Some of you may have seen this on a couple other forums. Figured it may come in handy here also.
Ok. Never written a tech article, so Ill give it a whirl...reason being, there was some stuff I encountered that I really wasnt expecting, so maybe someone will stumble upon this and be a little better prepared than I was.
First things, obviously, need the new turbo and tools, and a truck to work on. Unhook the batteries.
I left the stock intake box/filter in, and just pulled the tube from it going to the turbo. Then I unhooked the intercooler boot. Actually I took out the cast elbow off the factory turbo before that, to see if it would hook directly to the new turbo. The clamps for the elbow are 7/8, as are the clamps on the intercooler boot.
Industrials website says for an 03/04, regardless of transmission, and 04.5+ automatics need an HX40 downpipe. I didnt know the stock elbow and exhaust would bolt up, but it does.
Heres the cast elbow Im talking about. Notice the locating pins. Just take a pair of Vise-Grips or pliers and pull them out.
Heres what you'll be looking at, with the elbow off, the intake off, and the intercooler boot unhooked:
Notice in the pic above. Right next to the oil filter is a wire disconnected. This goes to the wastegate on the stock turbo. I got a boost fooler from Industrial, and thats where it connects.
I originally was going to leave the manifold on, and just take off the turbo. Found out pretty quick that access to the two bolts closest to the block would be, well, difficult. Ended up taking the manifold off. The heat shield is held on by 15mm nuts. After removing that, the manifold bolts are 13mm. Heres where I ran into some things I had overlooked.
Theres some metal tabs on the rear-most bolts, top and bottom. Of course, I didnt have anything that would cut through them. Obviously Cummins figured it would be funny to throw those on there, just to mess with people. I ended up getting irritated and just grabbed them with pliers and worked them back and forth until they tore. That was obstacle #1. Obstacle #2 was the coolant line heading to the heater...
You can see it run along the block in this pic. This is after removal of the turbo/manifold. The line runs up and connects to a hose. Theres also a bigger hose near the bottom (has the rag stuffed into it...) Unhooking this will drain most of your coolant. I really wasnt expecting to lose that much, so I made a pretty good mess...
The nut holding this line to the manifold bolt is 15mm. The lower bolt for this line is also 15mm.
Another view:
I left the oil supply and drain lines for the last. Oil drain has 2 10mm bolts. Oil supply line was 13/16.
You can see the drain line here:
Linear Mode
