APSGTO-TTS/04:  THIS IS A TUNER KIT.  CONSEQUENTLY, NO FUEL SUPPLY OR ENGINE MANAGEMENT IS SUPPLIED.  THESE CRITICAL ITEMS ARE AN INSTALLER RESPONSIBILITY

Verify that you have a G.M. workshop manual for the Pontiac GTO and that you have all necessary tools as listed..

CLEAN ALL AIR DUCTING PRIOR TO COMMENCING INSTALLATION.

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.

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

• PZTR5A-15 Stock – should only be used with totally stock exhaust system. Boost below 8 psi, ambient temperature below 60°F.
• PZTR6A-15 Service Option – should be used for general street operation work with cat-back exhaust system. Boost 8-9 psi, ambient temperature 60°-100°F.
• PZTR7A-15 Service Option – drag racing in an ambient temperature range of 60°-100°F.
• PZTR8A-15 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 93 (R+M)/2. (Equivalent to 98 RON). If a lower fuel octane rating is to be used, appropriate ECU retuning will be required (e.g. to retard ignition timing) and the possible installation and use of water/methanol injection system.

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

The APS turbo system 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 individual(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 16mm.
• 3/8” drive socket set c/w universal coupling – 10 to 22mm.
• Wrench – open end/box combination – 8 to 22mm.
• Allen key – 4 and 5mm.
• Socket – allen key – 17mm.

(2) Imperial

• Wrench – open end/box combination – ½” to ¾”.
• Tap – 9/16” UNF.

(3) General

• Electrical tape.
• Small angle grinder.
• Screwdriver set.
• Pliers – flat, point, side cutter, multi-grip.
• Soldering iron.
• Air hacksaw.
• 2.5” hole saw
• Electrical drill.
• Drill bit – 1/8”, 3/16”, ¼”, 3/8”, ½”.
• 90° drive adaptor – or 90° drill.
• Oxy welding equipment.
• 8mm Rivet Nut application Gun

(4) Sealants

• Permatex ultra copper – P/N 101 BR.
• Permatex ultra grey – P/N 599 BR.
• Loctite thread sealer – P/N 567.

1

Remove and discard the lower air tray.

2

3

4

The brackets are removed by unclipping and raising the AC condenser - and moving forward slightly to release brackets.

5

Remove the stock exhaust manifolds, front pipes, gaskets and all twelve manifold retaining studs. Discard the manifolds/studs. Retain the gaskets for re-use.

6

HINT: It is considerably easier unscrew the plug if an Allen key socket is used, along with an extension and breaker bar.

7

8

9

10

11

12

13

Strip the wires and carefully solder in the provided extension piece, (Item 69).

Wrap each connection individually with electrical tape and reinstall the plug onto the crank position sensor in the block.

Re install starter motor.

Re route crank position sensor loom as shown.

14

NOTE: Insert the shorter threaded length into the cylinder head

15

The RHS and LHS upper heat shields (Item 106) are identical, whilst the lower pieces are handed - LHS (Item110) and RHS (Item 107).

Each heat shield must be carefully folded around the respective exhaust manifold (Items 100 and 101)

Retain the upper heat shield using six 6mm x 1.0 x 10 mm stainless steel bolts (Item 108), 6mm x 20mm and stainless steel body washers (Item 109)

Retain the lower heat shield using four of the 7.9 mm x 360mm stainless steel tie straps (Item 111).

16

The LHS and RHS upper heat shields (Item 106) are identical, while the lower pieces are handed - LHS (Item 110) and RHS (Item 107).

Each heat shield must be carefully folded around the respective exhaust manifold (Items 100 and 101)

Retain the upper heat shield using six 6mm x 1.0 x 10 mm stainless steel bolts (Item 100), 6mm x 20mm stainless steel body washers (Item 109)

Retain the lower heat shield using four of the 7.9 mm x 360mm stainless steel tie straps (Item 111).

17

Retain with three 4.6mm x 200mm stainless steel tie straps (Item 73), as shown.

Wrap the left hand side knock sensor loom with heat wrap (Item 82).

19

This boss may require removal (grinding) for clearance to the new RHS exhaust manifold (Item 101).

20

Trial fit the RHS exhaust manifold (Item 101) and check the clearances to the engine and surrounding sheet metal.

There must be a minimum of 1/8” from any engine part, ¼” from any sheet metal.

Remove manifold and grind block or modify sheet metal as necessary.

Once satisfied with the clearances, remove exhaust manifold.

21

The LHS boss may require removal (grinding) for clearance to the new LHS exhaust manifold (Item 100).

22

23

Install the straight 14mm x 1.5 x 9/16” JIC adaptor (Item 230) and copper 14/20mm washer (Item 231) into the inboard horizontal water port as shown.

Install the extended banjo 14mm x 9/16” JIC fitting (Item 232), pointing upwards, in the outboard horizontal water port, with a 14mm x 1.5 banjo bolt (Item 233) and 14/20mm copper washers (Item 231), as shown.

The oil drain fittings will be installed at a later stage.

24

Install the LHS turbocharger fluid adaptors as per the right hand side turbocharger, with the exception that two straight 14mm x 1.5 x 9/16” JIC adaptors (Item 230) are installed together with 14/20mm copper washers (Item 231) in each horizontal water port.

The oil drain fittings will be installed at a later stage.

25

Apply Permatex Ultra Seal sparingly to the turbocharger mounting flange on the RHS exhaust manifold (Item 101) and install the turbocharger (Item 36). Retain with 8mm stainless steel flat washers (Item 104) and 8mm Selfloc nuts (Item 103).

NOTE: Apply pressure to the turbocharger in the direction shown ensure that the turbocharger is aligned on the studs. This ensures correct the turbocharger alignment for exhaust fitment.

Repeat to install the LHS turbocharger assembly (Item 35) to the LHS exhaust manifold (Item 100)

26

Raise the LHS manifold/turbocharger assembly up into the engine bay and onto the exhaust manifold studs (Item102) previously install into the LHS cylinder head.

Hint: Requires two people - one from above and the other below the vehicle.

Retain the manifold/turbocharger assembly to the head using 8mm washers (Item 104) and 8mm x 1.0 copper coated self locking nuts (Item 103) - do not tighten yet.

27

28

29

Install one smaller 6mm x 1.0 x 20mm stainless steel stud (Item 74) to the outlet flange of each turbocharger assembly.

30

31

Align the LHS wastegate as shown paying particular attention to the orientation of the boost pressure sensing hose port.

Install LHS wastegate (Item 80) into the LHS outlet pipe assembly (Item 60) and retain with flat washers (Item 64) and self locking nuts (Item 63) on the studs.

On the inlet side of the LHS wastegate (Item 80), retain using 8mm socket head bolts and washers (Supplied with wastegate assembly) through the flanges.

Repeat the above for the RHS wastegate (Item 80).

Install the filters (Item 81) and a flat washer that is included with the wastegate assembly to the breather port in the top of each wastegate.

32

33

Retain using 8mm stainless steel flat washers (Item 4) and 8mm x 1.0 copper coated self locking nuts (Item 63) on the 8mm studs (Item 62) previously installed on the turbocharger.

Use a 6mm flat washer (Item 75) and 6mm x 1.0 copper coated self locking nut on the 6mm stud (Item 74) previously installed on the turbocharger outlet flange.

Apply Permatex Ultra Seal sparingly to the RHS turbocharger outlet pipe (Item 61) and repeat the above to install the RHS turbocharger outlet pipe (Item 61) to the RHS turbocharger assembly (Item 36).

34

Once level, tighten the exhaust manifold nuts (Item 104).

Check the alignment again after tightening the exhaust manifold nuts (Item 104).

35

Reconnect the stock steering shaft that was dismantled earlier back to the steering rack.

36

Support the hose (Item 47) using 178mm nylon cable ties (Item 48).

Repeat the above to install the LHS 2.5' length of 1/4" rubber wastegate boost sensing hose (Item 45) between the LHS wastegate (Item 80) and the LHS turbocharger (Item 35).

37

Otherwise, ensure that the O2 sensor port hex head plugs (Item 70) and 18/24mm copper washers (Item 71) are installed in the rear O2 sensor ports.

Progressively drill the hole for the return oil line using the following drill sizes:

1/8", 1/4", 5/16", 7/16", 1/2", 9/16"

Use caution as the stock plastic filler cap is fragile.

Tap the hole to 3/8" NPT.

Apply thread sealant to the adaptor (Item 223) and install into the rocker cover.

Install the other end of the coolant hose (Item 235) to the upwards pointing extended banjo fitting (Item 232) on the outboard water port of the RHS turbocharger.

Install the other end of the coolant hose (Item 229) to the straight adaptor (Item 230) on the outboard water port of the left hand side turbocharger.

Mount to the bottom of the engine block as shown using 12/15 hose support clamps (Item 237).

The oil return system components are of extremely high quality and highly robust for many years of trouble-free operation.

It is VERY IMPORTANT that the following instructions are adhered to and a great deal of attention is paid to the routing and connections.

Install the oil scavenge pump (Item 214) into oil pump bracket (Item 216) and retain with 60mm/80mm hose clamps (Item 217).

Orientate the hose clamps so that the tightening screw is located over the edge of the curved section of the mounting bracket (Item 216) and pointing down (as shown in subsequent images).

The mounting nuts, bolts, washers and rubber insulation pad will be installed in the following steps.

Cut a 3" length of the pump/rocker cover 1/2" rubber hose (Item 222A) and install onto the 90 deg hose adaptor (Item 211) on the "OUT" port of the oil pump (Item 214). Retain with a hose clamp (Item 212).

Install the entry end of the check valve (Item 240) adaptor (Item 241) to the other end of the previously cut 3" length of pump/rocker cover hose - NOTE Flow Direction - and secure with a hose clamp (Item 212).

Route the pump/rocker cover hose assembly (Item 222A&B) up to the RHS rocker cover adaptor (Item 232). Retain at both ends of the pump/rocker cover hose assembly (Item 222A&B) with hose clamps (Item (212).

Secure the pump/rocker cover hose assembly (Item 222A&B) with plastic tie straps (Item 239).

Wrap the oil drain hoses (Items 208A & 209A) with protective spiral wrap (Items 208B & 209B).

Install the 16mm banjo adaptors (Item 207) to each oil drain hose (Items 208A & 209A) and retain with hose clamps (Item 212).

Install the LHS turbocharger oil drain hose assembly (Item 208A) to the LHS turbocharger oil drain flanged adaptor with a well greased 16mm/20mm copper washer (Item 196) on each side of the banjo adaptor (Item 207) and retain with a 16mm x 1.5 banjo bolt (Item 206).

Repeat for the RHS oil drain hose (Item 209A).

Wrap the Y-piece/pump oil return hose (Item 213A) with protective spiral wrap (Item 213B) and install the hose to the Y-piece (Item 210). Retain with a hose clamp (Item 212).

Install the Y-piece/pump oil return hose (Item 213A) to the oil pump fitting at the oil pump port marked "IN".

Extend the oil sender wiring loom by cutting the stock loom 2" from the plug, soldering the loom extension (Item 197) and using heat shrink insulation to insulate and protect the joins.

The loom is routed alongside the stock LHS injector wiring loom and down the front of the engine.

• Oil supply block (Item 190) x 1
• Straight adaptor (Item 191) x 2
• Solenoid valve (Item 192) x 1
• Oil distribution block (Item 193)
• 45 degree adaptor (Item 194) x 2

Install the stock oil pressure sender unit into the 16 mm x 1.5 port in oil distribution block (Item 193).

Install the oil control solenoid valve assembly above the engine oil filter, in place of the stock oil gallery cover. Stock hardware and gaskets are used for retention.

Install the five 8/20mm hose support clamps (Item 200 around the turbocharger oil supply lines (Items 198 & 199) and attaching to the block via the stock oil pan bolts in the positions as shown.

Drill the three indicated ¼” holes.

Mark a 2.5” diameter circle, centrally between the three ¼”holes, using the indicated centre.

Drill the three ¼" holes and mark the centre of the 2.5" diameter hole to be drilled.

The support leg running from the duct down to the upper surface of the frame rail is mounted by drilling two 1/8” holes and fastening with two self tapping screws (Item 7).

Connect the flexible compressor inlet hose (Item 4) to the end of the stainless steel duct, retaining with a 50/70 mm hose clamp (Item 5).

The support leg running from the duct down to the upper surface of the frame rail is mounted by drilling two 1/8” holes and fastening with two self tapping screws. (Item 7)

Connect the flexible compressor inlet hose (Item 4) to the end of the stainless steel duct, retaining with a 50/70 mm hose clamp (Item 5).

Mark this black pipe as shown, 4" in a straight line from where it leaves the core.

Straighten the vertical aluminum pipe slightly and mark the height as shown, level with the top of outer chassis rail skin.

Install one of the flexible air conditioning hose assemblies (Item 149) on the end of the cut black pipe, as shown. Seat the sealing olive fitting, by tightening and then loosen slightly to allow rotation of hose. It is VERY important to hold the fitting on the end of the hose, perfectly in line with the run of the black pipe, as the nut is tightened. This is the receiver/dryer “IN” side.

Install the other flexible hose assembly (Item 149), as shown.

Seat the olive fitting by tightening and then loosen slightly to allow rotation of hose. Again, take care to ensure the hose fitting is kept in line with the aluminum pipe.

Wrap the hose fitting attached to the lower black pipe with sticky rubber strip (Item 175) for protection of the intercooler core.

Install rubber edging (Item 163) along the front edge of the front cross member as shown, in order to protect the intercooler.

Although shown mounted here for clarity, the receiver / dryer is not mounted to the intercooler, until after the intercooler is mounted in the car.

The lower hose simply sits on top of the cross member, behind the intercooler core. The upper hose will be mounted to the rear of the upper radiator support panel, after the intercooler and receiver / dryer are in place.

Mount the intercooler using the left hand side bracket (Item 134), right hand side bracket (Item 135) and 6mm x 1.0 x 16mm bolts (Item 136). Both brackets mount to the car using stock bolts, in stock positions as shown and are used to stabilize the intercooler assembly. The mass is supported by the cross member on which it is resting. (Do not install lower brackets yet).

Drill the stock locating hole to ¼” diameter.

Ensure that the hose fittings to receiver/ dryer are tightened.

Install the new receiver/dryer (Item 150) to the end of the intercooler, as previously shown, using 6mm x 1.0 x 25 mm bolt (Item 169) and the modified stock bracket.

Using a 2 ½" hole saw, drill as shown. Clean up all edges and paint to prevent corrosion.

Repeat the preceding steps on the LHS frame rail of the car.

Bend the stock brake line bracket from the stock 45 degrees to 90 degrees and carefully bend the brake line to clear the compressor discharge duct.

Re-install the modified brake line bracket.

Bend the stock brake line bracket from the stock 45 degrees to 90 degrees and carefully bend the brake line to clear the compressor discharge duct.

Re-install the modified brake line bracket.

Drill 1/8"holes and secure with self tapping screws (Item 142), as shown.

Drill 1/8" holes and secure with self tapping screws (Item 142), as shown.

Drill 3/16” diameter holes and secure with self tapping screws (Item 123), as shown.

The seemingly long 6mm x 1.0 x 30mm bolts (Item143) shown, are correct as they are subsequently used to also mount the revised power steering cooler.

Flare the ends using ball flaring tool.

Route the power steering lines alongside the right hand side intercooler inlet duct (Item 128), using tie straps (Item 172) for mounting purposes, as shown.

NOTE Ensure that the orientation of air cleaner element fits inside inner splash shield.

Install the LHS air cleaner element (Item 1) on the end of the LHS stainless steel compressor inlet duct (Item 2). Retain with a 50/70mm hose clamp (Item 5).

NOTE Ensure that the orientation of air cleaner element fits inside inner splash shield.

Place the template (Item 140) as shown on the bottom of the bumper beam.

Use the stock plastic plugs at each end to hold the template (Item 140) in position.

Mark the cut out section in the bottom surface of the beam.

Install the top template (Item 139) in position and mark the upper edge of the cut out in the rear face of the bumper beam.

Holes marked in the rear face of the bumper beam to permit routing of the intercooler discharge duct (Item 141).

Weld the new bumper beam blank off plate (Item 137) into the intercooler clearance relief.

Clean all cut and welded edges.

Paint to protect from corrosion.

This does take some strength to work through the inside of the bumper beam.

For vehicles where the inlet air temperature is sensed in the MAF meter, use the 5/8” blanking grommet (Item 166), retaining with super glue for security.

If your vehicle is equipped with a separate inlet air temperature sensor, then install the ½’ ID grommet (Item 167) and re install the stock sensor.

Install the rubber blank-off cap (Item 49) to the barb on the stainless steel joiner (Item 145).

Use a 70/90 mm hose clamp (Item 146) at the joiner. Use a 90/110 hose clamp (Item 148) at the throttle body.

Place a third hose clamp (Item 13) over the 1 ¼” ID discharge port in the side of the silicon throttle body inlet duct (Item 147).

Install the compressor by pass valve (Item 11) into the hose (Item 12) and port of the inlet duct (Item 147) as shown.

Tighten all clamps (Item 13).

Using a number 17 spring clip (Item 19) at each end, install the 3/8” x 12" long breather hose (Item 9) between the stock rocker cover breather and the previously installed hose barb adaptor (Item 10), routing as shown.

The LHS rocker cover has a breather in the back corner, just in front of the firewall. In some vehicles it is drilled and sealed with rubber plug. In others, the barb is there, but simply not drilled open. If fitted, remove the rubber plug. In any case, verify that the breather barb is open internally to the inside of the rocker cover. If not, remove the rocker cover and carefully drill to 1/4" ID ensuring that you DO NOT drill through the internal baffle.

An additional 29.5" breather vent line (Item 8) is then run from the rocker cover barb in the back corner, along the inside upper edge of the rocker cover, around the front of the cylinder head as shown and down to a hose barb adaptor (Item 10), installed in the stainless steel left hand side compressor inlet duct (Item 2). Number 17 hose clamps (Item 19) are used at each end.

On LS1 engines only, the stock rocker cover breather connects to a barb on the throttle body. This barb is sealed using rubber plug (Item 15) and clip (Item 16).

Re-install the stock battery and retain with the battery clamp assembly (Item 152).

The solenoid valve and scavenge pump wires (Item 221) run down to the front cross member beneath the radiator and across to the solenoid valve at the front lower left hand of the engine.

The scavenge pump wire connects to the scavenge pump mounted to the front cross brace.

Splice the purple oil pump wire (with no other color trace) in the loom (Item 221) to the stock purple wire inside the stock under-hood fuse box.

Install the relay support base which is part of the loom assembly (Item 221) to the relay mounting bracket (Item 224) and retain with two 5mm x 0.8 x 12mm bolts (Item 225), four 5mm washers (Item 226) and two 5mm x 0.8 self locking nuts (227).

Install the relay support bracket assembly (Item 224) to the rear battery clamp as shown.

Secure all wiring with 4" plastic tie straps (Item, 238).

Install the new windscreen washer bottle (Item 160) onto the bracket (Item 161). Retain with 6mm x 1.0 x 20mm hex head bolt (Item 156), 6mm flat washer (Item 157) and 6mm x 1.0 Nyloc nut (Item 158).

Remove the stock washer pump and grommet form the stock bottle and refit to the new bottle (Item 160).

Cut the stock washer pump loom 3” from the plug and solder in the extension loom (Item 162).

Retain with the stock bolts.

Route the 59" length of 4 mm vacuum hose (Item 14) forward on the engine along the inside edge of the left hand side rocker cover and connect the hose to the barb on the end of the compressor by pass valve (Item 11).

Note the position of the two stock holes that match the position of the two rear mounting holes in the APS lower shield (Item (65).

Remove the shield and drill 7/16" holes as positioned.

Using an 8mm Rivnut gun, install the two 8mm rivet nuts (Item 66) supplied.

Install the lower protective shield (Item 65) as shown, using stock bolts in the forward holes, 8mm x 1.25 x 25mm hex head bolts (Item 67) in the new rear holes.

Mark and drill 1/2" holes for clearance to the lower intercooler mounting bracket bolts, as shown.

Check clearances and install the modified lower air deflector.

Refill the engine coolant in accordance with the factory service manual.

WARNING DO NOT START THE ENGINE