2011-2013 LML DURAMAX COMPOUND-ADD 2011-2015 LML A Duramax TURBO KIT Add INSTALL A Turbo INSTRUCTIONS Compound Kit Installation Instructions 1-800-955-0476 - www.industrialinjection.com - info@industrialinjection.com
1-Disconnect both batteries. 2-Remove air filter assembly from truck. 3-Remove water bottle. 4-Remove battery on passenger side and battery tray. 5-Remove passenger fender wheel.
6-Remove plastic intake assembly by rotating plastic ring. 7-Remove cast intake assembly by removing bolts using a 13mm socket, Remove power wire going to the grid heater. 8-Remove plastic intake from stock turbo using an 8mm, undo the V band clamp all the way and take out.
9-Remove turbo cover using 10mm, Remove 3 bolts on top.
10-Remove EGR pipe/ EGR coolers/ EGR valve 11-Remove heat shield off of down pipe by removing 10mm bolts, remove upper V band clamp off of back of turbo, and remove lower V band clamp and bolt, and remove all 3 sensors from down pipe, remove heat shield of back of up pipes using 10mm.
12-Remove EGR support bracket. 13-Remove fuel filter assembly
14-Install new block off plates using stock gaskets and new supplied bolts, install new up pipe with new gaskets.
15-Install turbo support bracket using supplied hardware, install fitting using thread tape, into the support bracket, remove both 15mm bolts and 3 ground wires, install turbo in upper holes of block and reconnect all 3 ground wires. USE TOP MOUNTING HOLES
16-Install big turbo on turbo support bracket using supplied bolts and gasket; loosen both exhaust and compressor housing clamps to allow housing to rotate.
17-Install hot pipe using stock V band clamp and supplied bolts and gasket, install pipe to back of stock turbo using the V band clamp, tighten clamp so pipe can rotate a little. You will tighten tight later on, now pull the big turbo up to the flange and install gasket and bolts and tighten tight, then tighten V band clamp on stock turbo tight, and the exhaust housing on the big turbo tight. Make sure to move the A.C. lines away from the turbo.
18-Remove upper water line (back of turbo) install supplied hose to turbo, and install rubber block off plugs on the main water line. Also install rubber cap on the Thermostat housing. Two 2-3/8 3/8 IS FOR plugs THE for the WATER water PIPE pipe. One 1-1/4 1/2 IS FOR plug THE for the THERMOSTAT thermostat housing. HOUSING
19-Install the supplied cast aluminum 90 elbow to the stock turbo using supplied o-ring and clamp. You may need to leave the clamp use for alignment of 19-Install aluminum cast 90 degrees housing on to stock turbo using a the new elbow. O-ring Make and sure stock, to tighten clamp the tighten clamp up when snug. aligned You correctly. will need to leave a little loose for fine adjustments later. 20-Install stock intake assembly and pull the engine oil dipstick to the front of the intake assembly plug in all connectors and hookup power wire to the intake heater.
21-Remove the starter of the truck, and with 37/64 drill bit drill a hole in the top of the oil pan and use a 3/8-18 pipe tap and tap the hole. Install the supplied 45 degree 3/8 fitting (use Teflon tape on threads), reinstall starter. Hook up supplied oil drain hose using the 90 degree fitting and connect it to the 45 degree fitting just installed. It is recommended to remove the bottom section of the oil pan to completely remove metal shavings. Remove starter Drill and tap Install 45 fitting Use assembly lube on straight fitting Press oil drain hose on to 5/8 fitting Connect oil drain hose to 45 fitting in oil pan 21b-Install turbo oil feed line, remove banjo bolt from stock turbo and install new supplied banjo bolt. Use stock brass washers and use teflon tape on all pipe fittings. And route oil feed line properly.
22-Install cold pipe using supplied clamps and green o-ring. Connect charge pipe to the cast elbow using supplied 3.5 to 3 boot. During installation rotation of the compressor cover and charge pipe may be necessary for clearance.
23-Install new intercooler pipe with all supplied hardware and install sensor from stock plastic pipe.
24-Install intake and air filter install air sensor into pipe using supplies 8/32 machine screw make sure arrow on sensor is facing towards intake of turbo. Connect the sensor plug. 25-Install fuel filter with new bracket and hardware run new fuel lines and extend wires, solder all connections.
26-Install new coolant bottle. You will need to cut factory stud on the fender so the bottle sits flat. Using factory hardware, mount the front portion of the coolant 26-Install bottle. To new mount water the bottle rear portion, cut off see one images stud so below. water Connect bottle 1/2 sits flat, black use hose front from 10mm radiator bolt to and the self coolant tapper bottle. in rear Choose and one use of stock two supplied cap, use lower the ½ hose fittings (depending on year) and install in coolant bottle. Be sure to install supplied 1/4 hose and fitting to coolant bottle fill neck and vent to atmosphere. black hose for the upper overflow and connect the stock hose to the bottom port. CUT OFF STUD TO MAKE BOTTLE FIT Fig. A To mount, mark and drill hole in fender. Then install supplied bolt and hardware as shown in figure A. Coolant Bottle Tab Fender Bolt Nut Lock Washer Washer Nut Washer Washer Route to atmosphere Install fitting. Depending on the year hose sizes may vary. Routed from radiator
27-Install two piece 4 down pipe using supplied clamp. Be sure to adjust down pipe to allow clearance between the frame and fire wall. We highly recommend installing the two piece down pipe, then mark it, and tack weld it. Then remove it to completely weld the pieces together and re-install. Note: You may need to loosen the 10mm nut holding the A/C accumulator and push it towards the engine out of the way of the down pipe then re-tighten. For your convenience we have supplied an extra band clamp to use if you do not have the option of welding the two piece down pipe together. 27-Install down pipe using the 2 supplied clamps, pipe may need to be adjusted. 28-Relocation of Battery on the passenger frame using new battery tray and hardware.
29-Drill 3 holes into the fuse panel assembly, cut & grind the plastic flat for mounting screws. Apply insulation on back of fuse block to insure no contact between bolts & firewall. Shave the battery lips off for a better fit on the frame mount. Note the location for the fuse block. Be sure to label fuse block, wires, and fuses. The orientation of these do change to relocate the battery. Follow the diagram below for new fuse panel layout. DRILL HOLES FOR MOUNTING GRIND MIDDLE SECTION CUT THIS LIP OFF LIP IS REMOVED GLOW PLUG CONTROL MODULE INTAKE AIR HEATER TO FUSE BOX TO ALTERNATOR BATTERY POWER DRIVER SIDE STARTER BATTERY POWER DRIVER SIDE
Final Checklist & initial startup 1-After installing the fuse block ensure all wires are secured and free of heat sources. 2-Connect Battery Cables 3-Remove all tools from engine bay 4-Check for any loose/unplugged connectors 5-Check all coolant hoses & new coolant cap 6-Bleed the BorgWarner S400 turbo -This can be done by leaving the oil feed line loose on the turbo oil inlet -Start the truck for a second and turn off quickly -Repeat until you have oil coming out of the inlet line at the charger. -Tighten the oil line and clean off the oil 7-Start the truck and check for leaks -No leaks present, test drive the truck and get it to operating temperature -Re-check for any leaks 8-Install inner fender well, some of the fender wells may need to be cut out of the way from the exhaust turbine housing. Make sure the fender well does not push wires towards and heat source. 1-800-955-0476 - www.industrialinjection.com - info@industrialinjection.com