obs to sd turbo upgrade

[stroknit]

well here it goes guys iam back in town and starting the long trip to a better truck i hope...lol
first off let me say that this is a pretty tuff job so far a second set of hands would make it go alot smoother.. and in my case my shop dog... cant get her to tell the diffrence between metric and standard yet...lol
although iam a rookie to the diesels iam somewhat sharp when it comes to cars.

my truck is a 97 obs 4 door 2 wheel drive shortbed with 155,000 miles. this all started due to the old turbo seperating and tearing up the exhaust fins.

when my truck blew the turbo up ok well its not the trucks fault...lol i was 100 miles from home with the boat on the back. well in travels home i made the trans work hard enough to run it hot and ruin it too! wich in a way turned out to be a blessing.

started with removing the normal stuff the air cleaner and engine cover witch i do not have...lol

remove both batterys if you are planning on installing the sd intercooler.also the grill and headlight assembly.

i mentioned the trans having to come out being a blessing becouse it is next to impossible to get the old turbo,pedestal,up tubes,and down tube out without lifting the body.

after lifting the truck in the air remove the driveshaft disconect all electric connectors from the trans. etc.

support the engine oil pan with a jack and a piece of wood so you do not bend the pan! pull starter off and inspection cover bolts to get to the torque converter bolts 15mm
remove all 6 converter bolts turning the flex plate with a torque converter wrench. remove trans cooler lines on pass. side of trans open wrench 9/16

with trans jack under pan and secure start loosening bolts to the trans mount 18mmx2
than the outer bolts for the trans cross member nut 18mm
bolt 15mm there are 10 of these and it is a 3 piece cross member

remove shifter cable and bolts holding bracket 13mmx2

now back to the standard wrenches...lol bell housing bolts are 3/4 there are 6 of these also with everything supported you can remove all these bolts it has dowl pins.
once they are removed give it a few tugs and with the engine supported with no tension on either it pulls right off. this has been the easiest part of the whole trip so far....lol

after getting the trans out from under the truck it is time to start removing the exhaust up tubes and loosening the down tube. bolts on each up tube to manifolt are 10mm and nuts are 13mm. than remove bolts in the y connector also 10mm the up tubes should just pull from the y.
once these are out there is access to remove the stock crimped down tube.

go up top and remove clamp it is now loose from the turbo. next to the kitty if present =) remove the 2 15mm nuts from the collector. the down tube should drop out.
while under the truck remove the 2 rear 10mm bolts in the pedestal. time to get up on top again.

remove the intake "y" few hose clamps and 1 clamp to turbo exposing the other 2 10mm bolts in front of pedestal. remove the 2 10mm bolts and the turbo is free
thus clearing room for all the new goodies.
be sure to stuff rags in the intakes of the engine after removing the y.
thisis as far as i got in day 1 and trust me it is not an easy task it took most all day making sure i did not ruin anything or brake bolts etc.

i will add a few pictures of the progress so far. sorry to stop short but time for bed and back to work tomorrow but more work to be done after the money job is done tomorrow.PICT0221.jpg

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[mbwrench]

good luck--that is a crap load of work.

[Slated4Greatness]

Yes, good luck with the project!! Tons of work there but once you are done you will appreciate it that much more...

[Dano2000]

Good luck

[stroknit]

sorry it only let me post 3 pics. the first time i will try to get a few more up here and yes it is alot of work....lol but i know when done it will all be worth it!
gotta try to find a rear main seal today and the rest of my gaskets so it can all begin...lol thanks for the wishes guys i will need them when im cusing at this thing....lol gonna try to make my own lift kit as well before it gets back on the road... it can not be all that bad or too much diffrent than makin brackets to bag all my old cars and being a welder it should be pretty easy accept i will have to buy a pitman armPICT0223.jpg

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[stroknit]

PICT0226.jpg

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[stroknit]

PICT0231.jpg

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PICT0235.jpgok now a few comparisons...lol out with the old and in with the new

[fords4life]

Awesome pics! I knew the OBS turbo was smaller, but never seen them right next to each other. Looks like it's going to be a big difference. Only problem is that now you'll be hooked LOL. Then it's time for a fuel system, Big Oil, Bigger sticks........

Looks like a lot of frustrating fun to me. Lookin forward to seein the finished product and seein your seat of the pants thoughts afterwards.

[DryHeatDude03]

Nice! lotta work there, but it will be worth it in the end.

[stroknit]

well since iam here im getting ready to do a rear main seal.
thought maybe it was pedestal o-rings leaking but it is dripping while not even running so it is a rear main i think...
well im just gonna do it while the trans is out i will take some shots of it as well and post up in a bit.
as for a fuel system and stick it needs it anyways...lol if i had the money i would already be doin it thats for sure. even if i could find a set of california ab injectors i think they are 140's either way i will have to do them after i get this part done and driving again.
been thinking about doing electric fuel pump also when i do all that? anyone done that yet?

[Slated4Greatness]

I would verify that it is the rear main before going to all the trouble of replacing it. More than likely the oil is coming from the valley on top of the engine. The valley has a drain hole on the back passenger side so anything from the valley will end up leaking down the back of the engine appearing to be a rear main problem. JMHO..

[stroknit]

ok boys and girls yet another chapter in the venture of the obs turbo upgrade....lol

i believe i left off getting ready to do the rear main seal....

as for finding out if it came from the valley or the rear main it was a rear main and the oil pan also.
Attachment 852
its a 22 dollar seal so either way i was gonna do it cause i was here....lol plus once i got the trans out it was leaking anyways....lolAttachment 853
after removing the bolts in the flywheel and the adapter between the flywheel and crank there are 5 #8 bolts holding the seal in.
after prying the old seal off the new seal has a wear shim between the crank and the seal its self make sure it goes on with the new seal it is a very close tollerance piece...seal3.jpg

[stroknit]

the pan is kinda self explanitory so i will move to the drivers side exhaust manifold...
it is slightly diffrent than the obs manifold
the rear of the manifold where the up pipes join is a little longer you can see in the webbing in the picture
the pass. side is the same so no need to change itdmanifold.jpg

dmanifold2.jpg
the new one from the sd is on the left notice the webbing in the cast

[stroknit]

moving on to the top of the engine where it gets a little more technical....lol
replacing the intake runners.... and trust me boys and girls size matters....lol i dont care what your wife tells ya....lol ok sorry about that
i started with the pass. side seeing that it needed a little more modification..
the front of the intake runner needs to be pushed in about a 1/4 inch to clear the fuel line other than that it does not need anything more than normal just clean both surfaces really well and there are no gaskets here just silicone and dont be shy with it...lolintake1.jpg

engine.jpg

[stroknit]

dont worry i painted all the ugly areas....lol
Attachment 859
after both runners are installed.
now the next bit of buisness it gets a little tricky...lol knowing the turbo is a bit taller from the pedestal and the turbo its self you need to massage the firewall a bit
after trying to get it to move with a hammer for a few minutes i realized it was worthless....
so i pulled out the big guns.....lol ok just my rivet hammers from working on air craftscotty 022.jpg

scotty 021.jpg
one it starts to move it folds back like butter....