KC TURBOS KC300X Turbochargers 1999-2003 7.3 Powerstroke Instruction Manual

June 9, 2024
KC TURBOS

KC TURBOS KC300X Turbochargers 1999-2003 7.3 Powerstroke Instruction Manual
KC TURBOS KC300X Turbochargers 1999-2003 7.3
Powerstroke

REMOVAL

  1.  Disconnect Negative Terminal of Batteries.

  2. Remove the Engine Cover.

  3. Unplug the green hose from the compressor intake duct. Remove Intake duct and crankcase breather. Unplug and Label the red wastegate solenoid vacuum hose and pressure hose. Make sure to label each hose.

  4. Disconnect the charge air cooler Inlet and outlet pipes.
    Disconnect

  5. Label and disconnect the intake air heater element leads, Intake Air Temperature sensor electrical connector, Manifold Absolute Temperature (MAP) sensor electrical connector and pressure hoses.
    Disconnect

  6. Loosen the clamps and remove the compressor manifold. Cover intake manifold openings to prevent foreign objects from entering.
    Loosen the clamps

  7. Remove and discard compressor O-Ring.

Remove and discard compressor O-Ring.

  1. Loosen the Marmon Clamp and disconnect downpipe/exhaust outlet pipe.
    Loosen the Marmon Clamp

  2. Disconnect the exhaust back pressure valve.

  3.  Slide the retainer clip away from the exhaust back pressure valve actuator lever.

  4. Detach the exhaust back pressure valve actuator rod.
    Disconnect the exhaust

  5. Loosen the Marmon clamp (Cannot be removed while Turbocharger is installed)
    Loosen the Marmon clamp

  6. Remove the bolts that secure Turbo on Pedestal.

  7. Remove the Turbocharger.
    Remove the bolts

  8. Remove and discard the Pedestal O-ring seals.

  9. Remove the backpressure valve assembly from the old turbo and install on your new KC300X. Use Anti-seize compound and torque down the bolts to 15-18 lb/ft.
    Remove the backpressure valve

  10. BE SURE to inspect Turbo air inlet, exhaust inlet and all other old components for foreign material.

  11. Seat supplied pedestal O-Ring seals into pedestal, ensure these are seated properly.
    Seat supplied pedestal O-Ring

  12. Ensure the inlet Marmon clamp is positioned on the exhaust inlet pipe before installing the Turbocharger.
    Ensure the inlet Marmon clamp

  13. Install KC300X Turbo onto pedestal. Tighten bolts down to 18 lb/ft. Now reverse the removal procedure.
    Install KC300X Turbo

  14. Tighten Exhaust Inlet / Up Pipe Clamp Marmon Clamp and Ensure it is properly seated
    Tighten Exhaust

  15. Connect Downpipe and tighten clamp, ensure it is properly seated.
    Connect Downpipe

  16. Install new Compressor outlet O-Ring
    Install new Compressor

  17. Position Intake Manifold Spider in place and re-install hoses. Tighten hose clamps.
    Position Intake

  18. Re-install all labeled electrical and temperature connections. Ensure all lines and connectors are properly seated.
    Re-install all labeled electrical

  19. Connect Red Line to Wastegate Actuator. Install supplied Air Inlet Boot to Turbocharger and CCV Assembly, tighten down clamps. Connect green line to Air Inlet Tube
    Connect Red Line to Wastegate

  20. Re-Install crankcase breather assembly
    Re-Install crankcase

  21. Re-Install Factory Airbox

Before Starting the Truck:

  • Before start up ensure that you retrieved all tools and rags (for covering intake etc).
  • Ensure air filter is clean and piping is clean so nothing other than clean air can get sucked into the Turbo.

Start THE TRUCK TO ensure and check following:

  • Ensure that there is no leakage between Turbo and Pedestal
  • Ensure there is no abnormal noise.
  • Ensure there is no leaks between exhaust inlet and Turbocharger ( Up Pipes to Turbo)
  • If everything checks out, then there is no further break in needed and you can operate your truck as usual.

References

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>

Related Manuals