DOUBLE TIME DIESEL Part 1

This twin-turbo setup unites two different turbochargers, with a smaller primary turbo pressurizing a larger secondary unit, all but removing turbo lag often associated with traditional single turbo systems.

A surprising number of 4 Wheel Parts customers are farmers, contractors and others who rely on trucks to haul their businesses.
Just about everyone who"s ever hauled supplies across a mountain pass or towed hay while the sun shines has, at one time or another, wished for “a little more power,” as even the best factory engine options can fall short of expectations. Not surprisingly, several of the companies 4 Wheel Parts represents have addressed these shortcomings, including BD Diesel Performance. BD has been building diesel performance for over twenty years, with eight different divisions transforming our diesel dreams into road-ready realities.
As 4WP"s southeastern regional manager, overseeing 18 stores throughout the region, David Powell has gained a unique understanding of his customers, as he shares their desires and needs. Not satisfied with reading up on the companies" products he represents, Powell has incorporated a wide range of components into his own vehicles through the years, and here he"s about to do it again.
Traveling to events across many states, Powell"s Cummins Turbo Diesel-powered "07 Dodge Ram Super Cab is repeatedly tested to the limit pulling various loads including one of the 4WP trailers packed full of products destined for enthusiasts everywhere. While the trusted 5.9-liter six cylinder turbo diesel has never laid down on the job, there have been times when more power would have made Powell"s long hauls a lot shorter.
Hearing about BD"s Super B Twin Turbo kit for his pickup, it wasn"t long before Powell took this package off the shelf and scheduled the installation at 4WP"s store in Marietta, Georgia. From there, it was only a matter of hours until his tried and true hauler would take on entirely new capability.
While the typical installation is expectedly straightforward, Powell"s particular application was a bit more involved as he chose to stay with his existing intercooler system, which required special efforts to adapt with the Super B Twin Turbo package. Still, the modifications needed to unite these components were minor, adding only an hour or two beyond a purely factory bolt-on.
To begin the installation process, the existing turbocharger system, exhaust manifold and related plumbing, as well as the intake plenum and its ancillary hardware were removed. Then the mating surfaces were thoroughly cleaned to ensure the new components could be installed without any difficulties. Following a final review of the instructions, all the necessary components were gathered to make sure everything was ready to go, before the process began.
In all, this installation required approximately 15 hours for a highly experienced team of 4WP technicians to accomplish, those with lesser skills will almost certainly require more time to realize their goals. And for those thinking about doing this installation alone, think again, as there were many occasions when at least two people were needed to bring things together properly. Lastly, if you"ve never attempted this kind of installation before and are concerned about falling short of expectations, think about looking to 4WP"s professionals to get it right. In the long run, the added cost will save you money and aggravation.
When all was said and done, there was no question that BD Diesel Performance"s Super B Twin Turbo system was well conceived from the start, as every component fit as intended despite a few alterations required in this installation. Following a test drive, this Dodge pickup was elevated to a level of performance never realized before.
While the cost of this twin turbo package may have some questioning its worth, and the effort required to install it may have others wondering if it is within their skill set, the end result will more than justify these concerns. Loads that would have taxed the stock Cummins engine are definitely lightened with this exceptional update, and hills that were once a challenge will now pass without a thought. The combination of one turbocharger bolstering the other increased torque levels lower in the rev range, while additional horsepower gains further around the tachometer, eased the burden of even the heaviest loads. And all the while, exhaust gas temperatures remained well within safe expectations.
However, with these gains comes added pressure on the remaining drivetrain components, namely the transmission, which may require a few updates to hold up to such a capable and reliable system.

1. Before the new turbo system could be installed, the existing system had to be removed. Start by removing the battery cable to avoid difficulties. To allow access to the exhaust side of the engine, the inner fender liner must be removed, clearing the way for a good portion of the installation, which is done from below. This is easily accomplished by removing a few fasteners.	2. Early on, you"ll be reaching through the right fender well to access bolts securing the existing turbocharger and exhaust manifold.
3. A die grinder was used to cut the rear bracket supporting the water lines leading to the heater core. Later in the installation, the water line was remounted with new brackets supplied in the kit.	4. To create a path for the oil return line leading from the turbocharger to the oil pan, plugs in the lower portion of the block were drilled out, so that bolts could be temporarily fitted and used to pry the plugs out. Prior to drilling the plugs, a thin layer of grease was applied to the drill bit, thereby retaining any metal shavings that would otherwise contaminate the oiling system.
5. A bolt is threaded into the plug just far enough to provide enough leverage to pry the plug out of position. The same wrench was then used, beneath the shoulder of the bolt, to pry the plug out of its location. This entire process only took a few minutes, removing each of the plugs to make way for oil to return to the pan.	6. To fit the curved oil return line into the now accessible block, the side was carefully ground out of a plug socket, allowing the socket to fit over the tubular oil line and press it into place.
7. The rear return line is pressed into position, ready to be connected to the oil return line from above.	8. One of the old oil return lines adjoins a new line, that will lead from the turbos to the newly devised fittings in the block, above the oil pan.
9. A die grinder was used to shorten the oil return line to the required length to clear surrounding components.	10. Here"s the results of this simple yet involved process, as hot oil from the turbocharger overhead can return through this tube to the oil pan.
11. New studs were fitted to the intake manifold, to clamp down the polished BD Performance aluminum plenum. A new gasket was also carefully fitted, as manifold pressures need to be maintained at the junction.	12. Specifically made for this application, the sculpted intake plenum was carefully fitted, and fasteners evenly torqued to properly seal and support the assembly.
13. To be sure the special (Nomex silicone hose, capable of withstanding 100 pounds per square inch of boost) pressurized hoses, leading from the intercooler to the intake plenum, retain their seal, rugged spring-loaded T-bar hose clamps are utilized, as they allow for expansion while maintaining a grip on the hose.	14. Despite decades of experience between them, David Powell and Brian Maybry still take time to read instructions on involved installations like this, to avoid problems and speed the installation.