Adventures in diesel mechanics

[skyhighsami]

Yesterday I got my parts I ordered for my truck to help lay the ground work to make safe power with the tuner and help control EGTs and intake temps. I ordered new intercooler pipes in mandrel bent 3" to replace the 2 1/2" crush bent pipes, down pipe, and catless front pipe. I started yesterday about 6:30 and decided I would do the IC pipe and front pipe, they went pretty smooth so I thought I would attack the downpipe. Bad idea, I stopped working on it around 11:30 when the new one wouldn't slide into the turbo's exhaust housing. The pipe is ceramic coated so I filed the coating off and it still wouldn't fit. So tonight I will have to hit it with a Dremel to get the flange small enough to hopefully fit. Once I do that would heating the exhaust housing slightly be a good idea? I was hoping the heat would expand it enough so I could get the clamp on, I am afraid but just sanding the flange on the turbo I might end up with a leak if I go too far. Judging from the pieces I took off I should see some extremely nice gains once the ecu is tuned. What a pain in the ass

[linuxman51]

I saw that heap up on those weak ass jackstands this morning.

[XSivPSI]

Run the motor, that should heat up the turbine housing nicely.

[skyhighsami]

The absolute best part was the destructions that came with the downpipe. It said, "apply slight pressure to the stock downpipe and remove it from the bottom". I beat the fuck out of it with a hammer, used a breaker bar, finally took my ball joint breaker and wedged it behind the turbo and beat on it for about 5 minutes before the downpipe came out of the turbo. I want to know who can apply "slight pressure" to get it out. Plus the tranny dipstick has to come out, it has 2 bolts, one is at the top almost of the bellhousing. Very hard to get to.

[skyhighsami]

Finally got done and took it around the block....what a pain in the ass. I had to spend about 30 minutes with a Dremel on the flange of the downpipe, and then about 15 cleaning up the inside where the pipe alignment was a little off for my taste. Initial impression, little reduction in spool time or if there, and a little louder under WOT. However when the turbo comes on now it hits much harder and pulls a lot harder through the rpm range. I was told to expect 20-30whp, I was only expecting better spool time, and lower IAT and EGTs but the added power is much welcomed. Now on to handle the fueling with a lift pump, ported fuel fitting, FPR shim kit, and then load a badass tune.