STS Turbo C6 Z06 Corvette Manual

Copyright 2005

Squires Turbo Systems, Inc.

*

’06-’08 C-6 Z06 CorvetteInstruction Manual

12/26/07

’06-’08 C-6 Z06 CorvetteCongratulations on your purchase of a Squires Turbo System!

We’re confident you’ll be happy with the ease of installation and the performance of the patented remotemounted Squires Turbo System.

The installation is a straightforward process, but it is critical that you read through ALL of the instructionscarefully. If you do have any issues during the installation process, please contact your local STS PowerDealer where you purchased the system. If they are not available please call our customer service departmentat 866-WE-TURBO. We appreciate your business and would like to hear from you regarding your experiencewith the Squires Turbo System.

Squires Turbo Systems, Inc.165 N. 1330 W. Suite A4Orem, UT 84056Phone 866-WE-TURBO (Toll Free)Monday through Friday, 8:00am to 5:00 pm Mountain Time

We encourage you to read this manual completely for a couple reasons:• Verify the parts list to make certain your kit is complete before starting the installation (See the kits parts pageof this manual). If you discover shipping damage or shortage, please call us immediately.• Take a look at what is required for tools, time, and experience.• Review our limited parts warranty

All Squires Turbo Systems are protected by us patent # 7,134,282 and # 6,745,568. Any infringement of patentwill be pursued to the fullest effect of the US patent law.

U.S. Patent No. 6,745,568, Foreign Patents Pending

’06-’08 Z06 C-6 CorvetteIMPORTANT: It is the responsibility of the owner of the turbo system to make any necessary upgrades to thevehicle’s fuel system, engine and drive-train components, etc to ensure optimal performance and reliability andto prevent damage to engine and drive-train components. By installing this turbocharger system, the ownerunderstands and acknowledges the severity of the vehicle damage that may occur by turbocharging animproperly modified and tuned vehicle and accepts ALL risk and responsibility.

Our systems are designed for vehicles in good mechanical condition only. Installation on worn or damagedengines is not recommended and may result in engine failure, for which we cannot be held responsible . SquiresTurbo Systems, Inc. is NOT responsible for the engine or consequential damages. By proceeding with thisinstall you accept full responsibility for any damage that may occur.

It is also the responsibility of the owner to comply with all emissions laws in their state. At this point your SquiresTurbo System does NOT have a CARB EO number and is for Off-road use only in California.

Before you drive your vehicle we recommend:• Your vehicle be in good running condition• Change your fuel filter• Tune-up with spark plugs gapped to .035”.• 91 or higher octane fuel in the tank• Proper tuning and fuel system modifications• Install a boost gauge and test boost levels @ 5-6 psi• Test air/fuel ratios using a wideband O2 gauge (11.5:1 recommended)• Use caution until you are familiar with the system

Please remember to follow all safety rules that apply when working, including:• Wear eye protection• Do not work on a hot engine• Keep sparks and flames away from your work area - fuel is highly flammable

AVOID THESE COMMON MISTAKES!!!IMPORTANT: The installation of a turbocharger system on your vehicle is a major modification and should be takenvery seriously. It is critical that each step in this installation manual be performed in order and exactly as the manualshows. This will help you avoid installation problems as well as problems that arise after the installation is complete.There are many steps to the installation that may seem obvious but that require a step or procedure that may notseem like the obvious thing to do. Skipping steps and/or just installing the system by looking at the pictures in themanual typically will end up taking you more time and cause frustration. Please follow this manual exactly andcontact your STS Power Dealer or STS Customer Support if you need assistance or have questions. Below is a listof the most common mistakes that our Customer Support department receives technical calls about – all of whichcould be avoided if the instruction manual was followed carefully:

Avoid these common installation mistakes and save yourself time and frustration:

• Read the instruction manual completely before starting the installation• Follow the instruction manual during the installation process•Inventory all components to make sure you have everything before starting the installation• Account for all components, parts and tools necessary before starting the installation• If STS tuning was purchased, start the tuning process as per instructions BEFORE installing the turbocharger• Follow instructions EXACTLY when making electrical connections at the oil pump (oil pump is reversible!)• DO NOT ATTEMPT TO BOOST THE VEHICLE WITHOUT PROPER TUNING!!!•Follow tuning instructions and fill out tuning feedback forms completely•Follow instructions exactly to connect the wastegate properly• Make sure electrical system tests are performed and that oiling, PCV and alarm systems are working properly• Align and carefully install all silicone connections then retighten after first few heat cycles to avoid intake leaks• Use extreme caution when cutting and welding on the exhaust system to avoid debris that will damage the turbo• Test air/fuel ratios using a wideband O2 gauge (11.5:1 recommended)•Monitor the air fuel ratio and boost level with a wideband AFR gauge and a vacuum/boost gauge•Use caution when routing electrical harness and hoses to prevent damage from hot and/or sharp objects•Follow oil pump break-in and electrical system test procedures

’06-’08 C-6 Z06 Corvette Turbo System PartsPicture Key:

1: 3/8” PCV Vent Hose2: Stainless Oil Hose3: Wastegate Hose4: Stainless Oil Hose5: Stainless Oil Hose6: Dry Charger Covers7: STS Air Filters8: LH Turbo9: RH Turbo10: Wiring Harness11: Bolt/Hardware Kit12: T3 Gaskets13: Oil Adapter Flange14: Check Valve T15: LH Oil Pump16: RH Oil Pump17: STS Wastegates18: 1 Psi Switch19: PCV Switch Valve20: NGK Spark Plugs21: Silicone Hoses22: Hose Clamps

Diagram 1

Unpack the turbo kit and account for all parts as per Diagram 1. Inspect parts for shipping damage and make sure thereis no debris or packing material in any of the components that could potentially cause damage to the engine and/orturbochargers. Connect (-) terminal on oil pump to 12v and (+) terminal to ground using jumper wires and run oil pumpsfor 5 minutes to break in oil pump brushes.

(Note: Oil pumps will be very noisy during this process. Note that the oil pumps are reversible.)

11

86

12

14

4

15 16

18

13

20

3

1017

19

22

97

21

52

67

17

1

’06-’08 C-6 Z06 Corvette Turbo System Pipe Kit

Picture Key:

Z06 LE1: LH Exhaust InletC6 LE2: LH Tail PipeZ06 WGDL: LH Wastegate PipeC6 AI L1: LH Upper IntakeC6 AI 2: LH Middle IntakeC6 AI L3: LH Lower IntakeC6 L1: LH Pipe 1C6 2: LH Pipe 2C6 3: LH Pipe 3C6 L4: LH Pipe 4Z06 RE1: RH Exhaust InletC6 RE2: RH Tail PipeZ06 WGDR: RH Wastegate PipeC6 AI R1: RH Upper IntakeC6 AI 2: RH Middle IntakeC6 AI R3: RH Lower IntakeZ06 R1: RH Pipe 1C6 2: RH Pipe 2C6 3: RH Pipe 3Z06 R4: RH Pipe 4Z06 5: Front Intake PipeET: Weld-on Exhaust Tips

Diagram 2

Unpack the turbo kit and account for all parts as per Diagram 2. Check the insides of all pipes for any debris that couldpotentially enter the engine and/or cause damage to the turbochargers. Unpack all silicone hoses and hose clamps.Organize and match up the hoses with the appropriate clamps as some clamps will fit more than one size of hose.

C6 AI L1

C6 AI 2

C6 2

Z06 R4

Z06 5

C6 LE2

C6 AI R1

Z06WGDR

Z06WGDL

C6 L1

C6 2

ET

C6 3

ET

C6 RE2

Z06 R1

C6 3

Z06 RE1C6 L4

Z06 LE1

C6 AI 2

C6 AI R3 C6 AI L3

WASTEGATE INSTALLATION WARNING!

The boost reference hose from the intake manifold or compressor must be connected to the Front Boost Port fitting onthe wastegate(s). The Rear Vent Port on the wastegate must be vented to atmosphere. Applying boost pressure to theRear Vent Port of the wastegate and/or not applying boost pressure to the Front Boost Port will cause the wastegate to stayclosed and the turbo to over-boost. This will cause IMMEDIATE SEVERE damage to the vehicle’s engine!

It is the responsibility of the vehicle owner/operator to frequently inspect the wastegate and wastegate hoses to ensure that thewastegate hoses are connected properly, are in good condition and that the wastegate is functioning properly. The easiest wayto monitor boost levels is through a boost gauge. It is recommended that a vacuum/boost gauge be installed in all turbochargedvehicles.

Front Boost PortRear Vent Port

The wastegate MUST be connected as shown or IMMEDIATE SEVERE engine damage will result!

STS Wastegate Outlet

Inlet

READ COMPLETELY THROUGH INSTRUCTION MANUAL BEFORE STARTING THE INSTALLATION!

If you are using the STS Predator Tuning, please send your ‘backup file’ tune to STS before starting theinstallation so that your new modified tune can be received back by the time the installation is complete.If you did not receive instructions on how to do this, please request tuning information by sending emailto [email protected] and be sure to include complete information about your vehicle and yourcontact information. Once your ‘backup file’ has been received at STS, you should receive back yourmodified tune in 24-48 hours. This can be a point of frustration for you if you wait until the installation iscomplete before contacting STS to request your tune.

(IMPORTANT: Use anti-seize on all of the exhaust related bolts.)

(Note: When installing the intake tubing and hoses, align all hoses so that they are centered over thepipe gaps and position so that pipe gaps are at a minimum. Tighten clamps enough to hold hoses andpipes in place with clamp bolts positioned for maximum clearance. Final tightening of clamps will bedone after assembly is complete.

(IMPORTANT: The exhaust components of a turbocharged engine get EXTREMELY HOT and will meltany parts that are within a few inches of the exhaust system. Make sure that any hoses, wiring, or othercomponents that could be damaged are mounted away from the exhaust and/or shielded to preventdamage.)

’06-’08 C6 Z06 Dry Sump Engine Lubrication System The Z06 models have a racetrack-ready dry sump engine lubrication system. This high-performance system operates differently

than a standard engine lubrication system and requires a special procedure when checking the engine oil level. Follow thisprocedure closely when checking the engine oil level.

The engine oil level must be checked when the engine is warm. Cold oil level in the dry sump tank may not indicate the actualamount of oil in the system. With this system, engine oil is contained in an external tank, separate from the engine. Under normaloperating conditions, the oil pan under the engine does not store any oil. If the vehicle has been parked for an extended periodwithout the engine being started, some oil will seep back into the oil pan, reducing the amount of oil held in the dry sump tank andthere could be no engine oil at all showing on the dipstick. This is normal since the dipstick is designed to read engine oil level onlyafter the engine has run long enough to reach normal operating temperature. Do not add engine oil based on cold engine dipstickreadings. The engine oil level on the dipstick will also be inaccurate if checked while the engine is running.

To obtain an accurate engine oil level reading, warm up the engine to at least 175°F (80°C). Cold oil will not give a correct oil levelreading.

Once the engine is warm, turn off the engine. Checking the oil while the engine is running will result in an incorrect oil level reading. Wait at least five minutes (but not more than 20 minutes) to allow oil to drain and settle in the engine. Remove the dipstick from the external engine oil tank and clean it with a lint-free paper towel or a cloth. Re-insert the dipstick into

the external oil tank, pushing it all the way in until it stops. Remove the dipstick from the oil tank and read the level on the cross-hatched area. Oil levels that fall in the cross-hatched area are

normal.

When to Add Engine Oil (Z06 Only)

If the oil is below the cross-hatched area at the tip of the dipstick, add at least one quart/liter of the recommended oil through the oilfill cap opening in the oil tank. For engine oil specifications and crankcase capacity, see Capacities and Specifications in yourowners manual. Also see Racing or Other Competitive Driving for additional information on engine oil.

Notice: Do not add too much oil. If the engine has so much oil that the oil level gets above the cross-hatched area that shows theproper operating range, the engine could be damaged.

’06-’08 C-6 and Z06 Corvette RH Upper Intake

Diagram 3

RH Upper IntakePipe Mounting Bolt &

Fender Washer

STS Air Filter

RR Outer TailLight Harness

RR Outer TailLight Hole

Remove the 4 screws retaining the 4 tail lights and remove the tail light assemblies. Remove the factory bolt asshown in Diagram #3.

Install the RH upper air intake pipe (AI-R1) into the tail light cavity (mounting bracket first – then short end –followed by the large end) and secure to the body using the 6mm x 25mm bolt, lock-washer and fender-washersupplied, as well as using 3 additional flat-washers for spacers between the pipe bracket and the body asshown.

(Note: Factory wiring can be adjusted out of the way as to not interfere with the intake pipes.)

Install the new air filter onto the expanded end of the air intake pipe as shown in the diagram.

Repeat this process to install the LH upper air intake pipe (AI-L1) and air filter.

The Dry Charger filter covers can be installed at this time if desired or can be installed at a later date byremoving the tail lights. Reinstall the tail lights.

(Note: Dry Charger air filter covers are supplied with the turbo system and can be installed on the airfilters for added protection against dust and wet weather. They have a water-resistant coating whichrepels water. This coating is not permanent and will wear off. Washing the covers will decrease theeffectiveness of the covers so cleaning with water and/or a very mild soap will help extend the life of thewater resistant coating.)

(Note: Because of the lack of moving air under the vehicle during dyno testing, it is recommended toleave the tail lights out during dyno testing to allow the filters to be able to draw fresh cool air in.)

’06-’08 C-6 Z06 Corvette Stock Air Box Removal

Throttle Body

Diagram 4

Air Filter

MAF Sensor PCV Vent HoseConnections

Plastic EngineCover

Dry SumpReservoir

Remove both of the plastic engine covers that cover the ignition coils and valve covers. Remove the PCV vent hosethat runs from the intake duct just in front of the throttle body over to the dry sump oil reservoir (connection at sump istoward the front of the car) by releasing the lock tabs on the connectors. Use a 10mm socket to loosen the bolt ontop of the dry sump oil reservoir that is right next to the oil cap.

Unplug the MAF sensor electrical connector.

Remove the air box and intake ducting from the air filters to the throttle body. Remove the MAF sensor from theintake ducting. The MAF sensor should be clean and free of oil and contamination (clean sensor if necessary withMAF sensor cleaner) and set aside.

’06-’08 C-6 Z06 Corvette Wastegate and Blow Off Valve Hoses

Wastegate and Blow OffValve 4 Port Fitting

Wastegate Hose

Factory BrakeBooster hose

Diagram 5

Factory Brake BoosterCheck Valve

Hose To BOV

Spring Clamps

Front HarnessConnector

Cut the factory brake booster hose near the rear of the engine as shown in Diagram #5 and install one of theprovided spring clamps onto each section of the factory brake hose and slide the clamp at least 1 inch back fromthe end of the hose. Pivot the brake booster section of the hose out of the way.

Install the 124 inch long ¼” inch wastegate hose onto one of the small ports of the 4 port X fitting and securewith one of the small hose clamps provided. Cover the open end of the WG hose and route the wastegate hosedown along the firewall behind the engine along the driver’s side of the rear of the engine. The WG hose shouldexit under the vehicle just behind the engine at this point.

Install the large port of the X fitting into the engine side of the brake booster hose and secure with the clamp.

From the passenger side of the engine compartment, route the section of the front wiring harness with the 2quick connectors around the rear of the engine toward the brake booster as shown in the diagram. Route theconnectors down past the firewall along with the WG hose under the vehicle. They will connect to the rearharness later, then the harness will be pulled back up into position and harness connections finished.

(Note: The connectors can be taped to the WG hose so that they can be carefully pulled down under thevehicle using the WG hose. If you have difficulty getting the connectors through, the rear K-membernuts can be removed which will allow the rear of the engine to drop about ½ inch and give moreclearance between the body and the clutch bell housing.)

Install the remaining large port on the X fitting into the other section of the brake booster hose and secure withthe clamp.

Install the 64 inch long ¼ “ BOV hose onto the remaining small X fitting port and secure with a small hose clamp.Route this hose toward the front of the vehicle along the driver frame rail and over in front of the radiator.

(IMPORTANT: Use caution when routing the wastegate and BOV hoses. Make sure that all hoses arerouted away from any HOT, SHARP and/or MOVING objects which could damage the hoses. If this hosegets damaged, it can cause the turbo to boost uncontrollably and cause SEVERE and IMMEDIATEengine damage! Inspect this hose frequently and monitor boost levels at all times to prevent accidentalover-boost conditions.)

’06-’08 C-6 Z06 Corvette Stock Shroud Removal

External AirTemp Sensor

ChassisGround

Hood Light Plug

Diagram 6

Upper RadiatorSupport

UpperRadiator

Support Bolts

Push Clip

FrontRadiatorShroud

Oil CoolerBolts

Unplug the external air temperature sending unit from the passenger side of the front radiator shroud next to thehorns as shown in Diagram #6. Remove the 4 bolts that secure the plastic upper radiator support then unclip thecoolant hoses and remove the upper support.

Remove the 2 push connectors that secure the front radiator shroud to the air conditioning condenser brackets (oneon each side). Remove the hood light electrical connector from the radiator shroud.

(Note: This plug may be terminated and not actually be plugged into a light on the hood.)

Taking all necessary precautions recommended by the vehicle manufacturer and the equipment manufacturer, raisethe vehicle on a suitable vehicle hoist to allow access to the under-side of the vehicle.

(IMPORTANT: Before lifting the vehicle, read through the instruction manual and review the illustrations asto the work that will need to be performed while on the vehicle hoist. It will be necessary to place the hoistarms in specific locations to allow access to specific areas of the vehicle to facilitate the installation and toprevent having to readjust the location of the hoist lift points during the installation. Always use appropriatelifting equipment, jack stands or vehicle support equipment as well as proper lift points and take necessaryprecautions to prevent accidental damage to the vehicle and/or personal injury!)

’06-’08 C-6 Z06 Corvette Front Valence

Valence Nut

Side Air Damand Brake Duct

Front Valence Screws

Diagram 7

ValenceNut

Front Fender Liners

Air Dam

Lower Panel

Remove all 4 wheels from the vehicle.

Remove the 5 screws and the 2 outer nuts securing the lower valence as shown in Diagram #7. Remove the 3 boltsto remove the lower center panel.

(Note: The center panel will not be reinstalled.)

Remove the 4 push connectors to then remove the front air dam (passenger side first). Remove the 2 screwssecuring the lower brake duct inlets (leave the outer air dam attached to the brake duct inlet) and the upper boltsecuring the brake duct outlet (just under the front upper control arm frame bracket) to remove the brake coolingduct, duct inlet and lower side air dam as one assembly. Repeat to remove the other side.

’06-’08 C-6 Z06 Corvette Front Air Duct

Radiator Fan

4 Air Duct Screws

Lower FrontValence

Diagram 8

Air DuctGrill

Pull the lower front valence down and remove the 4 screws from on top of the plastic duct between the front shroudand the grill as shown in Diagram #8. Remove the 2 push connectors at each side to release the duct from the outeredge of the grill then remove the 2 rear push connectors to release the duct from the shroud and remove the ducting.

(Note: The plastic center air duct will not be reinstalled.)

Remove the 2 metal retaining rings that lock the oil cooler hoses into the oil cooler. Place a suitable container underthe fittings then carefully rotate and remove the oil hoses from the cooler and let the cooler and hoses drain into thecontainer.

(Caution: There is oil in the oil cooler so use a suitable container and caution when removing the hoses andthe cooler.)

Remove the 2 push connectors that secure the front of the radiator shroud to the front cross member. Carefullylower the front radiator shroud (with oil cooler) and remove it from the vehicle. Cap off the oil hoses and the inlet andoutlet to the cooler to keep them clean and prevent oil from spilling.

Carefully remove the external air temperature sensor from the radiator shroud.

’06-’08 C-6 Z06 Corvette Horn Relocation

Lower RadiatorSupport

FactoryHorns

Diagram 9

HornBracket Nut

External Temp Sensor

Unplug the horn electrical connector. Remove the horn bracket bolt and remove the horn from RH side of thelower radiator support. Remove the horns from the bracket, turn the bracket over and reinstall the horns.Relocated the horn assembly to the outside of the lower radiator support as shown in Diagram #9. Use thesupplied 6mm x 35mm bolt, flat washers, lock washer and nut to fasten the horns to the existing upper hole inthe radiator support.

(IMPORTANT: Horn outlets will need to point downward so they do not accumulate water. Horn bracketmay need to be bent slightly. Loom connectors may need to be adjusted or horn wires lengthened to fitwith new horn location. If you have difficulty rotating the horns without lengthening the horn wires, youcan drill a 1/8” hole in the bottom of the plastic horn bell. This will allow the horn to be mounted with theoutlet facing up but still allow water to drain from the horn.)

Remove the factory screw and mount the external temperature sensor as shown in Diagram #9 and plug theharness connector into the sensor.

(Note: It is helpful to remove the RH brake duct to give easier access to the horns. Picture shown hasbrake duct removed from vehicle.)

’06-’08 C-6 Z06 Corvette Intercooler

4 RadiatorSupport Bolts

Lower FrontValence

Diagram 10

Intercooler

Intercooler Bolts

Loosen the 4 lower radiator support mounting bolts shown in Diagram #10. Remove the bolts one at a time andinstall 4 of the 3/8” flat washers between the frame and the radiator support on the rear bolts and 2 of the 3/8” flatwashers between the frame and the radiator support on the front bolts. This will lower the radiator cradleapproximately ¼” to give adequate clearance for Pipe 5 where it crosses over the radiator. Once all the spacershave been installed tighten the support mounting bolts.

(Note: Use caution when removing and installing the rear radiator cradle bolts as the flat washer on the boltmust remain in the groove near the upper surface or it can cause the bolt to cross thread into the frame.)

Pull the valence down and install the intercooler as shown. Center the intercooler from side to side and hold it upsnugly against the bottom of the front cross member. Mark the location of the mounting holes in the cross member.Remove the cooler.

(IMPORTANT: The intercooler can be lowered to rest against the radiator support to allow sufficient room todrill and tap the mounting holes. If cooler is left in place, BEFORE DRILLING HOLES - COVER THEINTERCOOLER OUTLET PORT to prevent debris from entering cooler. Do NOT center the cooler offsettoward the passenger side. For added clearance between the silicone intercooler hose and the oil coolerhoses, the intercooler can be mounted toward the driver side of the vehicle 1/8 to 1/4”.)

Center punch and drill the holes with a 5mm drill bit then tap to 6mm x 1.0 with the drill and tap supplied. Uselubrication on the tap. Reinstall the cooler and secure to the cross member with the 6mm x 20mm bolts, lockwashers and flat washers supplied. Torque to no more than 45 inch pounds as the cross member is made ofaluminum and can strip threads easily.

Install the 1.75” x 10” silicone hose and 2 hose clamps onto the driver side inlet of the intercooler and secure with thehose clamp. Install the 1.75” x 9” silicone hose and 2 clamps onto the passenger side inlet of the intercooler andsecure with the hose clamp.

INTERCOOLER INSTALLATION WARNING!

The installation of an intercooler is a great addition to any turbocharger system and can dramaticallyincrease the efficiency, power and reliability of your turbocharger system by lowering intaketemperatures and creating a denser intake charge. There is, however, a slight possibility that under somevery specific conditions that water may accumulate in the bottom of the intercooler. Because of thecooling and condensing effect of the intercooler on the air inside the cooler during some drivingconditions as well as after the engine has been shut off, accumulation of liquid inside the intercooler canoccur. Due to the airflow characteristics of an intercooler, the airflow through the bottom of the core maynot be enough to keep this liquid cleared out and could allow it to build to a substantial level. If thisoccurs, this liquid could be pulled up into the engine during a high airflow demand. A large amount ofliquid can cause a hydra-lock condition which will cause IMMEDIATE SEVERE damage to the engine asthe engine will not be able to compress the liquid during the compression stroke which will cause amechanical failure of the engine components. Conditions that could cause this problem would beextreme wet driving conditions, submerging the air intake system in water, high humidity and/or extremetemperatures.

The possibility of this rare condition can be greatly reduced and/or prevented. It is highly recommended that youperform one of the following methods:1- Regularly inspect the intake system and intercooler for signs of water accumulation and clean out anywater and/or oil (fluid) that is found inside the intake system.2- Drill a 1/8” hole in the bottom rear of the center intercooler tank and install a small sheet metal screwthat can be removed on a regular basis to inspect for liquid accumulation inside the intercooler and allowthat fluid to be drained from the cooler. (Note: The cooler will only drain when you physically remove thisscrew. If left unchecked, it could accumulate enough liquid inside the cooler to cause engine damage.)3- Drill a small 1/16” hole in the bottom rear of the center intercooler tank which will allow the boostpressure within the intercooler to automatically purge any liquid from the system through the hole. (Note:This small hole will not allow enough airflow to pass through it to affect performance but should allow any fluid inthe system to automatically drain. There is a risk that the hole could become plugged so it is recommended thatthe hole be checked to make sure it remains clear periodically.)

(Note: There is a remote possibility that this condition could occur in the intake tubing of the turbocharger systemwithout an intercooler. The above precautions could be taken by drilling a small hole in the lowest point of theturbocharger intake tubing as described in step 2 or 3.)

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’06-’08 C-6 Z06 Corvette Front Radiator Shroud

Diagram 11

MoveBack

Cut Here A

Cut Off FrontExtensions

Notch Here

Cut Hole Here

Slots Extended

B

C

Carefully remove the factory external air temperature sensor from the shroud. The radiator shroud must bereinstalled to aid the engines cooling system. Once modified the radiator shroud can be installed from under thehood and carefully slipped down into place.

Remove the 2 upper oil cooler mounting bolts from the sides of the radiator shroud. Slot the shroud as shown inDiagram #11A to allow the oil cooler to be tipped back at the top toward the radiator. This will give adequateclearance between the intercooler outlet and the oil cooler. Reinstall the bolts and secure the cooler.

Lower the vehicle to access under the hood. Install a clean rag into the intercooler outlet to prevent debris fromentering the intercooler. Trim the shroud as shown in Diagram #11B. It is best to take small amounts off andtest fit with each small amount taken off rather than take to much off the first time. Try to make the hole in thecenter fit as tightly as possible to pipe 5 so that the maximum amount of air will pass through the radiator. Bothsides of the shroud will need to be trimmed the same.

The shroud will have to be notched at the leading edge for clearance at the intercooler brackets. Once theshroud is close, install the shroud and test fit Pipe 5 between the intercooler and the throttle body and make anynecessary modifications. When modifications are close, install the 3.5” x 4” silicone adapter and 2 clamps ontothe intercooler outlet and secure the lower hose clamp. Trim the shroud as necessary so the shroud clears thesilicone. Once the shroud modifications are finished, install the two push connectors to secure the shroud to theAC condenser.

Install the MAF sensor into Pipe 5 using the supplied 4mm bolts then install Pipe 5 for final adjustments to theshroud. Line up Pipe 5 to make sure it fits but do not install the silicone at the throttle body at this time.

(Note: Make sure flow direction arrow is pointing toward throttle body. Do not connect the MAF sensorelectrical connector at this time.)

Locate the factory notches in the rear of the plastic upper radiator support bracket. Cut both notches deeper asshown in Diagram #11C allowing radiator hold down to be lower when installed.

’06-’08 C-6 Z06 Corvette Shroud, Pipe 5 and BOV

Throttle Body

IntercoolerMounts

MAF Sensor

Diagram 12

Blow OffValve

RadiatorMount Spacer

Bent Radiator Lip

Radiator ShroudReinstalled w/

AdditionalTrimming

Rotate Pipe 5 out of the way as shown in Diagram #12.

Carefully bend the front upper aluminum lip of the radiator rearward and down with a small crescent wrench to allowadequate clearance for Pipe 5 as shown in Diagram #12.

(IMPORTANT: Be careful not to damage the radiator.)

Install the two supplied radiator spacer bushing under the factory upper radiator rubber mounts as shown in thediagram. Re-install the plastic upper radiator support bracket and secure with the 4 factory bolts. Install the coolanthose into the support bracket clips.

Install the 16 inch long 3/8” hose onto the 90 degree fitting on the bottom of the Pipe 5 outlet and secure with the hoseclamp provided.

Read the Blow Off Valve instructions that came with the BOV. Install the O-ring onto the small V-band flange on thefront side of Pipe 5 then install the BOV and secure with the V-band clamp. Install the banjo hose fitting onto the top ofthe BOV with one sealing ring on each side of the fitting and secure to the BOV with the fitting port facing toward thedriver side of the vehicle.

Install the 4” x 3” silicone and 2 clamps onto the throttle body and secure with clamp.. Swivel Pipe 5 to line the outletup with the throttle body. Use a smooth hook tool to work the silicone over the outlet of Pipe 5 as you slip it into place.Center Pipe 5 between the intercooler and the throttle body and secure in place with the clamps at the throttle body andthe intercooler silicone adapter. Plug in the MAF sensor connector. Route the BOV hose over to the BOV, cut tolength and install onto the fitting.

(Note: High altitude BOV springs are available for elevations over 4000 feet.)

(IMPORTANT: Use caution when routing the wastegate and BOV hoses. Make sure that all hoses are routedaway from any HOT, SHARP and/or MOVING objects which could damage the hoses. If this hose getsdamaged, it can cause an over-boost condition and SEVERE and IMMEDIATE engine damage!)

’06-’08 C-6 Z06 Corvette Front Bumper Cover

OilCooler

Cut Out In Lower Valence

Diagram 13

Modified RadiatorShroud

Valence Mount

Lower RadiatorSupport Bracket

Taking all necessary precautions recommended by the vehicle manufacturer and the equipment manufacturer,raise the vehicle on a suitable vehicle hoist to allow access to the under-side of the vehicle.

(Note: It is recommended to file down the sharp edges of the AC condenser line connection on the RHside of the radiator to prevent sharp edges from damaging the silicone hose. It will also be necessary toclearance the radiator shroud enough to allow the upper oil cooler line to be bent to give more clearancebetween the cooler line and the silicone hose on the LH side of the radiator. Use caution when bendingthe oil cooler line to prevent kinking or damaging the line/hose. Leave the metal retaining clips out ofthe cooler at this time so that the lines can be removed easily for test fitting and modifications.)

Install the 2 plastic push connectors to secure the radiator shroud to the front cross member. Carefully bend thetop oil cooler line to allow more clearance for the silicone hose. Carefully cut a notch in the radiator shroud toallow the line to be pulled over closer to the radiator. Reinstall the metal retaining clips and the oil cooler lines.

Using a suitable cutting device, cut a notch out of each side of the lower front valence as shown in Diagram #13so that the edges match up when the lower valence is secured to the mount.

Install the center air dam onto the lower radiator support by inserting the driver side first then pushing the pieceinto place. Secure the center air dam with the 3 factory bolts and the two plastic push connectors.

Reinstall the screws to secure the front lower valence to the mounts shown in the diagram.

Reinstall the brake ducts and front lower air dams assemblies. Line up the locator tabs into the slots on thelower brake duct inlet. Install the front inner fender liner, the air duct inlet and the lower valence holes over thestud and secure the two screws, upper brake duct mounting bolt, and the lower valence nut on each side. Installthe 2 push connectors to secure the outer air dams to the center air dam.

’06-’08 C-6 Z06 Corvette Exhaust System Removal

Differential

4 Rubber Exhaust MountsK-Member

Nuts

Diagram 14

Sway Bar Bracket

Rear K -Member

Brake Duct

Fender Liner

Vacuum Lines

Transmission

With the vehicle raised, remove the splash shields at the rear of the front fender wells and remove the rearwheel well liners. Remove the rear brake ducts and the insulation pack from the rocker panels.

Loosen the factory exhaust clamps that secure the mufflers to the H-Pipe and remove the 2 sprung exhausthanger nuts just to the front of the transmission.

Remove the factory H-Pipe front flange bolts to lower the front of the H-Pipe and disconnect the rear 02 sensors.Label the connectors L & R. With help from an assistant, pull the H-Pipe out of the mufflers.

Remove the vacuum lines from the exhaust valve actuators on the rear of the mufflers. Remove the 4 rear swaybar bracket bolts/nuts from the rear K-Member. Pull the sway bar back and off the bolt then lower it down out ofthe way. Remove the rear rubber hangers from the mufflers and then remove the mufflers from the vehicle. Becareful not to damage any of the wires or hoses that are up above the rear differential.

(Note: It may be helpful to loosen the rear K-Member nuts to allow the K-Member to be lowered slightlyfrom the frame. This will give more clearance over the differential to aid in removal of the mufflers. Besure to tighten these nuts once system is installed and before driving vehicle!)

Remove the 2 rubber vacuum line adapters from the hard plastic vacuum lines that connected to the exhaustvalve actuators. Install the provided ¼” rubber vacuum caps onto the plastic lines to seal the lines.

’06-’08 C-6 and Z06 Corvette Oil Supply at Engine

Stainless OilSupply Hose

Oil Filter

Diagram 15

New AdapterPlate Bolts

Oil SupplyAdapter Plate

LH Pipe 4

Factory OilCooler Lines

Remove the nuts securing the factory catalytic converter to the exhaust manifold. Remove the LF oxygensensor and the LF catalytic converter to allow adequate access to the oil cooler adapter plate bolts shown inDiagram #15.

Remove the 2 factory bolts securing the oil cooler adapter plate to the engine right above the oil filter. Removethe plate and factory gasket. Clean the plate, engine, and gasket surfaces. Install the stainless oil supply line tothe oil supply adapter plate before installing adapter plate on car. Test fit the adapter plate and make anyadjustments to fitting angle and/or the hose hex for proper fit.

Install the 6mm x 45mm bolts provided through the cooler adapter plate, the factory gasket, the oil supplyadapter plate and the new gasket provided in that order.

(Note: The oil outlet fitting should be located on top of the plate. The fitting should point toward thefront of the vehicle. These factory gaskets are reusable if not damaged. Vehicles equipped withaftermarket headers may require that the oil cooler lines be CAREFULLY bent to clear headers.)

Install the assembly onto the engine as shown in Diagram #15 and tighten the bolts to secure in place.

Cover the open ends of the stainless oil supply hose and the ¼” wastegate hose with tape to prevent debris fromentering the hoses. Route the hoses as shown in the diagram keeping them away from any hot, sharp and/ormoving objects. Route the hoses along the factory fuel and brake lines down the driver side of the driveshafttunnel - keeping it away from any hot, sharp and/or moving parts and secure the hoses with nylon ties. Wrap thehoses with the heat tape provided where they run near high heat sources like the catalytic converter. Continuerouting the hoses along the factory brake lines up and over the rear differential to the back side of the reardifferential, securing the hoses along the way with the nylon ties provided. Reinstall the oxygen sensor andcatalytic converter. Tighten the flange bolts evenly to keep pipes aligned properly.

(IMPORTANT: Cover the open ends of the hoses with tape to prevent debris from entering the hosesduring the installation process.)

’05-’08 C-6 Z06 Dual Pump Mounting

Oil Pump Inlet

3# Pressure Switch Black & Yellow Wires

GroundGround

Oil Pump Inlet Oil Pump Outlet Oil Pump Outlet

Factory Heat Shield

3# Pressure Switch

Diagram 16

Green Accessory Wire

Oil Supply HosesOil Return Hose

Install the 22 inch long #6 stainless hoses onto the inlet ports of the oil pumps (port with pressure switch).

Using the self tapping screws provided, mount the oil pumps as shown in Diagram #16. Make sure the pumps areas close to both the heat shield and adjacent frame rails as possible. Leave approximately 1.5” from top of pump toheat shield.

(IMPORTANT: Make sure that there is still adequate clearance for the wiring to be installed onto the top ofthe pumps and the return lines on the inlet side of the pumps to be installed.)

Connect the black and white wires from each rear harness to opposite sides of the 3 psi pressure switches at theoil pump inlets. Install the yellow wires to the outlet sides of the pumps and the black wires to the inlet sides of thepumps.

(Note: Pumps are reversible so disregard the positive and negative signs on the top of the pumps. Alwaysput the yellow wire on the ‘outlet’ side and black on the ‘inlet’ side of the pump. Make sure electricalconnections are tight and secure.)

Connect the black wire with the large ring terminal to the rear factory heat shield mount near each pump for achassis ground as shown in above diagram.

Install the 132 inch long #6 stainless return hose onto the outlet port of the RH oil pump. Install the 144 inch long#6 stainless return hose onto the outlet port of the LH oil pump. Cover the ends of the hoses with tape and label‘L’ and ‘R’. Route the hoses over the differential and through the driveshaft tunnel toward the engine. Secure thewire harnesses and the oil return lines together in the middle with nylon ties provided as shown in the diagram.

(Note: It may be helpful to tape the wiring harness to the stainless return hose or to use a stiff wire to aidin guiding the wiring harness through the driveshaft tunnel. It is recommended that the front edge of thefactory heat shield be rolled forward and up in the middle so that it can’t damage the hoses or wiringharness.)

’06-’08 C-6 Z06 Hose and Harness Routing

Diagram 17

Oil Hoses andWiring Harnesses

Driveshaft Tunnel

Clutch Bell Housing

Aftermarket Headers

Route the wire harness from each pump up over the differential and through the driveshaft tunnel toward theengine. Connect the rear harnesses to the front harness connectors then secure the rear harnesses with thenylon ties provided. The connectors should end up approximately half way up the top side of the clutch bellhousing once the front harness is pulled back into position.

Route the two stainless #6 oil return hoses up over the bell housing to end up with the longer (144”) hose goingto the driver side valve cover and the shorter (132”) hose going to the passenger side valve cover.

The oil supply hose, the two oil return hoses and wastegate reference hose, as well as the two rear wiringharness sections should all route from the engine bay, down over the top of the bell housing and down thecenter of the car along with the factory fuel and brake lines in the driveshaft tunnel as shown in the diagram.

’06-’08 C-6 Z06 Corvette RH Turbo Assembly

Exhaust Outlet (RH E2)

Wastegate

Compressor Outlet

Vent This PortTo Atmosphere

Exhaust Hanger

Exhaust Inlet Pipe(Z06 RE1)

Turbocharger Shown with Optional Polished and Coated Housings

Diagram 18

Oil InletSupply Hose

RH Wastegate Dump Pipe

Assemble the RH turbocharger, T3 flange gasket, wastegate, RH exhaust inlet pipe as shown in Diagram #18.

Tighten all bolts evenly to facilitate lining up flanges evenly. Do NOT do final tightening until the turboassemblies are in place on the vehicle.

(Important: Make sure that the wastegate valve seat ring is properly positioned into the wastegate andthe gasket is in place before installing the wastegate to the flange. Make sure that there is 1 sealing ringon each side of the banjo hose fittings on the wastegate ports.)

The 6 turbine housing bolts can be loosened to allow the center section of the turbocharger to be rotated.Rotate the center section so that the oil outlet flange of the turbo faces straight down once the turbo assemblyhas been installed on the vehicle. Final tightening of the turbine housing bolts is 12 ft lbs once aligned properly.

Loosen the 6 compressor housing bolts and rotate the compressor housing so that the outlet of the compressorlines up with Pipe 1 once the turbo assembly has been installed on the vehicle. Final tightening of thecompressor bolts is 10 ft lbs once aligned properly.

Clean out the 16 inch long #4 stainless steel oil supply hose to remove any possible debris and then install thehose onto the fitting at the top of the turbocharger as shown.

Install the tail pipe (RH E2) onto the turbine housing using the four 8mm x 1.25 x 20mm bolts and lock washers.

Install the wastegate dump pipe (RWGD) onto the wastegate using the Allen bolts supplied with the wastegate.

Carefully install the finished RH turbocharger assembly over the differential and hang in place by installing theexhaust hangers into the factory rubber exhaust mounts.

’06-’08 C-6 Z06 Corvette LH Turbo Assembly

Diagram 19

Exhaust Outlet (LH E2)

Wastegate

Compressor Outlet

Vent This PortTo Atmosphere

Exhaust Hanger

Exhaust Inlet Pipe(Z06 RE1)

Oil InletSupply Hose

LH Wastegate Dump Pipe


Assemble the LH turbocharger, T3 flange gasket, wastegate, RH exhaust inlet pipe as shown in Diagram #19.

Tighten all bolts evenly to facilitate lining up flanges evenly. Do NOT do final tightening until the turboassemblies are in place on the vehicle.

(Important: Make sure that the wastegate valve seat ring is properly positioned into the wastegate andthe gasket is in place before installing the wastegate to the flange. Make sure that there is 1 sealing ringon each side of the banjo hose fittings on the wastegate ports.)

The 6 turbine housing bolts can be loosened to allow the center section of the turbocharger to be rotated.Rotate the center section so that the oil outlet flange of the turbo faces straight down once the turbo assemblyhas been installed on the vehicle. Final tightening of the turbine housing bolts is 12 ft lbs once aligned properly.

Loosen the 6 compressor housing bolts and rotate the compressor housing so that the outlet of the compressorlines up with Pipe 1 once the turbo assembly has been installed on the vehicle. Final tightening of thecompressor bolts is 10 ft lbs once aligned properly.

Clean out the 16 inch long #4 stainless steel oil supply hose to remove any possible debris and then install thehose onto the fitting at the top of the turbocharger as shown.

Install the tail pipe (LH E2) onto the turbine housing using the four 8mm x 1.25 x 20mm bolts and lock washers.

Install the wastegate dump pipe (LWGD) onto the wastegate using the Allen bolts supplied with the wastegate.

Carefully install the finished LH turbocharger assembly over the differential and hang in place by installing theexhaust hangers into the factory rubber exhaust mounts.

’06-’08 C-6 Z06 Corvette Exhaust

Stainless OilSupply Line

Rear WiringHarnesses

STS Exhaust Inlets (E1)

Wastegate Hose

Factory Exhaust Clamps

Diagram 20

Transmission

Install the factory H-Pipe exhaust back on the car by inserting the turbocharger inlet pipes (LHE1 and RHE1) intothe H-Pipe, connecting the sprung exhaust hangers, connecting the oxygen sensors and lining up the frontexhaust flanges. Line up all exhaust components as shown in Diagram #20 and tighten the front flange bolts tofactory specifications.

(Note: Leave the factory exhaust clamps at the E1 connection loose at this time so that the E1 and tailpipes can be lined up properly. Depth of the tail pipe tips can be adjusted with the depth of E1 into thefactory H-Pipe.)

(IMPORTANT: Use anti-seize compound on all exhaust related bolts/hardware.)

’06-’08 C-6 Z06 Corvette Exhaust & Turbo Assembly

LH & RH Exhaust Outlets

Diagram 21

OptionalPolished and

Coated Housings

Wastegate Hose T

Oil Outlet

LH & RH Wastegate Dump Pipes

Oil Supply Hose

Oil ReturnHose

Oil Supply T

Connect the stainless oil supply hose from the engine to the center port of the T fitting as shown in Diagram #21.Connect the two 16 inch long #4 stainless oil supply hoses from the top oil inlet port on the turbochargers to theoutlet ports on the oil supply T fitting as shown in the diagram. Fasten the oil supply hoses to the differentialcooler lines using the nylon ties provided.

(IMPORTANT: The supply hose from the engine must be flushed out before final assembly Note the flowdirection ARROW on each check valve – it should point toward the turbocharger.)

Connect the open ends of the 22 inch long #6 stainless hoses to the 90 degree fittings on the oil outlet ports atthe bottom of the turbochargers as shown in the diagram.

Install a 6 inch long ¼” hose onto each side port of the wastegate T fitting. Install the open end of the hosesonto the Front Boost Port of each wastegate as shown in Diagram #21 and on page 7. Cut the wastegate hosecoming from the front of the car to length and install onto the center port of the T fitting as shown.

The turbo housings must be clocked so that the oil inlet is straight up and the oil outlet is straight down. Onceinstalled, if the center section isn’t aligned properly, loosen the 6 turbine housing bolts and the 6 compressorhousing bolts. Rotate the center section until it is clocked so that the oil inlet/outlets are aligned vertically asshown. Retighten the turbine housing bolts to 12 ft lbs. Leave the compressor housings loose at this time.

(Note: When the turbocharger and all the tubing has been installed correctly, the installation should beidentical to the picture in Diagram #21. Make sure that the front edge of the factory heat shield has beenrolled up in the middle to prevent damage to the hoses and wiring harnesses.)

(IMPORTANT: If the rear K-Member nuts were loosened to lower the K-Member then tighten those nutsto factory specifications now.)

(Note: Do not install the weld on exhaust tips at this time. Do not install the rear sway bar yet.)

’06-’08 C-6 Z06 Corvette AI #2 and #3

AI 2

Diagram 22

RH Fender Bracket

RH Pipe 1Not In

Position

GroundWire

RH AI 1

Fender Bracket Studs

Bend LH Bracket End Up HereLH AI 1

Remove the 2 factory bolts and the 2 nuts from the 6mm studs shown in Diagram #22 and remove the rearfender brackets.

Install a 2.5” x 4” silicone hose and 2 clamps onto the lower end of each upper intake pipes (AI-1) and securethe clamp. Install the middle air intake pipes (AI-2) up into the silicone hose on the outlet of the AI-1 pipes.Temporarily hold the lower air intake pipes (AI-3) in place between the turbocharger and AI-2. Line up the pipesand tighten the clamp to secure the AI-2 pipes in place as shown in the diagram then remove AI-3.

(Note: Orient the clamps so that they can be accessed after the other pipes have been installed.)

’06-’08 C-6 Z06 Fender Bracket Modification

Diagram 23

Bend BracketUp Here

Cut Arc To Clear Pipe 1

Left Rear Fender BracketRight Rear Fender Bracket

Cut Arc To Clear Pipe 1

Cut an arc shape out of the rear fender brackets as shown in Diagram #23 so that Pipe 1 will clear the bracket.

The front end of the LH fender bracket must be trimmed so that it is flat with the bracket mounting surface or thelip of the bracket must be bent up flat with the mounting surface as shown in Diagram #22.

Debur the edges of the brackets and reinstall the brackets onto the vehicle.

(Note: On the driver side, reinstall the factory ground wire back in position with the factory bolt asshown in the diagram.)

Tighten the 2 bolts and the rear nut onto the rear stud only (leave front nut off at this time).

’06-’08 C-6 Z06 Corvette Pipe #1 & AI #3

AI-R2

Diagram 24

Modified RH Fender Bracket

PCV Vent Hose Fitting

AI-R3

RH Pipe 1

AI-R1

Lower Bracket Bolts

Battery TraySupport Bracket

Install a 2” x 2.5” silicone hose and 2 clamps onto each turbocharger outlet and secure with clamp.

(Note: The compressor bolts should be loose at this time. Rotate and ‘clock’ the compressor cover sothat it lines up properly with Pipe 1. Do not tighten the compressor cover bolts until all pipes are linedup properly.)

Slide the inlet end of Pipe 1 into the compressor outlet and rotate the pipe rearward to install the mountingbracket over the factory stud as shown. Line Pipe 1 up and secure to the stud with the ¼” fender washer andthe factory nut as shown in Diagram #24. Secure Pipe 1 into the compressor by tightening the hose clamp.

Install a 2.5” x 3” silicone and 2 clamps onto the outlet end of each AI-2 intake pipe and secure the clamps.

(Note: Orient the clamps so that they can be accessed after the pipes have been installed.)

Loosen the 2 upper bolts that mount the battery tray support bracket to the RH frame rail. Remove the 2 lowerbolts of the battery tray support bracket. Install 3 of the 10mm flat washers onto each lower bolt between thebracket and the battery tray as shown in the diagram. Tighten the support bracket bolts.

Install the 2.75” x 3” silicone hose and 2 clamps all the way onto the outlet end (larger end) of each AI-3 intakepipe. Install the inlet end of AI-R3 (this is the pipe with the hose barb fitting as shown in Diagram #24) into theoutlet end of AI-R2. Slide the silicone hose onto the RH compressor inlet. Align the air intake pipes and secureall the hose clamps as shown in the diagram. Repeat this process for the LH air intake pipes (AI-L3 does NOThave a hose barb fitting)

(Note: Check the tail pipes for proper alignment. Make sure that the turbochargers are sitting level. Ifthe turbochargers need adjustment, loosen the hose clamps and then align the pipes properly. Tightenthe hose clamps to help hold the turbochargers in place. Final tightening and alignment will be donelater but turbochargers need to be very close to their final position at this time.)

’06-’08 C-6 Z06 Corvette Rear Suspension

LHPipe 3

Cut Notch InFactory Pinch

Weld

RH Pipe 2

Diagram 25

Factory RR Lower Ball Joint Nut RH Pipe 3View Of LH Rocker Panel

From Inside LR Wheel Well

View Of RR Brake Rotor

Remove the rear lower ball joint nuts. Use a ball joint separator or tap on the side of the spindle where the balljoint stud taper is with a hammer to separate the lower ball joint from the spindle.

Raise the right rear spindle and rotor assembly up off of the lower control arm to allow clearance for Pipe 3 topass under the brake rotor and into the rocker panel. Securely support the spindle in this raised position.

Using a ‘saws-all’ cut approximately a ½” x 2” section of the factory pinch weld at each rocker panel as shown inthe Diagram #25. This will allow adequate clearance for Pipe 3 to slide into the rocker panel cavity. Cleandebris from rocker panel then paint the exposed metal surface to prevent rust.

Insert a clean rag into the long end (outlet) of each Pipe 3 to prevent any debris from entering the pipe duringinstallation.

Slide each Pipe 3 into the rocker panel as shown in Diagram #25.

’06-’08 C-6 Z06 Corvette Pipes 2-3 Mounting

RH Pipe 2

Diagram 26

RH Pipe 3

PCV Vent Hose

AI-R3 PCV Fitting

RH Pipe 1


Reassemble the spindle onto the ball joint and secure with the factory nut according to factory specifications.Repeat this process for the other side.

Install a 1.75” x 3” silicone hose and 2 clamps onto the outlet end of Pipe 1 and secure the clamp. Install a 1.75”x 3” silicone hose and 2 clamps all the way onto the inlet end of Pipe 3 (do not secure clamp yet). Install Pipe 2into Pipe 1 and then install the long end of Pipe 2 into the inlet end of Pipe 3. Slide the silicone hose up onto theoutlet of Pipe 2 and secure with clamp. Adjust Pipe 2 so that the top of Pipe 2 is flush with the top of the wheelwell and loosely secure in place with the clamps. Repeat this process for the other side.

(Note: At this time, the outlet end of Pipe 3 should be resting on the bottom of the rocker panel so that itwill align properly with Pipe 4. If the front of Pipe 3 is up too high, adjust Pipe 2 so that the outlet is NOTbeing held up too high. Once all intake pipes are connected, align and do final tightening of all intakepipes.)

Cover the open end of the 180 inch long 3/8” PCV vent hose and route it through the RH rocker panel along theRH Pipe 3. Install the hose onto the fitting at AI-R3 and secure with a hose clamp. Secure the hose to theintake pipes with the nylon ties provided as shown in Diagram #26. Pull the hose out near the oil sump reservoirto remove the slack in the hose.

’06-’08 C-6 Z06 Dry Sump Spacer Installation

Diagram 27

RH Pipe 3

PCV Vent HoseDry SumpOil

Reservoir

K-Member Nut

RH Pipe 4

AftermarketHeaders

Rear Mount

Front MountSpacer

Remove the front and rear lower dry sump mounting brackets. Discard the rear mounting bracket and bolts.Drill the large hole in the front mounting bracket to 7/16” using the drill bit supplied. Reinstall the front mountonto the reservoir. Install the spacer between the mounting bracket and the frame and secure with the 10mm x40mm bolt and lock washer provided as shown in Diagram #27.

Pull the slack out of the 3/8” PCV vent hose and feed the hose up behind the oil sump reservoir into the enginecompartment and secure with a nylon tie as shown in the diagram.

’06-’08 C-6 Z06 Corvette Pipe 4 and Front View

Rear K-MemberMounting Nuts

Diagram 28

PCV VentHose

Dry Sump Reservoir

Sway Bar Brackets

LH and RH Pipe 4

Rear SplashPanels Removed

Front K-Member

Fender Screw

Remove the screws at the lower rear corner of the front fenders to allow easier access to install the silicone hoseson the Pipe 3’s.

(Note: Be careful flexing the front fenders when accessing the connection between Pipe 3 and Pipe 4 asthe fender can crack or be damaged!)

Remove the rags from the outlet ends of each Pipe 3 and clean out any debris that may have entered the pipes.Install a 1.75” x 3” silicone hose and 2 hose clamps onto the outlet end of each Pipe 3 and secure the rear clampin a position where it can be accessed for tightening.

(Note: The front hose clamps can be accessed and tightened from below between the frame and theloosened fender. To access the rear clamps it is recommended that the hose clamps be tightened fromabove through the splash panel access to prevent hose clamp bolts from rubbing on the fender.)

Remove the large nut (21mm wrench) from the LR corner of the front K-Member and remove the rear bolt (13mmwrench) from the LF sway bar frame bracket as shown in Diagram #28. Install the LH Pipe 4 as shown in thediagram by installing the inlet end of LH Pipe 4 into the outlet end of LH Pipe 3. Guide Pipe 4 into place as youinstall LH Pipe 4 rear mounting bracket over the K-Member stud and insert the outlet of Pipe 4 into the siliconehose at the intercooler inlet. Loosely install the factory K-Member nut. Secure the front bracket to the sway barmount using the factory bolt and two 3/8” flat washers as spacers between the pipe bracket and the sway barframe bracket. Align LH Pipe 4 for maximum clearance and tighten the factory nut & bolt. Make sure the siliconehose is installed far enough onto the outlet of Pipe 4 (adjust hose back on the intercooler inlet to center the hosebetween Pipe 4 and the intercooler if necessary) then tighten the hose clamps. Repeat this process to install RHPipe 4.

(Note: Check for adequate clearance for the silicone hoses as they run past the radiator.)

’06-’08 C-6 Z06 Corvette Pipe 1, 2 and Turbo

LH Pipe 1

AI-L3 Intake Pipe

LH Pipe 2

LH Exhaust Inlet

Diagram 29

LH Tail Pipe &WastegateDump Pipe

Position Pipe 2 so that it is flush with the top of the wheel well as shown in Diagram #29. Center Pipe 2 so it fitsevenly in the wheel well. Position the silicone hoses at the inlet and outlet ends of Pipe 2 so that the gaps arecentered and that there is pressure applied upward to push the pipes against the body to hold them secure.Tighten the hose clamps to hold the pipes in position against the body. Do final tightening of the hose clamps atthe silicone hoses at Pipes 1, 2, 3 and 4.

(Note: It may be necessary to adjust the position of Pipe 3 slightly forward or back to facilitate properalignment of Pipe 1 to Pipe 2 and to keep proper pressure against the top so that the pipes don’t rattle.Make sure that all pipes are secure and have enough pressure against them to keep them from rattling.It is recommended to ‘test fit’ the rear brake ducts so that any adjustments to Pipe 2 and Pipe 3 can bemade at this time to allow adequate clearance so that the ducts will fit on final assembly when the innerfender liners are installed. Moving Pipe 3 forward can help with clearance issues. Hose clamps can betightened to 100 inch pounds.)

Repeat this process for the other side. Reinstall the screws at the lower rear edge of the front fenders.

(IMPORTANT: Make sure that all silicone hoses are spaced evenly over the pipe gaps and that pipegaps are at a minimum. Hose clamps need to be at least 1/8” away from the end of the silicone hose andat least ¼” from the end of the pipe. Rotate clamps so that they can be easily accessed for maintenancetightening. Hose clamps need to be retightened after several drive cycles and tightened periodicallyafter that.)

(Note: Installation of the rear inner fender shields, as well as the rear splash shields on the front wheelscan be done after the installation is complete and after the final tightening of the brackets and hoseclamps have been done. The hose clamps should also be retightened after several drive cycles. Keepthis in mind when installing the factory shields as they will need to be removed again to check theclamps.)

’06-’08 C-6 Z06 Corvette Exhaust & Turbo Assembly

Diagram 30

LH Oil Supply

Optional Upgrade Tips Shown

RH Oil SupplyOil Supply T and Check Valves

RH Oil ReturnLH Oil Return

Align the tail pipes as straight as possible using the following adjustments:

•In and Out adjustment of the E1 Pipes to the factory H-Pipe to position turbos forward or back (watch clearance atcompressor housing and sway bar)•Rotational adjustment of the E1 Pipes to the factory H-Pipe to align tail pipes and turbochargers horizontally (watchclearance of E1 to transmission and to frame rail)•Rotational adjustment at the 4-bolt turbine housing flange at E1 to align tail pipes and turbochargers horizontally•Rotational adjustment at the 2-bolt wastegate flange at E1 to align the wastegate dump pipes vertically•Rotational adjustment at the 2-bolt wastegate flange at wastegate dump pipe to equalize space between thewastegate dump pipe and the turbocharger tail pipe (E2)•Bend the exhaust hangers on the tail pipes to line up the turbochargers and tail pipes vertically and horizontally•Rotational adjustment at the 6-bolt compressor housing and turbine housing adjustment to align the compressoroutlet with Pipe 1 and also to align the center section so that the oil outlet is straight down as shown in diagrams

Tighten 6 compressor housing bolts to 10 foot pounds and the 6 turbine housing bolts to 12 foot pounds.

Do final tightening of all exhaust and intakes pipes. Do final tightening of all silicone hoses and clamps. Reinstall therear sway bar onto the K-Member. Check front and rear K-Member bolts for proper torque.

(IMPORTANT: Make sure turbochargers are mounted level and symmetrical. Check the turbochargerhousings for proper clocking and check tightness of the compressor and turbine housing bolts. Make sureall pipes and silicones are installed properly and lined up correctly to prevent any flow restrictions and thepossibility of connections coming apart. Disconnect the battery before welding as PCM damage may result.)

DISCONNECT THE BATTERY BEFORE WELDING! With the help of an assistant, install the ‘Weld-on’ exhaust tipsprovided (optional polished upgrade tips are shown) by aligning the tips and welding the tips onto the tail pipes (E2) asshown in the diagram. Make sure there is adequate clearance between the tips and the body. Make sure tips arespaced evenly and aligned correctly for best appearance. Carefully paint the welds to prevent rust. Final installationshould look as shown in Diagram #30.

’06-’08 C-6 Z06 Corvette Wheel Well Liners

Diagram 31

Front WheelWell Splash

Guard

Rear Wheel Well Liner

Heat Here

A

Rear WheelWell Liners

B

Carefully cut the front splash shields as shown in Diagram #31A so that they will clear the intake tubing. It maybe necessary to use a heat gun to stretch the plastic on the passenger front splash panel to allow moreclearance of the dry sump oil flange and lines. Heat the plastic and then push outward from the rear with asmooth object to give clearance as shown in Diagram #31A.

Carefully cut the rear inner wheel well liners as shown in Diagram #31B so that they will clear the intake tubing.

(Note: Make smaller cuts then test fit. Make small trim adjustments until the pieces fit nicely.)

Install the modified inner fender liners and splash guards back on the vehicle (unless you desire to install themafter the car has been driven and the hose clamps retightened).

(Note: The plastic fender liners will need to be removed again to access the silicones as they have to beretightened after first few heat cycles.)

Install the wheels back on the vehicle and lower the vehicle. Torque the lug nuts to factory specs.

’06-’08 C-6 Z06 Corvette Fuel Pump Wire

Solder Connectionat 14 gage GREYFuel Pump Wire

Fuse Box

Diagram 32

C-2ConnectorHarness

BlueHarness

Wire

C-2Connector

Bolt

Upper HarnessConnector

(Not This One)

BluePigtail

’06-’08 C-6 Z06 Corvette Fuel Pump WireLocate the fuse box at the passenger side of the engine compartment. Remove the fuse box lid.

Locate the GREY 14 gage 12 volt fuel pump wire in the factory C-2 wiring harness as shown in Diagram #32.

(Note: This is located in the lower harness connector that is secured to the aluminum bracket, just belowthe upper connector shown in the diagram. The connector comes apart by pressing the upper and lowerrelease tabs while pulling the release lever back.)

(IMPORTANT: There is more than one GREY wire in this loom. The wire you want to use is the larger ofthe grey wires. This wire is inside the harness that is connected to the C-2 Connector in the fuse block asshown in the diagram. The wire is located on the C-2 A-6 terminal. These letters and numbers are castinto the fuse block as well as the C-2 connector plug. The bolt shown in the diagram secures the C-2connector into the bottom of the fuse block. The top of the fuse block unclips and comes off if necessary.)

Once the GREY wire has been located, carefully strip back a small section of the insulation from the GREY fuelpump wire and solder the BLUE pigtail wire to the GREY wire.

(Note: The T-Tap provided with the kit is for temporary connection. It is recommended to solder the bluepigtail wire to the grey fuel pump wire for a trouble-free and permanent connection as shown in Diagram#32. Use heat shrink or electrical tape to cover and seal the new connection. Reinstall the wire loom overthe wire bundle and seal up the loom with electrical tape.)

’06-’08 C-6 Z06 Corvette Front Wire Harness

STS Blue Wire

STS Relays

Fuse Box

Inline Fuses

Diagram 33

RemoteBattery

Terminal

ReservoirMounting Bolt

Buzzer Harness

Carefully pull the slack out of the front wiring harness that runs behind the engine and over the clutch bellhousing. Position the wiring harness as shown in Diagram #33.

Remove the factory nut from the remote battery terminal on the fuse box. Install the 2 YELLOW/ORANGE inline-fused wires from the front STS wiring harness with the large ring terminal onto the remote battery terminal asshown in Diagram #33. Reinstall the factory nut and install the fuse box lid. Leave the 15 amp inline fuses outat this time.

Secure the Relays to the factory wiring harness with nylon ties as shown in the diagram.

Route the section of the harness with the RED and BLACK wires along the factory A/C lines, under the fuse boxand toward the front of the engine compartment to just behind the radiator support bolts.

Route the single BLUE STS harness wire toward the blue fuel pump wire connection near the fuse box. Do NOTconnect the BLUE wire to the pigtail at this time. This connection will be made at the end of the installationprocess.

(IMPORTANT: Route and secure the harness so that it does not come in contact with any Hot, Sharp orMoving objects.)

Tighten the dry sump oil reservoir mounting bolt near the oil cap.

’06-’08 C-6 Z06 Corvette Oil Alarm Buzzer

Green Accessory Wire

Oil Alarm Buzzers

Diagram 34

Electrical HarnessOuter Grommet

Electrical HarnessInner Grommet

From inside the passenger side of the vehicle, pull back the top of the floor mat and remove the kick panel belowthe glove box to allow access to the firewall. Pull back the rubber backed insulation to expose where the factorywiring harness goes through the firewall grommet. This is a 2 piece grommet with the inner piece being a thickrubber circle which can be removed from the outer grommet. This thick circle can be difficult to run wiresthrough so it is recommended that you pull the entire grommet assembly out of the firewall. Peal the outergrommet off of the inner piece and then pull the inner piece out away from the outer grommet. Carefully cut a Ushaped slot in the lower portion of the outer grommet just below where the factory harness goes through thefirewall. Replace the outer grommet back into the firewall.

From the engine bay, remove the two piezo buzzers from the harness and route this section of the harnessthrough the hole in the firewall grommet and into the passenger compartment as shown in Diagram #34.

(Note: This is also a good place to route the vacuum/boost hose through for a boost gauge. This is agood time to install any gauges or accessories which require routing through the firewall. It isrecommended to install a vacuum/boost gauge in all turbocharged vehicles so that the boost level canbe constantly monitored to prevent any over-boost conditions. A wideband air fuel ratio gauge is alsorecommended to be able to constantly monitor the air fuel ratio to prevent lean conditions under boost.An overboost or Lean condition can cause IMMEDIATE SEVERE ENGINE DAMAGE! It is theresponsibility of the owner/operator to constantly monitor boost, air fuel ratio and tuning parameters toprevent engine damage.)

From inside the passenger compartment, install the buzzers back onto the white and blue wires with the whitewire on the negative side and the blue wire on the positive side (The positive terminal is coated RED). Use theprovided nylon tie to secure the buzzers under the dash in a location that allows the buzzers to be unobstructedso the driver can hear the alarm, while making sure that it clears any sharp and/or moving objects.

Replace the insulation and reinstall the kick panel.

’06-’08 C-6 Z06 Corvette Valve Cover Removal

Coil Pack SparkPlug Wires

PCV Vent Hose Connector

5 Coil PackBracketStuds

Diagram 35

Coil Pack Connector

Remove the spark plug wires from the coil packs and spark plugs. Unplug the coil pack electrical connector.Remove the 5 studs from the coil pack mounting brackets. Remove coil pack mounting bracket with coil packs stillattached and set aside.

Remove the stock spark plugs and replace with new NGK TR6 spark plugs gapped at .035”. Use a small amountof anti-seize compound on the spark plug threads and torque to factory recommended specs.

Once the coil packs and all wires are out of the way, remove the PCV vent hose assembly by releasing the smalllever at the connector on the port at the rear of the driver side valve cover as shown in Diagram #35. Remove thePCV vent hose connectors at the port on the front of the passenger side valve cover and at the rear port on the drysump reservoir.

Remove the 4 valve cover bolts and carefully pull the valve covers off without damaging the gaskets.

(Note: The valve cover gasket can typically be cleaned and reused. If the gasket is damaged, replace itwith a new gasket.)

‘06-‘08 C-6 Z06 Corvette Valve Cover Modifications

Page 24

Diagram 36

Bend Baffle Here To Seal Against Cover

Same View For LH and RH Valve Cover

Page 25

After removing both valve covers, make sure to cover the valve train with clean cloth to prevent debris from getting into theengine. Turn the valve covers over and cut the baffle back just enough to expose the location of the new oil return fitting to beinstalled. Cut slots in the baffle and bend the end of the baffle down as shown in Diagram #36 so that it seals against the valvecover to isolate the returning oil from the PCV venting. This will prevent oil from getting on top of the baffle and allow oil to flowfreely back into the engine.

(IMPORTANT: The oil return fitting on the passenger side will return to the rear of the valve cover – the opposite end asthe valve cover vent tube. The oil return fitting on the driver side will return to the front of the valve cover – theopposite end as the valve cover vent tube. Both valve covers will look the same as the picture in the diagram.)

Clean off any of the sealant used to seal the baffle to the valve cover.

Mark and drill a 7/16” hole in the top rear of each valve cover at the location shown in Diagram #36. Carefully tap the valvecover using the ¼” NPT tap provided.

Use an appropriate cleaner such as “Brake Parts Cleaner” to flush out any debris in the valve cover, including the baffled part ofthe valve cover. Thoroughly debur and clean the new hole and valve cover of all metal shavings. Then use compressed air toblow out the valve cover and baffle entirely.

(WARNING: ANY METAL SHAVINGS LEFT IN VALVE COVER CAN CAUSE SEVERE ENGINE DAMAGE!)

Wrap the threads on the 90 degree #6 AN fitting with the thread tape and install into each valve cover with the fitting pointingtoward the rear of the engine. Clean the gasket surfaces, remove any protective cover put over the valve train and inspect tomake sure no foreign debris entered the engine. Reinstall both of the valve covers and torque hardware to factory specs.

Connect the previously routed stainless oil return hoses onto the new fittings at the rear of the RH valve cover and to the front ofthe LH valve cover.

(IMPORTANT: Check all oil line connections. Make sure ball joints and K-Member nuts are tight.Make sure wheels are tight!)

’06-’08 C-6 Z06 Corvette InjectorsFuel RailPressure

Port

Fuel Rail

Fuel Rail Mounting Bolts

FuelInjectors

Diagram 37

Fuel InjectorConnectors

Rear Fuel Rail Brackets

Bracket Bolt

WARNING: Any fire or smoking is absolutely prohibited during this process. Use extreme caution asfuel hoses and lines are pressurized and will leak when disconnected. Take all necessary precautionswhen servicing pressurized fuel lines and working with open fuel containers!

Depressurize the fuel system by removing the cap on the front of the driver side fuel rail and depressing theSchrader valve at the fuel pressure port shown in Diagram #37. Drain the pressurized fuel in to a suitablecontainer. Once the pressure is out of the fuel system, replace the protective cap on the fuel rail.

Make sure that the intake manifold is clean around the fuel injectors so that no debris can fall into the intakemanifold. Any debris that gets into the intake manifold could cause immediate SEVERE engine damage!

Referring to Diagram #37, remove the wiring harness mounting connectors from the LH fuel rail studs.Disconnect the 8 fuel injector harness electrical connectors from the fuel injectors. Remove the front bolts fromthe rear fuel rail brackets and loosen the rear bolts completely so that the brackets can be swivelled out of theway to access the fuel rails and fuel rail bolts.

Remove the 4 fuel rail mounting bolts/studs. Remove the bolt and bracket shown in the diagram. Remove thefuel rails and 8 injectors from the intake manifold, taking care that no debris falls into the holes in the intakemanifold. Remove the metal fuel injector retaining clips from each of the injectors. Using a small container tocatch the fuel, remove each fuel injector one by one and drain the fuel into the container. Make sure that the O-ring seals come out of the manifold and the rail with the injectors.

Install the metal retaining clips onto the new fuel injectors at the same location which they came off of the factoryinjectors. Lubricate the seals on the new injectors with silicone grease and carefully insert the injectors into thefuel rails until the metal retaining clips lock onto the rail.

Clean each of the injector ports in the rails to prevent any dirt or debris from entering the manifold or damagingthe O-ring. Reinstall the fuel rails onto the intake manifold making sure not to damage the injector seals as theinjectors fit into the manifold ports. Reinstall the fuel rail bolts and reinstall the fuel rail brackets and torquehardware to factory specifications. Reconnect the injector electrical harness connectors.

Install the coil packs in reverse order of removal and make electrical connections. Wipe a small amount ofdielectric grease into the spark plug boots then install the spark plug wires onto the plugs and coils.

’06-’08 C-6 Z06 Corvette PCV

1# PressureSwitch

STS Harness

BROWN Wire 16” Hose To Pipe 5 Port

BLACK Ground Wire

Vent Hose To Reservoir

Vent Hose To Rear

PCV Switch Valve

Diagram 38

Bolt the PCV Switch Valve to the front of the passenger side cylinder head as shown in Diagram #38 using the10mm x 20mm bolt and lock-washer supplied.

Locate the previously removed plastic PCV line off of the dry sump and using a razor blade knife, carefully cutthe plastic line off of the hose barb fitting connecting it to the dry sump without damaging the fitting. Once thehose barb has been removed, remove the small O-ring from the fitting and insert the barb into the 46 inch long3/8” hose. Connect the 46 inch long 3/8” inch hose onto the dry sump tank port. Route the hose along thefactory hoses and along the RH fuel rail and to the single port side of the PCV switch valve. Cut the hose tolength and secure to the single port (single port side) on the PCV Switch Valve with a hose clamp.

Connect the 2 inch long 3/8” hose onto the 90 degree fitting on the pressure switch assembly and secure with ahose clamp. Connect the 16 inch long 3/8” hose from Pipe 5 port onto the straight fitting on the pressure switchassembly and install the pressure switch assembly as shown with the short hose connected to the port on thePCV switch valve closest to the metal switch valve body (lower port on dual port side) and secure the hoses withhose clamps.

Reinstall the factory plastic PCV vent hose onto the rear port of the dry sump reservoir, the rear port of the LHvalve cover and the front port of the RH valve cover. Route the previously installed 180 inch long 3/8” hose(coming from the RH rocker panel) along the A/C lines towards the radiator and to the top port of the PCV switchvalve (furthest away from the metal body) on the dual port side as shown in the diagram. Cut the hose to lengthand secure the hose with a hose clamp and nylon ties.

Connect the RED wire from the STS harness onto one of the terminals of the 1 psi pressure switch. Connectone end of the short BROWN extension wire onto the opposite terminal of the pressure switch and connect theother end of the extension wire to the terminal on the PCV Switch Valve. Leave the protective cap off of thepressure switch until electrical system checks have been done.

(IMPORTANT: DO NOT OVERTIGHTEN NUT ON THE PCV SWITCH VALVE!)

Remove the factory nut from the ground terminal stud at the RF frame rail as shown in Diagram #38. Install theBLACK ground wire from the STS harness onto this terminal and secure with the factory nut.

’06-’08 C-6 Z06 Corvette PCV Check Valve

Diagram 39

PCV Check Valve

Factory MoldedPCV Hose

(Throttle Body toIntake Manifold)

Moulded PCV Hose

Remove the molded factory rubber PCV hose between the intake manifold port directly behind the throttle bodyand the crank case vent port under the intake manifold as shown in Diagram #39. Note the direction which thehose was installed from the factory. Clean the hose and intake manifold port of any oil. Install the small brasscheck valve securely into the center of the hose so that the snap ring is facing away from the intake manifold asshown in Diagram #39. Reinstall the PCV hose onto the vent port and the intake manifold as shown in thediagram.

(Note: This check valve must be installed carefully as to not damage the valve. This valve will preventthe flow of boost from the intake manifold into the crank case but will allow the venting of crank casegasses to flow through the check valve into the intake manifold. Newer model vehicles may have aplastic hose. This hose can be removed by releasing the locking clips on the hose connectors. Discardthis hose and install the moulded rubber hose supplied with the kit as shown in the diagram. Secure thehose to the intake manifold port using the supplied hose clamp.)

Recheck the wiring and hose routing under the hood to make sure all hoses and wires are routed properly andcannot be damaged by hot, sharp and/or moving objects. Do final tightening of all hose clamps and brackets.

Reconnect the battery cables and install the 15 amp fuses into the inline fuse holders in the STS harness.

’06-’08 C-6 Z06 Corvette Tuning

Diagnostic Port

Diagram 40

Predator With STSLogo Display

IMPORTANT: CONTACT YOUR LOCAL STS POWER DEALER OR STS CUSTOMERSUPPORT BEFORE INSTALLING THIS TUNING SOFTWARE AS THE UNIT SENT WITHTHIS KIT MAY NOT CONTAIN A STS PRODUCTION TUNE AND WILL NOT LOADDIRECTLY ONTO THIS VEHICLE!!! A READ OF THE FACTORY TUNE WILL HAVE TO BEMADE WHICH WILL HAVE TO BE MANUALLY RETUNED AND RELOADED ONTO THEVEHICLE!!! IF THE PREDATOR DOES NOT DISPLAY THE STS LOGO, DO NOT INSTALLTHE PREDATOR TUNE ONTO THE VEHICLE AS SEVERE ENGINE DAMAGE ANDDRIVABILITY PROBLEMS WILL RESULT!!!

Read completely through the instructions on the Diablosport Predator. Pull any fuses as directed in theDiablosport Predator instruction manual and read the warnings about possible damage to PCM duringprogramming.

Locate the Diagnostic port directly under the steering wheel and plug the connector on the STS Predator ontothe diagnostic port as shown in Diagram #40. If the Predator does NOT display the STS logo, follow theinstructions that you received from STS as per loading the new STS tune onto the Predator and then loading thetune onto the vehicle. This process should have been started before the turbo installation as per instructions onPage 8 of this manual.

(IMPORTANT: If the Predator does NOT display the STS logo, DO NOT INSTALL THE PREDATORTUNING on the vehicle as it may be a performance tune for a STOCK naturally aspirated vehicle and nota TURBOCHARGED vehicle. In this case, IMMEDIATE and SEVERE engine damage and DRIVABILILTYPROBLEMS may result! Contact your local STS Power Dealer or call STS Customer Support at 866-WETURBO for further information regarding tuning.)

If the STS logo properly displayed after power up, read and follow the on-screen prompts and select “TUNE IT”.Read and follow the on-screen directions to install the STS tuning onto the vehicle. Select the transmission typeand select “Install Performance” to finish installing the tune onto the vehicle. Once installed, ESCAPE back tothe main menu and select DIAGNOSTICS. Select “READ LIVE DATA” to monitor the OBDII PCM parametersfor timing, O2 readings, and Knock Retard to make sure that the tuning is correct for your vehicle.

’06-’08 C-6 Z06 Corvette Engine View

BOV Hose

Diagram 41

Blow Off Valve

(Note: Leave the plastic engine covers off until engine has been started and you have verified that thereare no fuel leaks at the injector rails or injectors.)

With the tuning installed on the vehicle, remove the #6 stainless oil supply lines from the oil inlet fitting at thecheck-valve T assembly and insert it into a suitable container. Start the vehicle and let it IDLE ONLY until theoil lines are flushed out well (usually about ½ quart) then shut off the engine. Clean the fittings and reinstall theoil line onto the fitting.

ELECTRICAL SYSTEM TESTS:Temporarily connect the BLUE STS wire (NOT the soldered pigtail) to the 12v+ remote battery terminal. Thisshould turn on the oil pumps. With the pumps running, use a jumper wire and connect it across the pressureswitch terminals at each of the oil pump inlets individually to test each alarm circuit. This should cause the oilwarning alarm to sound in the passenger compartment. Make sure that both oil alarms are working. Removethe jumper wire.

Use the jumper wire to connect the two terminals of the pressure switch located near the PCV Switch Valve onthe RF cylinder head. You should hear and be able to feel the PCV Switch Valve ‘click’ each time power isapplied to the solenoid.

Connect a test light to the soldered BLUE pigtail wire at the fuel pump wire. With the oil pumps still running,start the engine. The test light should illuminate just before the engine starts and stay ON while the engine isrunning. Shut off the engine. The test light should turn OFF just after engine stops. If the BLUE wire does notpass this test, you probably have soldered into the wrong wire. Engine should be OFF.

Once electrical system tests are complete, install the rubber protective caps onto the three pressure switches.Connect the BLUE STS wire to the soldered BLUE pigtail wire. Start the vehicle and check for oil leaks and/orfuel leaks. Check to see that the oil alarm buzzer does not sound during this process. You should faintly beable to hear the oil pumps running. Shut the engine off. Install the plastic engine covers.

Check and top off the engine oil (it will typically take ½ to 1 quart). This procedure must be done according tothe GM recommended procedure: Start the engine and let it come up to operating temperature. As per the GMprocedures (see Page 9 of this manual), shut the engine off and let it sit on a level surface for at least 5 minutesthen check the oil level. Add the appropriate amount of oil then recheck according to GM procedures. Whencompleted, the final installation should look identical to Diagram #41.

Test drive vehicle as per the tuning instructions which you received with your STS tune. If you are not using theSTS tune, make sure that the tuning is correct BEFORE boosting the vehicle! Make sure that the turbochargeris working properly and producing the proper amount of boost. The standard kit should produce about 5-psiboost. The air fuel ratio at WOT and/or under boost should be at least 11.5:1 or richer (.920v+ on OBDII O2sensors). There should be NO consistent knock retard under boost and absolutely NO audible detonation.Boosted timing should be in the 14 degree range. If you experience lean air fuel ratios and/or knock retard oraudible detonation during boost, DO NOT DRIVE THE VEHICLE! Contact your local STS Power Dealer and/orSTS Customer Support immediately!

After the test drive, recheck ALL connections, clamps and brackets for proper tightness and routing.

(IMPORTANT: Inspect the wiring harness routing near the engine and exhaust system for any evidenceof the loom melting due to high heat. If the loom is getting too hot, reroute the harness and secureharness to protect it from excessive heat.)

Vehicle performance should increase over the next few days of driving as the turbocharger breaks in, allowingquicker spool-up, and as the computer relearns and adjusts to boost conditions. The “Check Engine” light maycome on during the next few weeks of driving, as the computer will see sensor values that are out of the “normalrange” of what it is used to seeing. The light should go off and reset each time you drive the vehicle. It isrecommended that you check and keep track of any trouble codes that are set in the computer to make sure thatno damage is done to your vehicle. Report any trouble codes to your tuner.

The oil pumps should decrease in noise level as oil temperature rises and also decrease over time as the pumpsbreaks in.

If you experience any problems refer to the Trouble Shooting Guide. If you can’t solve the problem that isrelated to the turbocharger system please email or contact your local STS Power Dealer or contact STSTechnical Support at [email protected] or (866) WE-TURBO.

TROUBLESHOOTING GUIDEOil pump alarm sounds • Check to see if oil pump is working• If pump is working, check oil pump electrical connections to see they aren’t reversed• If pump is not working, check inline fuse in main harness and electrical harness connections• Check relays to make sure they are plugged in properly

Oil pump is noisy• Oil pump will be slightly noisy upon startup and when cold but should get quieter as system warms and as pump wears in• Jumping pressure switch electrical connectors on charge air tube should run pump at high speed• If pump always runs at high speed, check pressure switch continuity, secondary relay continuity, and harness for shorts.• Check to see if oil pump or housing are rubbing on frame and that rubber insulators are in good shape

Turbo won’t boost, produces low boost, or has excessive spool time• Check intake tubing for any leaks at tubes or hose connections• Check exhaust system for any leaks• Check wastegate to see that valve isn’t stuck open• Spool up time will decrease as the turbocharger breaks in and should improve over first few days of driving• Check condition of air filter or pre-charger filter cover

Detonation• Check for lean condition, O2 readings should be above .900 volts at WOT• Check Octane rating of fuel and use premium fuel only• Check boost level to see that it isn’t running too much boost• Check wastegate and hose connections

TROUBLESHOOTING GUIDESqueaking or rattling noise• Check to see that all mounts and tubing is secure• Check to see that tubing and hose clamps are not rubbing on any moving parts

Check engine light• Check all sensor electrical connections• Pull codes with diagnostic scanner and follow diagnostic flow charts• If MAF code appears check and clean MAF sensor of any oil residue or contaminants• Trouble code may reset on it’s own with time as computer relearns and recognizes higher sensor readings as normal values• Clear out code and let computer relearn new values and see if code reoccurs

Gas smell and fuel tank pressurization• Check to see that fuel tank Evap solenoid is working properly

Excessive engine blow by or smoking• Check condition of gaskets and seals and look for oil leaks• Check condition of PCV valve. A bad valve will let boost into crank case• Check to see that the PCV switch valve hoses are routed correctly and that the valve is switching properly• Check the 1 psi pressure switch to see that it is powering the BROWN wire at 1 psi• Check cylinder compression to verify engine is in good condition• Check oil pump operation and for any flow restrictions

Burning smell• Check to see that all wiring harnesses and hoses are routed properly and away from hot exhaust• Check to see that external resistor in main wiring harness is routed away from harness and other low-heat parts• Check to see that there are no shorts in electrical wiring harness• Check oil pump operation and for any flow restrictions

Squires Turbo Systems – Safety Warning - Please Read!

IMPORTANT

Oil System Warning BuzzerYour STS™ Turbo System is equipped with a safety system that will alert you in the event that your oil pump fails. Thissystem is a buzzer that will be heard inside your vehicle. If you hear this buzzing sound, immediately shut the engineoff and safely pull over to the side of the road and contact the nearest STS Power Dealer. Serious engine damage canoccur if the pump stops while your engine is running. With the pump stopped oil will flow out of the turbo and will notreturn to the engine.

Premium FuelSquires Turbo Systems recommends that you only use Premium Fuel, 91 Octane or higher, on vehicles equipped withthe STS™ Turbo System. Premium fuel reduces pinging and early detonation which can cause significant damage toyour vehicle.

Engine PingingIf you hear pinging in your engine, back off the throttle immediately. Pinging can cause significant damage to theengine. If you hear pinging, call your local STS Power Dealer immediately.

Heavy TowingThe STS Turbo System, like other turbo and supercharger systems, under certain heavy towing situations can createmore power than a stock engine can handle. Squires Turbo Systems does not recommend using this system for heavytowing purposes.

Vehicle modificationsSTS Turbo Systems were designed to fit stock vehicles. If you have modified your vehicle, modifications to the turbosystem or your vehicle may be necessary to ensure the proper fit and safe use of the STS Turbo System. Inform yourPower Dealer of any aftermarket changes to your vehicle.

For Off Road Use Only in California

STS Safety Warning and Warranty NoticeSAFETY WARNING – PLEASE READThe STS™ turbo system is designed to provide enhanced power and engine performance. It could cause severedamage to your vehicle if it is not properly installed or if your vehicle is not properly maintained for the system.Under some circumstances, improper installation or use of the STS™ turbo system could result in seriouspersonal injury or even death.

Neither Squires Turbo Systems, Inc. nor its authorized dealers can accept responsibility for the propermaintenance or the proper operation of your vehicle. Please take all necessary precautions to use the STS™turbo system strictly in accordance with all instructions and warnings.

WARRANTY NOTICE – PLEASE READThe liability of Squires Turbo Systems, Inc. and its authorized dealers relating to your use of the STS™ turbosystem is strictly limited. Please read the STS™ turbo system limited warranty carefully. In most cases, thewarranty is limited to repair or replacement of the system itself and does not cover:

• Any damage to your vehicle or other property that results from your use of the STS™ turbo system• Any personal injury or death that results from your use of the STS™ turbo system• Any adverse effect of the STS™ turbo system on other warranties• Under some circumstances, applicable law may specifically prohibit us from disclaiming responsibility fordamage to your vehicle and/or for personal injuries or death caused by your use of the STS™ turbo system, inwhich case our responsibility will be as provided by law. However, we urge you to exercise the utmost care inproperly installing and using the system so as to avoid personal injury and/or damage to your vehicle. You areresponsible for using the system safely and for evaluating the effect of such use on other warranties.

Squires Turbo Systems, Inc. warrants to you, the original purchaser of an STS™ turbo system (the “System”), the that System will be free from defectsin material and workmanship for a period of one year after the date the System is shipped to you, or, if the System is originally installed on your vehicleby an authorized STS™ service dealer, for a period of one year after the date of installation. This warranty does not apply to any System that has beendisassembled, repaired, or otherwise altered by any person other than an authorized STS™ service dealer, nor does it apply to any System that fails asa result of misuse, accident, improper installation, improper or inadequate maintenance, racing, neglect, or any use in an application or environment forwhich you know or should know the System is not designed or approved.

Who Makes this WarrantyThis warranty is made by Squires Turbo Systems, Inc., 165 N. 1330 W., Suite A4, Orem, Utah 84057, or by the authorized STS™ servicedealer who installed your System.Who is Covered

This warranty extends only to the original purchaser of the System for use on the motor vehicle on which the System originally isinstalled.What is Covered

This warranty covers defects in materials or workmanship in all parts of the System as originally installed on your vehicle. If the System is determined duringthe warranty period to be defective, and you comply with the terms of this Limited Warranty, an authorized STS™ service dealer or Squires Turbo Systems,Inc., as applicable, will replace any defective parts, or, if replacement is not commercially practicable or cannot be timely made, refund the original purchaseprice for the System. This warranty covers parts only. If Squires Turbo Systems, Inc. or its authorized STS™ service dealer performs any repair work or installsany replacement part for the System under this warranty, you may be charged for labor costs.

Where and How to Obtain Warranty ServiceYou can obtain warranty service from any authorized STS™ service dealer or directly from Squires Turbo Systems, Inc. It is your responsibility to deliver or shipthe defective System to an authorized STS™ service dealer or to Squires Turbo Systems, Inc. at your expense, together with a copy of your invoice or workorder and a description of the claimed defect prior to the expiration of the warranty period. To obtain information regarding the location of authorized STS™service dealers or other information regarding this warranty, you may call 1-866-WE-TURBO.

Exceptions and ExclusionsThis warranty is conditioned upon (i) proper installation and (ii) the vehicle and the System receiving reasonable and necessary maintenance during thewarranty period. The warranty does not cover any failure of the System that is caused by misuse, accident, racing, neglect, or any use in an application orenvironment for which you know or should know the System is not designed or approved.REPLACEMENT OF DEFECTIVE PARTS BY AN AUTHORIZED STS™ SERVICE DEALER, OR, IN APPLICABLE CIRCUMSTANCES, A REFUND OF THEPURCHASE PRICE OF THE SYSTEM, ARE THE SOLE REMEDIES AFFORDED UNDER THIS WARRANTY. IF ANY FAILURE OF THE SYSTEM CAUSESDAMAGE TO ANY OTHER PART OF YOUR VEHICLE OR INJURY TO ANY PERSON OR PROPERTY, THIS WARRANTY DOES NOT COVER SUCHDAMAGE OR INJURY.THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS ORIMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENTSHALL THE LIABILITY OF SQUIRES TURBO SYSTEMS, INC. RELATED TO THE SYSTEM EXCEED THE PURCHASE PRICE OF THE SYSTEM. SQUIRESTURBO SYSTEM, INC. SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES FOR CONSEQUENTIAL, INDIRECT, SPECIAL, OR INCIDENTALDAMAGES ARISING FROM OR IN CONNECTION WITH THE USE OF THE SYSTEM ON THE VEHICLE. (SOME STATES DO NOT ALLOW THEEXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TOYOU.)THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

LIMITED ONE-YEAR WARRANTY

Documents

STS Turbo C6 Z06 Corvette Manual