Polaris Ranger TURBO Installation Guide. POLARIS RANGER DIESEL TURBO KIT Installation Guide ( )

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Nicholas Hoover
5 years ago
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1 POLARIS RANGER DIESEL TURBO KIT Installation Guide ( )

Legal in California only for racing vehicles which may never be used on the highway. 1. Breather Line 2. Breather Adapter 3. Breather Adapter 4. Turbo Mount 304SS 5. Hose Clamps (5) 6.

2 Legal in California only for racing vehicles which may never be used on the highway. 1. Breather Line 2. Breather Adapter 3. Breather Adapter 4. Turbo Mount 304SS 5. Hose Clamps (5) 6. Turbo Flange Bolts (6) 7. Turbo Flange Bolt 8. Turbo Hose Clamps (2) 9. Turbo Gasket 10. Turbo Gasket 11. Turbo Gasket 12. Turbo 13. Wastegate Cap 14. Waterlines w/ Hose Clamps 15. Waterlines w/ Hose Clamps 16. Waterline Hose Clamps (4) 17. Breather / Water / Oil Lines Hose Clamps (6) 18. Breather / Water / Oil Lines Hose Clamps (4) 19. Waterline Adapter 304SS 20. Waterline Adapter 304SS 21. Hose Clamp 22. PPE Performance Silicone Hose 1 3/4 ( ) 23. Intake Adapter Hoses* *Cut Stock Intake Tube to produce these piece 24. Intake Adapter Hoses* *Cut Stock Intake Tube to produce these piece 25. PPE Performance Silicone Hose 1 1/2 ( ) 26. Intake & Exhaust Tube 304SS 27. Upper turbo feed tube 28. Intake & Exhaust Tube 304SS 29. Intake & Exhaust Tube 304SS 30. Muffler Mount 304SS 31. Oil Return 32. Oil Return Bolts (2) 33. Muffler Bracket Bolts (2) 34. Muffler Mount Bolts (2) 35. Oil Feed / Return Fitting 36. Oil Feed / Return Bolts (2) 37. Oil Line Feed 38. Oil Line Return 39. Oil Feed Line Adapter for Oil Pressure Sensor 40. Exhaust Heatshield Bolts 2

3 3 - Polaris Ranger TURBO Installation Guide

4 4 - Polaris Ranger TURBO Installation Guide

5 5 - Polaris Ranger TURBO Installation Guide

Polaris was inspired when they added a diesel-powered model to their line of Ranger UTV s, and PPE was no less inspired when they engineered a complete turbocharger system for it.

Adding the PPE Polaris Ranger Turbo Kit to the Ranger s 904cc, 3-cylinder diesel engine will raise the horsepower rating by up to 9hp. That s a 30+% increase over the stock Rangers 24hp output!

6 Polaris was inspired when they added a diesel-powered model to their line of Ranger UTV s, and PPE was no less inspired when they engineered a complete turbocharger system for it. That s right, for those Ranger owners, including the US military, who want the benefits of a diesel engine but want and need more power, PPE now offers their Polaris Diesel Turbo Kit. Adding the PPE Polaris Ranger Turbo Kit to the Ranger s 904cc, 3-cylinder diesel engine will raise the horsepower rating by up to 9hp. That s a 30+% increase over the stock Rangers 24hp output! At the heart of the PPE kit is a high-quality, water and oil-cooled Garrett GT1241 turbo that produces 8-10psi of power-giving pressure. The PPE Polaris Ranger Turbo Kit features 304 Stainless Steel, precision TIG-welded intake and exhaust tubes and all parts and instructions necessary for an easy install. The innovative PPE design retains the factory air box and muffler and has been fully dyno-tested for optimum reliability. As with all PPE products, you can depend on high-quality design and construction to get you to the fun and back again. STEP 1-6

7 STEP 2 squeeze the sleeve about 3/8-inches from the STEP 3 STEP 4 7

8 STEP 5 STEP 6 is installed onto the engine and clutch mounting bolts. SPECIAL NOTE: 8

9 STEP 7 1) to be routed correctly. STEP 8 STEP 9 outer ring of the breather must be coated with 9

10 STEP 10 STEP 11 unit. STEP 12 STEP 13 wastegate actuator rod. 10

11 STEP 14 - onto the activation arm. STEP 15 Loosen all bolts surrounding the turbo but only remove the two holding the wastegate STEP 16 Thread the clevis onto the wastegate rod as far as it can go. STEP 17 this mounting bolt is aligned with the edge of bolts so the housing can t rotate any longer. 11

12 STEP 18 originally installed. STEP 20 is tension on the arm. The clevis should slide hold the wastegate valve closed. Note: some wastegates may need to have threaded rod STEP 19 Fully tighten all of the housing bolts. STEP 21 turbocharger housing. 12

13 STEP 22 housing. STEP 23 - (Before installing the turbo you will need to prime it with oil through the small port on the bottom of the turbo itself. With oil primed in the turbo you will need to spin the blades to lubricate the bearing.) 13

14 STEP 24 - STEP 25 Route axle breather hose so that it does STEP 26 STEP STEP 28 14

15 STEP 29 - SPECIAL NOTE been removed. STEP 30 STEP 31 STEP 32 remove oil pan 15

16 STEP 33 DO NOT drill hole with oil pan attached to the engine or metal shavings will contaminate oil. STEP 34 Do not allow gasket material to block oil return hole. STEP 35 STEP 36 16

17 STEP 37 STEP 38 STEP 39 17

18 STEP 40 STEP 41 - STEP 42 - STEP 43 shield. 18

19 STEP 44 STEP 45 STEP 46 sending unit using anti-seize on threads. STEP 47 Install lower tube that from air box to 19

20 STEP 48 STEP 49 the lower tube. STEP 50 your motor. STEP 51 STEP 52 cables away from turbocharger housing. 20

05-08 GT. Hellion Power Systems Mustang Kit Instructions

05-08 GT. Hellion Power Systems Mustang Kit Instructions Hellion Power Systems 05-08 Mustang Kit Instructions 1. Disconnect Battery 2. Drain Radiator, keep fluid for re-installation. 3. Remove air box and inlethoses. 6. Next, underneath, punch oil pan for turbo