So, you have decided to do this swap. After reading all of the write ups and all the advantages and disadvantages of the turbos, we decided to do one.
Things you will need:
1. Another vehicle to drive while you do all the fab work!! It took me about a week to do this swap and fab work.
2. Exhaust Manifold and turbo from a 6.7 Cummins. Manifold MUST be from a 6.7 Cummins. The turbo flange is different from all the other flanges from 1st, 2nd, and 3rd gen trucks.
3. A controller from Fleece Performance to control the turbo.
4. A STOCK down pipe from a 3rd Gen truck.
First things first, disconnect the battery cables!!! Then begin removing the stock turbo and exhaust manifold.
(You can recoup some of you cost on this swap by selling you stock manifold to someone with a 3rd gen.) If your truck is an Automatic, you will have to either relocate the tranny cooler or bypass it and remove it. We opted to remove our cooler and reroute the tranny lines. If it's a Manual truck, don't worry about the cooler.
Now begins the fun part. Fabrication!! Start by installing your new manifold onto the truck. You might find it is easier to have the turbo already bolted up to the manifold as it can be a rather tight fit to try and put it on after putting the manifold on.
Make sure to route coolant lines to the turbo. If you do not have coolant going to the turbo, you can possibly cook the electronics in the turbo
We used a flexible turbo drain on ours since the stock one from the truck wouldn't work. We removed the freeze plug closest to the rear of the engine just above the oil pan. Take special care to make sure you don't accidentally knock it into the engine. We took a long screwdriver and a hammer and tapped on one side of it till it started to "spin" in the hole. After that, we pulled it out using a good pair of pliers. If you want to, you can reuse that freeze plug and install it into the already open turbo drain hole, or use some other method of blocking off that hole. To fabricate the piping going to the Inter cooler, we used 3" exhaust piping, and swelled one end of it to fit the stock boot going to the Inter cooler.
Install the exhaust elbow onto the new turbo, and then turn it to where your down pipe will mate up to it. If you already have 4" exhaust, you'll be in good shape. If not, now's the time to upgrade to 4" or go buy an adapter to reduce from 4" to 3" if you still have the stock exhaust on your truck.
All that's left now is to hook up all the connections for the controller. Make sure to keep all loose wires tied up out of the way. Mount the controller under the hood somewhere and mount the knob to control the vanes in the turbo, and the switch to turn the exhaust brake on and off.
And that's it! Sounds simple enough, but like I said before, it took a week of fabrication to get everything hooked up and in working order.
Here's a small video so you can hear the turbo screaming while playing with the knob for the controller. Kinda sounds like a jet engine!!