BD Twin Turbocharger Kit (12V)

BD Twin Turbocharger Kit (12V)
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
BD Twin Turbo Kit
1994-1998 Dodge 12v 6BTA
Part# 1045310
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION.
* Picture as shown features recommended optional 3-piece HD Exhaust Manifold
(BD P/N# 1045970)
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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6-Jul-05
12V Dodge Twin Turbo Kit #1045310
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K I T C O N T E N T S :
Please check to make sure that you have all the parts listed in this kit before you start
un-assembling your truck.
DODGE 12V TWIN TURBO KIT (BD# 1045310)
1405230
1405217
1453109
1452985
Primary Turbo
(Un-wastegated)
Qty: 1
Secondary Turbo
(Wastegated)
Qty: 1
Primary Turbo Oil
Drain
Secondary Turbo Oil
Drain
Qty: 1
Qty: 1
1453120
1453400P
1453600
Primary Turbo Support Bracket
Primary Air Outlet Pipe
Qty: 1
Primary Exhaust Outlet Pipe
Qty: 1
Qty: 1
1453601
Down Pipe V-Band Clamp
Qty: 1
1459122P
1100740
1453700P
4” Stainless Steel
Down Pipe Clamp
Qty: 1
Air Filter to Primary Turbo
Pipe
Qty: 1
1453500
1045971
1453300P
Secondary Air Inlet Pipe
Qty: 1
1453110 & 1453116
or
Intercooler Extension Pipe
Qty: 1
Primary to
Secondary Exhaust
Pipe
Qty: 1
Exhaust Manifold
Gasket Set
Primary Oil Drain
Qty: 1
Qty: 1
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
3
3931346
3914383
Oil Pan Gasket
Qty: 1
Pick-up Gasket
Qty: 1
PRIMARY TURBO HARDWARE KIT (BD# 1453192)
1453111
1120031
1453121
1453122
1453114
Upper Oil
Drain Bolt
Qty: 2
Oil Drain
Washer
Qty: 2
Pri. Support
Bolt
Pri. Support
Washer
Qty: 1
Qty: 1
Oil Drain Hose
Clamps
Qty: 2
1453980
1453982
1453983
Turbo
Mnt. Bolt
Qty: 4
Turbo Mnt.
Nut
Qty: 4
Turbo Mnt.
Washer
Qty: 8
1453115
Oil Feed Adapter
Qty: 1
1405926 (0406)
Down Pipe V-Band Clamp
Qty: 1
SECONDARY TURBO HARDWARE KIT (BD# 1453292)
1453980
1453982
1453983
1604102
1604103
1453113
Turbo Mnt.
Bolt
Qty: 2
Turbo Mnt.
Nut
Qty: 2
Turbo Mnt.
Washer
Qty: 4
Lock
Washer
Qty: 2
Bolt
Oil Drain
Clamps
Qty: 2
1453316
1405912
Spacer Plate
Qty: 1
Flange Gasket
Qty: 1
Qty: 2
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
4
TURBO HEAT SHIELD KIT (BD# 1459110)
1459111
1459112
1459113
Heater Wrap
Qty: 1
Inner Wrap
Qty: 1
S/S Wire
Qty: 48”
HOSE & CLAMP KIT (BD# 1453492)
1405222
1405221
4”i.d. Hose
(4” each)
Qty: 2
3”i.d. Hose
(4”/each)
Qty: 2
1405213
1405211
1453701
Clamp (4.11”)
Clamp (3.25”)
Clamp (4”)
Qty: 2
Qty: 4
Qty: 2
1453130
1453112
7/8” Upper Oil Drain
Hose (4”)
Qty: 2
Oil Feed Hose
Qty: 1
AIR BOX KIT (BD# 1453892)
1453800
72-90009
1453803
1453802
1453801
Air Box
Qty: 1
Air Box Filter
Qty: 1
Bolt
Qty: 3
Washer
Qty: 3
Spacer
Qty: 1
If you believe you are missing parts in your kit, please call (800) 887-5030 to
arrange for replacements.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
5
A turbocharger is driven solely on exhaust energy. Therefore, if the vehicles
current exhaust manifold is cracked or is leaking, it is recommend that new
exhaust gaskets and a heavy-duty exhaust manifold be used.
For the purpose of the instruction manual, the term “primary turbo” refers to
the larger un-wastegated turbo and the term “secondary turbo” refers to the
smaller wastegated turbo
Installation should occur on a cold vehicle, as turbo and exhaust components
become very hot with use.
The BD twin turbo system is recommended for trucks with 400-500 RWHP with
a maximum efficient boost pressure of 52psi. Note that even a well maintained
Cummins head gasket might blow around 60-65psi. This number varies depending
on injection timing and engine compression.
Also note that a stock transmission will not handle this power and torque,
transmission modifications are a must.
Options
Description
BD ‘X’ Torque Converter
BD Transmission
BD High Flow Injectors
Heavy Duty Exhaust Manifold 12V
BD X-Monitor
Head Studs
BD High Pressure Intercooler Boots
Part #
1070215X
CALL
CALL
1045970
1085200
CALL
1405220
When upgrading from the Super ‘B’ Single, you must ensure that the wastegate
spacer is installed correctly on the inside of wastegate, as well as the outer set
hole on the wastegate arm be used to actuate the lever arm. Failure to do so will
result in very high boost pressure. This needs to be done with the turbocharger
off the vehicle, see the last section for assistance.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
6
Battery Disconnect
Disconnect the negative terminals on both of the vehicle’s batteries, and then
disconnect the positive terminals.
Installation
1. Record radio settings and disconnect both battery terminals on both
batteries.
Remove two
exhaust bolts
2.
Lay a protective cover over
the passenger side fender to
eliminate any scratches.
3.
Remove the air box assembly
and intake tube from inlet of
turbocharger.
4.
Remove the two 13mm bolts
connecting the exhaust down
pipe to the turbo flange.
5.
Remove the cast aluminum elbow attached to the turbo compressor housing
outlet. You will need to loosen the ‘V’ band clamp and the band clamp with a
7/16” deep socket.
Be sure not to lose the o-ring from the aluminum
elbow, as you will re-use the aluminum elbow assembly later.
6.
Remove the black steel intercooler
tube. You will need to loosen the
band clamp on the intercooler using
a 7/16” deep socket.
7.
Remove the turbo oil feed line (top
of turbo) from the turbo by
holding the 19mm turbo fitting
with a wrench and remove the
13/16” line fitting – place line to
the side. As well you may now remove the 19mm oil feed fitting.
Remove air box
Remove oil
feed line
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
7
8.
Unbolt the turbo oil drain tube (bottom of turbo) by removing the two
10mm bolts.
9.
Remove the lower hose clamp
on the turbo oil drain boot and
remove the oil drain tube and
hose as an assembly as you will
need the re-use the hose
later.
10. Remove the four nuts holding
the turbo to the exhaust
manifold with a 15mm wrench–
remove the stock turbo and set it aside.
Oil Drain
11. Remove the stock down pipe and intermediate pipe from the exhaust
system.
12. Remove the nut holding the heater core line to the exhaust manifold stud
using a 15mm socket.
13. Remove the exhaust manifold
bolts with a 13mm socket.
Remove the spacers and finally
the manifold at this time. Be
sure not to loose the spacers.
14. Discard all exhaust manifolds
gaskets and clean then engine
block and exhaust manifold
mating surface.
Manifold bolts
& spacers need
to be removed
15. Reinstall the exhaust manifold in an inverted manner so the turbo flange
faces upward. Use the provided manifold gaskets and the factory bolts,
spacers and retainers and torque to 32 ft lbs with a 13mm socket.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
8
Note: If you have purchased
a heavy-duty aftermarket
manifold, you will need to
install it in the same inverted
manner. Please consult the
manifold’s instructions for
complete installation.
Invert Manifold
upside down
Turbo Preparation & Installation
To alleviate any fit problems, all turbocharger support bolts, housing bolts and
clamps must be loose. Once everything has fit together, then tighten all
bolts.
16. Remove the primary and secondary turbos from their boxes and remove any
paper that may be in the inlets or outlets. It is critical that nothing is left
inside of the turbos.
17. On both turbos, loosen the 4
bolts that secure the exhaust
housing to the turbo body
with a 13mm wrench. Then,
loosen the 8 bolts that are
securing the turbo intake
housing to the body with a
13mm wrench. This will allow
the two housings to rotate
freely.
Be careful not to
Loosen all bolts
loosen the housings off too
much as they will fall off and possibly damage the turbo wheels.
clamps should only be loose enough to clock the housings.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
The
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
9
18. Thread the previously uninstalled OEM 19mm oil feed adapter into the
secondary turbo. This is the adapter that was removed from the factory
Holset turbo.
19. Install the long oil drain adapter onto the bottom of the secondary turbo
with the supplied gasket and two 8mm X 25mm bolts and lock washers with
a 13 mm socket.
20. On the larger primary turbo make sure that the brass 90° adapter points
towards the engine with the compressor housing facing forward.
21. Install the short oil drain adapter onto the bottom of the primary turbo
with the supplied gasket and two 3/8” X 1-1/4” NC bolts and lock washers
with a 9/16” wrench.
Critical Step
22. Squirt fresh oil down the oil feed port of both turbo chargers while slowly
rotating the compressor wheel.
23. Remove the 1/8 NPT plug using
a 7/16” wrench from the top of
the oil filter head and install
the supplied JIC fitting.
Remove fitting and
install JIC fitting.
24. Mount the secondary turbo to
the exhaust manifold;
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
10
Stock Manifold
Mount the turbo to the manifold using the two factory studs and nuts, the
supplied gasket, two 3/8” X 1-1/2 NF bolts, two 3/8” nuts and the four 3/8”
flat washers. You will need to use two separate 9/16” wrenches.
Aftermarket Manifold
Remove the studs from your stock turbo and stock manifold for reinstallation
into your aftermarket Heavy Duty Manifold. Install the turbo with the
gaskets on either side of the spacer plate and reuse the factory mounting
nuts.
25. Using a supplied V band
clamp (labeled 995L2-0406),
loosely clamp the primary
turbo support elbow to the
secondary turbo with a
7/16” deep socket. Ensure
the 7/16” clamp hardware is
on the side of the pipe to
allow for the installation of
the secondary turbo heat
shield.
26. Using the supplied four
bolts (3/8” X 1-1/2” NF),
nuts, and eight 3/8” flat
washers along with the
supplied gasket, loosely bolt
the primary turbo to the
bottom flange of the elbow.
Loosely tighten
V band clamp
Mount bracket to block
and turbo adapter.
27. Install the primary turbo
support bracket on the two
bolts of the primary turbo
mount flange closest to the
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
11
engine and to the engine block with the supplied bolt (12mm x 1.75 x 25)
and lock washer. Now tighten the bolts and V band clamp.
28. Now that the exhaust housings are in their proper locations, the turbo
center sections can be twisted so that the turbo oil feeds are pointing
straight up and drains are pointed at the block adapters. Tighten the
exhaust housing bolts. Note that you may adjust the factory block oil
drain adapter to help align the system.
Primary Oil Drain Adapter Installation
ENGINES WITH A FROST PLUG IN THE SIDE OF THE BLOCK
29. On the lower right side of engine, 6” from the rear of the engine block
(just above the oil pan), there is a frost plug that caps an oil drain port
that leads to the engine crankcase. This frost plug needs to be removed to
serve as the oil drain for the primary turbo.
Great care needs to be taken when removing the frost plug so that it isn’t
forced into the oil pan.
The frost plug can be removed by
coating a drill bit with grease (to
catch any metal shavings) and by
drilling a small hole in the center
of the frost plug. Insert a sheet
metal screw into the hole and pry
the frost plug out with a pair of
pliers.
Remove frost
plug and press
in oil adapter
Coat the lower portion of the
supplied oil drain block adapter with Loctite or Anaerobic sealer and gently
tap the spout into the block.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
12
ENGINES WITHOUT A FROST PLUG IN THE SIDE OF THE BLOCK
29. Drain engine oil and leave out drain plug.
30. Clean off paint on the side of the pan between 3rd and 4th bolt as shown.
31. Center punch the pan 1 3/16” from top lip between the 3rd and 4th bolts
32. Cut the marked oil drain hole using a 7/8” hole saw. You may want to use
grease to ease the cleaning of the pan later on.
33. Clean the pan with brake clean and install supplied tube in the hole and with
the silicone hose to the turbo drain tube you installed earlier, make sure to
use the supplied clamps to secure it so it won’t move while welding.
34. Tack weld the tube into the pan, then remove the silicone hose and clamps.
35. Unbolt oil pan, pull down pan to gain access to the oil pickup tube, unbolt
the pickup tube and drop it into the pan. To remove the oil pan you may
have to unbolt engine mounts and raise the engine.
36. Once the pan is removed, clean pan thoroughly making sure to get all the
debris out of the inside on the pan and complete the welding of the oil
drain adapter.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
13
37. Clean and paint any bare metal areas of the oil pan to reduce corrosion.
38. Place the clean oil pickup tube in the pan, while placing the new pan gasket
on the outside of the pan. Now slide the pan into place. You will need to
insert the pickup tube gasket in place before tighten the oil pickup tube to
18 ft lbs. This step is rather tight; you will have to slide your arm into
place.
39. Once the oil pickup tube has
been installed, you can tighten
the pan bolts to 18 ft-lbs.
40. Reinstall/Retighten the engine
mounts (75 ft lbs), as well
install the oil drain plug with
the gasket, and fill with 11.5
quarts of fresh oil.
41. Once the engine is secured, reinstall the silicone oil drain
hose to the primary oil drain
tube with the supplied hose
clamps.
42. Discard the factory oil drain hose and use the 4” supplied secondary turbo
drain. This hose will attach to the factory drain adapter. Use the hose
clamps to secure the connection. You will need to slide the oil drain
adapter as far as possible away from the wastegate arm to prevent any
contact. In some rare cases the wastegate arm may need to be bent.
43. Install the factory oil feed line into the 19mm oil feed adapter that will be
installed in the secondary turbo (hold the fitting with a 19mm wrench and
tighten the line with a 13/16” wrench), this line should run on the engine
side of the turbo.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
14
44. Install the primary turbo oil feed line from the JIC fitting you installed
earlier in the filter housing to the inverted flare on the primary turbo, the
line should run between the turbo and engine.
NOTE: All oil drains and feeds should be vertical.
45. Remove the factory intercooler horn and boot from the factory intercooler
pipe and place them on the new intercooler pipe provided.
46. Install the cast aluminum elbow and intercooler tube assembly to the
compressor outlet of the secondary turbo and the lower intercooler boot.
Secure with the factory v-band clamp and the two boot band clamps (use a
7/16” deep socket to tighten all clamps)
Do not forget to re-install the orange o-ring in the cast aluminum elbow
before connecting the elbow to the compressor housing. You can now
install the intercooler tube in place to the elbow and the intercooler.
47. The compressor housing of
the primary turbo should still
be loose and so adjustments
can be made as required.
Move the compressor housing
around so that the fit is
secure and the tubes will not
hit anything when the engine
torques over.
Slide boots over
and secure with
hose clamps
48. Install a 4 inch silicone boot on both the primary turbo and secondary
turbo compressor housing inlets – also slide two Heavy Duty 4” band clamps
on to each boot for easier installation later.
49. Install a 3” silicone boot on the compressor outlet of the primary turbo and
slide two Heavy Duty 3” band clamps onto the boot.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
15
50. Slide the 90-degree steel pipe into the compressor outlet boot on the
primary turbo and point the pipe outlet towards the front of the vehicle.
51. Install a 3” silicone boot on
the 3” ‘U’ 180° pipe and slide
two Heavy Duty 3” band
clamps onto the boot and
install it between the short
90° on the primary to the
secondary turbo 4” inlet.
52. Once all intermediate pipes
are lined up, the heavy-duty
hose clamps can be tightened
as well as the bolts on the
primary turbo compressor housing.
Trim excess hose
53. Loosely secure the new down pipe to the primary turbo using the supplied
V-band clamp. Note that you will have massage the firewall to allow enough
clearance for the down pipe.
Be sure to align all exhaust pipes, and then tighten the V band clamp on
the back of the turbo. Once this is done you can finally clamp and weld
the appropriate exhaust components.
54. In each kit there is a 17”
section of sliver exhaust
wrap, along with a 16” tan
section. You will need to
stack these two pieces of
wrap on top of each other,
Fold the four sides over and staple.
Slide the SS wire through length-wise.
so that the silver wrap can
be folded over the tan wrap on all four sides. Note that the silver side
should be facing out, so that the tan wrap is fixed against the white side of
the wrap. You will need to staple all four folds to secure them in place.
Once secure, run the 40” stainless wire through the folds length-wise. You
will need to do this on both sides.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
55. Install the turbo heat
shield as shown over the
top of the secondary
turbo exhaust housing and
secure with the stainless
wire. Completely wrap the
blanket around the turbo
housing, then tighten and
tie off with the stainless
steel wire.
16
Wrap blanket tightly around housing.
56. Install the air box spacer
on the stud at the front closest to the engine. This stud is lower than the
other two.
57. Insert the 4” intake tube
into the air box and then
into the silicone boot in
the compressor-housing
inlet of the primary
turbo. Install air box
onto the factory studs
using the three supplied
¼” NF nuts and the three
supplied ¼” flat washers.
Air box should
be installed on
these studs.
58. Using a 7/16 deep socket
tighten the two band clamps on
the silicone boots – ensure all
pipes have good contact with
the boots and at least 1/8” of
boot sticks out past each
clamp.
59. Install the supplied air filter
by inserting it onto the pipe
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
17
after it has passed through the air box and secure it with the supplied 4”
hose clamp.
60. Re-connect the battery terminals and refill engine coolant. Double check
all connections to make sure that they are all secure and free from any
damage. You now may start the vehicle, once the vehicle has start and is up
to temperature re-check for leaks and ensure that all the air is out of the
coolant system.
Note: The exhaust housings of the turbos may smoke slightly when new, as
manufacturing residue on housing must burn off.
Twin Turbo Testing
It is highly recommended that allow the turbochargers to break in, before any
high power test runs. Slowly allow the turbo to come up to boost. Ideally the
intake manifold pressure should not go above 52psi. You may have to adjust the
waste gate with shims or a bleed orifice to ensure this boost level.
While driving listen for any odds noises such as a boost least or perhaps piping
rubbing against the vehicle. Once the vehicle has gone though a number of heat
cycles it is highly suggested to retighten all clamps, bolts and nuts.
Periodically retighten all clamps and check for any oil or boost leaks.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
18
Wastegate Adjustments
To adjust the wastegate you can add shims the base of the pressure cylinder
behind the wastegate bracket. The more shims, the higher pressure. Keep in
mind there is already a 1/4” shim installed. In situations where the customer is
developing too much boost pressure, this shim can be removed. To generate
more boost pressure you will need to add to the shim stack. Keep in mind that
this system is designed to operate around 53psi; BD will not be responsible for
any failures above this boost pressure to the turbo chargers or head gaskets.
Note if you have purchased the single to twin upgrade kit you will need to install
the supplied wastegate shim, and moved the actuator rod to the outer most hole.
You will need to remove the sir clip to do this, be care not to lose the clip.
Shim inserted.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6-Jul-05
12V Dodge Twin Turbo Kit #1045310
19
BD ENGINE BRAKE, INC.
LIMITED WARRANTY STATEMENT
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS
THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.
DISCLAIMER OF LIABILITY
BD Engine Brake Inc., its successors, distributors, jobbers, and dealers (hereafter “BD”) shall in no way be
responsible for the product's proper use and service. THE BUYER HEREBY WAIVES ALL LIABILITY CLAIMS.
BD disclaims any warranty and expressly disclaims any liability for personal injury or damages. BD also
disclaims any liability for incidental or consequential damages including, but not limited to, repair labor, rental
vehicles, hotel costs, or any other inconvenience costs by reason of use or sale of any such equipment. The
BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this
agreement and the BUYER agrees to indemnify BD and to hold BD harmless from any claim related to the item of
any equipment purchased.
This warranty shall not apply to any unit that has been improperly stored or installed, or to misapplication,
improper operation conditions, accidents, neglect, or which has been improperly repaired or altered or otherwise
mistreated by the BUYER or his agent. BD also assumes no liability regarding the improper installation or
misapplication of its products. It is the installer's responsibility to check for proper installation and if in doubt,
contact the manufacturer.
LIMITATION OF WARRANTY
BD Engine Brake Inc. (hereafter "BD") warrants to the BUYER that any parts purchased shall be free from
defects in material workmanship. A defect is defined as a condition within the product that would render the
product inoperable. BD gives Limited Warranty as to description, quality, merchantability, fitness for any
product’s purpose, productiveness, or any other matter of BD's product sold herewith. BD shall be in no way
responsible for the product’s open use and service and the BUYER hereby waives all rights other than those
expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by
BD and the BUYER.
The Warranty is Limited to one (1) year from the date of sale. Until BD has approved the claim, the consumer
may be responsible for these costs.
A Return Material Authorization (RMA) number, obtained in advance from BD, must accompany all products
returned for warranty consideration. All products must be returned, shipping prepaid, to BD and must be
accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by BD and
repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which have
been replaced, become the sole property of BD.
This warranty is in lieu of all other warranties or guaranties, either expressed or implied, and shall not extend to
any consumer or to any person other than the original purchaser residing within the boundaries of the continental
U.S. or Canada.
IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY
PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF
PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE OF PURCHASE FOR
A FULL REFUND.
Damaged or blown head gaskets will not be covered under warranty, it is the responsibility of the user to regulate
cylinder pressures to protect the head gasket.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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