BD Diesel 1046200 Turbocharger Installation Instructions

BD Diesel 1046200 Turbocharger Installation Instructions
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
BD SUPERMAX Turbocharger
2001-2004 Chevrolet/GMC LB7 Duramax Turbo Kit
Part# 1046200
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION.
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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3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
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KIT CONTENTS:
Please check to make sure that you have all the parts listed in this kit before you start the disassembly
your truck.
DURAMAX 2001-04 LB7 “SUPERMAX” SINGLE TURBO KIT (BD# 1046210)
1406200
1462327
1462321
1462326
SuperMAX Turbo
Check Valve
Turbo End Adapter
12mm O-ring Plug
Qty: 1
Qty: 1
Qty: 1
Qty: 1
1462323
1462324
1462325
14mmx JIC -6 Adapter
Lower Oil Feed Line
Upper Oil Feed Line
Qty: 1
Qty: 1
Qty: 1
1462310
1406210
1462410
Lower Oil Block Gasket
Turbo Adapter (Pedestal)
Feed Pipe Gasket (Upper)
Qty: 1
Qty: 1
Qty: 2
1462300
1405913
1462301
1110062
Oil Outlet Block
Oil Drain Gasket
Oil Outlet Mounting
Stud
Oil Outlet Mounting
Nut
Qty: 1
Qty: 1
Qty: 2
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
3
1462420
1462430
1462440
1040142
Feed Pipe Gasket (Lower)
Turbo Mount Stud
Turbo Mount
Nut
Heat Wrap
Qty: 1
Qty: 4
Qty: 4
Qty: 2
1459113
1453516
1453517
1405926
Heat Wrap Wire
Header Wrap
Header Wrap Clamp
Turbo V-Band
Clamp
Qty: 5 ft.
Qty: 10 ft.
Qty: 36 in.
Qty: 1
1100740
1462601P
1405222
1453701
S/S Exhaust Clamp
Inlet Pipe
4” Silicone Hose
4” Hose Clamp
Qty: 1
Qty: 1
Qty: 4”
Qty: 2
1330149
1462901
1462110
1462115
Hose Clamp
Dipstick Tube Clamp
Coolant Hose
Coolant Hose Hold-down
Qty: 2
Qty: 1
Qty: 20 in.
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
1462900
Dipstick Tube
Qty: 1
1462501
Turbo Down Pipe
Qty: 1
1110032
1462101
1300131
Lock
Washer
Heat Shield Bracket
Zap Strap
Qty: 2
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
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3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
5
Pre-Installation
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.
Installation should occur on a cold vehicle, as turbo and exhaust components become
very hot with use.
The BD SuperMax Turbocharger System is recommended for trucks with 400-550
RWHP with a maximum efficient boost pressure of 45psi. For optimum performance,
the turbo should operate between 40–45psi.
Upgrade Options
Description
BD Allison Torque Convertor
BD Allison H/D Transmission
BD X-Monitor Digital Gauge Package
BD Deep Sump Transmission Pan
BD Cool Down Timer
Part #
1030230
CALL
1086210
1061600
1081150
Pre-Installation
Record your radio settings if you prefer as you will lose them once your batteries are
disconnected.
Disconnect the negative terminals on both of the vehicle’s batteries, and then
disconnect the positive terminals.
If the stock turbocharger has failed, perform the following steps to verify the condition of the
#4 camshaft. Although this oil feed does not supply the BD turbo, it is always recommended to
check the state of your engine.
A. Visually inspect for correct alignment of the #4 camshaft bearing oil hole through the
turbocharger oil supply hole in the block.
B. Turn the engine over by hand (1/2 turn) and inspect for camshaft bearing movement,
indicating a spun camshaft bearing.
C. If the bearing is spun the engine MUST be replaced.
CAMSHAFT BEARING HOLE
MUST BE VERTICAL AND
NOT MOVE WITH ENGINE
CAMSHAFT LUBRICATION
GROOVE, WILL ROTATE
WITH ENGINE
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Installation
Removal of Stock Turbo & Parts
REMOVE
Remove the factory plastic engine cover
or intake plenum. You can also remove
the intake tube, but you can leave the air
box in place.
Using the petcock on the bottom of the
radiator, drain the engine coolant into a
clean container to reuse later.
REMOVE
Using a 1/2” breaker bar, relax the belt
tensioner and remove the belt.
Disconnect the Air Conditioning clutch
and high-pressure cutout electrical
connectors.
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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3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
MOVE TO SIDE
Using a 15mm socket, remove the four
A/C compressor mounting bolts to move
the A/C compressor for easy access to
the turbo assembly. Be careful not to
discharge the A/C line.
Using a 10mm socket, remove the three
upper heat shield mounting bolts, and
remove the heat shield protecting the
exhaust turbine housing. Two of the
bolts and the heat shield will be reused
later.
REMOVE CLAMP AND FOLD
BACK
Using a 7/16” deep socket, remove the
compressor outlet clamp and fold the
silicone elbow back for access.
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
7
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Remove the factory wastegate hose and
breather hose using pliers. The breather
hose runs from the drivers side valve
cover to the passenger side valve cover
under the wastegate actuator. Beneath
the waste gate actuator you will find a “T”
- Disconnect the breather hose at this
point and push/pull the line to the side
for easier access to the turbo.
Using a 10mm socket, remove the air
intake heater connection, MAP sensor
mounting bolt, and unplug the MAP
sensor.
Using a 10mm socket with a swivel
attachment, remove the three bolts
holding the compressor inlet elbow to the
compressor housing. Remove the inlet
elbow.
REMOVE
Using a 13mm socket, remove the two
nuts holding the transmission dipstick
tube to the transmission bell housing and
remove the tube.
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
8
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Using a 10mm wrench, remove the three
rear heat shield mounting bolts. This will
allow you to remove the heat shield
protecting the down pipe.
To ease access to rear of the turbo, you
can remove the transfer case vent.
Using a 10mm wrench, remove the four
drivers side feed pipe heat shield bolts:
three from the top and one from the
bottom.
Using a 12mm - 12 point, remove the
four bolts that secure the down pipe to
the turbo. As well, you will need to use a
14mm wrench to remove the remaining
two nuts from the two studs.
Remove the support bracket that
secures the down-pipe just above the
marmon flange.
You should now be able to remove the
down-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
9
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Remove the front curved section of the
exhaust from the “4-bolt” flange to vband clamp. This is located underneath
the truck.
REMOVE
Using a 12mm - 12 point socket, remove
the six upper feed pipe bolts. Note that
they may extremely difficult to remove
and may require heat to break them
loose or penetrating oil.
Using a 12mm deep socket, remove the
oil drain flange nuts that secure the drain
tube to the center of 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
10
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Remove the coolant supply lines from
the brass check valve from the top of the
engine.
Remove the coolant outlet lines from the
turbocharger.
Using a 14mm socket, remove the oil
supply line banjo bolt from the top 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
11
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
LOOSEN TO ALLOW
REMOVAL
Using a Torx T55, loosen the Banjo bolt
holding the lower coolant fitting in place
to ease removal. You do not need to
remove it.
Using an 18mm socket and extension,
remove the three turbo assembly
mounting bolts. These bolts secure the
turbo assembly to the top of the block.
Remove the turbo assembly, then the
down pipe up through the engine
compartment.
Using a 14mm socket, remove the oil
feed line banjo bolt from the center
block.
You can now remove the remainder of
the lower turbo coolant line that you
loosened earlier from 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
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3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
13
Turbo Installation
OIL DRAIN
Install the 12mm ORB plug into the
factory turbo oil supply port. Be
sure not to tighten the plug so
much that the O-ring is distorted.
OIL SUPPLY
Install the four studs into the turbo
pedestal by screwing together two
nuts onto the studs and tighten the
assembly into the pedestal.
Install the turbo to the cast
pedestal with the steel gasket and
supplied nuts, tighten with 15mm
wrench.
DOUBLE NUT THE
STUDS TO INSTALL
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Install the two step studs for the oil
drain spacer into the bottom of the
turbo and tighten with vice grips.
Install the oil drain spacer with a
gasket on each side.
14
GASKET
SPACER
GASKET
STUDS
There are three paper oil drain gaskets: two are the same for
the upper spacer adapter and one that is different for the tube
to engine to block connection.
BEFORE INSTALL INLET FITTING YOU MUST PRE-OIL THE TURBO USING
15W-40 OIL.
Install the factory oil drain tube with the
two 5/16” NF nuts and lock washers
and tighten to the bottom of the spacer.
OIL
INLET
FITTING
You may need to grind a 1/16” off of the
factory drain tube flange to allow
clearance between the flange and the
compressor housing short head bolt.
Install the JIC – NPT oil inlet fitting into
the turbo oil supply port facing in the
same direction as the compressor
outlet.
DO NOT USE TEFLON TAPE OR PIPE
DOPE FOR SEALING PIPE THREAD.
IF SEALANT IS REQUIRED, USE
LOCTITE 592 p/n 59241.
OIL DRAIN TUBE
WITH SPACER
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Install the oil drain gasket on the two
studs on the block. Pay attention to the
proper orientation of the gasket.
Remove the old gasket residue first
before applying the new gasket.
Install the complete turbo assembly
(pedestal and all) into the vehicle
making sure to align the oil drain flange
over the two studs at the rear of the
engine. Tighten to 15 lbs-ft of torque.
You will need to reuse the three bolts
you removed earlier to secure the
complete assembly down to the block.
Leave the bolts loose until you fully reinstall the two feed pipes.
IF YOU HAVE BD’S NEW HIGH FLOW DURAMAX MANIFOLD, YOU
SHOULD INSTALL IT NOW.
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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3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
16
Re-install the feed pipes with the
new supplied gaskets.
You will
need to reuse the old bolts. Make
sure to use an anti-seize grease
before assembling. Tighten to 39
lbs-ft of torque.
Once tight, you can fully secure the
three pedestal bolts to 80 lbs-ft of
torque.
CUTOFF STUD
Using a cutoff wheel, remove the
upper stud protruding from the
firewall for the heat shield on the
passenger side of the engine
compartment.
PRY BAR LEVERAGE POINT
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
17
CUTOFF STUD
BEND BACK FIREWALL
HERE
Using a larger pry bar, massage the
firewall in the area shown, being
careful not to pry against anything that
will break. There is an engine-lifting
bracket on the back of the passenger
side head that works well as a
leverage point. This is necessary to
accommodate the larger down pipe.
PRY BAR
If a long pry bar does not work, you
can use a small hydraulic bottle jack to
adjust the firewall.
Cleanup loose paint and repaint the
firewall to protect it from rust.
PLEASE NOTE THAT IT IS CRITICAL THAT SUFFICIENT ROOM IS MADE
AVAILABLE FOR THE EXHAUST DOWN PIPE. FAILURE TO DO SO WILL
CAUSE THE EXHAUST PIPES TO VIBRATE AGAINST THE FIREWALL.
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
Re-install the MAP sensor and
install the newly supplied coolant
hose from the brass check valve to
the return line. Use the new clamps
and the hold down clamp as shown.
NEW COOLANT
HOSE WITH CLAMP
On 2001 trucks, the MAP sensor is
located in a different position. You
can use the nylon zip ties to secure
the hose.
Re-install the
silicone boot.
compressor
outlet
Install the dipstick tube and dipstick;
make sure that it is fully seated into
the transmission. Install the dipstick
hold down clamp onto the inside bolt
of the engine-lifting bracket.
The dipstick tube may need slight
tweaking as every truck is slightly
different.
CLAMP
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
18
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
19
Wrap the down pipe as shown. If
you pre-moisten the exhaust wrap it
will shrink much tighter.
You will need to slip it up from
underneath the vehicle.
Be sure not to wrap the flange area
of the down pipe where the clamp is
placed.
Use the provided V-band clamp to
secure it to the back of the turbo.
1st
Insert the S/S header clamp into the
locking clip all the way until the
clamp material presses against the
stop.
Wrap the clamp material around the
pipe and insert it into the opposite
end. Pull tight and hammer down
the locking tabs.
Pull tight and
hammer down
locking tabs.
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
2nd
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
20
Install the two pieces of silver heat
shield to further insulate the down
pipe from the firewall; hold it in place
with the stainless wire provided.
Modify and Re-install your exhaust
to fit to the new down pipe.
Note if you have an exhaust brake
installed you will need to weld the
down-pipe
to
the
exhaust
connection. The stainless clamp will
not hold enough back pressure.
STAINLESS
EXHAUST CLAMP
Thread the upper oil line into the
exit/output of the check valve.
Thread the lower oil line into the
entry/input of the oil line. Both these
threads are pipe threads, so do not
use Teflon tape.
A very small
amount of liquid pipe dope may be
used.
With the line assembled, oil should
be able to flow to the turbocharger
but should not be able to drain back.
With the vehicle on the hoist, locate the oil filter/cooler assembly. Just to the right of the
assembly on the block you will be able to see a 19mm bolt that leads to the engine oil
rail. You will need to remove this bolt.
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
21
Once the bolt is removed, clean the
taper area and thread in the
M14x1.5 adapter.
Be sure to
remove the outer washer that holds
the O-ring in place. Also, lubricate
the O-ring before tightening.
You can now thread the feed line
onto the adapter and route the
complete auxiliary line up towards
the top of the engine. Route the line
away from the exhaust manifold,
charge pipe and the steering shaft.
Secure the line just above the frame rail to the hard fuel line. Ensure that everything is
secure and will not vibrate.
Before connecting the turbo oil feed
line, pre-fill the line with oil. Once
you have filled the line with oil you
can connect the line to the turbo.
Install the upper heat shield support
bracket
on
the
two
upper
compressor housing bolts. Make
sure the bracket is level and the
bolts are installed tight.
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
22
CUT ALONG LINE
Modify the factory heat shield with a cutoff
wheel as shown, stay to the outside of the
two spot welds. Install it with two of the
three original mounting bolts.
Install the powder coated air inlet elbow and plastic air inlet pipes. Use the provided 4”
clamps and silicone hose (cut hose to 2 ¼” long) for the elbow-to-turbo inlet connection.
When installing the inlet elbow, the fit will be very tight. It is recommended to install the
silicone hose and clamp to the elbow first, and then install it to the inlet of the turbo.
IF YOU ARE USING THE AFE TORQUE TUBE STAGE II KIT, YOU WILL
HAVE TO CUT A SECTION OFF OF THE SMALL END OF THE ELBOW TO
ACCOMMODATE THIS KIT. IF YOU HAVE THE FACTORY AIRBOX TUBE
YOU WILL NOT NEED TO CUT THIS PIPE.
Reconnect the pre heater and map sensor plugs. Re-install the breather hose to the “T”
on the passenger side. Re-mount the A/C compressor and hook up the high pressure
cutout and A/C clutch electrical connectors. You can use an extra piece of reflective
heat shielding to protect the A/C line that runs over top of the turbo. Re-install the belt
and refill the cooling system. Re-install the intake silencer plenum - note that 2001 year
vehicles will not be able to reuse the plastic intake silencer.
BEFORE STARTING THE ENGINE REMOVE THE OIL FEED LINE FROM
THE TURBO AND PRE-FILL THE FEED LINE.
Reprogram the vehicle’s radio stations and settings if desired.
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
23
Road Test
Before performing a road test, be sure that all clamps are tight and that nothing is
rubbing against the engine.
You will need to check for sufficient room between the down pipe and the firewall. To
do this, accelerate the vehicle in reverse turning both left and right. Then accelerate the
vehicle forward while turning left and right. If any unusual noise is heard, you may have
to re-adjust the down pipe and firewall.
On the test drive, ensure that there are no boost leaks, or worse, any exhaust leaks.
Once the test drive has been successful, you will need to re-tighten all of the exhaust
and intake bolts.
Please note the turbocharger should not exceed 40psi of boost pressure. If you are
experiencing low boost, you can adjust the wastegate (shortening the rod) to increase
the waste gate opening pressure.
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
3/26/2007
Duramax SuperMax Turbocharger (Part # 1046200)
24
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 and 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
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