PowerMax Diesel Upgrade For Cummins Engines 00.5-007.5 Dodge Ram With Cummins 5.9L Item 3 4 5 6 7 8 9 0 3 4 5 6 7 8 Parts List Description Turbocharger Ancillary kit 773069- (includes) Installation Instructions Gasket Kit 76909-36 Turbine inlet gasket Oil drain gasket Turbine inlet bolt 400677-045 Turbine inlet washer 707447-3 Water Line Kit 76406- Water line, inlet (small) Water line, outlet (large) Banjo bolt Crush Washer Oil inlet fitting kit 759359- Oil fitting, inlet O-ring seal (small) O-ring seal (large) Bolt Installation Instructions 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) Qty 4 7/6 deep-well socket 7mm socket 8mm -point socket 0mm socket 3mm socket 4mm socket 0mm hex socket or Allen wrench Tools Needed 3mm open end wrench 4mm open end wrench 3/6 open end wrench Torque wrench 6 extension NOTE: Bolt and fastener sizes may be different from one model year to the next depending on OE specifications. Different tools than those listed above may be required. Recommended Other Items Factory Service Manual Safety glasses Catch basin for engine coolant Engine coolant (quantity per service manual) Anti-seize compound Oil filter Oil (quantity per service manual) IMPORTANT INFORMATION - PLEASE READ CAREFULLY We recommend that this turbo upgrade kit be installed by a qualified automotive technician. If you have any doubts as to your ability to install this turbo upgrade kit, consult with a local automotive repair company. Please be sure to carefully read all of the attached instructions prior to starting the installation process. If you have any questions about the enclosed parts or the instructions, call the distributor that you purchased the kit from for clarification. Prior to the PowerMax Kit installation, be sure that the vehicle is parked on a level surface and the engine is cool. Engine fluids and components can be extremely hot following normal vehicle operation. Avoid direct contact of engine fluids or components with your skin; may cause personal injury. NOTE: It is recommended that the oil and oil filter are changed prior to installing the Garrett turbocharger. This will provide clean oil to the new turbocharger. To ensure optimal performance, always follow oil and filter change intervals per the Factory Service Manual. The turbocharger comes with the actuator pre-calibrated for stock boost level. The actuator can be adjusted to achieve higher boost and each half turn of the actuator rod end will raise boost by approximately.5 psi. Increased boost places additional stress on the entire drivetrain. Excessive boost will lead to overspeed of the turbocharger, which is not covered by any warranty. Refer to spec sheet for maximum boost recommendations.
Installation Instructions Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3). Disconnect the negative terminal from both batteries.. Drain engine coolant according to the service manual. 3. Loosen the clamp on the compressor inlet hose and remove hose (Fig. ). Leave the hose attached to the air filter housing. Fig. 4. Unclip the three clips on the top of the air filter housing and unplug the connector (Fig. ). Remove the top of the air filter housing with the hose still attached and set aside. Connector Fig. 5. Loosen the clamp at the compressor housing outlet (Fig. 3). This clamp will be reused. Fig. 3
Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) 6. Remove the oil line from the top of the stock turbocharger (Fig. 4). Fig. 4 7. Using a rag, move the oil line out of the way (Fig. 5). 8. Remove the two bolts on the oil drain flange, located on the bottom of the turbocharger (Fig. 6). Set the two bolts aside. Separate the oil drain from the turbocharger center section. Inspect the oil drain flange for remaining gasket material. Remove gasket material prior to Garrett turbocharger installation. Fig. 5 Fig. 6 9. Remove the nut from the exhaust v-band clamp and slide the it down (out of the way) over the exhaust (Fig. 7). Fig. 7 3
Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) 0. Remove the two rear exhaust flange nuts located on the bottom of the turbocharger flange and set aside (Fig. 8). While supporting the turbocharger, remove the front two flange nuts and set aside. Carefully remove the stock turbocharger from the vehicle. Front Rear Fig. 8. Disconnect and remove the coolant hose (Fig. 9) from the tube and move it out of the way. Fig. 9. Remove the coolant tube assembly from the engine (Fig. 0). This assembly will not be used with the Garrett turbo upgrade kit. Remove this tube assembly Hose couple with clamps Fig. 0 3. Place the Garrett turbocharger on a workbench. Using the smaller (inlet) water line, one banjo bolt and two crush washers from kit 76406-, install the water line on the center housing as shown in Fig. (continued on next page). Fig. 4
Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) 4. In order to tighten the banjo bolt, it may be necessary to use a 0mm Allen wrench and a combination wrench together, as shown in Fig.. It may be necessary to rotate the water line after installing the turbocharger. Test-fit the turbo before fully tightening the line. On some vehicles, slight adjustment of the water line bends may be necessary. Gently bend the line if there is any interference with nearby components. 5. The short water line will use the port nearest to the turbine housing inlet flange as shown in Fig.3. It runs behind the turbine inlet flange, under the exhaust manifold and connects to the nearby stock water line. Water line runs behind the turbine inlet flange Fig. Fig. 3 6. Use the turbine inlet gasket from kit 76909-36 and place it on the studs on the stock manifold as shown in Fig. 4. Note: It is recommended to place anti-seize compound onto the stud threads prior to installation. 7. Obtain the four stock nuts that were set aside in Step 0 and the two turbine inlet bolts from the kit. Carefully install the Garrett turbocharger onto the studs and hand-tighten the back nuts. Apply antiseize compound to the bolt threads and install the bolts and nuts as shown in Fig. 5. Torque to 3 lbf ft. Fig. 4 Fig. 5 5
Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) 8. Connect the smaller (inlet) water line with the straight hose couple supplied and fasten with the supplied clamps. Tighten the banjo bolt using a 0mm hex key. 9. Use the oil drain gasket from 76909-36 kit and place it on the stock oil drain flange as shown in Fig. 7. Fig. 6 0. Using the stock bolts, assemble the oil drain flange onto the center housing of the turbocharger as shown in Fig. 8. Torque to 8 lbf ft. The oil drain flex-tube may need to be adjusted to fit properly. Fig. 7 Fig. 8. Use the last banjo bolt and two crush washers from kit 76406-. Route the large end of the long water line up to the water port on the center section and assemble using a 0mm hex socket as shown in Fig. 9. Do not tighten the banjo bolt yet. Banjo Bolt Water Line Crush Washers Fig. 9 6
Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3). Find the 90 black silicone elbow in water line kit 76406-. Install the large end of the elbow on the vertical tube near the oil filter, where the stock water line was connected (Fig. 0). Insert the end of the new long water line into the small end of the elbow. It may be necessary to adjust the bends on some vehicles to ensure proper fitment. Bend the new water line gently to adjust the fitment. Once the line fits is properly located, tighten the hose clamps. Torque the banjo bolt on the turbo to 30 lbf ft. Fig. 0 V-Band 3. Install the stock exhaust elbow onto the turbine housing outlet using the stock upper v-band clamp. Fig. 4. Install the stock lower v-band clamp to connect the exhaust elbow to the vehicle exhaust. V-Band 5. Install the stock compressor outlet hose and clamp. Fig. Outlet hose and clamp Fig. 3 7
6. For trucks equipped with a boost control solenoid, remove the solenoid from the OE turbocharger (see Fig. 4). Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) Boost control solenoid 7. Remove the compressor plug from the Garrett turbocharger (see Fig. 5) you will not need the plug. Install the boost control solenoid in the Garrett turbocharger. Reconnect the power connector for the boost control solenoid. For trucks without a boost control solenoid, leave the plug installed in the compressor housing. Plug Fig. 4 8. Use the oil inlet fitting and larger O-ring from kit 759359-. Install the O-ring into the groove on the bottom of the fitting as shown in Fig 6. Fig. 5 Fig. 6 9. Using the two bolts supplied in kit 759359-, install the fitting onto the Garrett turbo s center housing using a 8mm -point socket as shown in Fig. 7. Pay close attention that the O-ring did not come out of the bottom groove during installation. Torque to 7 lbf ft. Install the small O-ring from kit 759359- onto the oil inlet fitting. Bolts O-Ring Fig. 7 8
Part Number: 75936-000 (Stage ) 75936-00 (Stage ) 75936-00 (Stage 3) 30. Assemble the stock oil line onto the fitting as shown in Fig. 8. 3. Assemble the hose onto the compressor housing inlet as shown in Fig. 9 and tighten the clamp. Torque to 7 lbf in. 3. Clamp the top of the air filter assembly into place and reconnect the plug on top of the hose. 33. Refill the engine coolant per the service manual. 34. Check the engine oil level. 35. Attach the negative battery terminals on both batteries. 36. Start the vehicle and allow it to idle until the engine is at operating temperature. Check for leaks. 37. Once it is confirmed that there are no leaks, you are ready to enjoy your new PowerMax turbocharger upgrade kit! Fig. 8 Fig. 9 NOTE: The turbocharger comes with the wastegate actuator pre-calibrated for stock boost levels. The actuator can be adjusted to achieve higher boost and each half turn (shortening the rod) will raise boost by approximately.5 psi. Increased boost places additional stress on the entire drivetrain. Excessive boost will lead to overspeed of the turbocharger, a condition which is not covered under warranty. Maximum recommended boost for this turbocharger is 40 psi. After adjusting the rod, apply 30-35 psi to the actuator to extend the rod, which will ease reinstallation of the rod end on the wastegate crank pin. Reinstall the retaining clip on the pin. Garrett by Honeywell makes no guarantee that the engine or drivetrain will be able to handle increased boost. Any adjustments are made at the user s own risk. Honeywell Turbo Technologies Garrett Independent Aftermarket Honeywell International Inc. 30 W. Lomita Blvd. Torrance, CA 90505 9