How to Install a Borgwarner S300 Turbo on Your Cummins 6.7l for 150 Extra Horsepower

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Installing a BorgWarner S300 turbocharger on your Cummins 6.7L engine can significantly enhance its performance, adding up to 150 extra horsepower. This guide provides step-by-step instructions to help you through the installation process.

Tools and Materials Needed

  • BorgWarner S300 Turbocharger Kit
  • Socket set
  • Wrenches
  • Torque wrench
  • Ratchet extensions
  • Oil catch pan
  • New gaskets and seals
  • Silicone sealant
  • Shop manual for your Cummins 6.7L

Preparation Steps

Before starting the installation, ensure that your vehicle is parked on a level surface and the engine is cool. Disconnect the battery to prevent any electrical issues during the installation.

Remove the Existing Turbocharger

Begin by removing the stock turbocharger. Follow these steps:

  • Remove the intake ducting connected to the turbo.
  • Disconnect the exhaust downpipe from the turbo.
  • Unplug any electrical connectors attached to the turbo.
  • Loosen and remove the oil feed and return lines.
  • Unbolt the turbo from the manifold and remove it from the engine.

Prepare the New Turbocharger

Once the old turbo is removed, prepare the BorgWarner S300 turbocharger for installation:

  • Inspect the new turbo for any damage or defects.
  • Install new gaskets and seals as per the manufacturer’s instructions.
  • Apply silicone sealant to the mating surfaces to ensure a good seal.

Installing the BorgWarner S300 Turbo

Now it’s time to install the new turbocharger. Follow these steps carefully:

  • Position the turbocharger onto the exhaust manifold.
  • Secure the turbo with bolts and use a torque wrench to tighten them to the specified torque settings.
  • Reconnect the oil feed and return lines, ensuring they are tight and leak-free.
  • Reattach the exhaust downpipe to the new turbo.
  • Reconnect any electrical connectors that were unplugged.
  • Install the intake ducting back onto the turbo.

Final Steps

After successfully installing the turbocharger, follow these final steps:

  • Reconnect the battery.
  • Start the engine and let it idle for a few minutes to check for leaks.
  • Perform a test drive to ensure everything is functioning correctly.
  • Monitor the turbo performance and engine parameters using a diagnostic tool.

Conclusion

Installing a BorgWarner S300 turbo on your Cummins 6.7L can provide a substantial increase in horsepower and performance. With the right tools and careful installation, you can enjoy the benefits of your new turbocharger.