1998-04 Impreza RS 2.5-liter Turbo Kit

AVOTurboworld Turbo system Fitting Instructions
for the 2001-2004 2.5-liter Subaru Impreza RS
Congratulations on purchasing AVO Turboworld’s Bolt-on Turbo Kit for the Subaru 2.5-liter RS. You are now
the proud owner of a Turbosystem that draws on experience gained by not just 10 years of Subaru high
performance tuning, but more importantly 25 years of experience designing, manufacturing, installing and
modifying turbochargers.
Not only will this Turbosystem greatly increase your engine’s power over stock, but it will also be user friendly
to drive and will remain so for many years of trouble free operation, with proper installation, servicing and
maintenance.
Contents
Chapter
Page
Orientation
2
Tools and Consumables Required
6
Pre-Installation Preparations
7
Disassembly
8
Turbo Oil Return System
9
Turbocharger Assembly
9-10
Turbocharger Cooling + Lubrication
11-12
Turbocharger Intake System
13-14
Mechanical Systems Check
16
Engine Management Installation
17+18+19
Turbosystem Testing
20
Operation and Maintenance
21
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Page 1 of 24
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Orientation
Thank-you for choosing AVO Turboworld’s Subaru 2.5Ltr Turbo system! Many hundreds of hours
have been spent testing and developing this final turbocharger, with a large amount of work going
into ensuring the Turbosystem seamlessly integrates with the stock engine, transmission and
electronics package. The end result is this complete package solution for turbocharging your
naturally aspirated Impreza RS.
But Before grabbing a bunch of spanners and attacking your car take a moment to
STOP AND THINK
Read these supplied installation instructions thoroughly from start to finish – do you understand all
of the mechanical operations required? Are you sure that you can adequately complete all of the
mechanical operations required? Do you understand all of the terminology used in this installation
manual? Your installation skills will have a big effect on whether or not your new turbosystem will
perform to its full potential and give years of trouble free operation, without seriously damaging
either your engine or your wallet.
Prior to starting the installation, make sure that your car is in excellent mechanical condition and that
there are no outstanding faults or problems. This Turbosystem has been designed to work only with
a car that is in good state of repair. Pre-existing problems or faults can result in improper operation
and/or failure of your engine or Turbosystem. This is your responsibility to ensure. No matter how
carefully we design our Turbosystem’s, this is one area we have no control over and cannot be held
responsible.
This Turbosystem is designed to run on high-octane unleaded fuel. Always use the highest grade of
fuel available in your area. This is essential for correct operation of your car and your new
Turbosystem - failure to use high-octane fuel can result in engine damage. Prior to installation of
this Turbosystem ensure that you already have a full tank of high-octane fuel. If in doubt drain the
fuel tank and refill with high-octane fuel.
Check all parts supplied with the Turbosystem prior to installation for the following;
a) Verify that all parts noted on the Turbosystem kitting list have been supplied. Contact AVO
Turboworld or selling agent if any parts are missing.
b) Make sure that all parts are in good condition and have not been damaged during shipping etc.
c) Take time to make sure you can identify the individual parts supplied to the relevant sections in the
attached fitting instructions.
d) Remember to fill out the attached warranty form and send it in to AVO Turboworld to activate your
product warranty.
AVO Turboworld is committed to constantly improving our range of products as well as our standard
of customer service. If during the course of installation you find any errors contained in our
instructions, or there are areas that could be improved to make installation easier, feel free to either
email us at [email protected] or fax us at +613 95844008 with your comments / suggestions.
AVOTurboworld – For All Your Turbo Needs
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Kitting List
Note: Check this kit list before starting the install to make that you have all these parts.
1 x Exhaust & Turbo Charger
Assembly
1 x Fitting Instructions
1 x Front Pipe with Cat
PN: 2CJ92T01
25cm x Fire Sleeve
PN: 5Q9BBT01
1 x Oil Drain Fitting
PN: PBSPTC01
1 x Braided Oil Drain Hose
PN: ERZPCT01
1 x Oil Supply Fitting
PN: PBDZWC01
1 x Braided oil Supply Hose
PN: ER3FBT01
1 x Power Air Filter
PN: ENLEC001
1 x Steel Inlet Pipe
PN: 2BLOXT01
2 X 40/60 Hose Clamps
PN: MCF24C01
2” x 2” Silicone Hose
PN: EMH25C01
1 x 32/50 Hose Clamp
PN: MCE04C01
1 x 38mm Blank off Plug
PN: FNFY7T01
1 x 31mm Blank off Plug
PN: FNEW7T01
1 x 12mm Plastic Straight
PM: 7JBM5S02
2 x 12mm Plastic T Piece
PN: 7JBM5S01
1 x 13mm Oil Breather Hose
PN: EN6MBT01
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1 x 5/16” Brass T Piece
PN: 7TJH4T01
4 x 10/16 Hose Clamps
PN: MCBP4C01
2 x 10/16 Hose Clamps
PN: MCBP4C01
100cm High Press. Fuel Hose
PN: ES6H7T01
46cm x5/16 Water Hose
PN:EN0H7T01
35cm x 5/16 Water Hose
PN:ENYH7T01
2 x 70/90 Hose Clamps
PN: MCK54C01
2” x 2 3/4” Blue Silicone Hose
PN:EMK05C01
1 x Intercooler Assembly
with a extra Injector
1 x Intercooler Air Scoop
PN:6H997T01
2 x 50/70 Hose Clamps
PN:MCS634C01
1 x Moulded Rubber Hose
PN: FNHE7C01
1 x 25/40 Hose Clamp
PN: MCDY4C01
6 x 30cm long Cable Tie
PN: KJXE7T01
1 x RH Intercooler Stay
PN: RBVTTT02
1 x LH Intercooler Stay
PN: RBXVTT01
4 x 8x1.25mm Nut
PN:1BEHUT01
4 x 8mm Spring Washer
PN:ABBHUT01
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4 x 8mm Flat washer
PN: ABBHUT01
4 x 8x1.25mm x 25mm Bolt
PN:ABEHUT25
2 x 8mm Spring Washer
PN: ABBHUT01
2 x 8x1mm x 25mm Bolt
PN:ABDHUT2525
4 x 10mmx 1.5mm Nut
PN:ABFJUT01
4 x 10 X 1.5mm x 40mm Bolt
PN:ABFJUT40
1 x 35/40 Hose Clamp
PN: MCDY4CO1
1 X Molded Black Rubber Hose
PN: FNEJ7CO1
1 x 32/50 Hose Clamp
PN: MCEO4CO1
1 X 100mm x 38mm Black Hose
PN: FNF67T01
300mm x4mm Vacuum Hose
PN: ENXD7T01
1 x 4mm Plastic T Piece
PN: 7JSD5501
1 x BOV Assembly
PN: S2A97G00A001A
1 x Injector Loom
PN:V299ST01
1 x SMT Computer
PN:91997X01
1 x SMT Computer Loom
PN: W199SX01
1 x Map Sensor
PN:9299SX01
1 x Computer Program
PN:
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Tools Required
Consumables Required
Metric Combination Spanner Set
Metric Socket Set
Phillips point and Flat Blade Screwdriver Set
Putty Knife or Similar
Trolley Jack and 4 Axle Stands
Vehicle Lift (If Available)
Electric Hand Drill
Drill Bit Assortment Kit
Multimeter
Access to Gas welding set
Engine Oil Drain Pan
Soldering Iron
Side Cutting Pliers / Wire Strippers
Boost Pressure Gauge
New Engine Oil and Filter
Engine Coolant (For Topping Up Level)
High Temp O2 Sensor Safe Silicone Sealant
Subaru Oil Pan Silicone Sealer
Aerosol Brake / Parts Cleaner or Similar
WD40 Or Similar Penetrating Oil
Electrical Insulation Tape
Rosin Core Electrical Solder
3mm Diameter Heat Shrink
Subaru 2.5RS Owners Manual
Surgical Gloves or Similar
Loc-tite Pipe Thread Sealant (or similar)
Pre-Installation Preparations
1) Select a proper location for installation. You will need a hard flat paved surface in order to
safely jack up and support your car.
2) Disconnect Negative Battery Terminal
3) Jack up front and rear of car. Support with axle stands. Refer to your Vehicle owner’s manual
for information on where to correctly place the jack and axle stands so as not to damage any
mechanical parts of your car.
4) Make sure the engine has cooled sufficiently for work to commence.
5) Drain all oil from the engine sump (oil pan) into a proper oil-drain pan.
NOTE! Extreme caution must be exercised when working underneath your car. Under no circumstances
should you ever work under a un-supported/improperly supported car. Use only dedicated Automotive Axle
support stands. Serious injury/and or Death can result. Care must be taken when handling used engine oils,
avoid contact on unprotected skin. Ensure that all waste oils/solvents are disposed of in an environmentally
friendly approved manner.
Disassembly
Step 1 – Remove factory air-cleaner box and air intake pipes from the throttle body and inner
guard area. Take care when removing the oil system breather hoses to ensure that they are not
damaged or disconnected from the engine. Remove the factory air-cleaner box mounting brackets.
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Step 2 – Remove and discard engine lifting/engine wiring harness-mounting bracket as shown in
(Fig 3+4) diagram.
Fig 3: Engine Lifting bracket and wiring
harness
Fig 4
Step 3 - Re-secure the wiring harnesses with plastic cable ties as shown in (Fig 5+6). This is to
make room for the Turbocharger, which will fit in this area.
Fig 5: Use plastic cable ties to secure
harness.
Fig 6: Re-route wiring for turbo.
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Step 4 – From underneath the car carefully un-plug and then remove the two oxygen sensors from
the factory Catalytic Converter/intermediate section (Fig 7). Spray both sensors with WD-40 to
assist with removal, as they can be difficult to remove. Take care not to damage the sensor body or
mounting threads during removal. Un-bolt and remove stock Catalytic Converter/center sectional
and discard.
Fig 7: Stock Catalytic Converters/center section
Step 5 – The air-conditioner receiver drier needs to be relocated to provide enough room for the
turbocharger assembly. Carefully push the receiver drier towards the engine bay firewall
approximately by one inch as shown in (Fig 7). Remove the high-pressure A/C line chassis railmounting clip and carefully bend the A/C pressure line in towards the Right Hand Suspension strut
tower. Refer to (Fig 8)
Caution! Be extremely careful when bending air conditioner hoses. Only bend hoses enough to
provide adequate clearance. Air conditioner systems contain gas at very high pressure. OverStressing air conditioner lines can result in a discharge of high-pressure gas. Exposure to this can
result in serious injury.
Fig 8: Push receiver drier towards engine
bay firewall.
Fig 9: Push high-pressure A/C line in
against suspension strut.
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Step 6 – Remove Cruise control actuator assembly
From its stock mounting point at the front of the Right Hand suspension strut tower. Disconnect
vacuum hose from intake manifold, electrical connector and cruise control cable from throttle
butterfly. Take note of actuator adjustment. Keep Cruise control actuator in a safe place for re-fitting
at a later stage. (Fig 10)
Fig 10: Cruise control actuator
Step 7 – Remove Power steering hose mounting clamps from the side of the intake manifold.
Loosen 17mm Banjo nut for the power steering discharge pipe (Fig 11). Loosen only enough to
allow movement of the pipefitting. Wrap rag or paper towel around fitting to catch any fluid that may
leak out. Remove and re-fit rear power steering mounting clamp to the power steering pipes so that
it is facing downwards (opposite to original position) (Fig 12) while carefully rotating the high
pressure power steering hose downwards. This is to allow enough clearance for the Turbo intake
pipe. Re-tighten the power steering banjo bolt.
Fig 11: Loosen Banjo Power Steering bolt.
Fig 12: Re-fit hose bracket facing
downwards.
Step 8 – Remove the engine accessory drive belt cover from above the power steering pump and
alternator. Remove alternator belt and then remove alternator assembly. This is done to gain access
to the stock oil pressure switch. Wrap insulation tape around Alternator wiring harness connections
so that there is no risk of short circuits etc.
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Step 9 – Drain engine oil (if you have not already done this step) Mark Oil Pan for position of Turbo
oil Drain fitting. (Fig 13) Remove Oil level dipstick from the engine and start removing all Engine Oil
Sump Pan bolts. The rear oil pan bolts are accessed through holes in the suspension crossmember. (Fig 14) Use a putty knife or similar and carefully pry between oil pan and engine block
and separate oil pan from cylinder block. Once the oil pan is loose from the engine block the engine
oil pick-up needs to be unbolted to allow removal of the sump pan. Be careful not to loose the oil
pick-up sealing “O” Ring.
Fig 13: Mark the position of the oil drain on
oil pan.
Fig 14: Access hole for rear oil.
Turbo Oil Return System
Step 10 – Drill marked hole in Engine Oil pan with ??? diameter drill bit. Using a gas welding set
braze the turbocharger oil drain fitting (Item ??) to the oil pan. Once this fitting is welded into the
sump, pressure test the weld to ensure that it will not leak once it is refitted to the engine.
Use putty knife or scraper blade to clean the old oil pan sealant, check the sealing surface of the oil
pan for any damage sustained when removing oil pan from engine. Repair as required. Carry out
the same procedure for the sealing surface on the engine block.
Using aerosol parts/brake cleaner thoroughly clean all metal shavings / debris from the inside of the
oil pan and engine block sealing surface. Clean all traces of oil/grease from the sealing surfaces of
both the engine oil pan and the engine block.
NOTE! It is very important that all traces of metal shavings are cleaned from the oil pan before fitting
to engine. Even the smallest metal shavings or pieces of sump sealant could potentially cause serious
engine damage.
Apply a good coating of Loctite pipe thread sealant to the Turbo oil drain fitting (Item??) and screw
fitting into engine oil pan. Do not over tighten fitting.
Step 11 – Apply a bead of Subaru oil pan sealer to the sealing surface of the oil pan. Re-fitting of
the oil pan is the reverse process of removal. Be sure to re-install the engine oil pickup at the same
time.
NOTE! It is very important that the engine oil pickup “O” ring is not damaged during installation.
Damage to this “O” ring can result in oil system failure and serious engine damage.
Wipe off any excess oil pan sealer with paper towels or rags.
Step 12 – Disconnect wiring connector from stock oil pressure switch and carefully un-screw from
the engine block. Apply a small amount of Loctite pipe sealant to the threads of the supplied AVO
Turbo oil feed adaptor fitting (Item 40) and screw into engine block. Carefully tighten adaptor fitting
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so that the stock oil pressure switch can be installed in the 12 O’clock position (Fig 15) Install stock
oil pressure switch. Use a spanner to support oil pressure adaptor fitting while tightening stock oil
pressure switch.
NOTE! Do not over tighten adaptor fitting or stock oil pressure switch, fitting or switch may break off
as a result.
Fig 15
Turbo Charger Assembly
Step 13 – The turbocharger comes pre-assembled to simplify installation, but always double check
and inspect to ensure bolted joints, oil and water fittings are tight before fitting the turbocharger to
the engine.(Fig 16)
Fig 16: Turbocharger sub-assembly
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Step 14 - The turbocharger subassembly including turbocharger up-pipe is installed from
underneath the vehicle. Carefully feed the turbocharger subassembly up through the space behind
the RH cylinder head. Loosely install Turbocharger Up-Pipe mounting bracket (Fig 17) to hold
turbocharger in place.
Coat Stock 2 bolt stainless steel exhaust gasket with High Temp sealant and fit in the flange joint
between stock exhaust headers and the new Turbocharger up-pipe. (Fig 17+18) Using two of the
supplied exhaust bolts and nuts hand tighten the exhaust flange joint.
At the other end of the turbo catalytic converter pipe coat the existing exhaust gasket with high temp
sealant and bolt up using the supplied exhaust bolts. (Fig 18)
Fig 17: Turbocharger up-pipe support
bracket
Fig 18: Coat gasket with high-temp sealant.
Fig 19: Turbocharger sub-assembly
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Turbo Charger Assembly
Step 15 – Coat turbo outlet flange with high temp sealant. There is no need for a gasket between
the turbo outlet and the turbo Catalytic converter pipe. Fit the turbo Catalytic converter pipe to the
turbocharger and bolt up hand tight using the supplied copper nuts and stainless steel washers. (Fig
18) Install Turbo catalytic converter pipe to Transmission casing mounting bracket (Fig 19) using
the original retaining bolt. Install only finger tight.
Fig 19
Fig 20
At the other end of the turbo catalytic converter pipe coat the existing exhaust gasket with high temp
sealant and bolt up using the supplied exhaust bolts. (Fig 20)
Step 16 – Fully tighten all nuts and bolts previously hand-tightened. Check alignment of exhaust
pipes to ensure adequate clearance to surrounding components. Tighten the turbocharger up-pipe
mounting bracket (Fig 17), Turbocharger up-pipe to stock exhaust header flange (Fig 18),
Turbocharger outlet flange to Catalytic converter pipe (Fig 19), Catalytic converter pipe support
bracket (Fig 20), and finally the Catalytic converter pipe to stock exhaust system joint (Fig 18).
Step 17 – Re-Install previously removed front and rear Oxygen sensors. Secure front oxygen
sensor harness with plastic cable ties to ensure that wiring harnesses don’t touch the turbo up-pipe
or catalytic converter pipe.
Turbo Charger Cooling + Lubrication
Step 18 – Route the turbocharger oil drain hose down past the back of the RH cylinder head, (Fig
15+12) and then between the RH exhaust manifold and RH engine mount. Connect Oil drain hose
to fitting previously welded into Oil pan and tighten hose fitting. Do not over tighten.
NOTE! When fitting the Turbocharger Oil drain hose, care should be taken to ensure that the drain
hose does not touch the turbocharger up pipe and RH exhaust manifold. It should also be fully clear
of the RH front driveshaft. Failure to do so can result in engine oil leakage and is a potentially serious
fire risk.
Step 19 – Route Braided Turbocharger oil supply hose (Item 41) under intake manifold past the
back of the power steering pump (Fig 20) Screw fitting into the oil pressure switch adaptor and
carefully tighten fitting. Don’t overtighten fitting! Route Braided Turbocharger oil supply hose from
under the intake manifold and pass it down underneath the front of the turbocharger compressor
housing. Attach hose fitting to turbocharger oil supply and carefully tighten. (Fig 21)
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NOTE! Pay attention that the Turbocharger oil supply hose is well clear of any rotating engine parts
and does not touch hot exhaust parts. Carefully check to ensure that are not twisted, kinked or will
chafe on sharp engine parts. Failure to do so can result in a high-pressure engine oil leakage and is a
potential serious fire risk.
Fig 21: Direction of turbocharger oil feed pipe.
Fig 22: Route turbocharger oil feed under front
of compressor cover.
Do not re-fit the alternator. This will be done after the engine has been test run to check for oil leaks.
Turbo Charger Cooling + Lubrication
Step 20 – The Turbocharger has two different length hoses for its water-cooling circuit. The longest
Turbocharger cooling hose, 460mm (18 Inches) long connects to the Stock engine block coolant
crossover pipe. (Fig 23) The remaining Turbocharger cooling hose, 350mm (13.75 Inches) long
connects to the Stock throttle body heater hose at the throttle position sensor side of the throttle
body. (Fig 24). Route the Turbocharger cooling hoses from the turbocharger to the throttle body and
the engine block coolant crossover pipe. Route Turbocharger coolant hoses along the same path as
the Turbocharger oil supply hose. Cable tie coolant hoses securely.
NOTE! Pay attention that Turbocharger Cooling hoses are well clear of any rotating engine parts and
does not touch hot exhaust parts. Carefully check to ensure that it is not twisted, kinked or will chafe
on sharp engine parts. Failure to do so can result in coolant loss and potential damage to the engine
or turbocharger
Remove stock rubber coolant pipe that fits between the Throttle body and the engine coolant
crossover pipe and discard. Using supplied hose clamps (Item 33) attach Turbocharger cooling
hoses. Tighten hose clamps. If this is done quickly there is no need to drain the engine of coolant.
Fig 23: Engine block coolant crossover pipe.
Fig 24: Throttle body heater hose connection.
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Top up engine coolant level (If required) and pressure test for any coolant leaks at the throttle body,
Engine Block crossover pipe or the Turbocharger Banjo bolts.
Turbo Charger Air Intake System
Step 21 – Fit the 2.25” Silicone hose joiner (Item 78) to the Turbocharger compressor cover inlet.
(Fig 25) Use the two supplied hose clamps. (Item 79) Fit the metal Turbocharger intake pipe noting
that the Blow-Off valve return fitting faces upwards. Fit Airfilter and Airfilter mounting bracket.
Tighten all mounting bolts and clamps. (Fig 26)
Fig 25
Fig 26: Air filter mounted.
Step 22 – Fit short black breather hose and one of the supplied plastic 3/8” T pieces (Item 77) to
the turbocharger air intake pipe breather fitting (Fig 27) Plug one end of this T piece into the factory
PCV Valve connector hose. The remaining end of this T piece plugs into the other supplied plastic
3/8” T piece. (Fig 28) The Two Ends of this last T piece is used to join the Passenger side and
Drivers side cam cover breather vent ports. Use the supplied long black plastic breather hose (Item
76) along with the supplied 3/8” straight plastic hose joiner (Item 75)
Route this long plastic breather hose from the stock Drivers side cam cover breather hose to the
other side of the engine. (Fig 29)
Fig 27: Turbocharger intake breather hose.
Fig 28
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Turbo Charger Air Intake System
Step 23 – Fit Turbocharger discharge hose to the Turbocharger compressor cover, the end with
the 115 Degree bend is the Turbocharger end. (Fig 29) Fit supplied clamps but don’t tighten.
Spraying hose connections with WD-40 will assist with sliding hose connections on.
Fit the supplied 2.75” silicone hose joiner (Item 85) to the intercooler discharge. Fit intercooler
discharge and loosely clamp to throttle body using the supplied hose clamps (Item 86)
Fit other end of Turbocharger discharge hose to intercooler, this is the end with the 90 degree bend.
Check to make sure that the compressor discharge hose is not kinked or twisted.
Using supplied mounting nuts and bolts (Item 89+90+91) and fit RH and LH Intercooler mounting
brackets (Item 99+100) to the intercooler and inlet manifold. (Fig 30) Re-use the rubber mounting
bushes and sleeves from the stock airbox mounting brackets and bolt down the intercooler.
Fig 29
Fig 30
Step 24 – Fit supplied AVO Turboworld Sequential Blow-Off valve (Item 95) to intercooler (Fig 29)
using supplied short rubber hose joiner (Item 93) and hose clamps (Item 94)
Connect Blow-Off valve Vent return to Turbocharger intake pipe using supplied short rubber hose
joiner (Item 97) using supplied hose clamps (Item 98)
Connect Blow-Off Valve vacuum hose (Item 96) to the spare vacuum fitting on stock intake
manifold. (Fig 27)
Turbo Charger Air Intake System
Step 25 - Remove RH inner Fender plastic liner panel. Position Cruise control actuator inside of
inner fender area (Fig 31) Fit up Cruise control actuator as show, mark holes through stock
mounting bracket and drill two new 6mm mounting holes. Use supplied 6mm bolts and nuts to
attach Cruise control actuator to inner fender area.
NOTE! Use care when drilling the inner fender so as not to drill through wiring looms and other engine
bay accessories. Check carefully before drilling holes. Always use approved eye protection when
drilling.
Cut Cruise control wiring connector and extend wiring loom. Ensure all electrical joints are soldered
and properly insulated. Reconnect to vehicle wiring harness.
Run vacuum hose from intake manifold through inner fender and re-connect to Cruise control
actuator.
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Pass Cruise control actuator cable through inner fender and re-connect to the throttle butterfly.
Secure cruise control wiring loom, vacuum cable and actuator cable with plastic tie cables.
Step 26 – Remove the blanking plate from underneath the Stock Hood scoop. Fit the supplied
Fibreglass Intercooler scoop shroud (Item 83) to the underside of the stock hood. (Fig 31) Fit
supplied rubber seal to Intercooler Hood shroud. (Item 84)
Check installed height of intercooler hood shroud and seal by slowly closing the hood. If there is
insufficient clearance do not slam hood shut. Remove fibreglass shroud and trim to allow adequate
clearance.
Fig 31
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Mechanical Systems Check
Step 27 – Refill engine with engine oil and fit new oil filter. Check to ensure that all oil and coolant
connections are tight. Make sure that there are no loose hoses, pipes or cables near rotating engine
accessories.
Re-Connect Negative Battery Terminal.
Have assistant start engine, while the engine is running check and inspect the following items for
coolant, oil and exhaust leaks.
NOTE! Exercise extreme caution when working around the engine while it is running. Always
maintain safe distance from hot exhausts and rotating engine parts and accessories. Be aware of
loose items of clothing, neckties and jewellery. Always switch off engine prior to attempting any sort
of mechanical work or adjustments.
Step 18 – Turbocharger Oil Drain hose and Oil Pan Fitting.
Step 19 – Turbocharger Oil supply feed hose at Turbocharger and Engine block.
Step 14 – Turbocharger exhaust Up-Pipe to stock exhaust header flange.
Step 15 – Turbocharger to Catalytic Converter pipe and stock exhaust system.
Step 16 – Oxygen Sensors.
Step 20 – Turbocharger Cooling hose connections at Throttle body, engine block and Turbocharger.
Switch off Engine
Step 28 – Repair any Oil, Coolant or Exhaust leaks as required. Check engine oil level and engine
coolant level. Top up as required.
Step 29 – Re-install alternator, alternator belt. Re-tension alternator belt. Adjust belt tension until
strong thumb pressure deflects the alternator drive belt by approx 0.5” Don’t overtighten. Re-fit
Accessory drive belt cover.
Step 30 – Restart engine and turn steering wheel from lock to lock. Check and inspect power
steering hose banjo (Step 7) for power steering oil. If required, top up with approved power steering
fluid.
Switch off Engine
Disconnect Negative Battery Terminal
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Page 18 of 24
Created on 5/15/08 7:27 PM
Engine Management Installation
Step 31 – Pull back carpet from passenger side front foot well to expose alloy footplate for stock
engine control computer. Remove alloy footplate, disconnect wiring harness from stock engine
control computer (Fig 32) and remove engine computer from foot well.
The additional AVO Turboworld Engine control computer fits alongside the stock engine control
computer.
Fig 32
Step 32 - attached wiring diagram for installation of the AVO engine control computer. All wiring
joints must be soldered and insulated with heat shrink and high quality electrician’s tape.
Do use add-on crimp connectors for building a bridge harness as they give unreliable connections
and can result in erratic operation.
NOTE! Some model cars have wiring colours that are different from what is marked on the attached
wiring diagram. Use pin position references for connection. Always verify with voltmeter that the
correct circuits are being connected to avoid damage to the AVO / Stock engine control unit and stock
electrical system. If in doubt consult AVO Turboworld or seek advice of professional auto electrician.
Step 33 – Run supplied vacuum hose from AVO engine control unit to inlet manifold through the
engine bay firewall. Tee into the stock fuel pressure regulator vacuum hose.
NOTE! The vacuum hose connection between the intake manifold and the AVO Engine control unit is
very important for correct operation of the Turbosystem. Check to make sure that this vacuum hose is
not twisted, kinked, disconnected, blocked or connected to wrong manifold fitting prior to starting
engine.
Step 34 – Install supplied AVO fuel cut defender as per supplied wiring diagram.
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Page 19 of 24
Created on 5/15/08 7:27 PM
2.5Ltr Wiring Instructions
AVO ECU Circuit
INJ 1
INJ 1
INJ 2
INJ 2
IG 1
IG 2
PWR GROUND
SIG GROUND
+12 VOLT
TRIG 1 CRANK
TRIG 2 CAM
ETEMP
O2 Sensor
AVO Fuel Cut
AVO Wire Colour
Brown
Brown
Orange
Orange
Blue
Blue/Black
Black 2.00mm
Black 1.25mm
Red
White (shielded)
White/Black(Shielded)
Yellow
White
Stock ECU Circuit
Injector 1
Injector 3
Injector 2
Injector 4
Ign 1+2
Ign 3+4
ECU Ground
Sensor Ground
ECU Main Relay
Crank Sensor
Cam Sensor
Eng Coolant Temp
Front O2 Sensor
Map Sensor Signal
Stock ECU Pin
Volt Meter
B134-4
B134-14
B134-13
B134-15
B134-25
B134-26
B134-8
B136-21
B136-1
B135-1
B135-2
B136-14
B134-22
B136-5
Operation
Chk Continuity
Chk Continuity
Chk Continuity
Chk Continuity
Chk Continuity
Chk Continuity
0 Ohms To Earth
0 Ohms To Earth
+12Volts KOEO
13.08Kohm To Earth
13.08Kohm To Earth
1.0-1.4V KOEO
0-1.0V KOEO
2.4-4.8V KOEO
Cut
Cut
Cut
Cut
Cut
Cut
Tee
Tee
Tee
Tee
Tee
Tee
Tee
Cut
AVO ECU 17 pin Connector (Wire Side View)
INJ1
Brown
IG1
Blue
INJ2
Orange
IG2
Blue/
Black
RPM
Brown/
White
Pump
Purple
IG3
Blue/
White
Fan
Brown/
Black
+12 V
Red
Trig1
Yellow
E Temp
Yellow
TPS In
White/
Blue
TPS +5
Red/
Blue
(Black Screened)
P Gnd
Black
S Gnd
Black
Trig2
Blue
O2
White
2.00mm
1.25mm
(Grey Screened)
NOTE! Shaded terminals have no connection. Tie and insulate un-used wires securely to prevent
short circuits.
Stock Subaru 3 Plug Multi-Pin Connector (Wire Side View)
8
23
35
7
22
34
21
6
20
33
5
19
32
18
31
17
30
16
15
29
14
28
4
13
27
3
12
26
11
2
10
25
1
9
24
7
19
28
6
18
27
5
17
4
16
26
Connector B134
15
25
14
24
13
12
23
11
22
Connector B135
7 8 6 5 4
3 2 1
20 19 18 17 16 15 14 13 12 11 10 9 8
30 29 28
27 26
25 24 23
22 21
Connector B136
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[email protected]
3
10
Page 20 of 24
Created on 5/15/08 7:27 PM
2
9
21
1
8
20
2.5Ltr Wiring Instructions
NOTE: We no longer supply this version of the kit. The above diagram is for reference only
for current owners of this older kit.
AVOTurboworld – For All Your Turbo Needs
Tel +61 3 95844699
Fax +61 3 95844008
www.avoturbo.com
[email protected]
Page 21 of 24
Created on 5/15/08 7:27 PM
AVOTurboworld – For All Your Turbo Needs
Tel +61 3 95844699
Fax +61 3 95844008
www.avoturbo.com
[email protected]
Page 22 of 24
Created on 5/15/08 7:27 PM
Turbosystem Testing
Step 35 – Re-fit stock engine control computer and connect negative battery terminal. Start engine
and check that the engine starts, idles and revs up normally. If the engine fails to start or runs badly,
blows black smoke etc stop immediately and re-check vacuum hose connection followed by all
electrical connections to the stock engine control computer.
Step 36 – AVO Turboworld recommends that fuel mixtures are verified using an air fuel ratio meter
to check that the stock fuel pump and fuel system is operating correctly. Under full throttle the air
fuel ratio should be 11.9 to 1_or around Lambda 0.82. When testing fuel mixtures drive car
carefully, slowly applying full throttle while monitoring fuel mixtures.
At the same time as checking fuel mixtures, monitor boost pressure to ensure correct specification,
boost pressure is checked by using full throttle in 3rd gear from 1500 rpm through to 6000 rpm. If
boost pressure is 6 psi then no further adjustment is required.
If Turbo boost is higher then 6 psi the AVO Turboworld engine control unit has a built-in overboost
protection feature that will activate, cutting fuel to protect the engine.
If Turbo boost is lower then 6-psi engine power will be affected.
What to do if Turbo Boost is too High
1) Check boost actuator vacuum hose for loose connections and / or damage.
2) Check boost actuator for misaligned, bent or damaged mounting bracket
3) Re-adjust actuator rod arm. Removing rod arm and lengthening rod (Dimension A) will lower boost
pressure (Fig 34) Always adjust actuator rod arm by half turn increments before re-testing boost
pressure.
4) Road test and re-check boost pressure. If still too high repeat steps 3 –
4.
What to do if Turbo boost is too Low
1) Check for any loose or damage connections between the turbocharger
and the throttle body.
2) Check boost actuator for damaged or misaligned mounting brackets
3) Re-adjust actuator arm rod. Removing rod arm and shortening rod will
increase boost pressure. (Fig 34) Always adjust actuator rod arm by
half turn increments before re-testing boost pressure.
4) Road test and re-check boost pressure. If still too high repeat steps 3 –
4.
NOTE! If at any time the engine operates roughly, pings or has fuel mixtures that are too lean or too
rich or is overboosting, stop testing immediately and consult AVO Turboworld or selling dealer for
advice.
Step 37 – After initial testing is finished and is within specifications for fuel mixture and boost
pressure, refit alloy footplate over the top of the stock engine control unit and AVO engine control
computer. Take note not to pinch or cut wiring looms when bolting down the footplate. Re-fit carpet
over alloy footplate.
Step 38 – Re-check all oil, coolant and exhaust system joints and connections to verify that they
are all tight and leak free. Double check that all hoses and wiring harness are secure and are have
adequate clearance between hot exhausts and rotating engine parts.
Check engine oil and coolant levels. Top up if required.
Operation and Maintenance
Engine / Turbocharger
Always use the highest-grade unleaded fuel available in your area.
AVOTurboworld – For All Your Turbo Needs
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Page 23 of 24
Created on 5/15/08 7:27 PM
AVO Turboworld recommends that an intermediate oil change is done in between the factory
recommended services. At this time re-check that all bolted joints are tight and that the engine is
free of oil and coolant leaks.
For operation in hot climates or for severe use fit spark plugs that are one heat range colder than
stock.
After extended driving at full throttle always let the engine idle for 2 minutes prior to shutdown to
prevent damage to the turbocharger due to heat-soak.
AVO Turboworld Blow-Off Valve
AVO Turboworld recommends that every 6months or 10,000miles that the Blow off Valve (BOV)
should be removed, disassembled and the following items checked and inspected.
a) Check brass BOV piston for signs of damage or seizing. Any minor scratches or damage can be
polished out carefully with 1200 grade emery paper.
b) Inspect BOV piston bore for scoring or signs of seizing. Any minor scratches or damage can be
polished out carefully with 1200 grade emery paper.
c) Clean all parts thoroughly with brake cleaner and allow to dry completely.
d) Re-assemble all parts lubricating BOV brass piston with a light coating of transmission or sewing
machine grade oil.
NOTE! – If in any doubt contact AVO Turboworld prior to disassembly of your AVO Billet BOV
AVO Turboworld Airfilter
At 10,000 mile intervals (5000 miles for dusty / sandy operating conditions) remove your power filter
element for servicing using the following procedure.
a) Air filter can be cleaned using K+N Airfilter service solvent and re-oiled with K+N Airfilter oil. Follow
instructions included with K+N Airfilter service kit on Airfilter service. Do not use gasoline or other
harsh solvents for power filter cleaner. Do not use compressed air to dry filter as this will damage
the cotton filtration media.
b) At the same time as servicing your power filter carefully check and inspect the filter for signs of
damage to the cotton weave or filter body. Replaced if required.
Job Done-Enjoy your car!
AVOTurboworld – For All Your Turbo Needs
Tel +61 3 95844699
Fax +61 3 95844008
www.avoturbo.com
[email protected]
Page 24 of 24
Created on 5/15/08 7:27 PM