The Dodge Durango SRT is no stranger to high performance, but even the factory twin-scroll turbochargers leave room for improvement. The BWoR (Boost Works on Race) Turbo Upgrade Kit is engineered to push the 6.2L HEMI Hellcat engine in your Durango SRT well beyond stock output, delivering consistent power gains of 150–200 wheel horsepower without sacrificing daily drivability. This detailed guide covers everything from tool selection and safety to the actual swap, post-installation checks, and the critical tune required to unlock your upgrade's full potential.

Understanding the BWoR Turbo Upgrade Kit

Unlike universal turbo kits, the BWoR system is platform-specific. It replaces the factory twin-scroll units with larger compressor and turbine wheels, redesigned housings, and upgraded wastegate actuators. The kit includes all necessary adapter brackets, gaskets, and hardware, making it a direct bolt-on for the 2018–2024 Durango SRT. Key performance characteristics include:

  • Compressor wheel upgrade: 58mm billet wheel with extended tip technology for increased airflow (15–20% over stock).
  • Turbine housing: Divided T4 inlet with 0.85 A/R ratio to retain spool characteristics while supporting higher flow.
  • Wastegate actuators: Dual electronic units with adjustable spring pressure to prevent boost creep.
  • Included hardware: New oil feed and drain lines, coolant hoses, and stainless steel exhaust flange studs.

Before starting, verify that the kit is compatible with your specific Durango SRT model year and that any necessary supporting mods (fuel system, intercooler, etc.) are already in place or planned. For official specifications and part numbers, refer to the BWoR product page.

Tools and Materials Required

Gather all items before you begin to avoid interruptions. Beyond the upgrade kit itself, you will need:

  • Socket set (metric): 8mm–22mm, including deep sockets for tight spaces. A ½-inch drive torque wrench (20–150 ft-lb range).
  • Wrenches: Combination wrenches in 10mm, 13mm, 15mm, 18mm, and a flex-head ratcheting wrench for hard-to-reach bolts.
  • Pry bars and picks: For stubborn hose clips and electrical connectors.
  • Oil drain pan: Capacity of at least 6 quarts for coolant/oil catch.
  • Shop towels and brake cleaner: To clean mating surfaces and gaskets.
  • Safety equipment: Mechanic gloves, safety glasses, and a fire extinguisher rated for flammable liquids.
  • Jack and jack stands: The vehicle must be lifted approximately 12 inches for under-engine access. Use stands, not just the jack.
  • Coolant refill: Mopar OAT coolant (premixed) or equivalent – plan for 2 gallons.
  • Thread locker: Loctite 243 (medium strength) for turbo mounting bolts.
  • Anti-seize compound: For exhaust flange studs and O2 sensor threads.

Preparation and Safety

Begin by parking the Durango SRT on a level surface. Engage the parking brake and chock the rear wheels. Disconnect the negative battery terminal and isolate it to prevent accidental contact. Allow the engine to cool completely – the exhaust manifolds and turbo housings can retain heat for hours after shutdown.

Engine Bay Access

Remove the engine cosmetic cover by unscrewing the four 10mm bolts (or push clips on some models). Detach the air intake duct from the throttle body and remove the entire intake assembly. This includes the air filter box, Mass Air Flow (MAF) sensor, and connecting tubes. Label electrical connectors with painter's tape to avoid confusion during reassembly.

Fluid Drainage

Position the drain pan under the radiator petcock and drain approximately 1.5 gallons of coolant into approved containers. The coolant will need to be replaced; do not reuse it. Also loosen the oil feed line banjo bolt at the block (if accessible) to drain residual oil from the turbo oil lines. This prevents oil spills when disconnecting lines later.

Removing the Stock Turbochargers

The Durango SRT uses two turbochargers mounted low on the engine block, one per cylinder bank. Access is tight, so proceed methodically.

Disconnecting Pipes and Hoses

  • Unclip the charge air cooler (CAC) pipes from each turbo outlet. These are large rubber hoses with constant-tension clamps. A flathead screwdriver can assist, but use care not to puncture the hose.
  • Remove the downpipe bolts (three 13mm nuts each) connecting the turbo outlets to the exhaust system. Soak the bolts with penetrating oil if corroded.
  • Disconnect the wastegate vacuum lines – these are small rubber hoses that connect to the electronic actuators. Mark their orientation (some are color-coded).
  • Unplug the knock sensors and oxygen sensors (O2) near the turbos. Use O2 sensor sockets (22mm) to avoid damaging the connectors.

Unbolting the Turbochargers

Support each turbo from below with a jack and a block of wood. The mounting bracket has four bolts per turbo: two M10 bolts into the block and two M8 bolts into the oil return flange. Use a torque wrench set to 35 ft-lb for M10 and 18 ft-lb for M8 when reinstalling. Carefully slide each turbo out of the engine bay, tilting as needed to clear the frame rail. Keep the intake ports covered with clean rags to prevent debris entry.

Installing the BWoR Turbo Upgrade Kit

Inspect the new turbos out of the box. Rotate the compressor wheel by hand to confirm smooth spinning with no scraping. Apply a light coat of engine oil to the bearing housing through the oil feed port before installation – this provides initial lubrication on startup.

Gasket and Line Preparation

Clean the exhaust manifold mating surfaces with a razor blade and brake cleaner. Install the new copper gaskets provided in the BWoR kit. Do not use sealant on these gaskets. Attach the oil drain hose to the bottom of the turbo cartridge using new crush washers (included). Tighten to 20 ft-lb. Connect the coolant hoses – note that the inlet and outlet are marked with arrows on the housing; flow direction matters for proper cooling.

Mounting the Turbo

Position the new BWoR turbo into the engine bay. Align the mounting bracket holes and start all bolts by hand. Torque in the sequence: M10 bolts to 35 ft-lb, M8 bolts to 18 ft-lb. Use thread locker on the M10 bolts. Reinstall the oil feed line with new washers (tighten to 12 ft-lb only – overtightening can crush the banjo fitting). Connect the wastegate actuator rods to the wastegate arm and secure with cotter pins.

Reconnecting Ancillaries

Attach the charge air cooler pipes and tighten clamps. Reconnect the downpipe to the turbo outlet flange, using new gaskets. Torque downpipe nuts to 25 ft-lb. Reinstall O2 sensors and electrical connectors. Pay attention to routing – keep wires away from heat sources.

Post-Installation Checks and Break-In Procedure

After assembly, double-check every clamp, bolt, and electrical connection. Reinstall the engine cover and air intake assembly. Refill the cooling system with fresh OAT coolant, following the bleed procedure:

  • Remove the radiator cap and fill to the cold fill line.
  • Start the engine and let it idle for 2 minutes. Rev to 2000 RPM for 10 seconds, then return to idle. Repeat 3 times to purge air.
  • Top off coolant and install the cap. Monitor temperature gauge for the first drive.

Perform a visual smoke or pressure test on the intake and exhaust system. A shop blower or a dedicated smoke machine can reveal leaks. For a basic check, spray soapy water on all connections while the engine idles – bubbles indicate leaks. Tighten clamps as needed.

The first startup should be smooth. Allow the engine to reach operating temperature (190–210°F). Check oil pressure on your scan tool or gauge – should be 30–50 psi at idle. Drive gently for 50 miles, varying RPM but not exceeding 3500 RPM. This seats the turbo bearings and wastegate system.

Tuning and Calibration

A stock Durango SRT engine control unit (ECU) cannot compensate for the increased airflow from the BWoR turbos. Without a custom tune, you risk lean conditions, detonation, and potential engine damage. Use a reputable tuner or software like HP Tuners with a supported Dodge SF4+ device.

Key tuning adjustments include:

  • Airflow models: Recalibrated MAF and speed-density tables to match the larger turbos.
  • Fuel system: Increase injection pulse width and enable auxiliary injectors if installed. A higher flow fuel pump (e.g., Hellcat DW400) is recommended for 700+ whp.
  • Boost control: Set target boost pressure (typically 14–18 psi on pump gas) and wastegate duty cycle.
  • Torque management: Reduce torque reduction during shifts to maintain acceleration under boost.

For a safe baseline, consult Durango SRT Forum tuning guides or work with a remote calibration shop experienced with HEMI platforms.

Testing and Performance Validation

After tuning, perform controlled tests to verify the upgrade.

Data Logging

Log parameters: boost pressure (PSI), intake air temperature (IAT), exhaust gas temperature (EGT), fuel trims (STFT/LTFT), and knock (KR). Acceptable values on 93 octane:

  • Boost: 14–18 psi peak
  • IAT: Within 30°F of ambient after cruise
  • Fuel trims: ±10% at wide open throttle
  • Knock retard: 0° at peak boost (momentary 1° is acceptable)

Road Test

Drive on a safe, empty road. Perform three wide-open-throttle pulls from 40–80 mph. Monitor gauges. The car should pull hard without hesitation or surge. After each pull, check for smoke or fluid leaks. Let the engine idle for 60 seconds before shutdown to cool the turbos.

Maintenance and Care

The upgraded turbos impose higher thermal and oil demands. Adopt the following schedule:

  • Oil change: Every 3,000 miles with full synthetic 5W-40 (e.g., Castrol Edge Supercar).
  • Turbo oil feed filter: Inspect and clean every oil change (BWoR includes an inline filter).
  • Coolant flush: Every 30,000 miles to prevent gelling around turbos.
  • Wastegate checks: Annually, ensure actuator rods move freely and cotter pins are intact.

If you notice increased oil consumption or smoke under deceleration, the turbo oil seals may be compromised. Immediate inspection is required – do not drive the vehicle in this condition.

Conclusion

Installing a BWoR Turbo Upgrade Kit transforms your Durango SRT into a track-capable SUV with power levels that rival many dedicated sports cars. The mechanical installation, while demanding, is within reach of an intermediate DIYer with proper tools and patience. However, the tune remains the critical success factor – invest in professional calibration to protect your engine and realize the full potential of the hardware. With careful break-in and diligent maintenance, your upgraded turbos will deliver years of exhilarating performance. For community support and build threads, check out Ram Forum where many SRT Durango owners share their upgrade experiences.