HX35W upgrade for Dodge Cummins 5.9L - Part 2Step-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)
- 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.
Step 2: Install flange and attach exhaust housing
Use 13mm wrench, or socket.
Step 3: Install gasket and attach the oil drain tube
Use a ratchet and a 4″ extension to reach the rear 10mm bolt.
Step 4: Install the compressor v-band clamp
Use 11mm socket.
Step 5: Install oil line
Install oil line adapter using 19mm wrench.
Step 6: Connect oil supply line
Connect oil supply line using 21mm wrench while holding the adapter fast with a 19mm wrench.
Step 7: Replace the lower portion of the air cleaner box
Use E12 inverted torx socket to tighten 3 plastic fasteners.
8a) Put the air filter in…
8b) Position the pipe and the top of the air filter box together…
8c) Clip the box shut…
8d) Tighten the hose clamp on the turbo inlet with 8mm socket.