cookie, if you can, please make this a sticky......
corresponding pictures can be found in my gallery (it wouldnt let me put them right into the post), hope everyone enjoys
-Brandon

Turbo Removal and Installation<?xml:namespace prefix = o ns = "urn:schemas-microsoft-comfficeffice" /><o></o>

1) Drain engine oil and let truck sit until cool.

2) Remove the intake system.

3) Remove the intake y pipe and boots and plug up intake plenum openings (shop rags do the trick well.).

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4) Unbolt the turbo downpipe.

5) Unplug the ebpv wiring harness and unscrew the harness from the compressor housing of the turbo. Unhook the ebpv actuator by sliding the retaining collar back on the actuator rod and pulling the actuator rod off of the valve.

6) With a 13mm socket and a breaker bar ratchet or impact gun, loosen and remove the top two exhaust collector flange bolts.

7) Weld a short 13mm open ended wrench at a 90* angle to the end of a piece of 1/2” pipe. Use vise grips pliers on the other end of the pipe to turn the wrench. Use the newly constructed wrench to break free the bottom passenger side nut on the exhaust collector flange. Back the nut the rest of the way out by hand

8) With the breaker bar ratchet, a 3/8” extension, and a 13mm swivel socket, break free the bottom, driver side nut on the exhaust collector flange. Back the nut the rest of the way out by hand.

9) Reach under the turbo pedestal and feel the four 10mm bolts holding the turbo to the pedestal. A small mirror helps to find the bolts and also check for any leaks from the turbo pedestal where it meets the oil passages to the block. If there is an oil leak present from where the block meets the pedestal, the o-rings between the pedestal and block will have to be replaced. The pedestal can be removed much easier after the turbo is removed. My pedestal didn’t leak, so I did not remove the pedestal to replace those two o-rings.

10) Using a combination of different length 10mm combination wrenches, loosen and remove the four 10mm bolts on the underside of the turbo pedestal which are holding the turbo to the pedestal.

11) If your hands do not fit under the pedestal, or you need to replace the pedestal o-rings, unbolt the four 10mm bolts on the pedestal using a combination of extensions, swivels, and 10mm (I believe) sockets. The rear, driver’s side pedestal bolt is brutal to access with the ebpv actuator in place.

12) Once all the bolts holding the turbo to the pedestal and the exhaust housing to the collector flange have been removed, the turbo can be removed from the pedestal by pulling it up and out.

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13) Unbolt the ebpv from the exhaust housing using an 8mm, 12pt wrench or socket.

14) Clean the ebpv butterfly valve of excessive carbon buildup and check the valve for proper, uninhibited function.

15) Bolt cleaned ebpv to exhaust housing of new turbo.

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16) Inspect the new turbo and lubricate the bearing (through the bottom two oil passages on the center section) with engine builder’s lube. Rotate the shaft several times by turning the compressor wheel by hand. Add a small amount of new engine oil and repeat the rotating step to ensure that the turbo bushing will have proper lubrication on startup.

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17) Remove the old metal gasket from the exhaust collector flange on the up-pipes and replace with a new metal gasket.

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18) Place new o-rings on the turbo center section oil passages (I used a little bit of grease to hold the o-rings in place while placing the turbo back on the truck).

19) Place the turbo onto the pedestal and seat against the exhaust collector flange. Check for proper fit against the collector flange and the pedestal.

20) Reach under the turbo pedestal and hand thread the four 10mm bolts intot the turbo and tighten with 10mm wrenches.

21) Attach the two 13mm nuts and two 13mm bolts to the exhaust collector flange and tighten very snugly. (I used a little anti-sieze on these.)

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22) Reattach the downpipe and ebpv actuator rod.

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23) Unplug intake plenums and reinstal the intake y-pipe and boots to intake plenums and turbo compressor outlet.

24) Reattach ebpv wiring harness to turbo compressor housing and plug back in.

25) Reattach intake system.

26) Recheck all bolts for tightness.

27) Refill engine with engine oil and replace oil filter.

28) Start truck and check for leaks (oil, air, exhaust).

29) Allow truck to idle for a few moments to ensure oil finds its way up into the turbo before moving. This also provides valuable time to plaster an ear to ear grin on your face.

30) Enjoy!

 

Nice Job! Would be a nice sticky. either way Link saved!!