PowerMax Diesel Upgrade For Duramax Engines

Transcription

PowerMax Diesel Upgrade For Duramax Engines
Installation Instructions
2001-2004 Chevrolet / GMC 6.6
(Silverado/Sierra Duramax LB7 Diesel
Parts List
Item
1
2
3
4
5
6
7
Part Number: 766172-0001
Tools Needed
Description
Qty
Turbocharger
PN 765563-1 Exhaust Outlet Kit
Exhaust Elbow
V-Band Clamp
V-band Clamp Nut
Heat Shield
Bolt, Heat Shield M6x1-10
Exhaust Elbow Bracket
Bolt, Bracket M8x1.25-20 12-point
Washer, Bracket Bolt M8
PN 765562-1 Turbine Inlet Kit
Turbine Inlet Adapter
Bolt M10x1.5-25
Turbine Inlet Gasket
PN 765565-1 Water line Kit
Passenger-side Water Line
Driver-side Water Line
Bolt, Banjo M14
Crush Washer
PN 765564-1 Oil Line Kit
Oil Outlet Gasket
Oil Outlet Adapter
Bolt, Oil Outlet (M8x45)
Oil Inlet Adapter
Bolt M8x1.25-20 12-point
O-ring, Oil Inlet Adapter
Oil Inlet Line
Crush Washer
PN 765561-1 Compressor Inlet Kit
Compressor Inlet Adapter
Compressor Inlet Gasket
Bolt, Compressor Inlet (M6x1-25)
Instructions, installation
1
1
1
1
1
1
3
1
1
1
1
1
4
1
1
1
1
2
2
1
2
1
2
1
2
1
1
4
1
1
1
3
1
Safety glasses
Catch basin for engine
coolant
7/16” deepwell socket
8mm 12-point socket
10mm socket
12mm socket
13mm socket
14mm socket
15mm socket
16mm socket
16mm combination
wrench
17mm socket
10mm hex socket
Torque wrench
Various extensions and
adapters
• NOTE: Bolt and fastener sizes may be different
from one model year to the next depending on OE
specifications. Different tools than those listed above
may be required.
Recommended Other Items
Item
1
Description
Qty
2
2
Turbine Inlet Gasket
Exhaust Manifold Pipe Gasket
2
3
Oil Drain Gasket – Block
1
4
Coolant (Gallons)
2
IMPORTANT INFORMATION - PLEASE READ CAREFULLY
We recommend that this turbo upgrade kit be installed by a qualified automotive technician. If you have any doubts as to
your ability to install this turbo upgrade kit, consult with a local automotive repair facility. Please be sure to carefully read all of
the attached instructions prior to starting the installation process. If you have any questions about the enclosed parts or the
instructions, call the distributor that you purchased the kit from for clarification.
Prior to installation, be sure that the vehicle is parked on a level surface and the engine is cool. Engine fluids and
components are extremely hot during normal vehicle operation. Avoid direct contact of engine fluids or components with
your skin; may cause personal injury.
Doc. 737639-26 (Rev - )
www.TurboByGarrett.com
1
Return Policy
Only unused and complete merchandise will be accepted for return subject to inspection and
acceptance by Honeywell Turbo Technologies. No goods will be accepted without prior return
authorization from Honeywell Turbo Technologies. No returns are accepted after thirty (30) days
from original ship date from Honeywell. All accepted returns are subject to a 20% restocking charge
- NO EXCEPTIONS.
Damaged Shipments
The customer must file a claim with the shipping company if goods arrive in a damaged condition.
The customer must also notify the distributor from which the goods were purchased with pertinent
information.
Refused Shipments
Sending a shipment back to The Garrett Garage (or Honeywell) does not automatically give rise to a
complete refund or credit. Honeywell Turbo Technologies may, at its sole discretion require different
payment means for any shipment refused and then reshipped. It is the customer’s responsibility to
make all arrangements with Honeywell Turbo Technologies for disposition of refused shipments.
Shortage or Discrepancy Claim
Shortage or Discrepancy claims must be reported within forty-eight (48) hours of receipt of goods to
the distributor from which the goods were purchased. The Honeywell distributor will determine the
best solution on how to address shortages or discrepancies.
Limited Warranty
Honeywell Turbo Technologies warrants to the original purchaser of its Turbocharger Products that
such Turbocharger Products will, for a period of 1 year from date of shipment and subject to the
Limitations on Warranty, be free from defects in materials and workmanship. For approved warranty
claims Honeywell Turbo Technologies will, at its sole discretion, either credit the original purchaser
in an amount equal to the original purchase price, or replace the applicable Turbocharger Product
free of charge, within 60 days of Honeywell Turbo Technologies’ approval. This is purchaser’s sole
and exclusive remedy and provides the complete financial responsibility of Honeywell Turbo
Technologies for a warranty claim. To be eligible for reimbursement, Customer must (a) submit all
warranty claims to Honeywell Turbo Technologies within 30 days of the discovery of the alleged
Turbocharger Product defect; and (b) complete and return a Returned Material Authorization Form.
Consumers are required to work through Honeywell’s distributors in order to process any warranty
claims.
When Honeywell Turbo Technologies requires the examination of a failed part, Honeywell Turbo
Technologies will promptly notify Customer and will await receipt of the failed part before further
processing the warranty claim. If Honeywell Turbo Technologies ultimately determines that the
failed part is covered under the Limited Warranty, Honeywell Turbo Technologies will reimburse
Customer for the actual cost of ground shipment for any part found to be defective.
Doc. 737639-26 (Rev - )
1
Limitations on Warranty
The Limited Warranty does not apply to any parts: (a) not used in accordance with Honeywell Turbo
Technologies’ written instructions (b) for which no fault is found; (c) that have been modified in any
manner not specifically approved by Honeywell Turbo Technologies; (d) for which an inspection
indicates that reasonable and proper installation and/or preventative care and maintenance has not
occurred; (e) that have been subject to damage attributable to or caused by misuse, abuse or
vandalism; mishandling, improper shipping or other transit related damage; acts of god or
insurrection; foreign object entry; any part not supplied by Honeywell Turbo Technologies; any repair,
maintenance or service by anyone other than Honeywell Turbo Technologies; or any other acts that
are beyond Honeywell Turbo Technologies’ reasonable control; or (f) attributable to parts not
supplied by Honeywell Turbo Technologies. Honeywell Turbo Technologies expressly disclaims any
and all warranties relative to the foregoing circumstances.
Honeywell Turbo Technologies shall not be liable to Customer under any circumstances for
any special, incidental or consequential damages, including without limitation, damage to or
loss of property other than for Turbocharger Products; damages incurred in installation,
repair or replacement; lost profits, revenue or opportunity; loss of use; losses resulting from
or related to downtime of Turbocharger Products; the cost of replacement transportation,
power, or compression; the cost of substitute products; or claims of third parties for such
damages, howsoever caused, and whether based on warranty, contract, and/or tort (including
negligence, strict liability or otherwise).
The Limited Warranty is the only warranty made by Honeywell Turbo Technologies for any of
its turbochargers and related parts and/or services, and is in lieu of and excludes all other
warranties, expressed or implied, including warranties of merchantability or fitness for a
particular purpose. Honeywell Turbo Technologies hereby disclaims all other warranties not
expressly set forth. Some jurisdictions do not allow for the exclusion of implied warranties, so
the above exclusions may not apply to you, however if implied warranties do apply they are
limited to the original purchaser and for a period of one (1) year from the date of shipment.
Diagnosing Your Vehicle
Do not rely on diagnostic software without seeking the advice of an ASE certified mechanic.
Diagnostic software should only be used as a general guideline to help you facilitate the repair of
your car. If you experience or suspect any malfunction of vital safety equipment, such as your brakes,
exhaust, motor, transmission, fuel delivery system, your car’s structural integrity or any other
potentially life threatening malfunction, cease driving your vehicle immediately and seek professional
help. Always consult your owner’s manual.
Vehicle Modification Notice
Any modifications to your car are AT YOUR OWN RISK. You should consult the owner’s manual and
service manual. You should also contact your car’s manufacturer to determine what effects
modifications may have on your safety, warranty, performance, etc. Please also contact your local
authorities to determine whether your intended modifications will make your car illegal to drive on
public roads. A vehicle modified by the use of competition parts may not meet the legal requirement
for use on public roads. It is your responsibility to comply with federal, state, and local laws prior to
driving your vehicle on public roads.
Doc. 737639-26 (Rev - )
2
OTHER PRECAUTIONS
Observe all safety precautions and warnings contained in the installation instructions. Wear eye and
ear protection and appropriate protective clothing. When working under or around the vehicle support
it securely with jack stands. Use only the proper tools. Exercise extreme caution when working with
flammable, corrosive, and hazardous liquids and materials.
LEGAL INFORMATION
The Garrett turbo kits are for use off the public roadways. Federal law restricts the removal or
modification of any part of a federally required emission control system on motor vehicles. Also,
many states have enacted laws which prohibit tampering with or modifying emission or noise control
systems. Vehicles which are not operated on public roadways may be exempt from certain
regulations, however the buyer is strongly urged to check all applicable local and state laws and is
ultimately responsible for compliance with the applicable laws and regulations.
Contact Information for Questions
Please contact the Honeywell distributor from which the equipment was purchased for any questions
regarding this Shipping/Returns/Cancellation Policy, for notifications to Honeywell Turbo
Technologies, and for instructions on processing damaged shipments and authorized returns.
Honeywell Turbo Technologies
Garrett Independent Aftermarket
Honeywell International Inc.
3201 W. Lomita Blvd.
Torrance, CA 90505
Doc. 737639-26 (Rev - )
3
1. Prepare the work area. Since this installation
requires handling turbocharger and exhaust
components, the vehicle should be cold. A top-side
creeper will be a very valuable to ease this job.
Alternatively, rolled shop towels can provide some
cushion when laying over the engine while working
on the turbocharger and exhaust pipes. Have a
shop light handy.
2. Raise the hood fully. Locate and disconnect the
negative lead from both batteries.
Fig. 1
3. Raise the vehicle as per the manufacturer’s
approved procedure.
Failure to properly support the
vehicle can result in serious
injury or death.
Remove the right front wheel/tire. Remove the right
front fender inner liner. (Fig. 1)
Fig. 2
4. Using a 7/16 deep socket, remove the exhaust
pipe to the exhaust outlet clamp. Move the clamp
onto the exhaust pipe.
(Fig. 2)
5. If equipped with an automatic transmission,
using a 13mm wrench, remove the transmission
fluid fill tube to bell housing nuts. (Fig. 3)
Fig. 3
Doc. 737639-26 (Rev - )
2
6. Position the transmission fluid fill tube to the
right side of the vehicle. The tube does not require
removal from the transmission.
8. Using a 10mm socket, remove the left exhaust
pipe heat shield bolts and insulators (4) . (Fig.4, one
of four bolts shown)
9. Position the left exhaust pipe heat shield in
order to access the left exhaust pipe to exhaust
manifold bolts. Do not remove the heat shield from
the vehicle at this time.
Fig. 4
Important: Do not bend the exhaust
pipe at the expansion area.
10. Using a 12mm 12-point socket, remove the left
exhaust pipe to exhaust manifold bolts (3). (Fig. 5)
11. Remove and discard the gasket.
Fig. 5
Doc. 737639-26 (Rev - )
3
Important: Do not bend the exhaust pipe at
the expansion area.
12. Using a 12mm 12-point socket, remove the right
exhaust pipe to exhaust manifold bolts (3). Using a
14mm socket, remove the downpipe support
bracket bolt. (Fig. 6.)
Fig. 6
14. Remove the lower bolt for the exhaust outlet
shield.
15. Lower the vehicle.
16. Loosen the outlet duct clamp at the upper
intake manifold cover. (Fig. 7)
Fig. 7
17. Remove the upper intake manifold cover from
the outlet duct.
18. Pull the cover off of the pin at the rear of the
the cover and remove upper intake manifold cover.
19. Drain the engine coolant. Refer to
Manufacturer’s recommended procedure.
Doc. 737639-26 (Rev - )
4
20. Loosen the inlet duct clamps at the turbocharger
and the mass air flow/intake air temperature sensor
(MAF/IAT) sensor. (Fig. 8)
21. Remove the inlet duct from the turbocharger
and MAT/IAT sensor.
Important: After removing the charge-aircooler ducts, cover the turbocharger openings
and the ducts with tape to prevent entry of
debris.
Fig. 8
22. Loosen both of the charge-air-cooler outlet duct
to intake hose clamps. (Fig. 9)
Important: Do not use a screw driver or other
tool to pry the hose loose. The hose can be
torn or damaged. Loosen the hose by twisting.
23. Remove the hose from the charge-air-cooler
duct to the intake manifold tube.
24. Loosen the clamp on the turbocharger
compressor discharge hose. (Fig. 10)
Fig. 9
Important: Do not use a screw driver or other
tool to pry the hose loose. The hose can be
torn or damaged. Loosen the hose by twisting.
25. Remove the compressor discharge hose from
the turbocharger compressor.
Fig. 10
Doc. 737639-26 (Rev - )
5
26. Disconnect the A/C compressor clutch electrical
connector. (Fig. 11)
27. Disconnect the A/C Cut Out switch electrical
connector. (Fig. 12)
28. Remove the drive belt as per the manufacturer’s
approved procedure.
29. With a 15mm socket, remove the A/C
compressor mounting bolts (4).
Fig. 11
30. Move the A/C compressor with the hoses
attached to the right side of the engine
compartment.
31. Disconnect the turbocharger outlet coolant hose
from the coolant bypass valve (Fig. 13). Then
remove the hose from the turbocharger water line.
It will be reused in step 70.
Fig. 12
32. Disconnect the turbocharger inlet coolant hose
from the turbocharger. This hose is located under
the wastegate actuator on the passenger-side of the
turbo.
33. Disconnect the PCV hose from the tube
assembly. (Fig. 14)
34. Position the hose out of the way.
Fig. 13
Fig. 14
Doc. 737639-26 (Rev - )
6
35. Using a 10mm socket, remove the wire
connector from the intake heater. (Fig. 15)
** For California Emissions Spec vehicle:, Remove
wire connector from the elbow assembly pressure
transducer (Red Arrow). Using a 14mm socket,
loosen and remove two nuts holding the elbow
assembly to the intake manifold cross over tube,
and lift the elbow off of the studs and move out of
the way.
36. If equipped, remove the intake air heater relay
module mounting nuts and move the module away
from the turbocharger. (Fig. 16)
Fig. 15
37. Using a 10mm socket, remove the 3 bolts
holding the heat shield to the turbocharger. (Fig.
17)
36. Remove the turbocharger heat shield.
39. Remove the remaining 2 bolts for the exhaust
outlet heat shield.
40. Remove the exhaust outlet heat shield.
Fig. 16
Fig. 17
Doc. 737639-26 (Rev - )
7
***Removing the bolts and nuts in the next few
steps may be difficult. Use plenty of penetrating oil
and be on your best behavior…***
41. Remove the 4 bolts (12mm 12-point socket) and
the 2 nuts (17mm socket) for the exhaust outlet.
(Fig. 18 & Fig. 19, turbo shown removed for clarity)
Fig. 18
42. Move the exhaust outlet aside in order to access
the right exhaust pipe to turbocharger bolts.
43. Remove and discard the exhaust outlet gasket.
Fig. 19
44. Using a 12mm 12-point socket, remove the right
exhaust pipe to turbocharger bolts (3). (Fig. 20)
45. Separate the right exhaust pipe from the turbine
housing, being careful not to bend the pipe at the
EGR expansion area, if equipped.
Fig. 20
Doc. 737639-26 (Rev - )
8
47. Move the exhaust outlet to one side in order to
access the left exhaust pipe.
48 Remove the left exhaust pipe heat shield from
the vehicle
49. Using a 12mm 12-point socket, remove the left
exhaust pipe to turbocharger bolts (3). (Fig. 21)
50. Remove the left exhaust pipe.
Fig. 21
52. Using a 14mm socket, remove the turbocharger
oil supply hose banjo bolt, and washers. (Fig. 22)
Discard the used washers but save the banjo bolt as
it will be reused in step 83.
53. Move the oil supply hose out of the way.
Fig. 22
54. Using a 12mm socket, remove the turbocharger
oil drain pipe nuts at the flywheel housing. (Fig. 23)
Fig. 23
Doc. 737639-26 (Rev - )
9
55. Using a 17mm socket, remove the three
turbocharger mounting bolts. (Fig. 24 & Fig. 25)
It is helpful to use a “wobble” extension to get the
socket to fit on the bolt head.
56. Remove the turbocharger and oil drain pipe as
an assembly. Be careful to not let any dirt or debris
drop into the oil drain passage.
57. Remove the exhaust outlet pipe from the top.
Fig. 24
Fig. 25
58. Remove the oil feed line from the top of the
block by removing the banjo bolt. (Fig 26)
Fig. 26
Doc. 737639-26 (Rev - )
10
59. Using a 12mm socket, remove the oil drain line
bolts and remove the oil drain line from the stock
turbocharger (Fig. 27). Clean any gasket material
from both oil drain line flanges on the oil drain line.
60. Using a 12mm socket, remove the top clamp
plate/pin assembly from the stock turbo, keeping
the clamp and bolt. Remove the adjacent clamp
plate and bolt, keeping the clamp plate and
setting aside the bolt. (Fig. 28)
Fig. 27
61. Set the stock turbo aside, as it will no longer
be used. Now comes the preparation of the Garrett
PowerMax turbo for installation into the vehicle. Be
very careful not to let any foreign objects enter
into any of the turbo passageways or foul any
blades on the compressor or turbine wheels.
61. Using a 13mm socket, remove the top clamp
bolt on the Garrett PowerMax turbo (Fig 29). Using
a 12mm socket, install the top clamp/pin assembly
and bolt from the stock turbo (Fig 30). Tighten the
bolt to 13.5 N.m(120 lb-in).
62. Remove the wastegate actuator assembly from
the turbo by removing the hose from the actuator
nipple and applying 30psi to the actuator. Remove
the circlip and lift the rod end off of the pin.
Release pressure slowly to prevent actuator
damage. Using a 8mm 12-point socket, remove the
two bolts holding the bracket to the turbine
housing, and set the actuator aside. It will be
reinstalled later in steps 79 and 80.
Fig. 28
Fig. 29
Fig. 30
Doc. 737639-26 (Rev - )
11
64. Using a 13mm socket, remove the lower two
bolts and clamp plate from the Garrett PowerMax
turbo (Fig. 31). Install the single clamp plate
removed from the stock turbo onto the Garrett
PowerMax turbo as shown and torque to 13.5
N.m(120 lb-in). (Fig. 32)
Fig. 31
The other hole will be left open for this application.
65. From the PN 765562-1 Turbine Inlet Kit, find
the Turbine Inlet Adapter, Turbine Inlet Gasket,
and (4) M10x1.5-25 Bolts. Install the Garrett
PowerMax turbo to the Turbine Inlet Adapter using
the supplied Turbine Inlet Gasket and (4) M10x1.525 bolts (Fig 36). With a 16mm wrench, tighten all
4 bolts to 75Nm/55ft-lb.
**The Powermax Turbine Inlet Adapter has two
bosses that have been placed on the casting to
allow for installation of a pre-turbo pyrometer for
measuring Exhaust Gas Temperature. If you want
to use these, simply drill and tap the casting to fit
the pyrometer of your choice prior to mounting it
to the turbocharger**
66. From the PN 765564-1 Oil Line Kit, find the Oil
Inlet Fitting, O-ring, and (2) M8x1.25-20 bolts.
With an 8mm 12-point socket, install the Oil Inlet
Fitting to the center housing oil inlet flange with
the O-ring and Bolts. Ensure that the o-ring is
properly seated in the groove on the underside of
the fitting. Tighten the bolts to 23Nm(17 lb ft).
Doc. 737639-26 (Rev - )
Fig. 32
Fig. 36
Fig. 37
12
67. From the 765564-1 Oil Line Kit, find the Oil
Feed Hose and (2) Copper Crush Washers. Install
the new oil feed hose to the block. Reuse the
existing banjo bolt with the supplied new copper
crush washers. With a 14mm socket, tighten the
turbocharger oil supply hose banjo bolt to 34 N.m
(25 lb ft). (Fig. 38)
Fig. 38
68. From the 765564-1 Oil Line Kit, find the Oil
Outlet Adapter,(2) Oil Outlet Gaskets, and (2)
M8x1.25-45 bolts. Install the oil drain line to the
upgrade turbo using the supplied adapter, 2
gaskets, and bolts. Be sure to use the supplied
gaskets between the drain line flange and the
adapter, and between the adapter and the turbo
oil outlet. With a 13mm socket, tighten the oil
drain pipe bolts to 21 N~m (190lb-in). (Fig. 39).
Due to the close fit, some trimming of the gasket
or grinding of the adapter and oil drain flange may
be necessary to keep these parts from contacting
the turbocharger backplate.
69. From the 765565-1 Water Line Kit, Find the
Driver’s-side Water Line, M14 Banjo Bolt, and (2)
Crush Washers. Install the Driver’s-side Water Line
Banjo
to the center housing, using the supplied Banjo
Bolt and 2 Crush Washers. (Fig. 40) Using a 10mm Bolt
hex socket, tighten the Banjo Bolt to 40 N.m (30 lb
ft).
Doc. 737639-26 (Rev - )
Gaskets
Fig. 39
Driver’s
side
waterline
Crush
Washers
Fig. 40
13
70. Install the Rubber coolant line removed from
the stock turbo in step 31 onto the coolant pipe as
shown. (Fig. 40)
Fig. 40
71. From the 765561-1 Compressor Inlet Kit, Find
the Compressor Inlet Adapter, Compressor Inlet
Adapter Gasket, and (3) M6x1-20 bolts. Install the
compressor inlet elbow onto the compressor inlet
using the supplied gasket and (3) M6x1-20 bolts.
Be sure to orient as shown. Mount the wastegate
hose positioning clamp on the top bolt. Using an
8mm socket, tighten bolts to 3.4 N-m (30 lbf-in).
(Fig. 41)
72. Clean the following gasket surfaces:
All exhaust pipe flanges
Both exhaust manifold flanges
Fig. 41
73. Verify that the turbocharger lower heat shield
is properly positioned on the engine block. (Fig.
42)
Fig. 42
Doc. 737639-26 (Rev - )
14
74. From the 765564-1 Exhaust Outlet Kit, Find the
Exhaust Elbow, the Heat Shield, and (3) M6x1-10
Bolts. Install the Exhaust Elbow Heat Shield onto
the Exhaust Elbow with the supplied M6x1-10
Bolts. With an 8mm socket, tighten bolts to 3.4 Nm (30 lbf-in). (Fig. 43)
75. From the passenger-side wheel well, slip the
Exhaust Elbow assembly into place between the
engine and firewall. Leave it loose for now.
Passenger-side Water Line. Insert the Passengerside Water Line into the rubber coolant inlet hose
just above the passenger-side valve cover. Do not
put clamp into place yet. Rotate the line up to keep
it out of the way during turbocharger installation.
(Fig. 44)
Fig. 43
Passenger
side
waterline
Clamp
Fig. 44
76. Fit the turbocharger in place on the engine,
making sure that the oil drain flange fits over the
studs for the mating flange on the back of the
block.
Doc. 737639-26 (Rev - )
15
77. Install the three turbocharger mounting bolts.
Using a 17 mm socket, tighten the turbocharger
mounting bolts to 108 N-m (80 lb ft ). A wobble
extension or socket will be extremely helpful in
tightening these bolts.
remaining M18 Banjo Bolt and (2) Crush Washers.
Rotate the Passenger-side water line from step 75
down to meet the port on the center housing.
Connect the line to the center housing using the
supplied M18 Banjo Bolt and Crush Washers. Using
a 10mm hex socket, torque the banjo bolt to 40 Nm (30 lb ft). Install the clamp onto the waterline
that was left loose in step 75. (Fig. 45)
Fig. 45
79. Re-install the wastegate actuator onto the
turbocharger.
Note: The turbocharger comes with the
actuator pre-calibrated for stock boost level.
The actuator can be adjusted to achieve
higher boost and each half turn will raise
boost by approximately 1.5 psi. Increased
boost places additional stress on the entire
drivetrain. Excessive boost will lead to
overspeed of the turbocharger, which is not
covered by any warranty. Refer to spec
sheet for maximum boost
recommendations.
Fig. 46
Place the rod end over the wastegate lever pin and
position the actuator in place. Apply 30-35 psi to
the actuator nipple to extend the actuator. Bolt the
actuator to the turbine housing using the bolts
removed in step 62 and using an 8mm 12-point
socket, torque to 23 N-m (17 ft lb). (Fig. 46)
80. Install the retaining clip onto the wastegate
lever pin. (Fig. 47). Release pressure on the
actuator. Replace the boost hose and clamp.
Doc. 737639-26 (Rev - )
Fig. 47
16
81. Install the oil drain pipe nuts. With a 12mm
socket, tighten to 21 N-m (15 ft lb). (Fig. 48)
82. Pre-lube the turbocharger by pouring about 4-5
oz of clean oil into the oil inlet fitting.
Fig. 48
83. From the 765564-1 Oil Line Kit, Find the
remaining (2) Crush Washers. Position the Oil Inlet
Line over the Oil Inlet Adapter on the turbocharger
and install the stock banjo bolt removed in step 52.
and new Crush Washers. Using a 14mm socket,
tighten the oil inlet banjo bolt to 34 N-m (25 lb ft).
(Fig. 49) Be sure to position the line so that it does
not rub on any other surface or component.
84. *** For California Emissions Spec vehicles:
Using a NEW gasket, install the elbow assembly
onto the intake manifold cross over tube studs.
Using a 14mm socket, install the nuts and tighten
to 10 N-m (89 in lb). Re-install wire connector to
the elbow assembly pressure transducer.***
Fig. 49
85. Position the left exhaust pipe. Install the left
exhaust pipe to the turbocharger with NEW gasket.
Align the gasket at the turbocharger with the tab
on the gasket facing inward. To aid in installing the
pipe to the turbocharger, temporarily install one of
the pipe to manifold bolts. With a 12mm 12-point
socket, tighten the left exhaust pipe to
turbocharger bolts to 53 N.m (39 lb ft). (Fig. 50)
86. Position the left exhaust pipe heat shield, but
do not install the bolts.
Fig. 50
Doc. 737639-26 (Rev - )
17
87. Install the right exhaust pipe, with a NEW
gasket, to the turbocharger. Align the gasket at the
turbocharger with the tab on the gasket facing
inward. To aid in installing the pipe to the
turbocharger temporarily install one of the pipe to
manifold bolts. Install the right exhaust pipe to
turbocharger. With a 12mm 12-point socket,
tighten the right exhaust pipe to turbocharger bolts
to 53 N m (39 lb ft). (Fig. 51)
Fig. 51
88. From the 765563-1 Exhaust Outlet Kit, Find the
V-band Clamp and V-band Clamp Nut. Place the Vband Clamp over the exhaust outlet pipe. Install
the Exhaust Elbow to the turbocharger, and fit the
V-band clamp over the flange. Install the V-band
clamp nut and tighten snugly but not fully tight.
(Fig. 52)
Fig. 52
89. Connect the PCV hose to the tube assembly.
(Fig. 53)
Fig. 53
90. Connect the turbocharger inlet coolant hose to
the turbocharger coolant bypass valve. (Fig. 54)
Fig. 54
Doc. 737639-26 (Rev - )
18
91. Install the inlet air heater relay. Using a 13mm
socket, torque the nuts to 21 N-m (15 ft lb). (Fig.
55)
Fig. 55
92. Connect the wire terminal and the nut to intake
air heater. Using a 10mm socket, tighten the
intake air heater nut to 4 N.m (35 lb in). Connect
the wire connector to the intake manifold pressure
sensor. (Fig 56)
Fig. 56
93. Position the A/C compressor.
94. Install the A/C compressor mounting bolts (Fig
57, yellow arrow). With a 15mm socket, tighten
the A/C compressor mounting bolts to 50 N.m (37
lb ft). Connect the A/C cut out switch electrical
connector and A/C clutch electrical connector.
(Fig 57, red arrows)
95. Install the drive belt. Refer to Drive Belt
routing diagram on the plastic cowl under the
hood.
Doc. 737639-26 (Rev - )
Fig. 57
19
96. Install the charge air hose to the compressor
discharge. Position the clamp as shown for proper
clearance. Using a 7/16” deep socket, tighten the
clamp to 6 N m (53 lb in). (Fig. 58)
97. Install the charge air cooler outlet hose to the
intake manifold tube. The hose is marked DUCT
which connects to the charge air cooler outlet duct.
The hose is marked ENG which connects to the
Intake manifold. Align the marks on the hose with
the alignment marks on the pipe and tube. Position
the clamps as shown for proper clearance Using a
7/16” deep socket, tighten the clamps to 6 N m
(53 lb in). (Fig. 59)
Fig. 58
Important: The outlet duct must be fully
seated against the positive stop feature on
the inlet.
99. If using an aftermarket intake system, install
it now as per the manufacturers instruction. Skip to
step 103.
Fig. 59
100.If using the stock air filter setup, install the air
inlet duct to the turbocharger on one end and the
MAF/IAT sensor/airbox at the other end. (Fig. 47)
Install the upper intake manifold cover over the pin
on the turbo and insert the hose connection into
the inlet duct.
Important: The outlet duct must be fully
seated against the MAF/IAT sensor with the
edge of the seal in the vertical position.
Fig. 60
Tighten the outlet duct clamps at the turbocharger,
MAF/IAT sensor, and cover. Using an 8mm socket,
tighten the clamps to 6 N m (53 lb in).
(Fig. 60 & 61)
Fig. 61
Doc. 737639-26 (Rev - )
20
101. Raise the vehicle.
102. Install the right exhaust pipe with a NEW
gasket to exhaust manifold. Align the tab on the
exhaust pipe gasket facing outward.
103. Install the right exhaust pipe bolts. Using a
12mm 12-point socket, tighten the exhaust pipe to
exhaust manifold bolts to 53 N m (39 lb ft). (Fig.
62)
Fig. 62
104. Install the left exhaust pipe with a NEW
gasket to the exhaust manifold. Align the tab on
the exhaust pipe gasket facing outward.
105. Install the left exhaust pipe bolts. Using a
12mm 12-point socket, tighten the exhaust pipe to
exhaust manifold bolts to 53 N.m (39 lb ft).
(Fig. 63)
106. Position the left exhaust pipe heat shield.
Fig. 63
107. Install the left exhaust pipe heat shield bolts.
Using a 10mm socket, tighten the left exhaust pipe
heat shield bolt to 8 N-m (71 lb in). (Fig. 64, 1 of 4
bolts shown)
Fig. 64
Doc. 737639-26 (Rev - )
21
108. If equipped position the transmission fluid fill
tube. Align the tube to be centered in the relief in
the exhaust down pipe.
109. Install the transmission fluid fill tube nuts.
Using a 13mm socket, tighten the transmission
fluid fill tube nuts to 18 N.m (13 lb in). (Fig. 65)
Fig. 65
110. Install the Exhaust Elbow outlet to exhaust
pipe clamp. To assist in positioning the clamp on
the flanges use a suitable screw jack to hold the
exhaust pipe in position. Tighten Tighten the
exhaust pipe clamp to 40 N m (30 lb ft). (Fig. 66)
Fig. 66
111. From the 765563-1 Exhaust Outlet Kit, Find
the Exhaust Elbow Bracket, M8x1.25-20 12-point
Bolt, and Washer . Install the Exhaust Elbow
Bracket between the Exhaust Elbow and exhaust
manifold bracket using bolt removed in step 12,
and the bolt and washer from the kit. Using a
14mm socket, tighten the manifold bolt to 53Nm
(39 lb ft). With an 8mm 12-point socket, tighten
the downpipe bolt to 23Nm (17 lb ft). Re-install the
plastic fender liner and replace the right front
tire/wheel assembly. Torque lug nuts to 190Nm
(140 lb ft)
Fig. 67
112. Lower the vehicle.
Doc. 737639-26 (Rev - )
22
113. Tighten the turbine housing outlet/downpipe
v-band nut to 13 Nm (10 lb ft). (Fig 68)
Fig. 68
114. Fill the cooling system according to the factory service manual. Verify that the engine
oil level is correct.
115. Connect both battery negative cables. Refer to the owners manual.
116. Now retrace your steps to verify that everything has been re-installed, re-tightened, or
re-connected and that there are no loose wires, hoses, or fasteners. Make sure you have
retrieved all rags, tools, etc. from the work area.
DO NOT OPERATE the engine without all inlet ducting in place
117. Start the vehicle and allow it to idle until the engine is at operating temperature.
Check for leaks or any abnormal noises or operation.
118. Once it is confirmed that there are no issues, you are ready to enjoy your new
PowerMax turbocharger upgrade kit!
Honeywell Turbo Technologies
Garrett Independent Aftermarket
Honeywell International Inc.
3201 W. Lomita Blvd.
Torrance, CA 90505
Doc. 737639-26 (Rev - )
23

PowerMax Diesel Upgrade For Duramax Engines

Transcription

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