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TERMS AND CONDITIONS The following Terms and Conditions are effective November 1, 2006 and are subject to change without notice. SHIPPING DAMAGE CLAIMS A claim for damage in transit must be made by the customer directly to the shipping agency as soon as the damage is discovered. TurboKits.com is not liable for the condition of the merchandise as handled by the shipper once the shipper has accepted delivery from TurboKits.com. RETURNED GOOD AUTHORIZATION TRACKING NUMBER TurboKits.com will only accept product returns, repair orders / upgrades, and warranty requests that have been approved and are returned with a corresponding Return Authorization (RA) tracking number. Contact TurboKits.com for approval and the RA number. Write the RA 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. RETURN POLICY All returns & cancellations are up to the sole discretion of TurboKits.com. Return must be made within 15 days of receipt. Please open and inspect all packages as soon as they are received. There will be a 20% cancellation / restocking fee assessed to all returns. Installed parts are not eligible for return. "Custom Order" and "Made to Order" parts are sold "as is" and are not eligible for return or cancellation. No goods will be accepted without prior return authorization from TurboKits.com. Call for approval and RA (Return Authorization) number. *No returns will be accepted without an RA number. *No returns will be accepted after ninety (15) days from the original shipping date from TurboKits.com unless approved. *All approved returns are subject to a 20% restocking charge NO EXCEPTIONS. *The original invoice must accompany the return. *Approved returns will be issued credit only. REFUSED SHIPMENTS Sending a shipment back to TurboKits.com does not automatically constitute the right to a refund or credit. TurboKits.com may, at its discretion, require different payment means for any reshipped refused shipments. It is the customer's responsibility to make all arrangements with TurboKits.com for disposition of the refused shipment. Customer is responsible for all outgoing and return shipping and handling charges regardless of disposition of refused shipment. WARRANTY PROGRAM TurboKits.com will repair or replace any new TurboKits.com products that fail, including products used in racing or competition applications, for a period of one year from the original date of purchase. Warranty is limited to TurboKits.com products and does not include progressive or subsequential damage and does not cover removal or installation labor or associated parts. Warranty is non-transferable and must be processed via the original purchaser from TurboKits.com. Contact TurboKits.com for return approval, RA (Return Authorization) number, and shipping method PRIOR to sending the product to TurboKits.com. Our Customer Service Representative will provide packaging and shipping instructions. Please include your invoice with the shipment. TurboKits.com 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.
3) Remove factory air box (see Fig. 3) 4) Remove intake flapper control switch (see Fig. 4) 5) Remove Mass Air Sensor from stock air box (see Fig. 5) *note: place this in a clean place for reinstallation 6) Remove Stock Intake Tube (See Fig. 6) *note: now is a good time to clean throttle body if needed
7) Unplug factory injectors (see Fig. 11) 8) Remove stock fuel rail (see Fig. 12) *note: Make sure you keep the factory fuel rail spacers
9) Remove factory fuel injectors (place paper towels into holes to stop fuel from leaking into intake), remove factory injector o-rings and swap o-ring onto supplied injectors, they may be loose, but will seal under the pressure of the fuel rail bolts. (see Fig. 13, 14, 15) 10) Install supplied injectors back into intake plenum using lubrication; you can use some of the fuel that leaks from the stock injectors or o-ring lubrication. Be careful not to tear or rip the stock o-rings as this may cause a vacuum leak. Make sure the grommets are not crimped when installing the injectors back into the intake plenum. Reinstall the fuel rail spacers and the fuel rail. (see Fig. 16)
11) **IF YOU PURCHASED THE DROP IN INJECTORS SKIP THIS SECTION**Cut factory fuel injector clips from harness at the clip, making sure you leave enough wire to wire in the supplied clips, trim back harness covering to expose injector wires. (see Fig. 17, 18) *note: a crimp/splice tool makes this job much faster 12) Remove grommet from supplied injector clips, slide wires through the grommet and then clip, making sure you keep the common ground location consistent on all injector clips. (see Fig. 19, 20) 13) Strip wire about inch, crimp supplied injector pins onto wire, install pins into supplied clip and reinstall onto supplied injectors. (see Fig. 21, 22, 23) *note: these will snap and lock into place on the clip & injector
4) Drain oil (see Fig. 28) 5) Drain transmission fluid (see Fig. 29)
6) Remove passenger side wheel 7) Remove strut mounting bolts (see Fig. 30) 8) Remove wheel speed sensor bracket and brake line bracket (see Fig. 31)
9) Remove axle nut (see Fig. 34) 10) Pull wheel hub out as to remove the axel from the transmission (see Fig. 35) 11) Remove axel (see Fig. 36, 37) this allows ample room for installing manifold & turbo
13) Remove header bracket (see Fig. 38) 14) Remove lower factory header heat shield to allow access to header nuts (see Fig. 39) 15) Unbolt upper factory header heat shield and move to the side
5) Crimp and cut heater core supply line (see Fig. 46) 6) Attach supplied plastic barbs to stainless steel braided -8 water supply lines (see Fig. 47)
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7) Attach supplied stainless steel -8an water lines to each end of cut heater core supply line using supplied worm drive clamps (see Fig. 48) *trick, tighten worn gear clamps partially before installation
8) Install 2 Coupler & (2) t-Bolt Clamps to turbo outlet 9) Install Turbocharger & Manifold to the engine. Now is a good time to replace the factory gasket, torque to factory specs (see Fig. 49) *note, insert turbo end first and then rotate 180 degrees as you bring the manifold up to the manifold studs. This is very tight and tricky, but it does fit, be patient. 10) Install the (2) -8an Stainless water lines onto the turbocharger & supplied blue aluminum AN hose fittings (see Fig. 49)
11) Gently push the power steering line towards the block to make room for the air filter (see Fig. 50) 12) Install supplied K&N Filter & tighten (see Fig. 51) *note, if you slip the front of the filter through the wheel well it makes it much easier to attach to the turbo inlet.
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13) Remove engine mount damper (see Fig. 52) 14) Take soft rubber mallet and dent stock heat shield, not mandatory, but good idea to while youre under there (see Fig. 53)
15) Install supplied M8 x 40mm Stud into far bolt hole on the turbocharger (see Fig. 54) 16) Install downpipe with supplied bolts, washers & high temp RTV silicone (see Fig. 55, 56, 57) *trick, install front bolt & washer first, this allows you to rock the downpipe as you install the nut onto the stud, use alan wrench for the bolts 17) Reinstall engine mount damper & 1st 02 sensor 18) Here is where you have a muffler shop install a high flow CAT and 3 all the way back or have them tie into your current exhaust.
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19) Remove factory oil pan, mark oil pan 2.5 from the inside and as far to the top as possible (see Fig. 61) 20) Drill a pilot hole and use a stepper bit to drill hole out to 9/16ths (see Fig. 62) 21) Tap hole with 3/8th NPT tap (see Fig. 63) *note, using grease on the tap helps keep debris down to a minimum 22) Install supplied 3/8th NPT drain line fittings into oil pan using High Temp RTV Silicone (see Fig. 64) 23) Reinstall factory oil pan using High Temp RTV Silicone. (see Fig. 64)
24) Install supplied -10an stainless steel braided oil drain line to the appropriate fittings on the turbo & oil pan (see Fig. 65) *note the line must not have even the slightest uphill, ball bearing turbos are very temperamental with oil back up and pressure, any sag in the line can cause oil seal issues with the turbo.
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25) Remove factory oil pressure sending unit harness plug and factory sending unit (see Fig. 66) 26) Install factory oil pressure sending unit into supplied oil tee (see Fig. 67) 27) Install oil tee into factory oil pressure sending unit location (see Fig. 68) *note, 1/8 NPT tap lightly screwed into the stock location first make this easier. DO NOT FORCE. 28) Install oil feed fitting to oil feed tee (see Fig. 68) 29) Install oil feed line to oil feed fitting (see Fig. 68) 30) Wire tie oil feed line to center cross member (see Fig. 69) 31) Reinstall factory oil pressure sending unit harness clip.
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2) Install Pipe #1 w/ 2 couplers and T-Bolt Clamps (see Fig. 71, 72)
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3) Install Pipe #2 w/ 2 2.5 coupler, 2.5 and T-Bolt Clamps (see Fig. 72, 73, 74) *note, you will have to trim the plastic undercarriage for this pipe to fit
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5) Install Pipe #3 w/ (2) 2.5 Couplers and T-Bolt Clamps & add BOV (see Fig. 75, 76) *note, you may have to trim the plastic undercarriage for this pipe to fit
6) Install Pipe #4 w/ 2.5 Coupler & T-Bolt Clamps (see Fig. 79, 80)
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7) Support Intercooler with jack stands or muffler stands to aid in alignment as you attach Pipe #2 & #3 (see Fig. 81) *note: align intercooler with bottom of radiator support as a guide.
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8) Mount BOV onto Pipe #3 and install w/ 2.5 Couplers & T-Bolt Clamps. 9) Mount Factory MAF onto Pipe #4 w/ supplied screws 13) Align intercooler to the center of the bumper opening (see Fig. 89) 14) Align bracket to the bottom of the radiator support and front of the intercooler tab and drill 2 pilot holes with 1/8th bit (see Fig. 90) 15) Install intercooler brackets with supplied self tapping screws (see Fig. 90) 16) Align front of bracket with FMIC tabs, drill hole w/ 9/32nd Drill Bit , install and tighten with supplied M6 bolts, nuts & washers (see Fig. 90) * note: wait to reinstall all of the undercarriage plastic until you test the install for leaks.
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19) Reinstall passenger side axel, wheel speed sensor, brake line and fill tranny with gear oil. *note: now is a good time to upgrade to high grade gear oil 20) Remove Valve Cover Vent from Throttle body and cap Throttle body with supplied rubber cap. (1ZZ see Fig. 93, 2ZZ see Fig. 94) * note: leave the valve cover vent hose open to the atmosphere.
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Wiring ECU *** This kit includes a base map only, professional tuning to your specific application is strongly suggested ***
1) Locate the factory ECU 2) Remove the factory plugs. (see Fig. 96) * note: leave the factory ECU unplugged until you are ready to start the vehicle. This will allow it to reset all stored fuel trims, etc. 3) Wire ECU according factory manual wiring instructions, or use TurboKits.com Plug n Play Harness
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7) Install Water Injector following the included instructions; do not over tighten the plastic fittings they will crack. * note: only for water injection upgrade 8) Vacuum Lines: Run 1st tee off throttle body & Remove VSV Plug (see Fig. 97), run lines to BOV, Wastegate, Boost Gauge and Pressure sensor from water injection. (see Fig. 98, 99) * note: make sure you wire tie all fittings.
Setting Up AEM FIC: Great info here: http://forum.aempower.com/forum/index.php/topic,24954.0.html Setting COM Port: http://www.youtube.com/watch?v=HEmhw0v8Y4o&feature=player_embedded Open the base_cal.fi6 map in FIC folder on your hard drive. Then File --> Save As --> Rename it to Turbo-Base. Next step is to open the Turbo-Base.fi6 file and click connect to FIC. A warning box will come up telling you that the maps don't match and to either pull from the FIC or write to the FIC. You want to pull FROM FIC. Once this is done, click File --> Save As --> Rename it to Turbo-Base-2 to have as a backup. Disconnect the FIC and close the map. Then re-open the Turbo-Base.fi6 file and click connect to FIC. Next find the "Set Up" menu at the top and click Set Up --> Calibration --> a separate box will open up which will allow you to set the TPS (Throttle Position) and the RPMs. These are self explanatory settings and the software will walk you through the steps. Once the RPMs & TPS are set, you are done, the MAP is already on the FIC. Start the car, let it warm up and idle, check for leaks, etc. Once the car is warm, shut it off and carefully (we use a oven glove) retighten the bolts on the manifold to head, manifold to turbo and turbo to downpipe. The initial heat cycle of the parts will give you a great opportunity to crank everything down.
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Final Checklist
Review these instructions to make sure that all fasteners, clamps & electrical connections have been installed & torqued correctly. 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. Reinstall the body work in the reverse order of its removal. Refill all fluids (oil and coolant) to factory recommended levels. Use regular non synthetic (factory weight) motor oil for the first 500 miles to allow the turbo rings to seat properly during the turbo break-in. The use of synthetic oil (with the factory recommended oil weight) is strongly recommended after proper turbo break-in, 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. The use of premium octane unleaded fuel (94 where available, if not 93 or 91) is required for proper engine performance and to reduce the possibility of internal engine damage from detonation.
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