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AVO Turboworld's Bolt-on, Instructions Manual

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AVOTurboworld – For All Your Turbo Needs

Tel   +61 3 95844699

Page 1 of 25

Fax  +61 3 95844008

Created on 6/17/08 12:30 PM

www.avoturbo.com
[email protected]

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 C 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

Summary of Contents for Turboworld's Bolt-on

Page 1: ...tantly 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 I...

Page 2: ...ms 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 turbosystems 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 c...

Page 3: ...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 Blue Silicone Hose PN EMH25C01 1 x 32 50 Hose Clamp PN MCE04C01 1 x 38mm Blank off Plug PN FNFY7T01 6 x 30...

Page 4: ...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 1 x 31mm Blank off Plug PN FNEW7T01 1 x RH Intercooler Stay PN RBVTTT02 ...

Page 5: ... 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 Moulded 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 S...

Page 6: ...e 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 owners 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 eng...

Page 7: ...scard 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 ...

Page 8: ...ir 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 rail mounting clip and carefully bend the A C pressure line in towards the Right Hand Suspension strut tower Refer to Fig 8 Caution Be extremel...

Page 9: ...0 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 pipe fitting Wrap rag or paper towel around fitting to catch any fluid that may leak out Remove and refit rear power steering mounting clamp to the power steering pipes so that...

Page 10: ...welding set braze the turbocharger lower oil drain fitting PN PBSPTC01 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 require...

Page 11: ...o engine block Carefully tighten adaptor fitting 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 Char...

Page 12: ...bracket Fig 17 to hold turbocharger in place Coat stock 2 bolt stainless steel exhaust gasket with high temperature 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 ...

Page 13: ...the turbo catalytic converter pipe coat the existing exhaust gasket with high temperature sealant and bolt up using the supplied exhaust bolts Fig 20 Step 16 Tighten all nuts and bolts previously only installed by hand Check alignment of exhaust pipes to ensure that there is adequate clearance with surrounding components You need to tighten the turbocharger up pipe mounting bracket Fig 17 turbocha...

Page 14: ...l supply hose PN ER3FBT01 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 over tighten 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 suppl...

Page 15: ... 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 turbocharg...

Page 16: ...nted Step 22 Fit the short black breather hose and one of the supplied plastic 12mm T pieces PN 7JBM5S01 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 12mm T piece Fig 28 The two ends of this last T piece is used to join the passenger side and...

Page 17: ...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 PN FNF67T01 using supplied hose clamps Item 98 Co...

Page 18: ...terfly 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 ...

Page 19: ...f 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 b...

Page 20: ... 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 volt meter 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 ...

Page 21: ...Tee TRIG 2 CAM White Black Shielded Cam Sensor B135 2 13 08Kohm To Earth Tee ETEMP Yellow Eng Coolant Temp B136 14 1 0 1 4V KOEO Tee O2 Sensor White Front O2 Sensor B134 22 0 1 0V KOEO Tee AVO Fuel Cut Map Sensor Signal B136 5 2 4 4 8V KOEO Cut AVO ECU 17 pin Connector Wire Side View INJ1 Brown IG1 Blue IG2 Blue Black IG3 Blue White 12 V Red Trig1 Yellow Black Screened E Temp Yellow TPS In White B...

Page 22: ...44699 Page 22 of 25 Fax 61 3 95844008 Created on 6 17 08 12 30 PM www avoturbo com avo avoturbo com 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 ...

Page 23: ...AVOTurboworld For All Your Turbo Needs Tel 61 3 95844699 Page 23 of 25 Fax 61 3 95844008 Created on 6 17 08 12 30 PM www avoturbo com avo avoturbo com ...

Page 24: ...amage 2 Check boost actuator for a 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 fo...

Page 25: ...e 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...

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