BD Twin Turbo Cobra Kit

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1 17 March Dodge Cobra Kit (I-00377) 1 BD Twin Turbo Cobra Kit Dodge HPCR Machined BD turbochargers only BUILDERS KIT Installation reccomendations to aid asssembly Does not include detailed instructions This is an installation guidline. Do not attempt without installation expereience. Read installation notes prior to install. This kit will require a race tuner and deletion of the EGR cooler. UNLESS AN EO# IS LISTED, THIS PRODUCT IS LEGAL IN CALIFORNIA. FOR RACING VEHICLES ONLY, WHICH MAY NEVER BE USED UPON A HIGHWAY.

2 17 March Dodge Cobra Kit (I-00377) 2 Order Guide Kit PN Years BD Cobra Kit Secondary Turbo Turbo Turbine Primary Turbo SXE 76mm - 1.0AR 476 SXE SXE 80mm - 0.9AR 476 SXE SXE 80mm - 0.9AR 476 SXE SXE 80mm - 0.9AR 480 SXE SXE 80mm - 1.0AR 480 SXE SXE 80mm - 1.0AR 480 SXE SXE 80mm - 1.0AR BD SXE 80mm - 1.0AR BD 486 l SXE 80mm - 1.0AR BD S467 83mm - 1.0AR 488 SXE S467 83mm - 1.1AR 488 SXE S467 83mm - 1.1AR 488 SXE Name Inducer Size Potential Crank Horsepower Min Rated Peak Max Flow (Lb/min) *RPM to Spool **Transient Response BD Single Turbo Kit Guide Super B Single 58mm Super B Killer 63mm Super B Killer SXE 61mm Super B Special 64.5mm Super B Special SXE 63mm Super B mm Super B 600 SXE 64.5mm Super B mm Super B 650 SXE 66mm Super B 700 SXE 69mm Rumble B (369 SXE) 69mm Rumble B (467) 67mm Rumble B (472) 72mm S476 SXE 76mm S480 SXE 80mm BD mm S488 SXE 88mm S588 SXE 88mm S594 SXE 94mm K44 107mm BD Compound Turbo Kit Guide Tow Twin 58mm/66mm RT700 58mm/71mm RT mm/74mm Cobra 76 61mm/76mm Cobra mm/80mm Cobra 86 66mm/86mm Cobra 88 67mm/88mm BD Triple 74mm/2x74mm *Suggested RPM based on 5.9L 24V. Value will vary depending on engine application, displacement, turbine selection and supporting modifications **Estimated turbocharger response comparison

3 17 March Dodge Cobra Kit (I-00377) 3 Kit Contents T T Manifold; with Wastegate Port Exhaust Manifold Gasket Set LP Turbo Bracket Qty: 1 Qty: 1 Qty: Battery Box Air Box Air Box Support Blanket: T4 Turbine Qty: 1 Qty: 1 Qty: 1 Qty: CU CU Oil Drain- Coolant Tube 5 Air Filter Oil Drain-Primary Secondary 5/8 Qty: 1 Qty: 1 Qty: 1 Qty: B Turbo Oil Feed (-6JIC 90 x - Bracket; Front 1-1/8 Barb x Air Intake Seal 6JIC) Mount ¾ NPT Qty: 2 Qty: 20 & 27 Qty: 1 Qty: 1

4 17 March Dodge Cobra Kit (I-00377) 4 Mounting Hardware M6-1.0x12mm Flange Nut; Jam M6x1 M6-1.0 U-Nut ¼ Washer Qty: 8 Qty: 2 Qty: 5 Qty: FT M8 Flange Nut Insulated Clamp 1 M8-1.25mm Bolt #152 Viton O-Ring Qty: 1 Qty: 2 Qty: 3 Qty: 1 FT #244 Viton O-Ring Gasket; Dodge MAF Gasket; Dodge IAT 5.9L O-Ring; 10mm x 2.5 Qty: 1 Qty: 1 Qty: 1 Qty: FT Support Bracket Bolt Support Bracket Bolt; Flange Nut M10-1.5mm (M10x1.5x20) Washer (M10) M8x1.25 Qty: 2 Qty: 2 Qty: 2 Qty: 2

5 17 March Dodge Cobra Kit (I-00377) FT Turbo Oil Inlet Adapter ORB-6JIC 1/8 NPT x -6JICM #8-32 SS Screw (1/4MPTx-6JIC) Fitting Qty: 1 Qty: 2 Qty: 4 Qty: D FT Hex Plug; ½ 5/8 barb x1/2 NPT Nut; M6x1 Flange Qty: 1 Qty: 1 Qty: 1 Boots & Clamps Clamp; Spring Clamp; 1-1/4 Coolant Line 1- Hose; Heater 5/8 26mm Gear 1/8 x5/8 Qty: 6 Qty: 1 Qty: 8 Qty: TCC Coolant Line Clamp; V-Band Clamp; V-Band Boot; Silicone 5/ x3.5 Qty: 1 Qty: 1 Qty: 1 Qty: 1

6 17 March Dodge Cobra Kit (I-00377) HS-96 Clamp; Clamp; Boot; Silicone Clamp; 5"-7" x3.5 Qty: 5 Qty: 1 Qty: 1 Qty: B P Stainless Steel Down Reducer; 5 x5.5 Clamp; V-Band 5.88 Pipe Clamp Qty: 1 Qty: 1 Qty: 1 Piping Primary Inlet 3.5 Primary Outlet 3.5 Secondary Inlet Qty: 1 Qty: 1 Qty: 1

7 17 March Dodge Cobra Kit (I-00377) Cobra Casting Downpipe 5 Exhaust Downpipe Qty: 1 Qty: 1 Cobra S400 Mounting Hardware RG-VT10481 Stud M10- Stud M10- Nut M10- S400-T6 Hot Pipe 4.81 V-Band Clamp 1.5 x x mm Qty: 1 Qty: 2 Qty: 4 Qty: 6 Qty: 1 Cobra S300 SX-E Mounting Hardware FT RG SXE-T6 Hot Stud 3/8 - Stud M10- Nut 3/8 Nut M V-Band Pipe x 35 NC 1.5mm Clamp Qty: 1 Qty: 2 Qty: 4 Qty: 2 Qty: 4 Qty: 1

8 17 March Dodge Cobra Kit (I-00377) 8 Year Dependent Parts FT Fitting; ¾ NPTx ¾ NPT 90 Plate; MAF Block Off 3.5 CAC Inlet Tube Boot; Silicone 3.5 x3.5 Qty: 1 Qty: 1 Qty: 1 Qty: 1 Years Fitting; ¾ NPTx ¾ NPT 90 Deg Fitting; Barb 1-1/8 x ¾ NPT 3.5 CAC Inlet Tube Qty: 1 Qty: 1 Qty: 1 Qty: Boot; Silicone 3.25 x3.5 Coolant Tank Plug; 1 Barb Heater Hose; 4 Qty: 1 Qty: 1 Qty: Tube; Crank Breather 6.7L Clamp; 11/ Qty: 1 Qty: 2

9 17 March Dodge Cobra Kit (I-00377) 9 Turbocharger Oil Feed/ Drain Layout (Primary/ Secondary) Item No. Part No. Description Qty STUD; M10 x 1.5 x FT STUD;3/8-16x2" 2 2 CU Oil Drain; Cummins Primary 1 CU Oil Drain; Cummins Secondary NUT; M10x1.5 Small Flange NUT, 3/8 NC Turbo Oil Inlet 1/4MPT X -6JIC B -6JIC 90 X -6JIC HOSE Fitting; ORB x -6 JIC Adapter; Oil Feed 1/8NPT x -6MJIC mm O-ring Drain; Block Adapter 1

10 17 March Dodge Cobra Kit (I-00377) 10 Coolant Lines Layout Item No. Part Number Description Qty Coolant Tube; Dodge 5/8" Line 1 2 FT Fitting;3/4NPT x 3/4 NPT 90d Fitting; Coolant Hose Clamp Fitting; Coolant Hose Block Fitting; Barb 1.125"-3/4" Coolant Line;1-1/8x 5/8x 6.25L Clamp; Spring CTB-26mm Clamps;1-1/4 Gear (HS12) Hose; Heater 5/8" ID (in) 8" Coolant Line; Dodge 5/8" TCC S Clamp; Insulated 1"( ) Nut, M8 Flange Bolt, M Flange Bracket; Engine Hoist Mount 1

11 17 March Dodge Cobra Kit (I-00377) 11 Turbocharger and Piping Layout

12 17 March Dodge Cobra Kit (I-00377) 12 Item No. Part No. Description T4 Manifold; T4 Waste gate Bracket; T6 Primary Support M10 x Mounting Bracket Bolts M10 x Mounting Bracket Washer 2 5 Primary Turbo Adapter;T6 S400 HM Hot Pipe Adapter;T6 S300 SX-E HM Hot Pipe STUD; M10 x 1.5 x T6 Dual Volute Gasket NUT; M10x1.5 Small Flange STUD; M10 x 1.5 x T4 Dual Volute Gasket 1 12 Secondary Turbo /5 Adapter; FM V-Band S400 4" /5 Adapter; HM V-Band S RG-VT Clamp; V-Band 4.81" (.207") 1 RG Clamp; V-Band 4.21" (.14") Pipe; Primary Outlet Tube 1 17 FT O-ring; #152 (.139) 3.25" Viton Boot; Silicone 3.5"x 3.5" 4ply Boot; Silicone 3.5"x 3.5" 4ply Boot; Silicone 3.25 x3.5 4ply Clamp; Clamp; V-Band 4.50" Pipe; Secondary Inlet 1 23 FT O-ring; #244 Viton(.139) 4.25id Clamp; V-Band P Reducer Sleeve; 5 1/2" x 5" 1 26 HS-96 Clamp; 5" - 7" Worm Gear Pipe; Primary Intake Gasket; Dodge MAF Gasket; Dodge IAT Plate; MAF Block Off BD Intake 1 31 FT Screw;#8-32 x 9/16 Pan Head SS D 3 Hex Plug; ½ /8 x 1/2 Npt Pipe; CAC 3.5" Pipe; CAC 3.5" Clamp; Intercooler Boot 3"-3.5" x 4" Intercooler Boot 2.75"-3.5" x 5" Cobra Casting; 5 Downpipe Clamp; V-Band 5.88" B Clamp; SS Exhaust Lap 5" Exhaust; Dodge S400 Twin Downpipe D 3 Plug; Hex Head ½ NPT Fitting, 5/8 Barb x ½ NPT Tube; Crank Breather 1 1 Included with S400 Cobra kit 2 Included with S300 SX-E Cobra kit 3 Included in vehicles 4 Included in vehicles 5 Installed on compressor cover Qty

13 17 March Dodge Cobra Kit (I-00377) 13 Air Box & Battery Tray Layout Item No. Part Number Description Qty Air Box Air Box Bracket Nut; Jam M6x Bolt; M6-1.0x Battery Box U Nut; M Extruded Washer, Flat - 1/4" Air Filter 1 9 HS-96 Gear clamp Air Intake Seal Air Intake Seal 27"

14 17 March Dodge Cobra Kit (I-00377) 14 Installation Notes & Recommendations BUILDERS KIT DOES NOT INCLUDE STEP-BY-STEP INSTRUCTIONS THIS IS AN INSTALLATION GUIDELINE. DO NOT INSTALL WITHOUT PREVIOUS TURBO INSTALLATION EXPERIENCE. Recommendations: - Remove passenger battery, battery box, fender liner, 2 nd oil drain frost plug, and coolant lines near turbo. Drain the coolant and A/C system prior to install trucks will require the coolant bottle to be removed. - Remove the passenger side shock tower and shock. - The AC lines and transmission dip-stick tube will need to be re-shaped to fit. - If you have a steel receiver/dryer, we recommend replacing it with an aluminum one to help persuade lines into place. - Install the ¼ NPT x JIC oil feed lines and oil drain studs prior to turbo install. - Install the exhaust manifold and gaskets ( T4 & T4), but do not install studs on the T4 outlet. Ensure the waste gate port is facing downward. - Install coolant lines , , and trucks will require the use of the included 90 degree NPT fitting and will require installation of the NPT adapter block , , and Mount using 2x insulated clamps ( ). Use supplied stud on the primary turbo mounting bracket and M8 threaded hole on cylinder 6 fuel line protector and onward trucks will require the engine hoist mount to be replaced ( ). Remove alternator and replace bracket. - Install primary turbo bracket ( ) with the bolts ½ turn away from tight (the bracket should be able to move slightly). Tighten these bolts after the hot pipe has been attached to the secondary turbo. - Install the 4x ( ) 35mm long studs into the hot-pipe. Mount the hot pipe ( / ) to the 96mm turbine housing using a T6 dual volute gasket and 2x M10 nuts ( ). The remaining 2x M10 nuts will be installed after the turbo is mounted.

15 17 March Dodge Cobra Kit (I-00377) 15 - Mount the battery box and battery. Insert U-nuts to battery box for grid heater relay, air box support, and OEM battery tie down mount prior to installing the battery box. - Push on the supplied 5 M6x1 U- nuts onto the battery box Re-use the OEM battery tie down bracket by bolting it into the supplied M6 U-nut. - Loosen the turbo cartridge clamps (do not remove clamps) and orient the turbine housing and compressor cover in the configuration shown (orient for installation only). Re-tighten the clamps before moving the turbo. - Install the primary turbo onto the primary turbo bracket ( ) and install the remaining M10 nuts to hand tight. - Install the remaining 4x M10 studs, T4 gasket, and waste gate or waste gate cap onto the T4 exhaust manifold. - Mount the secondary turbine housing onto the manifold. Align the hot-pipe up with the secondary turbine housing and attach using the supplied V-band clamp. Tighten the primary bracket ( ) bolts and M10 nuts after the turbine outlet clamp is tight. - Install the primary and secondary turbo oil drain and feed lines trucks will require the coolant overflow tank to be installed. Use the supplied 1 plug and 1 hose to plug the bottom drain. Clip the coolant tank onto the battery box and fasten in place with supplied M6 bolt and nut. Connect the radiator overflow hose onto the vertical barb. - Install the primary outlet tube ( ) with supplied O-ring prior to installing the secondary inlet tube ( ). Ensure the O-ring is not pinched or torn during install. - Install air box bracket with 2x M6 bolts, nuts, and washers to Clock the secondary compressor cover to ensure the CAC tube does not interfere with the hood or plastic cowling. Centre the boots and ensure all clamps installed behind any tube beat to keep boots from slipping. - Mount 20 of to 5 inlet diameter of air box. Mount 27 of to upper edge of air box. - Boot locks are recommended to be installed on both sides of the 3.5 CAC tube. Due to hood clearance, it is recommended to install boot-lock mounts on the underside of the compressor cover outlet/ CAC tube.

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