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INSTALLATION INSTRUCTIONS
TURBOCHARGER SYSTEMS:
2004- Scion TC
Manual Transmission Only
P/N 15152 (No Catalytic Converter)
Turbonetics, Inc. * 2255 Agate Court * Simi Valley, CA * 805-581-0333 * TurboneticsInc.com
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READ THIS FIRST: Study these instructions completely before proceeding. Engine and/or turbocharger damage may occur if any component within these instructions is improperly installed. Turbonetics, Inc or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation. This complete turbocharger system can be installed using common tools and automotive procedures, but installer must have a thorough knowledge of automotive engine operation
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TORQUE RECOMMENDATION: When removing and re-installing factory fasteners, refer to the Toyota / Scion service manual for torque values. When installing fasteners included in this kit, refer to the following chart: Fastener Torque Torque Size (Pound-Feet) (Newton-Meters) 1/4" or 6mm 10 13 5/16” or 8mm 19 25 3/8” or 10mm 33 45 NPT fittings 2-3 turns past finger tight TURBOCHARGER SYSTEM PARTS LIST: QTY P/N DESCRIPTION P/N 15152 1 11118 Turbocharger, E50 / Stg.2 / Ball
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QTY P/N DESCRIPTION QTY P/N DESCRIPTION HOSES / CLAMPS PARTS LIST: 2 30128-4 Silicone Hose Coupling, 2.0” 1 30444-4 Silicone 45’ Elbow, 2.50” 1 30162-4 Silicone Hose Coupling, 3.0” 3 ft. 30827 Hose, Oil Drain – 5/8” 1 30172-4 Silicone Hose Coupling, 2.50” 1 31072-4 Silicone Hose Coupling, 1.50” 1 21364 Silicone Hose Coupling, 2.50” 4 30275-200 T-Bolt Clamp – 2.0” x 6.50” long 8 30275-250 T-Bolt Clamp – 2.50” 1 30380-4 Silicone Hump Connector, 2 30275-300 T-Bolt Clamp – 3.00” 2.
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P/N 11118 P/N 5-340 P/N 10781 P/N 10843 P/N 11124 P/N 21238 P/N 11126 P/N 21241 P/N 21240 P/N 21242 P/N 21239 60133 revG Page 5 of 38
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P/N 21243 P/N 31040 P/N 21279 P/N 21286 P/N 31080 P/N 60133 60133 revG Page 6 of 38
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Prepping the Vehicle for Turbo Kit Installation 1. Jack up the vehicle to a workable height and secure vehicle with jack stands. SEE FIGURE 1 FIGURE 1 2. Using a 10mm socket, remove undercarriage plastics splash guard. SEE FIGURE 2 & 3 FIGURE 2 FIGURE 3 Removing the Front Fascia 1. Using a 10mm socket, remove the bolt inside the fender well. SEE FIGURE 4 & 5 FIGURE 4 FIGURE 5 60133 revG Page 7 of 38
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2. Using a small flat head screwdriver, carefully insert the screwdriver in the indented slot on the plastic trim clip and pry upwards. SEE FIGURES 6, 7, & 8 FIGURE 6 FIGURE 7 FIGURE 8 3. Remove front fasica by pulling it forward 4. Remove foam bumper reinforcement. SEE FIGURE 9 FIGURE 9 5. Remove plastic air dams on each side of the vehicle. Air dams are secured to the vehicle with the plastic trim clips that can easily be removed by using
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FIGURE 10 Exhaust Disassembly 1. Unplug O2 sensor and remove the plastic securing ring that holds the wire to the radiator hose. SEE FIGURE 11 FIGURE 11 2. Remove the cosmetics plastic engine cover by unscrewing two 10mm nuts. SEE FIGURE 12 FIGURE 12 60133 revG Page 9 of 38
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3. Remove the factory exhaust head shield by unscrewing the three 12mm bolts and one 12mm nut. SEE FIGURE 13 & 14 FIGURE 13 FIGURE 14 Note: Careful while removing the heat shield, it tends to get caught up with the O2 sensor and other things in the area. 4. Unscrew the O2 sensor with a 7/8” open end wrench or with a O2 sensor socket. SEE FIGURE 15 FIGURE 15 5. Using a 14mm socket, remove the stock catalytic converter support brackets. SEE FIGURE 16 & 17
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6. Unbolt spring loaded bolts that connects the stock catalytic converter to the down pipe. SEE FIGURE 18 FIGURE 18 7. Save the exhaust crush ring gasket, this will be used when installing the new supplied down pipe. 8. Remove the five bolts that hold the stock exhaust manifolds to the head with a 12mm wrench. SEE FIGURE 19 FIGURE 19 Stock Intake Disassembly 1. Unplug the mass air sensor and remove the two Phillips screws that mounts the sensor to the factory air box. S
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2. Carefully lift the mass air sensor out of the factory air box and set it aside. You will be re-installing the sensor on a supplied intake pipe at a later time. 3. Remove the engine breather hose by pinching the tabs on the hose clamps with your finger or a pair of pliers and push the clamp away from the motor. SEE FIGURE 21 FIGURE 21 4. Loosen hose clamp that connects the intake tube to the air box. SEE FIGURE 22 FIGURE 22 5. Remove the factory intake tube that connect
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6. Remove the sensor that is mounted to the factory intake tube by inserting a small flat head screwdriver between the sensor bracket and the intake tube bracket. SEE FIGURE 24 FIGURE 24 7. Remove the factory air box by unbolting the three 10mm bolts inside. SEE FIGURE 25 FIGURE 25 8. Remove the factory cold air intake tube by unscrewing the Phillips screw that mounts the factory cold air intake tube to the body. There is another Phillips screw that holds the tube to the
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Fuel System Upgrade 1. Cut the vacuum hose that connects to the throttle body in half and install the supplied T-fitting in the orientation. SEE FIGURE 27 & 28 FIGURE 27 FIGURE 28 2. Unplug the four factory injectors by squeezing the tab on the side of the plugs and pulling upwards. 3. Disconnect the plug to the VVTi actuator by the passenger side of the fuel rail. 4. Unbolt both 12mm nuts that holds the fuel rail to the head. SEE FIGURE 29 FIGURE 29 5. Remove
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6. Remove stock fuel injectors from the fuel rail. Careful not to lose any of the o-rings when removing them. 7. Connect the new supplied injector pig tails to the factory harness by cutting the stock injector connector plugs off the factory harness. Cut wires around 2 ¾” from the edge of the connector, leaving enough wire length to connect the new plugs. SEE FIGURE 31 FIGURE 31 8. Crimp the new supplied connectors to the factory harness. Make sure the polarities are corre
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9. Remove the o-rings from both the top and bottom of the stock injector and install them on the new supplied injectors (P/N 21382). SEE FIGURE 34, 35, & 36 FIGURE 34 FIGURE 35 UPGRADE STOCK SUPPLIED INJECTOR P/N #21382 STOCK SUPPLIED FIGURE 36 10. Slightly coat the outside of both o-rings with grease to ease installation of the injectors to the head and the rail. 11. Carefully insert the injector to the bungs on the head making sure the o-rings doe
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Installing Turbo Oiling System Turbo Oil Feed 1. Locate the oil sending unit on the driver’s side of the head. On top of the radiator hose connection. SEE FIGURE 37 FIGURE 37 2. Unplug the wires that are connected to the sensor and using a 24mm socket, remove the sensor from the head. 3. Re-tap the threaded hole using the supplied 1/8-27 NPT tap. Make sure you coat the tap with a lot of grease so no chips from the re-thread will enter the motor. 4. Apply a small amou
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Turbo Oil Drain 1. Using the supplied center punch (P/N #21273) and a hammer, punch a hole through the oil pan. Do not use a drill, by using a center punch, the material that bends over is used for threading. SEE FIGURE 39, 40, & 41 FIGURE 39 ~1.0” ~2.25” FIGURE 40 FIGURE 41 2. Coat the supplied 3/8” NPT tap (P/N #30809) with grease to insure no metal debris will enter the pan and tap the hole you just made. SEE FIGURE 42 FIGURE 42 60133
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3. Apply a small amount of high temp RTV to the threads of the supplied 3/8” NPT to 5/8” barb brass fitting (P/N #30133) and the threads in the oil pan as shown in the picture below. Thread the fitting into the pan and tighten. SEE FIGURES 43, 44, & 45 FIGURE 43 FIGURE 44 FITTING P/N #30133 FIGURE 45 Assembling the Turbo and Mounting it to the Manifold 1. Thread the four supplied M10x1.25 studs (P/N #30806) onto the turbo mounting pad on the manifold. SEE FI
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2. Slide the supplied turbo inlet gasket (P/N #30263) onto the four studs and mount turbocharger onto the manifold as shown in picture 47. 3. Secure the turbocharger to the manifold using the supplied flat washer (P/N #30804), lock washer (P/N #30805), and nut (P/N #30803), in those respective order. SEE FIGURE 47 FIGURE 47 4. Install the supplied oil drain flange (P/N #20259) to the turbocharger with a supplied oil drain gasket (P/N # 30141)in the middle. Secure the flange
