Installing the Borgwarner S300sx Turbo on Your Challenger: a Complete Step-by-step Guide

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Installing a turbocharger can significantly enhance the performance of your Challenger. The BorgWarner S300SX Turbo is a popular choice among enthusiasts for its efficiency and power potential. This guide will walk you through the process of installing the S300SX Turbo on your Challenger, ensuring you achieve optimal results.

Tools and Materials Needed

  • BorgWarner S300SX Turbo
  • Turbocharger installation kit
  • Basic hand tools (sockets, wrenches, etc.)
  • Torque wrench
  • Intercooler piping
  • Boost gauge
  • Oil feed line
  • Oil drain line
  • Silicone couplers
  • Zip ties
  • Shop towels

Preparation

Before starting the installation, ensure you have a clean working environment. Gather all the tools and materials listed above. It’s also advisable to disconnect the battery to prevent any electrical issues during the installation process.

Step 1: Remove the Stock Components

The first step in installing the BorgWarner S300SX Turbo is to remove the stock components that will be replaced. This includes the stock intake manifold, exhaust manifold, and any associated piping. Follow these sub-steps:

  • Disconnect the intake and exhaust systems.
  • Remove the stock intake manifold bolts and lift off the manifold.
  • Remove the exhaust manifold by unbolting it from the engine.
  • Take out any necessary sensors or wiring harnesses attached to these components.

Step 2: Install the Turbocharger

With the stock components removed, it’s time to install the BorgWarner S300SX Turbo. Follow these steps carefully:

  • Position the turbocharger onto the exhaust manifold.
  • Secure the turbo using the provided bolts from the installation kit.
  • Ensure the turbo is aligned properly with the exhaust and intake ports.
  • Torque the bolts to the manufacturer’s specifications using a torque wrench.

Step 3: Connect the Oil Lines

Proper oil supply and drainage are critical for the turbo’s operation. Follow these instructions to connect the oil lines:

  • Install the oil feed line from the engine to the turbocharger.
  • Ensure the line is secure and free from kinks.
  • Connect the oil drain line from the turbo back to the oil pan.
  • Make sure all connections are tight to prevent leaks.

Step 4: Install the Intercooler and Piping

To maximize performance, an intercooler is essential. Here’s how to install it:

  • Position the intercooler in front of the radiator.
  • Use silicone couplers to connect the intercooler piping to the turbo and throttle body.
  • Ensure all clamps are tight and secure.
  • Check for any potential interference with other components.

Step 5: Reconnect Electrical Components

With the turbo and intercooler installed, it’s time to reconnect any electrical components that were previously disconnected:

  • Reconnect any sensors that were removed during the initial steps.
  • Ensure all wiring harnesses are secure and properly routed.
  • Double-check that no wires are pinched or exposed.

Step 6: Install the Boost Gauge

Monitoring boost levels is crucial for turbocharged engines. Follow these steps to install a boost gauge:

  • Choose a location for the boost gauge, preferably on the dashboard or A-pillar.
  • Run the vacuum line from the intake manifold to the gauge.
  • Secure the gauge in its mounting location.

Step 7: Final Checks and Reconnect the Battery

Before starting the engine, perform a final inspection of all connections and components:

  • Check all bolts and fittings for tightness.
  • Inspect the oil lines for any signs of leaks.
  • Ensure all electrical connections are secure.
  • Reconnect the battery and prepare for startup.

Step 8: Start the Engine and Test

With everything installed and checked, it’s time to start the engine:

  • Start the engine and let it idle for a few minutes.
  • Monitor the boost gauge for proper readings.
  • Check for any leaks around the oil lines and turbo connections.
  • Take the car for a test drive to ensure everything is functioning correctly.

Conclusion

Installing the BorgWarner S300SX Turbo on your Challenger can greatly enhance its performance. By following this step-by-step guide, you can ensure a successful installation. Always remember to consult your vehicle’s manual and manufacturer guidelines for specific details related to your model. Enjoy the added power and performance!