98-02 LS1 F-Body Instruction Manual

Transcription

1 98-02 LS1 F-Body Instruction Manual Squires Turbo Systems, Inc. * Copyright 2005

2 98-02 LS1 F-Body Congratulations 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 remote mounted Squires Turbo System. The installation is a straightforward process, but it is critical that you read through all of the instructions. If you do have any issues during the installation process, please contact your local STS Power Dealer where you purchased the system. If they are not available please call our customer service department at 866-WE- TURBO. We appreciate your business and would like to hear from you regarding your experience with the Squires Turbo System. Squires Turbo Systems, Inc. 165 N W. Suite C4 Orem, UT Phone 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 (See the kits parts page of 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 U.S. Patent No. 6,745,568, Foreign Patents Pending Page 2

3 IMPORTANT: It is the responsibility of the owner of the turbo system to make any necessary upgrades to the vehicle s fuel system, engine and drive-train components, etc to ensure optimal performance and reliability and to prevent damage to engine and drive-train components. By installing this turbocharger system, the owner understands and acknowledges the severity of the vehicle damage that may occur by turbocharging an improperly modified and tuned vehicle and by proceeding with install accepts ALL risk and responsibility. Our systems are designed for vehicles with engines and drive-train that are in good mechanical condition only. Installation on vehicles with weak, worn or damaged components is not recommended and may result in engine failure, for which we cannot be held responsible. Squires Turbo Systems, Inc. is not responsible for any engine or consequential damages. By proceeding with this installation you accept full responsibility for any damage. It is also the responsibility of the owner to comply with all emissions laws in their state. At this point your Squires Turbo System does NOT have a CARB EO number and this system 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 (two steps colder heat range) gapped to or higher octane fuel in the tank Proper tuning Install a boost gauge and test boost 5-6 psi maximum to prevent SEVERE ENGINE DAMAGE! 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 Page 3

4 98-02 LS1 5.7L F-Body Kit Parts Picture Key: 1: Pipe 1 2: Pipe 2 3: Pipe 3 4: Pipe 4 5: Pipe 5 6: Pipe 6 7: Pipe7 8: Intake Pipe 9: Exhaust Inlet (E1) 10: Tail Pipe (E2) 11: Oil Return Hose 12: Oil Supply Hose 13: Oil Pump 14: TiAL Wastegate 15: Rear Wire Harness 16: Front Wire Harness 17: Instruction Manual 18: Turbocharger 19: Air filter 20: Silicone Hoses 21: V-Band Clamp 22: Hose Clamps 23: Oil Cap Assembly 24: 1 psi Switch Diagram 1 Unpack the turbo kit and account for all parts as per Diagram #1. Check the insides of all pipes for any debris that could potentially enter the engine and/or cause damage to the turbochargers. Connect (-) terminal on oil pump to 12v and (+) terminal to ground using jumper wires and run oil pump for 5 minutes to break in oil pump brushes. Note: Oil pump will be very noisy during this process. 4

5 WASTEGATE INSTALLATION WARNING! The wastegate MUST be connected as shown or IMMEDIATE SEVERE engine damage will result! Wastegate Rear Vent Port Front Boost Port Step 2: Unpack the wastegate and read the manufacturer s directions. The boost hose from the intake manifold must be connected to the Front Boost Port fitting on the wastegates. The Rear Vent Port on the wastegate must be vented to atmosphere. Applying boost pressure to the Rear Vent Port of the wastegate and/or not applying boost pressure to the Front Boost Port will cause the wastegate to stay closed and the turbo to over-boost uncontrollably. This will cause IMMEDIATE SEVERE damage to the vehicle s engine! It is the responsibility of the vehicle owner to frequently inspect the wastegate and wastegate hoses to ensure that the wastegate hoses are connected properly, are in good condition and that the wastegate is functioning properly. The easiest way to monitor boost levels is through a boost gauge. Page 5

6 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. READ COMPLETELY THROUGH INSTRUCTION MANUAL BEFORE STARTING THE INSTALLATION! (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 the pipe gaps and position so that pipe gaps are at a minimum. Tighten clamps enough to hold hoses and pipes in place with clamp bolts positioned for maximum clearance. Final tightening of clamps will be done after assembly is complete The PUSH-LOCK style oil return hoses and fittings are a very tight fit and are difficult to install but once installed, do not require a hose clamp.) (IMPORTANT: The exhaust components of a turbocharged engine get EXTREMELY HOT and will melt any parts that are within a few inches of the exhaust system. Make sure that any hoses, wiring, or other components that could be damaged are mounted away from the exhaust and/or shielded to prevent damage.) Page 6

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8 Factory Hose & Check Valve LS1 pipe 7 and T-Body Hose For PCV Check Valve Pipe #7 IAT Sensor Silicone Elbow MAF Extension Diagram 2 8

9 Disconnect Mass Air Flow sensor electrical connector and remove Intake Air Temperature sensor and MAF sensor, intake ducting and air box. IAT sensor can be left connected to air box lid or secured to upper radiator cover with nylon tie if stock air box lid is not reinstalled. Install 4 x3 molded silicone elbow onto throttle body with clamp and tighten securely. Place another hose clamp onto hose. (Note: group silicone hose pieces together with appropriate sized hose clamps, as some clamps will fit more than one hose size.) Install a 2 x 3 silicone hose onto the small end of pipe #7 and secure with hose clamp then install pipe #7 into throttle body elbow and secure with hose clamp. (Note: If vehicle is equipped with a PS cooler in the upper radiator hose, the cooler can be removed from the plastic retainer and the retainer can be removed from the fan shroud by turning turn counterclockwise. Removing nylon ties from PS hoses and pulling all slack out of PS hoses and fan wiring harness toward driver side of vehicle will aid in installation of Pipe #7.) Remove the poly loom covering the 3 wires that are connected to the MAF sensor wiring harness plug. Cut these wires and splice in the supplied wiring harness extension and use heat gun to seal the shrinkwrap connectors. Wrap wires with supplied poly split-loom and route harness down near the bottom of the alternator and secure out of the way of any sharp, hot, or moving objects with nylon ties. (Note: Wires are cut staggered to assist in fitting the connectors inside split-loom.) Remove small molded hose off the intake manifold illustrated in diagram #2. Note which direction hose was installed from the factory. Clean hose and port on intake of all debris. Clean the hose, PCV valve and intake manifold port of any oil. Install the small brass check valve securely into the center of the hose so that the snap ring is facing AWAY from the intake manifold. Reinstall the PCV hose onto the intake manifold as shown in Diagram #2. 9

10 98-02 Camaro PCV and Evap. System Hose From Front Single Port On Switch Valve To Valve Cover Hose From Lower Dual Port Side On Rear Of Switch Valve To T-Body Throttle Body PCV Switch Valve (Plastic End Up) PCV Breather Filter On Top of Dual Port Side Silicone Elbow Single Brown Wire To Switch Valve Goes Here Switch Valve Mounting Bolt And Bracket Diagram 5 10

11 Assemble PCV switch valve as shown in Diagram #5 then install PCV switch valve onto thermostat housing with bolt, lock washer, and nut as shown in diagram #5. Remove the stock PCV vent hose from front of RH valve cover and RH of throttle body. Connect the 3/8 hose from the front (single outlet side) of the switch valve to the valve cover. Connect the 3/8 hose from the rear (below the vent filter on the dual outlet side) of the switch valve to the throttle body port and secure both hoses with hose clamps. Route single brown wire from STS harness to switch valve, staying away from any hot, sharp or moving objects, and secure to switch valve with nut and washer. 11

12 98-02 LS1 PCV Pressure Switch In Car View Supplied 18 hose 1 psi pressure switch 2 red wires Plug W/O boost gauge Splice this section into Factory Vacuum line 2 brown wires Factory elbow from bottom vacuum line at intake manifold STS wiring harness Diagram 6 Replace plug for this barbed fitting if using boost gauge 12

13 Assemble the STS PCV system as shown in diagram #6. Then splice poly T into the factory pcv system after rubber elbow shown in diagram #4 & #7. Once T is spliced in route the part of the STS wiring harness with the 2 red wires and 2 brown wires to the 1# pressure switch and connect the wires to opposite sides of the 1# pressure switch. If using boost gauge remove 1/8 pipe plug from 1# pressure switch brass T and install supplied barb fitting. 13

14 98-02 LS1 Wiring Harness Secondary Relay Resistor Main Relay Fuse Box Battery Ground Block Battery Power Block Diagram 3 14

15 Connect and route the front wiring harness to the following terminals as shown in Diagram #3, leaving the fuse out of the harness at this time: Connect the Red fused lead to the remote battery positive terminal. Bolt the ground strap to the factory ground terminal on fender as shown with the 6mm nut provided. Secure the main relay to ground harness. Route the secondary relay (one with inline resistor) and secure to factory wiring harness with nylon tie and make sure that the hood doesn t contact relay or harness when shut. (IMPORTANT: Make sure that the inline resistor doesn t contact wiring harness or other components that are not heat resistant. This resistor gets VERY HOT! DO NOT TOUCH THE RESISTOR WHEN IT IS HOT.) 15

16 98-02 Camaro Buzzer & Hi/Low Switch Firewall Grommet PCM Bracket Bolts Remove the two bolts holding the factory plugs to the PCM using a 8mm socket and pull factory harness out of the way. Then remove the two bolts on the PCM mounting bracket and remove PCM from car to access the rubber grommet in firewall. Route buzzer and oil pump hi/low switch along firewall behind the PCM and through rubber grommet into the passenger compartment. This grommet is also a good place to route the boost gauge reference. Reinstall computer and bracket in reverse order of removal. 16

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18 98-02 LS1 Fuel Pump Power Supply Grommet in firewall behind computer Computer Red T-tap into green and white wire at computer through this harness ( 98 only) Factory elbow for splicing in STS PCV system Red T-tap into green and white wire at computer through this harness ( only) Pressure switch gets tucked back in here after connecting to wires from STS harness Diagram 4 18

19 Route the wiring harness along the firewall toward the passenger side of the engine compartment and secure the relays to the factory harness with nylon ties as shown in Diagram #4. Leave plug to be connected to back frame harness on top of engine at this time. Locate fuel pump 12v supply wire in factory computer harness as shown in diagram #7 (For 98 models, this is a dark green wire with a white tracer that comes out of the Blue C2 computer connector at terminal #37. For models, this is a dark green wire with a white tracer that comes out of the Red C2 computer connector at terminal #9). Install the red T-Tap connector into the appropriate fuel pump relay supply wire. (Note: Using a test light this wire should be hot when engine is running and will only be hot for about 2 seconds when ignition is on without the engine running, then it will shut off unless engine is started.) Use a jumper wire to apply 12v to the single blue wire to run electric oil pump for 2-3 minutes then connect blue wire to T-Tap connector and carefully reinstall the computer. (Note: Install any gauges or accessories that require wires through the firewall before reinstalling the computer.) Run single blue wire from STS harness to the previously installed t-tap and connect. 19

20 98-02 LS1 Oil Return to Valve Cover Oil Return Hose STS Wiring Harness STS Oil Cap Diagram 7 20

21 Remove stock oil fill cap from valve cover and install provided cap with quick disconnect fitting. Slide the 120 3/8 pushlock hose onto the barb end of the quick connect fitting of the STS oil cap. Feed oil return hose back along valve cover and firewall. Cover open end of hose to prevent debris from entering the hose and route the hose behind the engine and down along the driver side of the transmission. Connect the quick connect fitting to the oil cap. (IMPORTANT: Make sure hose is routed away from all hot, sharp, or moving objects!) Raise and support the vehicle on suitable jack stands or on a vehicle hoist. (IMPORTANT: Always use appropriate jack stands or vehicle support equipment to prevent personal injury!) Tie the front of the back frame harness to the oil return line from under the vehicle. From the top of the vehicle pull the oil return line backup through the engine compartment until the back frame harness is in the engine compartment. Then connect the front harness to the back frame harness and drop the harnesses and oil return line back down behind the motor and over to the driver side of transmission. 21

22 98-02 LS1 Oil Supply at Engine Original factory plug turned upside down and Tapped out 1/8 NPT Oil supply brass Braided stainless oil supply hose (to turbo) Diagram 8 22

23 Remove the aluminum oil pressure port block off plate above the oil filter on the engine block. (Note: The Catalytic converter can be pulled away from the engine slightly with a pry bar to give enough clearance to remove the 2 bolts securing this plate.) Drill the existing, partially drilled hole the rest of the way through into the oil port with a 21/64 drill bit and then tap the hole to 1/8 NPT. Clean debris from ports and install the 45 degree #4-AN fitting and reinstall the plate upside down onto the block with the factory gasket as shown in Diagram #8. (Note: The factory gasket can be reused if it is good shape.) Connect the stainless flex hose to the #4 AN fitting and route the oil supply line, return hose and backframe wiring harness along LH side of transmission tunnel and back along the same path as the factory fuel lines. (Note: Do not secure any lines or wires until all are in place and routed correctly. Cover the open end of the hose with tape to prevent debris from entering hose during installation.) 23

24 98-02 LS1 MAF - Intake IAT Sensor Pipe #7 Pipe #6 MAF Sensor MAF Wiring Harness Extension Pipe #5 Optional Blow Off Valve Diagram 9 24

25 Install a 3.5 X 2.5 silicone hose and clamps onto each side of the MAF sensor then install pipe #6 into outlet side of the MAF and secure with hose clamp but don t do final tightening until all pipes are installed and lined up correctly. (Note: MAF sensor is DIRECTIONAL so make sure that the flow direction arrow on the side of the MAF sensor points toward the throttle body.) Install a 2.5 x3 silicone hose and clamps onto the inlet end of pipe #7. Install the MAF sensor and pipe #6 assembly into pipe #7 and secure with hose clamp as shown in diagram #9. Reconnect the MAF and IAT sensor electrical connectors. (Important: Make sure that the connector wires are secured away from any hot, sharp and/or moving objects to prevent damage to the wires.) 25

26 98-02 LS1 Pipe 3,4 Pipe #4 Rear Control Arm Bolt Supplied 7/16 Bolt And Washers Pipe #4 Rear Mounting Bracket Insert Supplied Sub-Frame Connector Bracket Here Pipe #3 Left rear tire Diagram 10 26

27 Remove the bolt securing the front of the left rear control arm to the sub frame. Slip the SFC bracket (1 x 3/8 bar with 2 tapped holes) into the front sub frame tube that the control arm bolts to. Line up the bracket so that the threads of one hole is accessible through the factory hole in the sub frame. Position pipe #4 against the rear sub frame so that the lower control arm bolt can be inserted through the bracket on Pipe #4, the sub frame, and the control arm and then reinstall the factory nut. Install one of the 7/16 bolts with a lock washer, and a flat washer through Pipe #4 bracket and into the SFC bracket inside of the rear sub frame. 27

28 98-02 LS1 Pipe 4 mounting Pipe #5 Pipe #4 Front Mounting Bracket Wiring Harness And Oil Hoses Insert Supplied Sub-Frame Connector Bracket Here Pipe #4 Pipe #4 Rear Mounting Bracket Pipe #3 Diagram 11 28

29 Insert the other SFC bracket into the rear of the front left sub frame so that the threaded holes are accessible through the factory holes. Position the front of pipe #4 so that the holes line up with the factory holes in the front sub frame and install the remaining two 7/16 bolts with washers. Securely tighten the three 7/16 bolts and the factory lower control arm bolt. (Note: Pipe #4 SFC can be welded to the sub frame and reinforced as necessary if desired.) Install one 2.25 x3 silicone hose with 3 clamps onto each end of Pipe #4 and secure the hoses with the clamps. If installing a blow off valve go onto next page. If not installing a blow off valve go to page #30 29

30 LS1 BLOW OFF VALVE INSTALLATION Factory brake hose Brake booster check valve 1/4 hose to BOV Install the BOV into pipe #5 with band clamp making sure that the O-Ring is positioned correctly. Remove the check valve from the brake booster and from the factory vacuum hose to intake manifold. Insert the supplied T fitting into the factory brake hose and secure with the factory clamp. Install the check valve into the x3 supplied hose and install hose onto T fitting and secure with 2 supplied hose clamps. Install the check valve back into the brake booster. Install the 1/4 vacuum hose onto the remaining T fitting port and route the hose down to the blow off valve and cut to length, keeping length as short as possible. Make sure that hose is routed away from sharp and/or hot objects. Secure the hose onto the T fitting and the blow off valve with hose clamps. (Note: For high altitude applications a lighter (9#) spring is available to quicken valve response with 30low vacuum engines.)

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32 98-02 LS1 Pipe 5 Mounting Pipe #5 LF Lower Control Arm Pipe #5 Mounting Bracket LR K-Member Nut Oil Supply Line Diagram 12 32

33 Remove the factory nut securing the LF lower control arm to the K-Member. (Note: Mark the location of this nut before removal so that it can be put back in the same location as this is an alignment adjustment bolt.) Install pipe #5 into pipe #4 and onto the protruding bolt from the K-Member and then slip up into the MAF sensor inlet hose as shown in Diagram #9. Install and securely tighten the K-Member nut and secure the hose clamps. (Note: Make sure that the MAF sensor and related hoses and clamps, along with Pipe #6 and #7 are positioned correctly to clear the drive belt and pulleys. Any interfering pieces can be repositioned by loosening the clamps, repositioning the piece, and retightening the clamps.) 33

34 98-02 LS1 Oil Pump Installed Yellow Wire To Outlet Side Of Oil Pump Black Wire To Inlet Side Of Oil Pump Rear STS wiring harness ground Protective rubber Cap over pressure switch Two wires to pressure switch Oil outlet Oil Pump Oil return hose To oil cap Diagram 13 Oil inlet Oil in from turbo 34

35 Mount the oil pump to the frame rail as shown in Diagram #13 using the 4 self tapping screws provided. Install the wiring harness connections onto the oil pump and pressure switch as follows: The Yellow wire in the rubber cap connects to the terminal nearest the oil pump outlet. The Black wire in the rubber cap connects to the terminal nearest the oil pump inlet. The White and Black wires together each connect to a separate terminal on the pressure switch. The single Black wire is connected to the frame with a self tapping screw and the star washer provided. Route the oil return hose to the oil pump and cut the length to fit. Install the return hose onto the fitting at the oil pump outlet as shown in Diagram #13. Install the short section of 3/8 oil return hose onto the fitting at the oil outlet of the turbocharger. Route the hose up and over the plastic splash shield to the oil pump. Cut the hose to length and install the hose onto the fitting at the oil pump inlet as shown in Diagram #13. 35

36 98-02 LS1 Turbo and Exhaust Tailpipe K&N Air Filter Turbo Air Inlet Exhaust Inlet Turbo Oil Inlet Wastegate V-Band Clamp Turbine Housing Turbo Oil Outlet Diagram 14 Compressor Housing 36

37 Assemble the turbocharger, large flange gasket, wastegate, and exhaust inlet pipe as shown in Diagram #14. Tighten all bolts evenly to facilitate lining up flanges evenly. Install the 7/32 boost hose from the fitting on the compressor housing to the front wastegate fitting as shown in Diagram #14. Install the 3 x 3 silicone hose onto the compressor inlet with 2 clamps and secure with clamp. (Important: Make sure that the wastegate valve seat ring is properly positioned into the wastegate before installing the wastegate to the flange.) 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 is installed. Tighten the turbine housing bolts to 14 ft lbs after installation. Loosen the 6 compressor housing bolts and rotate the compressor housing so that the outlet of the compressor faces as shown in Diagram #14. Tighten the compressor bolts to 12 ft lbs after installation. Install the 3 turbo inlet tube into the silicone hose on the compressor until it touches the compressor housing and secure with a hose clamp as shown in Diagram #14. Install the K&N air filter onto the filter adapter and secure with the hose clamp. Loosely install the V-Band clamp and the tail pipe onto the outlet of the turbine housing so that the tail pipe can be rotated if needed to properly line up the turbo assembly. 37

38 98-02 LS1 Underneath Overview Wastegate STS Exhaust Inlet Factory Exhaust Air Intake Pipe Oil pump Exhaust Outlet Pipe 2 Wiring harness with oil supply and return Pipe 3 Pipe 4 Diagram 15 38

39 Remove factory muffler by cutting exhaust I pipe as close to the muffler as possible. Once muffler and tail pipes are removed, clean the I pipe of rust and carbon deposits and install the turbo assembly onto the stock exhaust pipe and place supplied exhaust clamp onto inlet pipe but don t tighten clamp until assembly is in final position. (Note: It may be necessary to have the included 2 adapter pipe welded to the I pipe before turbo assembly can be installed if the factory I pipe doesn t extend far enough after the 90 degree bend before it attaches to the factory muffler. If this is the case, make sure that it is welded on straight to facilitate lining up the turbo assembly correctly. You may want to have turbo assembly in place before final welding is done.) Position turbocharger center housing with oil outlet facing as near straight down as possible. Rotate exhaust turbine and compressor housing to align turbo as shown in diagram #15. (Note: The compressor outlet should be as close to pan-hard rod as possible with rear axle in fully extended position.) Lightly secure the turbine housing and compressor housing bolts and hose clamps. Once you are sure of position of turbo assembly, tighten the exhaust clamp securing turbo inlet pipe to stock exhaust pipe. (Note: It is recommended that this joint be welded to ensure best possible sealing and strength, however, don t weld or do final tightening until installation is complete.) Install one 2 x3 silicone hose and clamps onto compressor outlet and insert pipe #1 into the hose and secure clamps then install a 2 x3 silicone hose and 2 clamps onto the large end of pipe #1 as shown in diagram #15. Slip pipe #2 up and over rear end housing and into pipe #1 and secure with clamp as shown in diagram #15. Insert the outlet end of pipe #3 into the inlet end of pipe #4 39

40 98-02 LS1 Turbo Side View Pipe 2 Compressor Housing Bolts Turbo oil outlet hose Goes to oil pump inlet Pipe 1 Diagram 16 40

41 Once turbo assembly and pipes are all in position remove tape covering the ends of the supply and oil return hoses. Aim the oil supply line into a suitable oil container and start motor to flush out oil line. Allow car to run until there is a steady stream coming from the line. Once line is flushed out you may shut the car off and install supply line to the top of the turbo. Then install return line to the bottom of the turbo. Secure both lines away from any hot sharp or moving objects. 41

42 98-02 LS1 Turbo Intake Mounting Bend Hanger Down Stock exhaust hanger Air filter Turbo inlet tube Oil Supply Line Vent To Atmosphere Diagram 17 42

43 The hanger located on the air intake pipe may be bent down as shown in diagram #17 to tuck the air filter up closer to the underside of the car. 43

44 ELECTRICAL SYSTEM TESTS: With the ignition key in the ON position and the engine not running, toggle the switch on the main relay. This will manually override the pump controls and run the oil pump on HIGH speed. You should hear the pump get audibly louder when the switch is in the HIGH position. This can be used to help troubleshoot any oiling system problems and can be used for extreme cold weather and/or racing conditions to ensure optimal oil scavenging from the turbos. Return this switch to the LOW position to perform the following tests. Once the electrical system tests are performed, switch the override switch back to HIGH for the first 50 miles of driving then return the switch to the LOW position for normal operation. With the engine running, use a jumper wire to connect the two terminals of the pressure switch near the PCV switch valve. You should hear oil pump get louder and be able to feel the PCV switch valve click. Remove jumper wire and connect it across pressure switch terminals at the oil pump inlet. This should cause buzzer alarm to sound in passenger compartment. Remove the jumper wire and shut off the engine. Once electrical system tests are complete, install the rubber protective caps on the two pressure switches and reinstall the rear splash panel. (Note: The pump over-ride should be set to the normal operating mode for tuning as the PCV vent will pull non-metered air in while the pump is in the HIGH speed mode. During normal operation, the PCV system functions normally and pulls in metered air to prevent idle and/or drivability problems.) Page 44

45 Check and top off engine oil. With the oil cap off, hold the cap over the oil fill neck and start the vehicle to check for oil flow out of the oil return hose. If oil is squirting out of the cap, shut engine off and reinstall the oil cap. Test drive vehicle and make sure that the turbocharger is working properly and producing the proper amount of boost. The standard kit should produce about 5-psi boost. Recheck all connections, clamps, and brackets for proper tightness and routing. (Important: Inspect the wiring harness routing near the transmission and exhaust system for any evidence of the loom melting due to high heat. If the loom is getting too hot, reroute the harness and secure harness to protect it from excessive heat.) Vehicle performance should increase over the next few days of driving as the turbocharger breaks in, allowing quicker spool-up, and as the computer relearns and adjusts to boost conditions. The Check Engine light may come on during the next few weeks of driving, as the computer will see sensor values that are out of the normal range of what it is used to seeing. The light should go off and reset each time you drive the vehicle. It is recommended that you check and keep track of any trouble codes that are set in the computer to make sure that no damage is done to your vehicle. The oil pump should decrease in noise level as oil temperature rises and also decrease over time as the pump breaks in. If you experience any problems refer to the Trouble Shooting Guide. If you can t solve the problem that is related to the turbocharger system please or contact your local STS Power Dealer or contact STS Technical Support at support@ststurbo.com or (866) WE-TURBO. Page 45

46 TROUBLESHOOTING GUIDE Oil 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 Check inline voltage resistor for voltage on each side of resistor 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 Page 46

47 TROUBLESHOOTING GUIDE Squeaking 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 If MAF code appears, tube that goes into MAF sensor can be adjusted closer or further away from sensor to tune MAF readings higher or lower 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 for proper operation of the PCV switch valve and the 1 psi switch Check cylinder compression to verify engine is in good condition Check oil pump operation and for any flow restrictions Check the operation of the check valve at the turbocharger oil inlet, it should not leak when not running 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 Page 47

48 Safety Warning IMPORTANT Squires Turbo Systems Safety Warning - Please Read! Oil System Warning Buzzer Your STS Turbo System is equipped with a safety system that will alert you in the event that your oil pump fails. This system is a buzzer that will be heard inside your vehicle. If you hear this buzzing sound, pull over to the side of the road as soon as possible and contact the nearest STS Power Dealer. Serious engine damage can occur if the pump stops while your engine is running. With the pump stopped oil will flow out of the turbo and will not return to the engine. Premium Fuel Squires Turbo Systems recommends that you only use Premium Fuel, 91 Octane or better, on vehicles equipped with the STS Turbo System. Premium fuel reduces pinging and early detonation which can cause significant damage to your vehicle. Engine Pinging If you hear pinging in your engine, back off the throttle immediately. Pinging can cause significant damage to the engine. If you hear pinging, call your local STS Power Dealer immediately. Heavy Towing The STS Turbo System, like other turbo and supercharger systems, under certain heavy towing situations can create more power than a stock engine can handle. Squires Turbo Systems does not recommend using this system for heavy towing purposes. Vehicle modifications STS Turbo Systems were designed to fit stock vehicles. If you have modified your vehicle, modifications to the turbo system or your vehicle may be necessary to ensure the proper fit and safe use of the STS Turbo System. Inform your Power Dealer of any aftermarket changes to your vehicle. Page 48

49 LIMITED ONE-YEAR WARRANTY Squires Turbo Systems, Inc. warrants to you, the original purchaser of an STS turbo system (the System ), the that System will be free from defects in 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 vehicle by 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 been disassembled, repaired, or otherwise altered by any person other than an authorized STS service dealer, nor does it apply to any System that fails as a result of misuse, accident, improper installation, improper or inadequate maintenance, racing, neglect, or any use in an application or environment for which you know or should know the System is not designed or approved. Who Makes this Warranty This warranty is made by Squires Turbo Systems, Inc., 165 N W., Suite C4, Orem, Utah 84057, or by the authorized STS service dealer 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 is installed. 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 during the 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 purchase price for the System. This warranty covers parts only. If Squires Turbo Systems, Inc. or its authorized STS service dealer performs any repair work or installs any replacement part for the System under this warranty, you may be charged for labor costs. Where and How to Obtain Warranty Service You can obtain warranty service from any authorized STS service dealer or directly from Squires Turbo Systems, Inc. It is your responsibility to deliver or ship the 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 work order 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 WE-TURBO. Exceptions and Exclusions This warranty is conditioned upon (i) proper installation and (ii) the vehicle and the System receiving reasonable and necessary maintenance during the warranty 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 or environment 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 THE PURCHASE PRICE OF THE SYSTEM, ARE THE SOLE REMEDIES AFFORDED UNDER THIS WARRANTY. IF ANY FAILURE OF THE SYSTEM CAUSES DAMAGE TO ANY OTHER PART OF YOUR VEHICLE OR INJURY TO ANY PERSON OR PROPERTY, THIS WARRANTY DOES NOT COVER SUCH DAMAGE OR INJURY. THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE LIABILITY OF SQUIRES TURBO SYSTEMS, INC. RELATED TO THE SYSTEM EXCEED THE PURCHASE PRICE OF THE SYSTEM. SQUIRES TURBO SYSTEM, INC. SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES FOR CONSEQUENTIAL, INDIRECT, SPECIAL, OR INCIDENTAL DAMAGES ARISING FROM OR IN CONNECTION WITH THE USE OF THE SYSTEM ON THE VEHICLE. (SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.) THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. Page 49

50 STS Safety Warning and Warranty Notice SAFETY WARNING PLEASE READ The STS turbo system is designed to provide enhanced power and engine performance. It could cause severe damage 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 serious personal injury or even death. Neither Squires Turbo Systems, Inc. nor its authorized dealers can accept responsibility for the proper maintenance 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 READ The liability of Squires Turbo Systems, Inc. and its authorized dealers relating to your use of the STS turbo system is strictly limited. Please read the STS turbo system limited warranty carefully. In most cases, the warranty 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 for damage to your vehicle and/or for personal injuries or death caused by your use of the STS turbo system, in which case our responsibility will be as provided by law. However, we urge you to exercise the utmost care in properly installing and using the system so as to avoid personal injury and/or damage to your vehicle. You are responsible for using the system safely and for evaluating the effect of such use on other warranties. For Off Road Use in California Page 50

51 STS Towing Warning The STS Turbo System is NOT recommended for towing and/or heavy hauling. The Turbocharger will produce more than adequate power and torque for towing. However, turbocharged stock engines, combined with the heavy loading of the engine and extended boost conditions during towing, can produce the following potentially damaging conditions: Extreme exhaust gas temperatures (in excess of 1500F) can damage Catalytic Converters, Valves, and Stock Pistons. High air intake temperatures (in excess of 200F) can raise combustion temperatures which may cause detonation. Extended high RPM driving can cause lean fuel mixtures (in excess of 12:1) resulting in high combustion and exhaust gas temperatures which may cause detonation. Heavy loads will produce full boost at very light throttle conditions which may cause lean fuel mixtures (at light throttle positions the PCM is running in Closed Loop which maintains 14.7:1 air fuel ratios). High combustion temperatures can develop more heat than the stock spark plugs can dissipate (stock spark plug heat range is too hot) which can cause spark plug damage and detonation. Heavy loading and high exhaust temperatures can cause Boost Creep and an Over-Boost condition which may cause severe engine damage. High torque combined with heavy loads can cause extreme transmission temperatures which can damage transmission and/or drive-train components. Extended driving periods of high horsepower production can create more combustion heat than the stock cooling system (radiator) can control which may cause engine overheating and severe engine damage. WARNING: USE CAUTION AND GOOD JUDGEMENT AND TOW AT YOUR OWN RISK! DO NOT LET THE ENGINE DETONATE DURING BOOST! ANY AUDIBLE DETONATION (PINGING) WILL DAMAGE YOUR ENGINE! Page 51