I bought a used 6.5 turbo setup on eBay. It had most of the parts, but the few that were missing made it much more challenging. Ill post the main steps to give anyone considering it a good idea of what they are in for. Its defiantly worth it in the end. I can now hang with traffic when getting on the expressway.
Step one- remove old intake and passenger side exhaust manifold. If you plan on using a manual waste gate control, go ahead and install it on the turbo. You will also most likely have to cut a hole in the floor. My first cut was enough to clear manifold then i test fit turbo to figure out the finale cut.
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Step two - Figure out how you will drain the turbo. YOU CAN NOT HOOK IT INLINE WITH THE COOLER!!. A few guys tried this and blew some seals. You also run the risk of a runaway in the right conditions. It is designed to be drained by gravity only. Option 1 is to modify the oil pan or the valve cover for the drain to flow to. Option 2 - Upgrade mechanical fuel lift pump to electric in order to install the piece for the oil drain from the turbo to connect to.If you dont get this piece with turbo , as was my case, you have to make one. I bought a chrome fuel pump delete plate for a 350 small block, drilled and tapped a 1/2 inch NPT hole, Used a 1/2 inch brass street elbow, and a brass 5/8 barbed fitting. I cut all but the last barb off to clear the drain tube. I suggest screwing the plate to a piece of wood for the drilling and tapping part. Also, tap a little, test fit pipe and repeat until the elbow screws in tight facing up. Cut a 2 inch piece of 5/8 heater hose and put it on the barbed fitting with a hose clamp and hit it with wd-40 to make it easier to insert drain tube. Install it on the engine. You will need 2 short bolts to replace the ones that held the fuel pump.
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Step three -If you are using a pyrometer go ahead an install the sensor port on the inside top of turbo exhaust manifold just below where the turbo bolts on. there is a perfect square spot on the oe manifolds. Install turbo oil drain tube, Install 6.5 turbo exhaust and intake manifolds. You have to use 2 exhaust gaskets to get enough clearance for the injectors, or you can replace them with the short injectors which requires new lines as well. check the injector return hoses for clearance. I had to shorten mine a little.
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Step one- remove old intake and passenger side exhaust manifold. If you plan on using a manual waste gate control, go ahead and install it on the turbo. You will also most likely have to cut a hole in the floor. My first cut was enough to clear manifold then i test fit turbo to figure out the finale cut.
View attachment 30
Step two - Figure out how you will drain the turbo. YOU CAN NOT HOOK IT INLINE WITH THE COOLER!!. A few guys tried this and blew some seals. You also run the risk of a runaway in the right conditions. It is designed to be drained by gravity only. Option 1 is to modify the oil pan or the valve cover for the drain to flow to. Option 2 - Upgrade mechanical fuel lift pump to electric in order to install the piece for the oil drain from the turbo to connect to.If you dont get this piece with turbo , as was my case, you have to make one. I bought a chrome fuel pump delete plate for a 350 small block, drilled and tapped a 1/2 inch NPT hole, Used a 1/2 inch brass street elbow, and a brass 5/8 barbed fitting. I cut all but the last barb off to clear the drain tube. I suggest screwing the plate to a piece of wood for the drilling and tapping part. Also, tap a little, test fit pipe and repeat until the elbow screws in tight facing up. Cut a 2 inch piece of 5/8 heater hose and put it on the barbed fitting with a hose clamp and hit it with wd-40 to make it easier to insert drain tube. Install it on the engine. You will need 2 short bolts to replace the ones that held the fuel pump.
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Step three -If you are using a pyrometer go ahead an install the sensor port on the inside top of turbo exhaust manifold just below where the turbo bolts on. there is a perfect square spot on the oe manifolds. Install turbo oil drain tube, Install 6.5 turbo exhaust and intake manifolds. You have to use 2 exhaust gaskets to get enough clearance for the injectors, or you can replace them with the short injectors which requires new lines as well. check the injector return hoses for clearance. I had to shorten mine a little.
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