3 - Jegs
Contents
1. 1 Fitting Tee 3 4 Barb to 6AN 4 Spacer Round Frame Brace 1 Fitting 3 8 Npt X 5 8 Stra 2 Bolt 1 4 20 X 5 8 Serrated 30862 Bung 2 Fitting 1 8 Npt X 5 32 Str Fitting Tee 1 4 NPT Fitting 14 to 1 8 Adapter 1 30307 Fitting 1 8 Npt X 5 32 90 2 30554 Fitting Oil Line 1 8 Npt X 4 90 30998 Fitting Coupler Union 3 4 31003 Bolt Hex M10 1 25 X 40mm Pe ical 31071 Head Cap asa Fitting Reducer Tee 1 4 1 4 31141 3 16 31155 Bolt Banjo 16mm Bolt Hex Hd M10 1 25 X 2 31166 50MM 4 2 30566 Bolt 1 4 20 x 1 2 Hex Head 4 2 Screw 5 16 18 X 1 Hex Hd 1 Bolt M6 1 0 X 16MM 3 Bolt M8 1 25 X 50mm Hex 3 Washer Flat 5 16 or M8 1 Washer Flat M6 11 Washer Lock 5 16 or M8 2 Washer Split Lock M6 Hex Nut M8 1 25 Nut Hex M6 HARDWARE KIT 11252 FUEL COMP TS PARTS LIST 2 1 1 1 1 1 2 8 31022 Fuel Injector Siemens 60lb 8 31119 Injector Wire Harness Adapter 31222 Harness MAF Extension 31159 Slit Loom High Temp 3 8 HARDWARE KIT 11310 CLAMPS PARTS LIST 30232 Clamp V Band 2 1 2 30242 Clamp V Band 3 30612 Hose Clamp Worm Drive 20 30616 Hose Clamp Worm Drive 44 2 ml Ls 9 30817 Hose Clamp Worm Drive 5 8 31125 250 Exhaust Band Clamp 2 50 31167 Hose Clamp Worm Drive 72 maa HARDWARE KIT 11316 HOSES PARTS LIST 10724 Oil Supply Hose Assy 4X 36 21364 Silicone Hose Coupling 2 1 22. 17 Install the exhaust y pipe P N 21677 on the ends of the catalytic converters The v band flange on the pipe extends towards the driver side when installed If necessary to ease installation loosen one bolt on each of the catalytic converters with a 15 mm socket SEE FIGURE 123 126 60164revC Page 40 of 75 TW NN g vw bp a VARIN A TIN J 4 p FA IS PISO UI 1 LA F TURBO SYS iv TEMS FIGURE 123 FIGURE 124 FIGURE 126 a 4 18 Using a 13 mm socket loosen the lower bolt on the front of the transmission bell housing The bolt is located on the driver side of the bell housing SEE FIGURE 127 FIGURE 127 60164revC Page 41 of 75 LM TURBO SYSTEMS 19 Install exhaust pipe 2 P N 21678 onto the v band flange at the end of the exhaust y pipe The end of exhaust pipe 2 that contains a bracket is the end that attaches to the y pipe Use the included 2 5 v band clamp P N 30232 to loosely secure SEE FIGURE 128 amp 129 FIGURE 128 FIGURE 129 20 Set the bracket on exhaust pipe 2 underneath the loosened bolt on the front of the transmission bell housing Loosely secure the bracket with the bolt SEE FIGURE 130 FIGURE 130 21 Using a 13 mm socket remove 3 oil pan bolts from the bottom of the engine block The bolts are located at the front most part of the oil pan SEE 131 8 132 FIGURE 131 FIGURE 132 Va 60164revC Page 42 of 75 22 23 TUREO SVSTEMS
3. W LZ 4 ZA No 7 SAE 5W 20 60164revC Page 17 of 75 rF F F See oS Va a em E TJ TTO a 77 O J f Xl gt y 4 TOL Je LOLA Cy at am ad f TURBO SYS 19 Unplug the MAF sensor wiring harness The MAF sensor is located on the air box Pull up on the tab then the plug will disconnect SEE FIGURE 37 amp 38 FIGURE 37 TA FIGURE 38 mb AL 20 Loosen the hose clamp holding the intake arm onto the throttle body SEE FIGURE 39 21 Remove the entire intake assembly from the engine bay This includes the rubber intake arm breather hose and air box Gently tug upwards on the air box to pull its rubber grommets free of the engine bay 22 Unclamp and remove the overflow hose from the coolant reservoir The coolant reservoir is located on the passenger side and attached to the radiator support SEE FIGURE 40 FIGURE 40 60164revC Page 18 of 75 TUREO SVSTEMS 23 Unclamp and remove the overflow hose and from the upper driver side of the radiator Set the hose and clamps aside for later use SEE FIGURE 41 FIGURE 41 24 Disconnect the lower reservoir coolant feed hose from the thermostat housing The thermostat housing is located below the power steering fluid reservoir on the driver side of the engine bay SEE FIGURE 42 FIGURE 42 25 Using an 8 mm socket remove the 2 bolts holding the coolant reservoir in place Save the hardware for use in later steps SEE FIGURE
4. TUREO SVSTEMS 25 Using a 72 hose clamp P N 31167 to secure the 4 0 diameter hump coupler P N 30630 4 onto the turbocharger inlet Place another 72 hose clamp P N 31167 on the open end of the coupler SEE FIGURE 216 FIGURE 216 26 Using an 8 mm socket loosen the bolt on the front of the driver side valve cover SEE FIGURE 217 FIGURE 217 a PPP PE yy aa pp TIARA Yeu 27 Place the new intake tube in the engine bay The end of the tube farthest from the MAF sensor is the end that faces the turbocharger inlet Attach the flex hose from the blow off valve to the large port in the new intake tube Secure using a 20 hose clamp P N 30612 SEE FIGURE 218 amp 219 FIGURE 218 FIGURE 219 a Filter Side 60164revC Page 67 of 75 28 TUREO SVSTEMS Insert the new intake tube into the open end of the 4 0 hump coupler on the turbocharger inlet Loosely secure with the hose clamp Place the intake tube bracket underneath the loosened bolt on the valve cover Loosely secure the bracket with the bolt SEE FIGURE 220 FIGURE 220 a 29 Install the included air filter P N 31163 on the open end of the intake tube Loosely secure with the included hose clamp SEE FIGURE 221 FIGURE 221 Tost eae 30 Adjust the air intake tube and air filter so that they do not contact any other parts in the engine bay Once 31 adjusted tighten all the hose clamps and the valve cover bolt for the brack
5. lr REO SYSTEMS INSTALLATION INSTRUCTIONS TURBOCHARGER SYSTEM 2005 2006 Ford Mustang GT Manual Transmission P N 15168 2007 Ford Mustang GT Manual Transmission P N 15178 Turbonetics Inc 2255 Agate Court Simi Valley CA 805 581 0333 TurboneticsInc com TU REO SVSTEMS 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 00AM 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 components in the parts list are missing contact Turbonetics
6. Install the included up pipe bracket P N 21679 with the included 3 M8 1 25 x 40 mm bolts P N 30576 40 and 3 M8 flat washers P N 30589 Use a 12 mm socket to tighten the bolts SEE FIGURE 133 amp 134 FIGURE 133 FIGURE 134 Install the included downpipe bracket P N 21671 on the two lower studs on the A C compressor The studs can be found at the bottom of the A C compressor which is just above the subframe on the passenger side Position the bracket so that it extends out towards the passenger side of the engine bay Secure using 2 M6 nuts P N 30665 and Loctite threadlocker SEE FIGURE 135 amp 136 FIGURE 135 mu i FIGURE 136 24 Wrap downpipe 1 P N 21666 with 2 rolls of heat wrap P N 31007 secure with safety wire P N 31093 SEE FIGURE 137 60164revC Page 43 of 75 FIGURE 137 25 Set downpipe 1 in the car from the top of the engine bay The bracket end of the pipe extends down between the A C compressor engine mount and steering rack SEE FIGURE 138 amp 139 FIGURE 138 _ _ _ _ FIGURE 139 26 Wrap the exhaust up pipe P N 21665 with 1 1 4 rolls of heat wrap Wrap the straight end of the pipe with the T4 flange Secure the heat wrap with safety wire P N 31093 SEE FIGURE 140 FIGURE 140 60164revC Page 44 of 75 TUREO SVSTEMS 27 Install 2 M10 1 25 x 42 mm threaded studs P N 30806 into the T4 flange on the exhaust up pipe The studs thread into the 2 holes on the part of th
7. SEE FIGURE 146 FIGURE 146 34 Place a 3 0 v band clamp P N 30242 on the end of downpipe 1 SEE FIGURE 147 FIGURE 147 NG piro 60164revC Page 46 of 75 TUREO SVSTEMS 35 Using a 13 mm socket loosen the lower bolt on the front of the transmission bell housing The bolt is located on the passenger side of the bell housing SEE FIGURE 148 FIGURE 148 36 Install downpipe 2 P N 21667 onto the end of downpipe 1 Loosely secure with the v band clamp Loosely secure the pipe bracket to the transmission bell housing using the previously loosened bolt SEE FIGURE 149 amp 150 FIGURE 149 FIGURE 150 37 Install 2 M8 1 25 x 30 mm studs P N 30860 in the 2 hole flange on the exhaust up pipe The flange is located on the passenger side above the steering rack SEE FIGURE 151 FIGURE 151 60164revC Page 47 of 75 TUREO SVSTEMS 38 Install 2 M8 1 25 x 30 mm studs P N 30860 in the 2 hole flange on downpipe 2 The flange is located near the passenger side motor mount SEE FIGURE 152 FIGURE 152 ef a WEN AA 39 Wrap the threads of the included 1 8 NPT x 5 32 straight fitting P N 30306 with Teflon tape or other thread sealant Install the fitting into the port in the base of the Evo wastegate P N 10781 SEE FIGURE 153 FIGURE 153 40 Mount the included Evo wastegate to the 2 hole flange on the exhaust up pipe Orient the wastegate outlet flange so that it points to
8. TUREO SVSTEMS 12 Route the oil feed line up from the oil filter housing behind the power steering pump and up to the top of the turbocharger center housing Using an 13 mm wrench tighten the line to the 90 fitting SEE FIGURE 175 amp 176 FIGURE 175 l FIGURE 176 13 Mate the v band flange on downpipe 1 to the outlet of the turbine housing Loosely secure using a 3 0 v band clamp P N 30242 For clearances and accessibility direct the v band clamp bolt towards the nut securing the turbine housing to the up pipe SEE FIGURE 177 amp 178 FIGURE 177 FIGURE 178 aa IN 14 If downpipe 1 has a bung welded on then coat the threads of the included M18 bolt P N 30862 with anti seize Install the bolt into the threaded bung on downpipe 1 Tighten with a 17 mm socket SEE FIGURE 179 60164revC Page 56 of 75 15 Go back and look over all the exhaust piping Adjust the pipes so that they do not rub against the body or other components Ensure that electrical components are not resting on any hot pipes Extra zip ties are included for use at the installer s discretion Tighten down the v band clamps the up pipe and downpipe flange connections the exhaust clamps etc Also remove the support wire used to hold up a portion of the factory exhaust during the install INTAKE PIPE INSTALLATION 1 Place the included o ring P N 30468 into the recess of the large 2 bolt flange on boost tube 1 P N 21673 SEE FIGURE 180 FI
9. outlet of the blow off valve extends upwards Install the 1 5 inlet air filter P N 31184 to the discharge of the blow off valve Secure the filter to the blow off valve by tightening the hose clamps that is included with the filter SEE FIGURE 187 amp 188 FIGURE 187 FIGURE 188 60164revC Page 59 of 75 T 10 TUREO SVSTEMS Slide a 45 2 5 diameter coupler P N 30444 4 over the driver side intercooler inlet Loosely secure with a 36 hose clamp P N 30615 Place another 36 hose clamp on the free end of the coupler Place a 36 hose clamp P N 30615 on the free end of the coupler attached to boost tube 1 Install boost tube 2 P N 21674 between the intercooler and boost tube 1 Slide the pipe into the couplers and loosely secure with the hose clamps SEE FIGURE 189 amp 190 FIGURE 189 FIGURE 190 2 NI Adjust the turbo to intercooler piping on the driver side so that the pipes are not resting on any part of the body work Once adjusted tighten the hose clamps to hold the pipes in place Slide the 2 50 diameter hump connector P N 30380 4 on the short straight of boost tube 3 P N 21675 Loosely secure with a 36 hose clamp P N 30615 SEE FIGURE 191 Slide the 6 5 long 2 50 diameter coupler P N 21364 onto the long straight of boost tube 3 Loosely secure with a 36 hose clamp P N 30615 SEE FIGURE 191 FIGURE 191 Place a 36 hose clamp P N 30615 on the open end of the hump co
10. 24 11 Using a 10 mm socket loosen the 2 bottom bolts on the ECU bracket The bolts do not need to be completely removed as the ECU bracket is slotted SEE FIGURE 26 amp 27 FIGURE 26 FIGURE 27 12 Using a 10 mm socket remove the 2 upper bolts on the ECU bracket SEE FIGURE 28 8 29 FIGURE 28 FIGURE 29 60164revC Page 15 of 75 TURBO SVSTEMS 13 Remove the ECU from the engine bay SEE FIGURE 30 FIGURE 30 14 Remove the plastic covering from the top and bottom ECU plugs The covering is clipped into the back of the plug covering the wires SEE FIGURE 31 FIGURE 31 15 Reroute the ECU wiring harness underneath the fuse box This routes the ECU wiring harness on the side of the ECU opposite from the stock location SEE FIGURE 32 FIGURE 32 60164revC Page 16 of 75 TUREO SVSTEMS 16 Reinstall the ECU into the engine bay Secure it using a 10mm socket and the factory bolts Plug the wiring harness back into the ECU Also reconnect the plug on the extended portion of the harness SEE FIGURE 33 FIGURE 33 17 Using an 8 mm socket remove the bolt securing the air box to the engine bay The air box is located on the driver side of the engine bay SEE FIGURE 34 FIGURE 34 18 Remove the PCV vacuum hose from its port on the passenger side cylinder head The hose will unclamp from the fitting once a tab has been pushed to the side SEE FIGURE 35 amp 36 FIGURE 35 FIGURE 36
11. 43 FIGURE 43 60164revC Page 19 of 75 TUREO SVSTEMS 26 Remove the coolant reservoir and lower feed hose from the engine bay SEE FIGURE 44 FIGURE 44 27 Remove the metal clips from the coolant reservoir bolt holes Set aside for later use SEE FIGURE 45 amp 46 FIGURE 45 FIGURE 46 Es i 28 Cut the coolant feed hose approximately 7 1 4 below the bottom of the coolant reservoir Set the coolant reservoir with hose fragment still attached aside for later use SEE FIGURE 47 amp 48 FIGURE 47 FIGURE 48 60164revC Page 20 of 75 TUREO SVSTEMS 29 Locate the coolant line bracket and electronic signal noise filter just below the coolant inlet on the passenger side of the engine Using a 15 mm socket remove the nut securing the coolant line bracket and the electronic signal noise filter SEE FIGURE 49 FIGURE 49 bugis i 30 Reinstall the electronic signal noise filter on the stud below the coolant inlet on the passenger side of the motor Install with the Ford label facing away Carefully bend the device away from the coolant inlet Secure with the factory nut SEE FIGURE 50 FIGURE 50 31 The A C lines need to be carefully bent into new positions as shown in the following pictures Bend the lines so that they run close to the radiator fan shroud and the passenger side frame SEE FIGURE 51 54 60164revC Page 21 of 75 MY TURBO SVE TEMS FIGURE 52 INJECTOR INSTALL
12. 75 Fd LI TEMS PREPARING THE VEHICLE FOR TURBO KIT INSTALLTION 1 Jack the vehicle up to a workable height Secure the vehicle with jack stands 2 Using an 8 mm socket unbolt the battery terminals SEE FIGURE 1 FIGURE 1 3 Using an 8 mm socket remove the battery strap and then remove the battery from the vehicle SEE FIGURE 284 3 FIGURE 2 _ FIGURE 3 s s 4 Using a 10 mm socket remove the 3 bolts securing the battery tray in the engine bay and remove the tray from the vehicle SEE FIGURE 4 4 5 FIGURE4 FIGURE 5 60164revC Page 10 of 75 TUREO SVSTEMS 5 Set the battery aside for re installation upon completion of turbo kit installation FRONT END AND ENGINE BAY PREPARATION 1 Using a 5 5 mm socket remove the 7 bolts holding the black plastic undertray in place Remove the undertray SEE FIGURE 6 FIGURE 6 2 Remove the front portion of the inner fender liners from both front wheel wells Use a flat head screwdriver to pop out the plastic fasteners Not all fastener locations are depicted SEE FIGURE 7 amp 8 FIGURE 7 FIGURE 8 lt N Unplug the front blinker and side marker lights on both sides of the car The plugs are located just inside the bumper at each end SEE FIGURE 9 8 10 60164revC Page 11 of 75 TW NW g aan Va V ae sae a a SL MG G 1 LA Pi P fij TEMS TURBO SYS FIGURE 9 FIGURE 10 4 Using a 10 mm socket remove the 4 nuts 2 o
13. N 30589 into the now empty holes in the bumper support SEE FIGURE 70 8 71 FIGURE 70 FIGURE 71 60164revC Page 26 of 75 T TURBO SVSTEMS Place one of the included 0 25 inch thick spacers P N 21704 on each of the 2 newly installed bolts on the passenger side of the bumper support Place the passenger side intercooler bracket P N 21681 on the bolts with the spacers Secure with 2 M8 1 25 nuts P N 30653 and 2 M8 lock washers P N 30593 SEE FIGURE 72 FIGURE 72 Place one of the included 0 25 inch thick spacers P N 21704 on each of the 2 newly installed bolts on the driver side of the bumper support Place the driver side intercooler bracket P N 21680 on the bolts with the spacers Secure with 2 M8 1 25 nuts P N 30653 and M8 lock washers P N 30593 SEE FIGURE 73 FIGURE 73 Install the intercooler P N 5 312 between the newly installed intercooler brackets Secure to the brackets using 2 1 4 20 x 1 2 bolts P N 30566 and 1 4 lock washers P N 30596 Tighten down using an 11 mm or 7 16 wrench SEE FIGURE 74 8 75 60164revC Page 27 of 75 TUREO SVSTEMS FIGURE 74 _ KS FIGURE 75 WATER LINE INSTALLATION 1 Locate the two heater hoses to the side of the stock battery location Disconnect both the 5 8 diameter heater hose and the 3 4 diameter heater hose at their hard line connections SEE FIGURE 76 FIGURE 76 2 Cuta piece of the included 5 8 diameter rubber hose
14. P N 30827 to a length of 2 5 Also cut a piece of the included 3 4 diameter rubber hose P N 31027 to a length of 2 5 SEE FIGURE 77 FIGURE 77 3 4 5 8 60164revC Page 28 of 75 T TUREO SVSTEMS Slide one end of the 2 5 long 5 8 hose onto the included 5 8 barbed t fitting P N 21651 use a hose clamp P N 30817 to secure Slide one end of the 2 5 long 3 4 hose onto the included 3 4 barbed t fitting P N 21652 use a hose clamp P N 30817 to secure SEE FIGURE 78 FIGURE 78 Install the 5 8 fitting and hose assembly onto the 5 8 barbed hard line in the engine bay Direct the threaded portion of the t fitting towards the passenger side Secure with a hose clamp P N 30817 SEE FIGURE 79 Install the 3 4 fitting and hose assembly onto the 3 4 barbed hard line in the engine bay Direct the threaded portion of the t fitting towards the passenger side Secure with a hose clamp P N 30817 SEE FIGURE 79 FIGURE 79 Install the heater hoses onto the ends of the appropriate t fittings The 5 8 hose goes onto the 5 8 fitting and the 3 4 hose goes onto the 3 4 fitting Secure with the factory clamps SEE FIGURE 80 60164revC Page 29 of 75 FIGURE 80 8 Using a 1 8 drill bit drill a hole in the oil pan Locate the hole on the driver side of the pan approximately 3 4 in from the front of the pan and 1 174 up from the bottom As the hole is drilled oil will po
15. customer service staff Although this turbocharger system has been designed to use many of the factory emissions controls 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 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 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 e Ford factory service manual for your model year Mustang e A large table or bench and plenty of adjacent available workspace e Standard selection of automotive tools primar
16. downpipe 2 Use a 3 0 v band clamp P N 30242 to loosely secure downpipe 3 to downpipe 2 NOTE It may assist installation to briefly remove the exhaust y pipe while installing downpipe 3 SEE FIGURE 160 8 161 60164revC Page 50 of 75 TURO SVSTEMS FIGURE 160 FIGURE 161 TT 47 Insert the bracket on downpipe 3 into the rubber exhaust hanger from the stock exhaust piping SEE FIGURE 162 FIGURE 162 48 Slide the 2 50 exhaust clamps over the joints between the stock exhaust piping and downpipe 3 Loosely secure SEE FIGURE 163 FIGURE 163 60164revC Page 51 of 75 TURBO SYSTEMS TURBO INSTALLATION 1 Install the supplied oil drain flange P N 20259 to the bottom of the turbocharger center housing with the supplied oil drain gasket P N 30141 Secure the flange to the turbocharger using 2 of the supplied M8 1 25 x 20mm P N 30700 bolts with M8 lock washers P N 30593 2 Wrap the thread of the 1 2 14 NPT x 5 8 hose barb brass fitting P N 30244 with Teflon tape or other thread sealant Thread the fitting into the oil drain flange on the bottom of the turbo center housing Tighten the fitting with a 7 8 wrench SEE FIGURE 164 FIGURE 164 wages 3 Wrap the threads of a 1 8 NPT x 5 82 90 boost fitting P N 30307 Insert the fitting in the threaded hole on the turbocharger compressor cover SEE FIGURE 165 FIGURE 165 4 Using 2 M16 banjo bolts P N 31155 attach the 2 included 5
17. mm of clearance Use an M8 bolt to check it should barely fit in the space If there is not enough space use a washer between the up pipe bracket and the engine SEE FIGURE 169 FIGURE 169 8 Direct the water lines downwards off the center housing Slide both of the water lines into a heat shield sheath P N 31042 one at a time Route the lines along the back of the radiator shroud and along the side of the ECU following the A C lines Secure the water lines to the ECU bracket with a zip tie P N 2 43620 SEE FIGURE 170 FIGURE 170 9 Direct the ends of the water lines towards the heater hose t fitting at the back of the engine bay Run the lines along the side of the cylinder head Secure the lines to an empty threaded boss on the cylinder head using the included loop strap P N 31006 M6 1 0 x 16 mm bolt P N 30575 and M6 washer P N 30591 SEE FIGURE 171 amp 172 60164revC Page 54 of 75 TUREO SVSTEMS FIGURE 171 FIGURE 172 10 Using an 11 16 wrench tighten the water lines to the t fittings previously installed in the heater hoses Either one of the lines can be attached to either fitting Ensure that there are no kinks in the lines before securing them SEE FIGURE 173 FIGURE 173 z 11 Install the 1 8 NPT x 4AN 90 fitting P N 30554 into the oil filter at the top of the turbocharger center housing NOTE Do not use any thread tape or sealant SEE FIGURE 174 FIGURE 174 60164revC Page 55 of 75
18. 2 water lines P N 21657 52 to the turbocharger center housing When installing the lines place one M16 copper crush washer P N 31156 on the banjo bolt before placing it in through the water line Place another M16 copper crush washer on the banjo bolt after the water line before threading it into the center housing Direct the ends of the water lines downwards towards the oil drain flange Tighten the banjo bolts using a 24 mm socket SEE FIGURE 166 60164revC Page 52 of 75 TUREO SVSTEMS FIGURE 166 5 Insert the turbocharger P N 11308 BB into the engine bay The T4 exhaust flange on the turbocharger turbine housing mates to the T4 flange on downpipe 1 The turbine housing faces towards the passenger side of the engine bay while the compressor housing faces towards the driver side Connect the 5 8 oil drain line to the 5 8 barbed fitting installed on the bottom of the turbocharger center housing Secure with a hose clamp P N 30817 NOTE You may need to loosen the turbine and compressor housing cover bolts in order to clock them into the necessary positions SEE FIGURE 167 FIGURE 167 6 Secure the turbocharger to downpipe 1 using 4 M10 nuts P N 30803 and 4 M10 lock washers P N 30805 Tighten using a 14 mm socket SEE FIGURE 168 FIGURE 168 a i 60164revC Page 53 of 75 TUREO SVSTEMS 7 Check the clearance between the side of the compressor cover and the alternator pulley There should be about 8
19. 207 FIGURE 208 EFRR IU a n Ng 7 r Wy CA Na win 60164revC Page 64 of 75 TOURED SVSTEMS 20 Install the coolant reservoir on the new bracket Secure using an 8 mm socket and the factory bolts SEE FIGURE 210 21 Cut a 23 long piece of the included 3 4 hose P N 31027 Using a hose clamp P N 30817 secure one end of the hose to the coolant port on the thermostat housing Route the other end of the hose towards the bottom of the coolant reservoir SEE FIGURE 211 FIGURE 211 22 Insert half of the included hose coupler fitting P N 30998 into the open end of the 3 4 hose Secure using a hose clamp P N 30817 Insert the other half of the hose coupler into the hose attached to the bottom of the coolant reservoir Secure with a hose clamp P N 30817 SEE FIGURE 212 60164revC Page 65 of 75 TUREO SVSTEMS FIGURE 212 xX 3 23 Install the factory coolant overflow hose between the top of the coolant reservoir and the port at the top driver side of the radiator Secure using the factory hose clamps SEE FIGURE 213 8 214 FIGURE 213 mis ag N FIGURE 214 AA y INA 2 Say aA Ss Ki IA a AN 3 i e f te ae a AR at at Pe Lay ri Fir the fi gt Ans at vi Das a NG ra px 24 Using a T20 torx driver remove the MAF sensor from the factory air box SEE FIGURE 215 FIGURE 215 60164revC Page 66 of 75
20. ATION 1 Unplug all 4 injectors on the passenger side of the engine Push the plastic tab on the side of the plug in order to disconnect it SEE FIGURE 55 FIGURE 55 Ce Na MLT r P ps Al PP Pa 4 L x Sea oe a si a n 4 4 d Wis E a Ci W t paaa ra A nas j vy NAG NG iinei Waw he MiMi yy 60164revC Page 22 of 75 TUREO SVSTEMS 2 Pull the plastic wiring harness support brackets off the studs securing the fuel rail Using a deep 8 mm socket remove the 2 bolts securing the fuel rail SEE FIGURE 56 FIGURE 56 3 Find a container to hold fuel Pull the fuel rail with injectors away from the engine Hold them over the container NOTE Fuel may squirt out of the engine as the injectors are removed SEE FIGURE 57 FIGURE 57 4 Using a flathead screw driver pop both sides of the metal injector clip off of the metal retainer on the fuel fail The injector will separate from the fuel rail along with the metal clip Drain any fuel out of the rail and into the container SEE FIGURE 58 FIGURE 58 60164revC Page 23 of 75 TUREO SVSTEMS 5 Repeat the last step with the injector at the opposite end of the fuel rail and remove the final 2 injectors from the rail SEE FIGURE 59 FIGURE 59 6 Remove the metal clips from the stock injectors Place them on the new injectors P N 31022 as pictured SEE FIGURE 60 amp 61 FIGURE 60 FIGURE 61 Lubricate
21. FIGURE 110 11 Pull back on the metal clips on the sides of the exhaust couplers in order for them to slide Slide the couplers downstream on the exhaust pipes to free the crossover section of the exhaust Remove the crossover pipe Leave the clamps for later use SEE FIGURE 111 113 FIGURE 111 FIGURE 112 fa Ca ba ag 60164revC Page 38 of 75 TUREO SVSTEMS 12 Using a 10 mm socket remove the two upper radiator brackets from the radiator support SEE FIGURE 14 amp 115 FIGURE 114 FIGURE 115 4 13 Using a 7 16 drill bit to drill 2 new holes in both radiator brackets Locate the new holes as shown in the following figure SEE FIGURE 116 FIGURE 116 14 Reinstall the upper radiator support brackets Use the new holes to secure the brackets to the radiator support SEE FIGURE 117 8 118 FIGURE 117 60164revC Page 39 of 75 TUREO SVSTEMS 15 Place the factory plastic radiator shroud back in its original position on the upper radiator support Using a permanent marker mark the locations for the new required holes on the radiator brackets Using a 1 4 drill bit carefully drill a new hole in each bracket for the radiator shroud plastic fasteners Set aside the plastic radiator shroud for reinstallation in later steps SEE FIGURE 119 amp 120 FIGURE 119 FIGURE 120 ay pang gt T y UU AA emer ta KH lt w LE Pa a hA gy oe T aa o t AA PE Ai gt AA e SA A To
22. GURE 180 2 Install the Raptor blow off valve P N 11296 into the flange on boost tube 1 Secure the blow off valve to the pipe using 2 1 4 20 x 5 8 bolts P N 30248 and tighten with a 3 8 wrench SEE FIGURE 181 60164revC Page 57 of 75 TUREO SVSTEMS FIGURE 181 3 Wrap the threads of the included 1 8 NPT x 5 32 straight fitting P N 30306 with Teflon tape or other thread sealant Install the fitting into the threaded port in the cover of the blow off valve SEE FIGURE 182 FIGURE 182 4 Slide the 9 50 long 2 5 diameter coupler P N 21725 onto the turbo end of boost tube 1 Loosely secure the coupler to the tube with a 36 hose clamp P N 30615 Place boost tube 1 into the engine bay Direct the coupler in first it fits between the driver side of the radiator and the subframe SEE FIGURE 183 185 FIGURE 18 60164revC Page 58 of 75 THT s E omy Va Voy sey AE I naa Vor ffi a i P JN 4 si A fine Me ff iI Ss AS y J LA we fi j Ng LZ T gt y TEMS TURBO SYS FIGURE 184 E FIGURE 185 5 Slide the 45 2 5 diameter coupler P N 30444 4 onto the end of the turbocharger compressor outlet Loosely secure with a 36 hose clamp P N 30615 SEE FIGURE 186 FIGURE 186 6 Slide the blow off valve end of boost tube 1 P N 21673 into the open end of the 45 coupler on the compressor outlet Loosely secure with a 36 hose clamp P N 30615 Position boost tube 1 so that the
23. IGURE 195 amp 196 for 05 06 model years and FIGURE 197 amp 198 for 07 model years FIGURE 195 FIGURE 196 05 06 MUSTANG GT Coolant Pipe P N 21695 To Radiator FIGURE 197 07 MUSTANG GT Coolant Pipe P N 21754 16 Place the included turbine heat shield P N 31172 over the turbocharger turbine housing Secure using safety wire P N 31093 SEE FIGURE 199 FIGURE 199 60164revC Page 62 of 75 SABONWEINGS TUREO SVSTEMS 17 Place the factory metal coolant reservoir mounting hole clips on the new coolant reservoir bracket P N 21682 SEE FIGURE 200 202 FIGURE 200 RELOCATE BRACKET P N 21682 FIGURE 201 FIGURE 202 18 On the 05 06 model year vehicles mount the coolant reservoir bracket P N 21682 in the engine bay on the driver side strut tower Secure with a 10 mm socket and the factory bolts SEE FIGURE 203 amp 204 FIGURE 203 FIGURE 204 RELOCATE BRACKET P N 21682 60164revC Page 63 of 75 TUREO SVSTEMS 19 On the 07 model year unscrew the two nuts on the driver side shock tower that is closes to the engine and install the supplied radiator reservoir relocate bracket adapter P N 21761 and secure using the factory hardware Mount the coolant reservoir relocator bracket P N 21682 to the bracket adapter P N 21761 using a 10mm socket and factory bolts SEE FIGURE 205 209 FIGURE 205 FIGURE 206 RADIATOR RESERVOIR RELOCATER BRACKET ADAPTER P N 21761 FIGURE
24. STEMS 18 Install the 4AN x 36 long oil feed line P N 10724 onto the 90 end of the fitting assembly installed into the oil filter housing Route the free end of the line up to the top of the engine bay behind the power steering pump SEE FIGURE 96 FIGURE 96 EXHAUST PIPE INSTALLATION 1 Using a 15 mm socket remove the 4 lock nuts securing the front sway bar to the subframe Let the bar hang down from the endlinks SEE FIGURE 97 FIGURE 97 2 Using a piece of heat wrap P N 31007 and a zip tie P N 2 43620 Secure heat wrap around the cam sensor The cam sensor is located on the front of the engine behind the radiator fan shroud on the passenger side SEE FIGURE 98 60164revC Page 34 of 75 FIGURE 98 F aN 3 Wrap the crank sensor wiring harness and the A C compressor wiring harness with heat wrap P N 31007 Route the wiring harness around the A C compressor Secure it with a couple zip ties P N 2 43620 or safey wire P N 31093 to the A C line The A C compressor is located just above the steering rack on the passenger side SEE FIGURE 99 amp 100 FIGURE 100 FIGURE 99 4 Wrap a portion of the power steering line with heat wrap P N 31007 Wrap a two inch portion of the line as it comes out of the steering rack on the passenger side Secure using safety wire P N 31093 SEE FIGURE 101 FIGURE 101 ap 60164revC Page 35 of 75 TUREO SVSTEMS 5 Relocate the ground wire fr
25. Silicone Hose Coupling 4 25 ID 21790 4 x2 25 L 21657 52 Water Supply Hose 52 30542 B Silicone Vac Hose 5 32 30827 21725 Hose Silicone 4Ply 30302 4 Silicone Hose Coupling 4 30380 4 Silicone Hump Hose 2 1 2 2 30444 4 Silicone Elbow 45deg 2 1 2 2 25 31027 Hose Gen Purpose 3 4 ID 60164revC Page 5 of 75 TUREO SVSTEMS P N DESCRIPTION P N DESCRIPTION HARDWARE KIT 11309 GASKETS PARTS LIST 2 43620 Cable Ties Nylon 8 1 2 20142 Gasket Deltagate Evo 30141 Gasket Oil Drain T3 T4 31006 Loop Strap 1 0 Diam 1 4 Hole 31007 Heat Shield Wrap 1 5 Wide 31042 Heat Wrap 1 0 Diam 30143 Gasket Turbine Inlet T4 31156 Washer Crush 16mm 30468 O Ring Base Flange Godzilla HARDWARE KIT 11307 IC MOUNTING PARTS LIST 21680 Bracket Ic Mounting 30593 Washer Lock 5 16 or M8 21681 Bracket Ic Mounting 30653 Nut Hex M8 1 25 21704 Spacer Round Aluminum 31076 Bolt Hex M8 1 25 x 30mm 30589 Washer Flat 5 16 or M8 60164revC Page 6 of 75 TURO SVSTEMS P N 10781 P N 11296 P N 11294 P N 11252 P N 21669 60164revC Page 7 of 75 TUREO SVSTEMS P N 21670 P N 21671 P N 21672 P N 21674 _ P N21675 P N 40300P P N 21679 P N 21682 P N 21695 P N 21754 P N 21761 60164revC Page 8 of 75 TUREO SVSTEMS P N 5 312 P N 31172 o P N 60164 60164revC Page 9 of
26. all the black split loom P N 31159 onto the MAF extension harness P N 31222 trim the split loom as necessary 2 Plug the supplied MAF extension harness to the factory MAF meter that is installed in the cast intake pipe P N 21780S Route the new extension harness under the throttle body intake manifold to the other side of the vehicle SEE FIGURE 233 237 FIGURE 233 60164revC Page 72 of 75 ITS F aag VET Va a Nam SAGA TJ sn dal T7 A E SG 4 j 4 ii WIN MG G 1 LA i P f tat am ad TURBO SYS 3 Plug the MAF extension harness onto the factory MAF harness making sure both plugs are in contact with each other Using the supplied tie wrap secure both plugs together by inserting the tie strap in the middle of one harness and around to the middle of the other harness SEE FIGURE 238 240 FIGURE 238 FIGURE 239 my CLEAN UP 1 Using a hammer knock the factory bolts out of the lower subframe brace Place the brace in a clamp With the factory nuts threaded onto the tips of the bolts tap the nuts with a hammer until they break loose SEE FIGURE 235 amp 236 FIGURE 235 FIGURE 236 60164revC Page 73 of 75 TUREO SVSTEMS 2 Reinstall the front lower subframe brace using new hardware Insert 2 M10 1 25 x 40mm bolts P N 31003 into one end of the brace Place a 0 80 thick spacer P N 21705 on both bolts Repeat for the opposite end of the brace Install the brace back in the stock location an
27. 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 original 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 60164revC Page 75 of 75
28. d secure using 4 M10 nuts P N 30803 with 4 M10 lock washers P N 30805 SEE FIGURE 237 239 FIGURE 237 FIGURE 238 3 Review these instructions to make sure that all fasteners clamps amp electrical connections have been installed and torqued correctly 4 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 engine movement 5 Reinstall the body work and battery in the reverse order of its removal 6 Refill all fluids oil power steering and coolant to factory recommended levels The use of synthetic motor 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 3 000 miles 7 The use of premium octane unleaded fuel is required for proper engine performance and to reduce the possibility of internal engine damage from detonation ECU REPROGRAMMING 1 The SCT Uploader P N 21898 is preloaded with the tune for your vehicle To upload the tune to your vehicle follow the instructions that came with the SCT uploader 60164revC Page 74 of 75 TURO SVSTEMS NO FAULT NO HASSLE WARRANTY PROGRAM TURBONETICS will repair or replace at our expense any new TURBONETICS Spearco products that fail including products us
29. e flange that angles in towards the pipe SEE FIGURE 141 28 Install the turbo support bracket P N 21670 onto the T4 flange of the up pipe using 2 M10 1 25 x 50mm bolts P N 31166 The bracket sits on the pipe side of the flange It is installed in the 2 holes on the part of the flange that angles away from the pipe SEE FIGURE 141 amp 142 FIGURE 141 FIGURE 142 29 Insert the exhaust up pipe through the top of the engine bay The v band flange mates up to the end of exhaust pipe 2 that was installed in hot pipe installation step 19 Loosely secure with a 2 5 v band clamp P N 30232 Loosely secure the turbo support bracket to a stud on the engine block using the factory nut The stud is located just below the coolant inlet it holds the electronic signal noise filter SEE FIGURE 143 8 144 FIGURE 143 FIGURE 144 s a Cii N 30 Place the included T4 exhaust gasket P N 30143 on the T4 flange on the up pipe 31 Using the included M8 1 25 x 20 mm bolt P N 30700 and M8 lock washer P N 30593 loosely secure downpipe 1 to the bracket installed on the A C compressor SEE FIGURE 145 60164revC Page 45 of 75 32 Before proceeding further re secure the front sway bar by reattaching the u brackets to the subframe with the factory nuts 33 Using 2 of the included M8 1 25 x 20 mm bolts P N 30700 with 2 M8 lock washers P N 30593 secure the exhaust up pipe to the bracket installed in hot pipe installation step 22
30. ed 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 covered 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
31. et Cut the included 3 8 diameter hose P N 30828 to a length of 27 Insert one end of the hose onto the small port on the air intake tube Route the hose behind the alternator and underneath the throttle body to the vacuum port on the passenger side cylinder head The port is located by the oil cap No hose clamps are necessary to secure the hose SEE FIGURE 222 amp 223 60164revC Page 68 of 75 TUREO SVSTEMS FIGURE 223 t WAKE 32 Install the included 4 silicone coupler P N 21790 4 onto the throttle body Secure using the factory hose clamp from the stock intake Place a 72 hose clamp P N 31167 on the round end of the coupler SEE FIGURE 224 amp 225 FIGURE 224 FIGURE 225 an moa VP 33 Install the factory MAF meter into cast intake pip P N 21780S and secure the sensor to the tube using the factory screws SEE FIGURE 226 FIGURE 226 60164revC Page 69 of 75 TUREO SVSTEMS 34 Insert the cast intake pipe P N 21780S into the coupler on the throttle body The oval end of the tube is the end that mates to the throttle body Insert the other end of cast intake pipe P N 21780S into the coupler at the of the cast elbow P N 40300P Loosely secure with the hose clamps SEE FIGURE 227 amp 228 Eup 227 FIGURE 228 35 Adjust boost tube 3 and boost tube 4 so they do not rest on any of the body work or other components Once positioned tighten all hose clamps 36 Cut a piece of the inc
32. ily metric sizes e Anassortment of zip ties and or thin gauge steel wire e The ability to securely lift the vehicle at least a few feet off the ground e NPT thread sealant e Loctite threadlocker e Replacement engine oil and oil filter e Hammer e Drill e Bench Clamp J Small Container 60164revC Page 2 of 75 TURO SVSTEMS TORQUE RECOMMENDATION When removing and re installing factory fasteners refer to the Ford 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 1 4 or 6mm 5 16 or 8mm 3 8 or 10mm NPT fittings 2 3 turns past finger tight TURBOCHARGER SYSTEM PARTS LIST DESCRIPTION P N 15168 P N 15178 a ae lp L 1 11294 Hardware Kit Nuts Bolts Fittings X X 1 41252 Hardware Kit FuelParts X X 1 11310 Hardware Kit Clamps X X a ee 6 lt X lt gt lt gt lt 60164revC Page 3 of 75 QTY P N DESCRIPTION Eh o Filter Air 1 5 Inlet Intercooler Core Assembly Badge Polydome Jelly Top Instr Raptor Instr Evolution Instr Installation 60164revC Page 4 of 75 TUREO SVSTEMS P N DESCRIPTION P N DESCRIPTION HARDWARE KIT 11294 NUTS BOLTS FITTINGS PARTS LIST Flange Oil Drain 1 2 Npt 8 30803 Nut Hex M10 1 25 Fitting Tee 5 8 Barb to 6AN 8 30805 Washer SplitLock M10_
33. ing The oil filter housing is located near the bottom of the engine block on the driver side Unplug the wiring harness from the sensor Using a 13 16 deep socket remove the oil pressure sensor SEE FIGURE 89 91 FIGURE 89 nge i FIGURE 90 15 Make a fitting assembly out of a 1 4 NPT t fitting P N 30975 1 4 NPT to 1 8 NPT adaptor fitting P N 30976 amp a 90 4AN x 1 8 NPT fitting P N 30554 Coat the threads of the 1 4 to 1 8 adaptor fitting with Teflon tape or other thread sealant Insert it into the 1 4 NPT t fitting in the hole opposite the male threaded portion Coat the 1 8 NPT threads of the 90 fitting with Teflon tape or other thread sealant Insert it into the end of the 1 4 NPT adaptor fitting just installed in the t fitting SEE FIGURE 92 60164revC Page 32 of 75 TUREO SVSTEMS FIGURE 92 1 4 NPT T Fitting 1 4 to 1 8 NPT Fitting 16 Coat the threads of the 1 4 NPT t fitting with Teflon tape or other thread sealant Install the fitting assembly into the oil pressure port on the oil filter housing This is the location from which the oil pressure sensor was removed SEE FIGURE 93 FIGURE 93 l 17 Coat the threads of the oil pressure sensor with Teflon tape or other thread sealant Install the oil pressure sensor into the open location on the 1 4 NPT t fitting now located in the oil filter housing SEE FIGURE 94 amp 95 60164revC Page 33 of 75 TUREO SV
34. luded 5 32 diameter silicone hose P N 30542 BK Attach one end of the hose to the fitting installed in the compressor housing Route the other end down to the wastegate Attach the hose to the fitting installed in the wastegate base 37 Cut a piece of the included 5 32 diameter silicone hose P N 30542 BK Attach one end of the hose to the fitting installed in the cover of blow off valve Route the other end of the hose to the driver side cylinder head The end of the hose attaches to the t fitting installed near the fuel rail Gapping the Spark Plugs 1 Remove the 8 factory coil packs 4 per side from the head of the engine by unbolting the bolt using a 7mm socket SEE FIGURE 229 amp 230 FIGURE 229 FIGURE 230 natte 7 NG 1 a NA i Na WA Pa f iz NG O i Naig n mani TELL 60164revC Page 70 of 75 TUREO SVSTEMS 2 Carefully lift each coil pack up and set it to the side SEE FIGURE 231 FIGURE 231 3 Using a 9 16 spark plug socket and a long extension carefully remove the spark plug from the engine Making sure no debris falls into the spark plug hole when the plug is removed 4 Once the plugs are removed gap each of them to 0 030 0 032 SEE FIGURE 232 FIGURE 232 5 Double check all plug to make sure they were gapped correctly and re install everything in reverse order 60164revC Page 71 of 75 TUREO SVSTEMS CONNECTING THE MAF METER HARNESS 1 Inst
35. n each side of the car holding the bumper assembly onto the fenders SEE FIGURE 11 amp 12 FIGURE 11 FIGURE 12 5 Remove the black plastic radiator cover Using a flat head screwdriver pop out the plastic fasteners Using an 8 mm socket remove the 2 top bolts holding the bumper one on either side of the radiator cover SEE FIGURE 13 15 FIGURE 14 60164revC Page 12 of 75 a a VPN a paaa r PAO NN TITE LY TURBO SYSTEMS FIGURE 15 6 Slightly pull the bumper forward Unplug both of the fog lights The plugs are located behind the light assemblies SEE FIGURE 16 amp 17 FIGURE 16 FIGURE 17 7 Carefully remove the front bumper If there is great resistance check to ensure that all fasteners have been removed and all lights are unplugged SEE FIGURE 18 20 FIGURE 18 FIGURE 19 yr T TT 60164revC Page 13 of 75 FIGURE 20 8 Drain the coolant from the radiator through the drain plug located underneath the radiator on the passenger side SEE FIGURE 21 FIGURE 21 Fa 4 amp 9 Remove the passenger side upper radiator hose SEE FIGURE 22 amp 23 FIGURE 22 B o FIGURE 23 60164revC Page 14 of 75 10 Locate the ECU in the engine bay next to the fuse box on the passenger side Unplug the ECU Pull up on the grey clips to unlock the plugs Also unplug the large plug that extends off the ECU wiring harness It is located to the driver side of the ECU SEE FIGURE 24 8 25 FIGURE
36. nnector on boost tube 3 Install boost tube 3 onto the passenger side intercooler outlet The hump connector attaches to the intercooler while the long 2 5 diameter straight coupler P n 21364 is directed to the side of the bumper support and into the engine bay Place a 36 hose clamp P N 30615 on the end of the long straight coupler P N 21364 SEE FIGURE 192 60164revC Page 60 of 75 TURBO SYSTEMS FIGURE 192 13 Install the cast transition elbow P N 40300P with the 2 5 diameter side attached to the 2 5 diameter silicone hose that is attached to one end of intercooler boost tube P N 21675 Secure the cast transition elbow P N 40300P to the silicone hose coupling with a supplied 36 hose clamp P N 30615 SEE FIGURE 193 FIGURE 193 14 Install a 4 diameter silicone hose coupling P N 30302 4 onto the 4 diameter side of the cast transition elbow P N 40300P Slide 2 74 hose clamp P N 31167 over the 4 diameter silicone hose coupling SEE FIGURE 194 FIGURE 194 60164revC Page 61 of 75 TUREO SVSTEMS 15 Slide a 1 5 diameter coupler P N 31000 on either end of the new coolant pipe P N 21695 Secure the couplers to the pipe with 2 20 hose clamps P N 30612 Secure the long straight end of the coolant pipe to the passenger side of the radiator using a 20 hose clamp P N 30612 Secure the other end of the pipe to the coolant inlet on the engine with a 20 hose clamp P N 30612 SEE F
37. om the lower motor mount bolt to the upper bolt The ground wire is located on the passenger side of the engine SEE 102 6 Wrap the oil level sensor wiring harness with heat wrap P N 31007 The oil level sensor is located on the passenger side of the engine oil pan Route the oil level sensor harness and the starter wiring harness above the engine mount Using a zip tie P N 2 43620 secure the starter harness to the oil level harness SEE FIGURE 103 amp 104 FIGURE 103 B FIGURE 104 Oil Level Harness 7 Using a 15 mm socket remove the 4 lock nuts holding the front lower subframe brace The brace is located just below the transmission bell housing There are 2 nuts at each end of the brace SEE FIGURE 105 amp 106 60164revC Page 36 of 75 A i a PA EM IN A Fa a ME 7 Lah f 7 i d i Fp J Gal MY TURBO SYSTEMS FIGURE 105 ee FIGURE 106 8 Cut the stock exhaust 2 5 downstream from both of the catalytic converters Make the measurement starting at the weld bead on the catalytic converters SEE FIGURE 107 8 108 FIGURE 107 Oo FIGURE 108 9 Support the hanging exhaust pipes with coat hanger wire safety wire or welding rod SEE FIGURE 109 FIGURE 109 60164revC Page 37 of 75 NW AA p AN in W 1T SON A y NW tS Fi F 4 O f GU PI Ja y Pr j 4 j 4 5 KA YY TURBO SYSTEMS 10 Using a 15 mm socket loosen the 4 bolts for the exhaust coupling clamps SEE FIGURE 110
38. the o rings on the new injectors using motor oil or similar lubricant Install the new injectors onto the fuel rail Be sure that the plugs will face away from the engine Seat the injectors into the cylinder head Be sure they are properly seated in order to avoid any leaks Re secure the fuel rail with the original nuts SEE FIGURE 62 60164revC Page 24 of 75 FIGURE 62 DA LA PP maling W iy i i PA Hs 8 Attach the included injector plug adaptors P N 31119 onto the injector plugs Plug in all the injectors SEE FIGURE 63 FIGURE 63 FI Before installing the injectors on the driver side of the engine install a plastic t fitting P N 31141 into the vacuum line Cut the vacuum hose approximately 9 5 inches away from the fuel pressure MAP sensor The MAP sensor is located on top of the fuel rail Install the t fitting between the 2 hose sections SEE FIGURE 64 8 65 FIGURE 64 i FIGURE 65 Fuel Pressure MAP Sensor 60164revC Page 25 of 75 IO Cal f 1 t y i p o M TURBO SYSTEMS 10 Repeat the injector install steps 1 8 on the driver s side of the engine SEE FIGURE 66 amp 67 FIGURE 66 FIGURE 67 INTERCOOLER INSTALLATION 1 Using a 13 mm deep socket remove the 4 inner 2 passenger side 2 diver side bolts from the front bumper support SEE FIGURE 68 amp 69 FIGURE 68 FIGURE 69 2 Install the 4 included M8 1 25 x 30 mm long bolts P N 31076 with 4 M8 flat washers P
39. ur out of the hole pushing out the metal shavings The drill bit may also be coated with grease in order to catch metal chips SEE FIGURE 81 8 82 FIGURE 82 1 174 9 Using a hammer and the included tapered center punch tool P N 21273 expand the hold drilled into the oil pan to 0 5781 NOTE Do not bottom out the center punch tool The hole could potentially become too large to properly tap SEE FIGURE 83 amp 84 FIGURE 83 FIGURE 84 60164revC Page 30 of 75 TUREO SVSTEMS 10 Liberally grease the included tap P N 30809 Use it to tap the hole in the oil pan The tap is tapered so check the hole with the included 3 8 NPT x 5 8 barbed fitting P N 30133 before using more than half the threads on tap SEE FIGURE 85 FIGURE 85 11 Using Teflon tape or other thread sealant coat the threads of the 3 8 NPT x 5 8 barbed fitting Install it into the oil pan SEE FIGURE 86 amp 87 FIGURE 86 FIGURE 87 12 Cut a piece of 5 8 hose P N 30827 to a length of 32 Install the hose on the end of the barbed fitting installed in the oil pan Secure with a hose clamp P N 30817 Direct the free end of the hose up to the top of the engine bay by the radiator fan shroud SEE FIGURE 88 FIGURE 88 r h a fa VE p z gi ors gt AA tan i Age EF 60164revC Page 31 of 75 TUREO SVSTEMS 13 Drain the rest of the oil from the engine 14 Locate the oil pressure sensor on the oil filter hous
40. wards the floor Secure it using 2 M8 nuts P N 30653 and 2 M8 lock washers P N 30593 SEE FIGURE 154 60164revC Page 48 of 75 TUREO SVSTEMS FIGURE 154 41 Place an exhaust gasket P N 20142 on the 2 bolt flange on downpipe 2 SEE FIGURE 155 FIGURE 155 42 Mate one end of the wastegate dump tube P N 21669 to the wastegate outlet flange with an exhaust gasket P N 20142 in between Loosely secure the tube to the wastegate using 2 5 16 18 x 1 bolts P N 30570 and 2 5 16 lockwashers P N 30593 SEE FIGURE 156 amp 157 FIGURE 156 FIGURE 157 J To Wastegate To Downpipe 2 60164revC Page 49 of 75 43 44 45 46 TUREO SVSTEMS Loosely secure the other end of the wastegate dump tube to the 2 bolt flange on downpipe 2 using 2 M8 nuts P N 30653 and 2 M8 lockwashers P N 30593 SEE FIGURE 158 FIGURE 158 Once the wastegate dump tube is fully installed tighten the 4 bolts that secure it Note Make sure the wastegate dump tube does not become pre loaded in order to prevent the flex joints from cracking Place the included 2 50 exhaust clamps P N 31125 250 over the ends of the stock exhaust piping Place one clamp on each of the 2 pipes SEE FIGURE 159 FIGURE 159 S g Install downpipe 3 P N 21668 between downpipe 2 and the stock exhaust piping Direct the non flanged end of downpipe 3 into the stock exhaust pipes before mating the v band flange with that on the end of
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