Super B Turbo Charger Install
 

Hello All , I purchased a Super B from BD Power - The Leaders in Diesel Performance

I have 150 HP Injectors , Air Dog , ATS intake and Exhaust Manifolds , BHAF Intake , Mr. Bobs Hoses , Quadzilla Adrenaline , Suncoast TC and VB , and a few other goodies but thats the major stuff , Running this on a Stock Hy35 Charger that wasnt too happy about it , Ive had an HX35/12 , HX35/16 , HX35/21 on my truck and ended up going back to the HY , So now it was time to stop messing around so i got a Super B .

Ill start with the review

2 Negatives ,

1. The Charger should come supplied with a new Oil Return line I spent an hour trying to use the wrong tools for the job to bend it as it was hitting the Wastegate (Even resorted in using a Log Splitter for a press :D), after throwing some tools I picked up the install manual and low and behold
" You may need to Bend the Wastegate Arm to prevent rubbing oil return line "
ARGH ! I hate to have to bend parts on my new turbo to get it to fit , But thats what i had to do , a $10 part could of been supplied to prevent this all the way around

2. "One Time at Band Clamp" ... Band Clamps Suck I aways get them tightened down to the point i cant anymore and i can still twist the exhaust inside it ... ARGH !!! ... Welder time , The end of the down pipe could of been flanged to go over existing 4" pipe and a real exhaust clamp could of been used

As for the Negatives that it !

Positives , OMG is this the same truck , First drive resulted in a Speechless Announcement when returning to the garage where my brother was ,

Brad
How was it ?

Me
:nshock:

Brad......
:run:

And he took it for a "JOY RIDE"

Got back and :rocking:

Its really that much different It Pulls so hard and lays you back in the seat that it just about takes your breath away . Its going to take me sometime to "Get Used to it" Its Crazy Fast and Right Now , Compared to the HY35 there is no comparison , Where it was running 50lb of boost the S300 is 20 Pounds and is Pulling your brains out , Fresh Cool air and not Nasty Head Gasket blowing Drive Pressure ,

When it comes to adding Bombs for Seat of the pants difference on first test drive , Nothing has came close and i have ran just about ever programmer on the market and a few thats not ,I had everything in place , Injectors , Fuel Supply Tranny Ect ... and the Turbo was the last piece of the puzzle , and Man Or Man does this thing ROCK !!!

And Now For Some Photos of the install ...

Tail Gate Photo ,

Turbo , Downpipe , Towels , Oil and BHAF

http://inlinethumb10.webshots.com/38...600x600Q85.jpg

Here it is Super B , S300

http://inlinethumb53.webshots.com/40...600x600Q85.jpg

http://inlinethumb46.webshots.com/40...600x600Q85.jpg

http://inlinethumb19.webshots.com/15...600x600Q85.jpg

http://inlinethumb40.webshots.com/56...600x600Q85.jpg


Step 1 ALWAYS disconnect batteries

http://inlinethumb48.webshots.com/23...600x600Q85.jpg

Stock HY35 , ( 2002 Auto )

It looks dirty as hell because ive been soaking down the manifold bolts and downpipe and oil inlet and outlet for 3 days with penetrating oil , That and because ... Yeah its Dirty

http://inlinethumb56.webshots.com/37...600x600Q85.jpg

http://inlinethumb22.webshots.com/30...600x600Q85.jpg

http://inlinethumb04.webshots.com/29...600x600Q85.jpg

http://inlinethumb24.webshots.com/42...600x600Q85.jpg

BHAF intake and shield out of the way

http://inlinethumb55.webshots.com/12...600x600Q85.jpg

Tailgate View changing

http://inlinethumb03.webshots.com/20...600x600Q85.jpg

Oil Intake and Return Removed

http://inlinethumb14.webshots.com/80...600x600Q85.jpg

Downpipe Bolts / out ,

http://inlinethumb52.webshots.com/10...600x600Q85.jpg

http://inlinethumb22.webshots.com/96...600x600Q85.jpg

Remove Clamp from Inner Cooler Line

http://inlinethumb40.webshots.com/28...600x600Q85.jpg

Go ahead and loosen up the top clamp on your boot while your there

Remove manifold Nuts/Bolts (I cant remember stock) Then Pull the charger out of there

http://inlinethumb59.webshots.com/32...600x600Q85.jpg

Comparison Photos ....

http://inlinethumb34.webshots.com/29...600x600Q85.jpg

http://inlinethumb14.webshots.com/42...600x600Q85.jpg

http://inlinethumb09.webshots.com/41...600x600Q85.jpg

Tail Gate View Change ..

http://inlinethumb50.webshots.com/40...600x600Q85.jpg

Disconnect the Downpipe under the truck and pull it out of there , heres Mine compared to the one supplied

http://inlinethumb11.webshots.com/34...600x600Q85.jpg

And the hole it left

http://inlinethumb11.webshots.com/18...600x600Q85.jpg

It was much longer , What i ended up doing was running the new downpipe in to the engine compartment

http://inlinethumb54.webshots.com/87...600x600Q85.jpg

and Putting the new charger on and clamping the pipe for fitment purposes

http://inlinethumb42.webshots.com/57...600x600Q85.jpg

The Downpipe was on top of my Exhaust under the truck I Marked it and cut them both with a sawzall

http://inlinethumb14.webshots.com/26...600x600Q85.jpg

then clamped it with supplied clamp

http://inlinethumb54.webshots.com/29...600x600Q85.jpg

you will need the oil inlet fitting from your stock charger

http://inlinethumb48.webshots.com/26...600x600Q85.jpg

dont put it in your new one yet

http://inlinethumb59.webshots.com/27...600x600Q85.jpg

Heres the Super B in its new home

http://inlinethumb24.webshots.com/10...600x600Q85.jpg



ARGH !!! The oil outlet is not in place

http://inlinethumb45.webshots.com/30...600x600Q85.jpg

instead for taking the charger off , I took the oil outlet line off from the engine

http://inlinethumb47.webshots.com/15...600x600Q85.jpg


and moved it where it needed to be

Tighten up the 4 bolts/nuts connecting the charger to the manifold Use the new gasket that came with the charger

http://inlinethumb41.webshots.com/33...600x600Q85.jpg


Tailgate view changing :)

http://inlinethumb02.webshots.com/96...600x600Q85.jpg

Do up the Oil Return Bolts with antiseeze (Do all Bolts BTW)

Here you see the new oil return gasket (Supplied)

http://inlinethumb04.webshots.com/26...600x600Q85.jpg

Loosen up the four bolts holding the turbo together so you can rotate it to mate your inner cooler line and oil return line and the inlet and outlet on the charger are strait up and down

the next 2 photos show how you can move it very easy with the 4 bolts loosened


http://inlinethumb05.webshots.com/41...600x600Q85.jpg

http://inlinethumb06.webshots.com/42...600x600Q85.jpg

Connect the Oil return line to the charger

http://inlinethumb15.webshots.com/40...600x600Q85.jpg

OMG WTF the oil return line is hitting the Waste Gate ,,, ARGH !!

http://inlinethumb28.webshots.com/42...600x600Q85.jpg

Over the next hour the Return line was on and off the truck 10 times , bending it , smashing it , Pry bar , Big Hammer , Vise and even a log splitter was involved , Some Tools Flew some tears fell Then i read the manual and it says to bend the waste gate ... IE see first post

http://inlinethumb63.webshots.com/24...600x600Q85.jpg




Tail gate View Changing

http://inlinethumb30.webshots.com/39...600x600Q85.jpg

Now Add oil to the inlet of the charger (TOP) and spin the fins while you put it in , mine only took about a thimble full , Then add the oil inlet fitting from your stock charger and connect the oil inlet line , Then connect the intercooler line and Tighten up the 4 bolts on the charger that you used to spin it to make everything line up , Tighten up the down pipe clamp and everything else ..

http://inlinethumb13.webshots.com/42...600x600Q85.jpg


Beef up the ban clamp , IE See first post

http://inlinethumb36.webshots.com/17...600x600Q85.jpg

Reinstall Air Intake

http://inlinethumb03.webshots.com/41...600x600Q85.jpg

http://inlinethumb10.webshots.com/41...600x600Q85.jpg

http://inlinethumb22.webshots.com/10...600x600Q85.jpg

Farewell old friend

http://inlinethumb04.webshots.com/34...600x600Q85.jpg

When you fire it up it must idle for 3 mins to lubricate the charger ,

then Buckle Up and Celebrate .

End

DM

Cool...glad you like it.

My Super B rocked.....sorta miss that old truck.

sweetness, your gonna kill yourself on the slippery roads.....

Ill die with a smile :rocking:

im sure you will, it raining alot up there right now???? what are you doing with your HY??

Thats look good, nice install:U:

I heart slippery roads.... except in heavy traffic

my dodge is a death trap in the rain and its almost completely stock with 32 inch tires......

Tires break loose on wet roads at 60mph....

left hand turns on black top are always exciting:nshock:

I may be trading it for a lawn mower

lol

Pretty sweet,thanks for putting up the pictures!

i can do it at 60 when i lay into it on a concrete freeway.......mine will also kill the tires to about 55 spinning them, i cant wait to get some power in that truck, i might just get me one of those chargers.....

Looks good:U:

Good write up Chad. Congrats on the new charger I'm sure you already love it. But as the others said, be careful lol. You are now definetly part of the slippery roads are not your friend club lollollol.

Thanks ! , Its a Major PITA to stop and take a Photo when your trying to do something Ill admit that , but its fun to look back at them , It took me 2 hours to post this thread look at the times of the posts ... :D

Good story and pics...that oughta keep the odometer showin' ya a P0500 for a while:U:

Nice write up DM......

Exactly :up2:

Found an excuse to go in town today , The whistle is alot louder than the engine when taking off , Turns heads .. :D , Still haven't had the quad box over 4

SCHWEETNESS!!! :up:

All these computer skills Chad has aquired and still no video :(

The new camera dont take videos , its still a cool camera it has a little dot in the viewer and what ever its on is whats in focus

What kinda boost are you seeing?

SuperB
 

well this is mine pic just a day before i followed the same way,now its on since september and im accustomed to this turbo so its time for upgrade but as u said this is wonderfull :):U:

lol Sweet

haha im glad ur loving it, i loved mine and the new owner loves it as well, but im stepping it up to the special and may even throw my big spinny thing on there.

i dunno for special,i may grab one and fab a twin setup or take a 62 or 64 to make a twin setup...i just dont know whitch one to choose,BD wont sell the big one of the twin kit alone....
i want fast spool and low-midrange power over all top end power
does anybody know the size of the BD special?

I'm interested in the exhaust temps before & after the swap....150's and a Quad box, right?

yes , the EGT's have dropped , i never had it over 1000* before so i really cant judge it very well