BD DIESEL 1045768 5.9L Cummins Stock Replacement and Screamer Turbo Installation Guide

June 14, 2024
BD DIESEL

BD DIESEL 1045768 5.9L Cummins Stock Replacement and Screamer Turbo Installation Guide
Cummins Stock Replacement and Screamer Turbo

Pre-Installation

A new turbocharger will not solve the following failures:

  • Oil contamination
  • Restrictive oil drain
  • Over speed due to a boost leak or clogged air filter
  • Exhaust leaks due to faulty bellows, clamps, or seals

Turbo over speed will lead to premature turbo failure. Boost pressure can be used to estimate turbo speed. The table below shows maximum allowable turbo speed for a stock motor at 3500rpm. A turbo intake restriction, clogged filter, high altitude or boost leak will cause increased wheel speed.

Turbo Estimated Airflow (lb/min) Max boost (psi)
1045768 75 lb/min 39

Turbo Mount Exhaust Brakes

The BD Diesel Screamer turbo retains the factory turbine outlet. If your stock turbo has a turbo mount exhaust brake it can be transferred to your Screamer turbo. If you plan on purchasing an exhaust brake with your Screamer turbo buy according to the year of truck; see optional accessories section for year ranges and part numbers for BD Diesel exhaust brakes.

Kit Contents

Screamer| 407557 (Plug) 1453157 (Small O-ring) FT-920155095 (Large Oring)| | 1462430
---|---|---|---
| | |
Turbo; Screamer 03- 07 5.9L Cummins| Compressor Cover Plug with 2 O-rings| Oil Drain Gasket| Stud M10-1.5×30 – M10-1.5×42

3678603 FT-920156020 1462441

O-ring| O-ring| O-ring| Mounting
Nuts
O-ring| O-ring| Exhaust Elbow VBand| Mounting Nuts
Qty:1| Qty:1| Qty:1| Qty:4

Optional Accessories

Part| Description|
---|---|---
Exhaust Elbow ·        4.5-07: 1045100| Turbine outlet exhaust elbow.| Pipe
BD Diesel Exhaust Brake ·        03-04: 2023138·        04.5-07: 2023331· 06-07: 2023330| Turbo mount exhaust brake. Will work with a BD Diesel Screamer Turbo or a stock turbo.| Diesel Exhaust Brake
BD Diesel Boost Fooler ·        03-04: 1515935·        04.5-07:1515936| Increases available boost by intercepting the message from the MAP sensor to the ECM. Preventing it from setting an over- boost trouble code.| BD Diesel
Boost Fooler
BD Diesel Hose and Clamp Kit ·        10452515| Boots can withstand over 100psi and are secured by rugged, spring –loaded, stainless steel clamps.| BD Diesel Hose and Clamp Kit

Introduction

The BD Screamer turbo series is now available for the 2003-2007 Dodge 5.9L Cummins. The Screamer turbo is designed to be a drop-in stock-appearing performance turbocharger that increases boost, decreases drive pressure, and peak EGTs without affecting low-end drivability.

The 5.9L Cummins screamer turbo utilizes 63mm billet compressor wheel and a 67mm high-flow turbine wheel which offers increased turbine flow and efficiency. The screamer is capable of increasing horse power by 100whp over a stock turbo, and with supporting modification it is capable of 625hp.

Tools Required for Installation

  • 7mm-22mm Metric Socket and Wrench Set
  • 5/16”-9/16” Socket and Wrench Set
  • Hose Clamp Plier
  • Torque Wrench
  • 21mm Crows foot

Installation

Removal

  1. Disconnect the battery and raise the vehicle

  2. Remove the passenger side inner fender well with a 5/16’’ socke
    Installation Instruction

  3. Disconnect the exhaust pipe from the turbo exhaust elbow.

    • Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
    • Remove the exhaust pipe-toextension pipe clamp using a 11mm socket. Seprate the exhaust pipe and extension pipe
    • Remove the exhaust pipe-toturbo eblow clamp using a 10mm socket.
    • Remove the exhaust pipe from the tranmission support.
    1. Exhaust pipe to turbo clamp
    2. Transmissin support
    3. Exhaust pipe
      Installation Instruction
  4. Remove the exhaust elbow from the turbo by removing the v-band clamp using a 10mm socket.
    Note: Put this elbow aside, it will get used with thenew turbo.

  5. Turbo Exhaust Elbow
    Installation Instruction

  6. Remove the oil drain line from the turbo with a 10mm socket, discard the gasket.
    Installation Instruction

  7. Turbo oil drain tube bolt

  8. Turbo oil drain tube

  9. Disconnect the turbo oil feed using a 21mm wrench
    Installation Instruction

  10. Remove the two lower turbo mounting nuts with a 15mm socket and extension.
    Break lose the two upper turbo mounting nuts with a 15mm wrench
    Installation Instruction

  11. Lower the vehicle

  12. Disconnect the air intake hose using a 7mm socket
    Installation Instruction

  13. Air inlet tube

  14. Air filter housing

  15. Turbo

  16. On 04.5-07 trucks, you will need to disconnect the wastegate solenoid connector.
    Installation Instruction

  17. Disconnect the intercooler inlet pipe from the turbo compressor outlet. Use 7/16’’ socket for the hose band clamp.
    Installation Instruction

  18. Remove the two upper turbo mounting nuts with a 15mm wrench.
    Installation Instruction

  19. Remove the turbo and gasket from the exhaust manifold

  20. If the turbo is not being installed immediately, cover the opening to prevent material from entering into the manifold.

  21. Remove the turbocharger oil supply fitting and put it aside. This fitting will get used on the new turbo
    Installation Instruction

Installation

For 2003-2004.5 make sure the compressor cover plug with 2 O-rings is installed on the compressor cover.

For 2004.5-2007 make sure the solenoid is installed on the compressor cover.

Be sure to torque either the plug or solenoid to 13.5 Nm (10 ftlbs)
Installation Instruction

  1. Using the new gaskets (FT-920156020 & 3922794) provided in the kit, install the oil supply fitting from the old turbo to the Screamer turbo.Tighten fitting to 36 N.m (27 ft.lbs) with a 19mm socket.
    Installation Instruction

  2. From 2003 – 2004.5 the two rear manifold factory studs are too short so you must replace those two factory studs with the supplied studs (1462430)
    Installation Instruction

  3. Secure the turbo to the exhaust manifold with the two upper turbo mounting nuts. Use the NEW gasket provided with the turbo, and tighten nuts to 43 N.m (32ft. lbs) with a 15mm socket.
    Important! Improper torque of flange can lead to exhaust leak, gasket failure and flange damage
    Installation Instruction

  4. Raise the vehicle.

  5. Tighten the 2 lower turbo mounting nuts to 43 N.m (32 ft.lbs) with a 15mm socket.

Installation Instruction

  1. Using the new gasket provided in the kit, install the oil drain tube to the turbo. Tighten the drain tube bolts to 24 N.m (18ft.lbs) with a 10mm socket
    Installation Instruction

  2. Connect the exhaust elbow to the turbo using the new v-band clamp provided in the kit. Tighten the v-band clamp to 11.3 N.m (100in.lbs) using a 10mm socket.
    Installation Instruction

  3. Connect the exhaust pipe to the turbo and tighten the v-band clamp to 11.3 N.m (100 in.lbs) using an 11mm socket
    Installation Instruction

  4. Lower the vehicle

  5. On 04.5-07 trucks, connect the wastegate solenoid connector.
    Installation Instruction

  6. Pre lubricate the turbo. Pour 50 to 60cc (2 to 3 oz), of clean 15w40 engine oil in the oil supply inlet. Carefully rotate the turbocharger by hand to disturb the oil thoroughly

  7. Install and tighten the oil supply line with a 21mm wrench. Torque to 24 N.m (18 ft. lbs) with a 21mm crow’s foot
    Installation Instruction

  8. Position the intercooler inlet pipe to the turbo. With the clamp in position, tighten the clamp nut to 11 N.m (95 in. lbs) with a 7/16’’ socket
    Installation Instruction

  9. Position the air inlet hose to the turbo. Tighten the clamp to 4 N.m (35 in. lbs) with a 7mm socket.
    Installation Instruction

  10. Connect the battery and start the engine and check for leaks

Troubleshooting

Error Code Possible Causes Solution

P0234
Turbocharger Overboost Condition| ·   Wastegate Stuck·   Turbocharger and/or wastegate damaged·   Wastegate control valve damaged (04.5-07)| Install a BD boost fooler (1515935, 1515936) or consult with your preferred aftermarket tuning provider.
P0236
MAP Sensor Too High Too Long| ·   MAP sensor intermittent condition| Follow OE diagnostic testing procedure to determine the fault.

P0243
Wastegate Pressure Control PWM (04.5-07)

| ·   Fused ignition switch output open·   Wastegate solenoid control circuit open·   Wastegate solenoid control circuit shorted to ground·   Wastegate solenoid control circuit shorted to voltage wastegate solenoid.·   Engine control module| Follow OE diagnostic testing procedure to determine the fault.

P0299
Low Boost Pressure/ Turbocharger Underboost

| ·   Intake air system restriction·   Intake air system leak·   Boost pressure sensor
·   In rare instances with the Screamer, fueling conditions underperform for turbo requirements| Follow OE diagnostic testing procedure to determine the fault.
In the rare instance of under fueling, consult with your preferred aftermarket tuning provider.

1-800-887-5030
Internet: www.bddiesel.com

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