Well hears the progress on my truck as of last night. we started it last week.
Got the heads torqued down which isnt fun.The worst part was that my torque wrench only had an 18" handle and we have the motor kind of sitting on the ground as we were too lazy to build a cradle for it. My back and shoulders are killing me to say the least. Not too mention all of the coolant on the floor made for some interesting slips and falls that entertained the rest of the people standing around drinking and laughing at me.
In between torqueing of the heads we decided to mount the turbo. The pedestal is not a bolt up deal I learned. I spent a lot of time grinding it down to get it to clear the intake manifold. Then i had to grind another peg to clear the block. I then cleaned out the ports a little bit with the die grinder as they were left a little rough. Once that was done I had to drill the threads out of it in order to attach the 3" riser block as PPE sent me the pedestal for the 40 series instead of the 42 series. Finally that was done and we were able to get the riser bolted up only to find that it too and the gasket hit the manifold, so out came the grinder again.
Finally time to bolt up the turbo, we got it partially bolted up and realized that we forgot to attach to oil return pipe. We attached it only to find out there was no way to get it to attach to the block. we called it a night there, but i decided to finish the torque sequence on the heads. While waiting I decided to try installing the return pipe first before the turbo. Hey that worked. Now it was just a PITA to get the bolts in but I did, only to find out that i had to split the turbine housing from the rest of the turbo to gain acess to one of the nuts which meant removing the return pipe bolts again. After some wiggling I was able to get in there to tighten the turbo down. Now I was able to hook the oil lines up, however the return line gasket was kicking my arse so I gave up. Remind me that I need to install that incase I forget.
I finished the torque sequence of the heads an reinstalled the exhaust manifold.
I was on my way to have all of the front brackets back on until I found a gash in a coolant line that gets tucked behind the fan pulley. its the first part that has to go on before anything else up front can go on, so that put a big dent in the progress. Fortuneately I can get a new line tomorrow.
The biggest setback right now is that I found out It is highly suggested to replace the injector return line bolts as they tend to leak if reused. I have to install the return line before I can reinstall the injector harnesses and valvecovers. and of course the valvecovers have to be on before I can stay putting all of the stuff back on top of the motor.
another set back is that I have to wait for my FPR and CP3 rear plate to come back from SJD as they are being modified. This also puts a dent in it as I have to leave the fuel system partially together and cant install the wiring harness and intake bridge. Im expecting these on wednesday or thursday. Once they come in and we get them installed the motor can go back in the truck.
until then we are going to get as much motor work done as possible and get the E Locker installed and the front diff back in the truck.
The only worry I have now is that I dont have a good way to lift the motor. Yes getting it out was easy as the chains on my engine leveler for my cherry picker were just long enough. however the new turbo sits 8" higher than the old one so a longer chain is needed. No big deal but I dont know if my cherry picker lifts high enough to cget my motor set in place.
I also learned that if you let your trans sit, the fluid will settle into the pan and puke out the dipstick tube hole leaving a big puddle on the floor.
Still hoping to fire this thing next weekend. Then all we have to do is build the intake with air shutoff and the truck is road worthy again.
Heres some thumbnails just click them to make them bigger.
Got the heads torqued down which isnt fun.The worst part was that my torque wrench only had an 18" handle and we have the motor kind of sitting on the ground as we were too lazy to build a cradle for it. My back and shoulders are killing me to say the least. Not too mention all of the coolant on the floor made for some interesting slips and falls that entertained the rest of the people standing around drinking and laughing at me.
In between torqueing of the heads we decided to mount the turbo. The pedestal is not a bolt up deal I learned. I spent a lot of time grinding it down to get it to clear the intake manifold. Then i had to grind another peg to clear the block. I then cleaned out the ports a little bit with the die grinder as they were left a little rough. Once that was done I had to drill the threads out of it in order to attach the 3" riser block as PPE sent me the pedestal for the 40 series instead of the 42 series. Finally that was done and we were able to get the riser bolted up only to find that it too and the gasket hit the manifold, so out came the grinder again.
Finally time to bolt up the turbo, we got it partially bolted up and realized that we forgot to attach to oil return pipe. We attached it only to find out there was no way to get it to attach to the block. we called it a night there, but i decided to finish the torque sequence on the heads. While waiting I decided to try installing the return pipe first before the turbo. Hey that worked. Now it was just a PITA to get the bolts in but I did, only to find out that i had to split the turbine housing from the rest of the turbo to gain acess to one of the nuts which meant removing the return pipe bolts again. After some wiggling I was able to get in there to tighten the turbo down. Now I was able to hook the oil lines up, however the return line gasket was kicking my arse so I gave up. Remind me that I need to install that incase I forget.
I finished the torque sequence of the heads an reinstalled the exhaust manifold.
I was on my way to have all of the front brackets back on until I found a gash in a coolant line that gets tucked behind the fan pulley. its the first part that has to go on before anything else up front can go on, so that put a big dent in the progress. Fortuneately I can get a new line tomorrow.
The biggest setback right now is that I found out It is highly suggested to replace the injector return line bolts as they tend to leak if reused. I have to install the return line before I can reinstall the injector harnesses and valvecovers. and of course the valvecovers have to be on before I can stay putting all of the stuff back on top of the motor.
another set back is that I have to wait for my FPR and CP3 rear plate to come back from SJD as they are being modified. This also puts a dent in it as I have to leave the fuel system partially together and cant install the wiring harness and intake bridge. Im expecting these on wednesday or thursday. Once they come in and we get them installed the motor can go back in the truck.
until then we are going to get as much motor work done as possible and get the E Locker installed and the front diff back in the truck.
The only worry I have now is that I dont have a good way to lift the motor. Yes getting it out was easy as the chains on my engine leveler for my cherry picker were just long enough. however the new turbo sits 8" higher than the old one so a longer chain is needed. No big deal but I dont know if my cherry picker lifts high enough to cget my motor set in place.
I also learned that if you let your trans sit, the fluid will settle into the pan and puke out the dipstick tube hole leaving a big puddle on the floor.
Still hoping to fire this thing next weekend. Then all we have to do is build the intake with air shutoff and the truck is road worthy again.
Heres some thumbnails just click them to make them bigger.
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