BDDIESEL S361-76 SXE Super Single Turbo Kit Installation Guide

BDDIESEL S361-76 SXE Super Single Turbo Kit

Product Information

The Dodge Super SXE Single Turbocharger (I-00393) is a turbo kit designed for 1994-2002 Dodge 12/24v ISB trucks. It comes in four different variants: S361/76 SXE, S363/76 SXE, S363/80 SXE, and S364/80 SXE. The kit includes various components such as the turbo, clamps, gaskets, fittings, bolts, washers, and an oil drain gasket. Please ensure that you have all the parts listed in the kit before starting the installation.

It’s important to note that this product is legal in California for racing vehicles only and should not be used on highways unless an EO# is listed.

For further information and support, you can contact BD Engine
Brake Inc. at 1-800-887-5030 or visit their website at https://www.bddiesel.com.

Product Usage Instructions

1. Before installation, read all instructions provided in the manual.
2. Ensure that your vehicle’s exhaust manifold is not cracked or leaking. If it is, replace it with a new one along with new exhaust gaskets.
3. Perform the installation on a cold vehicle as turbo and exhaust components become very hot during use.
4. Inspect the turbocharger before installation and follow the recommended precautions provided by BD for replacing a turbocharger.
5. If you wish to upgrade your vehicle, consider options such as BD ‘X’ Torque Converter, BD Transmission, BD High Flow Injectors, BD Lift pump kit, BD High Flow Banjo Bolts, Heavy Duty Exhaust Manifold, BD High-Pressure Intercooler Boots, and BD Cool Down Timer 2. Refer to the manual for part numbers and further details.
6. If you are installing a BD Engine Brake with this turbo, you will require a Turbo Plate (PN# 1453238) and five M8-1.25 x 20mm bolts. Reuse the existing five hardened M8 washers.
7. Before starting the installation, record radio settings and disconnect both battery terminals on both batteries. First, disconnect the negative terminals, followed by the positive terminals.
8. Lay a protective cover over the passenger side fender to avoid scratches.
9. Remove the air box assembly and intake tube from the inlet of the turbocharger.
10. Disconnect the exhaust down pipe from the turbo flange by removing the two 13mm bolts.
11. Remove the two exhaust bolts.
12. Detach the v-band clamp on the turbo compressor-housing outlet that connects to the intercooler. Take care not to lose the orange o-ring from the intercooler inlet tube elbow. Also, cover the intercooler tube to prevent debris from falling inside.

Note: For detailed step-by-step instructions and illustrations, please refer to the complete installation manual available for download at www.bddiesel.com.

PARTS

Please check to make sure that you have all the parts listed in this kit before you start the disassembly of your truck.

DODGE 1994-2002 SUPER “SXE” SINGLE TURBO KIT

141526X| 1405926| 1100740
|

|

SUPER “SXE” TURBO| CLAMP; V-BAND DOWNPIPE| CLAMP; 4” SS DOWNPIPE
QTY: 1| QTY: 1| QTY: 1

1045928| 148062| 1453139
| |
DOWNPIPE| GASKET; OIL DRAIN| FITTING; 1/4MNPT x 3/8 INV FLARE (12v)
QTY: 1| QTY: 1|

1453152| 1130315| 1405986
| |
FITTING; 1/4MNPT x -6ORFS (24v)| BOLT; 3/8-16”x1”| BOLT; M10x1.5×45 MANIFOLD (24v)
QTY: 1| QTY: 2| QTY: 2

1452815| 1453251

|
WASHER; 3/8”| O-RING; 61mm x 3mm
QTY: 2| QTY: 1

Pre-Installation Notes

• A turbocharger is driven solely by exhaust energy. Therefore, if the vehicle’s current exhaust manifold is cracked or is leaking, it is recommended that new exhaust gaskets and a heavy-duty exhaust manifold be used.
• Installation should occur on a cold vehicle, as turbo and exhaust components become very hot with use.
• The BD Killer B system is recommended for trucks with 400-500 RWHP with a maximum efficient boost pressure of 45psi. For optimum performance, the turbo should operate between 37–45psi.

Pre-Installation Inspection

• When replacing a turbocharger BD recommends the following precautions be taken:
• Replace or clean the air filter.
• Change the engine oil and filter.
• Inspect Intake and CAC passages for debris, and clean them if necessary. In the case of a previous failure also include the following steps:
• Inspect CAC for debris and clean out if necessary.
• Inspect engine oil for debris. Flush system if debris was present. Ensuring that these steps are followed will prolong the life of your new turbocharger.

UPGRADE OPTIONS

• If you are installing a BD Engine Brake with this turbo you will require:
• (1) Turbo Plate PN# 1453238
• (5) M8-1.25 x 20mm bolts
• Reuse the existing (5) hardened M8 washers.

BATTERY DISCONNECT

• Record radio settings and disconnect both battery terminals on both batteries.
• Disconnect the negative terminals on both of the vehicle’s batteries and then disconnect the positive terminals.

INSTALLATION

• Lay a protective cover over the passenger side fender to eliminate any scratches.
• Remove the air box assembly and intake tube from the inlet of the turbocharger.
• Remove the two 13mm bolts connecting the exhaust down pipe to the turbo flange.
• Remove the v-band clamp on the turbo compressor housing outlet that connects to the intercooler. Be sure not to lose the orange o-ring from the intercooler inlet tube elbow. Also, make sure that you cover the intercooler tube so debris does not fall inside.
• Remove the turbo oil feed line un-bolt the turbo oil drain tube and cover the inlet to protect it from contamination.
• Remove the four nuts holding the turbo to the exhaust manifold. Remove the stock turbo and set it aside.
• Inspect the exhaust manifold for shrinkage, cracks and leaks. If none are found, remove the original turbo gasket and clean the turbo-mating surface. If any cracks are found, you will need to replace the manifold with a stock replacement or a heavy-duty aftermarket version.
• Remove the turbo downpipe. Note that it is assumed that the user has a full 4” exhaust system at the time of installation, not a CAT-Back system or stock exhaust.
• Remove the original gasket from the oil drain tube sealing flange and replace it with the new gasket provided.

• Install the Super “SXE” turbo with the supplied gasket and the four factory nuts (gasket direction is unimportant) to the exhaust manifold. Torque to 24 ft lbs.
• For 24V installations, two M10x1.5x45mm bolts have been provided. To be used with OEM nuts.

TURBO CLOCKING/ALIGNING (If Necessary)

Loosen the four bolts clamping the exhaust housing to the turbo body and rotate the body until oil feed drains are straight up and down. Re-tighten the four bolts. Loosen the eight bolts clamping the turbo compressor housing to the body and rotate housing to align with intercooler tube. You need to align the compressor outlet to the stock cast aluminium elbow with the orange O-ring in it. Now tighten the eight bolts holding the compressor housing to the body to secure its position.

• A new compressor outlet O-ring has been provided. Lubricate the O-ring and install it between the turbo and outlet elbow. Re-use the factory V-Band Clamp. Adjustment of the first intercooler boot may be required for a proper fit.
• Connect the oil drain tube to the bottom of the turbo using the supplied gasket and the hardware.
• You will need to slide the oil drain adapter as far as possible away from the wastegate arm to prevent any contact.
• In some rare cases, the wastegate arm may need to be bent; you will then need to reset the wastegate adjustment to “crack open” (initial movement) at 45psi. Otherwise, you can purchase a 12-valve oil drain assembly Cummins P/N# 3918585.

Be sure to squirt fresh oil down the oil feed port while rotating the compressor wheel. This will ensure a smooth start-up and reduce the chance of damaging the bearings.

Truck| Oil Inlet Adapter

12V

| 1453139

1/4MPT x 3/8 Inv. Flare

24V

| 1453152

1/4MPT x -6 ORFS

• Install the appropriate oil inlet fitting adapter into the turbocharger. And connect the oil supply line.
• DO NOT USE TEFLON TAPE.
• DO NOT OVERTIGHTEN, YOU WILL CRACK THE BEARING HOUSING.
• Install the new downpipe to the rear of the turbo. It is highly recommended to loosely clamp all exhaust pieces together to ensure proper fit before tightening anything. Position all exhaust clamps 1/4” from joints and if possible, tack weld all pipes to prevent twisting.
• You can now install the factory air box and intake tube. Double-check all clamps to ensure they are tight.
• Reconnect negative battery terminals and start the vehicle. Check for any exhaust or oil leaks.
• Take it easy on the turbo for the first 100 miles to allow a proper break-in period. Be very cautious of any unusual sounds or leaks during this time.
• Note: The exhaust housing of the turbo may smoke when new as manufacturing residue on the housing must burn off.

**IMPORTANT*** When idled for any length of time some oil may leak from the turbo. If the performance/boost is satisfactory and the wheel is not touching the housing (There will be some small movement), the excess oil is not a concern. Simply wipe with a clean cotton cloth and continue use.

1994-95 Trucks

• When installing the turbo on 1994-95 trucks you will need to remove the steel wastegate line that is connected to the factory turbo and the AFC housing of the P7100 fuel injection pump.
• With this line disconnected you will need to plug off the connection point at the AFC housing with a 1/8” NPT plug.

CONTACT

• BD Engine Brake Inc.
• 1-800-887-5030 |
• https://www.bddiesel.com.

References

• BD Diesel USA - Diesel Performance Parts & Products
• BD Diesel USA - Diesel Performance Parts & Products

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