GReddy Turbo Kit
Contents
1. sa 0 N O O G amp DOAN O O Ss G N 0 0 O Q Q N Parts List Turbocharger TD05 18G 8cm 2 Wastegate GReddy Tial A5bar 2 Exhaust Manifold Right Side Ductile Iron Cast 1 Exhaust Manifold Left Side Ductile Iron Cast 1 Downpipe Adapter Right Side 1 Downpipe Adapter Right Side 1 Compression Pipe R C 1 502 Aluminum Elbow No 6 1 R C 2 50S Aluminum 1 R C 3 502 Aluminum Elbow No 21 1 L C 4 502 702 Aluminum 1 C 5 502 Aluminum 1 C 6 80S Aluminum 1 Airflow Meter Adapter 1 Suction Pipe R S 1 604 Aluminum 1 I R S 2 704 Aluminum 1 L S 3 602 Aluminum Elbow No 82 1 i L S 4 702 Aluminum 1 Airinx AY SB Blue 2 Airinx Hose Adapter S70 2 Oil Pressure Hose SUS R 600mm L 800mm 1 each Oil Pressure Union Fitting 3 Way Fitting 2 I 1 8PT 1 8 PT Straight 2 i 1 8PT 1 8 PF Straight 1 i 1 8PT 1 8 PF Male to Male 90 1 Oil Pressure Banjo Fittin Male and Female small 2 Copper Washer 102 t 1 0 4 Oil Return Pipe Right 162 1 Oil Return Pipe Left 162 1 Oil Pan with welded Oil Return Pipe 1 Vacuum Hose 55 x 100mm Blue 1 6S x 2000mm Blue 1 Radiator Reserve Hose T x 102 x 790mm CR60 Tube 1 Rubber Hose 15 x 1140mm Oil Return 440mm Blow By 300mm Power Steering 200mm 1 Silicone Hose 504 x 70mm __ Straight 6 80S x 80mm Straight 2 i 60 7 0S Reducer i 60 809 Reducer 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 542. 99 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 i 10 802 Reducer 1 Hose Band 12 8 4 160 10 9 I 505 32 12 i 60S 36 4 10 44 5 i 800 48 7 Power Steering Pump Fitting 1 Check Valve Nissan factory part 47478 51E00 1 Radiator Reserve Tank 1 Radiator Reserve tank Cap 1 Hose Fitting 8 90 1 Radiator Reserve Tank Bracket A_ B 1 Set Aluminum Spacer t 28mm 1 Airinx Bracket Right Left 1 Set Hose Fitting 169 Straight 1 Exhaust Manifold Gasket Nissan Factory Part 14036 AG010 1 Set Turbo Gasket TDOS In Out 4 Catalytic Converter Gasket Nissan Factory Part 20813 AL500 2 Oil Return Gasket TD Small 2 Thermo Cloth 100m x 1000mm Three Way fitting DO 60 1 Zip Ties 150mm 15 E Manage US Z33 1 i Harrness 1 I J Harness 1 i RPM signal adapter 1 Injectors 440cc_ with 4 aluminum fuel rail spacers 6 M5 x 15mm Stainless P 0 8 B S WE W__N 1 M6 x 15mm Stainless P 1 0 B_SW_ 6 M6 x 15mm Stainless P 1 0 B S WF W_ N 5 M6 x 40mm Steel P 1 0 B 1 M8 x 15mm Stainless P 1 25 B SW __ 6 M8 x 20mm Stainless P 1 25 B SW 2 M8 x 25mm Stainless P 1 25 B S W 4 M8x30mm_ _ Stainless Stud P 1 25 1 25 B SW _ N 8 M10 x 35mm ___ Stainless Stud P 1 25 1 25 B S W _ N 12 M10 x 45mm _ Stainless Stud P 1 25 1 50 B _ 2 1 Parts List 17 18 19 20 1 Parts List 1 Parts List 53 54 99 56 2 Factory Parts Removal When removing the
3. RED from GREEN and begin to flash If this happens shut the engine off and turn the ignition switch to ON position to go to Self Troubleshooting Mode While in the Self Troubleshooting Mode the L E D will show the error code Turn off the ignition Check the error code in the chart below and fix the problem The error code will show until the error is corrected
4. with AIRINX to the right passenger side turbo inlet using provided hose and hose clamps and secure the Airinx to the chassis as shown Bend the Power steering line over towards the pulley so that the S 2 clears the line Install the S 3 and the S 4 with AIRINX to the left driver side turbo inlet using provided hose and hose clamps and secure the Airinx to the chassis as shown Bend the A C line toward the engine so that the S 4 pipe clears the line Bend A C Line Airinx Bracket Compression Pipe Installation 1 Install the Air flow meter adapter on tot he air flow meter 2 Install the Compression pipe C 1 C 2 C 3 C 4 C 5 and C 6 by using the provided hose and hose clamps as shown Make sure to check all the clearance before securing the hose clamps When installing the airflow meter assembly make sure not to reverse the flow Part Used 7 8 9 10 11 12 13 34 35 38 41 43 44 66 67 Secure the bracket on C 6 to the Intake manifold Radiator Over Flow Tank Installation Remove the left side head light assembly and Install the provided radiator over flow tank as shown Connect the hose to the lid and reinstall the head light assembly Part Used 47 48 49 50 52 68 69 i A 1 TSE E Le pal ie ni r W al Fe _ e F i LC PSS I sz Le t r E 3 i E 3 E 1 Brake Check Valve Installation Install the provided check valve as shown Part Used 39 46 Inj
5. 51343332 PBIE1192E ECM Terminals and Reference Value iaia PREPARATION w ECM is located behind the passenger side instrument lower TEAR Fr panel For this inspection remove passenger side instrument bene irta tales cdi yn lower panel est ip vo E ALA AZ Remove ECM harness connector When disconnecting ECM harness connector loosen it with levers as far as they will go as shown at right Connect a break out box SST and Y cable adapter SST between the ECM and ECM harness connector Use extreme care not to touch 2 pins at one time Data is for comparison and may not be exact Loosen H Levar Protector E manage Installation 233 ECM HARNESS CONNECTOR foejto7 108 t09 110 111 t12 t15 9899 00 fot 102 Connector 18 5 BL R Male Female 18 7 Y R 18 16 PI R Splice E 18 10 G Was 18 3 W RPM Y 18 17 LB R RPM Y 18 8 PL R RPM Y 18 6 O R 18 18 B R 19 42 40 1 11 80 41 3 Color Code W White G Green B Black BL Blue BR Brown R Red GR Grey PL Purple Y Yellow O Orange LB Light Blue PI Pink E manage Installation Pin Wire Color Description ECU Pin Color x Code White MAPIN 54 Orange Airflow harness Side Meter Blue INJ 1 Red INJ1 Red Black EB BREE HBE state pote Red Red Yellow INJ3 Red INJ3 Red x Yellow _ Purple INJ4 White INJ4 Red x Red 51 ECU side Orange Ai
6. GReddy Turbo Kit 2003 Nissan 350Z VQ35DE Twin TD05 18G 8cm Installation Manual Please read the entire manual before installing this kit Application Chassis Nissan e This GReddy Turbo Kit is designed only for the vehicles specified above e GReddy Front mount intercooler kit is recommended with this kit e Premium grade gasoline 91 octane or higher is required with this Kit e Make sure that the vehicle is not equipped with any ECU upgrade chips e Use of GReddy Racing Spark Plugs ISO LONG 7 or NGK plugs colder than factory is recommended with this kit Important This installation should only be performed by a trained specialist who is very familiar with the automobile s mechanical electrical and fuel management system If installed by an untrained person it may cause damage to the kit as well as the vehicle GReddy Performance Products Inc is not responsible for any damage to the vehicle s electrical system caused by improper installation Make sure to follow the instruction and pay attention to the Important Warning and Caution notice through out the instruction Improper installation can be dangerous Please make sure to inspect the installation before operating the vehicle Call your GReddy Authorized dealer or GReddy Performance Products if there are any problems or questions regarding this product Se ee a a SS Q Ww G G G G G N N N N N N N N N N a
7. ectors Installation 1 Remove the upper intake manifold collector fuel rail assembly with injectors and regulator 2 Grind the top of the fuel rail as shown to clear the intake manifold Make sure not to grind too much Grind the part on the bracket that is raised down flat Clean the rail thoroughly after grinding 3 Install the 440cc injectors and reinstall the fuel rail using the provided spacer Part Used 65 4 Cut the factory injector connectors and solder in the provided connector harness How to solder Strip the end of wires Twist the end together 8 Solder the wires 4 Tape up the soldered area Make sure to solder Completely CES E manage Installation Install the e manage and the rpm adapter as shown in the diagram Make sure to solder all connections except for the ones that are supplied with the male and female connectors Part Used 61 62 63 64 Important Make sure you fully understand the diagram before attempting this installation Improper wiring can damage the ECM and the vehicle s electrical system GReddy Performance Product Inc will not be responsible for any damage caused by improper installation Please do not use crimp connectors or t tap connectors These can cause poor connection and prevent e manage to operate properly TROUBLE DIAGNOSIS ECM Harness Connector Terminal Layout ancopons Y lc 6059158 57 56 s5 52 53 52 5 23 22 21 20119 52 1140 99 38 37 3613
8. ety wire to wrap the thermo cloth Zip ties will melt from the heat and eventually will come off e Make sure that the fuel line connector is properly clicked in all the way e GReddy Performance Products Inc will not be responsible for any damage caused due to improper installation Caution e Make sure to check and double check this step This is the most important step in this install e Without proper clearance and thermo wrapping the fuel lines the fuel line connector can melt from heat and may catch on fire e Wrap the Starter and the Main Engine harness right above the transmission b _ IT housing Important FUS ge Make sure that the main engine harness is i properly wrapped and secured away from the pio Sas d fi 3 lt My ur al ns lt s _ a de r Lis _ ife Caution Without proper clearance and thermo wrapping the harness it melt and cause a short manifold and the wastegate when they are installed in the electrical system or may catch on fire Power Steering Line Installation 1 Remove the hose fitting off the power steering pump and install the provided fitting Parts Used 40 45 2 Cut the provided 152 hose to 200mm 8in and install it between the pump and the tank Parts Used 33 Oil Pan Installation Install the Oil pan with a silicone sealant Part Used 29 Oil Pressure Line Installation Install the oil press
9. pan as shown Part Used 27 28 33 40 57 67 Left Side Driver s Side 7 t Wastegate Installation Install the provided banjo fitting on to the bottom port of the wastegate Top Port is used for boost controller Install the wastegate using the provided gasket and hardware as shown Part Used 2 73 cha gm J Y i Se ES EN J I A Left Side Driver s Side Right Side Passenger s Side e Double check the clearance between the wastegate and the main engine harness on the right side passenger side Make sure that there is enough clearance to avoid the harness from getting to hot and melting Down Pipe Adapter Installation Install the down pipe adapter using the provided gasket and hardware as shown Part Used 5 6 55 70 72 Exhaust System Installation Install the catalytic converter and the exhaust system using the provided gasket and hardware as shown Part Used 56 75 Vacuum hose for Wastegate Installation Remove the factory engine cover Locate the rubber plug on the intake manifold and remove it Connect the 54 hose to the intake manifold and by using the three way fitting and connect the 6 hose to each of the wastegate fitting Suction Pipe Installation 1 2 3 Install the Airinx air filter to the Suction pipe S 2 and S 4 Part Used 14 15 16 17 18 19 33 36 37 40 42 43 44 52 53 67 Install the S 1 and the S 2
10. rflow I J Harness 18Pin Looking at harness side Meter RPM Brown Adapter Black ECM Red ground Green ECM i o Yellow i Power 16 Pink Red__ INJ5 21 Sky blue INJ 5 Light Blue INJ 6 Light INJ6 Red green x Black INJ GND Black ECM x Red x x ground Wire Color x Description x Color x Code Yellow x 60 ECU x Yellow Yellow Yellow Yellow Yellow RPM OUT 116 ECU ECM Black Red i Ground Starting the Engine 1 Refill the engine oil to factory spec Check all the hoses and wires connection then reconnect the negative side of the battery Turn the ignition to ON position 2 3 times to get fuel pressure Then check the injectors and the fuel rail for any fuel leaks Repair any fuel leaks before starting the engine Starting the engine with a fuel leak can cause fire in the engine compartment and can be very dangerous Remove the ECM fuse and crank the engine to get oil pressure to the turbo Until the oil light on the dash turns off Check for any oil leaks then reinstall the fuse and start the engine While idling check for any oil coolant or air leeks After inspection reinstall the under cover and other stock parts that was removed On the initial run be sure to have a boost gauge to check the turbo actuator setting This turbo kit is preset to boost between 0 4kg cm to 0 45kg cm It Is very important that you monitor
11. stock parts make sure you read over the factory repair manual for proper procedures 2 1 Disconnect the negative terminal of the battery 2 2 Drain the engine oil coolant and power steering fluid 2 3 Disconnect the air flow meter 2 4 Remove the Air cleaner assembly with airflow meter intake tube and breather hose 2 5 Remove the Top Radiator Hose and the Water Pipe Located above the Right Exhaust manifold 2 5 Disconnect the primary and secondary O2 sensor and remove the exhaust manifold and catalytic converter 2 6 Remove the exhaust manifold 2 Remove oil pan Please refer to the factory service manual for detail instructions f or removing the oil pan 2 8 Remove the upper intake manifold collector fuel rail assembly with injectors and regulator 3 Turbo Kit Installation Thermo Cloth Installation e Remove the bracket securing the fuel line right below the right side shock tower and disconnect the fuel line Flip the connector so that the line points up and reconnect the line Double wrap the fuel and evap Line using safety Wire Leave the top bracket off and secure the bottom back on as shown Parts used 58 This picture shows the turbo already installed Important e Make sure that the fuel line is secured away from the turbine housing when the turbo is installed Some bending of the lines is necessary to achieve good clearance e Make sure the lines are properly wrapped twice e Make sure to use saf
12. the boost pressure and make sure not to over boost Over boosting can cause engine damage This completes the Turbo Kit installation Important It is very important that you monitor the boost pressure and make sure not to over boost Over boosting can cause engine damage GReddy Performance Products Inc is not responsible for any engine damage caused by over boosting increased boost modification to the kit and or misuse of the product NO WARRANTY is offered Due to lack of control over proper installation and use of this product NO WARRANTY is offered for this kit e manage Information Important e The e manage included in this kit is preprogrammed for the this turbo kit e Do not attempt to adjust any of the setting in the e manage e Any adjustments made can cause damage to the e manage engine and the factory ECU O ACTIVE C INTERACTION Not street legal if removed O Important As of 11 25 03 this kit is not a street legal kit Please ignore the label on the e manage ACTIVE L E D 2 When the ignition is turned on it will illuminate and flash GREEN 3 When it reaches to the A A V setting RPM range it will illuminate and flash ORANGE 4 When an error is detected it will flash RED INTERACTION L E D 1 This will illuminate when there is a connection with PC Checking Error Codes When the unit is powered up and if there are any errors the ACTIVE L E D will turn
13. ure line to engine block using provided fittings Part Used 20 21 22 23 24 600mm line is for the right side and 800mm line is for the left side Oil Pressure Oil Pressure 1 8PT 1 8PF Line Sensor 1 8PT 1 8PT 3 Way Fitting Op 3 Way Fitting 1 8PT 1 8PT 1 8PT 1 8PF dia Engine Block Oil Pressure Line Exhaust Manifold Installation 1 Remove all factory exhaust manifold stud bolt off from the cylinder head Install the provided M10 x 35mm stud bolts on to the cylinder head as shown Part Used 74 Install Stud Bolt Install Stud Bolt the engine suibua eu of e _ A Right Side Passenger s Side LE gi Left Side Driver s Side Turbocharger Installation 1 Install the turbocharger on to the exhaust manifold installed in the previous step For the left side remove the steering shaft joint before installing the turbo For the right side remove the bolts holding the starter and lower the starter before installing the turbo Part Used 1 25 26 55 71 72 13 e After the turbo installation double check the fuel line clearance by the turbo and the manifold on right side passenger side 2 Connect the Oil Pressure line to the turbo using the provided banjo fitting Parts Used 25 Oil Return Pipe Installation Install the oil return pipe using provided gasket and hardware Cut the provided 15 hose to proper length and install them between the oil return pipe and the oil
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