INSTALLATION INSTRUCTIONS TURBOCHARGER SYSTEMS
Contents
1. SYSTEMS INSTALLATION INSTRUCTIONS TURBOCHARGER SYSTEMS 2003 2004 Nissan 350Z VQ35 3 5L V6 Engine Manual Transmission Only P N 15134 No Catalytic Converter P N 15136 With Catalytic Converter P N 15138 No Cat Fuel or ECU Upgrade Turbonetics Inc 2255 Agate Court Simi Valley CA 805 581 0333 TurboneticsInc com READ THIS FIRST Study these instructions completely before proceeding Engine and or turbocharger damage may occur if any component within these instructions is improperly installed Turbonetics Inc or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation This complete turbocharger system can be installed using common tools and automotive procedures but installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle If in doubt contact Turbonetics technical support staff at 805 581 0333 between the hours of 8 00 and 5 00PM PST Monday through Friday Remove the turbocharger system from its carton 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 3 to verify that you have all necessary system components to proceed If any comp2. 1 11097 Hardware Kit Hoses Clamps X Xx _ 11 11098 Hardware Kit Nuts Bolts Fittings X X X __1__ 11099 Hardware Kit Gaskets Misc X X Xx _ 1 11100 Hardware Kit Fuel Components X 1 X 1 11103 ECU Return BoxKit X X S 11 21175 Tube Turbocharger to Intercooler X X Xx 1 21176 _ Tube Intercooler to MAF Sensor 1_ X X X 1 21177 _ Tube Intercooler to MAF Sensor 2_ X X X _ 1 21178 Tube Intercooler to MAF Sensor 3 X X X 1 21179 _ Tube MAF Sensor to Throttle Body X X 1 21180 _ Tube Air filter to Turbocharger X X X 1 21181 Tube Exhaust Crossover X X X _ 1 21182 Tube Exhaust U bend X X X _ 1 21183 Exhaust Y pipe r X X X _ 1 21184 Exhaust Turbine Hsg X X _ 1 21185 Tube Exhaust Downpipe 1 X X X _ 1 21186 Exhaust Downpipe 2 X X X _ 1 21200 Tube Exhaust Wastegate Discharge X X X __1__ 21204 _ Tube Exhaust Downpipe 3 No Cat X 1 21201 Tube Exhaust Downpipe 3 With Cat 1 XT 1 21213 Tube Assembly Replacement A C line X X Xx 1 30223 Heat Shield Tangential T4 housing X X X 1 21205 Support Bracket Downpipe 3 X X X 1 30775 Case of Oil Turbonetics TS 1 5W 30__ X X X 1 30815 AirFilter K a
3. bracket pointed out in FIGURE 33 to the right side of the cooler rotated 180 degrees from its original orientation Look closely at FIGURE 36 to see the orientation of the bracket pointed out by the arrows D Mount the cooler with rotated bracket inside the passenger side fender well as shown in FIGURE 35 amp 36 re using the factory mounting hardware removed in step A Re use one of the factory tapped holes to fasten the bracket to the fender well sheet metal E Re connect the rubber hoses circled in FIGURE 34 to the cooler using factory hose clamps NOTE It may be necessary to cut an inch or two off the length of one of the hoses use best judgment FIGURE 34 FIGURE 35 4 ri 2 60130_revC doc Page 19 of 32 FIGURE 36 a 37 Remove front sway bar mounting brackets shown in FIGURE 37 connected to the frame rail so that the sway bar dangles loosely under the car This step is optional but makes the next few steps easier 38 Drain the engine oil and remove the oil pan 39 Using a center punch mark and score the location of the oil drain Hole should be centrally located between the cast ribs of the engine block as shown in FIGURE 38 amp 39 40 Using a step drill or 1 8 drill bit drill a pilot hole into the engine block Increase drill bit sizes in small increments up to 9 16 hole NOTE Be careful not to push too hard when drilling so as to avoid hitting any interna
4. by simply pressing it into place Mount the valve assembly to the swivel mount on the previous tube using 1 O ring P N 30468 and 2 1 4 20 x 5 8 serrated head hex bolts Orient the valve with the horn facing towards the front of the car and tighten the bolts 60130_revC doc Page 30 of 32 FIGURE 78 85 Install 1 1 8 NPT x 5 32 hose fitting into the bottom port of the wastegate and 1 1 8 NPT x 5 32 hose fitting into the top port of the blow off valve pointed out in FIGURE 78 86 Cut approx 2 5 feet of 5 32 vacuum hose P N 30542 BK and route the hose from the upper intake plenum port shown in FIGURE 79 to the blow off valve fitting Cut approx 2 5 feet of the same hose and route it from the fitting on the wastegate to the fitting on the compressor housing installed in step 60 Loosely zip tie the hose as desired NOTE The operation of these turbocharger control devices rely on these hoses for pneumatic signals so do NOT pinch or crimp the hose in any way 87 Re install all factory hardware that can be re installed ECU sway bar intake cover bodywork etc FINAL CHECKLIST e Review these instructions to make sure that all fasteners clamps amp electrical connections have been installed amp torqued correctly e Check that all hose routings are free of any kinks or near any hot or abrasive surfaces that may cause wear over time Adjust or reroute as necessary to provide adequate slack for e
5. 1 0 hex bolts lockwashers amp nuts FIGURE 59 FIGURE 60 69 Install the third Downpipe P N 21201 or 21204 depending on which turbocharger system you purchased using V band clamp P N 30232 to connect to the second downpipe and 2 M10 x 40mm hex bolts flatwashers lockwashers amp nuts to connect to the 2 bolt flange 70 Install P N 21205 Support Bracket Downpipe 3 using the 2 factory transmission bolts pointed out in FIGURE 61 on one end and 2 M8 x 25mm hex bolts lockwashers amp nuts to connect to the bracket on the downpipe on the other end Use 8 flatwashers on both sides of the bracket total of 4 71 Install 2 O2 sensor plugs P N 30862 into the welded bosses near the rear of the downpipe pointed out in FIGURE 62 These bosses are for optional O2 sensors FIGURE 61 FIGURE 62 NOTE Now that all exhaust tubes loosely installed go thru and tighten all the hardware amp clamps 60130_revC doc Page 26 of 32 72 73 14 19 Install the bottom half of the 5 8 oil drain hose to the oil drain fitting in the block and secure with the attached hose clamp pointed out in FIGURE 60 Cut the length of the hose to suit so that no part of the hose is lower than the fitting in the block Route the hose downward from the turbocharger away from hot exhaust pipes and secure with zip ties If any heat shield wrap is left over use as needed Install the bottom half of the braided oil
6. gloves Turn the ignition switch to the OFF position amp 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 Nissan factory service manual for your model year 350Z A large table or bench and plenty of adjacent available workspace Standard selection of automotive tools primarily metric sizes An assortment of zip ties and or thin gauge steel wire The ability to securely lift the vehicle at least a few feet off the ground High temp automotive RTV sealant NPT thread sealant tape Replacement engine oil oil filter and power steering fluid 7 64 and 3 8 drill bits Step drill 1 8 9 16 range 60130_revC doc Page 2 of 32 TORQUE RECOMMENDATION When removing and re installing factory fasteners refer to the Nissan service manual for torque values When installing fasteners included in this kit refer to the following chart Fastener Torque Torque Size Pound Feet Newton Meters TURBOCHARGER SYSTEM PARTS LIST DESCRIPTION 15134 P N 15136 P N 15138 _ T j X X s
7. in FIGURE 57 will go thru the turbine housing turbine inlet flange amp previously installed turbo support bracket Tighten it using 1 M10 lockwasher amp nut on the underside of the support bracket and also tighten the factory A C compressor hex bolt holding the turbo support bracket Temporarily route the 5 8 oil drain hose down towards the fitting attached to the engine block 65 Attach amp tighten the Downpipe 1 pointed out in FIGURE 58 tube to the turbocharger turbine housing using 4 M10 1 50 x 20mm hex bolts amp lockwashers Tighten the v band clamp between the Downpipe 1 and Downpipe 2 tubes FIGURE 57 __ FIGURE 58 66 Install the 1 8 x 3 90 degree oil fitting P N 30551 to the filter fitting atop the turbo center housing using NPT thread sealant tape Install the braided oil supply hose P N 10721 to that fitting and temporarily route the hose down towards the bottom front of the engine 60130_revC doc Page 25 of 32 TURE SYSTEMS 67 Lift the front half of the car and take all necessary safety precautions to secure the vehicle 68 Install the Evolution wastegate P N 10781 to P N 21184 Exh Tube Ass y Turb Housing Inlet tube using 2 M8 x 30mm studs flatwashers lockwashers amp nuts Connect the wastegate discharge flange to P N 21200 Exh Tube Ass y W gate Disch tube using 1 wastegate gasket and 2 5 16 18 x
8. plastic intake cover with the Nissan logo 20 Remove top half of upper intake plenum FIGURE 22 60130_revC doc Page 15 of 32 21 22 23 24 25 26 Remove bottom half of upper intake plenum FIGURE 23 NOTE Once complete plug the 6 intake runner holes with a shop rag so that loose nut amp bolts don t fall into the engine You don t want to have to take the engine apart to retrieve lost parts FIGURE 22 FIGURE 23 Remove electrical connectors on all 6 fuel injectors and push aside Remove the bolts holding down the fuel rail Pull up on each side of the fuel rail to pull the injectors out of the lower intake plenum SEE FIGURE 24 Remove the metal retainer clips holding the fuel injectors to the fuel rail pointed out in FIGURE 24 and pull the injectors out of the fuel rail NOTE There will be some residual fuel in the rail so be prepared to get wet FIGURE 24 FIGURE 25 Sit down at a large open table layout the 6 factory injectors and the 6 new injectors P N 31001 next to each other and perform the following A Remove the o ring seals from the bottom of the factory injectors and slide them onto the bottom of the new injectors B Remove the o ring seals and fuel rail seals from the top of the new injectors 60130_revC doc Page 16 of 32 27 28 29 30 31 32 C Install the injector adapters Round aluminum part w 2 diameters P N 21211 onto the top of th
9. shield pointed out in FIGURE 29 This is easier to accomplish from the topside of the engine 60130_revC doc Page 17 of 32 FIGURE 28 33 Re install both halves of the upper intake plenum as well as any removed hoses clamps or electrical connectors reversing steps 20 amp 21 Don t re install the plastic intake cover or strut tower brace at this time 34 Lift the front half of the car and take all necessary safety precautions to secure the vehicle 35 Remove the plastic splashguard from under the front bumper cover the plastic inner fenders in front of the wheels the front bumper cover styrofoam bumper pad aluminum front bumper and any remaining plastic fascia pieces SEE FIGURES 30 32 Although not necessary it is convenient to remove the front wheels FIGURE 30 FIGURE 31 36 Relocate the power steering cooler to the passenger side inner fender well per the following steps A Remove power steering cooler complete with mounting brackets from its mounting position and disconnect the rubber hose connection pointed out in FIGURE 31 NOTE Be prepared with a drain pan to catch the used power steering fluid 60130_revC doc Page 18 of 32 FIGURE 32 B Remove all metal tubing and rubber hoses all the way back to the hose connection under the power steering fluid reservoir in the passenger side inner fender well circled in FIGURE 34 C Remove both mounting brackets from the cooler and re mount the left
10. 1 0 dia 1 4 hole 7 5 31007 Heat Shield Wrap 1 5 Wide HARDWARE KIT 11100 FUEL COMP TS PARTS LIST 6 21210 6 21211 Spacer Fuel Injector Adapter Fuel Injector ECU RETURN BOX KIT 11103 PARTS LIST 31009 31011 31038 ECU Return Box Pair of Foam Inserts Fedex Return Label 60130 revC doc 6 31001 Fuel Injector Upgrade 31002 Fuel Pump Upgrade 31039 Serial No Decal White 31043 Electronic Mat l Decal Red Page 4 of 32 P N 11096 P N 10843 P N 11097 P N 11100 21175 21176 21177 21178 60130_revC doc Page 5 of 32 P N 21181 21179 P N 21182 P N 21183 P N 21184 P N 21185 P N 21186 P N 21200 P N 21204 P N 21201 P N 21213 60130_revC doc Page 6 of 32 30223 21205 30815 11103 60130_revC doc Page 7 of 32 THIS PAGE LEFT BLANK INTENTIONALLY 60130_revC doc Page 8 of 32 PREREQUISITE STEPS Before getting your hands dirty while under the hood there are 2 prerequisite steps See the following 2 sections for detailed instructions regarding Tube Replacement and ECU Removal amp Shipping A C TUBE REPLACEMENT The first prerequisite step is to have a replacement air conditioning tube assembly included in the kit installed by a professional A C technician This is necessary because the turbocharger is located very close to this A C tube in its factory location so a replacem
11. IGURE 7 60130_revC doc Page 10 of 32 FIGURE6 11 Once removed from the car attach the Serial No decal P N 31039 to the ECU the location pointed out in FIGURE 8 and fill out the information on the label with a permanent black pen or thin tip marker NOTE All ECU s received with incomplete or illegible decals will be returned or discarded so please print clearly and completely First amp Last Name Who are you Mailing Address Where should we ship your ECU back to you Phone Number How can we contact you if any problems arise Model Year Manufacturer Name Model Name For example 2003 Nissan 350Z Touring Manufacture date of car Located on driver side door jam See FIGURE 9 Transmission Type Manual or Automatic V I N number Also located on driver side door jam See FIGURE 9 FIGURE 8 FIGURE 9 MFD BY NISSAN MOTOR CO if GVWR PNBV 181 me GAWR PNBE FR 1906 a a THIS VEHICLE CONFORMS TO MOTOR VEHICLE SAFETY BUMPER AND STANDARDS EFFECT ON THE SHOWN ABOVE JN1AZ34D amp PASSENGER CAR VOITURE DE TOURISME HII 12 Package your ECU in the return box P N 31009 using the supplied foam packaging inserts P N 31011 Fill in your address on the Fedex return label P N 31038 and apply it to the outside of the box Seal the box closed with the supplied Electronic decal P N 31043 13 Logon to www Fedex com or www Kinkos com to find the n
12. RE 50 FIGURE 49 FIGURE 50 56 Wrap the hose pointed out in FIGURE 50 with heat shield wrap P N 31007 as shown in FIGURE 51 You may want to secure the open end with a zip tie or steel wire 57 Install the loop strap P N 31006 around the hose from the previous step and secure it in the same place as the dipstick guide bracket re using the factory hex bolt All this to keep these parts shielded from the turbocharger heat 58 Install 2 8 x 30mm studs into the wastegate flange on P N 21185 Exh Tube Ass y Downpipe 1 Install this tube into position shown in FIGURE 52 loosely securing it to the Downpipe 2 tube with v band clamp P N 30232 While in the car connect P N 21200 Exh Tube Ass y W gate Disch to it Attach amp tighten the 60130_revC doc Page 23 of 32 59 60 61 2 parts together at the wastegate flange with 1 wastegate gasket and 2 M8 lockwashers amp nuts P Ns 20142 30593 30653 NOTE It is not possible to bolt these 2 parts together beforehand it must be done on the car The W gate tube has the same flange on both ends so the correct orientation will have the end with the bellows facing the ground This tube is pointed out in FIGURE 53 FIGURE 51 FIGURE 52 Install 3 M10 x 42mm studs and 1 turbine inlet gasket P Ns 30806 30263 onto the turbine inlet flange as circled in FIGURE 53 Place the turbocharger on a nearby open table and ins
13. Unit from the car and ship it to Turbonetics to load the new engine management program tuned specifically for your car with this turbo setup NOTE 1 You ll want to perform this step just before you are ready to start working on the car When you receive your ECU back from Turbonetics it will be re programmed for a turbocharged engine and therefore will no longer work properly with your naturally aspirated stock engine The included ECU return box kit P N 11103 includes a pre paid Fedex shipping label for express shipping so you can expect to receive your ECU back in 2 3 days NOTE 2 If in the future you choose to remove the turbocharger system for example before selling the car it is possible to re program your ECU back to naturally aspirated stock specs At that time contact Turbonetics customer service staff for details 9 Turn the ignition switch to the OFF position amp disconnect the battery 10 Remove the ECU located behind the passenger side lower dashboard Refer to the Nissan service manual for more detailed instructions but listed below is a general guideline on how to do this e Remove passenger side cup holder by releasing the retainer clip that keeps the assembly from coming completely out of the dashboard with a flat head screwdriver SEE FIGURE 6 e Remove fasteners the hold the lower dashboard in place e Locate the ECU and remove the electrical connectors amp fasteners holding it in place SEE F
14. e coupling hose at the intercooler connection 76 Install P N 21177 Tube Ass y I C to MAFS 2 by removing the 2 factory hex bolts pointed out in FIGURE 69 amp 70 and fastening the intercooler tube to the engine using these bolts It may be convenient to install the 45 degree hose coupling P N 30444 4 and 2 T bolt clamps P N 30275 250 to the upper end of the tube before installing it on the car FIGURE 67 77 Install P N 21176 Tube Ass y I C to MAFS 1 from the passenger side intercooler outlet to the tube from the previous step using 1 2 1 2 hump hose P N 30380 4 and 1 2 1 2 coupling hose P N 30172 4 and 4 T bolt clamps P N 30275 250 as seen in FIGURE 71 Use the coupling hose at the intercooler connection 60130_revC doc Page 28 of 32 FIGURE 71 x EEF awa AMAA SSSR Err Tree 78 Modify P N 30223 turbo heat shield as shown FIGURE 72 using sheet metal cutters or heavy duty scissors Install the shield over the turbocharger turbine housing and secure with steel wire 79 Install P N 30815 K amp N air filter to the P N 21180 Tube Ass y Filter to Turbo tube and then install that sub assembly to the turbocharger compressor inlet using 1 3 0 hose coupling P N 30162 4 and 2 3 0 T bolt clamps P N 30275 300 The air filter will rest on top of the intercooler as seen in FIGURE 73 80 Carefully route the 5 8 I D rubber hose added step 31 a
15. e new injectors with the larger diameter facing down towards the body of the injector pointed out in FIGURE 25 D Remove the o ring seals from the top of the factory injectors and slide them onto the top of the new injectors over the adapters The finished injectors should look like the one pointed out in FIGURE 25 With all o ring seals transferred to the new injectors you re almost ready to install the new injectors back into the car Install the round injector spacers P N 21210 into the injector holes in the lower intake plenum so that the new injectors will sit on top of them pointed out in FIGURE 26 Carefully install the new injectors into the fuel rail facing the same direction as the factory injectors You will not re use the factory metal retainer clips FIGURE 26 ___ FIGURE 27 Re install and bolt down both fuel rails taking care while pressing each injector down into the lower intake plenum to make sure each injector is properly seated on the injector spacers Re connect the electrical connectors to the injectors Remove the factory valve cover breather hose pointed out in FIGURE 28 Cut a length of 5 8 1 0 rubber hose P N 30827 to 5 1 2 feet Install this hose place of the factory hose removed in the previous step re using factory hose clamps on both ends Temporarily route the hose towards the front drivers side of the car until later in the instructions Remove the driver s side exhaust manifold heat
16. earest Fedex package drop off location and ship your ECU return box to Turbonetics 60130_revC doc Page 11 of 32 THIS PAGE LEFT BLANK INTENTIONALLY 60130_revC doc Page 12 of 32 TIME TO GET YOUR HANDS DIRTY With the prerequisite steps done and the car parked for a few days without an ECU its time to start working under the hood The steps from this point forward will progress smoother if you are prepared with the supplies listed on page 2 and although not necessary the ability to lift the vehicle more than a few feet i e a hydraulic lift will make installation a lot easier NOTE The following steps dictating removal of factory parts are purposely generic refer to the Nissan factory service manual for more detailed instructions and torque specs for all fasteners 14 Remove the factory fuel pump assembly A Remove the plastic cover from inside the passenger side storage space SEE FIGURE 10 B Remove metal access cover and temporarily push off to the side SEE FIGURE 11 FIGURE10 FIGURE 11 C Remove 6 hex bolts disconnect the electrical connection amp fuel connection from the top of the pump assembly NOTE Now would be a good time to extinguish your cigarette amp remove any other flammable items from the area D Carefully pull out the fuel pump assembly SEE FIGURE 12 and cover the exposed gas tank FIGURE 12 FIGURE 13 7 15 Sit down at a large open table and prepare to disassemble the fu
17. ed under the No Fault No Hassle Warranty Program Warranty is limited to TURBONETICS products and does not include progressive or subsequential damage and does not cover removal or installation labor or associated parts No warranty is made for any other claims for special indirect or consequential damages including but not limited to component removal or installation equipment downtime prospective profits or other economic loss Warranty will not be granted for recurring damage malfunction or failure due to improper installation misuse unauthorized repair or alterations or externally induced physical damage Warranty is non transferable and must be processed via the original purchaser from TURBONETICS Remanufactured units performance upgraded units and O E M replacement units are covered by a 90 day warranty or the O E warranty period TURBONETICS highly recommends that the installation of mechanical or electrical parts be performed by trained professionals Improperly installed products may lead to unsafe and unreliable conditions RETURN POLICY Only unused and complete merchandise may be accepted for return subject to inspection and acceptance by TURBONETICS No goods will be accepted without prior return authorization from TURBONETICS Call for approval and RGA Returned Goods Authorization tracking number No returns will be accepted without an RGA tracking number No returns will be accepted after ninety 90 days from the o
18. el pump assembly per the following steps You will need a small flathead screwdriver needle nose pliers 7 64 and 3 8 drill bits and metal wire cutters 60130_revC doc Page 13 of 32 A Release the plastic clip that holds the 2 halves of the spring loaded assembly together Be careful not to stress or break any of the electrical wires Set aside the coil springs Unclip and release the electrical connector pointed out in FIGURE 13 B Remove the plastic retainer clip pointed out in FIGURE 14 black rubber damper and fuel pump from the top half of the pump assembly FIGURE 14 FIGURE 15 C Remove the filter bag by releasing the metal retaining ring from the bottom of the fuel pump pointed out in FIGURE 16 D Break off the small plastic tabs on the topside of the new fuel pump P N 31002 as shown in FIGURE 17 This is necessary because the new fuel pump is slightly taller than the factory pump and these tabs keep it from installing properly FIGURE 16 FIGURE 17 E Install the filter bag and metal retaining ring on the new fuel pump in the same location F Remove the rubber seal pointed out in FIGURE 18 from the factory pump and install on the new pump in the same location G Installthe new pump into the fuel pump assembly by reversing the previous few steps H Remove the factory fuel pressure regulator by removing the plastic retainer clip pointed out in FIGURE 19 and prying the regulator out with a small flat
19. ent shielded tube assembly is supplied to move it away from the hot turbocharger HAZARDOUS Do not attempt to perform this step without proper training or equipment Take your car to a local auto repair shop that is capable of discharging and recharging the A C system on your car and have them perform the following 8 steps Don t forget to bring the replacement part P N 21213 FIGURE 1 1 Turn the ignition switch to the OFF position amp disconnect the battery 2 Using factory recommended procedures evacuate discharge the A C system 3 Remove factory air filter box assembly FIGURE 2 to provide easy access to the A C tube being replaced FIGURE 1 FIGURE 2 4 Remove factory A C tube as shown in FIGURES 3 and 4 Tube routes from the A C compressor front driver s side of engine one end towards the front mount heat exchanger on the other FIGURE 3 FIGURE 4 60130_revC doc Page 9 of 32 5 Install replacement A C tube assembly P N 21213 in same location See FIGURE 5 FIGURE 5 1 _ 7 a j F M m i 6 Using factory recommended procedures re fill charge the A C system Check for leaks 7 Re install the factory air filter box assembly and reconnect the battery 8 Start the car turn on the A C system amp re check for leaks ECU REMOVAL amp SHIPPING Once the A C tube is replaced and working properly the 2nd prerequisite step is to remove the ECU Engine Control
20. head screwdriver Carefully hold the regulator in a bench vice or similar and drill out the bottom orifice using a 7 64 drill bit only until the drill breaks through the first thickness of sheetmetal about 1 16 deep SEE FIGURE 20 This step is necessary because the orifice size restricts the flow capacity of the upgraded fuel pump 60130_revC doc Page 14 of 32 Deburr the hole and thoroughly clean out any remaining metal chips NOTE Take special care during this step as this regulator is not available as a replacement part from your local Nissan dealership If you destroy this part the dealership will only sell you the whole pump assembly FIGURE 18 FIGURE 19 J Remove amp discard the yellow plastic fuel nozzle pointed out in FIGURE 21 Again this step is necessary because the orifice size in this nozzle restricts the flow capacity of the upgraded fuel pump K Carefully hold the bottom half of the white plastic fuel pump housing in a bench vice or similar and drill 2 3 8 diameter holes in the side of the housing as shown in FIGURE 21 Location is not critical as long as the holes are near the bottom edge of the housing L Re assemble the fuel pump assembly by reversing the previous steps FIGURE 20 FIGURE 21 16 Re install the factory fuel pump assembly into the car by reversing step 14 17 Remove the strut tower brace 18 Remove factory air filter box assembly and intake tube FIGURE 2 19 Remove
21. l engine components when the drill bit breaks thru the casting use of a step drill will help prevent this from happening 41 Carefully thread the hole using the supplied 3 8 NPT tap The tap only needs to go into the casting far enough to create full threads approx 3 8 no further NOTE It is recommended to hand turn the tap to avoid cross threading This is a critical process you don t want to cross thread the engine block FIGURE 38 FIGURE 39 42 Deburr hole and thoroughly clean out any metal chips from inside of engine block Install the 3 8 NPT x 5 8 hose barb fitting P N 30133 using NPT thread sealant tape 60130_revC doc Page 20 of 32 43 44 45 46 47 Scrape off the excess factory sealant Apply a new bead of high temp RTV sealant to the oil pan sealing surface and re install the oil pan Remove the factory exhaust system SEE FIGURE 38 from the 3 bolt manifold to CAT flange back to the 2 bolt flange just before the first muffler Cut a length of heat shield wrap P N 31007 to 5 0 feet Wrap P N 21184 Exh Tube Ass y Turb Housing Inlet as seen in FIGURE 41 The heat wrap is adhesive backed so it should stay in place but as an added measure you may want to secure the end with a zip tie or steel wire FIGURE 41 NOTE During the next few steps only loosely secure the new exhaust tubes in place Once all exhaust tubes are loosely installed go thru and tighten all the ha
22. long the engine bay inner fender through the same hole that the first intercooler tube routes through and connect to the 5 8 hose connection on the filter to turbo tube re using the factory hose clamps pointed out in FIGURE 73 The hose can also be seen pointed out in FIGURE 77 FIGURE 73 81 Install P N 21179 Tube Ass y MAFS to T B tube to the factory throttle body using 1 3 0 hose coupling P N 30162 4 and 2 T bolt clamps P N 30275 300 as shown in FIGURE 74 82 Pre assemble P N 21178 Tube Ass y I C to MAFS 3 tube with the factory mass air flow sensor MAFS housing using 4 1 4 20 x 3 4 hex bolts flatwashers lockwashers amp nuts Install a 3 0 hose coupling P N 30162 4 and 2 T bolt clamps P N 30275 300 to the opposite end of the MAFS housing SEE FIGURE 75 60130_revC doc Page 29 of 32 FIGURE 74___ 83 Loosen the factory bolt from the front side of engine pointed out in FIGURE 76 and install the previous tube assembly using this bolt and connecting to the 45 degree hose coupling from step 76 and the tube in FIGURE 74 Reconnect the electrical connector to the MAFS housing it may be necessary to cut a factory zip tie to provide enough slack in the wire harness to reach the new MAFS housing location Installed assembly can be seen in FIGURE 77 FIGURE 76 ku Z 84 Install the polished discharge horn P N 20732P into the discharge of the Raptor blow off valve P N 10843
23. mp N o X X X _ 1 60130 Install Instructions L X X X gt x gt gt X lt gt gt x gt gt gt gt X gt OK OK X OK OK PK gt x gt lt OK lt lt lt lt OK OX gt gt X X OK OK X OK OK gt gt x lt gt gt gt 60130_revC doc Page 3 of 32 DESCRIPTION DESCRIPTION HARDWARE KIT 11097 HOSES CLAMPS PARTS LIST 6 30275 300 Band Clamp 3 0 30542 BK Silicon Vacuum Hose 5 32 30827 Hose Oil Drain 5 8 HARDWARE KIT 11098 NUTS BOLTS FITTINGS PARTS LIST Fitting 3 8 NPT x 5 8 Hose Straight Fitting 1 8 NPT x 5 32 Hose Straight 1 30307 Fitting 1 8 NPT x 5 32 Hose Elbow Fitting 1 8 NPT x 3 Straight Fitting 1 8 NPT x 3 Elbow Fitting 1 8 NPT Mx M x F Fitting 1 2 NPT x 5 8 Hose 45 4 2 30248 Hex Bolt 1 4 20 x 5 8 Lg 1 1 1 1 2 2 2 2 6 31003 Hex Bolt M10 1 25 x 40mm Lg 6 30589 FlatWasher 5 16 orM8 6 30804 Flat Washer M10 6 30596 Lock Washer 1 4 or M6 6 30653 Hex Nut M8 31004 Socket Hd Bolt M10 1 25 x 50mm Lg HARDWARE KIT 11099 GASKETS MISC PARTS LIST 2 1 1 1 30141 Gasket Oil Drain T3 T4 wu s 1 30263 Gasket Turbine Inlet T3 30468 O ring Flange Raptor 30809 Tap 3 8 NPT 31006 Loop Strap
24. ngine movement e Refill all fluids oil amp power steering to factory recommended levels e The use of synthetic oil with the factory recommended oil weight is strongly recommended as it will prolong the life of the turbocharger Regardless of factory recommended intervals the addition of a turbocharger requires that the oil be changed every 3000 miles e The use of premium octane unleaded fuel is required for proper engine performance and to reduce the possibility of internal engine damage from detonation e Cycle the ignition to the ON position several times to pressurize the fuel system amp check for any leaks e Start the vehicle and check for any oil power steering or air pressure leaks e NOTE It is normal for the vehicle to emit some amount of white smoke amp a strange odor for an hour or two of operation as the oils within the exhaust pipes burn off 60130_revC doc Page 31 of 32 NO FAULT NO HASSLE WARRANTY PROGRAM TURBONETICS will repair or replace at our expense any new TURBONETICS Spearco products that fail including products used in racing or competition applications for a period of one year from the original date of purchase All turbocharger and cartridge assemblies have a factory installed inline oil filtration device This filter device must remain in place if any warranty is to be considered under the No Fault No Hassle program Electrical components that fail due to misuse are not cover
25. onents in the parts list are missing contact Turbonetics customer service staff Although this turbocharger system has been designed to use many of the factory emissions controls P N 15136 includes a replacement catalytic converter it is not currently smog legal in California and therefore recommended for off road use only In other states check local laws regarding aftermarket modification to emission controlled vehicles This Turbonetics turbocharger system is available in 3 combinations P N 15134 and 15136 are intended for the typical enthusiast and include all necessary components and hardware to simply bolt on the turbo system and drive Both of these systems are identical except for 1 exhaust tube which does or doesn t contain aftermarket catalytic converter P N 15138 is intended for the tuner enthusiast who wants the freedom to choose his own fuel components and controls and includes all the same components and hardware as P N 15134 except NO fuel injectors fuel pump or ECU upgrade 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 Turbonetics reserves the right to revise the information presented herein or to discontinue the production of parts described at any time SAFETY REQUIREMENTS It is recommended to follow these precautions Always wear safety glasses amp
26. rdware amp clamps Loosen the left factory hex bolt and remove the right hex bolt holding the A C compressor in place pointed out in FIGURE 42 Install P N 21184 Exh Tube Ass y Housing Inlet tube into position as shown in FIGURE 43 using the A C bolts to loosely secure it in place FIGURE 42 p ku ka U U U 777 FIGURE 43 Either before or after loosely installing the Turb Housing Inlet tube install the Turbo Support Bracket P N 21202 circled in FIGURE 44 by loosening another of the A C compressor bolts on the driver s side top and sliding the slotted end of the bracket under the loosened A C bolt The end of the bracket with the hole should line up with one of the holes in the turbocharger inlet flange SEE FIGURE 44 60130_revC doc Page 21 of 32 FIGURE 44 48 Install P N 21183 Exh Tube Ass y Y Pipe into position shown in FIGURE 45 loosely securing it to the previous tube with v band clamp P N 30624 49 Remove factory O2 sensor near the 3 bolt flange on the driver s side exhaust manifold and install the O2 sensor plug P N 30862 in its place The 2 factory O2 sensors can be disconnected and set aside for now They will be re installed later in the instructions 50 Install P N 21182 Exh Tube Ass y U bend into position shown in FIGURE 46 loosely securing it to the previous tube with v band clamp P N 30624 Attach amp tighten the other end of the tube
27. riginal shipping date from TURBONETICS unless approved All approved returns are subject to a 15 restocking charge NO EXCEPTIONS The original invoice must accompany the return Accepted warehouse distributor and open account returns will be issued credit only RETURNED GOODS AUTHORIZATION TRACKING NUMBER TURBONETICS will only accept product returns repair orders upgrades and warranty requests that have been approved and are returned with a corresponding RGA Returned Goods Authorization tracking number Contact TURBONETICS for approval and the RGA number Write the RGA number clearly on the outside of the package and include it inside the package This is very important in allowing us to properly identify and process your request Failure to comply with this requirement will result in the delay of processing or the product being returned to you 60130_revC doc Page 32 of 32
28. supply hose to the engine per the following steps Be sure to use NPT thread sealant tape on all NPT connections A Remove the electrical connector and the oil pressure sensor from the engine block circled in FIGURE 63 Install the 1 8 Tee fitting P N 30562 into the block the vacated hole pointed out in FIGURE 64 Re install the pressure sensor into the opposite end of the fitting D Install the 1 8 NPT x 3 straight oil fitting P N 30544 into the Tee fitting E Install the braided oil supply line into the oil fitting from the previous step SEE FIGURE 64 FIGURE 63 FIGURE 64 Install the mounting brackets P N 21203 to the intercooler end tanks using 2 1 4 20 x 1 2 hex bolts amp lockwashers Install the intercooler P N 5 312 assembly to the car using the factory bolts as shown in FIGURE 65 amp 66 FIGURE 65 _ FIGURE 66 In the driver s side fender well pull the factory wiring harness pointed out in FIGURE 67 away from the sheetmetal to provide clearance for the intercooler tubing to fit under it Install P N 21175 Tube Ass y Turbo 60130_revC doc Page 27 of 32 TURE SYSTEMS to I C from the turbocharger compressor discharge to the driver s side intercooler inlet using 1 2 1 2 hump hose P N 30380 4 and 1 2 1 2 coupling hose P N 30172 4 and 4 T bolt clamps P N 30275 250 as seen in FIGURE 67 amp 68 Use th
29. tall the following parts Don t forget to use NPT thread sealant tape on all NPT fittings and remove all protective covers and tags from the turbocharger e 1 Oil drain gasket and 1 Oil drain flange 1 1 2 x 5 8 hose barb 45 degree fitting Orient the fitting as shown in FIGURE 54 2 M8 x 20mm hex bolts lockwashers amp nuts 1 1 8 NPT x 5 32 90 degree hose fitting installed into the port on the compressor housing discharge facing the same direction as the compressor discharge Cut a length of 5 8 D rubber hose P N 30827 to 1 1 2 feet Attach amp tighten this hose to the oil drain fitting from the previous step using 2 5 8 hose clamps P N 30817 one clamp on each end of the hose FIGURE 53 FIGURE 54 7 60130 24 of 32 62 Bend the aluminum tubing pointed out in FIGURE 55 approx 90 degrees downward over the frame rail as shown in the picture just enough to provide adequate clearance for the turbocharger oil drain fitting Temporarily install the turbocharger to check clearance and bend more as needed 63 Apply a bead of high temp RTV sealant to the rectangular downpipe flange face pointed out in FIGURE 55 FIGURE5S o FIGURE 56 64 Attach amp tighten the turbocharger to the turbine inlet flange using 3 M10 flatwashers lockwashers amp nuts and 1 M10 x 50mm socket head screw amp flatwasher thru the 4 hole This 4 fastener pointed out
30. to the exhaust manifold re using one of the factory studs amp nuts and 2 M10 x 40mm hex bolts lockwashers amp nuts Part Hardware Kit 11098 Attach amp tighten the O2 sensor removed in the previous step into the boss in this U bend tube circled in FIGURE 46 Recommend using anti seize lubricant on this connection FIGURE45 _ FIGURE 46 51 Install P N 21186 Exh Tube Ass y Downpipe 2 into position shown in FIGURE 47 loosely holding it in position with steel wire not fastened to anything This is done now because it is more difficult to install later in the instructions 52 Install P N 21181 Exh Tube Ass y Crossover into position shown in FIGURE 48 loosely securing it to the tube with v band clamp P N 30624 Attach amp tighten the other of the tube to the exhaust 60130_revC doc Page 22 of 32 manifold re using one of the factory studs amp nuts and 2 M10 x 40mm bolts lockwashers amp nuts P Ns 31003 30805 30803 FIGURE47 53 Lower the front half of the car 54 In order to provide clearance for the turbocharger it is necessary to bend some of the aluminum tubes out of the way Bend the silver colored tubing pointed out in FIGURE 49 and light yellow colored tubing behind it amp closer to engine towards the engine approx 1 4 or as far as possible as seen in the picture 55 Remove dipstick and dipstick guide bracket pointed out in FIGU
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