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HX35W upgrade for Dodge Cummins 5.9L - Part 2

Step-By-Step Instructions

Part 2: Installing your HX35W turbocharger on a Dodge Cummins 5.9L diesel engine.

Please note: This guide is based on our turbo upgrade kit for Dodge Cummins 5.9L trucks.  Not every Holset HX35W is configured the same, and as such other HX35W turbochargers may or may not fit your application. 

If you need help removing your stock turbo see part 1: Turbo removal

We know that some of the steps listed in this guide may be performed in various orders. We simply listed them this way.

You will need:

The Turbo (buy it here)

Fasteners and Gasket (these come with the turbo kit we sell)

Tools:

  • Sockets – 8mm, 10mm, 15mm. Deep 11mm
  • Ratchet and 4″ extension
  • Wrenches – 13mm, 15mm, 19mm, 21mm

 

 

Step 1: Attach the turbo to the exhaust manifold

Attach the turbo to the exhaust manifold with the exhaust gasket in place. Use a 15mm wrench and ratchet with 15mm socket.

HX35W Turbo installation

HX35W Turbo installation

 

 

HX35W Turbo upgrade new gasket

HX35W Turbo upgrade new gasket

HX35W Turbo upgrade new gasket

HX35W Turbo upgrade new gasket

 

Step 2: Install flange and attach exhaust housing

Use 13mm wrench, or socket.

HX35W Turbo upgrade new flange

HX35W Turbo upgrade new flange

HX35W Turbo upgrade new flange

HX35W Turbo upgrade new flange

HX35W Turbo upgrade

HX35W Turbo upgrade

HX35W Turbo upgrade

HX35W Turbo upgrade

 

 

Step 3: Install gasket and attach the oil drain tube

Use a ratchet and a 4″ extension to reach the rear 10mm bolt.

Turbo upgrade dodge 5.9 cummins engine

Turbo upgrade dodge 5.9 cummins engine

Turbo upgrade dodge 5.9 cummins engine

Turbo upgrade dodge 5.9 cummins engine

Turbo upgrade dodge 5.9 cummins engine

Turbo upgrade dodge 5.9 cummins engine

.

 

Step 4: Install the compressor v-band clamp

Use 11mm socket.

Turbo upgrade dodge 5.9 cummins engine

Turbo upgrade dodge 5.9 cummins engine

 

 

Step 5: Install oil line

Install oil line adapter using 19mm wrench.

Dodge Cummins 5.9 Turbo Up Grade Holset Hx35w 59

Dodge Cummins 5.9 Turbo Up Grade Holset Hx35w 59

 

 

Step 6: Connect oil supply line

Connect oil supply line using 21mm wrench while holding the adapter fast with a 19mm wrench.

Dodge Cummins 5.9 Turbo Up Grade Holset Hx35w 61

 

Step 7: Replace the lower portion of the air cleaner box

Use E12 inverted torx socket to tighten 3 plastic fasteners.

intake air dodge 5.9 cummins

intake air dodge 5.9 Cummins

Step 8: 

8a) Put the air filter in…

Cummins turbo upgrade

Cummins turbo upgrade

 

8b)   Position the pipe and the top of the air filter box together…

Dodge Cummins engine 5.9

 

8c)  Clip the box shut…

Dodge Cummins air filter

 

 

8d)  Tighten the hose clamp on the turbo inlet with 8mm socket.

Turbo upgrade dodge 5.9 Cummins engine

Turbo upgrade dodge 5.9 Cummins engine

 

Step 9: Collect your tools, and go for a drive!

Cummins holset HX35W turbo upgrade bolt in

Cummins holset HX35W turbo upgrade bolt in by EKG Diesel

If you don’t find the parts you need just ask!

Please Give Us A Call

330-636-1570

If you don’t find the parts you need just ask!

Please Give Us A Call