If you love sheer power, and you want a car that produces 1,000 bhp, you now have three to choose from - and that is without going to the tuners like Ruf ofr Callaway, who will get this much power from engines that are currently in the 500- 700 bhp range. The tjree in the 1000 bhp club are the Bugatti Veyron 16.4, the Bristol Fighter T, and the Koenigsegg CCXR. Theoretically, these are all good for 250 mph in theory, but not in practice.
First on the scene was the Bugatti Veyron 16.4, the world’s fastest and most powerful exotic car, with a top speed of 248 mph.
Engineering masterpiece
The Bugatti Veyron 16.4 is quite an engineering masterpiece, with a W-16 8.0 liter cylinder engine mid-mounted driving through a seven-speed semi-automatic gearbox to all four wheels – four-wheel drive is definitely a good idea with this amount of power. Not only is it immensely fast, but with four-wheel drives it is very stable. It has ceramic brake discs and an air brake to help you slow down from over 125 mph.
A very surprising addition to the 1,000 bhp plus club is the Bristol Fighter T, which has an engine developing 1,012 bhp, just 11 more than the Bugatti! This is a front-engine, rear-drive car designed for high-speed touring.
To be precise, the V-10 engine in the Fighter T whacks out 1,012 bhp at 5,600 rpm. Bristol says that the top speed of the car is around 270 mph, but it has a limiter at 225 mph, which is just 4,.500 rpm in top! Not many will be made, making this a really exotic car.
Acceleration is not as good as you might expect – or maybe it is just modesty at Bristol Cars – at 'under 3.5 seconds' whereas the Bugatti Veyron is well under 3 seconds. The difference is largely academic – like the top speeds – but a mid-engined four-wheel drive car will accelerate more quickly than a front-engined rear-drive car. The Bristol Fighter just doesn't have enough weight on the rear wheels to get under 3 seconds.
Twin turbo V-10
How did they get this huge amount of power? Well, like the other Bristol Fighters, the T has a tuned Chrysler V-10 engine of 8 liters. For the Fighter T they have added a pair of water-cooled turbochargers to almost double power so they could exceed that magic 1,000 bhp figure, getting 1,012 bhp at 5,600 rpm, with 1,036 lb ft (1,400 Nm) of torque at 4,500 rpm. That is quite a high speed for maximum torque, but the engine still produces a massive 800 lb ft (1,080 Nm) of torque from 3,000 rpm, upward.
The Bristol Fighter S has a top speed of over 200 mph, partly owing to good aerodynamics, but The Fighter T is an absolute stormer with a power-to-weight ratio of about 600 bhp per ton and a top speed of well, you name it!
Koenigsegg CCXR runs on ethanol
Now, along comes Koenigsegg with the Koenigsegg CCXR, based on the CCX supercar, but now this version is able to run on ethanol biofuel - E85. Because ethanol has an octane rating of over 100 RON – like racing fuel in the 30s - it gives more power than gasoline, as Saab has demonstrated.
In the Koenigsegg CCXR, power is up from 806 bhp – more than enough for almost everyone – to 1,018 bhp! Peak torque is an incredible 780 lb ft (1,060 Nm) at 6,100 rpm. That's 25% more power.
With ethanol, power increases of 15-25% can be obtained for any engine so long as it is optimised with high compression ratio and other changes. In other words, don't just pull up at a gas station, put ethanol in your tank and get 20% more power. It doesn't work unless the engine is designed to run on it.
But that is not so difficult to do, and with George Bush trying to get more ethanol used in the USA, expect more to follow this route. After all, almost everyone loves power, even if they drive a car that is not very fast.
John Hartley is editor of http://www.fast-autos.com, an online magazine devoted to fast cars and supercars, where you can read the latest articles about fast cars. He has written from many of the world's top auto magazines, and has written many books about cars and the auto industry, including 'Suspension and Steering Q&A' and 'The Electronics Revolution in the Motor Industry'.
From the time I can remember, each year my father, three brothers, myself and our grandfather would take a week away in the summer and go on a tour of old cars shows around the country. We would try to see different old cars shows each year (you'd be amazed by how many there are to choose from!). So I guess you could say that I have come to my love for old cars honestly. It has literally been growing in me since the time I can remember. My mother, grandmother and sisters would take that same week each year to enjoy at our lakeside cabin, and even though we offered for them to join us for the old car shows, they never seemed interested.
At first, I loved going to the old cars shows because it was a great time to spend with the guys I loved most. My dad didn't get very much time off of work, so when he did we made sure to enjoy it. I didn't care too much about what we saw or what we did at the old cars shows, I just loved hanging out with my brothers and goofing around with my dad and grandpa.
As I got older, my love for this beloved week of summer changed a little bit as I actually started to enjoy the whole purpose of our trip: to see as many old cars and learn about them as we possibly could in a week. Hour after hour in the car was spent discussing old cars and talking about the intricacies of each make or model. We would stop by our public library each year before the trip and gather as many books and magazines about old cars as we could. It was simply astouding to see how much had been written and published on the subject within a year.
The more I learned about old cars, the more I too became fascinated with them. I have always loved anything to do with history, and I guess I figure that old cars are historical in the sense that they teach us about the history and progression of automobiles in our country. There is nothing I love more than finally seeing a make and model of an old car that I have been anticipating viewing for a year. I'll admit that I have even gotten emotional a few times as I have finally gazed upon an old car that I had been dreaming about all year.
If you don't have a love for old cars yet, I'd suggest that it isn't too late. Grab some books, do an online search, or get yourself to an old cars show as soon as you can! You won't be sorry.
How to Install Borla Performance Rear Section Exhaust System (Part number 11744, 11766) on Chevy Corvette
How to Install Borla Performance Rear Section Exhaust System on Chevy Corvette
PN– 11744, 11766
Precision manufactured using high quality austenitic stainless steel; this system is designed to endure years of heavy use. Installing a Borla Performance Exhaust System on your vehicle will eliminate the restrictive design of the stock exhaust, allowing your engine to discharge exhaust gas easier. The result is more horsepower and torque, longer engine life, and a distinctive throaty growl- all this, with easy bolt-on installation. These installation instructions have been written to help you in the installation of your Borla Performance Exhaust System. Please read it completely before installing your system.
Thank you for purchasing a Borla Performance Rear Section Exhaust System.
Borla Performance Rear Section Exhaust System (Part number 11744) has been designed for 2005-2008 Chevrolet Corvette C6 equipped with a 6.0L or 6.2L V-8 engine and automatic or manual transmissions. Borla Performance Rear Section Exhaust System (Part number 11766) has been designed for 2009 Chevrolet Corvette C6 equipped with a 6.2L V-8 engine and automatic or manual transmissions.
Borla Performance Industries recommends that an exhaust shop or professional after market parts installer, who has all the necessary equipment, tools and experienced personnel needed for proper installation, should perform the installation of this system. However, if you decide to perform the installation, we recommend someone should help you. Ensure the installer uses all under car safety precautions including eye protection.
Please take time to read and understand the following…
By installing your Borla Performance Exhaust System, you indicate that you have read this document and you agree with the terms stated below.
It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Borla Performance Exhaust System
Borla Performance Industries assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products and/or systems.
Included with your Borla Performance Exhaust System is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Borla Performance Exhaust System, please give us a call at the number provided on the warranty card.
Minimum Required Tool List:
TOOLS:
1. 3/8” Drive Ratchet
2. 3/8” Drive Extension 3”
3. 13mm Socket
4. 15mm Socket
5. Pry Bar
SHOP SUPPLIES:
1.Spray Lubricant
Borla Performance Rear Section Bill of Materials
1.Left over axle pipe
2.Right over axle pipe
3.2.50” Accuseal™ clamp (qty 2)
4.Muffler assembly
Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If the vehicle has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always wear eye protection when working under any vehicle.
Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of your new Borla Performance Rear Section Exhaust System.
Taking all under car safety precautions, lift the vehicle using a hoist or hydraulic lift. Once this has been done, you may begin the removal of your old exhaust system from your vehicle.
Note: Before removing the original exhaust system from your vehicle, please compare the parts you have received with the bill of materials provided on the previous page to assure that you have all the parts necessary for the installation of your new Borla Performance Rear Section Exhaust System.
Original Exhaust System Removal
Note: With a used vehicle, we suggest a penetrating spray lubricant to
be applied liberally to all exhaust fasteners and allowing a significant
period of time for the chemical to lubricate the threads before
attempting to disassemble.
1. Loosen the clamps shown in figure 1 located just under the
transmission at the rear of the vehicle.
2. Using a 13mm socket, unbolt the spring hangers located just in
front of the clamps as shown in figure 2. Place the bolts aside for
use during the installation of your new exhaust system.
3. With a muffler stand or an additional person to hold the h-pipe
assembly up into position, using a 15mm socket, unbolt the
flanges shown in figure 3 located just behind the catalytic
converters. Place the hardware and gaskets to the side for use
during the installation of your new exhaust system.
4. Remove the h-pipe assembly from the vehicle by dropping the
front down as shown in figure 4, than sliding the rear portion out
of the factory over axle pipe/muffler assemblies .
5. Using a spray type lubricant, lubricate the hangers shown in figure
5 at the rear of the vehicle just above the tip assemblies.
6. Beginning with the driver’s side of the vehicle, remove the
hangers from the rubber isolators and remove the muffler
assembly from the vehicle as shown in figure 6.
7. On vehicles equipped with automatic transmissions, remove the
passenger’s side heat shield from the fuel tank. Using a set of
pliers or something similar, bend the tab down as shown in figure
7.
8.Repeat step 6 for the removal of the passenger’s side muffler assembly.
Warning: Use extreme caution during installation. Torque all fasteners according to manufacturer’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks.
1.Place a clamp over the expanded end of left (driver’s side) and right (passenger’s side) inlet pipes located on the muffler assembly as shown in figure 8.
2.Insert left (driver’s side) and right (passenger’s side) over axle pipes into their corresponding muffler inlet pipes as shown in figure 9. Do Not tighten clamps.
3.Carefully guiding the over axle pipes through the exhaust openings, place the muffler/over axle pipe assembly into position as shown in figure 10 making sure to install the hangers into the rubber isolators.
4.Re-install the H pipe assembly in the opposite order of removal and using the original hardware, reinstall the spring hangers.
5.Check your exhaust system for proper clearance under the vehicle and also for tip alignment.
6.Once position has been determined to be correct, tighten the Accuseal clamps to 32-35 ft. lbs.
7.Using the original hardware, reinstall the heat shield.
8.Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.
9.Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly positioned clamp) and repair as necessary.
Note: When you first start your vehicle after the installation of your new Borla Performance Exhaust System, there may be some smoke and fumes coming from the system. This is a protective oil based coating used in the manufacturing of mandrel bent performance exhaust tubing. This is not a problem and will disappear within a very short period of time after the exhaust has reached normal operating temperatures.
How to Install Borla Exhaust System on Ford Mustang
How to Install Exhaust System on Ford Mustang V6 & Mustang GT
PN– 11789, 11790, 11791, 11792, & 11793
These instructions have been written to help you with the installation of your Borla Performance Exhaust System. Please read this document completely before beginning the installation of your system.
Please compare the parts in the box with the bill of materials provided to assure that you have all the parts necessary for this installation.
To ensure this part number fits your specific model year, please visit our website for the latest model year listings at www.BORLA.com.
Thank you for purchasing a Borla Performance Rear Section Exhaust System.
Borla Performance Rear Section Exhaust System (PN-11792, 11793) have been designed for the Mus- tang V6 with a 3.7L engine/automatic or manual transmissions.
Borla Performance Industries recommends that an exhaust shop or professional after market parts installer perform the installation of this system. However, if you decide to perform the installation on your own it is recommended that two people are used. This installation should not be performed by one person due to the risk of injury. Ensure the installers use all under car safety precautions including eye protection.
Please take time to read and understand the following…
By installing your Borla Performance Exhaust System, you indicate that you have read this document and you agree with the terms stated below.
It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Borla Performance Exhaust System
Borla Performance Industries assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products and/or systems.
Included with your Borla Performance Exhaust System is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Borla Performance Exhaust System, please give us a call at the number provided on the warranty card.
Minimum Required Tool List:
TOOLS:
13/8” Drive Ratchet
23/8” Drive Extension 3”
315mm Socket
4Pry Bar
5Flat blade screwdriver
SHOP SUPPLIES:
1 Spray Lubricant
Borla Performance Rear-Section ™ Bill of Materials
2
2
1
1
1.R/H muffler assembly
2.L/H muffler assembly
Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If the vehicle has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always wear eye protection when working under any vehicle.
Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of your new Borla Performance Exhaust System.
Taking all under car safety precautions, lift the vehicle using a hoist or hydraulic lift. Once this has been done, you may begin the removal of your old exhaust system from your vehicle.
Note: Before removing the original exhaust system from your vehicle, please compare the parts you have received with the bill of materials provided on the previous page to assure that you have all the parts necessary for the installation of your new Borla Performance Exhaust System.
Original Exhaust
System Removal
Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fas- teners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble.
1.Lubricate hangers and rubber isolators on the rear mufflers.
2.Loosen the passenger side ball-clamp behind the rear axle pipe and carefully remove right-side muffler from hangars. Do not discard clamps as they will be used for installation of your new exhaust.
(See Fig. 1)
3.Repeat above step for left-side muffler. (See Fig. 2)
Warning: Use extreme caution during installation. Torque all fas- teners according to manufacturer’s torque values and tighten- ing sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks.
Figure 1
Figure 2
Borla Performance
Exhaust System Installation
1.Insert the expanded end of the (driver-side) L/H muffler assembly into OE ball clamp and install the hangers into the rubber isolators. (See Fig. 3)
2.Repeat step 2 for the installation of the (passenger-side) R/H muffler assembly.
3.Check your exhaust system for proper clearance under the vehicle and also for tip alignment. (See Figs. 4)
4.Once position has been determined to be correct, tighten the Accuseal™ clamps to 32-35 ft. lbs.
7.Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.
8.Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly posi- tioned clamp) and repair as necessary.
Note: When you first start your vehicle after the installation of your new Borla Performance Exhaust System, there may be some smoke and fumes coming from the system. This is a protective oil based coating used in the manufacturing of mandrel bent per- formance exhaust tubing. This is not a problem and will disap- pear within a very short period of time after the exhaust has reached normal operating temperatures.
Congratulations!!! You have completed the installation of the world famous Borla Performance Stainless Steel Exhaust Sys- tem.
How to Install Greddy Twin Turbo Kit on Infiniti G35
GReddy Turbo Kit
2003 Infiniti G35 Coupe (VQ35DE) Twin TD05-18G 8cm2
Installation Manual
Please read the entire manual before installing this kit.
Application:
Make
Model
Chassis
Year
Infiniti
G35 Coupe (6 speed MT)
CPV35
2003
·This GReddy Turbo Kit is designed only for the vehicles specified above.
·GReddy Front mount intercooler kit is recommended with this kit
·Premium grade gasoline (91 octane or higher) is required with this Kit.
·Make sure that the vehicle is not equipped with any ECU upgrade chips.
·Use of GReddy Racing Spark Plugs ISO #7 or NGK plugs (colder than factory) is recommended with this kit.
Important
1.This installation should only be performed by a trained specialist who is very familiar with the automobile’s mechanical, electrical and fuel management system.
2.If installed by an untrained person, it may cause damage to the kit as well as the vehicle.
3.GReddy Performance Products Inc. is not responsible for any damage to the vehicle’s electrical system caused by improper installation.
4.Make sure to follow the instruction and pay attention to the “Important”, “Warning!” and “Caution!” notice through out the instruction.
5.Improper installation can be dangerous! Please make sure to inspect the installation before operating the vehicle.
6.Call your GReddy Authorized dealer or GReddy Performance Products if there are any problems or questions regarding this product.
1. Parts List
1.
Turbocharger TD05-18G 8cm2
2
2.
Wastegate (GReddy / Tial)
.45bar
2
3.
Exhaust Manifold
(Right Side)
Ductile Iron Cast
1
4.
Exhaust Manifold
(Left Side)
Ductile Iron Cast
1
5.
Downpipe Adapter
(Right Side)
1
6.
Downpipe Adapter
(Right Side)
1
7.
Compression Pipe
R
C-1
(50Æ Aluminum Elbow No.6)
1
8.
“
R
C-2
(50Æ Aluminum)
1
9.
“
R
C-3
(50Æ Aluminum Elbow No.21)
1
10.
“
L
C-4
(50Æ-70ÆAluminum)
1
11.
“
C-5
(50Æ Aluminum)
1
12.
“
C-6
(80Æ Aluminum)
1
13.
Airflow Meter Adapter
1
14.
Suction Pipe
R
S-1
(60Æ Aluminum)
1
15.
“
R
S-2
(70Æ Aluminum)
1
16.
“
L
S-3
(60Æ Aluminum Elbow No.82)
1
17.
“
L
S-4
(70Æ Aluminum)
1
18.
Airinx
AY-SB (Blue)
2
19.
Airinx Hose Adapter S70
2
20.
Oil Pressure Hose SUS (R=600mm, L=800mm)
1 each
21.
Oil Pressure Union Fitting
3-Way Fitting
2
22.
“
1/8PT – 1/8 PT Straight
2
23.
“
1/8PT – 1/8 PF Straight
1
24.
“
1/8PT – 1/8 PF Male to Male 90°
1
25.
Oil Pressure Banjo Fitting
Male and Female (small)
2
26.
Copper Washer 10Æ
(t=1.0)
4
27.
Oil Return Pipe
Right
16Æ
1
28.
Oil Return Pipe
Left
16Æ
1
29.
Oil Pan with welded Oil Return Pipe
1
30. Vacuum Hose
5Æ x 100mm
(Blue)
1
31.
“
6Æ x 2000mm
(Blue)
1
32.
Radiator Reserve Hose
7Æ x 10Æ x 790mm CR60° Tube
1
33. Rubber Hose 15Æ x 1140mm
(Oil Return 440mm, Blow By 300mm, Power Steering 200mm)
1
34.
Silicone Hose 50Æ x 70mm
Straight
6
35.
“
80Æ x 80mm
Straight
2
36.
“
60Æ - 70Æ
Reducer
2
37.
“
60Æ - 80Æ
Reducer
2
38.
“
70Æ - 80Æ
Reducer
1
39.
Hose Band
12Æ #8
4
40.
“
16Æ #10
9
41.
“
50Æ #32
12
42.
“
60Æ #36
4
43.
“
70Æ #44
5
44.
“
80Æ #48
7
45.
Power Steering Pump Fitting
1
46.
Check Valve (Nissan factory part #47478-51E00)
1
47.
Radiator Reserve Tank
1
48.
Radiator Reserve tank Cap
1
49.
Hose Fitting
8Æ
90°
1
50.
Radiator Reserve Tank Bracket
A / B
1 Set
51.
Aluminum Spacer
t=28mm
1
52.
Airinx Bracket
Right / Left
1 Set
53.
Hose Fitting
16Æ
Straight
1
54.
Exhaust Manifold Gasket
(Nissan Factory Part # 14036-AG010)
1 Set
55.
Turbo Gasket
TD05 In / Out
4
56.
Catalytic Converter Gasket
(Nissan Factory Part # 20813-AL500)
2
57.
Oil Return Gasket
TD Small
2
58. Thermo Cloth
100m x 1000mm
4
59.
Three Way fitting
5Æ - 6Æ
1
60. Zip Ties
150mm
15
61.
E-Manage
(US-Z33)
1
62.
“
Harrness
1
63.
“
I/J Harness
1
64.
“
RPM signal adapter
1
65.
Injectors
440cc (with 4 aluminum fuel rail spacers)
6
66. M5 x 15mm
Stainless
P=0.8
B S/W
F/W
N
1
67.
M6 x 15mm
Stainless
P=1.0
B S/W
-
-
6
68. M6 x 15mm
Stainless
P=1.0
B S/W
F/W
N
5
69.
M6 x 40mm
Steel
P=1.0
B
-
-
-
1
70.
M8 x 15mm
Stainless
P=1.25
B S/W
-
-
6
71.
M8 x 20mm
Stainless
P=1.25
B S/W
-
-
2
72.
M8 x 25mm
Stainless
P=1.25
B S/W
-
-
4
73.
M8 x 30mm
Stainless Stud
P=1.25 – 1.25
B S/W
-
N
8
74.
M10 x 35mm
Stainless Stud
P=1.25 – 1.25
B S/W
-
N
12
75.
M10 x 45mm
Stainless Stud
P=1.25 – 1.50
B
-
-
-
2
1. Parts List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1. Parts List
21
22
23
24
25
26
27
28
29
30 - 33
34 - 38
39 - 40
45
46
47
48
49
50
51
52
1. Parts List
53
54
55
56
57
58
59
60
61
62
63
64
65
66 - 75
2. Factory Parts Removal
When removing the stock parts, make sure you read over the factory repair manual for proper procedures.
2-1 Disconnect the negative terminal of the battery.
2-2 Drain the engine oil, coolant and power steering fluid. 2-3 Disconnect the air flow meter.
2-4 Remove the Air cleaner assembly with airflow meter, intake tube, and breather hose.
2-5 Remove the Top Radiator Hose and the Water Pipe (Located above the Right Exhaust manifold).
2-5 Disconnect the primary and secondary O2 sensor and remove the exhaust manifold and catalytic converter.
2-6 Remove the exhaust manifold.
2-7 Remove oil pan (Please refer to the factory service manual for detail instructions f or removing the oil pan.)
2-8 Remove the upper intake manifold collector, fuel rail assembly with injectors and regulator.
3. Turbo Kit Installation
Thermo Cloth Installation
·Remove the bracket securing the fuel line right below the right side shock tower and disconnect the fuel line. Flip the connector so that the line points up and reconnect the line. Double wrap the fuel and evap Line using safety Wire. Leave the top bracket off and secure the bottom back on as shown.
(Parts used #58)
(This picture shows the turbo already installed)
Important!
·Make sure that the fuel line is secured away from the turbine housing when the turbo is installed. Some bending of the lines is necessary to achieve good clearance.
·Make sure the lines are properly wrapped twice.
·Make sure to use safety wire to wrap the thermo cloth. Zip ties will melt from the heat and eventually will come off.
·Make sure that the fuel line connector is properly clicked in all the way.
·GReddy Performance Products, Inc. will not be responsible for any damage caused due to improper installation.
Caution!
·Make sure to check and double check this step. This is the most important step in this install.
·Without proper clearance and thermo wrapping the fuel lines, the fuel line connector can melt from heat and may catch on fire.
·Wrap the Starter and the Main Engine harness right above the transmission bell housing.
Important!
Make sure that the main engine harness is properly wrapped and secured away from the manifold and the wastegate when they are installed.
Caution!
Without proper clearance and thermo wrapping the harness, it melt and cause a short in the electrical system or may catch on fire.
Power Steering Line Installation
1.Remove the hose fitting off the power steering pump and install the provided fitting.
(Parts Used #40, 45)
2.Cut the provided 15Æ hose to 200mm (8in) and install it between the pump and the tank.
(Parts Used #33)
Oil Pan Installation
Install the Oil pan with a silicone sealant.
(Part Used #29)
Oil Pressure Line Installation
Install the oil pressure line to engine block using provided fittings.
(Part Used #20, 21, 22, 23, 24) 600mm line is for the right side and 800mm line is for the left side.
Exhaust Manifold Installation
1.Remove all factory exhaust manifold stud bolt off from the cylinder head. Install the provided M10 x 35mm stud bolts on to the cylinder head as shown.
(Part Used #74)
2. Install the Exhaust Manifold using provided gasket and hardware.
(Part Used #3, 4, 54, 74)
Left Side (Driver’s Side)
Right Side (Passenger’s Side)
Turbocharger Installation
1. Install the turbocharger on to the exhaust manifold installed in the previous step.
*For the left side, remove the steering shaft joint before installing the turbo.
*For the right side, remove the bolts holding the starter, and lower the starter before
installing the turbo.
(Part Used #1, 25, 26, 55, 71, 72, 73)
Check Clearance
Left Side (Driver’s Side)
Right Side (Passenger’s Side)
* After the turbo installation, double check the fuel line clearance by the turbo and the manifold on right side (passenger side).
2. Connect the Oil Pressure line to the turbo using the provided banjo fitting.
(Parts Used #25)
Oil Return Pipe Installation
Install the oil return pipe using provided gasket and hardware. Cut the provided 15Æ hose to proper length and install them between the oil return pipe and the oil pan as shown.
(Part Used #27, 28,33, 40, 57, 67)
Left Side (Driver’s Side)
Right Side (Passenger’s Side)
Left Side (Driver’s Side)
Right Side (Passenger’s Side)
Wastegate Installation
Install the provided banjo fitting on to the bottom port of the wastegate. (Top Port is used for boost controller)
Install the wastegate using the provided gasket and hardware as shown.
(Part Used #2, 73)
Left Side (Driver’s Side)
Right Side (Passenger’s Side)
*Double check the clearance between the wastegate and the main engine harness on the right side (passenger side). Make sure that there is enough clearance to avoid the harness from getting to hot and melting.
Down Pipe Adapter Installation
Install the down pipe adapter using the provided gasket and hardware as shown.
(Part Used #5, 6, 55, 70, 72)
Exhaust System Installation
Install the catalytic converter and the exhaust system using the provided gasket and hardware as shown.
(Part Used #56, 75)
Vacuum hose for Wastegate Installation
Remove the factory engine cover. Locate the rubber plug on the intake manifold and remove it. Connect the 5Æ hose to the intake manifold and by using the three way fitting and connect the 6Æ hose to each of the wastegate fitting.
(Part Used #30, 31, 59)
Suction Pipe Installation
1. Install the Airinx air filter to the Suction pipe S-2 and S-4.
2.Install the S-1 and the S-2 (with AIRINX) to the right (passenger side) turbo inlet using provided hose and hose clamps and secure the Airinx to the chassis as shown. Bend the Power steering line over towards the pulley so that the S-2 clears the line.
Bend Away
Airinx
Bracket
3.Install the S-3 and the S-4 (with AIRINX) to the left (driver side) turbo inlet using provided hose and hose clamps and secure the Airinx to the chassis as shown. Bend the A/C line toward the engine so that the S-4 pipe clears the line.
Bend A/C
Line
Airinx
Bracket
Compression Pipe Installation
1.Install the Air flow meter adapter on tot he air flow meter.
2.Install the Compression pipe C-1,C-2,C-3,C-4,C-5, and C-6 by using the provided hose and hose clamps as shown. Make sure to check all the clearance before securing the hose clamps.
*When installing the airflow meter assembly, make sure not to reverse the flow.
Remove the left side head light assembly, and Install the provided radiator over flow tank as shown. Connect the hose to the lid and reinstall the head light assembly.
(Part Used #47, 48, 49, 50, 52, 68, 69)
Brake Check Valve Installation
Install the provided check valve as shown.
(Part Used #39, 46)
Injectors Installation
1.Remove the upper intake manifold collector, fuel rail assembly with injectors and regulator.
2.Grind the top of the fuel rail as shown to clear the intake manifold.
Make sure not to grind too much. Grind the part on the bracket that is raised down flat. Clean the rail thoroughly after grinding.
3.
Install the 440cc injectors and reinstall the fuel rail using the provided spacer.
(Part Used #65)
4.
Cut the factory injector connectors and solder in the provided connector harness.
How to solder
①Strip the end of wires
② Twist the end together
③ Solder the wires
④ Tape up the soldered area
(Make sure to solder
Completely)
E-manage Installation
Install the e-manage and the rpm adapter as shown in the diagram. Make sure to solder all connections except for the ones that are supplied with the male and female connectors.
(Part Used #61, 62, 63, 64)
Important!
·Make sure you fully understand the diagram before attempting this installation.
·Improper wiring can damage the ECM and the vehicle's electrical system.
·GReddy Performance Product, Inc. will not be responsible for any damage caused by improper installation.
·Please do not use crimp connectors or t-tap connectors. These can cause poor connection and prevent e-manage to operate properly.
E-manage Installation
E-manage Installation
I/J Harness (18Pin)
* Looking at harness side.
e-manage
Factory ECU
Pin #
Wire Color
Description
ECU Pin #
Color
Code
3
White
MAP IN
51
Orange
Airflow
(harness Side)
Meter
5
Blue/
INJ 1
23
Red/
INJ 1
Red
Black
6
Orange/
INJ 2
42
Black/
INJ 2
Red
Red
7
Yellow/
INJ 3
22
Red/
INJ 3
Red
Yellow
8
Purple/
INJ 4
41
White/
INJ 4
Red
Red
10
Green
MAP
51 (ECU side)
Orange
Airflow
OUT
Meter
11
brown
RPM
RPM
Brown
Adapter
12
Black
GND
116
Black/
ECM
Red
ground
13
Red
+B
119
Green/
ECM
Yellow
Power
16
Pink/Red
INJ 5
21
Sky blue
INJ 5
17
Light Blue/
INJ 6
40
Light
INJ 6
Red
green
18
Black/
INJ GND
1
Black
ECM
Red
ground
Sensor Adapter
Wire Color
Description
Yellow
RPM IN
Yellow
RPM IN
Yellow
RPM IN
Yellow
RPM IN
Yellow
RPM IN
Yellow
RPM IN
Brown
RPM OUT
Black
GND
Connect to
Pin #
Color
Code
60 ECU
PU/ W
IG#5
61 ECU
L/R
IG#3
62 ECU
Y/R
IG#1
79 ECU
GY/R
IG#6
80 ECU
GY
IG#4
81 ECU
G/b
IG#2
18 - 11
Brown
RPM
e-manage
116 ECU
Black/Red
ECM
Ground
Starting the Engine
1.Refill the engine oil to factory spec.
2.Check all the hoses and wires connection, then reconnect the negative side of the battery.
3.Turn the ignition to “ON” position 2-3 times to get fuel pressure. Then, check the injectors and the fuel rail for any fuel leaks.
*Repair any fuel leaks before starting the engine. Starting the engine with a fuel leak can cause fire in the engine compartment and can be very dangerous.
4.Remove the ECM fuse and crank the engine to get oil pressure to the turbo. (Until the oil light on the dash turns off) Check for any oil leaks, then reinstall the fuse and start the engine.
5.While idling, check for any oil, coolant, or air leeks.
6.After inspection, reinstall the under cover and other stock parts that was removed.
7.On the initial run, be sure to have a boost gauge to check the turbo-actuator setting. This turbo kit is preset to boost between 0.4kg/cm2 to 0.45kg/cm2 .
It is very important that you monitor the boost pressure, and make sure not to over boost. Over boosting can cause engine damage.
This completes the Turbo Kit installation.
Important!
·It is very important that you monitor the boost pressure, and make sure not to over boost. Over boosting can cause engine damage.
·GReddy Performance Products, Inc. is not responsible for any engine damage caused by over boosting (increased boost), modification to the kit, and/or misuse of the product. NO WARRANTY is offered.
·Due to lack of control over proper installation and use of this product,
NO WARRANTY is offered for this kit.
e-manage Information
Important!
·The e-manage included in this kit is preprogrammed for the this turbo kit.
·Do not attempt to adjust any of the setting in the e-manage.
·Any adjustments made can cause damage to the e-manage, engine and the factory ECU.
Important!
As of 11/25/03 this kit is not a street legal kit. Please ignore the label on the e-manage.
ACTIVE L.E.D.
(2)When the ignition is turned on, it will illuminate and flash GREEN.
(3)When it reaches to the A.A.V. setting RPM range, it will illuminate and flash ORANGE.
(4)When an error is detected it will flash RED.
INTERACTION L.E.D.
3. This will illuminate when there is a connection with PC.
Checking Error Codes
When the unit is powered up and if there are any errors, the ACTIVE L.E.D will turn “RED” from “GREEN”, and begin to flash.
If this happens shut the engine off and turn the ignition switch to “ON” position to go to Self Troubleshooting Mode. While in the Self Troubleshooting Mode, the L.E.D. will show the error code. Turn off the ignition. Check the error code in the chart below and fix the problem. The error code will show until the error is corrected.
ACTIVE L.E.D.
INTERACTION L.E.D.
