Mustang GT 05-09
Contents
1. 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 FIGURES 14 amp 15 FIGURE 14 FIGURE 15 60164 revG Page 59 of 87 P F i r Fi E i fe m rr F 14 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 FIGURES 16 amp 17 FIGURE 16 FIGURE 17 EET DW i Ha 15 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 18 FIGURE 18 EC 60164 revG Page 60 of 87 16 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 all 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 INTERCOOLER PLUMBING INSTALLATION jm Use a 2 piece of 1 hose and two clamps to attach2. 39 Slip 2 72 clamp over support bracket P N 22073 on driver side and P N 22074 on passenger side Bolt brackets to transmission bell housing bolt P N 30943 and washer P N 30804 SEE FIGURE 58 amp 59 FIGURE 58 FIGURE 59 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 1 FIGURE 1 60164 revG Page 54 of 87 3 Wrap the threads of the 1 8 NPT x 3 16 hose barb P N 30307 with Teflon tape or other threads sealant Insert the fitting in the threaded hole on the turbocharger compressor cover SEE FIGURE 2 FIGURE 2 4 Using two M16 banjo bolts P N 31155 attach the 2 included 52 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 wa
3. 60164 revG Page 23 of 87 1 j y EN i e d Yi i 30 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 FIGURES 53 56 FIGURE 53 FIGURE 54 60164 revG Page 24 of 87 i o Vad ILIA EO G YS TE MS INJECTOR INSTALLATION 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 1 FIGURE 1 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 2 FIGURE 2 60164 revG Page 25 of 87 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 3 FIGURE 3 4 Using a flathead screw driver pop both sides of the metal injector clip off of the metal retainer on the fuel rail 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 4 FIGURE 4 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 5 FIGURE 5 60164 revG Page 26 of 87 6 R
4. TURBO SYSTEMS www Turboneticsinc com INSTALLATION INSTRUCTIONS TURBOCHARGER SYSTEM 2005 2009 Ford Mustang GT Manual Transmission P N 15168 1 Turbonetics Inc 14399 Princeton Avenue Moorpark CA 805 581 0333 TurboneticsInc com PURB ONE E TUREO SYSTEMS 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 amp 4 to verify that you have all necessary system components to proceed If any components in the parts list are missing contact Turbonetics
5. PARTS LIST 6 30612 Hose Clamp Worm Drive 20 31167 Hose Clamp Worm Drive 72 30616 Hose Clamp Worm Drive 44 31260 Hose Clamp Worm Drive 24 30817 Hose Clamp Worm Drive 5 8 31287 Hose Clamp Pinch 30941 Hose Clamp Worm Drive 52 31288 Hose Clamp 3 8 Pinch 31125 250 Exhaust Band Clamp 2 50 30242 Clamp V Band 3 31125 300 Exhaust Band Clamp 3 00 HARDWARE KIT 11316 HOSES PARTS LIST ne Hose Coupling 4 25 ID Silicone Trans Hose 2 5 3 0 upply Hose ime TUS Silcone 45 Elbow 2 5 034 Sione Elbow 4 amp deg 2 1 2 HARDWARE KIT 11309 GASKETS PARTS LIST ee ea ee 5 31156 asher Crush 16mm 20142 Gasket Deltagate Evo 31299 Heat Wrap p Roll 30141 Gasket Oil Drain T3 T4 8 31300 Tie Heat Wrap 30143 Gasket Turbine Inlet T4 30468 O Ring Base Flange Godzilla 31006 Loop Strap 1 0 Dia 1 4 Hole 31042 Heat Wrap 1 0 Diam HARDWARE KIT 11307 IC MOUNTING PARTS LIST 1 21680 Bracket Ic Mounting 4 30593 Washer Lock 5 16 or M8 1 21681 Bracket Ic Mounting 4 30653 Nut Hex M8 1 25 4 21704 Spacer Round Aluminum 31076 Bolt Hex M8 1 25 x 30mm 30589 Washer Flat 5 16 or M8 60164 revG Page 6 of 87 P N 10781 P N 30359 P N 11252 P N 11310 P N 11309 P N 11361 P N 21908 60164 revG Page 7 of 87 fee TEMS P N 21670 P N 22073 22074 P N 22038 P N 220
6. 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 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 o
7. 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 11361 into the coupler at the of the cast elbow P N 11411 Loosely secure with the hose clamps SEE FIGURES 51 amp 52 FIGURE 51 FIGURE 52 Throttle Body Side 30 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 31 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 compressor housing Route the other end down to the wastegate Attach the hose to the fitting installed in the wastegate base 32 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 unscrewing loosening the bolt using a 7mm socket SEE FIGURES 1 amp 2 FIGURE 1 FIGURE 2 60164 revG Page 74 of 87 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 Gap the 8
8. the passenger side and attached to the radiator support SEE FIGURE 42 FIGURE 42 60164_revG Page 21 of 87 24 25 26 Unclamp and remove the overflow hose from the upper driver side of the radiator Take out the hose and clamps set it aside for later use SEE FIGURE 43 FIGURE 43 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 On 07 09 model year remove hose going to lower radiator hose from reservoir SEE FIGURE 44 FIGURE 44 Using an 8 mm socket remove the 2 bolts holding the coolant reservoir in place SEE FIGURE 45 FIGURE 45 60164 revG Page 22 of 87 Ld f m i F 7 FF 27 Remove the coolant reservoir and lower feed hose from the engine bay SEE FIGURE 46 FIGURE 46 28 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 51 FIGURE 51 Electronic Signal Noise Filter 29 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 52 FIGURE 52
9. FIGURE 11 FIGURE 12 60164 revG Page 65 of 87 TURBO SYSTEMS FIGURE 13 FIGURE 14 FIGURE 15 12 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 FIGURES 17 amp 18 for 05 06 model years and FIGURES 19 amp 20 for 07 09 model years FIGURE 17 FIGURE 18 60164 revG Page 66 of 87 Coolant Pipe P N 21695 To Radiator FIGURE 19 07 09 MUSTANG j q To Radiator Coolant Pipe P N 21754 13 Place the included turbine heat shield P N 31172 over the turbocharger turbine housing Secure using heat wrap tie P N 31300 SEE FIGURE 21 FIGURE 21 14 Coolant Degauss overflow reservoir P N 22031 For model year 05 06 install fittings using pipe thread sealant in coolant reservoir as shown in figure 22 For 07 09 install fittings using pipe thread sealant as shown in figure 23 FIGURE 22 FIGURE 23 P N 31306 P N 31306 60164_revG Page 67 of 87 FLURBU SYSTEMS 05 06 Mustang P N 31307 15 Attach mounting bracket with 52 clamp underneath SEE FIGURE 24 FIGURE 24 16 For years 05 06 connect the 3 4 hose from thermostat housing to coolant
10. P N 31076 with four M8 flat washers P N 30589 into the now empty holes in the bumper support SEE FIGURES 3 amp 4 FIGURE 3 FIGURE 4 3 Place one of the included 0 25 thick spacers P N 21704 on each of the 2 newly installed bolts on the passenger side of the bumper support 4 Place the passenger side intercooler bracket P N 21681 on the bolts with the spacers Secure with two M8 1 25 nuts P N 30653 and two M8 lock washers P N 30593 SEE FIGURE 5 FIGURE 5 I C Bracket E d 5 Place one of the included 0 25 thick spacers P N 21704 on each of the 2 newly installed bolts on the driver side of the bumper support 60164 revG Page 30 of 87 famam F ys TE MS 6 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 6 FIGURE 6 7 Install the intercooler P N 5 312 between the newly installed intercooler brackets Using the upper holes secure the intercooler 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 7 amp 8 FIGURE T FIGURE 8 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 1 FIGURE 1 60164_revG Pag
11. 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 8 FIGURE 8 60164_revG Page 57 of 87 A X476 FEO UN TURBO SYSTEMS ym 9 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 9 10 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 FIGURES 10 amp 11 FIGURE 10 FIGURE 11 60164 revG Page 58 of 87 12 7 Vd 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 12 FIGURE 12 E 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 13 FIGURE 13
12. back side of the fuel door Ensure surface is clean before adhering decal SEE FIGURE 2 FIGURE 2 60164 revG Page 83 of 87 LA TELADO 5 ys TE MS ECU REPROGRAMMING 1 Plug the included Diablosport up loader into the OBDII port located underneath the driver s side dash SEE FIGURE 1 3 FIGURE 1 FIGURE 2 2 Turn the ignition to ON position but do NOT start car Ensure the Performance Tune is highlighted and press the button in the middle on the Diablosport controller to begin SEE FIGURE 4 FIGURE 4 60164 revG Page 84 of 87 TEMS 3 Press Agree SEE FIGURE 5 FIGURE 5 4 Press Performance Tune then select Install Tune and press Turbonetics 9psi tune SEE FIGURE 6 NOTE Selecting Modify Tune will ONLY let you adjust correction for the speedometer for different tire sizes or gear ratios FIGURE 6 60164 revG Page 85 of 87 TEMS 5 Follow the simple on screen directions as it will guide you to reflashing the ECU SEE FIGURE 9 FIGURE 9 6 When you see this screen that says Turbonetics 9psi Tune In the vehicle You may drive it now it means that the programmer successfully reflashed your ECU It is now safe to unplug the Diablosport controller SEE FIGURE 10 FIGURE 10 7 Start the vehicle and check for any oil or coolant leaks prior to a test drive Test drive the vehicle check for oil coolant leaks again check all fluid levels and top off as ne
13. in place SEE FIGURES 25 28 FIGURE 25 FIGURE 26 60164 revG Page 45 of 87 17 Slip P N 22044 on to P N 22037 with two 2 72 clamps SEE FIGURES 29 amp 30 FIGURE 29 FIGURE 30 E t i y f eres 18 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 31 amp 32 FIGURE 31 FIGURE 32 60164 revG Page 46 of 87 19 Loosely Install the included up pipe bracket P N 21679 with the included 3 M8 1 25 x 40 mm bolts P N 30576 50 and 3 M8 flat washers P N 30589 SEE FIGURES 33 amp 34 FIGURE 33 FIGURE 34 20 Wrap P N 22036 with heat wrap as shown and secure with metal ties SEE FIGURE 35 FIGURE 35 60164 revG Page 47 of 87 21 22 23 24 25 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 Install 2 M10 1 25x42mm P N 30806 into flange as shown SEE FIGURES 36 amp 37 FIGURE 36 FIGURE 37 Bracket Insert the exhaust up pipe through the top of the engine bay Slip P N 22044 in to P N 22036 Loosely secure the turbo support bracket to a stud on the engine block using the factory nut It holds the electronic signal noise filter SEE FIGURES 38 amp 39 FIGURE
14. next to the battery using the 4 supplied self tapping screws First hold the MSD box against the fire wall and use a marker to mark the location of the four holes Set the box aside and drill a pilot hole in each of the 4 marked locations using a 3 32 drill bit SEE FIGURE 2 FIGURE 2 2 Connect the red wire from the MSD labeled BATT to the supplied fuse holder using a supplied yellow butt connector Crimp a supplied yellow ring terminal to the other end of the fuse holder and the black wire labeled BATT SEE FIGURE 3 FIGURE 3 60164_revG Page 78 of 87 3 Connect the grey plug to the grey plug on the lead coming out of the MSD box Bring the orange and red wires that are in the black plastic loom to factory fuel pump driver module in the trunk of the vehicle 4 Run the wires across the fire wall to the driver s side of the vehicle and down in the front of the brake booster Feed the wire down into the fender well alongside the fuel line SEE FIGURE 4 amp 5 FIGURE 4 FIGURE 5 5 Carefully pull back on the black plastic trim inside the fender well to gain access so you can continue to feed the wires to the bottom of the vehicle SEE FIGURE 8 amp 9 FIGURE 8 FIGURE 9 60164 revG Page 79 of 87 6 Remove the black plastic trim underneath the driver s side that protects the fuel line This will allow you to gain access and run the wires along side of the fuel lines to the rear of the vehicle Tie str
15. passenger side of the engine SEE FIGURE 6 FIGURE 6 60164_revG Page 40 of 87 IOIAEO SYSTEMS Lower Bolt 6 Wrap the oil level sensor wiring harness with heat wrap P N 31299 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 FIGURES 7 amp 8 FIGURE 7 EN FIGURE 8 Starter Harness 1 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 FIGURES 9 amp 10 FIGURE 9 FIGURE 10 60164 revG Page 41 of 87 pe SYITI TE MS 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 FIGURES 11 amp 12 FIGURE 11 i FIGURE 12 b ie 7 252 y 9 Support the hanging exhaust pipes with coat hanger wire safety wire or welding rod SEE FIGURE 13 FIGURE 13 60164 revG Page 42 of 87 P Fs Fi F fe m Ti F 10 Using a 15 mm socket loosen the 4 bolts for the exhaust coupling clamps SEE FIGURE 14 FIGURE 14 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
16. supplied spark plugs PN 31296 for 05 06 model years and PN 31297 for 07 09 model years each of them to 0 030 0 032 SEE FIGURE 4 amp 5 FIGURE 4 FIGURE 5 60164 revG Page 75 of 87 5 Double check all plugs to make sure they were gapped correctly and re install everything in reverse order INSTALLING THE AIR FILTER 1 Pull the two plastic tabs on the top filter cover towards the front of the vehicle FIGURE 1 FIGURE 1 r 2 Remove the factory air filter SEE FIGURE 2 FIGURE 2 3 Install new supplied air filter into factory air box SEE FIGURES 3 amp 4 60164_revG Page 76 of 87 i m LP COP Vay VE TPS rae i e E d AL pm Ja de i A NM oe F F i i i ail iR ae EF 4 of i r i r F F ia F FIGURE 3 AIR FILTER PN 31292 CONNECTING THE MAF METER HARNISS 1 Plug the supplied MAF extension harness to the factory MAF meter that is installed in the cast intake pipe P N 11361 Route the new extension harness under the throttle body intake manifold to the other side of the vehicle SEE FIGURES 1 4 FIGURE 1 FIGURE 2 60164_revG Page 77 of 87 Fo iP FEM wt TURIO SYS INSTALLING MSD FUEL PUMP BOOSTER FIGURE 1 e INDICATES CONNECTION FACTORY 12 VDLTS FROM INERTIA SWITCH BLACK FUEL PUMP DRIVER MODULE 1 8 DIAMETER VACUUM HOSE TO INTAKE MANIFOLD PHOTO COURTESY OF MSD 1 Mount the MSD fuel pump booster on the fire wall
17. 3 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 amp 10 FIGURE 9 E FIGURE 10 4 Using a 10 mm socket remove the 4 nuts 2 on each side of the car holding the bumper assembly onto the fenders SEE FIGURE 11 amp 12 FIGURE 11 FIGURE 12 60164_revG Page 13 of 87 1 y y IE fwd Yi I 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 13 FIGURE 14 FIGURE 15 60164 revG Page 14 of 87 HE y fy i F J Y 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 m s 60164 revG Page 15 of 87 fum SYITI TE MS 8 Drain the coolant from the arim through the drain plug located underneath the radiator on the passenger side SEE FIGURE 21 FIGURE 21 9 Remove the passenger side upper radiator hose SEE FIGURE 22 amp 23 FIGURE 22 NEN FIGURE 23 10 Locate the ECU in the engine bay next to the fu
18. 32 P N 21674 P N 21675 P N 11411 P N 21679 P N 22031 P N 21695 P N21754 P N 22079 60164 revG Page 8 of 87 P N 31292 60164 revG Page 9 of 87 TUREGO SYSTEMS TECHNICAL DRAWINGS Left Side Hot Right Side Hot 60164 revG Page 10 of 87 d ee J F t phe yf ff DY 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 2 amp 3 FIGURE 2 FIGURE 3 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 amp 5 FIGURE 4 FIGURE 5 60164 revG Page 11 of 87 TES 7 URED s Vs TE MS 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 60164 revG Page 12 of 87 ZZ TEMS
19. 38 FIGURE 39 NNa e i _ pe Up Pipe L Exhaust Pipe 2 Place the included T4 exhaust gasket P N 30143 on the T4 flange on the up pipe Before proceeding further re secure the front sway bar by reattaching the u brackets to the subframe with the factory nuts Using 2 of the included M8 1 25 x 20 mm bolts P N 30700 with two M8 lock washers P N 30593 loosely secure the exhaust up pipe to the bracket installed in hot pipe installation step 19 SEE FIGURE 40 FIGURE 40 60164 revG Page 48 of 87 26 Wrap downpipe P N 22041 as shown SEE FIGURE 41 FIGURE 41 27 Drop downpipe into position as shown SEE FIGURE 42 amp 43 FIGURE 42 i FIGURE 43 28 Slip P N 22042 over P N 22041 as shown SEE FIGURE 44 amp 45 60164 revG Page 49 of 87 FIGURE 44 To 22041 29 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 46 FIGURE 46 _ 30 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 47 FIGURE 47 _ 60164 revG Page 50 of 87 TEMS 31 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 bottom port in the base of the Evo wastegate P N 10781 SEE FIGURE 48 F
20. 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 16 FIGURE 16 60164 revG Page 38 of 87 EXHAUST PIPE INSTALLATION 1 Using a 15 mm socket remove the 4 lock nuts securing the front sway bar to the sub frame Let the bar hang down from the end links SEE FIGURE 1 FIGURE 1 2 Using a piece of heat wrap P N 31299 and a zip tie P N 2 43620 Secure heat wrap around the cam sensor he cam sensor is located on the front of the engine behind the radiator fan shroud on the passenger side SEE FIGURE 2 FIGURE 2 3 Wrap the crank sensor wiring harness and the A C compressor wiring harness with heat wrap P N 31299 Route the wiring harness around the A C compressor Secure it with a couple zip ties P N 2 43620 or heat wrap tie P N 31300 to the A C line The A C compressor is located just above the steering rack on the passenger side SEE FIGURES 3 amp 4 60164 revG Page 39 of 87 FIGURE 4 4 Wrap a portion of the power steering line with heat wrap P N 31299 Wrap a two inch portion of the line as it comes out of the steering rack on the passenger side Secure using heat wrap tie P N 31300 SEE FIGURE 5 FIGURE 5 F 5 Relocate the ground wire from the lower motor mount bolt to the upper bolt The ground wire is located on the
21. IGURE 48 32 Mount the included Evo wastegate to the 2 hole flange on the exhaust up pipe Orient the wastegate outlet flange so that it points towards the floor Secure it using 2 M8 nuts P N 30653 and 2 M8 lock washers P N 30593 SEE FIGURE 49 FIGURE 49 33 Place an exhaust gasket P N 20142 on the 2 bolt flange on downpipe 2 SEE FIGURE 50 FIGURE 50 60164 revG Page 51 of 87 HUE BY yy TE MS 34 Mate one end of the wastegate dump tube P N 21908 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 lock washers P N 30593 SEE FIGURES 51 amp 52 FIGURE 51 FIGURE 52 1 To Wastegate To Downpipe 2 35 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 lock washers P N 30593 SEE FIGURE 53 FIGURE 53 60164_revG Page 52 of 87 36 Once the wastegate dump tube is fully installed loosely tighten the 4 bolts that secure it 37 Support transmission and remove transmission mount Slip P N 22043 over P N 22042 with two clamps as shown SEE FIGURE 54 amp 55 FIGURE 54 To Factory Exhaust 38 Replace transmission mount Loosen muffler mounts and slip P N 22043 over factory exhaust with two clamps SEE FIGURE 56 amp 57 FIGURE 56 FIGURE 57 60164 revG Page 53 of 87 1 y y F d fwd Yi
22. ap the wires the fuel lines to secure it SEE FIGURES 10 amp 11 FIGURE 10 7 Locate the grommet underneath the trunk and run the wires into the trunk SEE FIGURES 12 amp 13 FIGURE 12 FIGURE 13 k x 8 Locate the fuel pump driver module that is bolted in the trunk by the spare tire SEE FIGURE 14 60164_revG Page 80 of 87 FIGURE 14 9 Cut the white wire on the harness that goes to the fuel pump driver module It is the first wire on the harness from the left side SEE FIGURE 15 FIGURE 15 10 Using the supplied blue butt connectors attach the red wire from the MSD harness to the white wire on the fuel pump driver module and the orange wire from the MSD harness to the white wire on factory harness Once completed tie strap the MSD wires to the harness SEE FIGURES 16 18 FIGURE 16 FIGURE 17 m PA b X JJ 60164 revG Page 81 of 87 FIGURE 18 11 Re install trunk liners CLEAN UP 1 Bolt offset brackets P N 22087 to both sides of sub frame with two M10 bolts P N 30943 and lock washers P N 30805 Bolt factory sub frame brace to offset brackets using factory nuts FIGURE 1 FIGURE 2 2 Review these instructions to make sure that all fasteners clamps amp electrical connections have been installed and torqued correctly 3 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 pr
23. bypass P N 30359 valve to pipe as shown P N 22032 SEE FIGURE 1 FIGURE 1 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 FIGURES 2 4 FIGURE 2 FIGURE 3 60164 revG Page 61 of 87 FIGURE 4 3 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 5 FIGURE 5 4 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 SEE FIGURE 6 FIGURE 6 60164 revG Page 62 of 87 5 T E EZZ Slide a 45 2 5 3 00 diameter coupler P N 22080 4 over the driver side intercooler inlet Loosely secure with a 52 hose clamp P N 309414 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 7 amp 8 FIGURE 7 iba 8 Adjust the turbo to intercooler piping on the driver side so tha
24. cessary If you are experiencing any issues of idling bucking running extremely rich or poor performance ensure that all hose clamps are tight and all hoses are installed properly and that there are no air leaks of any kind in the plumbing from turbo to intercooler to throttle body If you need any technical support call us our tech lines are open Monday through Friday from 8am to 5pm at 805 581 0333 or go to our website at www Turboneticsinc com to our forums under Tech Support Enjoy the boost 60164 revG Page 86 of 87 URBON EES 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 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
25. customer service staff INFORMATION REGARDING DIFFERENCES IN MODEL YEARS Ford made minor revisions in model year 2007 but there is no defined cut off date for these changes between 07 08 from Ford The major changes they made was changing the type of spark plugs thread size is a different diameter and minor changes to the cooling system thermostat location and rad hose were made This kit comes with spark plugs for both early and late model engines The easiest way to check if you have an early or late style engine is to check the color of the boots on the coil packs the boot that connects to the top of the spark plug The early style motors have BLACK boots and will use supplied spark plugs in this kit of P N 31296 the later style motors have BROWN plug boots and will use the P N 31297 spark plugs supplied in this kit If you have BROWN plug boots you will also have to change the thermostat which is supplied in this kit also 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 prop
26. e 31 of 87 2 Cuta piece of the included 5 8 diameter rubber hose 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 2 FIGURE 2 5 8 3 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 5 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 3 FIGURE 3 60164 revG Page 32 of 87 portion of the t fitting towards the passenger side Secure with a hose clamp P N 30817 SEE FIGURE 4 7 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 4 FIGURE 4 8 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 5 FIGURE 5 TURBO OIL DRAIN INSTALLATION 1 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 pour out of the hole pushing out the metal shavings The drill bit may also be coated with grease in o
27. emove the metal clips from the stock injectors Install them onto the new injectors P N 31282 as pictured SEE FIGURES 6 amp FIGURE 6 FIGURE 7 INJECTORS PN 31282 7 Lubricate 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 8 60164 revG Page 27 of 87 FIGURE 8 8 Plug the harness back on all the injectors SEE FIGURE 9 FIGURE 9 9 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 FIGURES 10 amp 11 FIGURE 10 FIGURE 11 Fuel Pressure MAP Sensor 10 Repeat the injector install steps 1 8 on the driver s side of the engine SEE FIGURE 12 amp 13 FIGURE 12 FIGURE 13 60164 revG Page 28 of 87 INTERCOOLER INSTALLATION 1 Using a 13mm deep socket remove the 4 inner 2 passenger side 2 diver side bolts from the front bumper support SEE FIGURES 1 amp 2 FIGURE 1 FIGURE 2 60164 revG Page 29 of 87 2 Install the four included M8 1 25 x 30 mm long bolts
28. erly 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 Ford factory service manual for your model year Mustang 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 NPT thread sealant Loctite threadlocker High Temp Sensor Safe RTV Sealant Replacement engine oil and oil filter Hammer Drill Bench Clamp omall Container 60164 revG Page 2 of 87 TERRE SYSTEMS e Pinch Hose Clamp Pliers 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 13 1 4 or 6mm p 5 16 or 8mm 3 8 or 10mm NPT fittings 2 3 turns past finger tight TURBOCHARGER SYSTEM PARTS LIST qu e 1 Coolant Reservoir EN E 1 31283 11 Fuel Controller Diab
29. et 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 FIGURES 35 amp 36 FIGURE 35 FIGURE 36 i EE ie 60164 revG Page 19 of 87 19 2005 2009 model year vehicles om to STEP 20 On 2010 model year vehicles using a pair of pliers oqueeze the two tabs on the hose clamp together and pull the plastic flex tube out of the factory intake pipe Set the flex tube to the side It will be re installed onto the new supplied intake pipe SEE FIGURE 37B FIGURE 37B 20 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 FIGURES 38 amp 39 FIGURE 38 FIGURE 39 ZH F F SFA 21 Loosen the hose clamps holding the intake arm onto the throttle body and the factory intake box SEE FIGURES 39 41 60164_revG Page 20 of 87 p PrF Be F fi j E d y F i a L fe F FIGURE 39 22 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 23 Unclamp and remove the overflow hose from the coolant reservoir The coolant reservoir is located on
30. exhaust pipes to free the crossover section of the exhaust Remove the crossover pipe Leave the clamps for later use SEE FIGURES 15 17 FIGURE 15 FIGURE 16 FIGURE 17 60164 revG Page 43 of 87 a y TEMS 12 Using a 10 mm socket remove the two upper radiator brackets from the radiator support SEE FIGURE 18 amp 19 FIGURE 18 FIGURE 19 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 20 FIGURE 20 60164 revG Page 44 of 87 i E P LL C R Va TURBO 5 YSTEMS 14 Reinstall the upper radiator support brackets Use the new holes to secure the brackets to the radiator support SEE FIGURES 21 amp 22 FIGURE 21 FIGURE 22 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 FIGURES 23 amp 24 FIGURE 23 FIGURE 24 upw F I 16 Slip the exhaust y pipe P N 22037 on the ends of the catalytic converters with two 2 72 clamps To ease installations loosen the bolts on each of the catalytic converters with a 15 mm socket Leave all clamps in this section loose until all parts are
31. ke hose SEE FIGURES 40 43 FIGURE 40 FIGURE 42 60164 revG Page 71 of 87 TURBO SYSTEMS FACTORY BREATHER HOSE 25 Insert the fittings that you just cut onto the breather port on the valve cover located by the oil fill cap Slide a pinch clamp P N 31288 onto the 3 8 hose you just routed underneath the throttle body from the turbo to filter pipe and insert the 3 8 hose onto the fitting and secure by crimping the pinch clamp using a pinch clamp pliers SEE FIGURES 44 amp 45 FIGURE 44 FIGURE 45 26 Install cast 90 deg intake pipe P N 11411 into boost tube P N 21675 with 44 clamp Install 4 coupler P N 30302 4 onto cast pipe with 72 clamp SEE FIGURE 46 amp 47 60164 revG Page 72 of 87 me FIGURE 46 FIGURE 47 2 At this stage tighten the compressor and turbine housing bolts that you loosened in the turbo installation procedure 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 FIGURES 48 amp 49 FIGURE 48 FIGURE 49 28 Install the factory MAF meter into cast intake pip P N 11361 and secure the sensor to the tube using the provided screws SEE FIGURE 50 FIGURE 50 60164 revG Page 73 of 87 A 3 g i 1 tm a i aT 27 i LY TURBO SYS TEMS 29 Insert the cast intake pipe P N 11361
32. lo rr eee NENNEN 60164 revG Page 3 of 87 A ee 31292 60164 revG Page 4 of 87 DESCRIPTION DESCRIPTION HARDWARE KIT 11294 NUTS BOLTS FITTINGS PARTS LIST Flange Oil Drain 1 2 Npt Fitting Tee 5 8 Barb to 6AN Fitting Tee 3 4 Barb to 6AN Fitting 1 4 to 1 8 Adapter Fitting 3 8 Hose 1 8 NPT gt aon Screw M4 0 7 x 10mm Button 2 31071 Head Cap Sr Fitting Reducer Tee 1 4 1 4 Fitting 1 8 Npt X 5 32 90 2 31141 3 16 dum Bolt Hex Hd M10 1 25 x Screw 5 16 18 X 1 Hex Hd 2 31166 50mm 30575 Bolt M6 1 0 X 16MM 31286 Fitting 1 2 NPT X 1 2 Straight Plug 7 NPT Hex Plug 74 NPT Socket Head Fitting 3 8 NPT x 7 Straight Fitting 72 NPT x 1 2 Straight Fitting 74 NPT Brass 8 30803 Nut Hex M10 1 25 Plug 54 NPT Brass Fitting 2 NPT x Straight Fitting T 5 32 Hose HARDWARE KIT 11252 FUEL COMP TS PARTS LIST 2 43620 Cable ties Nylon 8 8 31297 Spark Plug 07 09 Mustang 31222 Harness extension MAF snsr 31298 11 Fuel Pump Booster Prog d 8 31282 Fuel Injector 39Ib hr 31319 Fuse Block Blade Mini Fuses 31294 Check Valve Inline 3 8 Hose 31320 Fuse Blade 32v dc 30 amp 31295 Thermostat 160F 2007 2009 31321 Butt Splice Crimp 10 12 Awg 8 31296 Spark Plug 05 06 Mustang 60164 revG Page 5 of 87 DESCRIPTION DESCRIPTION HARDWARE KIT 11310 CLAMPS
33. 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 11 FIGURE 11 60164 revG Page 36 of 87 M TURE 8 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 AAN 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 12 TEMS FIGURE 12 1 4 NPT T Fitting 1 4 to 1 8 NPT Fitting 9 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 13 FIGURE 13 _ 60164_revG Page 37 of 87 a AEON 7 Ke S 2 TURES SYSTEMS 10 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 14 amp 15 FIGURE 14 FIGURE 15 11 Install the
34. ovide adequate slack for engine movement 4 Reinstall the body work and battery in the reverse order of its removal 5 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 60164 revG Page 82 of 87 TES 7 URED s YSTEMS 6 The use of premium octane 91 unleaded fuel is required for proper engine performance and to reduce the possibility of internal engine damage from detonation CARB EO SPARK PLUG GAP amp FUEL DECAL 1 Included with each Turbonetics Mustang GT turbo kit are adhesive backed decals with the CARB E O number that is associated with this product the spark plug gap spec and the premium fuel required decal Both the CARB E O and spark plug gap spec decal is required to be adhered in the engine compartment that is visible and easily located by Smog Check and Service technicians Turbonetics suggest adhering this label on the factory plastic upper cooling panel where the hood latch is located Clean plastic surface first to ensure there is no oil dirt debris that will prevent the sticker from adhering properly SEE FIGURE 1 FIGURE 1 CARB Decal TUM wmbr inu uui CARI Eni enr Can j FREQ SAAR Puna car Spark Plug 0 030 0 a f Pe yer Gap Decal i 2 Adhere the premium fuel required decal on the
35. rder to catch metal chips SEE FIGURES 1 amp 2 FIGURE 1 FIGURE 2 60164 revG Page 33 of 87 S weit sO or Aso Tf 6 ie de rui Fa FES F ri i J fa MEET Fo i F 7 LN Se MEET Oo 2 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 FIGURES 3 amp 4 FIGURE 3 FIGURE 4 3 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 1 2 barbed fitting P N 31285 before using more than half the threads on tap SEE FIGURE 5 FIGURE 5 60164 revG Page 34 of 87 4 Using Teflon tape or other thread sealant coat the threads of the 3 8 NPT x 1 2 barbed fitting Install it into the oil pan SEE FIGURES 6 amp 7 FIGURE 6 FIGURE 7 Cut a piece of 1 2 hose P N 31290 to a length of 32 Install the hose on the end of the barbed fitting installed in the oil pan Secure with a pinch hose clamp P N 31287 Direct the free end of the hose up to the top of the engine bay by the radiator fan shroud SEE FIGURES 8 10 FIGURE 8 FIGURE 9 nis FIGURE 10 60164 revG Page 35 of 87 6 Drain the rest of the oil from the engine 7 Locate the oil pressure sensor on the oil filter housing The oil filter housing is
36. rders 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 60164 revG Page 87 of 87
37. reservoir using 20 clamps For years 07 09 connect 1 hose from lower radiator hose to coolant reservoir SEE FIGURE 25 amp 26 FIGURE 25 FIGURE 26 17 Clamp coolant reservoir to power steering reservoir Connect the 5 16 hose from top of radiator to Coolant reservoir using stock clamps SEE FIGURE 27 amp 28 60164 revG Page 68 of 87 d P FN aum oum F F n _ x SYSTEM FIGURE 27 FIGURE 28 18 Using a T20 torx driver remove the MAF sensor from the factory air box SEE FIGURE 30 FIGURE 30 19 Install MAF block off plate P N 22034 onto stock air box using factory screws SEE FIGURES 31 amp 32 FIGURE 31 FIGURE 32 20 Reinstall stock air filter box SEE FIGURE 33 60164 revG Page 69 of 87 famam F ys 7 MS FIGURE 33 21 Install intake tube P N 22032 for model years from 05 09 and intake hose P N 22079 SEE FIGURE 34 22 Connect a 5 piece of 1 hose to intake tube using 1 fitting P N 22045 and two 24 clamps SEE FIGURE 35 Connect hose to bypass valve with 24 clamp SEE FIGURE 36 FIGURE 34 FIGURE 35 60164 revG Page 70 of 87 A f TURBO SYSTEMS ry FIGURE 37 23 Attach one end of 3 8 hose P N 31289 to intake tube and attach with pinch clamp SEE FIGURES 38 amp 39 FIGURE 38 F RI Sy FIGURE 39 4b 24 Cut one of the fittings off the factory breather hose that goes from the valve cover to the factory inta
38. se 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 next to the driver side of the ECU SEE FIGURES 24 amp 25 FIGURE 24 FIGURE 25 60164 revG Page 16 of 87 S wait sO or A ET B 0E F rae i J E MEE MEET To i r AN LN 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 FIGURES 26 amp 27 FIGURE 26 FIGURE 27 12 Using a 10 mm socket remove the 2 upper bolts on the ECU bracket SEE FIGURES 28 amp 29 FIGURE 28 FIGURE 29 13 Remove the ECU from the engine bay SEE FIGURE 30 FIGURE 30 60164 revG Page 17 of 87 TEMS 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 T ps M In a n Um n 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 60164 revG Page 18 of 87 FIGURE 33 17 Using an 8 mm sock
39. t 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 3 00 diameter connector P N 30440 4 on the short straight of boost tube 3 P N 21675 Loosely secure with a 36 hose clamp P N 30615 SEE FIGURE 12 60164 revG Page 63 of 87 EMS 9 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 9 FIGURE9 To Intercooler 10 Place a 52 hose clamp P N 30615 on the open end of the connector on boost tube 3 Install boost tube 3 onto the passenger side intercooler outlet The 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 10 FIGURE 10 60164 revG Page 64 of 87 11 For 05 06 model years skip to step 12 For 07 09 models replace thermostat by removing two M8 bolts on thermostat housing cover Remove factory thermostat and replace with 160F unit provided P N 31295 Using a 72 drill bit enlarge the ID of the PCV port just above the thermostat housing Use a small amount of grease to catch plastic Push check valve P N 31294 into PCV port with o ring visible as shown Replace factory hose onto port SEE FIGURE 11 16
40. ter lines downwards towards the oil drain flange Tighten the banjo bolts using a 24 mm socket SEE FIGURE 3 FIGURE 3 60164 revG Page 55 of 87 li He E a LY TURBO SYS TEMS 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 The oil inlet of the turbocharger should be aligned straight up at the 12 o clock position NOTE You will need to loosen all the turbine and compressor housing cover bolts in order to clock them into the necessary positions SEE FIGURE 4 FIGURE 4 Ensure oil inlet 1s eointed straight up in the 12 o clock position Loosen 6 bolts on each compressor and turbine housings then rotate housings and center section to correct orientation 6 Connect the 1 2 oil drain line to the 1 2 barbed fitting installed on the bottom of the turbocharger center housing Secure with a hose clamp P N 30817 SEE FIGURES 5 amp 6 FIGURE 5 FIGURE 6 60164 revG Page 56 of 87 7 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 7 s T 8 Check the clearance between the side of the compressor cover and the alternator pulley There should be about 8 mm of clearance
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