ZZP 2.4 Turbo Kit Instructions

Note: These instructions are intended for installers with previous turbo installation

experience. Some procedures will not be described in full detail. If you run into any

installation issues or have trouble comprehending any of the procedures, please contact

ZZPerformance or a qualified auto shop/technician to help you through the process.

1. Getting started: Remove the airbox ducting shown here.

2. Remove the MAF sensor from the airbox.

3. Remove the airbox lid and air filter.

4. Remove the lower half of the airbox.

5. Remove the passenger side headlight to access and remove the lower airbox ducting.

6. Remove the factory downpipe from the exhaust manifold and catback.

7. Remove the exhaust manifold from the engine.

8. Install the turbo oil feed fitting in the port shown below.

9. Install the turbo manifold at this time.

10. Remove the oil pan and install the new turbo oil pan or weld the aluminum bung into the oil pan.

11. Install the turbocharger to the turbo manifold.

12. Install the oil drain hose as shown.

13. Install the 5-bolt turbo downpipe and Primary O2 sensor.

14. Recirculated wastegate dump tube shown below.

15. Install the wastegate at this time.

16. Install the turbo inlet coupler and discharge coupler as shown below.

17. Install the air filter tube in the fender-well as shown below.

18. Vent hose from the valve cover connects to the new intake tube.

19. Connect the vacuum T to the intake, evap hose, and vacuum hose.

20. Non-intercooled charge tubing, intake tubing, and bypass valve configuration.

21. Typical boost controller mounting with additional line added for boost gauge:

Intercooler Installation

1. With the front bumper skin removed, install the front heat exchanger. The outer tabs slide in

behind the bumper support bolts and fasten with two additional nuts. The inner tabs bolt to

existing holes on the bottom of the bumper support. Wait until you are re-installing the bumper

skin before installing the inner bolts.

2. Pump mounting in driver side fender-well is shown below.

3. Hose routing and filler T are shown below.

4. Switched power to the pump can be obtained by connecting to the pink wire in the ABS harness.

5. Tape up the wires to avoid connection issues.

6. Power and ground wires connected to the intercooler pump are shown below.

7. Run the fill T up and next to the coolant bottle.

8. Mount the intercooler, charge tubes, and blow off valve. Connect the intercooler hoses.

9. Fill the intercooler system with a water/anti-freeze mix. Turn the key on to run the pump while

bleeding the air out of the system. It may take several minutes for most of the air to bleed out of

the system. Occasionally check the water level in the fill tube and add water as necessary.

10. Reinstall the bumper skin.