Installation Instructions Dodge PowerMax Turbo
Contents
1. I nstallation Instructions Dodge PowerMax Turbo Upgrade Kit Part Numbers 759361 0001 Stage 1 759361 0002 Stage 2 759361 0003 Stage 3 1998 5 2002 Dodge Ram 2500 amp 3500 Diesel Trucks Description Doc 737639 25 Rev Turbocharger Ancillary kit includes Gasket Kit includes Turbine inlet gasket Oil drain gasket Turbine inlet bolt Turbine outlet adapter kit includes Turbine outlet adapter Bolts Water Line Kit includes Water line inlet Water line outlet Banjo bolt Crush Washer Instructions installation Compressor housing clamp Oil inlet fitting kit includes Oil fitting inlet O ring seal O ring seal Bolt Ne Pe EH ANE EH ope Nee e 13mm open end wrench e 14mm open end wrench e 13 16 open end wrench e Torque wrench e 6 extension e 7 16 deep well socket e 7mm socket e 8mm 12 point socket e 10mm socket e 13mm socket e 14mm socket e 10mm hex socket e NOTE Bolt and fastener sizes may be different from ne mo enygar to the next depending of OE specifications Different tools than those listed above may be required Recommended Other I tems e Factory Service Manual e Safety glasses 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 this turbo upgrade kit be installed by a qualified autom2. Check for leaks 45 Once it is confirmed that there are no leaks you are ready to enjoy your new PowerMax turbocharger upgrade kit Doc 737639 25 Rev www turbobygarrett com 12
3. 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 Doc 737639 25 Rev www turbobygarrett com 2 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 Doc 737639 25 Rev www turbobygarrett com 3 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 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
4. 0001 Stage 1 2500 amp 3500 Diesel Trucks 759361 0002 Stage 2 759361 0003 Stage 3 Installation I nstructions cont d P7 NN 18 Using the smaller water line one banjo bolt and a 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 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 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 water line from kit 764062 1 and install into vehicle prior to the turbocharger installation Insert the tube into the hose Leave the clamp in the position on the hose as shown in Fig 19 Fig 19 Doc 737639 25 Rev www turbobygarrett com 6 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 as shown in Fig 20 Torque to 32 Ibf ft 23 Reinstall hose and clamp so that it is over the barb of the tu
5. 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 Doc 737639 25 Rev www turbobygarrett com 4 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 Place 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 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 Doc 737639 25 Rev www turbobygarrett com 5 1998 5 2002 Dodge Ram Part Number 759361
6. be 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 Doc 737639 25 Rev www turbobygarrett com 7 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 bolts from the kit 759360 1 Carefully install the Garrett turbocharger onto the studs and hand tighten the back nuts Put anti seize compound on the bolt threads and install the bolts and nuts as shown in Fig 24 Torque to 32 Ibf 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 exhaust elbow using the stock bolts as shown in Fig 27 Torque to 25 Ibf ft Doc 737639 25 Rev www turbobygarrett com 8 1998 5 2002 Do
7. dge 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 outlet 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 ae r ai line up to the water port on the center section and Ai si assemble using a 10mm hex socket as shown in y r T a Crush Fig 30 Torque to 30 Ibf ft P Watertine 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 www turbobygarrett com 9 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 cen
8. otive 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 www turbobygarrett com 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 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
9. ter 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 Doc 737639 25 Rev www turbobygarrett com 10 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 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 www turbobygarrett com 11 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
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