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Old 03-19-2011, 02:39 PM   #2
jlibert
 
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Name: jlibert
Title: Too Much Time
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Join Date: Jun 2007
Location: CA
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Posts: 3,454
22. Install electrical pigtail supplied in kit onto male connector near oil filter.
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23. Using bolts and spacers shown below, Install supplied spacers between Air Conditioning component and mounting bracket.
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Note: larger spacer installed on bottom, smaller spacer installed on top.
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24. Using supplied gasket, attach factory flexible oil drain line to top turbo with factory bolts.
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25. Install top turbo onto exhaust manifold. Verify that all steel gaskets are in place along with steel spacer.
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26. Rotate bottom turbo housing so that hot pipe aligns with exhaust flange on top turbo. Upon proper alignment of hot pipe, install factory v-band clamp.
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27. tighten exhaust housing bolts on top turbo. Leave intake housing fasteners loose.
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28. Tighten exhaust housing clamp on bottom turbo
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29. Attach factory oil drain line on top turbo to longer section of blue silicone hose that should already be installed into front port near oil pan.

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30. Fill top turbo with oil while rotating turbo shaft.
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31. Attach longer braided steel oil supply line to bottom turbo.
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32. Attach shorter braided steel oil supply line to top turbo.
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33. Install oil supply fittings onto factory oil filter housing. 45* fitting is installed on the rear of the housing where factory supply line was located. The 90* fitting is installed on top of the housing by removing the factory plug. Connect oil supply lines to fittings.

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Click the image to open in full size.
34. Loosen both 10mm bolts at top corners of intercooler. This step will allow the intercooler to be pulled forward to facilitate the installation of the top turbo to intercooler piping.
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35. Test fit piping without installing silicone boots. Rotate top and bottom turbo housings as needed to achieve proper alignment. Everything WILL line up properly, but some patience is required here. Every truck is a little bit different, some may require slightly different alignment than others.



36. Install intake boot and piping onto bottom turbo compressor housing. Secure clamps, and install intake air temperature sensor as shown here:
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37. Verify that charge air pipe connecting bottom turbo to top turbo has a rubber o-ring installed in the groove near the flange. This flange will be placed on the compressor outlet of the bottom turbo. Loosely install supplied clamp so that it attaches the piping flange to turbo flange.
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38. Secure intake piping and charge air piping by aligning tabs and installing the supplied bolt and lock nut.
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39. Slide silicone boot onto piping using soapy water or glass cleaner. Rotate piping so that it aligns with top turbo. Slide boot off of piping and over the outlet on the top charger and secure with supplied clamps. Tighten compressor housing clamp on bottom turbo after proper alignment is obtained.










40. With intercooler bolts removed, lift up on intercooler and pull it away from the engine. This step will allow a couple additional inches of clearance necessary to install piping from top charger to intercooler.
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41. With intercooler pulled back, install rubber boot on intercooler, then slide end of piping into boot. Slide other boot onto top turbo outlet. Connect piping to top turbo. Install and tighten boot clamps.
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Click the image to open in full size.

42. Remove factory intercooler piping boots on driver’s side of engine and replace with source automotive boots supplied in kit.
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Click the image to open in full size.
43. Install air filter and verify that it is not making contact with any other components. It is always a good idea to verify that no foreign objects have fallen into piping—double check before installing filter.
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44. Re-fill coolant lost when bending factory coolant line.
45. Double check all connections.
a. Oil supply line fittings tight?
b. Oil drain lines snugly inserted in block?
c. Turbos filled with fresh oil?
d. Coolant level ok?
e. Coolant hose clamps tight?
f. Turbo housing clamps and bolts tightened after rotating turbo housings into place?
Your engine compartment should look something like this:
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Take a minute to admire your hard work, and beautiful new set of twins.


If all steps above have been completed, connect battery cables and start engine. Let idle for 5 minutes. During initial startup and idle period, check for leaks. Shut down immediately if any leaking occurs.

Turbo seals are tight from the factory. Spool up will be a bit slow until seals have loosened up. Allow approximately 100 miles for proper break in.
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J.P. Libert
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