RZR XP - Aerocharger.com

RZR XP
Turbo System Installation Manual
V1.4
Table of Contents
Introduction ................................................................................................................................1
Tools Needed: ...............................................................................................................................3
Prepare Vehicle for Installation .......................................................................................................4
Remove Stock Air Plenum ..........................................................................................................4
Remove Stock Intake ..................................................................................................................5
Remove Stock Header ................................................................................................................7
Remove Stock Muffler ...............................................................................................................8
Modify Muffler Mounts ..............................................................................................................9
Cold Side ...................................................................................................................................11
Change Fuel Injectors ...............................................................................................................11
Install Air Plenum ....................................................................................................................13
Mount Donaldson ....................................................................................................................15
Install Intake............................................................................................................................16
Exhaust Installation .....................................................................................................................19
Install Header ..........................................................................................................................19
Install Muffler and Turbo ..........................................................................................................20
Air to Water Intercooler Install......................................................................................................26
Mount Radiator ........................................................................................................................26
Install Water Pump ...................................................................................................................27
Install Fill Neck .......................................................................................................................29
Run Hoses ...............................................................................................................................31
Electronics ..................................................................................................................................35
Install Gauges ..........................................................................................................................35
Install Wiring ..........................................................................................................................37
Install Aerocommander .............................................................................................................38
Hook up Pressure Control Lines.................................................................................................42
Clutching ................................................................................................................................46
Zip-Ties ..................................................................................................................................49
Race Clutching ........................................................................................................................51
Owners Operation and Maintenance ...........................................................................................51
INTRODUCTION
Congratulations on your purchase of the Aerocharger Turbo system for the RZR XP.
You are now the owner of the most powerful, reliable, and technologically advanced
turbocharger in the world. With your new intercooled turbocharger and fuel system
installed, you will experience substantial performance gains. Not only will you get
amazing performance but our unique system which combines VATN technology
(Variable Area Turbine Nozzle) and our nearly frictionless, non-flooded ceramic ball
bearing design will provide you with our famous zero turbo-lag.
This system is made and assembled by Aerocharger LLC. We manufacture turbo
systems with a passion.
The installation of this kit consists of three major components:
1. Installation of the turbocharger system
2. Installing the fuel control electronics
3. Installing the clutch kit
Note: Before getting started, refer to the Packing List and identify all the components
of your turbo system. This will also aid in the installation process.
WARNING!
Installation of the turbo system is not for the mechanically challenged! If you are
uncomfortable performing any of the tasks outlined in this manual, please refer to
trained professionals at your local performance shop. If you are performing the
installation of this system, it is suggested that you read this ENTIRE manual prior
to proceeding with the installation. It is also suggested that you review each
section as you progress to ensure everything is installed correctly.
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WARNING!
This system is designed for use on a STOCK RZR XP!
WARNING:
If your RZR has been modified, consult Aerocharger (913.541.0200) before proceeding.
This Turbo system is intended for use on a STOCK, well-maintained RZR with a strong
running, well-maintained engine. Installation of this kit on a brand-new vehicle with very
few miles/hours on them is NOT recommended. New engines require specific break-in
procedures that do not include adding forced induction! If your vehicle is brand new,
consult your local dealership and owner’s manual to determine proper break-in
procedures BEFORE continuing with this installation. Failure to do so may result in
significant internal engine damage. AEROCHARGER WILL NOT BE HELD
RESPONSIBLE FOR DAMAGE TO VEHICLES POWERTRAIN. Aerocharger is not
responsible for ECU tuning/ programming on RZRs that were not stock before the
installation of this turbo kit.
WARNING:
For best performance and reliability always use minimum 91-octane non-ethanol fuels
and listen for signs of detonation. IF DETONATION SHOULD OCCUR OR IF YOU ARE
UNSURE IF YOU ARE HEARING DETONATION, DECREASE THROTTLE
APPLICATION IMMEDIATELY and consult Aerocharger staff (913.541.0200).
Detonation should NOT be an issue with this kit provided if it is installed correctly,
though OEM factory shipped engine and parts inconsistencies are possible on any new
vehicle.
Note:
Aerocharger holds no responsibility for any powertrain damage that results from misuse
of this turbo system!
Note:
Read and understand ALL safety and technical precautions in this manual before
proceeding. Failure to comply with the instructions in this manual could result in
personal injury, property damage, voiding your warranty, and/or inconsistent/poor
performance from the turbocharger system. Contact Aerocharger for any questions or
concerns.
Do NOT let any debris (hard or soft) enter the existing air intakes or exhaust ports
during installation of this turbo kit.
Do NOT use any silicone sealants except as prescribed in this manual. Doing otherwise
can result in F.O.D. (Foreign Object Damage) to the turbo. This will void your warranty.
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TOOLS NEEDED:
1. Metric socket and wrench set (6mm-17mm)
2. Standard socket and wrench set (3/8”-9/16” and ¼”)
3. 7/8” Open Ended Wrench
4. Allen Wrenches 4mm, 5mm, 6mm, 3/16”
5. T25 and T27 torx wrench
6. Flat Head Screwdriver
7. Electric Drill
8. 2” hole saw
9. Razor Blade
10. Spring tool
11. Torque wrench
12. 4mm Allen wrench
13. Deburr Tool and/or ~100 Grit Sandpaper
14. Reciprocating saw, cutoff wheel, or hacksaw
15. 3/8” drill bit
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PREPARE VEHICLE FOR INSTALLATION
REMOVE STOCK AIR PLENUM
1. Loosen the hose clamps connected to the air plenum and remove the 2 bolts holding it in
position.
Use a ¼” Socket
and wrench to
loosen the
clamps
connected to the
throttle bodies
Use a 10mm
socket and
wrench to
remove the two
support bolts at
the top of the
plenum.
Remove the
rubber tube from
the back of the
plenum
Use a 6mm Socket and wrench to
loosen the clamp connected to the
intake
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2. Remove the plenum from the vehicle and discard it, it will no longer be needed.
REMOVE STOCK INTAKE
1. Use a T27 torx to remove the 9 screws from the driver side rear fender then remove the
fender
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2. Use a T27 torx to remove the bolts holding the stock intake in place and discard the
stock intake; it will no long be needed.
Remove the
plastic ring that
holds the rubber
tube in the
intake. Save it
this will be used
later.
3. Use a 10mm socket and wrench to remove the support bracket for the intake and
discard it; it will no longer be needed.
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REMOVE STOCK HEADER
1. Remove the seats and the panel behind the seats to get to the stock exhaust header
bolts.
Turn the
connector clips
and pull off the
cover
2. Use a 6mm allen wrench to remove the 6 bolts holding the stock header onto the
cylinder head.
3. Use a spring tool to remove the springs connecting the header to the muffler.
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4. Remove the stock header and set it aside, it will not be needed any longer.
REMOVE STOCK MUFFLER
1. Using a spring tool, remove the springs on the bottom of the muffler
2. Slide the muffler toward the passenger side of the vehicle to remove it. Discard the
muffler; it will not be needed any longer.
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MODIFY MUFFLER MOUNTS
1. Remove the rubber bushings in the muffler mounts by pushing them out and discard;
they will no longer be needed.
2. Cut out the provided template and use it to mark a cut line on the passenger side muffler
support bracket.
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3. Cover the throttle bodies to protect them from sparks and debris.
4. Use a cut off wheel, reciprocating saw, or hacksaw to cut off the bracket along the
marked line. Use safety goggles to protect your eyes from sparks.
5. Cut off the driver side muffler mount above the top hole using the same method
employed on the passenger side bracket.
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COLD SIDE
CHANGE FUEL INJECTORS
1. Use a 5mm allen wrench to remove the fuel rail bolts located on the throttle bodies.
2. Pull the fuel rail with the injectors out of the throttle bodies. To remove the injectors you
must first remove the metal clips holding the fuel injectors onto the rail.
CAUTION!!!
Fuel will leak from the rail and the injectors during this process; Make sure you are in a
well ventilated area and keep away from flames and heat sources!
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3. Disconnect the electrical connector attached to the injector and discard the stock
injectors, they will no longer be needed.
4. Push the injectors that came with your kit into the fuel rail where the stock injectors were
just removed. Push the black end of the injector into the fuel rail, the blue end goes to
the throttle body.
5. Use the clips from the stock injectors to hold the new injectors into the fuel rail. The clips
slide into a groove in the injector.
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6. Push the injectors and fuel rail into the manifold and mount the fuel rail in its original
position. Use a 5mm allen wrench to secure the fuel rail with the original bolts.
Make sure the
injector
connectors are
pointed upward.
And the clips are
attached from
the bottom to the
top.
INSTALL AIR PLENUM
Note: Installation photographs are of the air to water intercooled system, but the
installation of the plenum is the same for either system.
1. Using a 10mm socket and wrench, remove the bracket located above the differential that
originally supported the air plenum. Use a flat head screwdriver to remove the electrical
clip connected to the bracket.
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2. Loosen the outside hose clamps on the 2 pieces of silicone that will connect to the
throttle bodies.
3. Push the air plenum onto the throttle bodies, and be sure that it goes all the way on.
4. Tighten the hose clamps over the throttle bodies using a 7mm socket and wrench with a
long extension.
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MOUNT DONALDSON
1. Remove the two bolts near the back of the bed with a T27 torx.
2. Slip the mounting bracket included in the kit in-between the bed plastics and the frame.
Then retighten the bolts using a T27 torx.
3. Wrap the large hose clamp include with the kit around the Donaldson canister and using
a 8mm socket and wrench, tighten the clamp so that it loosely fits around the canister.
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4. Install the Donaldson filter by lifting it in place from under the bed. Loop the clamp over
the Donaldson mounting bracket, but do not tighten it.
INSTALL INTAKE
1. Remove the intake cover and pre-filter from the side panel. Then take a razor blade and
cut some of the plastic supports to create clearance for the new intake.
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2. Install the intake flange into the stock intake location. It will be a snug fit.
3. Clamp the 3” flexible tubing over then end of the intake flange using a 7mm socket and
wrench. Do not cover the 1” hole with the flexible tubing.
4. Using the plastic grommet that was removed from the stock intake, install it into the 1”
hole on the intake flange.
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5. Place the side panel back onto the vehicle. While doing this insert the rubber tube into
the plastic grommet that you just installed on the intake flange.
6. Replace some of the bolts in the side panel to hold it in place.
7. Route the hose behind the clutch vent to get it to the Donaldson filter. It is a tight fit.
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8. Secure the flexible tube to the inlet of the Donaldson using a 3” hose clamp and a 7mm
socket and wrench.
EXHAUST INSTALLATION
INSTALL HEADER
1. Install the new exhaust header.
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INSTALL MUFFLER AND TURBO
1. Remove the oil fill plug from the turbo with a 3/16” allen wrench, and empty 1 bottle of oil
into the turbo and replace the fill plug using a dab of red loctite, torque to 34-in-lbs.
2. Bolt the turbo loosely to the included muffler with the supplied hardware using a 13mm
socket and wrench. The bolts come with anti-seize already on them.
3. Prepare your mounting hardware. The exhaust spacer seats into the passenger side
muffler bracket that you previously cut shorter. One of the 5/16 hex head bolts and a 1”
washer hold the turbo on at that location.
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4. The other 5/16” button head bolt attaches the muffler to a slotted hole at the back of the
vehicle on the driver’s side. One rubber washer goes on the back side of the slotted
frame hole and the other 2 go on the inside. The flange nut is then screwed on to act as
a spacer for the muffler mount. Tighten it until it is snug. The nylock nut is then used to
hold the muffler in place.
Note: The photos above are not completely accurate as we have updated the
mounting hardware.
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5. Loosen the clamps on the air plenum and the Donaldson with a 7mm socket and
wrench. Then install the turbo muffler assembly from below. Move it into position and roll
it into the silicone on the Donaldson and the air plenum. Slip the turbo assembly onto the
mounting bolts and hand tighten the nuts to hold the turbo in place.
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6. With the turbo loosely held in place, install the donut gasket onto the header, then insert
the turbine inlet pipe between the turbo and the header. Put the provided gasket inbetween the turbine inlet and the inlet pipe. Then use a 17mm wrench and the provided
hardware to attach the inlet pipe to the turbine inlet. The bolts already come with antiseize on them.
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7. Using a 7mm wrench tighten the silicone couplers on the air plenum and Aerocharger.
8. Install the springs between the turbine inlet pipe and the exhaust header.
9. Tighten the turbine outlet bolts with a 13mm wrench.
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10. Tighten the mounting bolts with a 3/16” allen wrench and a ½” wrench.
11. Tighten the Donaldson air filter clamp with an 8mm socket and wrench.
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AIR TO W ATER INTERCOOLER INSTALL
Note: this part of the installation is for systems with air to water intercooler systems. If
you do not have an air to water system then you can skip ahead to the electronics
sections.
MOUNT RADIATOR
1. Remove the hood of the vehicle and with a T25 wrench remove the 5 screws holding the
shroud on.
2. The radiator drops down in front of the stock radiator and the lower bracket seats
underneath the frame gusset in front of the stock radiator.
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3. Use a 4mm allen head to attach the lower support to the frame. The bolts thread into
preinstalled threaded clips on the radiator.
INSTALL W ATER PUMP
1. Remove the parts from the water pump box. Slip the plastic mount over the pump and
connect the wire harness to the plug.
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2. Use a 3/8” drill bit to drill 2 holes in the foot well near the accelerator pedal. The first hole
is drilled at the approximate location shown in the photo. For the second hole use the
provided u-bolt to get the spacing and drill it horizontal from the first.
3. Put the u-bolt over the plastic piece on the pump.
4. Mount the pump using the two holes you just drilled. The outlet faces toward the front of
the vehicle as shown in the photograph.
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5. Use a 9/16” socket and wrench to firmly attach the pump to the foot well using the
provided nuts and washers.
]
INSTALL FILL NECK
1. Push the fill neck assembly onto the upward facing pump barb and tighten the hose
clamp using a 7mm socket and wrench.
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2. Route the hose attached to the radiator on the passenger side to the T-barb on the fill
neck.
3. Using a 7mm socket and wrench, tighten the hose and clamp onto the fill neck T-fitting.
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RUN HOSES
1. Remove the driver’s side rocker panel using a T27 torx and a flat head screwdriver.
These are the
plastic snaps
These are the
screws
2. Route the 2 heater hoses through the front wheel well in to the front compartment.
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3. Route one of the heater hoses around the front shock and attach it to the pump. Using a
7mm socket tighten the hose clamp.
4. Route the other hose toward the radiator on the driver’s side. Connect the hose to the
short hose barb included on the radiator. Use a 7mm wrench to secure the hose clamp
on the barb.
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5. Zip tie the top radiator support to the frame.
6. Reinstall the shroud over the hood with a T25 torx wrench.
7. Route the hoses along the cavity behind the rocker panel and around the battery
compartment.
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8. Route both of the hoses over the clutch cover and toward the air to water intercooler.
9. Route the hose connected to the pump to the bottom hose barb on the intercooler. Then
secure it with the supplied hose clamp using a 7mm socket wrench.
10. Route the hose connected to the radiator to the top hose barb on the intercooler. Then
secure it with the supplied hose clamp using a 7mm socket wrench.
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ELECTRONICS
INSTALL GAUGES
1. Using a razor blade remove the sticker on the driver side dash.
2. Using a drill and a 2” hole saw drill 2 holes in the driver side dash where you would like
to mount the gauges. Using a deburr tool, knife, or sandpaper to remove the plastic
burrs.
3. Install the boost gauge by inserting it into one of the newly cut holes and tightening the
supplied nuts by hand on the back of the gauge.
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4. Install the AFR gauge in the other hole. Secure it with the bracket and supplied nuts by
hand.
5. Route the supplied oxygen sensor line through the front wheel well were the coolant
hoses were just ran. Run it up into the dash and connect it to the AFR gauge.
6. Install the provided oxygen sensor in the bung on the muffler with a 7/8” open ended
wrench.
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7. Route the oxygen sensor cable from the gauge along the coolant lines back toward the
muffler. Connect the oxygen sensor to the cable.
INSTALL W IRING
1. Connect the barrel plug on the main wiring harness to the accessory plug by the 12V
outlet on the dash. Remove the spade connector from the back of the 12V outlet and
connect it to the male spade connector on the wiring harness. Connect the female spade
plug on the wiring harness to the back of the 12V outlet.
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2. Attach the two female spade connectors on the long red and black wires of the main
wiring harness to the boost gauge electrical terminals. This will power the light on the
boost gauge.
Note: this step is only for the Air to Water System
3. Route the power wires from the water pump through the foot well hole for the stock main
wiring harness. Connect the Weather Pack connector in line with the connectors on the
supplied wiring harness.
INSTALL AEROCOMMANDER
1. The Aerocommander is going to connect to the fuel injectors, the solenoid included with
the kit, and the battery ground. The Aerocommander also has 2 plugs to disconnect the
Aerocommander box from the wiring harness.
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2. Rout the 4 connectors that go to the injectors under the clutch vent so that they come
into the engine area right above the throttle bodies.
3. Connect the two smaller plugs to the stock injector plugs, and connect the larger plugs to
the fuel injectors.
4. Connect the lone connector on the Aerocommander harness to the solenoid valve
included with the turbo system.
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5. Connect the black wire with the eyelet to the negative terminal on the battery.
6. Connect the signal line coming off the solenoid valve to the signal line on the
Aerocommander.
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7. The Aerocommander can be positioned in multiple places on the vehicle. The simplest
place to position it is by routing the box through rubber part that goes around the
seatbelts. This positions the Aerocommander between the seats in an easily accessible
location.
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HOOK UP PRESSURE CONTROL LINES
1. Cut the idle air control line located behind the fuel injectors that connects to the
passenger side of the manifold. Insert the provided reducing T-connector in-line with this
line.
2. Connect the main vacuum line harness to the T-barb you just installed. The end to install
will be marked with a sticker that says “to manifold”
3. Pull the line connected to the fuel regulator out of the frame tube. Route it to the open Tbarb on the supplied vacuum line harness.
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4. Route the shorter line of the vacuum line harness down between the air plenum and the
3” flexible tubing. Attach this line to the blow-off valve. This line will be labeled “ to blowoff Valve”
5. Route the long line toward the front of the vehicle. It will first follow the 3” flexible tube
then follow the coolant hoses after that. Connect this line to the metal barb on the
supplied solenoid valve. This line will be labeled “to solenoid”
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6. Attach the solenoid valve with a zip tie to the frame member that the seat belt buckles
are attached to.
7. Attach the line that comes preinstalled on the solenoid to the Aerocommander. This line
will be labeled “to Aerocommander”
8. Attach the line that comes preinstalled on the air plenum to the boost controller. This line
will be labeled “to controller”
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9. Route the supplied line labeled boost gauge line along the heater hose. It will take the
same route the oxygen sensor cable took. Connect one end to the barb on the back of
the boost gauge and the other end to the open barb on the air plenum.
10. Reinstall the rocker panel on the driver side using the stock hardware and a T27 torx
wrench. Also, screw in the bolts that were not reinstalled earlier on the side panel.
11. Install the included filter onto the end of the rubber hose that was connected to the stock
air plenum. Secure it with a zip tie.
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CLUTCHING
1. Your turbo system comes with adjustable weights in order for you to fine tune your
clutching to your specific application. The weights come set up for 5lbs of boost at sea
level. Adjust them according to the chart in the box for your specific application. If you
use a tire diameter other than the stock tires you may have to adjust the weights to
compensate.
2. To install the weights start by removing the clutch cover using a 3/8" socket to remove
the screws on the cover. Then remove the cover.
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3. Use the tool that comes with your razor to open the secondary sheaves to remove the
belt.
4. Pry open the primary with a flat head screwdriver or a prybar and use a metal spacer to
hold it open. The photograph shows us using a spare clutch weight as a spacer.
WARNING: DO NOT GET YOUR FINGERS BETWEEN THE SHEAVE AND SPYDER
AS THE CLUTCH SHOULD SNAP SHUT!
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5. Using a 1/8” allen wrench and a 3/8” open ended wrench, remove the bolts and nuts
holding the stock weights in. then remove the stock weights and replace them with the
adjustable weights included with you turbo system.
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6. Finish up by replacing the stock bolts to hold the weights back in. Remove the metal
spacer holding the primary open. Reinstall the belt and put the cover back on and you
are done.
ZIP-TIES
1. Zip-tie the oxygen sensor cable to the coolant hoses. Then zip-tie the coolant hoses to
the frame in the rear.
2. Zip-tie the coolant hose in the front that connects to the pump to the frame member
above the front shock.
3. Zip-tie the bundle of hoses and lines together in front of the clutch by the battery.
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4. Zip-tie the wiring under the dash up and out of the way.
5. Zip-tie the vacuum lines by the air plenum out of the way, make sure not to pinch the
lines, this could cause fueling and boost problems.
6. Zip-tie the Aerocommander wires so that they will not get tangled in the driveshaft.
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RACE CLUTCHING
With the purchase of the race clutching upgrade, a new primary spring and secondary helix are
included with the turbo system. These parts require special tools to install. If you are unfamiliar
with the special tools or do not have access to them contact your local performance shop or
dealership to install the parts.
OWNERS OPERATION AND MAINTENANCE
Air/Fuel Ratio Gauge
We designed the tuning on our RZR XP Aerocharger kits to cover a wide variety of driving
conditions, altitudes, and temperatures. Depending on your environment you may want to fine
tune the Aero-Commander EFI controller to maximize performance
WARNING
Monitor your air/fuel ratio to ensure that it stays below 12.8 when the engine is under
heavy load.
General Air/fuel Ratio Guidelines:

AFR numbers are most important to monitor when the engine is under
heavy load. For example: acceleration, climbing a hill, etc.

The AFR will spike to very lean levels when decelerating. This is normal.

For any questions and concerns for proper Air/Fuel Ratios on your
Aerocharged RZR XP contact Aerocharger (913.541.0200)
Fuel
Always use at least 91 octane fuel for any boost level. For boost levels exceeding 7.5psi use at
least 100 octane fuel or higher. Aerocharger recommends the use of 110 octane fuel for all
situations.
Aero-Commander Tuning
For general guidelines and tuning instructions refer to your Field Guide (included with your kit)
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RZR XP Aerocharger Turbo System
By Aerocharger, LLC
(913.541.0200)
www.AEROCHARGER.com
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