Always use fuel with a minimum octane rating of 93 (R+M)/2. (Equivalent to 98 RON).

Transcription

1 Before Commencing Installation Verify that you have all necessary tools as listed. Clean all air ducting prior to commencing installation. The sequence of installation of each part is very important. It needs to be carried out exactly as outlined in the instructions. Failure to do this will result in an unnecessary level of frustration. Always use fuel with a minimum octane rating of 93 (R+M)/2. (Equivalent to 98 RON). Always use an oil graded for use with gasoline turbocharged engines. Depending on your chosen application, an engine oil cooler and/or larger capacity radiator may be required. The APS turbosystem is primarily intended for installation by qualified technicians in fully equipped workshops. If this installation is attempted in a non-professional environment, all personal safety obligations rest with the individual(s) concerned. The minimum requirements (and by no means an exhaustive list) are: Well ventilated environment. Clean flat and level floor. High quality vehicle stands. Required Tools (1) Metric ¼ drive socket set c/w universal coupling 6 to 16 mm. 3/8 drive socket set c/w universal coupling 10 to 20 mm. Wrench open end/box combination 8 to 22 mm. Hex key 4 and 5 mm. (2) Imperial Wrench open end/box combination ½ to ¾. (3) General Screw driver set. Pliers flat, point, side cutter, multigrip. (4) Sealants Permatex ultra copper P/N 101BR. Permatex ultra grey P/N 599 BR. Page 1 of 57

2 Loctite thread sealer P/N 567. Preliminary - APS350Z-TTSS/09 Installation Guide 1 350Z Disassembly NOTE IT IS RECOMMENDED THAT THE FACTORY SERVICE MANUAL BE FOLLOWED WITH STOCK COMPONENT REMOVAL AND REPLACEMENT. Remove the retaining clips and screws and remove the front bumper. (If unsure of this procedure, you should use the factory service manual or have qualified personnel undertake the work). This is suggested as the first step since the vehicle is still mobile at this stage and the work can therefore be undertaken away from the actual turbosystem installation location. In addition, it reduces the likelihood of body damage to the vehicle while undertaking the mechanical work. 2 Remove the battery shroud and RHS false firewall cover. Disconnect the earth cable from the battery. 3 RAISE VEHICLE 4 Remove the plastic undertray from beneath the engine, along with the plastic vertical side panels, which run from the undertray to the frame rails. Retain for later use. 5 Remove plastic vertical front panels from aluminum bumper beam and discard. 6 Remove aluminum impact beam and retain. 7 Drain all the engine coolant, (retain for later re-use). The drain plug is in the bottom of the radiator. 8 Drain all the engine oil, (replace with new oil after installation completion) 9 Remove the front Y pipe of the stock exhaust system. 10 Remove the K-Frame. 11 Remove the catalytic converter support bracket from the bottom of the transmission. Remove the rear 02 sensors. 12 Remove both catalytic converters. 13 Remove the front 02 sensors from the exhaust manifolds. 14 Mark the upper/lower steering shafts with a straight alignment line made with a straight edge and marker pen. Loosen the clamp bolts on either end of the universal joint and remove that component. NOTE DO NOT ROTATE STEERING WHEEL OR FRONT WHEELS AFTER DISCONNECTING THE SHAFTS. Page 2 of 57

3 15 Drain power steering pump oil, (retain for later re-use). 16 LOWER VEHICLE 17 Remove the air ducting between throttle body and MAF meter and discard. 18 Remove the complete air cleaner/maf meter assembly and discard. 19 Remove the MAF sensor and screws from the MAF housing and retain for later use. 20 Remove the front strut tower brace and the cosmetic engine cover. 21 Release the front belt tensioner and unplug the wiring from the air conditioner compressor. Unbolt the airconditioning compressor and carefully lower. Note: Do not disconnect the airconditioning lines. 22 Disconnect the coolant hose from the coolant tube on the LHS of the engine bay as shown. Remove the hard coolant pipes as shown. Page 3 of 57

4 23 Remove the LHS exhaust manifold heat shield. Remove the RHS exhaust manifold heat shield. 24 Remove the oxygen sensors from the LHS and RHS exhaust manifolds. Page 4 of 57

5 25 Remove the LHS and RHS exhaust manifolds and all of the exhaust manifold studs. Hint: Crack the exhaust manifold retaining nuts loose and remove the exhaust manifold studs with the nuts. 26 Remove and discard the engine coolant drain plug from the LHS of the engine block. Apply thread sealant to the coolant fluid adaptor (Item 195) and install into the engine block. Page 5 of 57

6 27 Install 5 short stainless steel exhaust manifold studs (Item 92) and 1 long stainless steel exhaust manifold stud (Item 93) to the LHS head as shown. 28 Install 6 short stainless steel exhaust manifold studs (Item 92) to the RHS head as shown. 29 Install the stainless steel braided coolant supply hose (Item 196) with the 45 deg end facing forward and up for clearance to the airconditioning compressor. Install the air conditioning compressor. Check clearance to coolant hose. Page 6 of 57

7 30 Route the stainless steel braided coolant hose (Item 196) under the air conditioning compressor pipes and rearward between the engine mount and the inner fender panel. Tighten the coolant hose (Item 196) and remove the air conditioning compressor again. 31 Remove the two brackets shown from the RHS of the engine bay. Remove the plastic protective clip from the fuel line and disconnect the fuel hose. Page 7 of 57

8 32 Bend the fuel line shown upwards and reconnect the fuel hose and plastic protective clip. Page 8 of 57

9 33 Install the heat shield (Item 73) and retain with a bolt (Item 75), washer (Item 76) and aluminium spacer (Item 74). Secure the top of the heat shield with a stainless steel tie strap (Item 77). Page 9 of 57

10 Intercooler - APS350Z-TTSS/09 Installation Guide 1 Remove the stock power steering cooler. 2 Remove the stock steel power steering fluid lines and bracket shown. Page 10 of 57

11 3 Remove the stock horns, air bag sensor, temperature sensor and unclip the wiring harness. 4 Cut the air bag sensor support bracket as shown. Drill the protrusion in the centre radiator support as shown using a 1 3/6" drill. Use caution when drilling to avoid damage to the condenser core. Page 11 of 57

12 5 Remove the stock washer fluid canister and relocate the wiring loom above the washer bottle as shown. 6 Relocate the air bag sensor to the original horn mounting location. Retain using a 25mm SEMS bolt (Item 141). Relocate the air temperature sensor as shown and relocate the wiring connection to behind the radiator support panel. Page 12 of 57

13 7 Install the RHS intercooler support bracket (Item 130) and LHS intercooler support bracket (Item 129). Retain using bolts (Item 131), flat washers (Item 133) and star washers (Item 132). Note: Do not tighten mounting bolts. 8 Install the intercooler assembly (Item 127) onto the two side intercooler support brackets. Retain using 20mm SEMS bolts (Item 120). Note: Do not tighten mounting bolts. 9 Install the centre intercooler support bracket (Item 128) on the stock hood latch as shown and retain using the stock bolt. Insert the 16mm SEMS bolts (Item 134) into the intercooler mounting holes. Note: Level the intercooler and tighten the mounting bolts. Page 13 of 57

14 10 Reconnect the stock power steering fluid hoses using the stock hose clamps and stock hose joiners. Support the power steering fluid hoses using cable ties around the power steering hoses and the stock earth lead underneath the hoses. Page 14 of 57

15 Oil Pan - APS350Z-TTSS/09 Installation Guide 1 Drain the engine oil. 2 Carefully remove the stock oil pan. Remove and discard the oil baffle (if fitted from stock) as shown. Remove the stock oil pickup unit. Page 15 of 57

16 3 Reinstall the oil pickup using the new O-rings (Item 181), spacer (Item 180), washers (Items 184 and 183) and bolts (Item 182). Note: Orientation. 4 Apply thread sealant to the return oil fittings (Item 173) and install into the APS oil pan (Item 174) as shown. Install the drain plug (Item 178) and drain plug washer (Item 179) Page 16 of 57

17 5 Apply sealant to the APS oil pan (Item 174) and install onto engine. Retain using 4 long bolts (Item 176) and 6 short bolts (Item 175) with washers (Item 177). Exhaust Manifolds & Turbochargers - APS350Z-TTSS/09 Installation Guide 1 Remove the starter motor in accordance with the factory service manual. Page 17 of 57

18 2 Using a rubber hammer, bend the stock engine mount heat shield downwards. 3 Secure the LHS exhaust manifold heat shield (Item 97) to the LHS exhaust manifold (Item 90) using a 12mm long 6mm stainless steel hex bolt (Item 99) and a 20mm x 6mm stainless steel body washer (Item 101). By applying gentle pressure to the heat shield, mould the heat shields around the LHS exhaust manifold. Repeat the process with the RHS heat shield (Item 98) and the RHS exhaust manifold (Item 91). Remove the heat shields as they will be installed at a later stage. Page 18 of 57

19 4 Install the turbocharger flange 8mm x 33mm stainless steel studs (Item 95) and the wastegate flange 6mm 30mm stainless steel studs (Item 102) to each exhaust manifold (Items 90 & 91). 5 Install the stock exhaust manifold gasket to the LHS cylinder head and install the LHS exhaust manifold (Item 90). Retain using the 10mm flanged nuts (Item 94). Repeat the process with the RHS exhaust manifold (Item 91). Page 19 of 57

20 6 Reinstall the heat shields (Items 97 & 98) that were formed earlier onto the exhaust manifolds (Items 90 & 91). Retain using 12mm long 6mm stainless steel hex bolts (Item 99) and 20mm x 6mm stainless steel body washers (Item 101). 7 Reinstall the stock engine coolant pipe over the LHS exhaust manifold. Page 20 of 57

21 8 Reinstall the air conditioning compressor. Apply firm pressure to the air conditioning line shown and bend in towards the timing cover. Check clearances as noted in the image. Reinstall and retension the air conditioning belt. 9 Install the five 8mm x 28mm stainless steel studs (Item 70) into the RHS turbocharger's (Item 36) turbine housing. Install the stainless steel braided oil supply hose (Item 189). Ensure that the hose is orientated towards the compressor housing as shown. Retain using 12mm washer (Item 186), 11mm washer (Item 187) and banjo bolt (Item 185). Page 21 of 57

22 10 Install the five 8mm x 28mm stainless steel studs (Item 70) into the LHS turbocharger's (Item 35) turbine housing. Install the stainless steel braided oil supply hose (Item 188). Retain using 12mm washer (Item 186), 11mm washer (Item 187) and banjo bolt (Item 185). Ensure that the 45 deg banjo fitting is orientated up towards the turbine entry flange. 11 Apply sealant to the LHS turbocharger (Item 35) entry flange and install onto the LHS exhaust manifold (Item 90). Retain using 8x10 mm selfloc nuts (Item 96). Repeat for RHS turbocharger (Item 36) installed on RHS exhaust manifold (Item 91). Page 22 of 57

23 12 LHS turbocharger: Install the oil drain (Item 165) and gasket oil drain gasket (Item 167) onto the LHS turbocharger. Retain using two 8mm x 16mm SEMS hex bolts (Item 168). Install the two coolant line straight adaptors (Item 197) and 14mm x 20mm copper washers (Item 179). Install the centre coolant hose (Item 198) and outer coolant hose (Item 196). Page 23 of 57

24 13 Route the centre coolant hose (Item 198) around the rear of the APS oil pan (Item 174). Support the coolant hose using two hose support clamps (Item 192). 14 RHS turbocharger: Install the oil drain (Item 165) and gasket oil drain gasket (Item 167) onto the RHS turbocharger. Retain using two 8mm x 16mm SEMS hex bolts (Item 168). Install the centre banjo fitting (Item 199) facing downwards and retain using a copper washer (Item 179) on each side and a banjo bolt (Item 200). Install the centre coolant line to the banjo fitting. Install the outer banjo fitting facing upwards and retain using a copper washer (Item 179) on each side and a banjo bolt (Item 200). Install the RHS outer coolant line (Item 201) to the banjo fitting. Page 24 of 57

25 15 Remove the stock coolant bleed tee-piece from the heater hose located near the RHS firewall. Install the new tee-piece (Item 202) and retain with the stock hose clamps. Page 25 of 57

26 16 Pass the RHS outer coolant hose (Item 201) up from the banjo fitting on the RHS turbocharger and install onto the tee-piece (Item 202) installed previously. Page 26 of 57

27 17 Install the LHS turbocharger drain hose (Item 169) between the LHS turbocharger drain fitting (Item 165) and the LHS oil pan drain fitting (Item 173). Note: Flow direction marked on the drain hose (Item 169) to the oil pan. Retain hose using hose clamps (Item 172). Page 27 of 57

28 18 Install the RHS turbocharger drain hose (Item 171) between the RHS turbocharger drain fitting (Item 165) and the RHS oil pan drain fitting (Item 173). Note: Flow direction marked on the drain hose (Item 171) to the oil pan. Retain hose using hose clamps (Item 172). Page 28 of 57

29 Ducting - APS350Z-TTSS/09 Installation Guide 1 Remove the air conditioning pipe support bracket. Carefully bend the air conditioning pipe towards the LHS chassis rail. 2 Install the LHS silicon connection hose (Item 7) to the LHS turbocharger compressor inlet and retain using a 50mm/70mm hose clamp (Item 11). Loosely place another 50mm/70mm hose clamp (Item 11) over the other end of the hose in readiness for the installation of the relevant duct. Note: The orientation of the hose clamps (as shown) is important for future access. Page 29 of 57

30 3 Install the LHS compressor outlet duct (Item 115) onto the LHS turbocharger using a flange gasket (Item 118) and retain using three 6mm x 20mm SEMS bolts (Item 120). Ensure that the outlet duct is vertical at the front of the engine bay. Allow approximately a 5/64" gap between the LHS compressor outlet duct and the engine coolant hose as shown. Page 30 of 57

31 4 Apply lubricant to the LHS silicon compressor inlet hose (Item 7) installed previously. Install the compressor inlet duct (Item 8) into the silicon hose (Item 7) using a rotating motion whilst feeding the duct into the silicon hose and tighten the hose clamp (Item 11). Check the clearance of the inlet duct (Item 8) to the LHS inner fender as shown and tighten the hose clamp (Item 11) from underneath. Page 31 of 57

32 5 Replace the stock hex head power steering reservoir bracket bolts (located on the RHS strut tower) with 6mm x 25mm B/H cap screws (Item 117). 6 Carefully bend the power steering pipe shown towards the power steering pump pulley. Ensure that there is 1/8" - 3/16" clearance between the pipe and pulley. Page 32 of 57

33 7 Install the RHS silicon connection hose (Item 7) to the RHS turbocharger compressor inlet and retain using a 50mm/70mm hose clamp (Item 11). Loosely place another 50mm/70mm hose clamp (Item 11) over the other end of the hose in readiness for the installation of the relevant duct. Note: The orientation of the hose clamps (as shown) is important for future access. 8 Apply lubricant to the RHS silicon compressor inlet hose (Item 7) installed previously. Orientate the RHS intake duct (Item 9) with the entry facing above and towards the opening in the RHS chassis rail. Install the compressor inlet duct (Item 9) into the silicon hose (Item 7) using a rotating motion whilst feeding the duct into the silicon hose and tighten the hose clamp (Item 11). Note: Position of wiring, earth lead and coolant hose. Page 33 of 57

34 9 Install the RHS compressor outlet duct (Item 116) onto the RHS turbocharger using a flange gasket (Item 118) and retain using a socket head cap screw (Item 119), a 6mm stainless steel star washer (Item 153) and a 6mm flat washer (Item 148) as shown - along with two 6mm x 20mm SEMS bolts (Item 120) as shown. Note the position of the wiring looms as shown. Note that the clearance to the power steering pipe previously bent should be tight. Page 34 of 57

35 10 Lubricate the stock O-ring and reinstall the stock water pipe at the RHS of the engine and under the RHS compressor outlet duct (Item 118). Ensure that all coolant hoses are fitted. Retain using the stock bolt to the RHS compressor outlet duct. 11 Reinstall the stock earth leads. Page 35 of 57

36 Turbochargers - APS350Z-TTSS/09 Installation Guide 1 Remove the stock alternator support bracket. 2 Unplug and remove the stock oil sender unit. Apply thread sealant and install the oil supply Tee-Piece (Item 190) ensuring that the orientation is as shown. Install the stock oil pressure sender unit and the adaptor fitting (Item 191) as shown. Reinstall the alternator support bracket. Page 36 of 57

37 3 Install the LHS turbocharger oil supply hose (Items 188). Route the hose around the front of the engine as shown and support the hose using two hose support clamps (Item 192) from the stock coolant pipe as shown. Retain using a nut and bolt (Items 193 & 194). Install the RHS oil supply hose (Item 189) as shown and route the hose over the RHS cross member as shown. Page 37 of 57

38 4 Unplug the stock knock sensor plug from the knock sensor harness. Unclip the knock sensor harness plug from the knock sensor harness plug support bracket. Unbolt and remove the stock knock sensor harness support bracket. Route the knock sensor plug over the main wiring loom and plug the knock sensor back into the knock sensor harness plug. Page 38 of 57

39 5 Reroute the stock oxygen sensor wiring loom to a position above the main wiring harness support bracket. 6 Wrap the stock wiring loom that is located down beside the RHS of the gearbox with the firesleeve (Item 45). Use the stainless steel ties (Item 44) to retain the firesleeve on the wiring loom. Support the fire sleeve/loom using a hose support clamp (Item 46). 7 Apply appropriate exhaust header heat wrap (Not Included) to the wastegate pipes (Items 37 & 38). Page 39 of 57

40 8 Apply high temperature nonhardening sealant to the RHS wastegate-to-manifold flange and install using 6mm washers (Item 103) and 6mm nuts (Item 104). Do not tighten yet. Apply high temperature nonhardening sealant to the turbocharger exhaust mounting flange of the RHS turbocharger outlet pipe (Item 79). Retain using copper nuts (Item 72) and washers (Item 71). 9 Install wastegate (Item 39) using studs (Item 40), washers (Item 41) nuts (Item 42 bolt (Item 43) in order to align wastegate pipe. Then tighten all relevant nuts and bolts. Install the stock Oxygen sensor to the turbocharger outlet pipe. Page 40 of 57

41 10 Apply high temperature nonhardening sealant to the LHS wastegate-to-manifold flange and install using 6mm washers (Item 103) and 6mm nuts (Item 104). Do not tighten yet. Apply high temperature nonhardening sealant to the turbocharger mounting flange of the LHS turbocharger outlet pipe (Item 78). 11 Install the wastegate (Item 39) to align the wastegate pipe. Then tighten all relevant nuts and bolts. Hint - tighten the wastegate pipe to manifold nuts from above. 12 Install the stock O2 sensor. Hint Install from above. 13 Grind the steering shaft universal joint as shown in order to clear the LHS turbine housing as the steering shaft rotates. Reinstall the steering shaft universal joint. Ensure that the steering shaft is free to turn - paying particular attention to the clamping bolt clearance. A dome head bolt may be required to provide additional clearance. NOTE: '06 model is not compatible. Page 41 of 57

42 14 Install the stock starter motor and retain using the stock mounting hardware. 15 Install the molded breather hose (Item 19) using 16mm spring hose clamps (Item 20) and a 16mm joiner (Item 18) as shown. Page 42 of 57

43 16 Assemble the air filters (Item 1) with the mounting brackets (LHS Item 2, RHS Item 6) and retain using 60/80 mm clamp (Item 21). Install the air cleaner hoses (Item 10) to the air filter assemblies and retain using 50/70 mm hose clamps (Item 11). 17 Remove the stock washer bottle filler tube situated at the front RHS of the engine bay. Feed the RHS air filter hose (Item 10) onto the RHS compressor inlet duct (Item 9) as shown. Retain using a 50/70mm hose clamp (Item 11). Page 43 of 57

44 18 Bend the air filter support bracket and mount to the inner fender bolt as shown. Mount the air filter as far forward as possible. This may require repositioning of wiring looms in the area. Reinstall the stock washer bottle filler tube. 19 Feed the LHS air filter assembly hose onto the LHS compressor entry duct and retain using 50/70 mm hose clamp (Item 11). Support the air filter assembly by fastening the air filter support bracket to the radiator support panel as shown and retain using a 6mm x 20mm SEMS bolt (Item 3), 6mm washer (Item 4) and 6mm nyloc nut (Item 5). Page 44 of 57

45 Impact Beam & Ducting - APS350Z-TTSS/09 Installation Guide 1 Place the bumper beam template (Item 155) on the top of the bumper beam and mark the area to be cut. Cut the bumper beam as shown. Fabricate and weld in new panels to replace those that were cut out. Note that the tow point also requires to be modified (narrowed). Page 45 of 57

46 2 Turn the modified impact beam over (underside) and measuring from the forward and RHS faces, mark the position of the power steering cooler mounting bracket holes. Drill 5/16 diameter holes into the underside of the impact beam. Note: The power steering cooler will be installed at a later stage. Page 46 of 57

47 3 Trim the stock horn bracket as shown. Install horn using the stock mounting bolt. Install the other horn onto the top-centre intercooler mounting bracket (Item 128) as shown. Retain using 6mm x 16mm SEMS bolt (Item 134). Page 47 of 57

48 4 Install the front impact beam. Page 48 of 57

49 5 Install the LHS intercooler entry duct (Item 123) using a 70mmID x 65mm silicon joiner hose (Item 125) and retain with two 60/80mm hose clamps (Item 126) as shown. 6 Install the RHS intercooler entry duct (Item 124) using a 70mmID x 65mm silicon joiner hose (Item 125) and retain with two 60/80mm hose clamps (Item 126) as shown. Note: The power steering cooler will be installed at a later stage. Page 49 of 57

50 7 Connect the LHS intercooler entry duct (Item 123) to the LHS compressor discharge duct (Item 115) using a 50mmID/63mm x 70mm silicon joiner hose (Item 121) and retain with a 40/60mm hose clamp (Item 122) and a 60/80mm hose clamp (Item 154). Repeat the above process to connect the RHS intercooler entry duct (Item 124) to the RHS compressor discharge duct (Item 116). 8 Install the power steering cooler support brackets (Item 146) to the RHS underside of the impact beam using 6mm x 20mm SEMS bolts (Item 120), 6mm nyloc nuts (Item 149) and 6 mm flat washers (Item 148). Use two hose support clamps (Item 147) as shown to support the power steering cooler and retain using 6mm x 20mm SEMS bolts (Item 120), 6mm nyloc nuts (Item 149) and 6 mm flat washers (Item 148). Page 50 of 57

51 9 Connect the100mm long hose (Item 56) to the LHS wastegate boost port. Retain with a spring hose clamp (Item 59). Connect the 300mm long hose (Item 57) to the RHS wastegate boost port. Retain with a spring hose clamp (Item 59). Connect the other hose ends to the tee-piece (Item 58) and retain with spring hose clamps (Item 59). Connect the 1400mm long hose (Item 55) to the teepiece as shown and retain with a spring hose clamp (Item 59). Route the 1400mm long hose (Item 55) over the LHS of the front crossmember. 10 Install the stock MAF sensor to the throttle body duct (Item 137) using the stock mounting screws. Page 51 of 57

52 11 Connect the blow off valve (BOV) (Item 12) to the BOV outlet hose (Item 14) using 25/40mm hose clamps (Item 15). Connect the BOV & Hose assembly to the LHS compressor inlet duct using a 25/40mm hose clamp (Item 15). Install the BOV inlet hose (Item 13) to the BOV using a 25/40mm hose clamp (Item 15). Lower the throttle body duct (Item 137) into position and connect the 1400mm long vacuum hose (Item 55) routed from the wastegates to the barb on the throttle body duct (Item 137) and retain with a spring hose clamp (Item 59). Page 52 of 57

53 12 Install the intercooler outlet hose (Item 135) and retain with a 80/100mm hose clamp (Item 136) at the intercooler outlet end and a 70/90mm hose clamp (Item 138) at the throttle body duct (Item 137) end. 13 Install the throttle body duct (Item 137) to the stock throttle body using 70/90 mm hose clamps (Item 138) and an 80mmID x 57mm silicon joiner hose (Item 139). Retain the throttle body duct (Item 137) to the front timing cover boss using a Teflon washer (Item 140) on each side of the bracket, a body washer (Item 142) on each side and a 6mm x 25mm SEMS bolt. Page 53 of 57

54 14 Trim the stock bumper support bracket for clearance to the intercooler outlet hose (Item 135). Apply a 4" long strip of protective rubber edging along the contact area between the bumper support bracket and the intercooler outlet hose (Item 135). Install the bumper support bracket and retain using the stock mounting hardware. 15 Install the right angle barb fitting into the coolant overflow canister. Install the radiator coolant overflow canister (Item 150) by inserting the mounting flange between the metal panel lip and the plastic cover as shown. Page 54 of 57

55 16 Install the coolant overflow hose onto the barb fitting at the base of the coolant overflow canister. Retain the coolant overflow canister with the stock mounting bolts as shown. 17 Remove the stock PCV hose. Using the image as a guide, cut a short section of hose equivalent to the main body length of the APS one-way valve (Item 22). Then install the one-way valve (Item 22) using the spring clips provided (Item 23) as shown (NOTE direction of arrow on one-way valve). Page 55 of 57

56 18 Place and align the bumper bar template (Item 156) onto the underside of the lowest air entry styling fin as shown. Trim the bumper bar fin as shown. Turn the template over and align onto the other side of the air entry styling fin and repeat the trimming process. Completion of Installation - APS350Z-TTSS/09 Installation Guide 1 Re-fill engine with oil. Due to the enlarged oil pan capacity, this will take 5.0 quarts, without oil filter. Check level on dip stick. This should be at the low level line. This is correct, as the pan floor/pump pickup has been lowered 12.0 mm. Do not over or under fill! Below 0 F ambient temperature, use SAE 5W-40 or 5W-50. Over 0 F ambient temperature use SAE 10W-40 or SAE 10W-50. Ensure the oil grade utilized is suitable for use with gasoline turbocharged engines. 2 Re-fill power steering system with its previously drained oil. 3 Bleed the engine cooling system NOTE IT IS CRITICAL THAT THE FOLLOWING PROCEDURE BE FOLLOWED EXACTLY! IT IS TIME CONSUMING, HOWEVER, ESSENTIAL! 1. Remove water return line (Item 166) from Tee piece (Item 167) in stock upper heater hose. 2. Fill radiator and coolant recovery reservoir (Item 126), with anti freeze coolant. It should take 10 quarts, including reservoir. It is important that the coolant is poured through the radiator filler neck at less than 1.5 quarts per minute, in order to allow air in the system to escape. 3. When the engine coolant overflows the connection at the Tee piece (Item 167), re-install water hose (Item 166) and tighten the connection. Page 56 of 57

57 4. Warm the engine to the normal operating temperature with the radiator cap installed. 5. Run the engine at 3,000 RPM for 10 seconds and then allow it to return to idle speed. 6. Repeat the above steps three times. 7. Stop engine and allow coolant temperature to drop below 120 F. o o Use a remote electric fan to assist in this process. If necessary, refill the radiator and reservoir up to the filler neck. Repeat steps 3 to 7 at least two more times (it may take more) with the radiator cap installed, until the engine coolant level no longer drops. 4 Check the cooling system for leaks with the engine running. Remember, water now runs through both turbochargers. 5 Fully warm the engine and listen for the sound of coolant flow through the heater unit, inside the car; while running the engine from idle to 3,000 RPM, with the heater control set at several positions between cool and warm. Repeat this action three times. If any sound is heard, continue to bleed excess air from the cooling system, by repeating steps 3 to 7 until the coolant level no longer drops. NOTE This procedure can be most frustrating; however it is a function of the stock cooling system design and has nothing to do with the APS turbosystem. It must be carried out identically with a totally stock vehicle! 6 The Accelerator Pedal Released Position/Butterfly Valve Closed Position Learning operation must be performed whenever the harness connector to the Drive By Wire butterfly assembly or stock computer has been unplugged. This is a standard Nissan requirement 1. Make sure that the accelerator pedal is fully released 2. Turn the ignition switch to the ON position and wait at least two seconds. 3. Turn the ignition switch to the OFF position and wait at least ten seconds. 4. Turn the ignition switch to the ON position and wait at least two seconds. 5. Turn the ignition switch to the OFF position and wait at least 10 seconds. 7 Verify that all hose clamps are tightened 8 Verify all components which are affected by engine movement have sufficient clearance to adjacent body panels. 9 Verify there are no oil, water or most importantly fuel leaks in either the engine compartment or on top of the fuel pump / sender unit. Replace the trim cover. 10 After a final check for fluid leaks, replace the cosmetic engine cover, strut tower brace and front bumper. Then replace the plastic undertray. Page 57 of 57