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INSTALLATION INSTRUCTIONS

TURBOCHARGER SYSTEM: 2000-2005 Celica 1ZZ / 2ZZ

TurboKits.com – 1000 Old County Cir., Windsor Locks, CT 06096 – 860-676-2929

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Read This First Study these instructions completely before proceeding. Engine and/or turbocharger damage may occur if any component within these instructions is improperly installed. TurboKits.com or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation. This complete turbocharger system can be installed using common tools and automotive procedures, but installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle. If in doubt, contact TurboKits.com Support at http://www.turbo-kits.com/support/ between the hours of 10:00AM and 6:00PM EST, Monday through Friday. Remove the turbocharger system from its carton and inspect for any obvious physical damage. All kit components are thoroughly inspected and carefully packaged prior to shipment from the factory. If any shipping damage is evident, contact your supplier and request that they process a claim with the shipper involved. Be sure to review the packing list to verify that you have all necessary system components to proceed. If any components in the parts list are missing, contact TurboKits.com Support at http://www.turbo-kits.com/support/. Although this turbocharger system has been designed to use many of the factory emissions controls, it is not “smog” legal in California, and therefore recommended for “off road” use only. In other states, check local laws regarding aftermarket modification to emission controlled vehicles. The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability. TurboKits.com reserves the right to revise the information presented herein or to discontinue the production of parts described at any time. SAFETY REQUIREMENTS: It is recommended to follow these precautions.

Always wear safety glasses & gloves. Turn the ignition switch to the OFF position & disconnect the battery. Always use properly rated jack stands when working under the vehicle. Prevent unexpected vehicle movement by using wheel chocks and/or parking brake. Operate the vehicle only in well ventilated areas. Do not smoke or use flammable items near or around the vehicle’s fuel system. Keep hands, clothing and other objects away from moving parts when engine is running.

SUPPLIES: It is recommended to have the following items before beginning installation.

Toyota factory service manual, for your model year Celica A large table or bench, and plenty of adjacent available workspace Standard selection of automotive tools, primarily metric sizes An assortment of “zip ties” and/or thin-gauge steel wire The ability to securely lift the vehicle at least a few feet off the ground High temp. automotive RTV sealant NPT thread sealant Replacement engine oil and oil filter Hammer Drill Loctite thread locker

Test Before Starting: It is recommended to have the following items before beginning installation.

Compression Test, this will tell you if the engine is healthy to begin with Disconnect the battery, this will reset the factory ECU Re-gap spark plugs to .028 while you have them out If you are going to bring the car to the DYNO afterwards, a BEFORE DYNO is needed as a baseline

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TERMS AND CONDITIONS The following Terms and Conditions are effective November 1, 2006 and are subject to change without notice. SHIPPING DAMAGE CLAIMS A claim for damage in transit must be made by the customer directly to the shipping agency as soon as the damage is discovered. TurboKits.com is not liable for the condition of the merchandise as handled by the shipper once the shipper has accepted delivery from TurboKits.com. RETURNED GOOD AUTHORIZATION TRACKING NUMBER TurboKits.com will only accept product returns, repair orders / upgrades, and warranty requests that have been approved and are returned with a corresponding Return Authorization (RA) tracking number. Contact TurboKits.com for approval and the RA number. Write the RA number clearly on the outside of the package and include it inside the package. This is very important in allowing us to properly identify and process your request. Failure to comply with this requirement will result in the delay of processing or the product being returned to you. RETURN POLICY All returns & cancellations are up to the sole discretion of TurboKits.com. Return must be made within 15 days of receipt. Please open and inspect all packages as soon as they are received. There will be a 20% cancellation / restocking fee assessed to all returns. Installed parts are not eligible for return. "Custom Order" and "Made to Order" parts are sold "as is" and are not eligible for return or cancellation. No goods will be accepted without prior return authorization from TurboKits.com. Call for approval and RA (Return Authorization) number. *No returns will be accepted without an RA number. *No returns will be accepted after (15) days from the original shipping date from TurboKits.com unless approved. *All approved returns are subject to a 20% restocking charge NO EXCEPTIONS. *The original invoice must accompany the return. *Approved returns will be issued credit only. REFUSED SHIPMENTS Sending a shipment back to TurboKits.com does not automatically constitute the right to a refund or credit. TurboKits.com may, at its discretion, require different payment means for any reshipped refused shipments. It is the customer's responsibility to make all arrangements with TurboKits.com for disposition of the refused shipment. Customer is responsible for all outgoing and return shipping and handling charges regardless of disposition of refused shipment. WARRANTY PROGRAM TurboKits.com will repair or replace any new TurboKits.com products that fail due to a manufacturer defect, including products used in racing or competition applications, for a period of one year from the original date of purchase. Warranty is limited to TurboKits.com products and does not include progressive or subsequent damage and does not cover removal or installation labor or associated parts. Warranty is non-transferable and must be processed via the original purchaser from TurboKits.com. Contact TurboKits.com for return approval, RA (Return Authorization) number, and shipping method PRIOR to sending the product to TurboKits.com. Our Customer Service Representative will provide packaging and shipping instructions. Please include your invoice with the shipment. TurboKits.com highly recommends that the installation of mechanical or electrical parts be performed by trained professionals. Improperly installed products may lead to unsafe and unreliable conditions.

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Preparing the Vehicle for Turbo Kit Installation 1) Remove intake plenum plastic cover (see Fig. 1 & 2) *note: re-install bolts so they are not lost 2) Remove passenger side engine cover (see Fig. 1 & 2) *note: reinstall all clips so they are not lost

3) Remove factory air box (see Fig. 3) 4) Remove intake flapper control switch (see Fig. 4) 5) Remove Mass Air Sensor from stock air box (see Fig. 5) *note: place this in a clean place for reinstallation 6) Remove Stock Intake Tube (See Fig. 6) *note: now is a good time to clean throttle body if needed

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7) Remove harness clip from EGR control module and loosen bracket (see Fig. 7) *note: EGR on 2ZZ Only

8) Remove EGR air pump and disconnect all harnesses (see Fig. 8, 9, 10) *note: EGR on 2ZZ Only

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9) Unplug factory injectors (see Fig. 11) 10) Remove stock fuel rail (see Fig. 12) *note: Make sure you keep the factory fuel rail spacers

11) Remove factory fuel injectors (place paper towels into holes to stop fuel from leaking into intake), remove factory injector o-rings and swap o-ring onto supplied injectors, they may be loose, but will seal under the pressure of the fuel rail bolts. (see Fig. 13, 14, 15) (12) Install supplied injectors back into intake plenum using lubrication; you can use some of the fuel that leaks from the stock injectors or o-ring lubrication. Be careful not to tear or rip the stock o-rings as this may cause a vacuum leak. Make sure the grommets are not crimped when installing the injectors back into the intake plenum. Reinstall the fuel rail spacers and the fuel rail. (see Fig. 16)

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13) **IF YOU PURCHASED THE DROP IN INJECTORS SKIP THIS SECTION**Cut factory fuel injector clips from harness at the clip, making sure you leave enough wire to wire in the supplied clips, trim back harness covering to expose injector wires. (see Fig. 17, 18) *note: a crimp/splice tool makes this job much faster 14) Remove grommet from supplied injector clips, slide wires through the grommet and then clip, making sure you keep the common ground location consistent on all injector clips. (see Fig. 19, 20) 15) Strip wire about ¼ inch, crimp supplied injector pins onto wire, install pins into supplied clip and reinstall onto supplied injectors. (see Fig. 21, 22, 23) *note: these will snap and lock into place on the clip & injector

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Removing Exhaust & Header 1) Remove factory 02 sensors from the stock cat pipe. (see Fig. 23) *note: it is a good idea to shoot them with liquid wrench 24hrs prior to installation 2) Remove factory cat pipe (see Fig. 24, 25) *note: save tension bolts 3) Remove factory plastic undercarriage covers (see Fig. 26, 27) *note as you can see in Fig. 27 this leaves the bottom completely open

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4) Drain oil (see Fig. 28) 5) Drain transmission fluid (see Fig. 29)

6) Remove passenger side wheel 7) Remove strut mounting bolts (see Fig. 30) 8) Remove wheel speed sensor bracket and brake line bracket (see Fig. 31)

9) Remove axel shaft support bracket (see Fig. 32, 33)

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10) Remove axle nut (see Fig. 34) 11) Pull wheel hub out as to remove the axel from the transmission (see Fig. 35) 12) Remove axel (see Fig. 36, 37) this allows ample room for installing manifold & turbo as 1 unit

13) Remove header bracket (see Fig. 38) 14) Remove lower factory header heat shield to allow access to header nuts (see Fig. 39) 15) Unbolt upper factory header heat shield and move to the side

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16) Cut factory EGR tube, the EGR ports will be capped by the supplied turbo header (see Fig. 40) *note: EGR on 2ZZ Only 17) Remove 12mm bolt holding EGR tube to block *note: EGR on 2ZZ Only 18) Unbolt factory header (5 bolts) (see Fig. 41)

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Installing Turbo & Manifold 1) The oil / water fittings on the turbo need to be tightened down and adjusted accordingly (see Fig. 42, 43) 2) Mount turbocharger to turbo manifold using nuts, washers, studs & high temp RTV silicone (see Fig. 44) 3) Install oil feed line to the top of the Turbocharger (see Fig. 44) 4) The turbocharger needs to be clocked, oil feed directly on top, oil drain directly on the bottom & the water fittings side to side (see Fig. 45) * note: to clock turbo loosen the 6 bolts on the back of exhaust & compressor housings and rotate. Also at this time rotate the compressor housing into the correct orientation for the #1 intercooler pipe and remount the actuator bracket. The actuator should not have any tension on it and the arm should easily attach to the flapper dowel without having to pull on the actuator rod. If the eyelet arm is too short, use the extension rod in your hardware kit. You may also need to flip the actuator bracket 180 degrees for best alignment. Now is also a good time to check the actuator rod and wastegate flapper on the exhaust side of the turbo for proper movement. Turbo Clocking Video: http://youtu.be/6gy0wBPW47k

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5) Crimp and cut heater core supply line (see Fig. 46) 6) Attach supplied plastic barbs to stainless steel braided -8 water supply lines (see Fig. 47)

7) Attach supplied stainless steel -8an water lines to each end of cut heater core supply line using supplied worm drive clamps (see Fig. 48) *trick, tighten worn gear clamps partially before installation

8) Install 2” Coupler & (2) t-Bolt Clamps to turbo outlet 9) Install Turbocharger & Manifold to the engine. Now is a good time to replace the factory gasket, torque to factory specs (see Fig. 49) *note, insert turbo end first and then rotate 180 degree’s as you bring the manifold up to the manifold studs. This is very tight and tricky, but it does fit, be patient. 10) Install the (2) -8an Stainless water lines onto the turbocharger & supplied blue aluminum AN hose fittings (see Fig. 49)

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11) Gently push the power steering line towards the block to make room for the air filter (see Fig. 50) 12) Install supplied K&N Filter & tighten (see Fig. 51) *note, if you slip the front of the filter through the wheel well it makes it much easier to attach to the turbo inlet.

13) Remove engine mount damper (see Fig. 52) 14) Take soft rubber mallet and dent stock heat shield, not mandatory, but good idea to while you’re under there (see Fig. 53)

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15) Install supplied M8 x 40mm Stud into far bolt hole on the turbocharger (see Fig. 54) 16) Install downpipe with supplied bolts, washers & high temp RTV silicone (see Fig. 55, 56, 57) *trick, install front bolt & washer first, this allows you to rock the downpipe as you install the nut onto the stud, use alan wrench for the bolts

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17) Reinstall engine mount damper & 1st 02 sensor 18) Install rear cat section and rear muffler section (see Fig. 58, 59, 60) *note, this is a slip fit set up 19) Adjust exhaust, install supplied muffler clamps (see Fig. 58, 59, 60) *note, the kit is meant to work with a 3” axel back muffler section, additional modification may be required for smaller exhaust. After properly aligning the exhaust we recommend going to an exhaust shop and having hangers added.

20) Remove factory oil pan, mark oil pan 2.5” from the inside and as far to the top as possible (see Fig. 61) 21) Drill a pilot hole and use a stepper bit to drill hole out to 9/16ths (see Fig. 62) 22) Tap hole with 3/8th NPT tap (see Fig. 63) *note, using grease on the tap helps keep debris down to a minimum 23) Install supplied 3/8th NPT drain line fittings into oil pan using High Temp RTV Silicone (see Fig. 64) 24) Reinstall factory oil pan using High Temp RTV Silicone. (see Fig. 64)

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25) Install supplied -10an stainless steel braided oil drain line to the appropriate fittings on the turbo & oil pan (see Fig. 65) *note the line must not have even the slightest uphill, ball bearing turbo’s are very temperamental with oil back up and pressure, any sag in the line can cause oil seal issues with the turbo.

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26) Remove factory oil pressure sending unit harness plug and factory sending unit (see Fig. 66) 27) Install factory oil pressure sending unit into supplied oil tee (see Fig. 67) 28) Install oil tee and BSP to NPT adapter into factory oil pressure sending unit (see Fig. 68) 29) Install oil feed fitting to oil feed tee (see Fig. 68) 30) Install oil feed line to oil feed fitting (see Fig. 68) 31) Wire tie oil feed line to center cross member (see Fig. 69) 32) Reinstall factory oil pressure sending unit harness clip.

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Intercooler & Piping 1) Lay out piping, couplers, clamps & FMIC to make sure you have everything needed (see Fig. 70)

2) Un-attach AC line and push it gently down and out of the way, this will add a slight bend to the line, be sure not to use too much force (see Fig. 71)

3) Install Pipe #1 w/ 2” couplers and T-Bolt Clamps (see Fig. 72, 73)

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4) Install Pipe #2 w/ 2” couplers and T-Bolt Clamps (see Fig. 73, 74)

5) Install Pipe #3 w/ 2” Coupler & 2” – 2.5” Transition Coupler and T-Bolt Clamps (see Fig. 76, 77, 78)

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6) Install Pipe #4 w/ 2.5” Coupler & T-Bolt Clamps (see Fig. 79, 80) *note, you will have to trim the plastic undercarriage for this pipe to fit

7) Support Intercooler with jack stands or muffler stands to aid in alignment as you attach Pipe #5 & #6 (see Fig. 81) *note: align intercooler with bottom of radiator support as a guide.

8) Mount BOV onto Pipe #5 and install w/ 2.5” Couplers & T-Bolt Clamps (see Fig. 82, 83) *note: you will have to trim the plastic undercarriage for this pipe to fit

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9) Mount Factory MAF onto Pipe #6 w/ supplied screws (see Fig. 84, 87) 10) Drill & Tap 9/32nd” hole in Pipe #6 on the 90 degree turbo before throttle body for water injection and install the nozzle, follow supplied instructions from water injection (see Fig. 87) *note: only water injection upgrade

11) Remove Factory ECU vent pipe and tube 12) Install Pipe # 6 w/ 2.5” & 2.5-3” Couplers & T-Bolt Clamps (see Fig. 88)

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13) Align intercooler to the center of the bumper opening (see Fig. 89) 14) Align bracket to the bottom of the radiator support and front of the intercooler tab and drill 2 pilot holes with 1/8th” bit (see Fig. 90) 15) Install intercooler brackets with supplied self tapping screws (see Fig. 90) 16) Align front of bracket with FMIC tabs, drill hole w/ 9/32nd” Drill Bit , install and tighten with supplied M6 bolts, nuts & washers (see Fig. 90) * note: wait to reinstall all of the undercarriage plastic until you test the install for leaks.

18) Once all of the piping and FMIC are installed, it should look like this (see Fig. 91, 92) *note: trimming required on undercarriage guard.

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17) Reinstall passenger side axel, wheel speed sensor, brake line and fill tranny with gear oil. *note: now is a good time to upgrade to high grade gear oil 18) Remove Valve Cover Vent from Throttle body and cap Throttle body with supplied rubber cap. (1ZZ see Fig. 93, 2ZZ see Fig. 94) * note: leave the valve cover vent hose open to the atmosphere.

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Wiring ECU *** This kit includes a base map only, professional tuning to your specific application is strongly suggest *** 1) Locate the factory ECU and open the cover. (see Fig. 95) 2) Remove the factory plugs. (see Fig. 96) * note: leave the factory ECU unplugged until you are ready to start the vehicle. This will allow it to reset all stored fuel trims, etc. 3) Wire ECU according factory manual wiring instructions, or use TurboKits.com Plug n Play Harness

7) Install Water Injector following the included instructions; do not over tighten the plastic fittings they will crack. * note: only for water injection upgrade 8) Vacuum Lines: Run 1st tee off throttle body & Remove VSV Plug (see Fig. 97), run lines to BOV, Wastegate, Boost Gauge and Pressure sensor from water injection. (see Fig. 98, 99) * note: make sure you wire tie all fittings.

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Setting Up AEM FIC: Great info here: http://forum.aempower.com/forum/index.php/topic,24954.0.html Video: Setting proper COM Port: http://www.youtube.com/watch?v=HEmhw0v8Y4o&feature=player_embedded Open the base_cal.fi6 map in FIC folder on your hard drive. Then File --> Save As --> Rename it to Celica-Base. Next step is to open the Celica-Base.fi6 file and click connect to FIC. A warning box will come up telling you that the maps don't match and to either pull from the FIC or write to the FIC. You want to pull FROM FIC. Once this is done, click File --> Save As --> Rename it to Celica-Base-2 to have as a back-up. Disconnect the FIC and close the map. Then re-open the Celica-Base.fi6 file and click connect to FIC. Next find the "Set Up" menu at the top and click Set Up --> Calibration --> a separate box will open up which will allow you to set the TPS (Throttle Position) and the RPMs. These are self explanatory settings and the software will walk you through the steps. Once the RPMs & TPS are set, you are done, the MAP is already on the FIC. Start the car, let it warm up and idle, check for leaks, etc. Once the car is warm, shut it off and carefully (we use a oven glove) retighten the bolts on the manifold to head, manifold to turbo and turbo to downpipe. The initial heat cycle of the parts will give you a great opportunity to crank everything down while it's hot.

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Final Checklist • Review these instructions to make sure that all fasteners, clamps & electrical connections are installed & torqued correctly. • Check that all hose routings are free of any kinks or near any hot or abrasive surfaces that may cause wear over time. Adjust or reroute as necessary to provide adequate slack for engine movement. • Reinstall the body work in the reverse order of its removal. • Refill all fluids (oil and coolant) to factory recommended levels. • Use regular non synthetic (factory weight) motor oil for the first 500 miles to allow the turbo rings to seat properly during the turbo break-in. • The use of synthetic oil (with the factory recommended oil weight) is strongly recommended after proper turbo break-in, as it will prolong the life of the turbocharger. Regardless of factory recommended intervals, the addition of a turbocharger requires that the oil be changed every 3,000 miles. • The use of premium octane unleaded fuel (94 where available, if not 93 or 91) is required for proper engine performance and to reduce the possibility of internal engine damage from detonation. Starting the Vehicle • Double check that all connections are correct, and that all bolts and studs have been fastened, as well as all intercooler pipes couplers. • Before starting up the car, make sure that all electrical connections are correct. Set the TPS & RPM within the AEM FIC. • Cycle the ignition to the “ON” position several times to pressurize the fuel system & check for any leaks. • Verify proper oil feed by disconnecting all of the spark plug wires from the spark plugs and take the oil feed line that connects to the turbocharger and place the end into a cup. Turn the car over to verify that oil passes through the line. Crank for an additional 15 seconds to make sure the oil coming through the line is fresh and clean. After verifying oil flow, reattach the line to the turbo. Then crank motor for (2) additional 15 second intervals to prime the turbo with oil before starting. Failure to follow these steps and the turbo break-in may void your turbo warranty. • Start the vehicle and check for any oil, power steering or air pressure leaks & recheck the oil and coolant level. • Verify that the gasoline in the tank is a minimum of 91 (preferably 93, 94) octane. • Start the car; allow 5-10 minutes to warm up without applying any throttle. After operating temperature has been achieved, proceed to test drive the car staying out of boost during the turbo break-in period. If the check engine light comes on, use code reader to verify error). Disconnect the negative terminal of the battery for at least 30 seconds and test drive it again. • Stop after initial test drive and check for oil leaks. Once cooled down, double check all nuts, bolts, fittings, and harnesses. • Testing Boost Levels: Slowly bring the car up to speed (staying in compliance of all posted speed limits). Place the transmission into a tall gear, 3rd works well, and slowly roll onto the throttle watching the boost gauge. Make sure the boost level stays within the operating parameters of the kits intended use. If you are unclear or not capable of this, a quick trip to the local DYNO for some DYNO runs and logging is an acceptable replacement (stay out of boost on the way there). At the same time you will need to monitor the Air Fuel Ratio (AFR) to assure they are within the safe operating parameters of the kits intended use. • NOTE: It is normal for the vehicle to emit some amount of white smoke & a strange odor for an hour or two of operation, as the oils within the exhaust pipes burn off. The MAP has already been loaded onto the FIC, make sure when you first connect to the FIC that you hit the “FROM FIC” button or you WILL overwrite the map and have to send the AEM FIC back to us. Also, the AEM FIC Map that is provided is ONLY A BASE MAP, Custom tuning to your specific set up is highly suggested. * Periodically, recheck the alignment of the system and hard piping to make sure that there is proper clearance. Also, check the filter for excessive dirt build up. Failure to follow proper maintenance procedures may cause damage to the turbo system and will void the warranty