ECO DIESEL ADD A TURBO KIT
Note: Please note this kit may require a few special hand tools for installation. Please make sure to have a supply of good quality hand tools, and or have a qualified shop/technician install your kit. This kit will require custom ecm calibrations' as well. Please make sure you have that lined out before installing your kit.
1-Disconnet battery. Locate coolant drain on bottom driver side of radiator, and using a clean bucket drain coolant. It may be re-used of clean. Jack up and properly support front passenger side of vehicle. Remove passenger front tire. Remove bolts and christmas tree clips from passenger inner fender liner, and remove inner fender liner.
2-Unplug Mass air flow sensor on air intake pipe, and unclip wiring harness from lower side of air box. Remove clamp on turbo inlet boot. Pulling up firmly on intake box will undo it from its rubber mounts, and remove air intake assembly. Remove the 4 bolts holding the air box assembly mount to the passenger front fender, and remove plastic mount.
3-Remove isolator from passenger side of engine as shown. Cut zip ties on exhaust transfer tube so insulation may be slid back that tube bolts may be exposed at each end. Remove bolts from each end of the transfer tube, and remove tube. Be sure o-ring stays in place in intake manifold where tube was removed, it will be re-used.
4-Unplug sensor connectors as shown. Unplug vacuum line that runs to actuator as shown. Locate supplied 1/8 vacuum cap, and plug port where vacuum line was just removed.
5-Pull back insulation on rear exhaust transfer tube pipe as shown so bolts may be accessed. Note: We have found these three bolts in this to be torqued very tightly from the factory. Please make sure proper tools are used. Remove two bolts on transfer tube pipe. Using a good T40 torx socket, remove the torx bolt that is facing the firewall on the back of the exhaust cooler as shown. Remove nuts/bolt from exhaust cooler mount's and remove cooler. Unclip wiring harness from side of cooler bracket. Remove bolts from wiring harness mount and remove bracket.
6-Remove two connectors from ecm and connector off main relay mounted on ecm mount bracket. Remove ecm bracket nuts on fire wall and wiring clips on ecm bracket. Remove ecm mount bracket and ecm from vehicle.
7- Be sure to spray the three flange nuts on the back of the factory turbocharger that holds exhaust downpipe to turbo with penetrating oil to prevent the threads from being damaged on removal. Remove v-band clamp holding exhaust to downpipe. Remove sensor from exhaust elbow as shown, and set aside. Remove the three nuts holding the factory exhaust elbow on the backside of the turbo. Remove factory elbow pipe from the vehicle.
8- Note: This next step tends to be a little messy, make sure to have a bucket or drain pan to catch coolant that will still be present in the heater hoses even though system was drained. Remove all red arrowed coolant clamps as shown. Remove the three bolts on the main cooler bracket as shown. Remove the bracket assembly and hoses from vehicle.
9- Locate HSM Intake manifold block plate and two 8mm head factory bolts, make sure factory o-ring remained in manifold and install plate as shown. Torque bolts to 10 inch lbs.
10-Unclip wiring harness off engine oil dipstick tube and remove factory mounting bolts as shown. Remove oil dipstick assembly from engine. Mark dipstick 1" down from the top and cut tube off flush at mark. De-bur and clean all debris out of dipstick tube. Locate HSM dipstick tube adapter/secondary turbo oil drain. Insure 90 degree hose barb and o-ring are in place, slide dipstick tube into adapter and install back onto the engine as shown. Note: Some clearance of the heat shield on the exhaust manifold may be required to get dipstick tube to fit properly. Using a smooth object such as a 2x4 and hammer, clearance heat shield as necessary. Locate supplied 6mmx1.0x45mm bolt and install it through adapter into upper oil pan. Torque to 14 ft lbs. Locate upper oil dipstick support bracket and 1/4x20x1 hardware kit. Install factory bolt through bracket into factory location. Torque factory bolt to 11 ft lbs and tighten 1/4 hardware.
11- Remove abrasive cover on lower heater hose at fire wall. Locate 14" of thermal heat sleeve and install it onto this heater hose. Locate supplied heater coolant hose's, heater hose "T", #8,12 hose clamps, and all thermal heat shield. Locate 14" piece of thermal heat shield and slide it onto the driver side heater hose where it comes out of firewall as shown. Locate plastic heater hose "T" and install 5/8 barb into driver side heater hose with one #8 clamp. "T" fitting will have one 5/8 barb and one 3/4 barb facing down towards passenger inner fender well, it will rest behind ecm bracket installed in a later step. Locate 90 degree 5/8x3/4 heater hose, 29" of thermal sleeve, one #8 hose clamp and one #12 hose clamp. Slide 29" of thermal sleeve over 90 degree heater hose and install short leg (3/4 side) onto engine fitting facing toward front of vehicle as shown. Install #12 hose clamp onto that end a tighten clamp. Slide thermal sleeve down hose touching or over the clamp. Route 5/8 end of that hose up behind where ecm bracket will go onto 5/8 barb of "T" fitting as shown. Tighten #8 clamp.
12- Locate 20" of 3/4 heater hose, 16" of thermal sleeve, and two #12 hose clamps. Install thermal sleeve onto 3/4 heater hose and install one end of hose onto the heater hose fitting behind the alternator using #12 hose clamp as shown and tighten clamp. Move other end of 3/4 heater hose up to heater hose "T" fitting, install on 3/4 barb with #12 hose clamp and tighten clamp.
13- Remove factory clamp at junction on passenger side heater hose a shown. Slide hose apart and install last section of 21" of thermal sleeve onto upper portion of factory hose. Slide heater hose back onto junction barb and re-install factory clamp. All hoses will have to zip tied out of harm's way or together as shown. It is up to how the installer feels is best once the rest of the parts have been installed.
14-Remove ecm and main relay from ecm bracket. Mark and cut ecm bracket as shown. Placing the ecm bracket in a vise and using a sawsall works best. De-bur bracket after cutting so there are no sharp edges. Drill a 1/4 hole in approximate location in ecm bracket as shown for a zip tie. Re-install main relay and ecm onto bracket. Re-install ecm bracket into vehicle on factory studs so that the heater hose "t" and hoses run behind bracket and are routed with no kinks. Using factory nuts tighten hardware. Re-connect ecm connectors and main relay plugs. Using provided zip ties, zip tie heater hose to ecm harness as shown.
15-NOTE: If the studs in the back of the turbo came out during exhaust pipe disassembly that attach three bolt flange to back of turbo, please make sure they can be cleaned and re-installed.
15a- Locate HSM intermediate pipe assembly. Insure factory gasket is on the studs on the factory turbocharger. Install pipe assembly onto turbocharger using factory nuts, leaving a little loose at this time. Locate 2 spacers and the two 10mmx1.50x35mm flange head bolts. Put spacer's onto bolts and install into support bracket on intermediate pipe into cylinder head. Torque nuts on back of factory turbocharger at this time to32 ft lbs. Torque support bolts to 36 ft lbs.
16- Locate HSM wastegate pipe elbow and wastegate assembly. Insure that wastegate seat is installed into bottom of wastegate as shown. Install plugs and fitting into wastegate head as shown. Make sure factory gasket is still attached to factory pipe for the two bolt wastegate inlet flange. Install HSM elbow onto the inlet side of the wastegate using the supplied clamp before putting into the truck. This will take a bit of pressure on the wastegate seat to get the clamp on correctly. Once the clamp is on leave it just a little loose so elbow can be rotated on wastegate. Install elbow and wastegate onto intermediate pipe on vehicle. Rotate elbow so all flanges line up. Using 5/16 bolts, flat washers, lock washers and nuts, install into the two bolt flange on other end of HSM elbow leaving loose at this time. Install clamp onto other end of wastegate flange insuring flanges are lined up, tighten clamp at this time. Tighten 5/16 hardware on other end of elbow to 25 ft lbs.
17-Locate turbocharger assembly. Install oil drain fitting onto bottom of turbo as shown using gasket and provided 3/8 hardware. Tighten drain bolts. Locate turbo mounting gasket, four 3/8x16x1.5 bolts, and four 3/8 flange nuts. Mount turbo using gasket and 3/8 hardware, tighten bolts to 35 ft lbs. Locate upper exhaust downpipe and exhaust v-band clamp. Position upper downpipe up into place, and install using exhaust band clamp, leaving a little loose so pipe may rotate. Locate lower downpipe and install onto upper using provided band clamp. Button up all exhaust components at this time. Inspect and tie all heater hoses and wiring at this time to make sure it is routed away from exhaust components.
18- Locate factory crankcase breather sensor under wiper cowl on factory turbo inlet boot. Unplug sensor. Rock and twist hose(will be tight) and pull out of factory inlet boot. Looking up from driver side rear of engine, loosen intake boot clamp. Remove factory turbo inlet boot from vehicle. Locate HSM custom 120 degree intake boot and 3.25 t- bolt clamp. Insure inlet on turbo is clean and has no oil residue , install boot onto turbo inlet and clamp so it may be accessed. Position boot and clamp as shown and tighten clamp. Locate HSM 2.5" intercooler pipe, 2.5" straight boot and three 3.0" t- bolt clamps. Using glass cleaner spray it inside boots that intercooler pipe will slide into. Slide pipe into boots on both turbocharger ends, make sure it fits correctly on each end. Install clamps and tighten.
19-Locate HSM oil supply line components as shown. There are two different ways to feed the turbo oil. If you have an HSM oil cooler installed on the vehicle, there is a port on the top side of it for oil supply to the turbo. This option: Remove 1/8 pipe plug from top of oil cooler plate. Use 45 degree 1/8 pipe thread to dash 4an fitting and install it in the top of the HSM oil cooler plate using thread sealer only on the pipe threads. Orient fitting away from engine just as it starts to get snug as pipe threads should. Make sure oil supply line is clear and clean of all debris and install onto oil supply fitting on oil cooler and turbocharger, tighten both fittings. Option 2: Locate factory oil pressure sensor on the driver side of the engine down below the oil filter cap. (1 wire connector) Remove sensor from oil filter housing. Locate HSM oil feed adapter and install factory oil pressure sensor into end of it. Torque sensor to 20 ft lbs. Install adapter into oil filter housing and torque to 20 ft lbs. Locate -4an 90 degree pipe fitting. Put thread sealer on the pipe threads only and install it into the oil feed adapter 1/8 pipe port. Orient fitting so the oil feed line can go onto it as shown. Tighten oil feed line fittings.
20-Locate two number 8 hose clamps and 22" turbo oil drain line. Install oil drain line onto bottom of turbo and the other end onto the oil drain adapter where the oil dipstick was previously installed. Tighten clamps.
21-Locate wastegate pressure regulator, fittings,clamp and 1/4 hose. Install 1/4 barb fitting into HSM Intake block plate or another suitable boost pressure source. Install plugs and fittings into regulator as shown in diagram. Run the "out" hose on the regulator to the port on the wastegate. Tighten clamp.
22-Re-install passenger side factory inner fender liner, and passenger tire. Torque lug nuts to factory spec. Remove factory MAF sensor from air intake assembly. Locate 90 degree intake boot and install MAF sensor into the reduced side of the boot with the flow arrow on the sensor going toward the turbo. Locate 4" worm gear clamps and install 90 degree intake boot onto turbo as shown. Orient so air filter may be installed and not rubbing on anything. Tighten all clamps. Locate MAF sensor extension harness and install into factory MAF connector. Plug other end into MAF sensor. Zip tie as needed.
23-Install factory crankcase breather hose fitting into breather hole on 90 degree intake boot. Locate breather sensor extension harness and install into factory breather sensor connector. Plug other end of connector into sensor.
24- Inspect all installed parts and fittings to insure they are tight and installed correctly. Refill engine cooling system with specified factory coolant. Reconnect battery. Start engine and verify there are no leaks. Enjoy your ECO DIESEL Turbo kit!!