1

(1) VERIFY WITH YOUR SUPPLYING DEALER THAT YOU HAVE THE CORRECT APS COMPUTER PROGRAM FOR YOUR PARTICULAR COMBINATION OF GASOLINE AND EXHAUST COMPONENTS

(2) Verify that you have all necessary tools as listed.

(3) Clean all air ducting prior to commencing installation.

(4) The sequence of installation of each part is very important. It needs to be carried out exactly as outlined in the instructions. Failure to do this will result in an unnecessary level of frustration.

(5) Choose a NGK spark plug, per the following application outline and ensure you have a set on hand.

PLFR5A-11 Stock - Should only be used with totally stock exhaust system. Boost below 8 PSI, ambient temperature below 60°F.

PLFR6A-11 Service Option - Should be used for general street operation work with cat-back exhaust system. Boost 8-9 PSI, ambient temperature 60°-100°F.

PLFR7A-11 Service Option - Drag racing in an ambient temperature range of 60°-100°F.

PLFR8A-11 Service Option - Road racing or any other forms of competition in an ambient temperature over 100°F.

Always use fuel with a minimum octane rating of 91 (R+M)/2. (Equivalent to 96 RON).

Always use an oil graded for use with gasoline-turbocharged engines.

Depending on your chosen application, an engine oil cooler and/or larger capacity radiator may be required.

The APS turbosystem is primarily intended for installation by qualified technicians in fully equipped workshops. If this installation is attempted in a non-professional environment, all personal safety obligations rest with the individuals(s) concerned.

The minimum requirements (and by no means an exhaustive list) are:

§ Well ventilated environment.

§ Clean flat and level floor.

§ High quality vehicle stands.

Required Tools

(1) Metric

· ¼” drive socket set c/w universal coupling – 6 to 16 mm.

· 3/8” drive socket set c/w universal coupling – 10 to 20 mm.

· Wrench – open end/box combination – 8 to 22 mm.

· Hex key – 4 and 5 mm.

(2) Imperial

· Wrench – open end/box combination – ½” to ¾”.

(3) General

· Screw driver set.

· Pliers – flat, point, side cutter, multigrip.

(4) Sealants

· Permatex ultra copper – P/N 101BR.

· Permatex ultra grey – P/N 599 BR.

· Loctite thread sealer – P/N 567.

350Z Disassembly

NOTE

IT IS RECOMMENDED THAT THE FACTORY SERVICE MANUAL BE FOLLOWED WITH STOCK COMPONENT REMOVAL AND REPLACEMENT.

(1) Remove the retaining clips and screws and remove the front bumper. (If unsure of this procedure, you should use the factory service manual or have qualified personnel undertake the work).

This is suggested as the first step since the vehicle is still mobile at this stage and the work can therefore be undertaken away from the actual turbosystem installation location. In addition, it reduces the likelihood of body damage to the vehicle while undertaking the mechanical work.

(2) Remove the battery shroud and LHS and RHS false firewall cover to windscreen. Disconnect the earth cable from the battery.

RAISE VEHICLE

(3) Remove the plastic undertray from beneath the engine, along with the plastic vertical side panels, which run from the undertray to the frame rails. Retain for later use.

(4) Remove plastic vertical front panel from aluminium bumper beam and discard.

(5) Remove aluminium impact beam and retain.

(6) Drain all the engine coolant, (retain for later re-use). The drain plug is in the bottom of the radiator.

(7) Drain all the engine oil, (replace with new oil after installation completion).

(8) Remove the front ‘Y” pipe of the stock exhaust system.

(9) Remove the catalytic converter support bracket from the bottom of the transmission. Remove the rear 02 sensors.

(10) Remove both catalytic converters.

(11) Remove lower K frame tubular support structure.

(12) Remove the stock 10mm stud from each exhaust manifold outlet flange. Trim the excess length of mounting stud, protruding through the stock heat shield, under the LHS floor.

(13) Remove the bolts retaining the steel oil pan and remove same, avoiding damage to the gasket-sealing surface. Remove the two retaining bolts and stock oil pickup. Discard the pan, all bolts. Retain the pickup.

(14) Remove the stock oil pressure sensor from lower front RHS of the engine. (Beside oil filter). Retain the sensor for re-use.

(15) Trim 1.0” from the low-pressure power steering oil return hose where it connects to the steering rack.

(16) Remove and discard the stock flexible clutch line, between chassis rail and slave cylinder. Remove stock slave cylinder heat shield.

LOWER VEHICLE

(17) Drain power steering pump oil, (retain for later re-use).

(18) Remove the stock power steering cooler, mounting brackets and cooler lines back to the stock connection immediately behind the radiator, adjacent to the RHS frame rail. Retain only the power steering cooler for re-use.

(19) Remove the air ducting between throttle body and MAF meter and discard.

(20) Remove the complete air cleaner/MAF meter assembly and discard.

(21) Remove the MAF sensor from the MAF housing and retain for later use.

(22) Remove the fuel cap in order to vent the fuel tank.

(23) Remove the front strut tower brace and the cosmetic engine cover.

(24) Unplug all the electrical wiring, coolant hose (below throttle body) and vacuum hose connections to components attached to the plenum chamber – upper.

(25) Remove the plenum chamber – upper.

(26) Remove the plenum chamber – lower.

(27) Remove the fuel rail assembly retaining bolts and isolators.

(28) Unplug the stock injector-wiring loom from the injectors. Remove complete fuel rail assembly, together with all six injectors.

(29) Remove the injector retaining clips and remove the stock injectors from the fuel rail assembly. Discard the injectors.

(30) Cover the six open ports in the intake manifold lower, in order to prevent foreign object entry.

(31) Remove the stock fuel injector-wiring loom. This unplugs from the main loom at the rear of the intake manifold and will usually require the cutting of a band of electrical tape around the main loom. Discard the stock fuel injector loom.

(32) Remove the stock spark plugs and discard.

(33) Remove the stock plastic air bleed Tee piece from the upper heater hose. Retain the clamps, discard the Tee.

(34) Bend the air conditioning line on top of the compressor towards the engine timing belt cover, leaving a 6mm gap between the line and cover.

(35) Release the belt tensioner and unbolt the air conditioning compressor from its mounting position on the side of the engine. Do not disconnect any air conditioning lines.

(36) Remove the 3/8” BSP tapered seal water drain plug from the side of the block immediately adjacent to the upper rear point of the air conditioning compressor and discard the plug.

(37) Remove both stock horns, the ambient temperature sensor and frontal impact sensor. Retain all parts for re-use.

(38) Remove the access trim in the cover panel behind the RHS seat. Remove the access panel in the floor covering the fuel/pump sender unit and disconnect the wiring harness.

(39) Disconnect the hard plastic line from the discharge port of the pump/sender unit. Cut the hard plastic line from both the stock quick connect hose end and the hard metal line running forward to the engine. Retain the stock quick connect hose end for re-use. Discard the hard plastic line.

(40) Remove the bolts retaining the pump / sender unit and remove same without damaging the fuel level sender float. Disassemble the unit, remove the stock fuel pump and stock fuel pressure regulator, and discard.

NOTE

IF NOT PROCEEDING WITH THE FUEL PUMP MODIFICATIONS STRAIGHT AWAY, IT IS SUGGESTED THAT THE OPENING IN THE TANK BE COVERED WITH STRIPS OF TAPE, IN ORDER TO PREVENT GASOLINE FUMES ESCAPING INTO THE WORK ENVIRONMENT.

350Z Assembly

1. TEST INSTALLATION OF TURBOCHARGER – DIAGRAM EMA/08 and TFA/08

(1) Install four 10mm studs (Item 73) in the rectangular flange of the turbocharger-mounting adaptor (Item 71). Install two 10mm studs (Item 73) and one 8mm stud (Item 75) in the triangular flange of the mounting adaptor (Item 71), which mates with the stock LHS exhaust manifold outlet flange.

(2) Temporarily install the turbocharger-mounting adaptor (Item 71) to the LHS stock exhaust manifold, using only the two 10mm nuts (Item 74), on the studs (Item 73). Re-use the stock exhaust manifold outlet flange gasket.

(3) Install the turbocharger assembly on the mounting adaptor (Item 71), retaining it with four 10mm nuts (Item 86) and four flat washers (Item 82).

(4) Install the oil drain/turbo mount bracket (Item 131) to the oil drain flange of the turbocharger, using two socket head bolts (Item 134), star washers (Item 149) and gasket (Item 133).

(5) Check alignment of the mounting holes in the oil drain/turbo mount bracket with the two bosses on the lower face of the bell housing. If these two holes do not correctly align, then the stock manifold retaining nuts must be loosened at the cylinder head. (Stock manifold heat shields will need to be removed and replaced). This will permit significant movement at the mount bracket (Item 131), allowing bolts (Item 130) and washer (Item 129) to be installed through the bracket and into the bosses on the bell housing. Then, re-tighten the exhaust manifold nuts at the cylinder head flange.

(6) Remove the turbocharger and oil drain/mount bracket (Item 131). Remove the turbocharger-mounting adaptor (Item 71). Ensure that no nuts/washers are misplaced, prior to final installation.

2. LOWER TURBOCHARGER WATER CONNECTION – DIAGRAM TFA/08

Install a straight adaptor, ³/₈^” BSP x ⁹/₁₆” JIC (Item 160) in the left hand side front of block coolant drain port, sealing with Loctite thread sealer. (Detail 10 of diagram – TFA/08 – water).

Connect the water hose assembly – LHS outer (Item 161) to the adaptor (Item 160), with the 45° hose end pointing forwards and slightly upwards. Do not tighten nut on 45° hose end. Hold the air conditioning compressor in position. Tighten the nut on the 45° hose end of the water hose assembly (Item 161), at the connection to the adaptor (Item 160), to clear the compressor.

Carefully routing the water hose assembly (Item 161) in front of the two air conditioning hoses coming off the compressor. The water hose assembly (Item 161) is then routed in a 180° bend back towards the firewall, outboard of the two air conditioning hoses. Re-install the air conditioning compressor, stock air conditioning drive belts and re-tension to factory specifications.

3. CLUTCH LINE INSTALLATION

Install new clutch line (Item 169) using copper washers, (Item 124) and re-using stock banjo bolt into the clutch slave cylinder. Carefully move the stock metal clutch line, where it passes beneath the LHS frame rail, forward an inch from its stock position.

4. COMPRESSOR INLET DUCT – DIAGRAM HFA/08

1.1 Remove the nut from the LHS engine mount lower retaining stud, below the cross member.

1.2 Raise the LHS of the engine, until the vehicle body also begins to lift.

1.3 Remove the stock air conditioning lines from the rubber grommets in the LHS false firewall.

1.4 Remove the stock steel brake line on the LHS shock tower from its plastic bracket and rubber grommet in the LHS false firewall. Lift the brake line above the upper surface of the shock tower. Remove the engine earth strap and connector from the inner fender.

1.5 Install the compressor inlet duct (Item 6) from above, between the stock air conditioning flexible hose and the inner fender. Replace the brake and air conditioning lines.

1.6 Lower the LHS of the engine, aligning the engine mount stud in the hole in the cross member. Install the stock nut and torque to factory specification.

1.7 Mount the compressor inlet duct (Item 6) to the inner fender, using the 6mm bolt (Item 22), through the tag on the duct and into the captive nut in the inner fender, used to terminate the stock engine earth strap. Do not tighten this bolt, at this time.

1.8 Hold the compressor inlet duct (Item 6) hard against the inner fender.

1.9 Place the duct support bracket (Item 20) on the lower face of the LHS chassis rail, mark holes and drill two ⅛” diameter holes. Install the bracket to the chassis rail using two self-tapping screws (Item 21). (Detail 1 of Diagram – HFA/08)

1.10 While maintaining maximum clearance from the duct to the stock exhaust manifold heat shield, attach the duct to the bracket, using a 50/70mm hose clamp, (Item 8).

5. AIR FILTER INSTALLATION – DIAGRAM HFA/08

Install air cleaner hose (Item 19), with hose clamp (Item 18) onto compressor inlet duct (Item 6). Route the air cleaner hose down between the inner fender and frame rail, ahead of inner wheel arch. Inspect clearance from air cleaner hose to exposed inner fender/frame sheet metal edges and glue protective rubber trim (Item 22) over exposed edges that may contact the air cleaner hose. Install the air filter assembly (Item 1) in the end of the air cleaner hose, clamping with hose clamp (Item 18) and a second hose clamp (Item 18) on the filter element. The air cleaner is supported by a bracket (Item 2), which is mounted to the lower left corner of the radiator support panel, using a hex head bolt (Item 3), washer (Item 4) and Nyloc nut (Item 5). The bracket is attached to the filter by the hose clamp (Item 18) immediately behind the element.

Install the ⁵/₈” breather hose joiner (Item 15), in the forward end of the stock breather hose that connects to the rear of the RHS camshaft cover, using the stock hose clamp. Install molded breather hose (Item 16) between joiner (Item 15) and ⁵/₈” barb on side of front end of the compressor inlet duct (Item 6). Retain the hose (Item 16) at both ends using spring clamps (Item 17).

6. GEARBOX/BELL HOUSING STOCK WIRING HARNESS RELOCATIONS

6.1 Unplug reverse light switch, speedometer, crank sensor plugs from stock sensors. Remove the loom from all plastic loom support clips as far along the loom as the grommet in the RHS false firewall.

6.2 Remove the loom support clip brackets on the top and side of the bell housing.

6.3 Install extended gearbox breather hose (Item 85) using hose joiner (Item 84). (Detail 8 of Diagram – EMA/08).

6.4 Re-position the loom forwards and upwards by mounting the loom clip normally attached to the top of the bell housing to the stock charcoal canister control valve-mounting bracket.

6.5 Route the loom between the stock small water hose and the stock temperature sensor mounted in the cast water cross over pipe at the rear of the engine, by removing and then re-fitting the small water hose.

6.6 Re-connect all the plugs into their sensors; however, the part of the loom running to the reverse light switch must be re-positioned over the top of the gearbox extension housing.

7. INSTALLATION OF CROSS-OVER PIPE – DIAGRAM EMA/08

7.1 Install two 10mm studs (Item 73) and one 8mm stud (Item 75) in the triangular flange, of the crossover pipe (Item 72). Install four 8mm studs (Item 75) in the small square flange.

7.2 Install the two heat shields (Item 77 and 78) and retain with steel tie straps (Item 80). Diagram EMA/08.

7.3 Install the crossover pipe (with heat shields attached), by feeding it over the top of the bell housing from the RHS.

7.4 Using the stock exhaust manifold outlet gasket, install the crossover pipe (Item 72) to the stock RHS exhaust manifold, using two 10mm nuts (Item 74) and one 8mm nut (Item 76) and one 8mm washer Item 83).

DO NOT TIGHTEN NUTS!

7.5 Ensure no part of the stock relocated wiring loom is within 1.0” of the outside of the heat shielding of the crossover pipe.

8. INSTALLATION OF TURBOCHARGER MOUNTING ADAPTOR - DIAGRAM EMA/08

8.1 Install the heat shield (Item 79) to the turbo mounting adaptor (Item 71) and retain with steel tie straps (Item 80). (Diagram EMA/08). Install the turbocharger mounting adaptor (Item 71) to the stock LHS exhaust manifold, using the stock gasket, two 10mm nuts (Item 74) and one 8mm nut (Item 87) and one 8mm washer (Item 83); while simultaneously feeding the four 8mm studs (Item 75) previously installed in the square flange of the crossover pipe, through the four matching holes in the square flange of the turbocharger mounting adaptor (Item 71). Ensure all mating surfaces are sealed with Permatex Ultra Copper, prior to installing turbo mounting adaptor (Item 71).

DO NOT TIGHTEN NUTS!

8.2 Install four 8mm nuts (Item 76) and 8mm flat washers (Item 83) on the four 8mm studs in the square flange connection between the crossover pipe and turbocharger-mounting adaptor. Tighten all four nuts.

8.3 NOW, TIGHTEN ALL NUTS AT THE OUTLET FLANGES OF BOTH STOCK EXHAUST MANIFOLDS.

9. INSTALLATION OF TURBOCHARGER

9.1 Install oil supply line (Item 153) in the oil inlet port of the turbocharger, using banjo bolt (Item 150) and copper washers (Item 151 and 152) so that the line routing is towards the engine, with the turbocharger in-situ. Tighten the banjo bolt (Item 150) so that the line is as far as possible from the turbine housing (i.e. angled towards the rear of the compressor housing).

9.2 Apply Permatex Ultra Copper to the mating surface and install the turbocharger on the turbocharger mounting adaptor (Item 71) using four 10mm nuts (Item 86) and four 10mm flat washers (Item 82).

DO NOT TIGHTEN NUTS!

9.3 Install the oil drain/turbo mount bracket (Item 131) and gasket (Item 133) to the oil drain flange of the turbocharger, using two socket head bolts (Item 134) and star washers (Item 149). If steps 2.1 through 2.6 have been performed correctly, the mounting holes in the drain/turbo mount bracket (Item 131) should align with the holes in the bosses in the lower surface of the bell housing. Install and tighten the two 10mm bolts (Item 130) and 10mm flat washers (Item 129).

9.4 Tighten the four 10mm nuts (Item 86) which retain the turbocharger to the turbocharger-mounting adaptor (Item 171).

9.5 Remove the drain/turbo mount bracket (Item 131) and all relevant fasteners/drain gasket. DO NOT LOSE!!

9.6 Install the two straight adaptors (Item 162) and copper washers (Item 144) in the water connection in each side of the turbocharger’s bearing housing.

9.7 Install 380mm flexible duct (Item 7) onto the lower end of the compressor inlet duct (Item 6), retaining with 60/80 hose clamp (Item 18). Ensure the flexible duct (Item 7) is placed over the compressor inlet of the turbocharger with the longer molded end to compressor inlet of the turbo and retained with 60/80 hose clamp (Item 18). The new clutch hose (Item 169) is routed under the flex duct.

10. WATER HOSE ASSEMBLIES – DIAGRAM TFA/08 – WATER

10.1 Connect the 90° hose end of the outer water hose (Item 161) to the adaptor (Item 162) installed in the outboard water port of the turbocharger, routed outside of the compressor inlet duct (Item 6) under the chassis rail. Connect the 45° hose end of the inner water hose (Item 166) to the adaptor (Item 162), in the inboard water port of the turbocharger and route the hose under and then up the RHS of bell housing, towards the heater hose.

10.2 Install the tee piece (Item 167) in the heater hose, in place of the stock heater hose plastic bleed port connector, previously removed. Ensure the ⁹/₁₆^”JIC tee takeoff points horizontally towards the engine.

10.3 Connect the 90°hose end of the inner water hose (Item 166) to the ⁹/₁₆^”JIC tee takeoff of the tee piece (Item 167). Tighten all nuts, while holding the water hose assemblies in order to prevent twisting of the Teflon braided line.

10.4 Re-install the drain/turbo mount bracket (Item 131), using the oil return gasket (Item 133), socket head bolts (Item 134) star washers (Item 149), into the turbocharger oil drain flange, 10mm bolts (Item 130) and flat washers (Item 129) into the bosses in the lower surface of the bell housing.

11. INSTALLATION OF TURBOCHARGER OUTLET – DIAGRAM TOA/08

Install the five studs (Item 58), in the five tapped holes in the rear of the turbine housing (Item 37). Install the turbine outlet adaptor (Item 64) to the rear of the turbine housing, sealing with permatex ultra copper and retaining with flat washers (Item 59) and self-locking nuts (Item 60). Tighten all nuts.

The actuator rod (Item 36) must now be connected to the pin of the small lever protruding from the side of the turbine outlet adaptor (Item 64). The actuator rod must be installed under tension (pre-load) from the actuator. The actuator rod (Item 36) should be adjusted to be 3/16” to ¼” short, in its relaxed position, prior to pulling out from the actuator, placing over the pin on the lever and retaining with the small circlip. Tighten the lock nut on the threaded section, against the end of the actuator rod (Item 36).

The intermediate pipe (Item 65) and, if re-connecting to the stock exhaust system, the adaptor cone (Item 67) can now be installed using gaskets (Item 69), bolts (Item 68), nuts (Item 60) and washers (Item 59).

If returning to the stock exhaust, bolts (Item 61), nuts (Item 63) and washers (Item 62) are used to connect to the stock flange. If APS’s true dual 2.5” system is being used, the cone is unnecessary, as an adaptor is available to make the transition directly from the APS intermediate pipe (Item 65).

With installation of any exhaust system, no bolts should be tightened, until all components are installed and the system can find its natural position. Carefully tighten all fasteners, moving backwards and forwards between flanges, ensuring no tightening action is placing the system under stress.

Never tighten fasteners from the front flange, moving back, locking up one flange after another!

Install the lower stock 02 sensors in the bosses provided at the front of the turbine outlet adaptor, facing inwards. Install plug (Item 53) and washer (Item 54) in the rear, onwards facing boss in the turbine outlet adaptor. This boss is provided for the installation of a wide band 02 tuning sensor.

12. TURBOCHARGER OIL SUPPLY TAKEOFF – DIAGRAM TFA/08-OIL

12.1 Install adaptor (Item 154G) in the¹/₈^”BSP port in the cylinder block, sealing with liquid Teflon.

12.2 Install adaptor (Item 154F) in the inlet port of the solenoid valve (Item 154), as indicated by flow direction arrow, carefully sealing with liquid Teflon.

12.3 Install adaptor (Item 154E) in the outlet port of the solenoid valve (Item 154) as indicated by the flow direction arrow on the body of the solenoid valve, carefully sealing with liquid Teflon.

12.4 Temporarily mount the solenoid assembly to the adaptor (Item 154G), previously installed in the cylinder block. Install the support bracket (Item 154A) to the rear of the solenoid, using bolts (Item 154E) and washers (Item 154D). Angle the solenoid to provide 1/8” clearance over hose.

Carefully bend the bracket by hand up towards the stock lower alternator bracket, until the solenoid support bracket end lies flat along the front face of the alternator bracket. Using the 6mm hole in the end of the solenoid support bracket as a template, mark a centre point on the alternator bracket.

12.5 Remove the solenoid/support bracket assembly. On the marked centre point, drill a 0.25” hole through the stock lower alternator bracket.

12.6 Re-install the solenoid/support bracket assembly. Install hex head bolt (Item 170) through the support bracket and alternator bracket. Install nut (Item 159) and flat washer (Item 142). Tighten all fasteners.

12.7 Install the tee piece (Item 155) onto the adaptor (Item 154E), positioning as illustrated and sealing with liquid Teflon.

12.8 Install the stock oil pressure sender unit in the rear facing port of tee piece (Item 155), install adaptor, (Item 156), (previously removed from the mechanical check valve), in the forward facing port of tee piece (Item 155), sealing with liquid Teflon.

12.9 Re-install the turbocharger oil supply line (Item 153) onto the adaptor (Item 156).

12.10 Plug the two wire loom (Item 154B) into the solenoid wires. Route the solenoid loom alongside the stock alternator loom, attaching it with seven tie straps (Item 168), until the solenoid loom is beside the loom wires powering the scavenge pump, at the scavenge pump power supply relay.

The small dark blue terminals (Item 154H) are wrapped around the red and black wires of the scavenge pump loom. They are closed by compression, using conventional pliers. The light blue terminals on the end of the solenoid loom are then attached to the dark blue terminals (Item 154H) , maintaining matching wire colors.

13. OIL PAN ASSEMBLY – DIAGRAM – TFA/08-OIL

Install the two “O” rings (Item 146) in the grooves either side of oil pump pickup spacer (Item 145). Using two hex head bolts (Item 147), flat washers (Item 148) and star washers (Item 149), install stock oil pump pickup and spacer. Tighten to 15 ft/lbs. (Detail 11 of diagram – TFA/08-oil).

Install the straight oil return adaptor (Item 138) into top facing RHS oil pan port. Install the plug (Item 126) in the LHS port, sealing with Loctite thread sealer. Install oil pan drain plug (Item 143) and copper washer (Item 144) into the drain port of the oil pan. Run a bead of Permatex Ultra Grey sealer around the flange face of the oil pan (Item 139).

Using the four long socket head bolts (Item 141) and four flat washers (Item 142), loosely mount oil pan to engine by the four through bolt positions.

Install all six socket head bolts (Item 140) and six flat washers (Item 142) through the outer flange holes. All bolts should be torqued to 10 ft/lbs. (Diagram – TFA/08-oil).

14. INSTALLATION OF SCAVENGE PUMP

14.1 Install the oil pump/transmission mounting bracket (Item 128) to the bosses in the lower surface of the gearbox, using the mounting rubbers and bolts from the stock catalytic converter support bracket. At the same time, install the stock rear 02-sensor plug bracket between the rear boss and the mounting bracket (Item 128). (Diagram TFA/08).

14.2 Install the scavenge pump mounting bracket, (Item 165) to the trans mounting bracket (Item 128) using two 6mm bolts (Item 125), flat washers (Item 142) and 6mm Nyloc nut (Item 159). (Diagram TFA/08).

14.3 Install two straight adaptors (Item 164), in the port of the scavenge pump (Item 163).

14.4 Install scavenge pump (Item 163) in mounting bracket (Item 165), inlet port to the bottom, outlet port to the top. Do not tighten clamp. Install the 45° hose end of the oil return hose assembly (Item 136) to the straight adaptor (Item 138) in the RHS of the oil pan (Item 139) and straight hose end to the adaptor (Item 164) in the outlet port of the scavenge pump. This will position the scavenge pump front/rear, following which mounting bracket (Item 165) can be tightened.

14.5 Install the oil drain hose assembly (Item 135) to the turbocharger oil drain, using banjo bolt (Item 132) and copper washers (Item 137). The 90°hose end is attached to the straight adaptor (Item 164), in the inlet port of the scavenge pump.

14.6 Install scavenge pump loom and relay assembly (Item 127) by routing loom up RHS of bell housing and connecting to power at stock fuse box assembly as shown. (Diagram – TFA/08 and images below).

03 Model – Red scavenge pump wire to black wire / yellow trace and black scavenge pump wire to earth.

04 Model onwards - Red scavenge pump wire to black wire / red trace and black scavenge pump wire to light blue wire / white trace.

NOTE

Do not apply power / run scavenge pump before first priming with engine oil. damage to the pump may result from running dry.

The scavenge pump is wired into the same timer circuit as the stock fuel pump. When the ignition is switched on, the scavenge pump (and stock fuel pump) will run for approximately 5 seconds before switching off automatically. After wiring and priming the pump with engine oil, check to ensure that the pump runs for 5 seconds when the ignition is switched on. The scavenge pump is very quiet - to check operation, have an assistant place a hand on the pump to check for operation.

NOTE

Do not attempt to start engine before first checking that the scavenge pump is primed and operational. If the engine is started before this procedure, the turbocharger may fill with engine oil and result in exhaust smoke emission.

15. TURBOCHARGER OIL SUPPLY – DIAGRAM TFA/08 – OIL

The oil supply hose assembly (Item 153), previously installed on the turbocharger, can now be routed forwards, above the LHS engine mount isolator, arcing around the front of the engine to the forwards facing adaptor (Item 156) and connecting to it with the 45° hose end, which is positioned upwards to clear the small water hose which leads to the engine oil cooler, above the filter.

The oil supply hose assembly (Item 153) is supported by back to back cushion clamps (Item 157) bolted together by a hex head bolt (Item 158), washer (Item 142) and Nyloc nut (Item 159). The double clamps are positioned in the centre of the arc, at the lower front left of the engine, by placing one clamp around the adjacent stock metal water line that supplies the oil cooler, the other around the oil supply hose assembly (Item 153). Also a cushion clamp (Item 157) to LHS front of block.

While hose end nuts are tightened, hold the oil supply hose assemblies in order to prevent twisting of the braided Teflon line.

16. POWER STEERING COOLER – DETAIL 4/5 – DIAGRAM FMI/08

Install power steering hoses only (Item 114). Install the hose joiners

(Item 113), in the stock power steering lines, on top of the RHS frame rail, immediately behind the radiator using the stock hose clamps. Install new power steering hoses (Item 114) and clamps (Item 115). Route the new hoses around the end of the frontal impact beam as illustrated.

Where the power steering hoses pass through the radiator support panel, they are protected by plastic sleeve on hose. The rubber edging (Item 121) is positioned on sharp edge of chassis rail top.

17. RE-LOCATION OF STOCK COMPONENTS, AHEAD OF RADIATOR

In order to make room for the installation of the intercooler, a number of OE components normally mounted in the area of the hood catch support must be relocated. These are:

(a) Wiring Loom

Disconnect the horn wiring loom plug from the flat panel at the upper front of the radiator. Unclip the female loom plug and re-mount behind the flat panel, using the stock holes. In addition, prior to their relocation, the hood catch support itself must be modified as follows:

Detail 7, diagram - FMI/08.

(i) the edge of round hole immediately below the four rivet bracket must be ground flat;

(ii) The LHS forward facing leg of the four-rivet bracket must be removed and ground flat.

(b) Horns

Both horns are removed from their stock position. The RHS horn is re-mounted in its stock mounting, after chamfering the ends of its bracket to allow it to be rotated upwards, as far as possible. The LHS horn is re-mounted entirely and will be re-mounted under one of the hex head bolts (Item 104) of the central upper intercooler-mounting bracket, following the intercooler’s installation. (Detail 9 of diagram – FMI/08).

The air bag sensor, originally mounted on the riveted bracket attached to the hood latch support, which has now been cut, is re-mounted at the LHS horn mounting position, orientated vertically.

(d) Ambient Air Temperature Sensor

The air temperature sensor can then be installed in the square hole above the RH horn bracket.

18. INTERCOOLER MOUNTING – DIAGRAM FMI/08

Loosely install the LHS intercooler mounting bracket (Item 99) and RHS intercooler mounting bracket (Item 100), using four 8mm hex head bolts (Item 101), star washer (Item 102), flat washer (Item 103) in the position usually occupied by the lower pair of stock bolts entering the front flange of each frame rail. Sit the intercooler (Item 97) in place on both brackets and loosely install two 6mm hex head bolts (Item 92) from beneath each mounting bracket, up into the tapped flanges welded to each end of the intercooler core. Loosely install upper mounting bracket (Item 98) using the stock hex head bolt, below the latch assembly. Before installing the two hex head bolts (Item 104), install the stock LHS horn bracket, on top of the mounting bracket (Item 98), under the rear most of the two bolts (Item 104).

All bolts can now be carefully tightened, ensuring no stress is placed on any bracket, or the intercooler assembly, itself.

Re-install the aluminum impact beam, verifying that it does not touch the intercooler. Grind clearance if necessary.

19. COMPRESSOR DISCHARGE DUCTING – DIAGRAM FMI/08

Install the silicon hose joiner (Item 93) together with two 40/60 hose clamps (Item 94) on the compressor discharge snout of the turbocharger. Install the silicon hose joiner (Item 95) together with two 60/80 clamps (Item 96) on the lower entry snout of the intercooler.

Install the compressor discharge duct (Item 91) from the front, routing between the engine and its mount. Insert in each silicon hose and tighten all clamps after ensuring clearance from all adjacent components.

20. SPARK PLUG INSTALLATION

Install the new spark plugs, gapped to 0.035”, previously selected and purchased.

21. FUEL INJECTOR INSTALLATION

Install all six fuel injectors (Item 172), after lightly greasing the upper/lower ‘O’ rings with rubber grease or Vaseline. Replace the stock fuel rails. Install injector loom (Item 173), carefully plugging in all six injectors and the multi-pin plug into the main loom. Re-install the plenum chamber lower/upper, in accordance with Nissan procedures.

22. INTERCOOLER OUTLET DUCTING – DIAGRAM FMI/08

Remove stock LH front bumper upper support bracket and retain for trial fitment later (Detail 12).

Place a hose clamp (Item 106) loosely over intercooler outlet, worm drive up facing forwards. Install the silicon intercooler outlet duct (Item 105), through the radiator support panel and slide the hose clamp over the hose end, but do not tighten.

Trial fit stock LH front bumper upper support bracket and inspect clearance to silicon outlet duct (Item 105). Mark and trim stock LH front bumper upper support bracket to clear silicon hose (Detail 12). Trim rubber edge (Item 121a) to allow for hole in stock front bumper upper support bracket and glue rubber edge into place.

Install the silicon hose joiner (Item 109) onto the throttle body. Install two hose clamps (Item 108) over the silicon hose, only tightening the one clamping the throttle body. Install the stock MAF sensor into the throttle body duct (Item 107), using stock retaining screws. Be careful handling the sensor as this is a delicate component.

Install rubber vacuum hose (Item 51) on the small barb adjacent to the MAF sensor-mounting boss. Install a spring hose clamp (Item 43), over the hose, in order to retain it on the barb.

Place a hose clamp (Item 108) over the silicon intercooler outlet duct (Item 105) and install the throttle body duct (Item 107) between that and the silicon joiner (Item 109) on the throttle body. Do not tighten any clamps.

The throttle body duct (Item 107) is mounted to a boss on the front of the cylinder head, using a hex head bolt (Item 111). The Teflon washers (Item 110) are placed either side of the bracket. Body washers (Item 112) are placed between the head of the bolt and outer Teflon washer and between the inner Teflon washer and mounting boss on LHS timing cover.

The two hose clamps (Item 108), at either end of the throttle body duct can now be tightened. The stock wiring loom plug on the MAF sensor can now be re-installed.

23. BLOW-0FF VALVE INSTALLATION – DIAGRAM HFA/08

Install blow-off valve outlet hose (Item 11) onto 1¼” barb coming off the side of the front of the compressor inlet duct (Item 6). Slide two hose clamps (Item 12) over the hose. Install the blow-off valve inlet hose (Item 10) on the 1¼” barb on the side of throttle body duct (Item 107); using hose clamp (Item 12). Slide a second clamp onto the hose, leaving it loose. Install rubber hose (Item 13) onto the hose barb on the end of the blow-off valve assembly (Item 9) retaining with spring clamp (Item 14). Install the blow-off valve assembly (Item 9) between the two hoses and tighten all clamps with the secondary discharge port pointing horizontally straight back.

24. Boost Control Kit – DIAGRAM BCK/08

Install wastegate control solenoid (Item 44), to mounting bracket (Item 46). Install the bracket (Item 46), to the forward side of the blow-off valve, using hex head bolts (Item 47), star washer (Item 48) and flat washer (Item 49). Ensure the correct bolts are used, as otherwise damage will occur to the blow-off valve. Install restrictor (Item 50) inside vacuum hose (Item 51). Install rubber hose (Item 51) (previously connected to the throttle body duct) to the hose barb in the end of the wastegate control solenoid (Item 44). Retain with spring clamp (Item 43).

Install vacuum hose (Item 40) to hose barb in the side of the wastegate control solenoid and retain with spring clamp (Item 41). Install joiner (Item 52) in the end of the vacuum hose. From the joiner, run vacuum hose (Item 42), to the wastegate actuator barb on the turbocharger. Retain with spring clamps (Item 43).

Install the wiring loom (Item 45) by routing it back from the solenoid, through the upper grommet in the false firewall, immediately adjacent to the LHS inner fender. Then around to the RHS of the vehicle between the two firewalls. The red power wire attaches to the battery terminal, with the fuse mounted to the rear battery hold down stud. The remainder of the loom is routed through the large loom grommet in the RHS lower face of the firewall, finally plugging into the one empty port in the rear of the loom plug that is installed in the smaller of the two boxes that comprise the APS engine management (Item 171), beneath the dashboard.

25. Power Steering Cooler – DETAIL 4/5 - DIAGRAM FMI/08

Install the new power steering brackets, (Item 116), by drilling one 0.25” diameter hole in the lower face of the frontal impact beam, positioned as dimensioned. Place two hex bolts (Item 92) down from the inside surface of the beam, through the new brackets and retain by Nyloc nuts (Item119) and flat washers (Item 118).

Place a hose support clamp (Item 117) over a flow tube at each end of the oil cooler. Using two hex head bolts (Item 92), flat washers (Item 118) and Nyloc nuts (Item 119), install the hose support clamps to the brackets (Item 116). Tighten all fasteners.

Connect the new power steering hoses (Item 114) to the oil cooler, using the stock hose clamps.

26. FUEL PUMP/SENDER UNIT MODIFICATIONS – DIAGRAM FSS/08

Install fuel pump (Item 174) in place of the original unit. In early production vehicles, the stock pump mounting is a little short for the new pump. It may be necessary to trim the lower rubber noise isolator pad and/or lengthen the slots that engage the clips retaining the two halves of the sender unit. The stock fuel pump inlet filter and electrical wiring plug should re-install without modification.

The stock large diameter plastic spacer and ‘O’ ring, from the stock regulator are transferred to the plug (Item 193). The small ‘O’ ring (Item 194) is placed over the small diameter of the plug (Item 193). The completed component is then re-installed in place of the stock regulator and retained in the stock housing by the stock spring clip. Install 90^o hose barb (Item 195) in threaded end of stock regulator replacement plug (Item 193). Install fuel hose (Item 196) onto 90^o hose barb (Item 195) and retain with spring clamp (Item 197).

A 31/64” hole must be positioned as illustrated and carefully drilled through the top of the sender unit flange. Ensure the dimensions are referenced from the flat face of the plug connector, not the support rib. Carefully de-burr and grease the edge of the hole.

Place the Dowty washer (in-built ‘O’ ring) (Item 190), over the threaded section of the 90^o bulkhead fuel return adaptor (Item 189). Insert the adaptor (Item 189) through the hole, orientating as illustrated. Place the flat washer (Item 191) over the threaded section of the adaptor (Item 189), beneath the sender unit flange. This will bear on the edges of some reinforcement ribs; however, this is not a problem. Install self-locking nut and tighten until minimal crush is applied to the Dowty washer on the top of the sender unit flange. Extreme pressure is not required!

Gently pry out the small plastic restrictor from the bottom of the pump/sender unit as detailed in Diagram FSS/08. This is a tight press fit component – do not use excessive force. Using small drill bits, progressively drill restrictor orifice to 1/8”. Reinstall restrictor back into pump/sender unit.

Place the two halves of the stock pump/sender unit together and insert the lower tube of the bulkhead fuel return adaptor (Item 189) inside fuel hose (Item 196) and retain with spring clamp (Item 197). Ensure the fuel hose is routed so as not to restrict the re-assembly of the two halves of the pump/sender unit. Complete the re-assembly of the two halves of the stock pump/sender unit and re-install into the fuel tank, in the stock configuration.

27. VACUUM/PRESSURE SENSING LINE – DIAGRAM FSS/08

Install a tee piece (Item 184) to the small barb at the front of the stock plenum chamber, as illustrated; using a short cut piece of vacuum line (Item 183) and three spring clamps (Item 185). Connect the vacuum line from the blow-off valve to the left pointing tee and retain with spring clamp (Item 185). Connect the balance of vacuum line (Item 183) to the right pointing tee and route the line down the RHS of the plenum chamber.

Make a small hole in the large loom grommet in the false firewall, immediately adjacent to the RHS rear corner of the engine. The line then runs through the large grommet wiring loom in the RHS lower face of the firewall, behind the RHS kick panel, under the RHS door scuff plate, up under the rear structure behind the seat to the regulator (Item 175), where it is retained by a spring clamp (Item 185).

Ensure the vacuum line is not kinked or crushed!

28. FUEL PRESSURE REGULATOR – DIAGRAM FSS/08

Attach the bracket (Item 179) to the end of the housing (Item 176), using two hex head bolts (Item 182). Install the three hose barbs (Item 177) into the regulator housing (Item 176), using Loctite thread sealer. Apply rubber grease or Vaseline to the ‘O’ ring on the regulator and install the fuel pressure regulator (Item 175) into the housing (Item 176) and retain with the circlip (Item 178).

The fuel hose (Item 187) connects the barb (Item 177) in the end of the regulator housing (Item 176) to the bulkhead fuel return adaptor (Item 189) and is retained by hose clamps (Item 188). The fuel hose (Item 186) connects the stock hose quick connect fitting end at the outlet of the pump/sender unit, with either barb (Item 177) in the side of the regulator housing (Item 176) and is retained by the hose clamps (Item 188).

Fuel hose (Item 186) is also used to connect the other barb in the other side of the regulator housing to the hard fuel line running forwards to the engine and is retained by two hose clamps (Item 188). Attach the previously installed vacuum line (Item 183) to the regulator (Item 175).

Mount the regulator housing/bracket assembly, using two hex head bolts (Item 180) and flat washers (Item 181) into two of the stock sender unit flange retaining holes, as illustrated.

29. AUXILIARY COMPUTER – DIAGRAM FSS/08

The stock computer is located behind the dashboard on the RHS of the vehicle. The stock loom must be unplugged from the stock computer and plugged into the loom adaptor. The loom adaptor is then plugged into the stock computer.

The vacuum line (Item 183), passing by this area, must be cut and a tee piece (Item 184) inserted and retained with three spring clamps (Item 185). A short length of vacuum line (Item 183) is then run from the branch of the tee to the barb on the small box, (supplied as part of Item 171), retained with spring clamps (Item 185).

The long length of shielded cable is routed back out through the large, main loom grommet, in the firewall. It then continues out through the false firewall via the loom grommet at the top, beside the RHS inner fender.

From here, it routes back and around the firewall, being careful to avoid any hot components. Then down to the stock crankshaft signal sensor which is located in the lower LHS of the engine block’s bell housing mounting face. Unplug factory wiring loom plug from crankshaft signal sensor and connect new shielded cable loom.

30. HEAT SHIELD FIRE SLEEVE

Install orange heat shield fire sleeve (Item 81) around the following components, in the vertical plane, up the RHS of the bell housing:

(a) Stock factory loom.

(b) APS inner water line (Item 166).

(e) Scavenge pump loom (Item 127).

Support all the preceding using bracket (Item 89) which is mounted to the stock lower hole in the RHS of the bell housing, using hex head bolt (Item 90) and tie straps (Item 87). (Detail 3 of diagram – EMA/08).

31. REPLACEMENT OF STOCK LOWER K FRAME

Replace the tubular support structure and ensure all eight bolts and two nuts are torqued to factory specification.

32. INSTALLATION OF LOWER PROTECTION SHIELD – DIAGRAM TOA/08

Install the lower protection shield (Item 70), between the stock rear plastic lower cover and the stock K frame. The shield is mounted into the stock captive nuts, using the stock bolts.

Completion of Installation

1. ENGINE OIL

Re-fill engine with oil. Due to the enlarged oil pan capacity, this will take 5.0 quarts without oil filter. Check level on dipstick. This should be at the low-level line. This is correct, as the pan floor/pump pickup has been lowered 12.0mm. Do not over or under fill! Below 0°F ambient temperature, use SAE 5W-40 or 5W-50. Over 0°F ambient temperature use SAE 10W-40 or SAE 10W-50. Ensure the oil grade utilized is suitable for use with gasoline-turbocharged engines.

NOTE

Do not apply power / run scavenge pump before first priming with engine oil. damage to the pump may result from running dry.

Do not start engine without first checking that the scavenge pump is operational. check to ensure that the pump runs for 5 seconds when the ignition is switched to the on position. The scavenge pump is very quiet - to check operation, have an assistant place a hand on the pump to check for operation. If the engine is started before this procedure, the turbocharger may fill with engine oil and result in exhaust smoke emission.

2. POWER STEERING OIL

Re-fill power steering system with its previously drained oil.

3. ENGINE COOLANT

NOTE

IT IS CRITICAL THAT THE FOLLOWING PROCEDURE BE FOLLOWED EXACTLY! IT IS TIME CONSUMING, HOWEVER, ESSENTIAL!

3.1 Remove water return line (Item 166) from Tee piece (Item 167) in stock upper heater hose.

3.2 Fill radiator and coolant recovery reservoir (Item 126), with anti freeze coolant. It should take 10 quarts, including reservoir. It is important that the coolant be poured through the radiator filler neck at less than 1.5 quarts per minute, in order to allow air in the system to escape.

3.3 When the engine coolant overflows the connection at the Tee piece (Item 167), re-install water hose (Item 166) and tighten the connection.

3.4 Warm the engine to the normal operating temperature with the radiator cap installed.

3.5 Run the engine at 3,000 RPM for 10 seconds and then allow it to return to idle speed.

§ Repeat this action three times.

3.6 Stop engine and allow coolant temperature to drop below 120°F.

· Use a remote electric fan to assist in this process.

· If necessary, refill the radiator and reservoir up to the filler neck.

3.7 Repeat steps 3.3 to 3.6 at least two more times (it may take more) with the radiator cap installed, until the engine coolant level no longer drops.

3.8 Check the cooling system for leaks with the engine running. Remember, water now runs through both turbochargers.

3.9 Fully warm the engine and listen for the sound of coolant flow through the heater unit, inside the car; while running the engine from idle to 3,000 RPM, with the heater control set at several positions between cool and warm.

· Repeat this action three times

If any sound is heard, continue to bleed excess air from the cooling system, by repeating steps 3.3 to 3.6, until the coolant level no longer drops.

NOTE

This procedure can be most frustrating; HOWEVER, it is a function of the stock cooling system design and has nothing to do with the APS turbosystem. It must be carried out identically with a totally stock vehicle!

4. ACCELERATOR PEDAL RELEASED POSITION / BUTTERFLY VALVE CLOSED POSITION LEARNING

This must be performed whenever the harness connector to the “Drive By Wire” butterfly assembly or stock computer has been unplugged. This is a standard Nissan requirement.

4.1 Make sure that the accelerator pedal is fully released.

4.2 Turn the ignition switch to the “ON” position and wait at least two seconds.

4.3 Turn the ignition switch to the “OFF” position and wait at least ten seconds.

4.4 Turn the ignition switch to the “ON” position and wait at least two seconds.

4.5 Turn the ignition switch to the “OFF” position and wait at least 10 seconds.

5. HOSES CLAMPS

Verify all hose clamps are tightened.

6. CLEARANCES

Verify all components that are affected by engine movement have sufficient clearance to adjacent body panels.

7. FLUID LEAKAGE

Verify there are no oil, water or most importantly, fuel leaks either in the engine compartment or on top of the fuel pump / sender unit. Replace the trim cover.

8. COMPLETION OF ASSEMBLY

After a final check for fluid leaks, replace the cosmetic engine cover, strut tower brace and front bumper. Then replace the plastic undertray.

NOTE

ENSURE THE CORRECT PROGRAM IS LOADED INTO YOUR APS COMPUTER FOR YOUR PARTICULAR COMBINATION OF FUEL OCTANE AND EXHAUST SYSTEM COMPONENTS.