Day Two
1. Get under car and remove the oil filter.
2. There is a brace that supports the intake manifold right above the oil filter that must be removed, you will not need it anymore.
3. Assemble the oil feed ‘T’s’ so that it looks like this: (Teflon Tape)
(You’ll have to angle the T’s to find the perfect angle so the oil filter and the two sensors, if you’re using an aftermarket oil pressure gauge, can clear the installation)
4. Feed the stainless steel line through so the other end sits from above the turbo. (note: there is a straight side and a 90 degree bend side to the line, make sure the 90 bend is at the end of the feed and the straight side is connecting to the turbo) (Note: stainless steel lines, if allowed to move back and forth, will eat through a lot of things! Make sure to take proper precautions!)
5. Bolt together the turbo and turbo manifold.
6. Bolt the two together onto the engine block but do not tighten the nuts yet.
7. Get under the car and bolt the downpipe to the turbo, do not let the other end hang freely.
8. Connect the supplied EGR pipe to the downpipe and connect the other end to the EGR valve.
9. Tighten the nuts to the manifold in FSM specified recommendations.
10. Tighten the bolts to the downpipe.
11. Slowly tighten the EGR pipe, alternate one between ends to make sure the pipe seats in fully.
12. Connect the oil feed and oil drain lines onto turbo, use Teflon tape.
13. Connect the forward O2 sensor.
14. Bolt exhaust section to end of downpipe, remembering the rear O2 sensor.
15. Connect intake piping, along with BOV, to the turbo and intercooler.
16. Reinstall radiator fans, they’re very hard to get back into place.
17. T the wastegate line into a source in the intake manifold before the throttle body.
18. T the blow off/recirculating valve into a vacuum source after the throttle body (note: there is emissions equipment connected to the intake plumbing that is not boost friendly, in particular the EGR system, you must buy check valves to install inline in these vacuum lines to make sure they only see vacuum and never boost.)
19. Install the air intake and MAF sensor; make sure the air filter is tightened down.
20. Refill oil and coolant, check for leaks.
21. Connect all electrical connections unplugged during installation.
22. Connect battery.
23. Remove ignition fuse and crank the ignition for a couple of seconds before returning fuse, this will allow the oil to pressurize.
24. Check for leaks before starting car.
25. Have a fire extinguisher handy while starting car.
26. Start vehicle, it may be difficult to start at first.
27. Allow engine to idle until engine warms up.
28. Check for leaks.
29. Take the vehicle for a spin but go easy, check for leaks again after.
30. Enjoy the boost!