt is just ridiculous too!! Put the oil drain tube on the turbo but then get the manifold bolts all started and while they are still loose you get the end of the tube situated in the block.
As for oiling the turbo, I can attest to the need for that. I did not oil my brand new stock turbo before I put it back on the truck and now it's making a howling noise. Now I have to buy another one to replace it...
The whole thing shouldn't take more than an hour or hour and a half.....

 

How did the exhaust line up?

 

I had to pull the exhaust back towards the front of the truck about 1" to hook it back up to the stock turbo...