Evolution Powersports 2017-2021 X3/Turbo R & 2020 Turbo RR Desert-Storm 395 & 420 Turbo Kit Installation Guide

Important Information & Disclaimers

NOTE: Expect a 24-48 hour delay from the time you request a tune until the file is enabled. Please create your Maptuner account before starting the project. Email maptunerx@evopowersports.com.

This is a high-performance upgrade! While safety features have been integrated, installing any turbo system requires care in operation and installation. Poor fuel, improper setup, or incorrect procedures can damage your engine.

• You have likely voided the sound and exhaust emission standards of your country, if applicable.
• This upgrade is intended for OFFROAD and RACING use only.
• This is a performance upgrade that may shorten the life of your engine, especially if installed incorrectly or operated without regard to your instruments.
• Fuel requirements must be adhered to! Poor fuel can destroy an engine in seconds.

Evolution Powersports bears no responsibility for damage caused to your vehicle by the installation of EVP products. The warranty on big turbo kits is 30 days from the date of purchase. Evolution Powersports, at its discretion, will determine whether a part meets warranty requirements. There is no warranty from EVP for your vehicle or its drivetrain. Although Evolution Powersports has been careful to supply high-quality parts, no liability is assumed for damage to the vehicle or personal injury from installing or using any of their products.

The installation of this kit is technical and mechanical. Mistakes can be very costly. If you are not qualified to install this kit, do not attempt it. Bring it to one of Evolution Powersports' qualified installation centers.

This kit will make your vehicle faster, climb higher, accelerate more quickly, and take a longer distance to brake than a stock-tuned vehicle. If you are not capable of controlling the vehicle with the added performance, do not install the kit.

High boost is hard on spark plugs; they must be changed frequently. If you experience misfire issues, gap and replace the spark plugs.

• A full exhaust and clutching are required for this kit and can be purchased separately.
• Do not allow a child or an unqualified driver to operate this vehicle.

Performance Specifications

Parts Included with Desert Storm 395 Kit

• EVP Desert Storm Billet Ball Bearing Turbo Upgrade
• Desert Storm DS 395 & 420 Install Kit
• Maverick X3 Silicone Charge Tubes with BOV Port
• Maverick X3 Blow Off Valve Kit
• Can Am X3 1300cc Injectors - Set of 3
• Maverick X3 Big Intake Outlet with New Silicone Boot
• Maptuner X for BRP Vehicles (Includes Maptuner X and BRP Cable)
• Ultra-High Efficiency Intercooler - with Race Core
• X3 HD Intake Plenum - Raw Aluminum
• Can Am Maverick X3 Rising Rate Fuel System
• High Performance Camshafts for Can Am X3 (Exchange)
• Can Am X3 Xtreme Duty Custom Age 625 Direct Replacement Head Stud Kit - Set of 8

Parts Included with Desert Storm 420 Kit

• Can Am X 450LPH Fuel pump
• EVP Engine Build

Recommended Parts

• Boost gauge
• AFR gauge

Required Parts

• EVP or other Full Exhaust

Required Tools

• Sockets (7mm, 8mm, 10mm deep, and 13mm deep)
• T40 Torx
• Side cutter / wire cutter
• 4mm Allen
• 10mm wrench
• Die grinder

Parts List for DS-360R and DS-420 Install Kit

Parts List for Rising Rate Fuel System Kit

Turbo Removal Instructions

1. Remove the panel between the seats that allows access to the turbocharger.
2. Remove and label pressure lines from the boost control solenoid going to the wastegate actuator, intake, and air box.
3. Remove the worm drive clamp holding the intake tube onto the turbo.
4. Remove the worm drive clamp on the top of the air box.
5. Using a 13mm socket, remove the 2 bolts behind the driver seat holding the air box to the firewall.
6. Remove the worm drive clamps or t-bolt clamps holding the charge tubes to the intercooler.
7. Using a 10mm socket, remove the fasteners (4) holding the intercooler in place. Unplug the intercooler fan. Remove intercooler assembly from vehicle.
8. Remove the nut on the V-band clamp holding the exhaust onto the turbo.
9. Remove the worm drive clamps holding the heat shielding on to the mid-pipe. Remove heat shields from mid-pipe.
10. Remove oil drain line from turbocharger by cutting the OEM clamp.
11. Remove the charge tube from the turbo outlet.
12. Remove oil supply line from top of the turbocharger.
13. Remove the nut securing the water line to the bottom of the exhaust manifold.
14. Using soft grip vise grips or hose clamps, pinch off the soft coolant lines that supply and return water to the turbo.
15. Remove the OEM clamps holding the soft coolant line to the hard line on top and bottom. Using a side cutter, cut clamps securing soft water lines to the hard lines.
16. Remove socket head cap screw securing hard water lines to turbocharger and remove the hard line.
17. Remove bolts securing exhaust manifold heat shields. The lower heat shield can be removed. The upper heat shield must stay on until the turbo is loose.
18. Using a 10mm socket or T40 Torx, remove the fasteners holding the exhaust manifold to the engine and remove the turbo from the vehicle.
19. Remove oil pressure sensor and OEM oil line. Save the copper washers.

EVP Turbo Install Instructions

1. Slide supplied fire sleeve over the supplied oil hose. Reinstall oil pressure sensor through the banjo side of the EVP oil supply hose. Reuse copper washers (install a copper washer on both sides of the banjo fitting).
2. Install the provided stud into the top hole of the center exhaust port. Thread stud in and back it out one full turn.
3. Reinstall the OEM exhaust gasket and install new turbo charger, reusing OEM fasteners.
4. Torque (2) of the retaining screws to 44 in-lb (approx. 4 ft-lb), following the order shown in Figure 2.
5. Torque retaining bolts to 17 ft-lb, following the order shown in Figure 3. On the final torque sequence, use a 4mm Allen wrench and hold stud while tightening copper nut with a 10mm wrench as close to 17 ft-lb as possible. Ensure at least 2 threads protrude from the nut.
6. Connect the oil line to the fitting on the top of the turbo and tighten it.
7. Reconnect the oil drain and use a 27mm pinch clamp to secure the oil line onto the turbo charger.
8. The OEM hard coolant line attachment bracket needs to be cut in the center of the 2 cooling ports (See Figure 4).
9. With the line bracket cut, put the new supplied O-rings on the coolant fittings. Use supplied retaining bracket to secure the turbo.
10. Connect the soft coolant hoses to the hard lines installed in step 9. Secure with 18mm pinch clamps.
11. Install the new upper charge tube onto the turbo.
12. Install EVP intake plenum (optional).
13. Reinstall the intercooler and connect the charge tubes and intercooler fan.
14. Connect the new V-flow to the air box and reinstall the air box to the firewall. Tighten the clamps on the v-flow. (See V-flow instructions for further detail).
15. Connect the 3 lines from the boost control solenoid to their corresponding locations.
16. Reinstall exhaust. Ensure to install the EVP supplied heat shield for the turbo exhaust housing. Additional heat shielding may be required. It is the customer's and/or installer's responsibility to determine what additional shielding may be required.

Fuel Pump Installation

NOTE: It is best to siphon all fuel out of the tank before starting this job.

NOTE: THE FUEL PUMP RELAY HARNESS MUST BE INSTALLED PRIOR TO POWERING UP THE DASH OR STARTING THE VEHICLE - FAILURE TO ADHERE TO THIS WILL DAMAGE YOUR ECU!

1. Remove plastics covering fuel tank. See picture for location.
2. Unplug electrical connector going into the top of the pump.
3. Unhook fuel hose by removing the red clip from the connection. Then push down on the fitting while pushing in on the back side of the fitting, then lift the fitting off the pump assembly.
4. Rotate pump assembly cap counterclockwise and remove. Remove assembly. (See pictures for clarification).

NOTE: Your fuel pump assembly MUST be the 172 HP Turbo R or 195 HP RR versions! If you have a 2017 X3 or a 120 Base Model that has not been updated to the Turbo R or RR pump assembly, this must be purchased separately!

Rising Rate Fuel System Installation

1. With the fuel pump on a workbench and all fuel drained from the pump assembly, press in on the tabs to release the housing covering the tank.
2. Cut the fuel return line here.
3. Mark the housing for cutting.
4. Drill a pilot hole.
5. Using a 1/2" drill bit, drill out the pilot hole.
6. Cut locating pin off pump with a side cutter.
7. Insert rubber grommet.
8. Insert brass fitting - VERY IMPORTANT! The fitting should be very tight going into the grommet.
9. Slide 10mm pinch clamp over cut end of fuel hose. Connect to the brass fitting previously installed in cap.
10. Install fuel pump into lower basket. Make sure the tab on the bottom of the pump is correctly oriented. Reinstall basket onto upper assembly.
11. Attach other free end of fuel supply hose to housing and clamp with 13.3mm pinch clamp.
12. Install block off hose onto return line barb.
13. Remove fuel pressure regulator from return.
14. Slide cover back over where regulator was removed.
15. Install fuel pump assembly back into tank in the reverse order from its removal.
16. Plug the electric connection into the pump.
17. Carefully align the tabs and reinsert the cap into the housing. Do not force it if it does not fit with moderate pressure; something is not correct. Recheck. See picture for fuel line and electrical connection.
18. Reinstall pump assembly.

Step 13: INSTALL EVP PLUG N PLAY FUEL PUMP RELAY HARNESS

1. Connect the yellow wire with the ring terminal and the relay to one of the bolts that secure the fuel pump protector strap to the frame. Ensure the ring terminal is grounded to the frame.
2. Replace the OEM fuel pump fuse with the supplied 20 amp fuse in location F5.

450LPH Pump Installation (420 Only)

1. After removing the plastic fitting in the above instructions, mark housing for cutting.
2. The housing should look like this when complete.
3. Cut locating pin off pump with a side cutter.
4. Before installing pump, install fuel hose using a heat gun. Use supplied 13.3mm pinch clamp to secure hose.
5. Install pump into housing and clip together. Wire pump as pictured: black to black and red to yellow. Ensure to heatshrink connections.
6. Install other end of fuel hose to housing and clamp using supplied 13.3mm pinch clamp.

Map Sensor Replacement

1. Replace the 2 OEM map sensors with the EVP supplied sensors. One sensor is located on the plastic intake manifold plenum. The second sensor is located on the throttle body.
2. For the throttle body map sensor, use the supplied adapter harness to make the electrical connection.
3. NOTE: It is possible to install the map sensor adapter harness to the OEM plug rotated 180 degrees. If you are getting MAP sensor codes or the vehicle is not running correctly, please check this.
4. Tighten the 2 OEM clamps that secure the throttle body. This WILL pop off if not tightened.

Clutching

NOTE: Clutching for 395-420 kits must be adjusted for an 8800-9000 RPM shift out.

NOTE: Running a 91-octane tune, clutching must be adjusted for an 8100 RPM shift out.

Launch Control (Optional)

NOTE: If Launch Control has been purchased as part of this kit, your engagement RPMs MUST be raised to at least 2600 RPMs, but preferably 3000 RPMs. The reason is that big turbos require more energy to spool, and it takes more RPMs to generate enough heat. Although Launch Control will work at 2600 RPM, it cannot build more than a few lbs of boost at 2600. At 3000 RPMs, 7-8 lbs of boost at sea level and modest air temperatures is possible.

Contact & Support

Thank you for choosing Evolution Powersports products. If you require further assistance, please call their Tech Support at (715) 247-3862.

Note: This product is exempt from emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code §§ 27156 and 38391]. This product is sold only for use in connection with EPA certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/that purchase this product represent and warrant that the product is purchased only in connection with EPA-certified, emission-regulations-exempt and noise-regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.