As some of you know i just replaced my hpop and it was a nightmare for me so my intentions in this thread is to help others not run into the problems I did so here it goes

First off if this is your first time tearing into this engine its gonna be some what intimidating but it can be done. The pump is about 700 with a $150 core depending where you get it i got all my parts from the dealer. But the pump isn't the only thing you need you also have gaskets and a ton of o-rings some can be re-used but if you are gonna go through all the work just do it right the first time and get all the parts you should replace.
Parts:
Hpop
Turbo oil drain tube update
Intake man. Gasket
Turbo o-ring and screw kit
Hpop o-ring kit
Hpop cover gasket
ICP
IPR or at the least the filter kit for it
ICP pig tail

If you have the extra time/money
Bullet proof egr cooler
Oil cooler
Oil cooler filter screen
re-condition turbo


Tools:
10mm ratcheting wrench
Good brand 10mm 6piont socket 1/4 drive and 3/8
Serpintien belt remover
Pnumatic ratchet for clamp on Y pipe
Pry bar
Deep 12mm socket
Torx bits
1/4 and 3/8 extentions with wobble heads preferred
Pipe wrench if needed
A friend if possible
Bolt extractor if needed if you strip out bolts on turbo
Telescoping magnet you will drop bolts and or sockets hopefully not into the engine like I did

The things you will need to remove
Belt
Alternator
Turbo and pedistal
Unplug all nessasry wires even the injectors plugged into the drivers side the look like they won't be in the way but you don't want to discover one is broken because it was like I did...
Oil filter
Oil filter and fuel filter housing
Intake manifold (03)
Hpop cover
egr cooler


My issues the turbo bolts were hard to get to they are kind of crowded in there I used a 1/4 extention and went under the wiring harness on the drivers side unfortunately i stripped that bolt out which sucked the clamp on the down pipe was easy the one on the y pipe needed a air ratchet because there was no room to turn a wrench there is also a bolt in the back that cant be seen but I assure you its back there

The heat shield I ended up having to bend it out of place because it wouldn't come out

The drive belt was no easy task which drove me crazy

There is a hose that looks like its connected to the egr cooler my hose was red with strange clips on it I was about to cut it off but realized the egr slides right out of it

The front most injector clip on passenger side could only be installed with intake manifold slightly lifted

If you are unlucky like me and this is your first time be prepared to spend a few days and a lot of frustrated hours working on it The whole job cost about 1300 I'm sure I'm forgetting some thing but just have patience and you will have a good running truck before you know it

 

I have an 06 and since I have plans of doing the same mods I was following your posts. Glad you got it all bolted back together and I hope it is a 1,000,000 miles before you need to do it again!

Thanks for this updated post

 

it just cost me $1600 to have mine changed. Fun Fun

 

I gotta say though its only challenging if you have never tore into this engine half the battle is the turbo once that's removed its all down hill I'd imagine if you were extremely organized like you had all the parts and all your tools laid out this job could be completely done in about 8 hours part if my problem was I kept loosing my tools but the job was totally woth the 1700 in labor I saved

 

This is a good example of why getting studs done is worth the cash and effort. If you got to dig into the motor like this you might as well get studs done at the same time. I know not everyone has the cash to drop for that kind of work. I took several months of buying parts before I had the stud work done.

I didn't see if you did a full oil change during the work. I'd suggest adding to the list the oil change fluids and filters. Maybe even add in the fuel filter kit as well.

+1 for brondondolon for wrenching it on your own. Makes you feel good doesn't it??

 

Thanks for the heads up! I got skooled when I did my EGR delete and have no worries about getting in there when/if my HPOP takes a dump. I made a few annotations in red that I thought would be helpful.

 

You dont need to use a tool to loosen the tension bar to get the belt on the alternator. If you get on top of the motor and have the belt in place everywhere except the alternator you can pull upward on the belt by hand against the tension pulley and easily attach it to the alternator.
Hope this helps many of you who are trying to get a socket or tool in the pain in the a** square tension access spot.

 

haha sounds like you got into it! I did tht and it took me about an hr.and a half. Second time around tho!
But yes. Patience with that turbo is key. I had mine out in 12 min. Flat. But if u lose ur.cool with it expect delays!

---AutoMerged DoublePost---

Thanx! Too bad I read this after I needed it!:/ next time!

 

It's good to hear I'm not the only one who struggled with that up pipe! And yes, oil change and coolant flush while your doing.