APS Intercooled Twin Turbo
APSGMF-TTS/01
Installation Guides
 

   
 
 

APS Intercooled Twin Turbo System Installation Guide - APSGMF-TTS/01
Before Commencing Installation:

APSGMF-TTS/01:  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 and that you have all necessary tools as listed.

A BMR KM003 K-Frame is required (not included) in order to install the APS Intercooled Twin Turbo System.

IF STOCK LS1 VALVE SPRINGS ARE STILL FITTED TO ENGINE, UPGRADED COMPONENTS SHOULD BE INSTALLED!

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.

  • TR55 Stock – should only be used with totally stock exhaust system. Boost below 8 psi, ambient temperature below 60°F.
  • TR6 Service Option – should be used for general street operation work with cat-back exhaust system. Boost 8-9 psi, ambient temperature 60°-100°F.
  • TR7IX Service Option – drag racing in an ambient temperature range of 60°-100°F.
  • TR8IX 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 – 1/8" NPT, 3/8" NPT.

(3) General

  • Small angle grinder.
  • Screwdriver set.
  • Pliers – flat, point, side cutter, multi-grip.
  • Electrical drill.
  • Drill bit – 1/8", 9/32", 11/32", 9/16"

(4) Sealants

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

(5) Adhesives - Super Glue
Torque Table - APS Fasteners
HEX Head Bolt (8.8)
Socket Head Bolt (10.9)
A286 Stud
N-m
Ft - lbs
N-m
Ft-lbs
N-m
Ft-lbs
M6 x 1.0
9.5
7
13.5
10
9.5
7
M8 x 1.0
26.0
19
36.5
27
26.0
19
M8 x 1.35
23.0
17
32.5
24
23.0
17
M10 x 1.25
50.0
37
72.0
53
50.0
37
M10 x 1.5
45.0
33
64.0
47
45.0
33
Step-by-step Guide
1 Ensure that the headlights are in the raised position and disconnect the battery terminals from the battery.
2 Remove the following items in accordance with the factory service manual:
  • Plastic under tray
  • Inner fenders
  • Front bumper
  • Hood
3 Remove the stock air filter assembly and stock ducting to the throttle body. Retain the stock Mass Air Flow meter and the stock temperature sensor and mounting grommet for re-installation at a later stage.
4 Remove the following components in accordance with the factory service manual.
  • Front bumper support beam
  • Windscreen washer bottle
  • Hood catch
  • Hood catch support bracket
5 Remove the horns , horn mounting bracket and the stock battery tray/radiator overflow bottle in accordance with the factory service manual.
6 Apply a liberal amount of penetrating thread unlocking oil and remove the exhaust system from the flanges shown.

Remove the oxygen sensors.

Remove the engine oil dipstick.
7 Remove the cat pipes and exhaust manifolds.
8 Drain the engine oil and coolant from the engine.

Remove the stock ignition coil packs and plug leads.

Note: If the stock LS1 valve springs are still being used, then upgraded valve springs must be installed. This is a convenient stage to do so.
9 Support the vehicle chassis and engine block securely.

Note that the oil pan will be removed at the next step after K-Frame removal - hence the engine block must be supported fully from points other than the oil pan.

Remove the stock K-Frame in accordance with the BMR instructions (except for supporting the engine by the oil pan - must be supported elsewhere).

10 Remove the engine oil pan and drill a 9/16" hole on the LHS of the pan in the position shown.

Tap the hole using a 3/8" NPT tap.

Apply thread sealant to the 3/8" NPT x 5/8" Barb Adaptor (Item 151) and install into the pan as shown.
11 Drill a 9/16" hole on the RHS of the oil pan in the position shown.

Tap the hole using a 3/8" NPT tap.

Apply thread sealant to the 3/8" NPT x 5/8" Barb Adaptor (Item 151) and install into the oil pan as shown.

Clean the modified oil pan thoroughly and reinstall.
12 Remove the stock engine mounts and discard the stock LHS shield shown.
13 Install the new LHS and RHS engine mounts (Items 110) supplied.
14 Install six new 8mm x 1.25 x 1.0 x 25mm (37mm O/L) stainless steel studs (Item 76) to the LHS cylinder head as shown.
15 Install five new 8mm x 1.25 x 1.0 x 25mm (37mm O/L) stainless steel studs (Item 76) to the RHS cylinder head as shown.

Install a shorter 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel stud (Item 73) in the position shown (4th from the front of the engine) in order to provide clearance for the dipstick.
16 Remove the stock oil cooler take-off cover above the oil filter. Drill and tap the outlet port on the cover with a 11/32" drill. Tap to 1/8" NPT thread.

Apply thread sealant to the 7/16" JIC run x 1/8" NPT branch Tee Adaptor (Item 141) and install into the oil cooler take-off cover. NOTE the orientation of the adaptor (Item 141) relative to the oil take-off cover

Install the oil cooler take-off cover assembly to the engine as shown. NOTE Orientation.
17 Remove the stock coolant plug from the rear of the RHS cylinder head and install the 12mm x 1.5 x 9/16" JIC straight adaptor (Item 161) with a 12/18mm Copper Washer (Item 145).
18 Install the RHS outer water hose (Item 160) to the adaptor (Item 161) installed previously to the RHS cylinder head.

Note the orientation of the hose - then tighten.
19 Remove the stock large coolant plug from the LHS of the engine block, just forward of the engine mount - Caution as engine coolant will flow out.

Apply thread sealant to the 28mm x 1.25 x 9/16" JIC adaptor (Item 153) and install the adaptor into the engine block as shown.

Install the LHS outer water hose (Item 154).
20 Modify the lower lip of the RHS chassis rail by bending outwards for clearance.

Clean the area and apply a coat of paint.

21 Repeat the above for the lower lip of the LHS chassis rail.
22 Wear sturdy protective gloves and form the LHS heat shield (Item 77) around the LHS exhaust manifold (Item 71). Secure the heat shield (Item 77) with 6mm x 1.0 x 12mm stainless steel bolts (Item 81) and 6mm x 16mm stainless steel washers (Item 80). Install two stainless steel tie straps (Item 82) as shown.

Install four 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel studs (Item 73) to the exhaust manifold (Item 71) outlet flange.
23 Wear sturdy protective gloves and form the RHS heat shield (Item 78) around the RHS exhaust manifold (Item 72). Secure the heat shield (Item 78) with 6mm x 1.0 x 12mm stainless steel bolts (Item 81) and 6mm x 16mm stainless steel washers (Item 80). Install a stainless steel tie strap (Item 82) as shown.

Install four 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel studs (Item 73) to the exhaust manifold (Item 72) outlet flange.
24 Install the 14mm x 1.5 x 9/16" JIC coolant adaptors (Item 155) and 14/20mm copper washers (Item 156) to the LHS turbocharger assembly (Item 41).

Install the short straight oil drain (Item 147) and gasket (Item 146) to the LHS turbocharger assembly (Item 41) and retain with 6mm x 1.0 x 16mm hex head bolts (Item 148).
25 Install five 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel studs (Item 63) into the LHS turbocharger flange as shown.

Install a single 6mm x 1.0 x 20mm stainless steel stud (Item 66) into the LHS turbocharger flange as shown.
26 Apply a thin coating of Permatex ultra copper sealant to the LHS exhaust manifold outlet flange and install the LHS turbocharger assembly (Item 41).

Ensure that the turbocharger is square on the studs and retain with four 8mm x 1.0 nuts (Item 74) and flat 8mm stainless steel washers (Item 75).
27 Install two 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel studs (Item 45) to the LHS wastegate (Item 43) and install the wastegate assembly (Item 43) with flange gasket (Supplied with wastegate (Item 43)) to the LHS outlet pipe (Item 61). Retain using 8mm Selfloc nuts (Item 47) and washers (Item 46) on the studs (Item 45) and S/H bolts and washers supplied with the wastegate (Item 43).
28 Install the filter (Item 44) and washer supplied with the wastegate (Item 43) to the rear port of the wastegate (Item 43).

Install the barb to the side port of the wastegate (Item 43) with an alloy washer at each side and retain using the banjo bolt supplied with the wastegate (Item 43). Note the orientation of the barb adaptor relative to the wastegate/outlet pipe assembly.
29 Apply a thin coating of Permatex ultra copper sealant to the LHS turbocharger outlet flange and install the LHS outlet pipe (Item 61) to the LHS turbocharger outlet. Retain with 8mm x 1.0 Selfloc buts (Item 64) and 8mm stainless steel washers (Item 65) in the positions shown. Use a 6.0mm x 1.0mm Selfloc nut (Item 68) and 6mm stainless steel washer (Item 67) in the position shown.
30 Install the LHS oil supply hose (Item 142) with a copper washer (Item 145) on either side of the fitting and retain with a banjo bolt (Item 144). Note the orientation of the oil supply hose (Item 142).
31 Install the 14mm x 1.5 x 9/16" JIC coolant adaptor (Item 155) and 20mm OD x 5mm thick washer (Item 163) to the RHS turbocharger assembly (Item 42).

Install the banjo fitting (Item 157) to the RHS turbocharger assembly (Item 42) with a 20mm OD x 5mm thick washer (Item 163) on the turbocharger side of the fitting and a 14/20mm copper washer (Item 156) on the outer side and retain with a banjo bolt (Item 158).

Install the short straight oil drain (Item 147) and gasket (Item 146) to the RHS turbocharger assembly (Item 42) and retain with 6mm x 1.0 x 16mm hex head bolts (Item 148).
32 Install five 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel studs (Item 63) into the RHS turbocharger flange as shown.

Install a single 6mm x 1.0 x 20mm stainless steel stud (Item 66) into the RHS turbocharger flange as shown.
33 Apply a thin coating of Permatex ultra copper sealant to the RHS exhaust manifold outlet flange and install the RHS turbocharger assembly (Item 42).

Ensure that the turbocharger is square on the studs and retain with four 8mm x 1.0 nuts (Item 74) and flat 8mm stainless steel washers (Item 75).
34 Install two 8 x 1.25 x 1.0 x 23.5mm (35.5mm O/L) stainless steel studs (Item 45) to the RHS wastegate (Item 43) and install the wastegate assembly (Item 43) with flange gasket (Supplied with wastegate (Item 43)) to the RHS outlet pipe (Item 62). Retain using 8mm x 1.0 Selfloc nuts (Item 47) and washers (Item 46) on the studs (Item 45) and S/H bolts and washers supplied with the wastegate (Item 43).

Install the filter (Item 44) and washer supplied with the wastegate (Item 43) to the rear port of the wastegate (Item 43).

Install the barb to the side port of the wastegate (Item 43) with an alloy washer at each side and retain with the banjo bolt supplied with the wastegate (Item 43). Note the orientation of the barb adaptor.
35 Loosen the V Band clamp on the RHS turbocharger (Item 42) and rotate in the direction shown in order to provide clearance for further installation steps.

Install the RHS oil supply hose (Item 143) with a 12/18mm copper washer (Item 145) on either side of the fitting and retain with a 12mm x 1.5 banjo bolt (Item 144).
36 Rotate back in the direction shown until 2mm clearance between the banjo bolt and stud is achieved.

Tighten the V Band clamp.
37 Apply a thin coating of Permatex ultra copper sealant to the RHS turbocharger outlet flange and install the RHS outlet pipe (Item 62) to the RHS turbocharger outlet. Retain with 8mm x 1.0 Selfloc nuts (Item 64) and 6mm stainless steel washers (Item 65) in the positions shown. Use a 6.0mm x 1.0mm Selfloc nut (Item 68) and 6mm stainless steel washer (Item 67) in the position shown.
38 Form the starter motor heat shield (Item 79) over the RHS exhaust manifold and turbocharger assembly and secure using a 360mm stainless steel tie strap (Item 82).
39 Install the stock RHS O2 sensor to the RHS outlet pipe (Item 62) and route the stock wiring forward as shown.
40 Remove the starter motor assembly.
41 Position the stock negative cable located at the RHS rear of the engine block as shown.
42 Remove the stock tag shown from the stock starter motor positive cable.
43 Position the stock exhaust manifold gasket on the RHS cylinder head studs.
44 Carefully raise the RHS exhaust manifold/turbocharger/outlet pipe assembly from below the vehicle and install onto the cylinder head studs. Note that this operation requires two people - one from above and one below.

Retain with 8mm x 1.0 nuts (Item 74) and 8mm stainless steel washers (Item 75). DO NOT fully tighten yet.
45 Route the stock O2 sensor and crank angle sensor wires behind the earth cable located on the RHS rear of the engine block.
46 Locate the starter motor on the engine but do not install. Connect the stock small power wire and then the main power cable.
47 Ensure that there is no contact between the wires.
48 Install the LHS oil Supply Hose (Item 142) to the rear port of the Oil Supply Adaptor (Item 141) installed earlier.
49 Install the LHS Outer Water hose (Item 154) to the outer coolant adaptor (Item 155) on the LHS turbocharger (Item 41)
50 Install the LHS stock front O2 sensor and wiring.
51 Connect the centre water hose (Item 159) to inner coolant adaptor (Item 155) on LHS turbocharger (Item 41). This hose is routed to the RHS turbocharger under the lower front portion of oil pan.

Install the LHS oil drain hose (Item 149) to oil drain (Item 147) and secure with 16/25 mm hose clamps (Item 152).
52 Connect the LHS boost sensing hose (Item 51) between the barb fitting on the compressor housing, to the barb fitting on the wastegate ensuring to secure using spring clips (Item 53).
53 Route the RHS turbocharger oil supply hose (Item 143) under the front lower portion of the oil pan to the forward facing port of the oil supply adaptor (Item 141) installed earlier.
54 Connect the RHS outer water hose (Item 160) to RHS outer water adaptor (Item 155).

On the RHS turbocharger, connect the centre water hose (Item 159) to the inner Banjo fitting (Item 157). Connect the RHS oil drain hose (Item 150) to the oil drain (Item 147) and oil pan adaptor (Item 151) securing with hose clamps (Item 152).

Install the boost sensing hose (Item 52) between the barb fitting on compressor housing and the barb fitting on the wastegate, securing with spring clips (Item 53).
55 Install the BMR K-Frame as per BMR instructions.

NOTE: RHS rear lower control arm bolt is installed from below.

56 NOTE: Remove locating tab.
57 NOTE: Stock wiring loom passes between K-Frame and engine mount on the RHS.
58 Install the stock EGR pipe to the RHS forward facing port on RHS exhaust manifold (note this may require loosening of the EGR valve mounting bracket). Secure with bolts (Item 83) using the stock gasket.
59 Install the starter motor.
60 Ensure adequate clearance of turbocharger compressor housing outlets to frame and BMR K member and fully tighten manifolds to cylinder head nuts (Item 74)
61 Secure the stock loom shown to the RHS outer coolant hose (Item 160) using a 4.8mm x 7" tie strap (Item 162).
62 The radiator support panel requires modification as described in the following steps.
63 Mark as shown.
64 Trim as shown.
65 Remove and discard the stock wiring loom support clip.

66 Mark and cut the lower seam on the LHS top radiator support panel as shown.
67 Mark and cut the lower seam on the RHS top radiator support panel as shown.
68 Carefully bend the lip forward.
69 After bending the lip.
70 Mark and cut a further 3 inches on LHS of the first cut and bend upwards.
71 View of modified lip.
72 Mark and cut a further 3 inches on RHS of the first cut and bend upwards.
73 Use Superglue to install the rubber edging (Item 138) to lower edge of radiator support panel.
74 Remove the stock radiator cooling fans by pushing upwards to unclip and remove from below vehicle.
75 Unplug the wiring harness from ABS brake unit.
76 To protect air con condensor during the installation of the intercooler assembly, place a sheet of thin cardboard over condensor.
77 To avoid damage to the finish of the intercooler outlet tank, use masking tape to cover the front curved section that may come onto contact with any panel work (not shown).

Carefully push the radiator and air condensor rearward while lifting intercooler (Item 98) into position.

78 Raise the intercooler assembly (Item 98) up.
79 Intercooler shown in position.
80 Locate the intercooler assembly (Item 98) on the rubber edging on the lower radiator support panel.
81 Install the upper brackets LHS (Item 99) RHS (Item 100).

82 Secure with 6mm x 1.0 x 14mm bolts (Item 105) to intercooler. Stock nuts mount the brackets to the radiator support panel. Do not fully tighten.
83 Discard the stock cruise control cable cover from the LHS chassis rail.
84 Remove the air pump and mounting bracket.

Discard the stock air inlet hose.
85 Remove the air pump from the stock mounting bracket.
86 Remove the stock mounting bushes from the stock air pump bracket (3 only)
87 Reinstall the stock mounting bushes to the air pump bracket (Item 115).
88 Bracket (Item 115) with bushes installed.
89 Install the stock air pump to the air pump bracket (Item 115) using stock bolts with 6mm washers (Item 122) and nyloc nuts (Item 121).
90 Lower the sway bar from chassis rails.
91 Install the LHS compressor discharge hose (Item 91) to the LHS turbocharger (Item 41) and retain with a 40/60mm hose clamp (Item 96) - Do not tighten yet.
92 Install the silicone joiner hose (Item 95) to the LHS intercooler entry and retain with a 60/80 mm hose clamp (Item 97).

NOTE: Stainless Steel Duct shown will be installed in the following steps.
93 Position the LHS discharge duct (Item 93) between the LHS discharge hose (Item 91) and the LHS intercooler entry joiner hose (Item 95) as shown.
94

Secure the LHS discharge duct (Item 93) to the stock brake hose bracket using a 8mm x 1.25 x 25mm bolt (Item 132) 8mm washer (Item 127) and 8mm x 1.25 nyloc nut (Item 131).

Install the LHS discharge duct (Item 93) to the compressor discharge hose (Item 91) using a 50/70mm hose clamp (Item 118).
95 Install the LHS discharge duct (Item 93) to the LHS intercooler entry joiner hose (Item 95) and retain with a 60/80 mm hose clamp (Item 97).
96 Tighten the 40/60mm hose clamp (Item 96) on the LHS turbocharger compressor discharge.
97 Install the RHS discharge hose (Item 92) to RHS turbocharger compressor outlet and retain with a 40/60mm hose clamp (Item 96).

Do not tighten yet.
98 Install the silicone joiner hose (Item 95) to the RHS intercooler entry and retain with a 60/80 mm hose clamp (Item 97).

NOTE: Stainless Steel Duct shown will be installed in the following steps.
99 Position the RHS discharge duct (Item 94) between the RHS discharge hose (Item 92) and the RHS intercooler entry joiner hose (Item 95) as shown.
100 Secure the RHS discharge duct (Item 94) to the stock brake hose bracket using a 8mm x 1.25 x 25mm bolt (Item 132), 8mm washer (Item 127) and 8mm x 1.25 nyloc nut (Item 131).

Install the RHS compressor discharge hose (Item 92) to the RHS discharge duct (Item 94) and retain with a 50/70mm stainless steel hose clamp (Item 118).
101 Install the RHS discharge duct (Item 94) to the RHS intercooler entry joiner hose (Item 95) and retain with a 60/80 mm hose clamp (Item 97).
102 Tighten the 40/60mm hose clamp (Item 96) on the RHS turbocharger compressor discharge.
103 Front view showing the intercooler assembly with the joiner hoses and LHS & RHS compressor discharge ducts installed.
104 Remove the top radiator stock rubber isolators from the stock plastic support.
105 Insert the stock rubber isolators into top radiator brackets (Item 114).
106 Align the intercooler outlet with centre of throttle body.

107

Allow 1/4" clearance from top radiator to the support panel.

Fully tighten intercooler mounting brackets (Item 99 &100).
108 Slide the top air direction duct (Item 107) forward from rear of intercooler outlet.
109

Install the radiator support brackets (Item 114) using 6mm x 1.0 x 20mm bolts (Item 124). Do not fully tighten.

110

Position 10mm x 24mm x 10mm body washers (Item 130) under the air direction duct (Item 107)

111

Install 6mm x 1.0 x 20mm bolts (Item 124) through the top air directional duct (Item 107) and body washers (Item 130) as shown.

Do not fully tighten.
112 Ensure that the air direction duct is level with the top of air condensor and drill two 1/8" holes through the top edge of the condensor.
113 Secure the air directional duct (Item 107) to the condensor using two 4.2mm x 16mm self tapping screws (Item 126).

Fully tighten the front air direction duct bolts (Item 124).
114 Overall view.
115 Reinstall the stock radiator fans from below.
116 Install the stock grommet and air temperature sensor to the intercooler outlet.
117 Install the stock air flow meter using a 90/100mm silicone reducer hose (Item 101) and MAF/Throttle body hose (Item 103).

Secure using 90/110mm (Item 102) & 80/100 (Item 104) stainless steel hose clamps.
118 Side view of the air flow meter installation.
119 Install the air pump assembly into the stock mounting holes. Install the air filter (Item 116) and secure with a 20/32mm hose clamp (Item 133).
120 Cut the filler neck of the stock radiator overflow bottle 7 1/2" from the top.
121 Install the battery tray (Item 113) by aligning the battery clamp mounting hole and securing the tray with a 8mm x 1.25 x 16mm B/H cap screw (Item 125), as shown.

122 Install the rubber grommet (Item 134) into the stainless steel radiator overflow bottle (Item 111).

123 Install the radiator overflow bottle (Item 111) from below, using B/H 8mm x 1.25 x 16mm screws (Item 125) with 5/16" I.D. x 1" O.D. S/S body washer (Item 128), 8mm flat washers (Item 127) and 8mm nyloc nuts (Item 131) to secure it in place.

124 Install the rubber pad (Item 109), in the floor of the battery tray in order to protect the bottom of the battery.
125 Install the radiator overflow bottle filler neck using a 42mm ID x 50mm joiner hose (Item 117). Secure it in place with 32/50mm hose clamps (Item 129).

126 Install the 3/8" ID x 29.5" overflow hose (Item 137), between the radiator filler neck and grommet (Item 134), in the radiator overflow bottle (Item 111).
127 Install the RHS air entry hose (Item 5) using 60/80mm hose clamp (Item 6), onto the compressor entry of the turbocharger (Item 42).

Place a second 60/80mm hose clamp (Item 6) around forward end of air entry hose, as shown.

128 NOTE: Hose clamp orientation
129 Install the RHS stainless steel air entry duct (Item 3) which is secured by the stock sway bar mounting bolts with two 10mm flat washers (Item 23) at each bolt, used as spacers between the stock sway bar mounting bracket and the brackets on the air entry duct (Item 3). Tighten 60/80mm hose clamp (Item 6) around air entry hose (Item 5).
130 Drill a 1/8" hole for the front support bracket of RHS S/S air entry duct (Item 3).
131 Secure the support bracket using self tapping screw (Item 24).
132 Install the Air filter (Item 1) using 60/80 hose clamp (Item 6).
133 Install the RHS blow off valve (BOV) inlet hose (Item 8) to the RHS discharge duct (Item 94) and retain with a 25/40 mm stainless steel hose clamp (Item 11).

Install the RHS BOV (Item 7) to the RHS BOV inlet hose (Item 8) and retain with a 20/32 mm stainless steel hose clamp (Item 21).

Install the BOV outlet hose (Item 10) to the BOV outlet port and retain with a 20/32 mm stainless steel hose clamp (Item 21). Install the other end of the RHS BOV outlet hose (Item 10) to the RHS air entry duct (Item 3) and retain with a 25/40 mm stainless steel hose clamp (Item 11).
134 Install the LHS turbocharger air entry hose (Item 4) and retain with a 60/80mm stainless steel hose clamp (Item 6), to the compressor entry of the turbocharger (Item 41).
135 The other end of the LHS air entry hose (Item 4) is positioned as shown in preparation for the installation of more components.

Loosely install a 60/80mm stainless steel hose clamp (Item 6) over the end of the hose.
136 Remove the stock inner air pump mounting bolt and steel sleeve.
137 Install two 10mm washers (Item 23) on each bolts between the stock sway bar mounting bracket and the bracket on the LHS air entry duct (Item 2) as shown.

Install the stock air pump bolt and sleeve through air entry bracket as shown.

Install the LHS air entry hose (Item 4) to the LHS air entry duct (Item 2) and retain with a 60/80mm stainless steel hose clamp (Item 6).
138 Secure the LHS air entry hose to the K-Frame with a tie strap (Item 25).
139 Ensure that there is adequate clearance to the steering shaft coupling.
140 Install the LHS air filter (Item 1) to the LHS air entry duct (Item 2) and retain with a 60/80mm stainless steel hose clamp (Item 6).
141 Install the LHS blow off valve (BOV) inlet hose (Item 8) to the LHS discharge duct (Item 93) and retain with a 25/40 mm stainless steel hose clamp (Item 11).

Install the LHS BOV (Item 7) to the BOV inlet hose (Item 8) and retain with a 20/32 mm stainless steel hose clamp (Item 21).

Install the LHS BOV outlet hose (Item 9) to the BOV outlet port and retain with a 20/32 mm stainless steel hose clamp (Item 21). Install the other end of the LHS BOV outlet hose (Item 9) to the LHS air entry duct (Item 2) and retain with a 25/40 mm stainless steel hose clamp (Item 11).
142 Overall view of the air intake system installation.
143 Install the 4mm ID x 127" vacuum sensing hose (Item 14) with a 3/16" steel tee-piece (Item 20) to the vacuum port at the rear of the stock intake manifold and retain with a spring clips (Item 19).

The vacuum sensing hose (Item 14) is used as part of the BOV circuit to be installed at a later step in the installation guide.

Note: the stock intake manifold has been removed in order to show the rear manifold pressure port details. This operation can be performed without removing the intake manifold.
144 Route the vacuum sensing hose (Item 14) along the RHS rocker cover as shown.
145 Remove the stock PCV hoses.
146 Remove the stock breather hose that runs from the RHS rocker cover to the throttle body and discard.
147 Cut a 2" length from the PCV hose (Item 17) and install the one-way valve (Item 16). Retain with spring hose clamps (Item 18).
148 Install the hose/one-way valve assembly between the RHS rocker cover and the PCV port in the front of the intake manifold. Retain with spring hose clamps (Item 18).
149 Install a blank off plug (Item 22) to the rear of the throttle body and retain with a spring hose clamp (Item 15).
150 Remove the rocker cover fitting from the stock breather hose.
151 The LHS rocker breather is routed to the RHS air intake as described below.

Install the LHS Breather Hose (Item 12) with stock fitting to the LHS rear rocker cover.

Route the breather hose (Item 12) behind the engine to the rear of the RHS rocker cover and along the RHS of the intake manifold towards the front RHS of the engine.

Route next to the battery tray as shown, down to the RHS air entry duct (Item 3) and secure using spring clips (Item 15) and tie straps (Item 26).

152 The RHS rocker breather is routed to the LHS air intake as described below.

Install the RHS breather hose (Item 13) to the barb in the rear of the RHS rocker cover.

Route breather hose (Item 13) behind the engine to the rear of the LHS rocker cover and forward along LHS of the intake manifold to the front LHS of the engine.

Route behind the power steering pump reservoir and the ABS unit to the LHS air entry duct (Item 2) securing using spring clips (Item 15).

153
Reinstall the dip stick.

154 Reinstall coil packs and spark plug leads.
155 Reinstall the air pump hoses to both exhaust manifolds using stock gaskets and 8mm x 1.25 x 16mm bolts (Item 83).

156 Cut foam edging (Item 120) as shown and adhere to the LHS & RHS sides of intercooler forward face.

157 Insert spire clips (Item 119) to the front air directional duct (Item 106).

158 Cut section from hood catch as shown.

158a Remove front section from hood catch.

158b

 Flatten edges on hood catch as shown.

158b

 Detail view of flattened edges.

159 Insert the hood catch into the front air directional duct (Item 106).
159a Secure using stock bolts (Finger tight).
159b Top view for reference.
160 Locate air directional duct (Item 106) onto the radiator support panel (Note fit hood release cable and route through notch on LHS of air directional duct) (Item 106).

160a Wiring loom located upwards along top of on intercooler.
160b Secure using stock bolts.
161 Install the stock front support bracket to the front of air directional duct (Item 106).

162 Install the stock windscreen washer bottle cap and pump using the stock grommet and cushion clamp (Item 136) securing using 6mm x 1.0 x 16mm bolt (Item 135) with washers (Item 123) and nut nyloc (Item 121) to windscreen washer bottle (Item 112).
163 Install the windscreen washer bottle (Item 112) to the front bumper support using 8mm x 1.25 x 16mm B/H cap screws (Item 125).

Note orientation of stock washer pump.

164 Trim front bumper beam as shown.

164a Discard cut section.
165 Trim front bumper inner panel as shown.

166 Mark the forward top LHS edge of bumper beam as shown.
166b Bend forward top LHS edge of bumper beam as shown.
167 Reinstall the modified front bumper beam.
168 Pull the front air directional duct (Item 106) forward from below and using it as a template, mark 4 holes in the modified lower front bumper beam in line with the holes in the duct.

Drill the 4 holes to 9/32" diameter as shown.

169 Insert spire clips (Item 119) into the 2 centre 9/32" holes previously drilled in front bumper beam.
170 Trim driving light support brackets as shown.

171 Mount driving lights using 6mm x 1.0 x 20mm bolts (Item 124) with 6mm washers (Item 123) and 6mm x 1.0 nuts (Item 121) using 9/32" outer holes, previously drilled in beam for location of inner holes in driving light brackets mark and drill 9/32" outer driving light bracket holes and mount driving lights as shown.

172 Support centre of air directional duct using 4.6mm x 16mm S/T screws (Item 108), into spire clips previously installed in centre holes in the bumper beam.
173 Route Vacuum sensing hose (Item 14) (that was previously installed on the tee piece at the rear of the intake manifold) beside the RHS of the radiator, to the front bumper beam. Cut 43.5" for the LHS BOV and 18" for the RHS BOV and install the Tee Piece (Item