APS Intercooled Twin Turbo
APSPG8-TTS/01
Installation Guides
 

   
 
 

APS Intercooled Twin Turbo System Installation Guide - APSPG8-TTS/01
Before Commencing Installation:

APSPG8-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 for the Pontiac G8 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 – 3/8 NPT”.

(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”.

(4) Sealants

  • Permatex ultra copper – P/N 101 BR - Hot surface sealing
  • Loctite sealer – P/N 569 - Thread sealing
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 Disconnect the battery (located in trunk). We recommend putting carboard over the latch after the battery is disconnected.
2 Remove the stock top radiator plastic panel.
3 Remove the stock throttle body duct and discard.
4 Unclip the stock Mass Air Flow meter wiring harness and remove the stock Mass Air Flow meter from the air filter box. Remove and discard the stock air filter box.
5 Remove the left and right plastic inner fender liners and plastic front under tray.
6 Remove the front bumper according to the factory workshop manual.
7 Remove the stock plastic bumper support panel.
8 Unclip the stock air directional duct from the radiator support panel.

9 Unclip the stock air temperature sensor from the stock air directional ducts.
10 Remove the stock windscreen washer bottle filler neck.
11 Unclip the stock windscreen washer bottle wiring harness and the stock washer hose.
12 Remove the stock hood catch cover and disconnect the hood release cable.

13 Remove the stock bumper beam, the stock air directional duct and the stock windscreen washer bottle as an assembly.
13a Assembly removed from vehicle.
14 Remove and discard the stock air directional duct and the stock windscreen washer bottle.
15 Retain the stock windscreen washer pump and the stock rubber grommet installed in the stock washer bottle.
16 Remove the tab and clips shown.

17 Disconnect the stock wiring from the LHS and RHS horns and the stock support clips.
18 Disconnect the stock LHS and RHS headlight plugs.
19 Disconnect the stock hood catch electrical plug.
20 Unclip the stock wiring harness from the radiator support panel.
21 Unbolt the stock air bag sensors (bolts located behind radiator support panel).

22 Carefully remove the radiator support panel with the headlights.

23 Modify the top lip of the stock LHS chassis rail as shown.
24 Carefully modify the front end of the stock lower air conditioning line as shown.

25 Carefully modify the air conditioning line along the inside edge of the LHS chassis rail as shown.
26 Install the stock windscreen washer motor grommet first, then the stock windscreen washer motor into the windscreen washer bottle (Item 143). Secure the motor using M6 x 16mm bolt (Item 133) and cushion clamp (Item 144).
27 Locate the new washer bottle (Item 143) using a self tapping screw (Item 148) into a stock 3/16" diameter hole at the front of LHS chassis rail. Mark and drill two 3/16" diameter rear holes as shown.
27a Secure the washer bottle using self tapping screws (Item 148).
28 Mount the intercooler brackets (Item 135) and (Item 136) to the bumper beam using M6 bolts (Item 134).

Note: Do not fully tighten.
29 Mount the intercooler (Item 121) to the LHS and RHS brackets (Item 135 & 136) using M6 bolts (Item 133). Fully tighten all the bolts ensuring the intercooler is level and has clearance to the bumper beam.
30 Carefully attach the radiator support panel to the bumper beam and intercooler assembly.

30a Re-mount the entire assembly to the vehicle (2 people are required). Ensure there is adequate clearance around the intercooler outlet to the previously modified frame rail lip and radiator support panel, as shown.
31 Refit the stock air bag sensors, wiring loom, radiator support clips and re-connect the horn wiring.

32 Install the stock Mass Air Flow meter, intercooler outlet hose (Item 137), with the 3.75" joiner hose (Item 139), the throttle body duct (Item 138), the 4" joiner hose (Item 140) between the stock throttle body and the intercooler outlet, as shown. Secure using hose clamps (Item 141) 70/90 x 1 and hose clamps (Item 142) 90/110 x 5.
33 Cut the stock windscreen washer filler neck 4" from mounting hole.
34 Connect the stock windscreen washer filler neck to the washer bottle (Item 143) using a hose (Item 145) and secure using hose clamps (Item 146).
35 Install the windscreen washer bottle extension hose (Item 151), routing alongside the stock wiring loom behind the radiator support panel.
36 Cut and extend the stock windscreen washer pump loom using loom extension (Item 147) and route to the windscreen washer pump.
37 Mount the stock air temperature sensor to the hood release cable using a 7" tie strap (Item 150).
38 Remove the stock RHS 02 sensor forward of the stock catalytic converter.
38a Remove the stock LHS 02 sensor forward of the stock catalytic converter.
39 Remove the stock catalytic converters.
40 Install the loom extension (Item 85) to the LHS 02 Sensor. Leave the RHS 02 sensor hanging.
41 Install M10 and M8 studs (Item 103 & 105) in the turbocharger adaptors (Item 101 & 102).
42 Install M8 and M6 studs (Item 73 & 76) in the turbocharger outlets.
43 Install the 9/16" JIC x 14mm x 1.5 adaptors (Item 209) to the water ports of the LHS and RHS turbocharger. Seal using copper washers (Item 210).
44 Install the oil drain flanges (Item 178) to the LHS and RHS turbochargers with gaskets (Item 177), using M6 bolts (Item 179).
45 Using sealant, install the LHS outlet pipe (Item 71), using M8 nuts (Item 74), M8 washers (Item 75), M6 nuts (item 77) and M6 washers (Item 78) to the LHS  turbocharger.
45a Using sealant, install the RHS outlet pipe (Item 72), using M8 nuts (Item 74), M8 washers (Item 75), M6 nuts (item 77) and M6 washers (Item 78) to the RHS turbocharger.
46 Using sealant, install the LHS turbocharger adaptor (Item 101) to the LHS turbocharger (Item 41) using M8 nuts (Item 106) with M8 washers (Item 107).
46a Using sealant, install the RHS turbocharger adaptor (Item 102) to the RHS turbocharger (Item 42) using M8 nuts (Item 106) with M8 washers (Item 107).
47 Install M8 studs (Item 73) in the wastegates (Item 81).
48 Install the LHS wastegate (Item 81) with the LHS wastegate flex adaptor (Item 83) with gaskets (Supplied with wastegates) to the LHS turbo assembly using M8 nuts (Item 74), M8 washers (Item 75), M8 capscrews and M8 washers (supplied with wastegates).
48a Install the RHS wastegates (Item 81) with the RHS wastegate flex adaptor (Item 84) with gaskets (Supplied with wastegates) to the RHS turbo assembly using M8 nuts (Item 74), M8 washers (Item 75), M8 capscrews and M8 washers (supplied with wastegates).
49 Loosen the V-Band on the RHS turbocharger assembly and rotate to install the 32" long RHS oil supply hose (Item 174), banjo bolt (Item 175) and copper washers (Item 176). Fully tighten the banjo bolt.
50 Rotate the RHS turbo so there is 1/16" clearance from the banjo bolt to the mounting stud as shown, then re-tighten the V-Band.
51 Install the 43.5" long LHS oil supply hose (Item 173) to the LHS turbocharger assembly using banjo bolt (Item 175) with copper washers (Item 176).
52 Install M10 studs (Item 79) to the rear of the outlet pipes.
53 Install the wastegate filters (Item 82) to the rear port of the wastegate (Washers are supplied with the wastegates).
54 Install the wastegate barb fitting to the forward port of the RHS wastegate.

NOTE: Orientation as pictured.

54a Install the wastegate barb fitting to the forward port of the LHS wastegate.

NOTE: Orientation as pictured.

55 Using sealant install the LHS and RHS turbocharger assemblies to the standard exhaust manifolds, securing using M10 x 1.25 nuts (Item 104). Use the stock exhaust system in order to correctly align the adaptors, before tightening the M10 x 1.25 nuts (Item 104). Install the M10 x 1.25 nuts in order to retain the exhaust system flanges.
56 Drain engine coolant
57 Remove the stock water gallery plug from the front of LHS of the cylinder block (Caution coolant will come out).
58 Using sealant, install the water adaptor (Item 207) to the engine block.
59 Remove the stock water gallery plug from the rear side of RHS cylinder head.
60 Install the water adaptor (Item 213) with a copper washer (Item 176).
61 Install the LHS outer water hose (Item 208) to the LHS outer turbocharger adaptor (Item 209). Route upwards along the chassis rail.
61a Connect the LHS outer water hose (Item 208) to the to the cylinder block adaptor (item 207).
62 Install the center water hose (Item 211) between the inner turbocharger water adaptors (Item 209) and route below the bell housing.
63 Install the RHS outer water hose (Item 212) to the RHS cylinder head adaptor (Item 213).
63a Route the RHS outer water hose (Item 212) upwards and forwards ensuring there is clearance from the spark plug boot.
63b Connect the RHS outer water hose (Item 212) to the to the RHS outer turbocharger adaptor (Item 209).
64 Disconnect the stock wiring harness from the stock oil pressure sender located at the rear of the stock intake manifold.
64a Remove the stock oil pressure sender.
65 Install the 7/16" JIC x 16mm adaptor (Item 161) with a copper washer (Item 162).
66 Cut the stock oil pressure sender wiring harness and connect the wiring loom extension (Item 172).
67 Install the oil supply take off hose (Item 163) to the adaptor (item 161) and route to the RHS of engine.
68 Assemble the oil distribution block assembly, using the oil supply block (Item 170), adaptor 1/8" NPTM x 1/4" NPTM (Item 169), solennoid (item 168), adaptor 90˚ 7/16" JIC x 1/4" NPT (Item 167) and adaptors 45˚ 7/16" JIC x 1/8" NPT (Item 171).

Note: Orientation of adaptors and use sealant.
69 Install solenoid mounting bracket (Item 164) using M4 cap screws (Item 165) and M4 washers (Item 166).
70 Install the oil supply assembly to the RHS cylinder head between No. 4 and No. 6 exhaust ports using an M10 bolt (Item 215) with an M10 spring washer (Item 216).
71 Connect the oil supply hose (Item 163) to the top adaptor (Item 167) of the oil supply assembly and reconnect the oil pressure sender harness.
72 Connect the turbocharger oil supply hoses (Item 173 & 174) to the adaptors on the oil supply assembly.
72a Ensure adequate clearance to the steering shaft, securing to the RHS water hose using a 7" tie strap (Item 214).
73 Install the RHS compressor discharge hose (Item 125) onto the compressor discharge of the RHS turbocharger. Install the RHS compressor discharge duct (Item 123), mounting with an M8 self tapping screw (Item 149) and the stock screws as shown. Install 40/60 hose clamps (Item 126) around each end of the compressor discharge hose.
74 Install the RHS intercooler entry duct (Item 128) using reducer hoses (Item 129 & 130), securing with hose clamps 40/60 (Item 126), 50/70 (Item 131) and 60/80 (Item 132).
75 Install the LHS compressor discharge hose (Item 124) to the compressor discharge of the LHS turbocharger.

Install the LHS compressor discharge duct (Item 122) mounting with M8 self tapping screws (Item 149) and protecting it with rubber edging (Item 152), as shown.

Install 40/60 hose clamps around each end of the compressor discharge hose.
76 Install the LHS intercooler entry duct (Item 127) using reducer hoses (Item 129 & 130), securing using hose clamps 40/60 (Item 126), 50/70 (Item 131) and 60/80 (Item 132).
77 Use a tie strap (Item 21) to secure the battery cable to the RHS side of engine block.
78 Modify the forward edges of the lower control arm supports by bending inwards.
79 Install hose sleeves (Item 8) to the LHS and RHS compressor air entry snouts.
80 Install the compressor air entry hose (Item 9) to the compressor snout securing with hose clamps 60/80 (Item 7).
81 Install the LHS compressor air entry duct (Item 3), securing with 60/80 hose clamps (Item 9)

NOTE: Orientation of duct, with weld closest to the compressor entry. Also note the shape of the LHS duct (Item 3). It has more of a true curved shape than the RHS duct (Item 6).

82 Install the hose joiner (Item 4) to the LHS air entry duct (Item 3) with 60/80 hose clamps (Item 7).

83 NOTE: To install the forward air entry ducts LHS (Item 2) and RHS (Item 5), the suspension must be at standard ride height and the tierod ends must be disconnected.
84 To install the LHS air entry duct (Item 2), push the steering rack in a fully inboard position.
85 Install the LHS air entry duct (Item 2) into the hose joiner (Item 4).

Mount the front end of the duct (Item 2), to the forward arm of the lower suspension as shown, using a 25/40 hose clamp (Item 14) and rubber isolator (Item 20).

Install a 14" tie strap (Item 21) around the duct (Item 2) to the stock power steering line.

86 Install the RHS compressor air entry hose (Item 9) and duct (Item 6) securing with 60/80 hose clamps.

NOTE: Orientation of duct, with weld closest to the compressor entry. Also note the shape of the RHS duct (Item 6). It has less of a true curved shape than the LHS duct (Item 3).
87 Install the joiner hose (Item 4) to the RHS compressor air entry duct (Item 6), securing using 60/80 hose clamps.

NOTE: Modify the stock power steering lines by carefully bending downwards.
88 To install the RHS front air entry duct, push the steering rack in a fully inboard position.
89 Install the RHS air entry duct (Item 5) into the hose joiner (Item 4). Mount the front end of the duct (Item 5) to the forward arm of the lower suspension as shown, using a 25/40 hose clamp (Item 14) and rubber isolator (Item 20).
89a NOTE: Ensure clearance to the steering shaft.
90 Remove the RHS rocker cover. 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 plastic filler cap is fragile.

Tap the hole to 3/8" NPT.

Apply thread sealant to the adaptor (Item 196) and install into the rocker cover.
91 Remove the stock breather hose from the valley cover to the inlet manifold and discard.

(Hose may not exist in US domestic vehicles).
92 Install the one way valve (Item 17) to the breather hose (Item 18), using No. 17 spring clips (Item 16)

Note: Flow direction of the valve.
92a Re-install the breather hose assembly between the valley cover and inlet manifold.

Note: Flow direction of the valve.
93 Install the RHS breather hose (Item 11) to the RHS rocker cover and route forwards.

Secure using No. 19 spring clips (Item 19).

93a Connect the RHS breather hose (Item 11) to the to the RHS air entry duct (Item 5).

Secure using No. 19 spring clips (Item 19).
94 Install the RHS air filter element (Item 1)
95 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 a 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.

Install the LHS breather hose (Item 10) to the rear of the LHS rocker cover and route forwards.

Secure using a No. 19 spring clip (Item 19).

95 Install the LHS breather hose (Item 10) to the rear of the LHS air entry duct (Item 2).

Secure using a No. 19 spring clip (Item 19).
96 Install the LHS air filter element (Item 1).
97 Install the by-pass valve (Item 12) and by-pass hose (Item 13) between the intercooler outlet hose (Item 137) and the LHS air entry duct (Item 2). Secure using 25/40 hose clamps. (Item 14).
98 Install the vacuum hose (Item 15) to the rear of the inlet manifold (twist blanking cap off stock vacuum port). Route forwards along the LHS cylinder head with the breather hose (Item 10) and connect to the by-pass valve securing it by using spring clips (Item 22).

99 Using sealant install the 90° 1/4" NPT x 1/2" hose adaptors (Item 185) to the scavenge pump (Item 187).
100 Install the scavenge pump (Item 187) onto the pump mounting bracket (Item 189), isolating with a 2.5" joiner hose (Item 188). Secure using hose clamps 60/80 (Item 190).

Note: Orientation of the pump, relative to its mounting bracket.
101 Using sealant install the 3/8" BSP x 1/2" hose barb adaptors (Item 198) to the check valve (Item 199).
102 Drill two 1/4" diameter holes in the front cross member for mounting the pump assembly as shown.
103 Install the oil scavenge pump (Item 187) and an oil pump mounting bracket (Item 189) assembly to the front crossmember using M6 x 20mm bolts (Item 191), M6 washers (Item 192) and M6 nyloc nuts (Item 193).
104 Install the LHS oil drain adaptors (Item 181) and RHS (Item 182), using banjo bolts (Item 180) with copper washers (Item 162).
105 Install the LHS and RHS oil drain hoses (Item 183) to the LHS and RHS turbocharger oil drain adaptors (Item 181 & 182) securing using hose clamps (Item 199). Support the RHS hose using a support bracket (Item 201) and a self tapping screw (Item 202) with a 7" tie strap (Item 214). Support the LHS hose with a tie strap (Item 214) around the stock loom, adjacent to the steering rack, as shown.
106 Install the LHS and RHS oil drain hoses to the scavenge pump using the 1/2" y-piece adaptor (Item 184) and the 3.5" long hose (Item 186). Secure using hose clamps (Item 199).
107 Install the 23.5" long oil return hose (Item 195) and 3.5" long hose (Item 186) with the 3/8" BSP check valve (Item 197) between the scavenge pump and RHS rocker cover adaptor. Secure using hose clamps (Item 199).

Note: The flow direction of the check valve.

108 Connect the 23.5" long LHS boost control hose (Item 51) to the barb adaptor of the LHS the turbocharger compressor cover.

Secure using spring clips (Item 52).

108a Connect the 23.5" long LHS boost control hose (Item 51) from the LHS turbocharger to the wastegate barb adaptor.

Secure using spring clips (Item 52).
109 Connect the 20.5" RHS boost control hose (Item 52) from the RHS wastegate barb adaptor to the barb adaptor of the RHS turbocharger compressor cover. Secure using spring clips (Item 53).
110 Secure hoses using 7" tie straps (Item 54) as shown.

Note: Overall view below the vehicle.

111 Install exhaust using M10 nuts (Item 80).
112 Remove relays from wiring loom (Item 194) and mount the relay mounting bracket (Item 200) using M5 bolts (Item 203) M5 washers (Item 204) and M5 nuts (Item 205).
113 Mount the relay assembly with the negative wire (Black) to the stock air filter box stud using an M6 nut (Item 193) with an M6 washer (Item 206). Connect the power supply wire to (Red) positive terminal.
114 Route the solenoid wiring to the rear of the engine bay and connect to the solenoid wiring harness.

Secure using 7" tie straps (Item 214).
114a Wire routing detail at rear of engine bay.
114b Wire routing detail at rear of engine bay.
115 Route the scavenge pump wiring down the inner fender and connect to the scavenge pump plug. Secure the wiring to the stock air conditioning line using a 7" tie strap (Item 214).
116 Remove the cover panel beneath the glove box compartment.
117 Unclip and lift the firewall cover and route the relay trigger wire through the rubber grommet in the firewall.
118 Locate, solder and insulate the relay trigger wire to the stock thick grey wire above fuse box.
119 Secure the relay wiring using a 7" tie strap (Item 214).
120 Remove the sections shown from the plastic under tray.

Note: Stock under trays may vary between different model vehicles.
120a Re-install the front bumper and trim the stock under tray as shown.

Note: Stock under trays may vary between different model vehicles.
121 Install the stock LHS  inner fender and trim as shown.
121a Secure the under tray using 7" tie straps (Item 23).
121b Install the stock RHS inner fender and trim as shown.
121c Secure the under tray using 7" tie straps (Item 23).
122 General views from above.

Completion of Installation
1 Ensure that the engine oil grade utilized is suitable for use with gasoline turbocharged engines.
2

Refill the engine coolant in accordance with the factory service manual.
3 Verify that all hose clamps and fasteners are tightened.
4 Verify that all components which are affected by engine movement have sufficient clearance to adjacent body panels.
5 Turn the ignition switch to the "ON" position and physically check that the oil scavenge pump is operating.

WARNING DO NOT START THE ENGINE
6 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.
7 Verify there are no oil, water or most importantly fuel leaks in either the engine compartment.
8 After a final check for fluid leaks, replace the cosmetic engine cover and any other auxiliary components that were removed during the installation.