Installation Instructions
Contents
1. failed part is covered under the Limited Warranty Honeywell Turbo Technologies will reimburse Customer for the actual cost of ground shipment for any part found to be defective Doc 737639 25 Rev www TurboByGarrett com Garrett 2 cerry wen 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 IMPORTANT INFORMATION PLEASE READ CAREFULLY Limitations on Warranty The Limited Warranty does not apply to any parts a not used in accordance with Honeywell Turbo Technologies written instructions b for which no fault is found c that have been modified in any manner not specifically approved by Honeywell Turbo Technologies d for which an inspection indicates that reasonable and proper installation and or preventative care and maintenance has not occurred e that have been subject to damage attributable to or caused by misuse abuse or vandalism mishandling improper shipping or other transit related damage acts of god or insurrection foreign object entry any part not supplied by Honeywell Turbo Technologies any repair maintenance or service by anyone other than Honeywell Turbo Technologies or any other acts that are beyond Honeywell Turbo Technologies reasonable control or f attributable to parts not supplied by Honeywell Turbo Technologies Honeywell Turbo Technologies expressly disclaims any and all warranties relative to the foregoing cir2. 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 10 Remove the two bolts on the oil drain flange located on the bottom of the turbocharger Fig 8 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 11 Remove the bolts on the exhaust elbow flange and set aside Fig 9 The bolt head is on the bottom side of the flange 12 Remove the two rear exhaust flange nuts located on the bottom of the turbocharger flange and set aside Fig 10 While supporting the turbocharger remove the front two flange nuts and set aside Carefully remove the stock turbocharger from the vehicle 13 Disconnect and remove the coolant hose Fig 11 from the tube and move it out of the way Fig 11 Doc 737639 25 Rev A www TurboByGarrett com Garrett 7 by Herne evel 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 14 Remove the nut on the coolant tube bracket and pull the bracket off of the stud Reinstall the nut Fig 12 and torque to 18 Ibf ft 15 Remove the coolant tube assembly from the engine Fig 13 This assembly will not be used with the Garrett turbo upgrade kit Retain the rubber hose and clamps 16 P
3. distributor will determine the best solution on how to address shortages or discrepancies Limited Warranty Honeywell Turbo Technologies warrants to the original purchaser of its Turbocharger Products that such Turbocharger Products will for a period of 1 year from date of shipment and subject to the Limitations on Warranty be free from defects in materials and workmanship For approved warranty claims Honeywell Turbo Technologies will at its sole discretion either credit the original purchaser in an amount equal to the original purchase price or replace the applicable Turbocharger Product free of charge within 60 days of Honeywell Turbo Technologies approval This is purchaser s sole and exclusive remedy and provides the complete financial responsibility of Honeywell Turbo Technologies for a warranty claim To be eligible for reimbursement Customer must a Submit all warranty claims to Honeywell Turbo Technologies within 30 days of the discovery of the alleged Turbocharger Product defect and b complete and return a Returned Material Authorization Form Consumers are required to work through Honeywell s distributors in order to process any warranty claims When Honeywell Turbo Technologies requires the examination of a failed part Honeywell Turbo Technologies will promptly notify Customer and will await receipt of the failed part before further processing the warranty claim If Honeywell Turbo Technologies ultimately determines that the
4. 00 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions 1 Disconnect the negative terminal from both batteries 2 Drain engine coolant according to the service manual 3 Loosen the clamp on the compressor inlet hose and remove hose Fig 1 Leave the hose attached to the air filter housing 4 Unclip the four clips on the top of the air filter housing Fig 2 Remove the top of the air filter housing with the hose still attached and set aside 5 Remove the three fasteners on the inside bottom of the lower half of the air filter housing Fig 3 Remove the lower half of the air filter housing and set aside along with the three fasteners Fig 3 Doc 737639 25 Rev A www TurboByGarrett com rrett 5 by Honeywell 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 6 Remove nut on compressor housing discharge V band Fig 4 and set aside 7 Slide V band down elbow reinstall nut loosely and move elbow down out of the way as shown in Fig 5 8 Remove the oil line from the top of the stock turbocharger Fig 6 9 Using a rag move the oil line out of the way Fig 7 Fig 7 Doc 737639 25 Rev A www TurboByGarrett com Garrett 6 by Hearne evel 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks
5. Garrett by Honeywell PowerMax Diesel Upgrade For Cummins Engines Installation nstructions Part Numbers 759361 0001 Stage 1 1998 5 2002 Dodge Ram 759361 0002 Stage 2 2500 amp 3500 Diesel Trucks 759361 0003 Stage 3 Parts List Tools Needed Description Turbocharger Ancillary kit 759360 1 includes Installation Instructions Compressor housing clamp Gasket Kit 716909 36 Turbine inlet gasket Oil drain gasket Turbine inlet bolt Turbine outlet adapter kit 764192 1 Turbine outlet adapter Bolts Water Line Kit 764062 1 Water line inlet Small Water line outlet large Banjo bolt Crush Washer Oil inlet fitting kit 759359 1 Oil fitting inlet O ring seal small O ring seal large Bolt 7 16 deep well socket 13mm open end wrench e 7mm socket e 14mm open end wrench e 8mm 12 point socket 13 16 open end wrench e 10mm socket Torque wrench e 13mm socket e 6 extension e 14mm socket e 10mm hex socket Item 1 2 3 4 5 6 7 8 9 10 11 omen Feet at ae sizes may be ee he next ending specifications l Dee tools a those litted above ay be required m e U N Recommended Other I tems m e e O UI amp e Factory Service Manual e Safety glasses e Catch basin for engine coolant e Engine coolant quantity per service manual e Anti seize compound e Oil filter e Oil quantity per service manual IMPORTANT INFORMATI ON PLEASE READ CAREFULLY We recommend that t
6. are should only be used as a general guideline to help you facilitate the repair of your car If you experience or Suspect any malfunction of vital safety equipment such as your brakes exhaust motor transmission fuel delivery system your car s structural integrity or any other potentially life threatening malfunction cease driving your vehicle immediately and seek professional help Always consult your owner s manual Vehicle Modification Notice Any modifications to your car are AT YOUR OWN RISK You should consult the owner s manual and service manual You should also contact your car s manufacturer to determine what effects modifications may have on your safety warranty performance etc Please also contact your local authorities to determine whether your intended modifications will make your car illegal to drive on public roads A vehicle modified by the use of competition parts may not meet the legal requirement for use on public roads It is your responsibility to comply with federal state and local laws prior to driving your vehicle on public roads Doc 737639 25 Rev www TurboByGarrett com Garrett 3 by Honpywml 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 IMPORTANT INFORMATION PLEASE READ CAREFULLY OTHER PRECAUTIONS Observe all safety precautions and warnings contained in the installation instructions Wear eye and ear protect
7. cumstances Honeywell Turbo Technologies shall not be liable to Customer under any circumstances for any special incidental or consequential damages including without limitation damage to or loss of property other than for Turbocharger Products damages incurred in installation repair or replacement lost profits revenue or opportunity loss of use losses resulting from or related to downtime of Turbocharger Products the cost of replacement transportation power or compression the cost of substitute products or claims of third parties for such damages howsoever caused and whether based on warranty contract and or tort including negligence strict liability or otherwise The Limited Warranty is the only warranty made by Honeywell Turbo Technologies for any of its turbochargers and related parts and or services and is in lieu of and excludes all other warranties expressed or implied including warranties of merchantability or fitness for a particular purpose Honeywell Turbo Technologies hereby disclaims all other warranties not expressly set forth Some jurisdictions do not allow for the exclusion of implied warranties so the above exclusions may not apply to you however if implied warranties do apply they are limited to the original purchaser and for a period of one 1 year from the date of shipment Diagnosing Your Vehicle Do not rely on diagnostic software without seeking the advice of an ASE certified mechanic Diagnostic softw
8. e into the hose Leave the clamp in the position on the hose as shown in Fig 19 Fig 19 Doc 737639 25 Rev A www TurboByGarrett com rrett by Honey 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 22 Remove the bolt and spacer from the bottom right location on the exhaust manifold Assemble the bolt and spacer onto the bracket of the Garrett supplied water line outlet or large as shown in Fig 20 Torque to 32 Ibf ft 23 Reinstall hose and clamp so that it is over the barb of the tube as shown in Fig 21 24 Fig 22 shows the water line properly installed prior to the installation of the turbocharger 25 Use the turbine inlet gasket from kit 716909 36 and place it on the studs on the stock manifold as shown in Fig 23 Note It is recommended to place anti seize compound onto the stud threads prior to installation Fig 23 Doc 737639 25 Rev A www TurboByGarrett com Garrett 10 by Aires evel 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 26 Obtain the four stock nuts that were set aside in Step 12 and the two turbine inlet bolts from the kit 759360 1 Carefully install the Garrett turbocharger onto the studs and hand tighten the back nuts Put ant
9. et for maximum boost recommendations 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 IMPORTANT INFORMATION PLEASE READ CAREFULLY Return Policy Only unused and complete merchandise will be accepted for return subject to inspection and acceptance by Honeywell Turbo Technologies No goods will be accepted without prior return authorization from Honeywell Turbo Technologies No returns are accepted after thirty 30 days from original ship date from Honeywell All accepted returns are subject to a 20 restocking charge NO EXCEPTIONS Damaged Shipments The customer must file a claim with the shipping company if goods arrive in a damaged condition The customer must also notify the distributor from which the goods were purchased with pertinent information Refused Shipments Sending a shipment back to The Garrett Garage or Honeywell does not automatically give rise to a complete refund or credit Honeywell Turbo Technologies may at its sole discretion require different payment means for any shipment refused and then reshipped It is the customer s responsibility to make all arrangements with Honeywell Turbo Technologies for disposition of refused shipments Shortage or Discrepancy Claim Shortage or Discrepancy claims must be reported within forty eight 48 hours of receipt of goods to the distributor from which the goods were purchased The Honeywell
10. his 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 NPP eR O wo CO N NEP EE ANE Eo EN eee N 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 1 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 she
11. i Seize compound on the bolt threads and install the bolts and nuts as shown in Fig 24 Torque to 32 lof ft 27 Install the hose onto the tube approximately 4 1 Install clamp onto the hose as shown in Fig 25 Note Do not install the hose too far onto the tube This could cause the hose to be pulled too tight 28 Reinstall the compressor discharge pipe onto the Garrett compressor housing using the stock V band and nut as shown in Fig 26 Torque V band nut to 72 bf in 29 Assemble the down pipe to the Garrett turbine outlet adapter or exhaust elbow using the stock bolts as shown in Fig 27 Torque to 25 Ibf ft Fig 27 Doc 737639 25 Rev A www TurboByGarrett com rrett 11 by iors evel 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 30 Use the oil drain gasket from 716909 36 kit and place it on the stock oil drain flange as shown in Fig 28 31 Using the stock bolts assemble the oil drain flange onto the center housing of the turbocharger as shown in Fig 29 Torque to 18 Ibf ft 32 Use the last banjo bolt and two crush washers from kit 764062 1 Pull the flexible end of the water A ES re line up to the water port on the center section and i i assemble using a 10mm hex socket as shown in i E F 7 a Crush Fig 30 Torque to 30 Ibf ft F Water
12. ion and appropriate protective clothing When working under or around the vehicle support it securely with jack stands Use only the proper tools Exercise extreme caution when working with flammable corrosive and hazardous liquids and materials LEGAL INFORMATION The Garrett turbo kits are for use off the public roadways Federal law restricts the removal or modification of any part of a federally required emission control system on motor vehicles Also many states have enacted laws which prohibit tampering with or modifying emission or noise control systems Vehicles which are not operated on public roadways may be exempt from certain regulations however the buyer is strongly urged to check all applicable local and state laws and is ultimately responsible for compliance with the applicable laws and regulations Contact Information for Questions Please contact the Honeywell distributor from which the equipment was purchased for any questions regarding this Shipping Returns Cancellation Policy for notifications to Honeywell Turbo Technologies and for instructions on processing damaged shipments and authorized returns Honeywell Turbo Technologies r Garrett Independent Aftermarket Honeywell International Inc alre 3201 W Lomita Blvd by Honeywell Torrance CA 90505 www TurboByGarrett com Doc 737639 25 Rev www TurboByGarrett com Garrett 4 by Honpywmi 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 35
13. lace the Garrett turbocharger on a workbench and remove the two compressor housing bolts and clamp shown in Fig 14 One of these bolts will be reused Note A single clamp will be used for the Dodge application to provide clearance for the stock drain flange 17 Install the compressor housing clamp provided in ancillary kit 759360 1 using one of the bolts from Step 16 as shown in Fig 15 Torque to 100 Ibf in Fig 15 Doc 737639 25 Rev A www TurboByGarrett com Garrett 8 by iors evel 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d ee Reco 18 Using the smaller inlet water line one banjo Ai bolt and two crush washers from kit 764062 1 install the water line on the center housing This water line will use the port nearest to the turbine housing inlet flange as shown in Fig 16 19 Position the water line so there is about a 1 4 1 2 of space between the tube and the turbine housing as shown in Fig 17 Using a 10mm hex socket torque to 30 Ibf ft 20 Use the turbine outlet adapter or exhaust elbow and the six bolts from kit 764192 1 and install onto the turbine housing using a 8mm 12 point socket as shown in Fig 18 Torque to 17 Ibf ft 21 Use the larger outlet water line from kit 764062 1 and install into vehicle prior to the turbocharger installation Insert the tub
14. llation I nstructions cont d 38 Install the air filter and the top of the air filter housing with the hose attached using the four stock clips as shown in Fig 35 39 Assemble the hose onto the compressor housing inlet as shown in Fig 36 and tighten the clamp Torque to 72 Ibf in 40 The installed PowerMax Kit is shown in Fig 37 41 Refill the engine coolant per the service manual 42 Check the engine oil level Doc 737639 25 Rev A www TurboByGarrett com Garrett 14 by Honeywell 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 43 Attach the negative battery terminals on both batteries 44 Start the vehicle and allow it to idle until the engine is at operating temperature Check for leaks 45 Once it is confirmed that there are no leaks you are ready to enjoy your new PowerMax turbocharger upgrade kit Honeywell Turbo Technologies Garrett Independent Aftermarket 4 Honeywell International Inc 3201 W Lomita Blvd Torrance CA 90505 by Honeywell www lurboByGarrett com
15. tine a Water Line Washers 4 33 Pre lube the turbocharger Fill the oil inlet hole with clean engine oil and rotate the compressor wheel by hand several times to distribute the oil thoroughly Refill the oil inlet hole one more time prior to installing the oil inlet fitting Doc 737639 25 Rev A www TurboByGarrett com Garrett 12 by Aires evel 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d 34 Use the oil inlet fitting and larger O ring from kit 759359 1 Install the O ring into the groove on the bottom of the fitting as shown in Fig 31 35 Using the two bolts supplied in kit 759359 1 install the fitting onto the Garrett turbo s center housing using a 8mm 12 point socket as shown in Fig 32 Pay close attention that the O ring did not come out of the bottom groove during installation Torque to 17 lbf ft Install the small O ring from kit 759359 1 onto the oil inlet fitting Fig 32 36 Assemble the stock oil line onto the fitting as shown in Fig 33 37 Using the stock three fasteners reinstall the lower half of the air filter housing as shown in Fig 34 Fig 34 Doc 737639 25 Rev A www TurboByGarrett com rrett 13 by Honeywell 1998 5 2002 Dodge Ram Part Number 759361 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Insta
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