** PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION **

Transcription

1 1 BD FORD 6.0L TURBOCHARGER KIT P/N# Application Description Ford 6.0L Turbo Kit Only Ford 6.0L Turbo Kit & Powder Coated X-Flow Intake Manifold Ford 6.0L Turbo Kit & Polished X-Flow Intake Manifold ** PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION **

2 2 K I T C O N T E N T S : Please check to make sure that you have all the parts listed in this kit before you start the disassembly your truck Ford 6L Turbo Cast Adapter Turbo Oil Supply Fitting Turbo Oil Supply Line Qty: 1 Qty: 1 Qty: 1 Qty: M Turbo Mount L Bracket Turbo Pedestal Mount SS Turbo Bolt Oil Line Clamp Qty: 1 Qty: 1 Qty: 4 Qty: Z Oil Line Adapter EGR Blocker Plate Compressor Outlet Adapter Oil Drain Tube Qty: 1 Qty: 1 Qty: 1 Qty: 1

3 A-0271 Washer Stud Nut Turbo Gasket Qty: 1 Qty: 4 Qty: 4 Qty: Comp. Outlet O-Ring Solder Sleeve Solenoid Replacement Assembly Compressor Outlet Clamp Qty: 1 Qty: 2 Qty: 1 Qty: M8 Lock Washer M8x1.25x25 Bolt Gear Clamp Boost Builder Assy. Qty: 2 Qty: 2 Qty: 1 Qty: 1 TURBO HEAT SHIELD KIT (BD# ) Heater Wrap Inner Wrap S/S Wire Qty: 1 Qty: 1 Qty: 48

4 4 INTAKE MANIFOLD KITS (Comes in / Kits) X-Power Flow Intake Kit X-Power Flow Intake Kit Qty: 1 Qty: 1 PRE-INSTALLATION A turbocharger is driven solely on exhaust energy. Therefore, if the vehicles current exhaust manifold is cracked or is leaking, it is recommended that the exhaust manifolds are decked by a reputable machine shop. Installation should occur on a cold vehicle, as turbo and exhaust components become very hot with use. The BD turbo system is recommended for trucks with RWHP with a maximum efficient boost pressure of 45psi. For optimum performance, the turbo should operate between 37 45psi. It is recommended that you install head studs before the turbo kit. By lifting the cab, the head stud and turbo install will be much easier. UPGRADE OPTIONS Description Part # BD Transmission CALL BD X-Monitor BD Cool Down Timer ARP HD Head Studs POSI-TAP CONNECTOR USAGE DIAGRAM Posi-Tap Connector Usage Diagram Insert Hot Wire Tighten Strip Leads Insert & Tighten Make sure to center the wire when tightening the pierced portion of the hot wire to make a solid connection.

5 5 BATTERY DISCONNECT Record all radio station presets and settings (if desired). Disconnect the negative terminals on both of the vehicle s batteries, and then disconnect the positive terminals. INSTALLATION Remove the push pins. Disconnect the 2 wiring harness push pins and position them aside. Loosen the gear clamp at the turbocharger inlet. Remove the turbocharger intake tube.

6 6 Disconnect the charge air cooler CAC inlet pipe. Disconnect the turbocharger variable vane control valve electrical connector. Remove the bolts for the oil supply tube. Remove the bolt and turbocharger oil supply. Save the O-Ring and bolt for later use.

7 7 Remove the bolt and the wire retainer. Remove the marmon clamp from the turbocharger outlet and save for later use. Remove the marmon clamp from the turbocharger exhaust inlet. Remove the turbocharger. Remove the 4 bolts and the turbocharger pedestal. Save the four bolts for later use.

8 8 If you are using the vehicle for a high performance RACE application, then please see the section on page 14 for the EGR blocker installation. Install the pedestal base ( M) using the 4 bolts for the OE base. An 11mm socket and extension should be used. Place the V-band clamps for the turbo exhaust inlets and outlets onto their respective pipes. These clamps should be left over from the removal of the factory turbo. Install the 4 studs ( ) into the cast adapter ( ) and place it onto the pedestal bracket ( ). Place the gasket (8-A-0271) in between the cast adapter and pedestal bracket. (Note: Do not use a dual volute exhaust flange gasket - the gasket must be a single opening style).

9 9 Use three of the M10 button head screws ( ) to secure it to the stainless pedestal mounted on the engine. Install the oil drain ( ) into the factory oil drain location. Ensure that it is fully seated inside of the hole. You will need to remove the O-Ring from the factory turbo oil drain and re-install it onto the new supplied oil drain flange. Install the turbo onto the S/S pedestal mounted in the truck. Inside the turbo box you will find another single opening exhaust (8-A-0271) flange gasket. Install this gasket between the turbo and the S/S L support plate. Loosely install the 4 nuts ( ) onto the studs thereby securing the turbo to the S/S L bracket. With everything loose, install the 4 th M10 button socket bolt through the wastegate support plate, and then use the M10 washer ( ) between the bolt and the wastegate plate. Keep this bolt loose while tightening the 4 nuts that secure the turbo turbine housing to the L bracket. Tighten the last button head bolt to secure the wastegate bracket in place.

10 Use the oil drain gasket from the turbo box and place between the turbo and the oil drain flange. Use the two M8 bolts ( ) and lock washers ( ) to secure the drain to the turbo. For model year trucks, you will need to install the oil fitting, into the factory oil supply hole. For year trucks, you will need to use the Z oil adapter. Re-use the factory O-Ring from the OE Oil supply line. Install the fitting with O-Ring into recessed hole. Secure the fitting in place with the S/S tab ( ) and the OE bolt. 10 Pre-oil the turbo with clean motor oil. Connect the oil inlet line ( ) to the fitting on the inlet of the turbo. Connect the other end of the oil line to the oil supply fitting you installed earlier. The 45 fitting should be installed at the turbo end. Ensure that the line does not contact or rub on anything. Install the compressor outlet adapter ( ) along with the O-Ring ( ) and V-band clamp ( ).

11 11 Clean the factory silicone boot and re-attach it using the factory clamp to the compressor outlet adapter. Be sure to clean the silicone boot with brake clean. Remove the bracket from the intake tube and reinstall it on the engine to support the IDM with two nuts. You will not be remounting the tube to the bracket. We have provided you with a new hose clamp ( ) to secure the CCV connection. The BD turbo sits higher than the stock turbo, so to accommodate this, the intake tube needs to installed at a downward angle and rotated slightly. Tighten all the intake clamps and reinstall the air filter tubing.

12 12 Reconnect all previous connections.

13 13 Locate the VGT solenoid wiring harness. Cut the factory connector off of the wiring harness and strip the remaining wires. Leave about 1.5 of wire left off the connector in case you need to resolder the connection. Use the two solder sleeves ( ) to solder the solenoid replacement unit ( ) to both of the wires. Allow the vehicle to idle for about 5-10 minutes and ensure that there are no oil leaks. Once the truck has finished idling, take the vehicle for a test run and ensure that there are no boost or exhaust leaks.

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15 15 EGR BLOCKER PLATE INSTRUCTIONS (RACE USE ONLY) This modification may set a SES light. Remove the exhaust inlet pipe-to-egr cooler clamps. Loosen the LH exhaust inlet pipe-toexhaust manifold nuts. Install the stainless blocker plate in between the pipes, and then re-tighten the clamp and manifold bolts.

16 16 LIMITED WARRANTY STATEMENT THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS. DISCLAIMER OF LIABILITY BD Engine Brake Inc., its successors, distributors, jobbers, and dealers (hereafter BD ) shall in no way be responsible for the product's proper use and service. THE BUYER HEREBY WAIVES ALL LIABILITY CLAIMS. BD disclaims any warranty and expressly disclaims any liability for personal injury or damages. BD also disclaims any liability for incidental or consequential damages including, but not limited to, repair labor, rental vehicles, hotel costs, or any other inconvenience costs by reason of use or sale of any such equipment. The BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the BUYER agrees to indemnify BD and to hold BD harmless from any claim related to the item of any equipment purchased. This warranty shall not apply to any unit that has been improperly stored or installed, or to misapplication, improper operation conditions, accidents, neglect, or which has been improperly repaired or altered or otherwise mistreated by the BUYER or his agent. BD also assumes no liability regarding the improper installation or misapplication of its products. It is the installer's responsibility to check for proper installation and if in doubt, contact the manufacturer. LIMITATION OF WARRANTY BD Engine Brake Inc. (hereafter "BD") warrants to the BUYER that any parts purchased shall be free from defects in material workmanship. A defect is defined as a condition within the product that would render the product inoperable. BD gives Limited Warranty as to description, quality, merchantability, fitness for any product s purpose, productiveness, or any other matter of BD's product sold herewith. BD shall be in no way responsible for the product s open use and service and the BUYER hereby waives all rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by BD and the BUYER. The Warranty is Limited to one (1) year from the date of sale. Until BD has approved the claim, the consumer may be responsible for these costs. A Return Material Authorization (RMA) number, obtained in advance from BD, must accompany all products returned for warranty consideration. All products must be returned, shipping prepaid, to BD and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by BD and repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which have been replaced, become the sole property of BD. This warranty is in lieu of all other warranties or guaranties, either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser residing within the boundaries of the continental U.S. or Canada. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE OF PURCHASE FOR A FULL REFUND. Damaged or blown head gaskets will not be covered under warranty. It is the responsibility of the user to regulate cylinder pressures to protect the head gasket and turbo.