APS Intercooled Twin Turbo
Installation Guides
 

   
 
 

APS Intercooled Twin Turbo System Installation Guide - APSCC6-TTS/06
Before Commencing Installation:

Verify that you have a G.M. workshop manual for the C6 Z06 Corvette 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.

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 (eg. 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 Disconnect the battery.
2 Remove the bonnet, front and rear inner fenders, bumper bar, front wheels and brake ducts as per factory manual.
3 Remove the stock engine covers.
4 Remove the stock air filter assembly and the stock flex hose.

Remove the stock MAF sensor from the stock air filter and retain the sensor.

5 Disconnect and remove the stock engine oil cooler.
6 Remove the stock ambient air temperature sensor.
7 Remove the stock radiator cooling shroud.
8 Remove the stock horns and the stock mounting bracket.
9 Drain the engine oil (both drain plugs).
10 Disconnect the stock oil hoses between oil pan and oil reservoir.

Remove CATS and stock exhaust system. Remove stock exhaust manifolds.

Fuel System (tank & underbody)
fs1 Remove the stock differential and gearbox assembly in accordance with the Factory Service Manual.
fs2 Unclip the wiring harness shown
fs3 Remove the stock fuel tank assembly in accordance with the Factory Service Manual.

Hint: removal of the stock support bracket makes for easier removal of the stock crossover tube.
fs4 Remove the stock fuel pump assembly from the fuel tank.

Hint: Unclip where shown.
fs5 Cut the stock fuel level sender unit wires so that the sender unit can be removed and installed into the APS swirl pot/pump assembly.
fs6 To remove the stock fuel level sender unit assembly, first unclip the stock lower pump assembly.
fs7 Remove the stock sender unit by depressing the clip shown and sliding the sender unit upwards.
fs8 Install the stock fuel level sender unit into the APS swirl pot/fuel pump assembly and retain with an 8mm socket head screw (Item 304M) and 8mm washer (Item 304L).
fs9 Carefully lower the swirl pot/pump assembly (Item 304) into the stock fuel tank ensuring that the RHS return hose is positioned in the centre of the fuel pumps.
fs10 Connect the RHS fuel supply hose as shown and lower the swirl pot/pump assembly (Item 304) fully into place in the stock fuel tank.
fs11 Insert a quick connect fitting (Item 281) and a 90 deg swivel fitting (Item 282) into the 15" fuel hose (Item 296). Install the protective spiral wrap (Item 297) over the hose assembly.
fs12 Install the fuel return hose assembly and fuel pump supply hoses (Items 284 & 285) as shown.

Connect the wiring loom connector (Item 298) as shown.

Note: Ensure that the orientation of the hoses are as shown.
fs13 Position the relay and wiring loom assembly (Item 298) as shown on the fuel tank.
fs14 Remove the stock fuel supply hose from the stock hard fuel supply line. This line will now be used as the new fuel return line.

Lift the fuel tank into the vehicle and route the fuel hoses above the chassis.

Refit the new fuel supply hoses (Items 284 & 285) and the new fuel return hose assembly between the chassis rail and the floor as shown.
fs15 Unclip the stock brake lines and lift the brake lines from the chassis rail.

Pass the fuel supply hoses (Items 284 & 285) between the chassis rail and the brake lines.

Drill a 5/32" hole into the chassis rail for the hose support clamp (Item 290).

Retain the fuel supply hoses (Item 284 & 285) using the hose support clamp (Item 290) and a self tapping screw (Item 294).
fs16 Secure the fuel supply lines (Item 284 & 285) using the support bracket (Item 289), hose support clamp (Item 290), 6mm x 1.0 x 20mm bolt (Item 291), 6mm flat washer (Item 293) and 6.0mm x 1.0 nyloc nut (Item 292).

Use the additional hose support clamps (Item 290) and brackets (Item 289) as shown to further support the fuel supply hoses (Item 284 & 285).
fs17 Route the fuel supply hoses (Items 284 & 285) above the stock clutch line along the LHS of the gearbox bell housing.
fs18 Connect the power and earth wires of loom (Item 298) to the relay next to the fuel tank as shown.

fs19 Tuck the relay wiring up between the chassis rail and the fuel tank.

Route the wiring with the fuel hoses towards the front over the bell housing to the RHS fuse box. Secure using tie straps (Item 295)
fs20 Reinstall the differential and gearbox assemblies.
fs21 Reinstall transmission tunnel cover.
11 Unclip the stock oxygen sensor plugs from the stock support brackets on the RHS and LHS. Discard the stock support brackets and stock mounting clips.

Remove the starter motor wiring stock clip.
12 Disconnect the stock clutch line from the master cylinder (at the rear LHS front wheel arch).
13 Remove the stock clutch line support bracket from bell housing.
14 Cut and connect new clutch line.

Cut the stock metal clutch line 1/2" from the flexible line crimping as shown and remove the flexible portion of the stock clutch line.

Install straight adaptors, 6mm Olive x 7/16 JIC (Item 104) on each end of the previously cut stock metal clutch line. When tightening the nut around the olive, in order to seal to the metal line, ensure that the adaptor is kept perfectly true to the metal line - otherwise leakage will result.

15

Install the fire sleeve (Item 103) over the APS flexible clutch line (Item 105).

Install both parts by connecting both straight adaptors (Item 104) and routing the new flexible hose assembly (Item 103 and 105) as shown in the three images.

View of the APS clutch line (Item 105) from under the vehicle.

16 Drain engine coolant.
17 Remove the stock water gallery plug from the LHS of engine (forward of engine mount).
18 Install the water take off adaptor (Item 202) with sealant.
19 Connect but do not fully tighten the APS LHS outer water hose (Item 203).
20 Install the LHS heat shield (Item 97) to the LHS exhaust manifold (91). Retain using bolts (Item 99), body washers (Item 100) and tie straps (Item 102).
21 Install the RHS heat shield (Item 98) to the RHS exhaust manifold (Item 92). Retain using bolts (Item 99), body washers (Item 100) and tie strap (Item 102).

NOTE: Do not install lower tie strap on RHS manifold yet.
22 Install the stainless steel turbo mounting studs (Item 94) to the LHS and RHS exhaust manifold outlet flanges.
23 Modify RHS inner transmission tunnel as shown using a ball pen hammer.
24 Install the LHS trans tunnel heat shield (Item 66) and mold to tunnel. Secure shield with self tappers. Use a large self tapper (Item 68), installed as shown and then drill 1/8" diameter holes for small self tappers (Item 69). Repeat for RHS
25 Install oil filter heat shield (Item 67) to oil cooler line connection blanking plate above the oil filter mounting flange; using stock bolt in rear hole, B/H bolt (Item 73) and body washer (Item 74), in forward hole.
26 Install earth extension (Item 106) to rear chassis rail, in order to move stock wiring loom rearward. Remove stock clip as shown. Secure extension using stock bolt. Secure stock loom to extension (Item 106) using bolt (Item 107) and nut (Item 108).
27 Modify stock lower bell housing vents by removing material as shown.
28 Disconnect steering shaft.
29 Install the exhaust manifold mounting studs (Item 95) to each cylinder head.
30 Install boost sensing hoses for wastegates. The LHS hose (Item 52) has the fire sleeve (Item 51) fitted, which is routed behind the clutch line and above the heat shield. It is then routed along the bell housing and under trans tunnel. NOTE: Length of hose length in trans tunnel is 16.5" from front edge of tunnel plate (NOTE: hose clamp fitted later).

31 Secure RHS boost hose (Item 53) to oil line next to bell housing using tie straps (Item 57). NOTE: Hose length from bend of lower oil line is 14".
32 Test the fit of both exhaust manifolds, (Items 91 &92) ensuring clearance of all hoses and wiring (The manifolds are installed from beneath vehicle).
33 Remove exhaust manifolds, (Items 91 & 92).
34 NOTE: NO SILICON TO BE USED ON ANY OIL SUPPLY, DRAIN FITTINGS OR GASKETS.

RHS Turbo (Item 42).

Connect oil supply hose (Item 176) to oil inlet port in turbocharger (Item 42) using banjo bolt (Item 177) with washers (Items 178 and 179). Note orientation.

Attach studs to rear of turbo (Five x Item 63) and (One x Item 70).

Install oil drain using gasket (Item 180), oil drain fitting (Item181), bolts (Two x Item 182) with star washers (Two x Item 183). Install water supply adaptor (Item 204) with copper washer (Item 205).

35 LHS Turbo (Item 41).

Connect oil supply hose (Item 175) using banjo bolt (Item 177) with washers (Items 178 and 179). Note orientation.

Attach studs to rear of turbo (Five x Item 63) and (One x Item 70).

Install oil drain using gasket (Item 180), oil drain fitting (Item 181), bolts (Two x Item 182) with star washers (Two x Item 183). Attach water supply adaptors (Two x Item 204) with copper washer (Two x Item 205).

36 Using the specified RTV sealant between the flanges, bolt RHS turbo (Item 42) to RHS exhaust manifold (Item 92) using nuts (Item 93) and washers (Item 96).
37 Install inner starter motor heat shield (Item 101) using S/S tie straps (Two x Item 102).
38 Using the specified RTV sealant between the flanges bolt LHS turbo (Item 41) to LHS exhaust manifold (Item 91) using nuts (Item 93) and washers (Item 96).
39 Clamp wastegates LHS (Item 43) and RHS (item 44) to outlet pipes, LHS (Item 61) and RHS (Item 62), using V band clamps supplied with wastegates.

Install boost hose banjo (Supplied with wastegates). Note orientation. Install filter plug (Item 45) with washer (Supplied with wastegates).

40 Use the specified RTV sealant on both LHS (Item 61) and RHS (Item 62) outlet pipes (as shown) to create a secure seal with the turbos. Then bolt outlet pipes (Items 61 & 62) and turbos (Items 41 &42) together using M8 nuts (Item 64) and M8 washers (Item 65), M6 nuts (Item 72) with M6 washers (Item 71).
41 Tuck stock oxygen sensor plugs between bell housing and trans tunnel, as shown.
42 Disconnect and remove stock brake hose brackets for both LHS and RHS, as shown.

Unclip stock ABS sensor wire for both LHS and RHS.
43 CAREFULLY bend stock brake lines upwards against chassis rail.
44 Position both LHS (Item 8) and RHS (Item 9) air entry ducts between chassis rail and lower cross member.
45 Remove stock oil filter and bend heat shield (Item 67) inwards towards oil pan.
46 Carefully lift manifold turbo outlet pipe assemblies from below vehicle (one person below and one person above) and rest on lower cross member.
47 Install stock oxygen sensors, as shown. If installing Cats, the secondary oxygen sensors must be relocated after the cats. NOTE: The stock rear sensor wiring must be lengthened, if cats are installed.
48 Connect boost sensing hose (Item 52) to LHS wastegate (Item 43) with spring clip (Item 56).
49 Lift LHS manifold, turbo, outlet pipe assembly onto the studs (Item 95) and install self loc nuts (Item 93) with washers (Items 96). DO NOT FULLY TIGHTEN.
50 Repeat above for RHS manifold, turbo, outlet pipe assembly.
51 Align rear flanges of turbine outlet pipes (Items 61 & 62) allowing for clearance of wastegates to trans tunnel.
52 Fully tighten exhaust manifold to cylinder head nuts (Item 93).
53 Reinstall stock oil filter.
54 Secure LHS boost hose (Item 53) to trans tunnel by drilling 1/8" diameter hole and using P clamp (Item 54), self tapping screw (Item 55) and tie strap (Item 57).
55 Connect boost hoses (Items 52 & 53) to 90° barb fitting on LHS and RHS turbocharger compressor housing outlets using spring clips (Item 56).
56 Install nitrile O-ring (Item 24) in the groove in the front of the turbo compressor housing.
57 Install both LHS (Item 8) and RHS (Item 9) compressor entry ducts to turbocharger compressor housings using M6 capscrews (Item 25) and M6 star washers (Item 26).
58 Drill 3.5" hole in the front inner guard panels (RHS shown).
59

Remove and discard the stock bolt on the forward upper control arm.

Some extra trimming may be required so that the air entry duct LHS (Item 4) and RHS (Item 5) fit flush with inner guard. These ducts are secured using M10 bolt (Item 29) and washer (Item 30).

Trim the underside as shown for clearance to the hose clamp to be installed at a later stage.

60 Once satisfied with the hole clearance, remove both ducts (item 4 & 5) (for later installation).
INTERCOOLER INSTALLATION:
61 Install RHS side air deflector (Item 144), retaining with plastic body clip (Item 150).

Install length of rubber edging (Item 146) cut to appropriate length, to forward edge of deflector (item 144) and affix with strong adhesive (super glue).

62 Drill 1/4" holes as shown in the front face of the stock radiator cover. Install two self tap body clips (item 148) over holes in upper duct (Item 143).

Place the upper edge of the upper duct (Item 143) behind the front face of the stock cover and retain using 4.8mm x 16mm self tapping screws (Item 149).

Install cut length rubber edging (Item 146) to forward edge of upper duct (Item 143) and affix with strong adhesive (super glue).

63 Install LHS and RHS outer intercooler brackets (Item 132). Ensure that the large hole is centrally located around boss on the underside of chassis rail.

Install stock mounting fasteners however do not fully tighten yet.
64 Install forward facing intercooler brackets (Item 133) to intercoolers (Items 130 and 131) ensuring that the brackets are square to the intercooler bosses, using 6mm x 14mm hex head bolts (Item 134).
65 Lower each intercooler from top (two people makes this step easier).

Install outer intercooler brackets (Item 132) to each intercooler using 6mm x 14mm hex head bolts (Item 134),
66 Position intercoolers 7/8" from inside chassis rail as shown.
67 Ensure that intercooler assemblies are level as shown.
68 Mark the position of centre intercooler mounting holes on front cross beam.
69

Remove the intercoolers from outside brackets and drill 1/4" holes where marked in front cross beam.

70 Reinstall intercoolers (Items 130, and 131) using self tappers (Item 139), ensuring that they are level and 7/8" from side chassis rails.
71 Measure the clearance between the intercooler front face and lower edge of front cross beam.

Ensure that there is 1 5/8" clearance.

NOTE: it is critical that this clearance is measured in order to facilitate installation of air deflection shields at a later stage.

72 To install the RHS intercooler air directional duct (Item 142), first remove the RHS intercooler inner mounting bracket (Item 133).

Install cut length rubber edging (Item 146) to rearward edge of duct (Item 142) and affix with strong adhesive (super glue).

Pass RHS air directional duct from underneath at an angle as shown. Raise and rotate the duct (Item 142) into position ensuring a snug fit to the front face of the intercooler.

Drill 3, 5/32" holes and secure with self tapping screws (Item 145)

Reinstall inner intercooler mounting bracket (Item 133).
73 Repeat above process for LHS intercooler air directional duct (Item142).
HORN RELOCATION:
74 Cut horn wiring 1 1/2" from plug and solder horn wiring extension (Item 147).
75 Mark and drill 0.25" holes as shown in fibreglass panel behind bumper beam RHS.

76 Mount one stock horn rearward of panel.
77 Mount second stock horn forward of panel.
78 Trim foam bumper support as required.
79 Trim 3/8" from stock bolt protruding below headlight on both LHS and RHS.
DUCT AND SILICON HOSE INSTALLATION
80 Fit air entry hose LHS (Item 6) and RHS (Item 7) to compressor air entry ducts LHS (Item 8), RHS (Item 9). Secure using hose clamps 70/90 (Item 10).
81 Feed air LHS entry duct (Item 4) rearward into silicon air entry hose (Item 6), securing with a 70/90 hose clamp (Item 16) and front upper control arm bolt (Item 29) and 10mm flat washer (Item 30). Repeat for RHS with item 5 and item 7.
82 Position air entry ducts LHS (Item 4) and RHS (Item 5) through hole previously cut in front wheel well panel.
83 Secure silicon air entry hose (Item 3) in a horizontal outward position using hose clamp 70/90 (Item 10) on both LHS and RHS.
84 Secure the blow off valve joiner duct (Item 2) to the entry hose (Item 30) using 70/90mm hose clamp (Item 10) on both LHS and RHS. Note orientation.
85 Secure stock brake line and ABS wire with tie strap (item 28) as shown.
86 Remove and modify stock lower spring support brackets by grinding flat as shown.
87 Modify front edge of cross member as indicated.
88 Secure compressor discharge ducts, LHS (Item 125) RHS (Item 126) under lower spring support.

Ensure clearance on cross member.

89 Install the compressor discharge hoses LHS (Item 121), RHS  (Item 122) securing with hose clamp 40/60 (Item 128) and 60/80 (Item 127).
90 Install intercooler inlet hoses LHS (Item 123), RHS (Item 124) to discharge duct LHS (Item 125), RH (Item 126) and the inlet ports of intercooler LHS (Item 130), intercooler RHS (Item 131), securing with hose clamps 60/80 (Item 127).
91 Install blow off valves (Item 11) to intercooler inlet ducts LHS (Item 123), RHS (Item 124) securing with 25/40 hose clamp (Item 13).

Install blow off valve outlet hose (Item 12) between blow off valve (Item11) and joiner duct (Item 12) securing with 25/40 hose clamps (Item 13).

Install air filter elements (Item 1) to joiner duct securing with 70/90 hose clamps (Item 10).
92 Route LHS turbo oil supply hose (Item 175) between oil pan and lower cross member forward of RHS turbo and upwards towards rear of RHS cylinder head.
93 Route RHS turbo oil supply hose (Item 176) below and forward of compressor housing and upwards between RHS turbo and RHS chassis rail towards rear of RHS cylinder head.
94 Connect LHS outer water hose (Item 203) to LHS outer water adaptor (Item 204) of LHS turbo.
95 Fully tighten LHS outer water hose (Item 203) to block water adaptor (Item 202).
96 Re connect steering shaft.
97 Connect centre water hose (Item 206) to LHS and RHS turbo inner water adaptors (Item 204), routing between oil pan and lower cross member, as shown.
98 Using soft vice jaws, clamp banjo fitting (Item 207) in a vice, fully tighten RHS outer water hose (Item 209) to banjo fitting (Item 207) orienting as shown.
99 Connect RHS outer water banjo fitting (Item 207) with hose (Item 209) to RHS outer water port of RHS turbo using banjo bolt (Item 208) with copper washers (Item 205).
100 Remove stock coolant plug from rear of RHS cylinder head. Install a 12mm copper washer (Item 178) and a coolant adaptor (Item 210).
101 Connect RHS outer water hose (Item 209) to coolant adaptor (Item 210) RHS rear cylinder head.
102 Remove the intake manifold.
103 Unplug and remove the stock oil pressure sender.
104 Install adaptor (Item 161) with copper washer (Item 184).
105 Connect oil take off hose (Item 162) to adaptor (Item 161) and route across engine at rear of RHS cylinder head.
106 Untape and cut stock oil pressure sender wire 1 1/2" from plug, as shown.
107 Solder and insulate loom extension (Item 174) and retape.

108 Reconnect stock oil pressure sender plug to end of loom extension (Item 174) (same as above) and route across engine at the rear of the RHS cylinder head.
109 Install T piece (Item 22) and 6mm hose 2" long (Item 23) and 134" long hose (Item 14) using spring clips (Item 20) to stock vacuum hose at rear of intake manifold. Position at the rear of the RHS cylinder head. Roll up 134" hose (item 14) and leave for later routing.
110 Connect vacuum hose (Item 23) to rear of intake manifold using spring clip (Item 20).
111 Reinstall stock intake manifold.
Fuel System - Engine Bay
fs22 Remove the original lower O-Rings from the injectors (Item 299) and install the new O-Rings (Item 301).

fs23 Wire in the new injector plugs (Item 300).
fs24 Install the fuel rail brackets (Item 263) to the LHS and RHS fuel rails (Item 261 & 262) and secure with 4mm x 0.7 x 20mm B/H bolts (Item 264).

Install the adaptor (Item 265) with O-Ring (Item 267) to the front of RHS fuel rail.

Install adaptors (Item 266) to the front of the LHS fuel rail fuel rail and rear of both fuel rails with O-Rings

Using sealant, install tee adaptor (Item 273) to adaptor (Item 266) in the front LHS fuel rail. Note orientation.

Using sealant install adaptors (Item 271) to adaptors (Item 266) in rear of both LHS and RHS fuel rails. Note orientation

The fuel hoses and regulator are to be installed later.
fs25 Install the fuel rail assemblies to the intake manifold with injectors (Item 299) and secure with 6mm x 1.0 x 20mm bolts (Item 291).
fs26 Discard the flat washer from the fuel pressure regulator shown.

Install a DOWTY washer (Item 275) and replace the locking nut.

Turn the adjusting screw in to increase pressure, unscrew to lower pressure. A starting point is 2.5 turns in from finger tight.

It is essential that a fuel pressure gauge be connected to the port provided for this purpose at the front of the LHS engine fuel rail. Set the fuel pressure regulation adjusting screw so the gauge shows 58 PSI at idle.

Tighten the locking nut.
fs27 Install a second DOWTY washer (Item 275) and dome nut (Item 274).

fs28 Install adaptors (Item 272) and plug (Item 268) into the regulator (Item 269) and install regulator mounting bracket (Item 270).
fs29 Install balance hose (Item 283) between the front LHS and RHS fuel rails.
fs30 Install the regulator with the mounting bracket to the stock inside brake master cylinder mounting stud.
fs31 Install the fuel supply hoses (Item 284 & 285) to the rear of the fuel rails.
fs32 Install the fuel hose (Item 279) from the front LHS fuel rail to the regulator.

Install the vacuum hose (Item 288) to the barb fitting on the side of the fuel pressure regulator (Item 269) and retain with a spring hose clamp (Item 20).

Apply thread sealant and install the barb hose fitting (Item 286) to the top of the LHS intercooler assembly.

Route vacuum hose along the LHS of the engine bay to the barb hose fitting (Item 286) and retain with a spring hose clamp (Item 20).
fs33 Install quick connect hose end (Item 281) and 90° swivel barb (Item 282) to the fuel injection hose (Item 276).
fs34 The hose assembly is routed from the regulator to the stock fuel supply line which is now used as the fuel return line.

fs35 Over all view of the fuel rails, regulator and the fuel hose routing.
112 OIL DISTRIBUTION BLOCK ASSEMBLY:
113 Assemble the oil distribution block (Item 166).

Be sure to use sealant on all threaded fittings.

NOTE ORIENTATION OF ALL FITTINGS.

READ AND TAKE NOTE OF STEPS 113 - 115 BEFORE ASSEMBLING OIL DISTRIBUTION BLOCK ASSEMBLY.
114 1: Assemble 90° 1/8"NPT x 7/16"JIC adaptor (Item 168) to block as shown.

2: Assemble ST 1/8"NPT x 7/16"JIC adaptor (Item 167) to block as shown.

3: Assemble ST 1/8"NPT x 1/4"NPT adaptor (Item 165) to block as shown.

4: Assemble stock oil pressure sender to block as shown.

5: Assemble solenoid (Item 164) to ST 1/8"NPT x 1/4"NPT adaptor (Item 165).

6: Assemble 90° 1/4"NPT x 7/16"JIC adaptor (Item 163) to solenoid (Item 164).

7. Assemble solenoid bracket (Item 169) to solenoid (Item 164) using cap screws (Item 170) with washers (Item 171) as shown.
115 NOTE SPECIFIC ORIENTATION AND ASSEMBLY AS SHOWN.
116 Remove stock bolt from rear RHS coil pack.
117 Install M6 bolt (Item 223) in place of stock coil pack mounting bolt, as shown. Install solenoid bracket (item 169) using M10 bolt (Item 172) with spring washer (Item 173) to rear of RHS cylinder head, as shown.

Connect oil take off hose (Item 162) to oil block adaptor (Item 163).
118 Connect LHS (Item 175) and RHS (Item 176) oil supply hoses to oil distribution block assembly.

Connect extended oil pressure sender wire to stock sender unit.

119 Using sealant, assemble 90° hose adaptor (Item 201) to oil scavenge pump (Item 193). Note orientation shown.

To assemble oil scavenge pump (Item 193) to bracket (Item 195) use the silicon sleeve (Item 194) and secure with hose clamps (Item 196).

Note inlet position and orientation as shown.

120 Carefully bend stock oil cooler hose rearward and remove stock ABS mounting bracket bolts (discard).
121 Install oil pump with bracket (Item 195) to cross member using bolts (Item 197) with washers (Item 198 and 199). Ensure there is clearance to oil line.
122 This photo is a reference for oil drain hoses - (Items 188, 189, 186 and 190), Y piece (Item 192), check valve (Item 214), barb (Item 215) and banjo adaptors (Item 185).
123 Using sealant assemble barb fittings (Item 215) to check valve (Item 214).
124 Fit viton O ring (Item 219) to oil return adaptor (Item 217) and barb fitting (Item 213) with sealant.
125 Remove stock oil filter cap from oil reservoir and remove stock mounting bolt.
126 Install oil return adaptor (Item 217) to oil reservoir using clamp (Item 218). Secure using stock mounting bolt.
127 Exchange stock caps from rocker cover and oil reservoir.
128 Read next step, take note of images and then install.

Install oil hoses (Item 190) to barbs (Item 201), previously installed in pump (Item 193). Connect Y piece (Item 192) to IN hose (Item 190) to pump.

Wrap spiral wrap (Items 186B, 188B and 189B) around oil hoses (Items 186A, 188A and 189A).

Connect the LHS (Item 188A) and RHS (Item 189A) oil drain hoses to Y piece (Item 192). The LHS hose (Item 188A) is routed forward of engine, under power steering rack and along LHS of oil pan to the LHS turbo. The RHS hose (Item 729A) is routed along the RHS of sump, towards the RHS turbo.

Install banjo adaptors (Item 185) using banjo bolts (Item 187) with copper washers (Item 184) to oil drains of turbos.

Connect LHS oil drain hose (Item 188A) and RHS (Item 189A) to banjo adaptors (Item 185).

Connect check valve (Item 214) to OUT hose (Item 190) on scavenge pump (Item 193). NOTE FLOW DIRECTION.

Connect oil return hose (Item 186A to check valve (Item 254) and barb (Item 213) in oil return adaptor (Item 217).

All the oil return hoses are secured using hose clamps (Item 191).

Use tie straps (Item 216 & 224) to secure LHS (Item 728A) and RHS (Item 729A) drain hose as shown.

129 Remove oil reservoir stock mounting bolts holding reservoir to chassis rail.
130 Connect oil reservoir hose (Item 220) between oil pan and oil reservoir using bolts (Item 221), washers (Item 198 and 199) and stock hose seals.

Install hose support clamp (Item 222) to lower bolt on turbocharger compressor housing, as shown.

Reinstall the stock oil factory hose between oil pan and oil reservoir.
131 Remount stock oil reservoir.
132 Install stock MAF sensor in cast inlet duct (Item 137).
133 Connect duct (Item 137) to intercooler using LHS intercooler outlet hose (Item 135) and RHS intercooler outlet hose (Item 136) hose secured by 70/90 hose clamps (Item 129).
134 Connect hose (Item 138) between duct (Item 137) and throttle body using 90/110 hose clamps (Item 140).
135 Remove and discard stock PCV hose between intake manifold and valley cover behind throttle body.
136 Cut PCV intake hose (Item 18) and install one way valve (Item 17) using spring clamps (Item 19).
137 Reinstall hose (Item 18) with one way valve (Item 17).
138 Unclip and discard stock breather tube from forward port on oil reservoir.
139 Remove stock breather tube between LHS rear rocker cover and T joint.
140 Install 10mm plug (Item 27) to T connection.
141 Connect RHS breather hose (Item 15) to the forward port on oil reservoir and route forward along inner guard and beside radiator.

Secure to stock quick connector using spring clip (Item 16).

142 Route 6mm vacuum hose (Item 14) previously connected to rear of intake manifold along same route as breather hose (Item 15).

Secure using ties (Item 21).

143 Connect LHS breather hose (Item 15) to stock quick connector rear of LHS rocker cover and secure with spring clip (Item 16).
144 Route LHS breather hose (Item 15) forward next to coil pack and beside radiator. Secure with tie (Item 21).
145 Route the vacuum hose (Item 14) below RHS intercooler and install the T piece (Item 22). Retain with spring clips (Item 20), After cutting the hose (Item 14) to an appropriate length.

Check the length required and cut off the remaining vacuum hose (Item 14) two lengths in order to connect the BOV's to the tee piece (Item 22) and route the hose behind the air conditioning condensor, below the radiator to each BOV, retaining with tie straps (Item 21) and spring clips (Item 20) at the tee piece.
146 Connect vacuum hose (Item 14) to each BOV (Item 11) using spring clips (Item 20).
147 Connect each breather hose (Item 15) to air filter joiner ducts (Item 2) using spring clips (Item 16).
148 Secure stock air temp sensor bracket to RHS radiator brace using tie (Item 21).
149 Locate under hood fuse box, remove lid and unbolt power connection.

Remove four fuse box body retaining bolts.

Unclip retaining clips to separate top from lower halves of fuse box.

150 Unclip fuse box retaining tabs and lift top half of fuse box.

Unplug loom connections.

151 Release retaining clips from grey loom plug and locate stock grey wire in the position shown.

Solder grey trigger wire from APS loom relay assembly (Item 200) and wrap with electrical tape.
152 Reinstall fuse box.
153 Install combined scavenge pump, oil control solenoid valve wiring loom relays (Item 200) by affixing to stock hood latch mechanism using 6mm x 20mm socket head bolt (Item 211) and 6mm body washer (Item 212), installed between relay bracket and hood latch.

Install two red loom power leads with round terminals to the under hood fuse power box terminal.

154 Install all three black loom earth leads with round terminals to stock earthing point under stock fuse box.
155 Route pump wiring along oil return hose to scavenge pump securing with ties (Item 216).
156 Connect solenoid plug to solenoid wire.
Connect the fuel pump positive wire and install the negative earth wire as shown.
Engine Oil Cooling System
ocs 1
 Install the two top oil cooler mounting brackets (Item 246) to the upper intercooler mounting holes using 6mm x 1.0 x 16mm bolts (item 249), star washers (Item 250) and body washers (Item 251).

Note: Do not fully tighten.
ocs 2
 Position oil cooler (Item 241) from below and secure to the top mounting brackets (Item 246) using 6mm x 1.0 x 14mm bolts (Item 248).
ocs 3
 Trim the stock lower left air directional spoiler as shown and refit to the lower support bar.
ocs 4
 Install the oil cooler lower mounting bracket (Item 247) using stock bolt, 8mm x 1.25 x 16mm bolt (Item 252), star washer (Item 253) and flat washer (Item 254).

The oil hoses are fitted later.
ocs 5
 Align oil cooler (Item 24) with intercoolers and tighten all mounting bolts.
ocs 6
 Route the stock oil lines to the RHS of radiator.

Note orientation.
ocs 7
 Remove the stock adaptors from the stock oil cooler inlet/outlet ports.

Install the stock oil cooler adaptors to the oil hoses (Item 242 & 243) and connect to the stock oil lines using stock circlips.

Note: Oil hose orientation.
ocs 8
 Install spiral wrap (Item 256) over hose connections.
ocs 9
 Connect oil hoses (Item 242 & 243) to inlet/outlet ports of oil cooler (Item 241) using banjo bolts (Item 244) and copper washers (Item 245).
ocs 10
 Secure oil lines using cable ties (Item 255).
ocs 11
 Install air centre directional duct (Item 141) with rubber edging (Item 146) from above. Drill 1/8" holes and secure using self tapping screws (Item 145).

ocs 12
 Trim front bumper as shown.
ocs 13
 Install the stock rubber seal.
157 Install exhaust intermediate pipe, LHS (Item 311), RHS (Item 312) using 3" gaskets (Item 316) and 2.5" gasket (Item 317) to outlet pipes using bolts (Item 314), washers (Item 313) and nuts (Item 315).
158 Insert rear exhaust adaptors, LHS (Item 319), RHS (Item 320) into intermediate pipes using sealant and clamps (318). Do not fully tighten.
160 Install rear mufflers, LHS (Item 321), RHS (Item 322) using 3" gaskets (Item 316), bolts (Item 314), washers (Item 313) and nuts (Item 315). Once aligned fully tighten all joints.
161 Trim front bumper directional duct as shown.
162 Trim LHS and RHS front inner fenders as shown.

Completion of Installation
163 Ensure that the engine oil grade utilized is suitable for use with gasoline turbocharged engines.
164 Re-fill power steering system in accordance with the factory service manual.
165 Refill the engine coolant in accordance with the factory service manual.
166 Verify that all hose clamps and fasteners are tightened.
167 Verify that all components which are affected by engine movement have sufficient clearance to adjacent body panels.
168 Turn the ignition switch to the "ON" position and physically check that the oil scavenge pump is operating.

WARNING DO NOT START THE ENGINE
169 Switch the ignition on and off several times to pressurize the fuel system.

Check all fuel connections closely for any signs of fuel leakage.
170 Once the operation of the oil scavenge pump is confirmed, start the engine and check the cooling system for leaks with the engine running. Remember, water now runs through both turbochargers.
171 Verify there are no oil, water or most importantly fuel leaks in either the engine compartment.
172 After a final check for fluid leaks, replace the cosmetic engine cover and any other auxiliary components that were removed during the installation.
173 Install the body clips (Item 280) to the LHS and RHS engine cover brackets (Item 277 & 278).

174 Mount engine cover brackets (Item 277 & 278).
175 Install the covers (Note: May need modifying near the fuel hose). Drill 1/4" hole and secure using M5 x 0.8mm x16mm B/H bolts (Item 287) with M5 washers (Item 302).