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Twin Install  (CR) Twin Install (CR)
jlibert
03-19-2011
I've seen several threads asking for help with twin turbo installation. Here are the installation instructions for Source Automotive's kit on a 2004.5 NV5600 4x4. Hope this helps.

-jp




Source Automotive Twin Turbo Installation Procedure, 2003-2007 Dodge, 5.9 Cummins Engine.
1. Open packages to verify that you have received all of the necessary parts.
2. Disconnect battery cables from both batteries, remove keys from ignition. Set parking brake. Failure to take these steps can result in serious injury or death!
3. Remove plastic inner fender as shown below. Several 8mm bolts hold it in place. There may be one or more plastic tabs used to hold wiring that will need to be detached from inner fender before it can be fully removed.
Click the image to open in full size.

Click the image to open in full size.



4. Remove existing turbocharger and exhaust manifold:
a. Disconnect and remove existing downpipe.
b. Remove existing intake/filter assembly.
c. By laying under the truck, firmly grip the turbo oil drain line and pull it out of the block. A bit of force may be required to pop the drain line out of the hole in the block.
d. Remove the braided steel oil supply line that runs to the top of the turbo.
e. Remove all bolts from exhaust manifold and pull turbo and manifold out in one piece. (help from another person may be necessary when lifting manifold/turbo out of engine bay)
Your engine should look something like this at this point:
Click the image to open in full size.

5. Remove rigid coolant line from blue silicone hose to firewall shown in picture above. A bucket should be placed below the line to contain coolant lost when line is removed.



6. Using a piece of pipe and a rubber mallet, reshape the rigid line as shown in the following images:
Tap rigid hose with rubber mallet to slightly flatten the factory bend.
Click the image to open in full size.

Slide a piece of pipe over the end of the rigid line as shown below, using the pipe to bend the rigid line into a shape that will clear the top turbo. After turbo is installed, additional adjustments may be needed. This took a first time installer less than 5 minutes to complete, it isn’t hard.
Click the image to open in full size.

rigid coolant line before bending:
Click the image to open in full size.
rigid coolant line after bending:

Click the image to open in full size.





7. If you choose to paint your exhaust manifold, VHT flameproof paint works great.
Click the image to open in full size.


Install the longer studs included from source automotive into the manifold. (the shorter studs supplied with the manifold will not be used) Apply never seize to studs. Install steel spacer and gaskets as shown below:
Click the image to open in full size.
8. Loosen the compressor and exhaust housing clamps on the primary (big turbo) just enough so that the housings can be rotated as needed later in the install. Attach the hot pipe to primary turbo as below.
Click the image to open in full size.
9. Remove secondary turbo (small turbo) compressor and exhaust housing bolts one at a time as shown below. Install never seize to threads and reinstall bolts loosely. This will allow the housings to be rotated to achieve proper alignment later in the install.
Click the image to open in full size.

10. Apply never seize to threads of brass pop off valves, and thread into discharge pipe as shown below. Valves should ultimately be adjusted so that they face downward. This will insure that water or debris doesn’t collect inside the valves.
Click the image to open in full size.

11. Install exhaust manifold using new gaskets shown below. The manifold will be installed upside down as shown below. Now is the time to install pyrometer probe into existing threaded ports on bottom side of manifold. If you choose to install the pyrometer on the top side of the manifold, the hole should be drilled and tapped with the manifold off of the vehicle. This will make it easier to clean shavings out of the manifold to prevent damage to turbos. Always use anti seize on pyrometer coupling threads.

Click the image to open in full size.
Click the image to open in full size.
12. Install short (shorter of the two blue silicone hoses supplied with the kit) blue silicone hose onto bottom turbo mount bracket. Install straight nipple with o-ring onto blue silicone hose. (using glass cleaner, or soapy water may help slide the silicone hose into place). The bracket should appear as it does here:
Click the image to open in full size.

13. Use the two small bolts supplied in the kit to attach bracket with hose and nipple in place to primary (big) turbo as shown below.
Click the image to open in full size.
Make sure to use supplied gasket between bracket and turbo oil drain. Verify that mounting bracket does not contact v-band housing clamps, and that turbo shaft spins freely after tightening both small mounting bolts.
14. Install oil supply fittings onto both turbos as shown below.
Click the image to open in full size.
15. Remove upper motor mount bolt as shown below. Loosen lower motor mount bolt closest to firewall to allow bracket to slide over it.
Click the image to open in full size.
16. Remove factory soft plug from block. This port will be used for the top turbo oil drain. Using a very small flat screwdriver, GENTLY tap only one side of the plug until it rotates in the hole. As soon as it rotates, remove it using a pair of needle nose pliars. Again, only gentle tapping will be required to move the plug. All tapping should be concentrated on the same edge of the plug so that it rotates in one direction and is not pushed inside the block. Removal of the passenger side wheel/tire may make this step easier to complete. See illustrations below.
Plug before removal:
Click the image to open in full size.
Plug tapped sideways, ready to be removed:
Click the image to open in full size.
Plug is out, you can relax now. 
Click the image to open in full size.
17. Install 90* oil drain nipple with longer section of blue silicone hose attached into block where soft plug was previously located. A small amount of clean oil should be applied to the o-ring on the drain line to help the line slide into the hole in the block.

18. Lower primary turbo with hot-pipe and mounting bracket attached, onto loosened motor mount bolt. Insure that the turbo oil drain line has aligned with fitting in engine block, and install bolt into existing threaded hole in block. Reinstall and tighten upper motor mount bolt. Tighten lower motor mount bolt. Verify that turbo shaft spins freely.
Click the image to open in full size.
19. At this point, the turbo should be mounted as shown below.
Click the image to open in full size.
20. This is the appropriate time to verify clearance between rigid coolant pipe and hot pipe. Reshape rigid coolant line as needed to achieve proper clearance. (pic shown without manifold installed….. your manifold will already be installed.)
Click the image to open in full size.
21. Fill bottom turbo with clean engine oil through oil feed line while simultaneously spinning turbo shaft by hand.
Click the image to open in full size................................................... ..................see next post  
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  #1  
jlibert on 03-19-2011, 03:39 PM
22. Install electrical pigtail supplied in kit onto male connector near oil filter.
Click the image to open in full size.

23. Using bolts and spacers shown below, Install supplied spacers between Air Conditioning component and mounting bracket.
Click the image to open in full size.
Note: larger spacer installed on bottom, smaller spacer installed on top.
Click the image to open in full size.
24. Using supplied gasket, attach factory flexible oil drain line to top turbo with factory bolts.
Click the image to open in full size.

25. Install top turbo onto exhaust manifold. Verify that all steel gaskets are in place along with steel spacer.
Click the image to open in full size.


26. Rotate bottom turbo housing so that hot pipe aligns with exhaust flange on top turbo. Upon proper alignment of hot pipe, install factory v-band clamp.
Click the image to open in full size.



27. tighten exhaust housing bolts on top turbo. Leave intake housing fasteners loose.
Click the image to open in full size.






28. Tighten exhaust housing clamp on bottom turbo
Click the image to open in full size.
29. Attach factory oil drain line on top turbo to longer section of blue silicone hose that should already be installed into front port near oil pan.

Click the image to open in full size.






30. Fill top turbo with oil while rotating turbo shaft.
Click the image to open in full size.

31. Attach longer braided steel oil supply line to bottom turbo.
Click the image to open in full size.






32. Attach shorter braided steel oil supply line to top turbo.
Click the image to open in full size.
33. Install oil supply fittings onto factory oil filter housing. 45* fitting is installed on the rear of the housing where factory supply line was located. The 90* fitting is installed on top of the housing by removing the factory plug. Connect oil supply lines to fittings.

Click the image to open in full size.
Click the image to open in full size.
34. Loosen both 10mm bolts at top corners of intercooler. This step will allow the intercooler to be pulled forward to facilitate the installation of the top turbo to intercooler piping.
Click the image to open in full size.
35. Test fit piping without installing silicone boots. Rotate top and bottom turbo housings as needed to achieve proper alignment. Everything WILL line up properly, but some patience is required here. Every truck is a little bit different, some may require slightly different alignment than others.



36. Install intake boot and piping onto bottom turbo compressor housing. Secure clamps, and install intake air temperature sensor as shown here:
Click the image to open in full size.

37. Verify that charge air pipe connecting bottom turbo to top turbo has a rubber o-ring installed in the groove near the flange. This flange will be placed on the compressor outlet of the bottom turbo. Loosely install supplied clamp so that it attaches the piping flange to turbo flange.
Click the image to open in full size.


38. Secure intake piping and charge air piping by aligning tabs and installing the supplied bolt and lock nut.
Click the image to open in full size.

39. Slide silicone boot onto piping using soapy water or glass cleaner. Rotate piping so that it aligns with top turbo. Slide boot off of piping and over the outlet on the top charger and secure with supplied clamps. Tighten compressor housing clamp on bottom turbo after proper alignment is obtained.










40. With intercooler bolts removed, lift up on intercooler and pull it away from the engine. This step will allow a couple additional inches of clearance necessary to install piping from top charger to intercooler.
Click the image to open in full size.
41. With intercooler pulled back, install rubber boot on intercooler, then slide end of piping into boot. Slide other boot onto top turbo outlet. Connect piping to top turbo. Install and tighten boot clamps.
Click the image to open in full size.
Click the image to open in full size.

42. Remove factory intercooler piping boots on driver’s side of engine and replace with source automotive boots supplied in kit.
Click the image to open in full size.
Click the image to open in full size.
43. Install air filter and verify that it is not making contact with any other components. It is always a good idea to verify that no foreign objects have fallen into piping—double check before installing filter.
Click the image to open in full size.
44. Re-fill coolant lost when bending factory coolant line.
45. Double check all connections.
a. Oil supply line fittings tight?
b. Oil drain lines snugly inserted in block?
c. Turbos filled with fresh oil?
d. Coolant level ok?
e. Coolant hose clamps tight?
f. Turbo housing clamps and bolts tightened after rotating turbo housings into place?
Your engine compartment should look something like this:
Click the image to open in full size.

Take a minute to admire your hard work, and beautiful new set of twins.


If all steps above have been completed, connect battery cables and start engine. Let idle for 5 minutes. During initial startup and idle period, check for leaks. Shut down immediately if any leaking occurs.

Turbo seals are tight from the factory. Spool up will be a bit slow until seals have loosened up. Allow approximately 100 miles for proper break in.
  #2  
WUnderwood on 03-19-2011, 06:17 PM
helluva write up

many thanks!
  #3  
K-Farms on 03-19-2011, 07:33 PM
nice, thank you
  #4  
lowdiesel on 03-19-2011, 08:29 PM
Now what about the thread on "How to convince your spanish wife to allow you to spend more money on your redneck truck".
  #5  
jlibert on 03-19-2011, 08:54 PM
Quote:
Originally Posted by lowdiesel View Post
Now what about the thread on "How to convince your spanish wife to allow you to spend more money on your redneck truck".
Looking at your sig, you've already convinced her.
  #6  
cumminsproud on 03-19-2011, 11:31 PM
great write up
  #7  
Red Sleeper on 03-20-2011, 12:36 AM
Awesome write up man! Great detail. Many thanks.
  #8  
jlibert on 03-20-2011, 12:45 AM
No problem guys.

Auto transmission installs will be a little different. This was a 64/480 combo, and at the time, Source didn't have any installation instructions. Rip was great to deal with, so I decided to do a write up during the install. As far as I know, the standard kit installs the same way.

-jp
  #9  
paulb on 03-20-2011, 10:56 AM
Great write up and pics.

Paul
  #10  
nomercy on 03-31-2011, 01:24 PM
I would love to have one of their kits just cant drop 5k on turbos/piping but I know their kits are top notch great write up
  #11  
luke7474 on 07-19-2011, 10:32 AM
great job
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