Duramax Turbo Installation Guide: Step-by-step Process for Ats 66mm and Stock Upgrades

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The Duramax engine is known for its power and reliability, making it a popular choice among truck enthusiasts. Upgrading your turbocharger can significantly enhance performance. This guide will walk you through the installation process for both the ATS 66mm turbo and stock upgrades.

Tools and Materials Needed

  • Socket set
  • Wrench set
  • Torque wrench
  • Flathead and Phillips screwdrivers
  • Intercooler piping
  • New turbocharger (ATS 66mm or stock)
  • Gaskets and seals
  • Oil and coolant

Preparation Steps

Before starting the installation, ensure that you have all the necessary tools and materials. Follow these preparation steps to make the process smoother:

  • Disconnect the negative battery terminal.
  • Drain the engine oil and coolant.
  • Remove the engine cover if applicable.
  • Take photos of the existing setup for reference.

Removing the Old Turbocharger

To install a new turbocharger, you must first remove the old one. Follow these steps carefully:

  • Remove the intake and exhaust pipes connected to the turbo.
  • Disconnect the wastegate actuator.
  • Unbolt the turbo from the manifold and the oil drain line.
  • Carefully lift the old turbo out of the engine bay.

Installing the New Turbocharger

Now that the old turbo is removed, you can proceed with the installation of the new turbocharger. Follow these steps:

  • Position the new turbocharger in place.
  • Secure the turbo to the manifold using the bolts and apply the specified torque.
  • Reconnect the oil drain line and ensure it is tight.
  • Reattach the wastegate actuator.
  • Install the new gaskets and seals to prevent leaks.

Connecting the Intercooler and Exhaust

With the turbo installed, you must connect the intercooler and exhaust to complete the installation:

  • Attach the intercooler piping to the turbo.
  • Secure all clamps and connections tightly.
  • Reconnect the exhaust pipe to the turbo outlet.
  • Ensure all connections are leak-free.

Final Steps

After the turbo and all components are securely installed, follow these final steps:

  • Refill the engine with oil and coolant.
  • Reconnect the negative battery terminal.
  • Start the engine and let it idle for a few minutes.
  • Check for any leaks or unusual noises.
  • Take the vehicle for a test drive to ensure everything is working properly.

Conclusion

Upgrading your Duramax turbocharger can greatly enhance your vehicle’s performance. By following this guide, you can successfully install the ATS 66mm turbo or a stock upgrade. Always remember to double-check your work and consult a professional if you encounter any issues.