1995-1998 Chevy / GMC C/K 6.5L Turbo Diesel Install Guide

1995-1998 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 3. 6. 14. Option 2: DRILLING AND TAPPING THE INTAKE MANIFOLD 1. Start by loosening the turbo coupling using a 5/16” Wrench. 2. Using a 13mm Socket remove the bolt for the support bracket, and unplug the two sensors. 3. Remove the Intake Manifold from the truck by removing the 6x10mm Intake Manifold bolts with a Socket. This will ensure that no shavings enter the Intake during the drilling and tapping process. 4. Mark the drilling location on the Intake Manifold using a marker and a Center Punch. 5. Starting with a 1/8” drill bit, drill your pilot hole into the Intake Manifold and gradually step up in drill bit size until you reach the Size R Drill Bit. 6. Use a 1/8-27 NPT tap to thread the hole. 7. Clean the Manifold with brake clean to remove all shavings. 8. Prepare the Boost Hose for installation by installing the Compression Nut and Ferrule Fitting over the Boost Hose. Apply Teflon Tape to the Ferrule Fitting Adapter. Wrap the tape clockwise on the male threads. 9. Install the Compression Adapter into the 1/8-27 NPT hole you tapped using an 11mm Wrench. 10. Reinstall the manifold to the engine and tighten bolts with a torque Wrench to 17 ft lbs. Note: Using a new gasket when reinstalling the manifold is highly recommended. 11. Plug in the two sensors. 12. Tighten the turbo coupling using a 5/16”Wrench. 13. Slide the Ferrule Fitting Cap and Ferrule onto the Boost Line. (Refer to diagram on previous page) 14. Insert the line into the Ferrule Fitting Adapter and tighten with a 3/8” Wrench. Note: Do not overtighten the Ferrule Fitting 15. Route the Boost Hose, without kinking, up to the firewall to the driver side of the engine bay and use Zip Ties to secure the boost line. Make sure there is no contact with any direct heat source or moving parts of the truck.