INSTALLATION MANUAL PTUNING FR-S/BRZ Turbo System (Tuner Kit

INSTALLATION MANUAL PTUNING FR-S/BRZ Turbo System (Tuner Kit
INSTALLATION MANUAL
PTUNING FR-S/BRZ Turbo System (Tuner Kit)
2013+ Scion FR-S | 2013+ Subaru BRZ
(Manual Transmission Only)
Part#: PTP-TBK-15000-RED/BLK/POL
Performance Tuning, Inc. | 9432 Center Point Lane | Manassas, VA 20110 | 703-257-1728 | Ptuning.com
READ THIS FIRST: Please read the entire installation manual before proceeding. Engine and/or turbocharger
damage may occur if any component within these instructions is improperly installed. This installation should
only be performed by a trained specialist who is familiar with the automobile’s mechanical, electrical and fuel
management system. Performance Tuning, Inc. (PTUNING) or any of its distributors cannot be held responsible
for damages as a result of negligent or improper installation. This turbocharger system can be installed using
common tools and automotive procedures. If in doubt, please contact PTUNING’s technical support staff at 703257-1728, between the hours of 10:00AM and 5:00PM EST, Monday through Friday.
Remove the turbocharger system from its packaging and inspect for any obvious physical damage. All kit
components are thoroughly inspected and carefully packaged prior to shipment from the factory. If any shipping
damage is evident, contact your supplier and request that they process a claim with the shipper involved. Be
sure to review the parts list on page three to verify that you have all necessary system components to proceed. If
any components in the parts list are missing, contact PTUNING’s customer service staff.
Although this turbocharger system has been designed to retain many of the factory emissions controls, it is not
CARB legal in California and therefore recommended for “off road” use only. In other states, check local laws
regarding aftermarket modification to emission controlled vehicles.
The use of premium grade gasoline (93 octane or higher) is required with this kit.
Although this turbocharger system can be purchased with the fueling package (Ecutek ProEcu license, injectors,
map sensors, and base map) final calibration of the base map for your specific vehicle and local atmospheric
conditions must be performed by a professional tuner before attempting to drive the vehicle under boost.
The information contained in this publication was accurate and in effect at the time the publication was approved
for printing and is subject to change without notice or liability. PTUNING reserves the right to revise the
information presented herein or to discontinue the production of parts described at any time.
IMPORTANT: Do not attempt to start up the vehicle after installation of the turbo system without first verifying
that the oil scavenging pump is connected and working properly. There is a procedure at the end of the
installation manual that must be performed to verify that the oil scavenging pump is functioning properly prior to
initial engine startup.
SAFETY REQUIREMENTS: It is recommended to follow these precautions.
 Always wear safety glasses & gloves.
 Turn the ignition switch to the OFF position & disconnect the battery.
 Always use properly rated jack stands when working under the vehicle.
 Prevent unexpected vehicle movement by using wheel chocks and/or parking brake.
 Operate the vehicle only in well ventilated areas.
 Do not smoke or use flammable items near or around the vehicle’s fuel system.
 Keep hands, clothing and other objects away from moving parts when engine is running.
SUPPLIES: It is recommended to have the following items before beginning installation.
MAN-15000-REV3
Page 2 of 67
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Scion FR-S or Subaru BRZ factory service manual, for your model year vehicle.
A large table or bench, and plenty of adjacent available workspace.
Standard selection of automotive tools, primarily metric sizes.
Utility knife
An assortment of zip ties.
The ability to securely lift the vehicle at least a few feet off the ground.
NPT thread sealant.
Replacement engine oil and oil filter.
Replacement factory exhaust header-to-overpipe 2-bolt gasket.
TORQUE RECOMMENDATION: When removing and re-installing factory fasteners, refer to the Scion or Subaru
service manual for torque values. When installing fasteners included in this kit, refer to the following chart:
FASTENER SIZE
TORQUE (FOOT POUND)
M6
12
M8
22
M10
30
BSP & NPT fittings (tapered thread)
2-3 turn past finger tight using Teflon sealant tape or liquid
TURBOCHARGER SYSTEM PARTS LIST (Included with Part# PTP-TBK-10004-RED/BLK/POL):
PACKAGE PART #:
PART #:
PTP-PKG-15000-1
PTP-CLP-90020-200
PTP-CLP-90020-250
PTP-CLP-90020-300
PTP-CLP-90020-400
PTP-HSE-90004
PTP-HSE-90080
PTP-HSE-90001
PTP-HSE-90081
MAN-15000-REV3
Qty/Kit DESCRIPTION
2.00" 304SS worm clamp (1-9/16" To 2-1/2"
3
Clamp Dia. Range, 1/2" Band Width)
2.50" 304SS worm clamp (2-1/16" To 3" Clamp
12
Dia. Range, 1/2" Band Width)
3.00" 304SS worm clamp ( 2-9/16" To 3-1/2"
1
Clamp Dia. Range, 1/2" Band Width)
4.00" 304SS worm clamp (3-9/16" To 4-1/2"
4
Clamp Dia. Range, 1/2" Band Width)
2.00" / 2.50" ID x 3" Long, 4-Ply Silicone Reducer
1
(Gloss Black)
2.00" x 2" x 2" 45 Degree, 4-Ply Silicone Hose
1
(Gloss Black)
2.50" ID x 3" Long, 4-Ply Silicone Hump Hose
1
(Gloss Black)
2.50" x 4" x 4" 90 Degree, 4-Ply Silicone Hose
1
(Gloss Black)
Page 3 of 67
PTP-PKG-15000-2
PTP-PKG-15000-3
PTP-PKG-15000-4
MAN-15000-REV3
PTP-HSE-90044
2
PTP-HSE-90027
1
PTP-HSE-90029
1
PTP-HSE-90082
1
PTP-HSE-90083
1
PTP-INT-15001-AB
PTP-INT-15001-C
1
1
PTP-GRO-15000-14
1
PTP-GRO-15010-12
PTP-FAS-90090-8
1
2
PTP-HSE-90046-72
1
PTP-FAS-90009-16
1
PTP-CLP-90012-13
PTP-CLP-90011-11
PTP-CLP-90011-12
PTP-CLP-90011-14
PTP-CLP-90011-17
1
4
3
2
2
PTP-FTG-90011
1
PTP-FTG-90021
1
PTP-CLP-90005-1120
PTP-HWR-90010-24
PTP-ADP-90044
1
1
1
PTP-FAS-90009-12
2
PTP-FAS-90016-8
PTP-FTG-90002
2
1
2.50" ID x 3" Long, 4-Ply Silicone Straight Hose
(Gloss Black)
2.50" / 3.00" ID x 3" Long, 4 Ply Silicone Reducer
(Gloss Black)
4.00" x 3" Long, ID 4 Ply Silicone Straight Hose
(Gloss Black)
2.50" x 10" x 6" 45 Degree, 4-Ply Silicone Hose
(Gloss Black)
4.00" x 10" x 0" 90 Degree, 4-Ply Silicone Hose
(Gloss Black)
FRS Intake Shroud Base
FRS Intake Shroud Mounting Bracket
Edge-Grip Rubber Seal, Top of intake shroud (137/8" length)
Rubber Edge Trim, edge around Coolant overflow
bottle (12" length)
M6 x 1.0 x 8mm SS Button Head Socket Cap Screw
1/4" ID x 72"L Gates Reinforced Rubber Vacuum
Hose (for WG & BOV)
M6 -1.0 x 16mm Hex Flange Bolt (JIS Class 10.9)
(Zinc)
Rubber-cushioned Loop Clamp, zinc-plated 1/2"
(13mm) diameter
11mm Spring Hose Clamp (Zinc Plated)
12mm Spring Hose Clamp (Zinc Plated)
14mm Spring Hose Clamp (Zinc Plated)
17mm Spring Hose Clamp (Zinc Plated)
1/8" NPT x 1/4" Barbed Hose Adaptor (Brass) (for
IC Piping #1 to Wastegate)
3/8" x 1/4" x 3/8" Brass Double-barbed Reducing
Tee Vacuum Fitting (for BOV)
11-20mm Worm-drive Hose Clamp (7/16" to
25/32" Clamp Diameter Range, 5/16" Band
Width)
ThermalShield Heat Shielding Tube 5/8" ID x 24"L
FR-S IC Piping Throttle Body Bracket
M6 -1.0 x 12mm Hex Flange Bolt (JIS Class 10.9)
(Zinc)
M4 x 0.7 x 8mm Button Head Socket Cap Screw
(18-8 SS) (For mounting Factory MAF Sensor)
1/8" NPT Brass Socket Hex Plug (3/16" Hex)
Page 4 of 67
PTP-PKG-15000-5
PTP-PKG-15000-6
PTP-PKG-15000-7
PTP-PKG-15000-8
MAN-15000-REV3
PTP-HSE-90023-48
1
PTP-HSE-15001-CUS
1
PTP-FTG-90006
1
PTP-FTG-90007
1
PTP-FTG-90008
PTP-HWR-90015-12
1
1
PTP-ADP-90009
1
PTP-FTG-90050-BLK
PTP-GSK-90006
1
1
PTP-FAS-90030-20
2
PTP-ADP-90021
1
PTP-HSE-15001
1
PTP-CLP-90010-200
1
PTP-HSE-15050-3
1
PTP-HSE-15002
1
PTP-ADP-90043
1
PTP-FTG-90051-BLK
1
PTP-FTG-90022-NIC
1
PTP-FTG-90052
1
-4AN Female-to-Female, Straight to Straight, SS
Braided Oil Feed Line, 48" Long (1/4 hose) (Black
PVC Coated)
-4AN Secondary Male-to-Female SS Braided Oil
Feed Line w/Check Valve
1/8" NPT Male to -4AN Male Fitting (steel) (oil
feed on cylinder head)
1/8" NPT Female Union Tee Fitting (Nickel-Plated
brass) (oil feed on cylinder head)
1/8" NPT Male to 1/8" BSP Male Hex Nipple
(Nickel-plated Brass) (oil feed on cylinder head)
ThermalShield Heat Shielding Tube 3/4" ID x 12"L
3/8" NPT Female Aluminum Oil Return Flange
(GT/T25)
-8AN Flare x 90 Degree 3/8" NPT Male Fitting
(Aluminum) (Black)
Oil Return Flange Gasket (GT/GTX)
M8 -1.25 x 20mm Hex Flange Bolt (JIS B1189 Class
10.9) (Zinc)
-4AN Male x 7/16-24 Male Inverted Male Oil Feed
Restrictor Fitting (w/ Restrictor Hole)(Preinstalled on Turbo)
-8AN x 25" Aeroquip Textile Braided Oil Return
Line 1 (-8AN 90 Degree x -8AN 90 Degree) (Turbo
Oil Return to Oil Pump Inlet) (Line 1 of 2)
2.00" 304SS worm clamp (1-9/16" To 2-1/2"
Clamp Dia. Range, 1/2" Band Width)
Abrasion Resistant Neoprene Rubber Tubing (3"
section, 7/8" ID, 1 1/8" OD, Black) for securing oil
return line to steering rack
-8AN x 41" Aeroquip Textile Braided Oil Return
Line 2 (-8AN Straight x 16mm Banjo) (Oil Pump
Outlet to Cylinder Block) (Line 2of 2)
PTUNING FR-S Cylinder Head Plate w/Oil Return
6061 Alum. (anodized black)
-8AN Flare x 45 Degree 3/8" NPT Male Fitting
(Aluminum) (Black)
-8AN x 3/8" NPT Male Union Fitting (Aluminum)
(Nickel Plated)
16mm x 1/2" Barb Banjo Bolt Adaptor Steel (Zincplated)
Page 5 of 67
PTP-PKG-15000-9
PTP-PKG-15000-10
PTP-GSK-90004-16
2
PTP-FTG-90062
1
PTP-HSE-15007-25
PTP-HSE-15008-20
PTP-HSE-15008-9
2
1
1
PTP-FTG-90071-65
2
PTP-FTG-90026
PTP-GSK-90004-14
PTP-CLP-90011-14
PTP-HWR-90010-12
2
4
4
2
16mm Copper Crush Washer
3/8" NPT Male x 3/8" NPT Female Brass check
valve 1 psi
PTFE Teflon SS braided line 14mm Banjo to -6AN
female crimped ends, 25” Long (3/8 hose) (BLACK
PVC COVER)
5/16" x 20" Gates Safety Stripe Heater Hose
5/16" x 9" Gates Safety Stripe Heater Hose
-6AN Male Flare x 5/16" Single Barb Fitting
(Aluminum)
14mm x 1.5 x 25mm Long Banjo Bolt (Steel) (Zincplated)
14mm Copper Crush Washer
14mm Spring Hose Clamp (Zinc Plated)
ThermalShield Heat Shielding Tube 5/8" ID x 12"L
PTUNING PnP Sealed Oil Pump Relay
Harness/Connector w/mini atm fuse holder (Prewired with plug for turbo oil pump)
Mini ATM Automotive Fuse (20 amp, Yellow)
Sealed Skirted Mini Relay (20/40amp, SPDT)
Skirted Mini Relay Mounting Bracket (Installed on
Relay)
1/8" x 7.5" Nylon Cable Tie (Black)
PTP-HAR-15001
PTP-ELE-90020-20
PTP-ELE-90004
1
1
1
PTP-ELE-90004-BR
PTP-FAS-90011
1
4
PTP-ADP-90077-R1
1
PTP-FAS-90030-16
2
PTP-FAS-90034-20
4
PTP-FAS-90035-19
4
PTUNING FR-S Electric Oil Pump Mounting
Bracket
M8 -1.25 x 16mm Hex Flange Bolt (JIS B1189 Class
10.9) (Zinc)
M4 x 0.7 x 20mm Hex Head Cap Screw, Fully
Threaded (Class 8.8, Zinc-plated)
M4 x 19mm OD Extra Large Steel Flat Washer
(Zinc-plated)
PTP-PKG-15000-12
PTP-ADP-90075-AB
PTP-ADP-90078
1
1
PTUNING FR-S Turbo Compressor Transmission
Bracket w/Support Arm (304SS)
PTUNING FR-S Turbine Heat Shield (304SS)
PTP-PKG-15000-13
PTP-ADP-90076
1
PTP-FAS-90009-16
1
PTP-PKG-15000-11
MAN-15000-REV3
PTUNING FR-S Rear Undertray Mounting Bracket
(304SS)
M6 -1.0 x 16mm Hex Flange Bolt (JIS Class 10.9)
(Zinc)
Page 6 of 67
PTP-PKG-15000-14
PTP-PKG-15000-15
PTP-FAS-90027-90
2
PTP-FAS-90028
2
PTP-FAS-90029
2
M8 x 1.25 x 90mm Hex Head Cap Screw, Partially
Threaded (Class 10.9, Yellow Zinc-plated) (For
Mounting Intercooler)
M8 x 24mm OD Extra Large Steel Flat Washer
(1.8mm-2.2mm Thick, Zinc-plated)
M8 x 1.25 Nylon-insert Flanged Lock Nut (Class 8,
Zinc-plated)
1
PTUNING FR-S 3" 304SS Polished V-band
Downpipe (w/ Recirculated WG Flange)
3.00" 304SS V-band Clamp (use w/ formed or
machined v-band flange)(For Outlet-end of
Downpipe)
O2 Bung Plug (Hex Countersunk socket) (Steel)
PTP-DNP-15000
PTP-PKG-15000-16
PTP-CLP-998ZD-0382
PTP-FTG-90001
1
1
PTP-PKG-15000-17
PTP-WGD-15001
1
PTTS-0504-3004
1
PTP-WGD-15002
1
PTTS-0504-3004
1
PTUNING FR-S 1.75" 304SS Polished Recirculated
WG Dump Tube w/Flex Bellows
TSWG45 1.75" WG Outlet V-band Clamp (w/ Nut
and Bolt) (For Hanger-side of WG Inlet Tube)
PTP-CLP-90100
PTP-CLP-90101
1
1
Tial Turbine Inlet V-band Clamp (GT30/GT35)
Tial Turbine Outlet V-band Clamp (GT30/GT35)
1
PTUNING Full 304SS Turbo 2-Piece Overpipe
w/Tial V-band Turbine Flange and TS 40mm WG
Flange (Tial V-band Flange, GT30R/GT35R)
2.375" 304SS V-band Clamp w/Quick Release
Latch (For 2-piece FR-S Overpipe Connection)
(Trimmed Tab)
PTP-PKG-15000-18
PTP-PKG-15000-19
PTP-PKG-15000-20
PTP-TBM-15000
PTP-PKG-15000-21
PTP-CLP-90200-238
1
PTP-PKG-15000-22
PTTS-0204-1002-S2K
1
PTTS-0204-3004
PTTS-0204-3005
1
1
PTTS-0505-3009
1
MAN-15000-REV3
PTUNING FR-S 1.75" 304SS Polished WG Inlet
Tube w/Hanger
TSWG45 1.75" WG Outlet V-band Clamp (w/ Nut
and Bolt) (For Hanger-side of WG Inlet Tube)
Turbosmart Race-Port BOV (PTUNING-Spec 22
In/Hg Spring, Black)
Turbosmart Race-Port V-band Clamp w/nut and
bolt
Turbosmart Race-Port Flange O-ring
Turbosmart 1/16" NPT x 1/4" Barb Vacuum
Fitting
Page 7 of 67
PTTS-0505-3010
1
Turbosmart 1/16" NPT Vacuum Plug
PTTS-0505-1006
1
PTTS-0505-3004
1
PTTS-0505-3005
1
PTTS-0505-3009
2
PTTS-0505-3010
PTTS-0505-3008
2
1
Turbomart Comp-Gate 40mm WG (7psi, Black)
Turbosmart 40mm WG Inlet V-band Clamp w/nut
and bolt
Turbosmart 40mm WG Outlet V-band Clamp
w/nut and bolt
Turbosmart 1/16" NPT x 1/4" Barb Vacuum
Fitting
Turbosmart 1/16" NPT Vacuum Plug (one preinstalled)
Turbosmart 74mm Locking Collar Tool
PTP-PKG-15000-24
PTP-INT-90001
1
PTUNING Blue SuperNano 3.5"x5.25"x6" Cone
Filter w/ 4" Inlet (includes worm clamp)
PTP-PKG-15000-25
PTP-FTR-90001
1
2.00"D x 1.5" L x 5/8" ID K&N Crankcase Filter
(Rubber Top)
PTP-PKG-15000-26
PTP-ELE-90100
1
Exa-Pump Electric Oil Scavenge Pump (Pre-wired,
12V DC)
PTUNING FR-S/BRZ Front Mount Intercooler
(32"W x 6.5"H x 3"D, 2.5" Inlet/Outlet)
PTP-PKG-15000-23
PTP-PKG-15000-27
PTP-INC-15001
1
PTP-PKG-15000-28
PTP-MAN-15000
1
PTDECALCOMP_LE_WHI
2
PTP-MSC-90000
1
PTP-SUS-15001
1
PTP-SUS-15001-BSH
2
PTUNING Front Sway Bar (21mm) (Gray)
PTUNING Front Sway Bar Bushings (21mm
Urethane Bushing) (Red)
PTP-PKG-15000-30
(Optional)
PTP-SUS-15001-LNK
2
PTUNING Front Sway Bar Adjustable End-Links
(Black/Gold)
PTP-PKG-15000-31
PTP-TRG-30305-FRS
1
(Turbo Option)
PTP-TRG-30310-FRS
1
PTP-TRG-30315-FRS
1
PTP-PKG-15000-29
MAN-15000-REV3
PTUNING FR-S/BRZ Turbo System Installation
Manual
PTUNING - tuned_for: competition (8.5" x 1.5" Window Decal) - WHITE Limited Edition
PTUNING - tuned_for: competition (License Plate
Frame)
Garrett GT3076R, Tial SS V-band HSG .63 A/R
(PTUNING FR-S, BRZ System)
Garrett GTX-3076R, Tial SS V-band HSG .63 A/R
(PTUNING FR-S, BRZ System)
Garrett GTX-3071R, Tial SS V-band HSG .63 A/R
(PTUNING FR-S, BRZ System)
Page 8 of 67
<Turbo Not Included>
<Custom Turbo>
PTP-ICP-15001
(Color Option)
PTP-ICP-15002
(Color Option)
PTP-ICP-15003
(Color Option)
PTP-ICP-15004
(Color Option)
PTP-ICP-15005
(Color Option)
MAN-15000-REV3
PTP-ICP-15001-P
1
PTP-ICP-15001-B
1
PTP-ICP-15001-R
1
PTP-ICP-15001-CC
1
PTP-MSC-10000
1
PTP-ICP-15002-P
1
PTP-ICP-15002-B
1
PTP-ICP-15002-R
1
PTP-ICP-15002-CC
1
PTP-ICP-15003-P
1
PTP-ICP-15003-B
1
PTP-ICP-15003-R
1
PTP-ICP-15003-CC
1
PTP-ICP-15004-P
1
PTP-ICP-15004-B
1
PTP-ICP-15004-R
1
PTP-ICP-15004-CC
1
PTP-ICP-15005-P
1
PTP-ICP-15005-B
1
2.0" 6061 Aluminum I/C Piping #1 (w/ 1/8" NPT
weld bung) (1 of 8) (Polished)
2.0" 6061 Aluminum I/C Piping #1 (w/ 1/8" NPT
weld bung) (1 of 8) (Black)
2.0" 6061 Aluminum I/C Piping #1 (w/ 1/8" NPT
weld bung) (1 of 8) (Red)
2.0" 6061 Aluminum I/C Piping #1 (w/ 1/8" NPT
weld bung) (1 of 8) (Custom Color =>):
PTUNING Aluminum Name Plate (PTUNING
Competition Turbo System)
2.5" 6061 Aluminum I/C Piping #2 (w/BOV flange)
(2 of 8) (Polished)
2.5" 6061 Aluminum I/C Piping #2 (w/BOV flange)
(2 of 8) (Black)
2.5" 6061 Aluminum I/C Piping #2 (w/BOV flange)
(2 of 8) (Red)
2.5" 6061 Aluminum I/C Piping #2 (w/BOV flange)
(2 of 8) (Custom Color =>):
2.5" 6061 Aluminum I/C Piping #3 (Below radiator
hose) (3 of 8) (Polished)
2.5" 6061 Aluminum I/C Piping #3 (Below radiator
hose) (3 of 8) (Black)
2.5" 6061 Aluminum I/C Piping #3 (Below radiator
hose) (3 of 8) (Red)
2.5" 6061 Aluminum I/C Piping #3 (Below radiator
hose) (3 of 8) (Custom Color =>):
2.5" 6061 Aluminum I/C Piping #4 (Lower PS) (4 of
8) (Polished)
2.5" 6061 Aluminum I/C Piping #4 (Lower PS) (4 of
8) (Black)
2.5" 6061 Aluminum I/C Piping #4 (Lower PS) (4 of
8) (Red)
2.5" 6061 Aluminum I/C Piping #4 (Lower PS) (4 of
8) (Custom Color =>):
2.5" 6061 Aluminum I/C Piping #5 (Lower DS) (5
of 8) (Polished)
2.5" 6061 Aluminum I/C Piping #5 (Lower DS) (5
of 8) (Black)
Page 9 of 67
PTP-ICP-15006
(Color Option)
PTP-ICP-15007
(Color Option)
PTP-ICP-15008
(Color Option)
MAN-15000-REV3
PTP-ICP-15005-R
1
PTP-ICP-15005-CC
1
PTP-ICP-15006-P
1
PTP-ICP-15006-B
1
PTP-ICP-15006-R
1
PTP-ICP-15006-CC
1
PTP-ICP-15007-P
1
PTP-ICP-15007-B
1
PTP-ICP-15007-R
1
PTP-ICP-15007-CC
1
PTP-ICP-15008-P
1
PTP-ICP-15008-B
1
PTP-ICP-15008-R
1
PTP-ICP-15008-CC
1
2.5" 6061 Aluminum I/C Piping #5 (Lower DS) (5
of 8) (Red)
2.5" 6061 Aluminum I/C Piping #5 (Lower DS) (5
of 8) (Custom Color =>):
2.5" 6061 Aluminum I/C Piping #6 (Upper w/MAF
Flange) (6 of 8) (Polished)
2.5" 6061 Aluminum I/C Piping #6 (Upper w/MAF
Flange) (6 of 8) (Black)
2.5" 6061 Aluminum I/C Piping #6 (Upper w/MAF
Flange) (6 of 8) (Red)
2.5" 6061 Aluminum I/C Piping #6 (Upper w/MAF
Flange) (6 of 8) (Custom Color =>):
4.0" 6061 Alum. Intake Tube #7 (Turbo Inlet) (7 of
8) (Polished)
4.0" 6061 Alum. Intake Tube #7 (Turbo Inlet) (7 of
8) (Black)
4.0" 6061 Alum. Intake Tube #7 (Turbo Inlet) (7 of
8) (Red)
4.0" 6061 Alum. Intake Tube #7 (Turbo Inlet) (7 of
8) (Custom Color =>):
4.0" 6061 Alum. Intake Tube #8 (Air Filter
Extension) (8 of 8) (Polished)
4.0" 6061 Alum. Intake Tube #8 (Air Filter
Extension) (8 of 8) (Black)
4.0" 6061 Alum. Intake Tube #8 (Air Filter
Extension) (8 of 8) (Red)
4.0" 6061 Alum. Intake Tube #8 (Air Filter
Extension) (8 of 8) (Custom Color =>):
Page 10 of 67
PTP-PKG-15000-1
PTP-PKG-15000-2
PTP-PKG-15000-3
PTP-PKG-15000-4
PTP-PKG-15000-5
PTP-PKG-15000-6
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PTP-PKG-15000-7
PTP-PKG-15000-8
PTP-PKG-15000-9
PTP-PKG-15000-10
PTP-PKG-15000-11
PTP-PKG-15000-12
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PTP-PKG-15000-13
PTP-PKG-15000-14
PTP-PKG-15000-15
PTP-PKG-15000-16
PTP-PKG-15000-17
PTP-PKG-15000-18
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PTP-PKG-15000-19
PTP-PKG-15000-20
PTP-PKG-15000-21
PTP-PKG-15000-22
PTP-PKG-15000-23
PTP-PKG-15000-24
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PTP-PKG-15000-25
PTP-PKG-15000-26
PTP-PKG-15000-27
PTP-PKG-15000-28
PTP-PKG-15000-29
PTP-PKG-15000-30 (Optional)
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PTP-PKG-15000-31
PTP-ICP-15001
PTP-ICP-15002
PTP-ICP-15003
PTP-ICP-15004
PTP-ICP-15005
PTP-ICP-15006
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PTP-ICP-15007
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PTP-ICP-15008
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1 – PREPPING THE VEHICLE FOR TURBO SYSTEM INSTALLATION
1. Using a 10mm socket or wrench, remove the negative and positive battery terminals.
2. Have some factory radiator coolant on hand to bleed the coolant system after the installation of the turbo
system. This will be necessary since the coolant lines for the water-cooled GT turbocharger will be added
during the installation process. Please refer to the factory service manual for details on bleeding the coolant
system.
3. Have at least a quart of motor oil on hand to top off the engine oil after the installation of the turbo system.
This will be necessary since the oil return line on the turbocharger will add some additional oil capacity. This
may also a good time to perform an oil change with some fresh synthetic oil.
4. Layout all the installation packages on a workbench and verify that you have received all the packages listed
at the beginning of this manual. Some packages are marked as optional and may not be included with your
kit. The instructions will refer to the individual packages through the entire manual.
5. Jack up the vehicle to a workable height and secure vehicle with jack stands if not using a vehicle lift. We
highly recommend the installation of the turbo system on a two-post lift. See FIGURE 1.1
FIGURE 1.1
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2 – REMOVING THE FRONT FASCIA AND ENGINE UNDER TRAY
1. Using a 10mm socket and flat head screwdriver remove bolts and clips attaching the front bumper. SEE
FIGURE 1.2 & 1.3
FIGURE 1.2
Figure 1.3
2. Unplug and remove the side marker lights. Using a Phillips screwdriver, remove the 4 body clips that
attaches the front bumper cover to the splash shield on each side of the bumper cover. Remove the two
retaining clips under the marker lights attaching bumper to fender using a flat head screw driver. SEE FIGURE
2.1 & 2.2
FIGURE 2.1
FIGURE 2.2
3. Gently pull each side of the bumper towards the outside. The bumper should “pop” out of its connections.
Pull bumper forward enough to disconnect front turn signals and/or fog lights.
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4. The bumper should now be free. Gently pull the bumper straight forward away from the car. With the
bumper off the car, locate the two plastic shields held in place by three silver screws and remove them using
a Phillips screwdriver. Set bumper aside in a safe place. . SEE FIGURES 2.3 & 2.4
Note: you will not need to remove the front lower plastic under-tray
FIGURE 2.3
Figure 2.4
5. Using a 10mm socket, remove the bolts holding the rear (black tray) Using 12mm socket and a flat head
screwdriver, remove the 8 bolt and 6 clips that secure the lower engine under tray to the chassis. SEE FIGURE
2.4
Note: both under-trays can be removed as one piece leaving the four bolts connecting the rear tray to the
front metal tray.
6. Trim rear (black) under tray as shown using the provided template below. SEE FIGURE 2.5 & 2.6
FIGURE 2.4
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FIGURE 2.5
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FIGURE 2.6
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3 – REMOVING THE STRUT CROSS-BAR, OEM AIR BOX AND SOUND TUBE
1. Use a 10mm and 12mm socket to remove the factory strut cross-bar and intake runner cover. SEE FIGURES
3.1
2. Use a 10mm socket and Phillips screwdriver to remove the factory intake and air box. SEE FIGURES 3.1 & 3.2
FIGURE 3.1
FIGURE 3.2
FIGURE 3.1
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3. Use a 10mm socket to remove the factory sound tube. Use a clip-removal tool to pry the sound tube hose
clips. SEE FIGURES 3.3 & 3.4
FIGURE 3.3
FIGURE 3.4
4. Disconnect the sound tube from the fire wall. SEE FIGURES 3.5 & 3.6
FIGURE 3.5
FIGURE 3.6
5. Using a plier and a rubber mallet, bend down the three tabs as shown to allow clearance for the turbo intake
tube. SEE FIGURES 3.7 & 3.8
Optional: If you have access to a grinder, you can remove the fuel injector cover and grind the spotwelds to completely remove tabs and spray paint over for a cleaner install. At this point, go ahead and
install the fuel injectors before re-installing the metal covers (If you purchased the optional fueling
package). See factory repair manual for details.
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6. Re-install injector covers (if previously removed).
FIGURE 3.7
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Figure 3.8
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4 – REMOVING THE WINDSHIELD FLUID RESERVOIR AND RELOCATING THE FACTORY
HORN
1. Using a flat head screwdriver, remove the two side air diversion panels. SEE FIGURE 4.1 & 4.2
FIGURE 4.1
FIGURE 4.2
2. Disconnect the windshield reservoir pump connector and plug the hose. Using a 10mm socket to remove the
bolts that secure the reservoir to the chassis. SEE FIGURES 4.3
FIGURE 4.3
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3. Using a 10mm socket, remove the front horn mounting bracket and loosen the bracket on the backside of the
horn as shown. SEE FIGURES 4.4 & 4.5
FIGURE 4.4
FIGURE 4.5
4. Rotate the horn bracket as shown and reinstall the horn and outside air temp sensor in the new location next
to the side of the radiator. SEE FIGURES 4.6 & 4.7
FIGURE 4.6
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FIGURE 4.7
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5 – REMOVING THE FACTORY OVER-PIPE, MID-PIPE AND CYLINDER HEAD PLATE
1. Remove the over-pipe and mid-pipe sections of the factory exhaust system (see factory service manual for
details). You will need the two 14mm nuts used to connect the over-pipe to the header for installation of the
turbo over-pipe later.
2. Remove the mid-pipe support bracket and transmissions lower case bolts shown. Put aside bolts for
installation of the turbo downpipe and PTUNING turbo compressor to transmission support bracket later.
The factory mid-pipe support bracket will not be reused. SEE FIGURE 5.1 & 5.2
FIGURE 5.1
FIGURE 5.2
3. Remove right lower transmission bell housing nut. Set aside to install PTUNING turbo compressor to
transmission support bracket later. SEE FIGURE 5.3
4. Remove factory metal cylinder block-off plate on the right cylinder head. Plate will not be reused. SEE
FIGURE 5.4
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FIGURE 5.3
FIGURE 5.4
5. Locate installation package PTP-PKG-15000-8. Clean cylinder head mating surface and apply a bead of Loctite
grey 5699 silicone gasket maker or factory silicone gasket maker onto cylinder head (Refer to factory service
manual for details). Install PTUNING FR-S cylinder head oil return plate, torque bolts to factory spec. Route oil
return line #2 from left side of the transmission over to the oil return plate just installed. Install 16mm banjo
bolt and copper crush washers (one on either side of the banjo fitting) into the banjo-end of oil return line #2
and clock line at 2 o’clock angle. The other end of the oil line #2 should droop over the transmission and
hang off to the left side of the transmission, where the oil scavenge pump will be mounted. SEE FIGURE 5.5,
5.6 & 5.7
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FIGURE 5.5
FIGURE 5.6
FIGURE 5.7
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6. Secure the oil return line #2 to the tab on the backside of the intake manifold with cable ties (zip ties) and
route the oil line as shown below. Pull the factory wiring harness of the metal retaining clip and push it down
and towards the center of the engine to make room for the turbo intake tube that will be installed later. SEE
FIGURE 5.8
FIGURE 9.3
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6 – REMOVING FACTORY SWAY BAR & END-LINKS
1. Remove the nuts connecting the end-links to sway bar and struts. Remove the two plastic clips
securing the plastic shield to the sway bar mounting brackets. Remove the eight bolts on the sway bar
mounting brackets (four bolts per side). Remove sway bar with mounting bracket assembly. SEE FIGURE 6.1
& 6.2
FIGURE 6.1
FIGURE 6.2
2. Remove the two bolts and two nuts attaching the sway bar to mount brackets. Make sure to note the sway
bar orientation. Set aside for later.
3. Locate installation package PTP-PKG-15000-30 (Optional) or use your existing front adjustable end-links. Set
adjustable end-links next to factory end-links. Adjust end-links about 2” shorter than factory end-links. Install
adjustable end-links on struts. SEE FIGURE 6.3
Note: Final adjustment will be made later.
4. Locate installation package PTP-PKG-15000-29. Using the supplied bushing and lubricant, lubricate the inside
of the new sway bar bushings and slide onto new sway bar. Attach new sway bar to mounting brackets and
torque to factory spec. Leave sway bar with mounting brackets aside to be installed later after the turbo is
installed. SEE FIGURE 6.4
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FIGURE 6.3
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FIGURE 6.4
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7 – INSTALLING OIL FEED TEE ADAPTER, TURBO OIL FEED, OIL RETURN & COOLANT
LINES
1. Locate installation package PTP-PKG-15000-9. Slip the supplied thermal wrap over the two turbo coolant
lines (Use a rod or compress air to help expand the thermal wrap to ease installation onto coolant lines).
Route both turbo coolant lines with the 14mm banjo fittings under the right side of intake manifold. It helps
to label the lines “S” & “L” (Long & Short) on banjo fittings with permanent marker to ease install on turbo
later on. Leave lines hanging on right side of transmission to bolt to turbo later on. SEE FIGURE 7.1 & 7.2
FIGURE 7.1
FIGURE 7.2
2. Remove factory coolant line off the throttle body and fit the 30” line (longer) onto it, reusing the factory
spring hose clamp. Install the supplied 90 degree barb fitting onto the open-end of the 25” coolant line
(shorter) and the other end onto the factory coolant line previously removed from the throttle body. Secure
both lines to the 90 degree barb fitting using the supplied 14mm spring hose clamps. SEE FIGURE 7.3 & 7.4
FIGURE 7.3
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Figure 7.4
Page 33 of 67
3. Remove factory oil pressure sensor (located on front left of the engine timing cover). SEE FIGURE 7.5
4. Locate installation package PTP-PKG-15000-5. Install NPT-to-BSP male straight fitting on timing cover where
factory oil sensor was just removed. BSP (brass color) thread must be threaded into the factory oil pressure
sensor port on the timing cover. Install NPT union tee fitting, using the center opening on the other end of
the straight fitting just installed. Make sure one end of the tee fitting is facing down and the other end facing
up at about 1 o’clock angle (when viewing from front of vehicle). Install supplied 1/8 NPT to -4AN male fitting
to the end facing up. SEE FIGURE 7.5 & 7.6
NOTE: Make sure to use Teflon tape or liquid thread sealant on the tapered NPT threads fittings and on the
oil pressure sensor.
FIGURE 7.5
FIGURE 7.6
5. Install the previously removed factory oil pressure sensor on the bottom of the tee fitting as shown. Connect
the 48” primary oil feed line to the -4AN fitting on top of the tee fitting and route the oil line to one side of
the oil filter and underneath the intake manifold and out the back, towards the locating of the turbo. The oil
feed line will be connected to the secondary oil feed line w/check valve in the next section. SEE FIGURE 7.7 &
7.8
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FIGURE 7.7
FIGURE 7.8
6. Release tension on serpentine belt and slide belt off the A/C compressor (refer to factory service manual for
details). Remove the three bolts holding the A/C compressor in place and move the compressor aside to
access the two EVAP line needed to be spring clamped. This step is necessary to prevent the possibility of the
two EVAP lines from popping off under boost. SEE FIGURE 7.9
7. Locate installation package PTP-PKG-15000-4. With the A/C compressor out of the way, locate the two EVAP
lines underneath the intake manifold (viewed from the front center of intake manifold), pull the two line out
of the nipple on the EVAP solenoid, slip on the supplied 12mm spring clamp on each end of the two lines and
re-install lines back onto EVAP solenoid using a pair of long needle nose pliers, use to squeeze the clamp
while simultaneously pushing the line back on the EVAP solenoid. Reinstall A/C compressor and serpentine
belt and torque to factory spec. SEE FIGURE 7.10, 7.11 & 7.12
FIGURE 7.9
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FIGURE 7.10
Page 35 of 67
FIGURE 7.9
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FIGURE 7.10
Page 36 of 67
8 - INSTALLING PTUNING TURBO 2-PIECE OVER-PIPE AND GT TURBO
1. Locate installation package PTP-PKG-15000-20 and PTP-PKG-15000-21. Install PTUNING over-pipe (with 2bolt flange) to the header, using a new OEM 2-bolt gasket (not provided) and factory M10 nuts previously
removed. SEE FIGURE 8.1
2. Install second piece of over-pipe to the first piece making sure the “T-bolt” clamp side is facing the inside
(towards compressor housing) and slight clocked towards the outside. Leave the clamp loose enough so that
two-piece over-pipe can still rotate. Be sure the male and female v-band flanges on the over-pipe are sitting
flush against each other. The nut on the t-bolt clamp should be facing downward. SEE FIGURE 8.2
FIGURE 8.1
FIGURE 8.2
3. Locate installation package PTP-PKG-15000-12. Install PTUNING turbo compressor transmission support
bracket and PTUNING FR-S turbine heat shield onto the transmission using the two transmission bolt and bell
housing nut removed in the earlier steps. SEE FIGURE 8.3 & 8.4
FIGURE 8.3
FIGURE 8.4
4. This step may not be necessary, if your GT turbo comes with the oil restrictor fitting preinstalled on the
CHRA. Locate installation package PTP-PKG-15000-6. Verify that the tiny pin-hole size opening on the -4AN
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oil feed restrictor fitting is not obstructed before installation. Install and tighten the fitting to the oil feed
port on top of the turbo CHRA.
5. Locate installation package PTP-PKG-15000-5. Install and tighten the secondary oil feed line with brass check
valve (short SS line) onto the oil restrictor fitting on the top of the turbo’s CHRA (center cartridge). Remove
the 3 bolts on the turbo compressor (opposite the turbine inlet as shown below). Slide the turbo into place
between the over-pipe and compressor support mount bracket and aligning the 3 bolt holes on the
compressor to the 3 slotted holes on the turbo mounting bracket. Hand-tighten the 3 bolts that holds the
compressor housing to the mounting bracket. The 3 bolts will be fully-tighten later, after final adjustments
are made. SEE FIGURE 8.5 & 8.6 & 8.7
NOTE: The turbocharger is pre-clocked prior to shipment and therefore does not need to be clocked. The
turbine inlet, CHRA, and compressor outlet are all located in the required position.
FIGURE 8.5
FIGURE 8.6
FIGURE 8.7
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6. Using the 12” thermal shield from package PTP-PKG-15000-5, slip the shield over the previously installed 48”
primary oil feed line (oil feed line coming off the tee fitting). Connect the 48” primary oil feed line to the
secondary oil feed line w/check valve and finally slide the thermal shield down, covering up the secondary oil
feed line.
7. Locate installation package PTP-PKG-15000-9. Using the supplied 14mm banjo bolts and crush-washers,
connect the previous installed turbo coolant lines “L” (long) to inside of the turbo CHRA facing the
transmission and coolant line “S” (short) to the outside of the turbo CHRA facing the passenger side of the
turbo and tighten banjo bolts. Each banjo fitting will use two crush-washers, one on each side of the fitting.
SEE FIGURE 8.7 & 8.8
NOTE: Make sure the turbo coolant lines are positioned, so that the coolant lines do not come into contact
with the turbine housing (hot side). The thermal heat shield on the coolant lines should be position so that
it touches the banjo fittings to insulate the coolant lines from the turbine housing.
FIGURE 8.7
FIGURE 8.8
8. Locate installation package PTP-PKG-15000-19. Rotate the over-pipe so the v-band flange on the over-pipe
and turbine inlet mates up. Using the supplied TIAL V-Band turbine clamp (smaller v-band clamp), bolt the
turbo to over-pipe. Make sure to position the clamp so that the t-bolt is located below the over-pipe as
shown). Leave clamp slightly loose but make sure the male/female v-band flanges are flush against each
other. SEE FIGURE 8.6
9. Locate installation package PTP-PKG-15000-17. Using a 12mm socket, remove the M8 bolt securing the rear
transmission mounting bracket to the rear of the transmission. Using the provided 1.75” v-band clamp,
install the wastegate inlet tube to the v-band flange on the over-pipe. Position the clamp so that the bolt is
position below the wastegate tube. Leave the clamp slightly loose so it can rotate. Using a 14mm socket,
remove the 10mm transmission mount bolt where the inlet tube hanger will bolt on. Rotate the other end of
the wastegate inlet tube so that the slotted hanger lines up with the bolt hole on the transmission mounting
bracket. Partially thread the 10mm bolt two to three full turns. SEE FIGURE 8.7 & 8.8
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FIGURE 8.6
FIGURE 8.7
FIGURE 8.8
10. Locate installation package PTP-PKG-15000-15 and PTP-PKG-15000-16. With over-pipe and turbine v-band
clamps slightly loose, Install downpipe to turbine outlet using the provided TIAL V-band clamp (larger clamp
from package PTP-PKG-15000-19). Position the t-bolt on the clamp facing in towards transmission and
pointing downward as shown. Leave slightly loose so it can rotate. SEE FIGURE 8.9
NOTE: The PTUNING downpipe includes provision for mounting an aftermarket wideband O2 sensor. If an
O2 sensor will not be installed at this time, simply plug up the O2 bung on the downpipe with the supplied
O2 bung plug. The v-band clamp included in package PTP-PKG-15000-16 will be used to connect the
downpipe to either a PTUNING DS-333 3” turbo exhaust system or a PTUNING 3” to 2-bolt exhaust adaptor
(must be purchased separately).
11. Rotate the downpipe so the mounting bracket holes line up to the transmission holes where the factory front
pipe mounting bracket was removed. Thread the two 12mm bolts removed earlier three full turns. Do not
tighten yet. SEE FIGURE 8.10
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NOTE: The downpipe mounting bracket may need to be push back slightly to allow the bracket to line up
with the two mounting holes on the rear of the transmission. The bracket may not sit flush with the
surface of the transmission mounting holes but the bracket is flexible and will conform to the mounting
surface when tighten later.
FIGURE 8.9
FIGURE 8.10
12. Locate installation package PTP-PKG-15000-18 and PTP-PKG-15000-23. Using a 4mm allen hex socket and
8mm wrench, install provided vacuum barb fitting and plugs onto the wastegate as shown. The top vacuum
fitting on the wastegate cap is left open to atmosphere. The bottom vacuum fitting below the wastegate
collar will later be connected to intercooler piping #1 for boost reference. SEE FIGURE 8.11
13. Loosely bolt on the wastegate dumptube with flex bellows to the wastegate using the smaller clamp included
in package PTP-PKG-15000-23. Using the larger clamp from package PTP-PKG-15000-23, loosely bolt the
bottom of the wastegate (inlet) to the wastegate inlet tube previously installed as shown. Rotate the
wastegate dumptube so that the v-band flange (male end) mates up with the v-band flange (female end) on
the downpipe. Using the supplied clamp from package PTP-PKG-15000-18, loosely install clamp, but make
sure the flanges are flush against each other. SEE FIGURE 8.12
NOTE: When handling the wastegate, be careful not to drop the wastegate valve seat located at the
bottom of the wastegate. The valve seat is held in placed once the wastegate is secured to the wastegate
inlet tube.
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FIGURE 8.11
FIGURE 8.12
14. IMPORTANT! Go back and fully tightening the v-band clamps and bolts in the following order:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
V-band clamp between front and rear section of over-pipe
V-band clamp between turbine inlet to over-pipe
V-band clamp between turbine outlet to downpipe
V-band clamp between over-pipe to wastegate inlet tube
12mm bolt (1) on rear transmission bracket to wastegate inlet tube hanger
V-band clamp between wastegate inlet tube to bottom of wastegate
V-band clamp between wastegate outlet to dumptube
V-band clamp between dumptube to downpipe
12mm bolts (2) on downpipe mounting bracket
13mm bolts (3) on compressor-to-transmission mounting bracket
15. Locate installation package PTP-PKG-15000-4. Slip the supplied thermal shield over the ¼” vacuum hose (Use
a rod or compress air to help expand the thermal wrap to ease installation onto vacuum hose). Install one
end of the vacuum hose with the supplied 11mm spring clamp to the bottom barb fitting on the wastegate
(the fitting marked “connect to IC piping #1” in figure 8.11). Slide the thermal shield until it touches the
spring clamp on the wastegate fitting. Using the supplied rubber cushion clamp and M6x16mm bolt, secure
the vacuum hose to the transmission tunnel of the car in the location shown below. Route the other end of
the vacuum hose towards the back of the intake manifold. The vacuum hose will be connected to the
intercooler piping #1 later. SEE FIGURE 8.13, 8.14, 8.15, 8.16
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FIGURE 8.13
FIGURE 8.14
FIGURE 8.15
FIGURE 8.16
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9– INSTALLING OIL SCAVENGING PUMP AND OIL RETURN FITTING
1. Locate installation package PTP-PKG-15000-8 and PTP-PKG-15000-26. Install -8AN to 3/8” NPT male union
fitting (silver) on left side of pump using Teflon sealant tape or liquid. (facing down once installed on vehicle)
SEE FIGURE 9.1 & 9.2
2. Install 3/8” NPT male to 3/8” NPT female brass check valve on right side of pump (facing upward once
installed on vehicle) using Teflon sealant tape or liquid. SEE FIGURE 9.1 & 9.2
3. Install -8AN flare to 45 degree 3/8” NPT male fitting (black) to brass check valve using Teflon sealant tape or
liquid. With the pump sitting sideways as shown below, tighten the -8AN flare 45 degree fitting (black) so that
opening on the fitting is facing at the 4 o’clock position or about 30 degree from the red horizontal line. SEE
FIGURE 9.3
FIGURE 9.1
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FIGURE 9.2
Page 44 of 67
FIGURE 9.3
4. Locate installation package PTP-PKG-15000-11. Bolt the oil scavenge pump to the oil pump mounting
bracket using the supplied four M4 bolts and washers. SEE FIGURE 9.3
5. Install the sway bar and sway bar mounting bracket assembly previously removed from vehicle and torque
the bolts and nut to factory spec. With the vehicle’s front wheels fully drooped and strut fully extended,
adjust the two end-links front sway bar so that there is a 1/8” clearance between the sway bar and the front
of the turbo compressor housing. Fully tighten the lock nut on the adjustable end-links. SEE FIGURE 9.4 &
9.5
NOTE: This step must be done before mounting the scavenge oil pump and bracket assembly to vehicle.
FIGURE 9.4
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FIGURE 9.5
Page 45 of 67
6. Mount the oil scavenge pump mounting bracket assembly onto the vehicle at the points shown using the
supplied two M8x16mm flange bolts. The third mounting arm on the oil pump mounting bracket will be
secured to the steering rack using the steering rack mounting bolt. Tighten the steering rack mounting bolt
to factory spec. SEE FIGURE 9.6 & 9.7
FIGURE 9.6
FIGURE 9.7
7. Install and tighten the previously routed oil return line #2 off the PTUNING oil return plate to the -8AN 45
degree fitting on the oil pump. Adjust the -8AN 45 degree fitting on the top of the oil pump outlet towards
the rear of the vehicle (if necessary) so that the oil return line #2 clears the transmission housing.
Note: The oil return line #2 should connect to the top of the oil scavenging pump port without any tight
bends or kinks.
8. Locate installation package PTP-PKG-15000-6. With the provided gasket and two M8x20mm bolts, install the
oil return flange on the bottom of turbo so that the opening on the 90 degree oil return fitting (black) is
facing towards the passenger side of the vehicle. SEE FIGURE 9.8
NOTE: The oil return fitting gasket will need to be trim slightly on the sides to clear the turbine and
compressor mounting bolts. Be careful not to cut away too much gasket material. SEE FIGURE 9.9
9. Locate installation package PTP-PKG-15000-7. Route the oil return line #1 from oil return flange (on turbo) to
the bottom straight fitting (silver) on oil scavenge pump. Position the two 90 degree hose-end on the oil line
#1 as shown below. Use the provided 3” long abrasion resistant rubber tubing to cover the middle section of
the oil return line (this will protect the oil line from the worm clamp and steering rack). Use the supplied
worm clamp to secure the middle section of the oil return line to the bottom of the steering rack as shown
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(Be careful not to crush the oil return line by over tightening the clamp). Adjust hose-end fittings to release
any tension on the line and tighten. SEE FIGURE 9.10
FIGURE 9.8
FIGURE 9.9
FIGURE 9.10
10. Route the oil scavenging pump wiring harness from the pump, up and towards the back of the intake
manifold. Then run the harness along the back of the intake manifold towards the battery to be connected
to the oil pump relay harness later. Secure the oil pump harness to the plastic tabs along the backside of the
intake manifold (previously used to mount the factory intake manifold engine cover) using cable ties (zip ties)
from package PTP-PKG-15000-10. SEE FIGURE 9.11 & 9.12
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FIGURE 9.11
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FIGURE 9.12
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10 – INSTALLING PnP PTUNING OIL PUMP RELAY KIT
1. Locate installation package PTP-PKG-15000-10. Insert metal relay mounting tab on the oil pump relay, bend
tab facing towards front of relay (metal tab may already be inserted on relay). SEE FIGURE 10.1
2. Remove 8mm bolt on the rear tab of the fuse/relay box in the engine bay. Bolt down the relay at this location
facing the Direct Injection module. SEE FIGURE 10.2
FIGURE 10.1
FIGURE 10.2
3. Plug relay harness into relay. Make sure the plug and relay are fully engaged.
4. Remove fuse/relay box cover. Locate 30amp wiper fuse and remove. Insert the 30amp wiper fuse into the
bottom fuse slot on the Tap-Fuse end of the relay harness (there should be a 20amp fuse in the top fuse slot
of the Tap-Fuse. Plug Tap-Fuse end to the wiper fuse slot. Route as shown. Reinstall fuse/relay box cover.
SEE FIGURE 10.3, 10.4 & 10.5
FIGURE 10.3
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FIGURE 10.4
Page 49 of 67
FIGURE 10.5
FIGURE 10.6
5. Locate ground wire located in front of the battery. Remove 8mm bolt, route relay harness ground wire to this
location and bolt down. SEE FIGURE 10.7
6. Connect the plug from the oil scavenge pump harness (previously routed over transmission) to the plug on
the oil pump relay harness and secure with cable ties (zip ties) to the vehicle harness next to the strut tower.
SEE FIGURE 10.7
FIGURE 10.7
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FIGURE 10.8
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7. Connect the oil pressure sensor terminal wire from the oil scavenging pump harness to the factory oil
pressure sensor. Connect the factory oil pressure sensor to the spare terminal on the end of the sensor as
shown. Secure the oil pump relay harness and secure with cable ties (zip ties) to the vehicle harness next to
the strut tower. Route the oil pressure terminal wire around the front of the cylinder head and oil cap and
underneath the intake manifold towards the back-center of the intake manifold. Secure the oil scavenging
pump harness to the factory harness next to the oil filler cap as shown using cable ties (zip ties). SEE FIGURE
10.9 & 10.10
FIGURE 10.9
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FIGURE 10.10
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11 – INSTALLING THE FRONT-MOUNTED INTERCOOLER, IC PIPING AND INTAKE
1. Locate installation package PTP-PKG-15000-14 and PTP-PKG-15000-27. Using a 13mm socket and wrench,
install the front-mounted intercooler as shown with the supplied M8x90mm bolts, washers and lock nuts.
The washer should be located on the front of the bumper support and the lock nut on the backside of the
bumper support. SEE FIGURE 6.1 & 6.2
FIGURE 11.1
FIGURE 11.2
2. Using a box cutter or sheer, trim off the top passenger-side portion of the plastic air shroud as shown to
create an opening for the new air intake shroud. Also trim away the factory foam covering the opening
behind the trimmed shroud. SEE FIGURE 11.3 & 11.4
FIGURE 11.3
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FIGURE 11.4
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3. If you have purchased the optional fueling package, remove the factory map sensor located on the intake
manifold and install the Omni Power map sensor. SEE FIGURE 11.5
FIGURE 11.5
4. Before installing the intercooler piping, have a bottle of Windex handy to help ease the installation of the
silicone couplers onto the intercooler piping. Spray a light mist of Windex on the inside edge of the silicone
couplers before installing it onto the intercooler piping. This procedure will allow you to easily adjust the
coupler on the piping once the piping is installed. The included worm clamp should be tighten loosely on the
coupler and then fully tighten once the desire position of the piping is achieved. It is recommended that the
screw head on the worm clamps be positioned so that it is easily accessible once all the piping has been
installed.
5. Locate installation package PTP-PKG-15000-1 and PTP-PKG-15000-2. Layout all the silicone couplers and
worm clamps on a workbench and set the correct worm clamp next to each end of the couplers. The 2”
clamps should be on the end of the 2” coupler, and 2.5” clamp next to the 2.5” coupler end, etc.
6. Locate intercooler piping #1 marked as package PTP-ICP-15001. Install the supplied ¼” barb hose adaptor
from package PTP-PKG-15000-4 onto the piping as shown. Install the 2” 45 degree coupler and 2”to2.5”
reducer coupler onto the piping, using the 2” worm clamps and 2.5” worm clamp as shown. Be sure to
position the orientation of the 45 degree coupler as shown. FIGURE 11.6
7. Route intercooler piping #1 over the top of the transmission bell housing, directly below the strut cross bar
mounting bracket (center of firewall). The 45 degree coupler end should be facing upward towards the front
of the car and the 45 degree coupler-end should be connected to the turbo compressor outlet. The piping
should sit along the left-side of the transmission bell housing and next to the back of the starter motor.
Secure all worm clamps. SEE FIGURE 11.7
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FIGURE 11.6
FIGURE 11.7
8. Using the supplied 11mm spring hose clamp from package PTP-PKG-15000-4, connect and secure the boost
reference line (from wastegate) to the barb hose fitting on the piping #1. NOTE: The rubber vacuum/boost
line supplied will need to be cut to the desire length. The remaining line will be used as a vacuum line for the
blow off valve. SEE FIGURE 11.8
9. NOTE: The rubber vacuum/boost line supplied will need to be cut to the desire length. The remaining line
will be used as a vacuum line for the blow off valve.
FIGURE 11.8
10. Locate installation package PTP-PKG-15000-22. On the blow-off valve (BOV), take the 4mm Hex Plug and
plug the port on the left side of the “Turbosmart” logo and an 8mm wrench; install the supplied barb fitting
to the right side of the logo. Use a tiny amount of Teflon thread sealant to insure an air-tight seal. SEE
FIGURE 11.9
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11. Locate intercooler piping #2 marked as package PTP-ICP-15002. Insert the BOV O-ring onto the BOV flange
on piping #2. SEE FIGURES 11.10
FIGURE 11.9
FIGURE 11.10
1. Install the V-Band clamp and the BOV and orient it as shown. Tighten the clamp using a 4mm hex socket or
Allen wrench. SEE FIGURE 11.11 & 11.12
FIGURE 11.11
FIGURE 11.12
12. Locate installation package PTP-PKG-15000-4. Remove the top two throttle body mounting bolts and install
the IC piping throttle body bracket. Position the bracket so that the two protruding threaded inserts on the
bracket is on top and facing towards the firewall. Install and torque the two throttle body bolts to factory
spec. Now position intercooler piping #2 so that mounting bracket hole lines up with the holes on the
throttle body mounting bracket. Using the supplied M6x12mm bolts (2), secure the piping #1 mounting
bracket to the throttle body mounting bracket. Using a 2.5” worm clamp from package PTP-PKG-15000-1,
secure piping #2 to the coupler connected to piping #1 as shown. SEE FIGURE 11.13 & 11.14
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FIGURE 11.13
FIGURE 11.14
13. Locate intercooler piping #3 and #4 marked as package PTP-ICP-15003 and PTP-ICP-15004. Using the 2.5”
hump-hose silicone coupler and 2.5” worm clamps, connect one end of the hump-hose to piping #2 (w/BOV)
and the other end to piping #3. Using the 2.5” 45 degree coupler and 2.5” worm clamps, connect one end of
the coupler to piping #3 and the other end to piping #4. Using the 2.5” straight coupler and 2.5” worm
clamps, connect the piping to the passenger-side intercooler end-tank. SEE FIGURE 11.15, 11.16 & 11.16B
FIGURE 11.15
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FIGURE 11.16
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FIGURE 11.16B
14. Locate intercooler piping #5 marked as package PTP-ICP-15005. Using the 2.5” straight coupler and 2.5”
worm clamps, connect one end of the coupler to the shorter-end of piping #5 and the other end to the
driver-side intercooler end-tank. Using the 2.5” 45 degree coupler, connect the short-end of the coupler to
the long-end of piping #5 and route the other end of the coupler through the opening underneath the driverside headlight. Adjust the position and angle of the coupler as shown in FIGURE 11.17 , 11.18, 11.19 & 11.20
NOTE: It is recommended that the plastic mounting-tab for the headlight plug, beneath the headlight, be
trimmed to allow additional clearance for 45 degree coupler connecting piping #5 and #6. SEE FIGURE
11.21
FIGURE 11.17
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FIGURE 11.18
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FIGURE 11.19
FIGURE 11.20
15. Locate intercooler piping #6 marked as package PTP-ICP-15006 and PTP-PKG-15000-4. Install the supplied
1/8” NPT hex plug (using Teflon thread sealant) onto the 1/8” NPT WMI bung on piping #1. SEE FIGURE 11.22
FIGURE 11.21
FIGURE 11.22
16. Using the 2.5” to 3” reducer coupler and 2.5” & 3” worm clamps, connect the 2.5”-end of the coupler to the
piping #6 (side where WMI bung is located) and the other 3”-end to throttle body. Secure the opposite end
of piping #6 to the piping #5 coupler using the 2.5” worm clamp. Adjust the piping on the coupler to allow
3/8” clearance between piping #2 and #6 and 1/4" clearance between piping #6 and the A/C compressor
pulley cover. FIGURE 11.20, 11.23 & 11.24
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FIGURE 11.23
FIGURE 11.24
17. Remove the factory MAF sensor from the factory air box and install the MAF sensor onto intercooler piping
#6 using the supplied M4x8mm button head socket cap screw(2) from package PTP-PKG-15000-4. Reconnect
the MAF sensor plug and route the sensor harness as shown. SEE FIGURE 11.25
FIGURE 11.25
18. Locate air shroud package PTP-PKG-15003. Install the supplied rubber edge trim around the front of the
shroud and trim off the excess edge trim. Install firmly press down the supplied edge-grip trim on top edge
of the shroud and trim off the excess trim. SEE FIGURE 11.26
19. Remove the two M6 bolts securing the factory radiator cap bracket, install the supplied air shroud mounting
bracket on top and secure the bracket with the two M6 bolts previously removed. FIGURE 11.27
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FIGURE 11.26
FIGURE 11.27
20. Remove one of the M8 bolts securing the factory hood latch, slide the air shroud into place so that the two
6mm holes on the shroud sits on top of the two 6mm holes on the air shroud support bracket. Position the
8mm mounting hole on the air shroud tab against the factory hood latch and secure the air shroud with the
previously removed M8 bolts and the supplied M6x8mm button head socket cap screws (2). Adjust the
position of the gray factory alternator harness as shown to allow clearance for the intake tube installed later.
FIGURE 11.28 & 11.29
FIGURE 11.28
FIGURE 11.29
21. Locate intake tube #7 and #8 marked as package PTP-ICP-15007 and PTP-ICP-15008. Using the supplied 90
degree 4” coupler and 4” worm clamp, slide the worm clamp and orient the position of the worm clamp
screw as shown in FIGURE 11.30. Install the shorter end of the 90 degree 4” coupler and clamp onto the
turbo compressor inlet as shown. Tighten the worm clamp just enough to keep the coupler in place (the
clamp will be fully tightened later once the intake tubes have been secured into place. SEE FIGURE 11.30 &
11.31
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FIGURE 11.30
FIGURE 11.31
22. The v-band clamp on the over-pipe will sit against the 4” coupler as shown. Also note the position of the
worm clamp screw on the coupler. The clamp screw should be positioned so that it can easily be tightened
from underneath the vehicle. FIGURE 11.32 & 11.33
FIGURE 11.32
FIGURE 11.33
23. Install a 4” worm clamp onto the other end of the 90 degree 4” coupler with the clamp screw positioned as
shown. Remove the top rear M6 bolt securing the Direct-Injection ECU to the passenger side of the motor
and line up the mounting bracket hole and install the M6 bolt and torque to factory spec. Install the supplied
4” straight coupler and 4” worm clamp onto the intake tube, position and tighten the clamp as shown. SEE
FIGURE 11.34 & 11.35
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FIGURE 11.34
FIGURE 11.35
24. Install a 4” worm clamp onto the other end of the 4” straight coupler with the clamp screw positioned as
shown. Slide the longer-end of the secondary intake tube onto the straight coupler so that the other end of
the secondary intake tube pointing downward and towards the passenger side fender. Installed the supplied
PTUNING 4” intake filter onto the other end of the secondary intake tube as shown. SEE FIGURE 11.36 &
11.37
FIGURE 11.36
FIGURE 11.37
25. Position the worm clamp crew on the air filter as shown and adjust the angle of the secondary intake tube
and coupler so that the filter is positioned as shown without coming into contact with the wiring harness,
fuse box, or radiator hose. The filter should be positioned so that the filter sits below the rubber edge trim
on the air shroud as shown when viewing the air filter form eye position. SEE FIGURE 11.38 & 11.39
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FIGURE 11.38
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FIGURE 11.39
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12 – Installing Vacuum Lines and Breather Filter
1. Locate installation package PTP-PKG-15000-4. Cut the vacuum hose coming off the intake manifold to the
brake boost in the position shown below. Connect the supplied 3/8”x1/4”x3/8” barbed Tee fitting onto the
either end of the cut brake boost vacuum hose. Using the left-over rubber vacuum hose from the WG boost
line installation, attach one end of the 1/4” vacuum hose to the 1/4” barb Tee and the other end to barb
fitting on the blow-off valve (BOV) (cut the 1/4” vacuum hose to desire length, leaving a bit of slack). Secure
the vacuum hose and brake boost hose with the supplied 11mm (2) and 17mm (2) spring clamps. Install BOV
vacuum line and T-vacuum fitting, breather filter. SEE FIGURE 12.1 & 12.2
FIGURE 12.1
FIGURE 12.2
2. Locate installation package PTP-PKG-15000-25. Connect the crank case breather hose (previously removed
from the factory intake tube) to the supplied breather filter using the supplied 7/16” worm clamp. Position
the breather filter between the A/C compressor and the intercooler piping #6 as shown. SEE FIGURE 12.3 &
12.4
FIGURE 12.3
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FIGURE 12.4
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13 – Installing Rear Undertray Mounting Bracket
1. Locate installation package PTP-PKG-15000-13. Temporarily mount the rear undertray to the vehicle chassis.
Install the supplied undertray mounting bracket in the position shown, using the supplied M6x16mm flange
bolt. Secure the bracket to the transmission rear cross member. Using an awl or small Phillip screwdriver,
punch a hole through the undertray where the other mounting hole on the other end of the mounting
bracket resides. Enlarge the punched hole and bolt the undertray to the mounting bracket using the factory
undertray bolt. Remove the undertray and set aside for now until after the final checklist in the manual has
been performed. SEE FIGURE 13.1
FIGURE 13.1
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14 – Final Checklist
2. Verify that all sway bar connections and mounting bolts are fully tightened to factory spec.
3. Verify that all transmission bolts previously removed and re-installed are fully tightened to factory spec.
4. Check all vacuum and boost lines connections on wastegate, blow-off valve, brake booster, and intercooler
piping to ensure that they are all secured and kink-free.
5. Verify that all vacuum fittings and NPT plugs on intercooler piping are secured and leak free.
6. Verify that all exhaust and turbine connection bolts are fully tightened.
7. Verify that all turbo oil feed and oil return line connections are fully tightened.
8. Verify that all turbo coolant line connections are fully tightened and secured.
9. Verify that all factory connector plugs have been re-connected.
10. Verify that the intercooler piping does not rub against any part of the vehicle chassis.
11. Verify that all silicone clamps are fully tightened.
12. Verify engine oil is at factory level. We highly recommend the use of synthetic motor oil to help prolong the
life of the turbocharger.
13. Only use premium unleaded fuel (93 octane or higher) for proper engine performance and to reduce the
possibility of engine damage from detonation.
14. Reconnect the negative and positive terminal on the vehicle battery. DO NOT ATTEMPT TO START THE
VEHICLE AT THIS TIME.
15. IMPORTANT! Verify the oil scavenging pump is connected and functioning properly, using the following
steps:
a. Turn the ignition key to the “ON” position (DO NOT START THE ENGINE).
b. Temporarily disconnect the two-wire terminals from the factory oil pressure sensor terminal. SEE
FIGURE 14.1
c. As soon as the two-wire terminal is removed, you should hear the scavenging pump turn on and the
relay ‘Click’. If the pump does not turn on, check all connections on the oil pump relay harness and
fuse terminal.
d. With the oil pump still on, reconnect the two wire terminals again and you should hear the pump
turn off. Verify that the two-wire terminal on the oil pressure sensor is on tight and will not come
loose from engine vibration. Use a plier if necessary to tighten the gap on the wire terminal-end
before re-connecting the terminal onto the oil pressure sensor.
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FIGURE 14.1
16. Cycle the ignition to the “ON” and then “OFF” position several time to pressurize the fuel system and check
for fuel leaks.
17. At this time, the engine ECU calibration map (Ecutek ProECU ROM file) should be loaded into the factory ECU
before starting the vehicle.
18. Start the vehicle and check for any oil, coolant, fuel, exhaust and vacuum leaks.
19. Bleed the engine coolant system to remove any air pockets from the coolant system. Add coolant if
necessary during the process. Please refer to the factory service manual for details on bleeding the coolant
system.
20. Re-install front and rear lower under trays, as well as any plastic splash shields removed during the
installation process.
21. Verify that all turn signal plugs and horn plugs are connected and re-install front bumper cover.
22. It is recommended at this time that the vehicle’s ECU calibration be calibrated and/or verified on a chassis
dynamometer with AFR reading before driving under boost.
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