What's in the Box
Installation
1
Remove panel between the seats that allows access to the turbocharger.
2
Remove and label pressure lines from the boost control solenoid going to the wastegate actuator, intake, and air box.
3
Remove the worm drive clamp holding the intake tube onto the turbo.
4
Remove the worm drive clamp on the top of the air box.
5
Using a 13mm socket remove the 2 bolts behind the driver seat holding the air box to the firewall.
6
Remove the worm drive clamps or t-bolt clamps holding the charge tubes to the intercooler.
7
Using a 10mm socket, remove the fasteners (4) holding the intercooler in place. Be sure to unplug the intercooler fan. Remove intercooler assembly from vehicle.
8
Remove the nut on the V-band clamp holding the exhaust onto the turbo.
9
Remove the worm drive clamps holding the heat shielding on to the mid-pipe. Remove heat shields from mid-pipe.
10
Remove oil drain line from turbocharger by cutting the OEM clamp.
11
Remove the charge tube from the turbo outlet.
12
Remove oil supply line from top of the turbocharger.
13
Remove the nut securing the water line to the bottom of the exhaust manifold.
14
Using soft grip vise grips or hose clamps pinch off the soft coolant lines that supply and return water to the turbo.
15
Remove the OEM clamps holding the soft coolant line to the hard line on top and bottom. Using a side cutter, cut clamps securing soft water lines to the hard lines.
16
Remove socket head cap screw securing hard water lines to turbocharger and remove the hard line.
17
Remove bolts securing exhaust manifold heat shields – lower heat shield can be removed. Upper heat shield must stay on until the turbo is loose.
18
Using a 10mm socket or T40 Torx remove the fasteners holding the exhaust manifold to the engine and remove the turbo from the vehicle.
19
Remove oil pressure sensor and OEM oil line (be sure to save the copper washers).
1
Slide supplied fire sleeve over the supplied oil hose. Reinstall oil pressure sensor through the banjo side of the EVP oil supply hose. Re-use copper washers (install a copper washer on both sides of the banjo fitting).
2
Install the provided stud into the top hole of the center exhaust port, thread stud in and back it one full turn (See Fig. 1).
3
Reinstall the OEM exhaust gasket and install new turbo charger, reusing OEM fasteners.
4
Torque (2) of the retaining screws to 44 in-lb. (about 4 ft-lb), following the order shown in Figure 2.
5
Torque retaining bolts to 17 ft-lb, following the order shown in Figure 3. On the final torque sequence use a 4mm Allen wrench and hold stud while tightening copper nut with 10mm wrench to 17 ft lbs. as you can. (Make sure you have at least 2 threads protruding from nut.).
6
Connect the oil line to the fitting on the top of the turbo and tighten it.
7
Reconnect the oil drain and use a 27mm pinch clamp to secure the oil line onto the turbo charger.
8
The OEM hard coolant line attachment bracket needs to be cut it in the center of the 2 cooling ports (See Fig. 4).
9
Now that the line bracket is cut, be sure to put the new supplied O-rings on the coolant fittings. Use supplied retaining bracket to secure the turbo.
10
Connect the soft coolant hoses to the hard lines installed in step 9. Secure with 18mm pinch clamps.
11
Install the new upper charge tube onto the turbo.
12
Install EVP intake plenum (optional).
13
Reinstall the intercooler and connect the charge tubes and intercooler fan.
14
Connect the new V-flow to the air box and reinstall the air box to the firewall. Tighten the clamps on the v-flow. (See V-flow instructions for further detail).
15
Connect the 3 lines from the boost control solenoid to their corresponding locations.
16
Reinstall exhaust - be sure to install the EVP supplied heat shield for the turbo exhaust housing. Additional heat shielding may be required. It is up to the customer and/or installer to determine what additional shielding may be required.
1
Remove plastics covering fuel tank. See picture below for location.
2
Unplug electrical connector going into the top of the pump.
3
Unhook fuel hose by removing the red clip from the connection. Then push down on the fitting while pushing in on the back side of the fitting – then lift the fitting off the pump assembly.
4
Rotate pump assembly cap counterclockwise and remove. Remove assembly. (see the pictures on the next few pages for clarification).
5
With the fuel pump on a workbench and all the fuel drained out of the pump assembly, press in on the tabs to release the housing covering the tank.
6
Install fuel pump assembly back into tank in the reverse order from its removal.
7
Install the EVP supplied fuel pump into the plastic housing that was removed in.
5
On the previous page. Make sure the pump is oriented and fitted correctly into the bottom of the housing - when properly oriented, the pump will drop into place and it will not rotate.
8
Plug the electric connection into the pump.
9
Carefully align the tabs and reinsert the cap into the housing – do not force it – if it does not fit in with moderate pressure, something is not correct – recheck. See picture below of fuel line and electrical connection.
10
Reinstall pump assembly.
11
Install EVP Plug-N-Play fuel pump relay harness.
12
Connect the yellow wire with the ring terminal and the relay to one of the bolts that secure the fuel pump protector strap to the frame. Make sure the ring terminal is grounded to the frame.
13
Replace OEM fuel pump fuse with the supplied 20 amp in location F5.
1
Replace the 2 OEM map sensors with the EVP supplied sensors: One sensor is located on the plastic intake manifold plenum. The second sensor is located on the throttle body.
2
For the throttle body map sensor use the supplied adaptor harness to make the electrical connection. NOTE: It is possible to install the map sensor adapter harness to the OEM plug rotated 180-degrees. If you are getting MAP sensor codes or the vehicle is not running correctly, please check this.
3
Tighten the 2 OEM clamps that secure the throttle body – this WILL pop off if not tightened.
Note: This product is exempt from the emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code§§ 27156 and 38391]. This product is sold only for use in connection with EPA certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/that purchase this product represent and warrant that the product is purchased only in connection with EPA -certified, emission-regulations-exempt and noise- regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.