ATP Turbo Installation Instructions: G60 TURBO

Rev. 1.0D

Estimated Install Time: 4.5 hours

Skillset required: Basic

  1. Preparation
    1. Drain oil from pan
    2. Loosen axle nut using 30mm socket and ½" breaker bar.
    3. Jack up passenger side of car until wheel is off the ground and support with jack stand.
    4. Unbolt axle from transmission using 8mm 12point male socket bit.
    5. Spray Liquid Wrench and allow to sit for 1 hour (or overnight) to free rusted nuts and bolts.

Concentrate on: 1. (3) Cat to downpipe bolts, (6) downpipe to manifold nuts/studs, (8) manifold to head nuts.
  1. Remove Stock components
    1. Unbolt stock downpipe and remove.
    2. Unbolt stock exhaust manifold and remove.
    3. Unbolt rubber boot from airbox to supercharger and remove airbox.
    4. Remove supercharger and install supercharger bypass serpentine belt.
  1. Remove intake manifold and modify
    1. Unbolt intake manifold
    2. Cut the rear hook on the back of runner #2 to clear the turbo housing
    3. Reinstall intake manifold
  1. Install turbo components

 

 

    1. Install turbo manifold with new factory exhaust manifold gasket.
    2. Bolt turbo to manifold.
    1. (4 flanged nuts and bolts) size 8mm x 30mm x 1.25 thread .
    2. Use 12mm and 13mm close end wrenches
    3. Use turbo -> manifold metal gasket.
    1. Bolt downpipe to turbo using supplied hardware as follows:
    1. Top 2 bolts: size 8mm x 25mm x 1.25 thread
    2. 1 bottom bolt: size 8mm x 16mm x 1.25 thread
    1. Bolt downpipe to catalytic converter

    2. Bolt on Pre-welded oil pan with 45 degree –10 Male JIC fitting
    3. Connect large (-10) oil fee line to bottom of turbo -> oil pan fitting.
    4. Screw 45 degree –4 JIC fitting to top of turbo.
    5. Screw straight –4 JIC fitting on open port on top of oil filter housing.
    6. Connect small (-4) oil feed line from top of turbo -> fitting on top of oil filter housing.

      7.  

       

       

    7. Connect turbo pressure hose from turbo to intercooler pipe next to radiator fan.
    8. Connect turbo air feed hose(s) from K&N cone filter to turbo inlet (on the side)
    9. Remove the bypass pipe from under the throttle body and install a blow off valve under throttle body.
  1. Turbo Wastegate Line

The turbo is capable of generating over 25 psi of boost on an 8v engine. The wastegate is designed to open under a set level of boost to prevent overboosting. The wastegate gets its signal from the nipple on the turbo. A ¼" line must connect the nipple on turbo to the wastegate actuator.
    1. Option 1: Connect ¼" hose from air nipple from turbo to air nipple on wastegate actuator to accept boost level built into the wastegate.
    2. Option 2: Connect an adjustable bleeder valve inline with the ¼" hose between turbo and actuator for adjustable boost.

Note: Turbo is shipped with wastegate set on ~6psi of boost with 1-2 psi variation. The turbo is capable of producing upwards of 25 psi of boost. A boost gauge is highly recommended to measure actual boost level generated by turbo. Turbo is adjustable by turning the actuator rod or using the manual boost controller on option 2 above.

 
  1. Boost Gauge
    1. Tee into the vacuum hose leading into the Fuel Pressure Regulator to supply a signal to the boost gauge.
  1. Initial Startup
    1. Refill engine with oil
    2. Disconnect coil wire and crank ignition to allow oil circulation through turbo system.
    3. Reconnect coil wire and start up car.
    4. Inspect for leaks and shut down car if any leaks are detected.