7 th Gen. Celica GTS Turbo Kit Installation Guide This kit has not been CARB approved and is intended for racing / offroad purposes only.

Transcription

1 7 th Gen. Celica GTS Turbo Kit Installation Guide This kit has not been CARB approved and is intended for racing / offroad purposes only. The purpose of this guide is to serve as a reference for use when installing a Stafford Fabrications 7 th Gen. Celica GTS Turbo kit. These instructions are in no way a substitute for technical skills or experience, nor are they intended to supersede any procedures listed in the factory repair manual. Please be sure to have your turbo kit installed by a qualified professional. Note to installer: Always remember to wear safety glasses when installing a turbo kit. If you have questions or need assistance please contact Stafford Fabrications during normal business hours. The vehicle depicted in this document was equipped with a Cold Air Intake, custom painted plastic, and a Nitrous Oxide system. As such some pictures may vary from what you may see on your car. Stafford Fabrication 208 W. Ave I Lancaster, CA Phone: staffordfabrication@yahoo.com STORE HOURS Pacific Time Monday Closed to the Public Tuesday - Thursday 9:00 AM - 6:00 PM Friday 9:00 AM - 3:00 pm (Racing at 4:00) Saturday 9:00 AM - 6:00 PM Sunday Closed

2 Tool List: Wrenches: 10 MM 12 MM 14 MM 17 MM 19 MM Sockets ¼ Drive: 10MM 12MM Sockets 3/8 Drive: 10MM 12MM 14MM 17MM 19MM Additional Sockets: ½ Drive 14MM 17MM 19MM 30MM 12 Point Phillips and flatblade Screwdriver

3 Installation Guide Step 1 Battery Removal: Step 1-A: Unfasten Negative Battery Terminal Use a 10MM wrench or socket Step 1-B: Unfasten Positive Battery Terminal Use a 10MM wrench or socket Step 1-C: Unfasten and Remove Battery Tie Down Use a 10MM deep socket Step 1-C: Remove Battery store it in a safe location Be sure to protect the terminals from potential shorting as sparks may occur.

4 Step 2 Trim Removal: Step 2-A: Unfasten and Remove pass. side plastic engine trim piece by depressing the center section of the Push pins and then removing the pins themselves. Use a screw driver tip Step 2-B: Unfasten and Remove plastic valve cover shield by removing the 4 female hex head bolts. Use a 5MM hex key or socket Step 2-C: Unfasten and Relocate small relay and fuse box on The driver s side by prying back on the lock tab and (*1) pulling up on the relay block. Then (*2) reposition it tucked behind the larger relay block. Use a finger or flat blade screw driver *1 *2 Step 2-D: Disconnect Mass Airflow Meter. Use fingers or needle-nose pliers Step 2-F: Remove the ECU cooling tube from the ECU case. Pull back on the tube (towards the front of the car) It should pop out with relative ease. Use fingers

5 Step 3 Engine Bay Dissasembly: Step 3-A: Unplug and remove EVAP purge VSV from intake. Use the appropriate head screw driver Step 3-B: Loosen intake coupler clamps at throttle body. Use the appropriate head screw driver or socket. Step 3-C: Remove vehicle side hose from EVAP CCV. Use fingers or pliers. Step 3-D: Disconnect the electrical connector from the EVAP CCV. Use fingers. Step 3-E: Remove the mounting bolts/nuts for the intake. Use 10MM deep socket on an extention.

6 Step 3 Engine Bay Dissasembly (cont.): Step 3-F: Remove insulating foam from the intake manifold. Use hands Step 3-G: Unplug fuel injector connectors. Use hands or needle nose pliers. Step 3-H: Unplug camshaft position sensor. Use hands or needle nose pliers. Step 3-I: Unplug coil packs. Use hands or needle nose pliers. Step 3-J: Remove the 2 nuts securing the wiring harness behind the coil packs. Use 10MM socket and ratchet.

7 Step 3 Engine Bay Dissasembly (cont.): Step 3-K: Remove insulating wiring harness from behind coils. Use hands Step 3-K: Remove bolt securing wiring harness and bolt securing The fuel rail bracket next to oil fill cap Use 10MM socket and extension. Step 3-L: Top bumper cover securing bolts. Use 10MM socket and extension. Step 4 Front Bumper Removal: Step 4-A: Jack up and support vehicle with Jack stands. Then remove front wheels. Use a jack and jack stands to raise and support car. Use an appropriate socket and ratchet or breaker bar to loosen and remove lug nuts. Step 4-B: Remove rear upper bumper cover bolts. They are located on both sides in the fender wells behind the plastics. Use 10MM socket and extension.

8 Step 4 Front Bumper Removal (cont.): Step 4-C: Remove the side marker lights from both sides by Unplugging the connector or removing the bulb assembly from the housing. Use hands Bumper skin as seen from in wheel well. Step 4-B: Remove bottom bumper cover bolts. They are located along the underside of the front bumper. Use 10MM socket. Step 4-C: Remove the Front Bumper cover. Use hands Step 5 Undercar Dissasembly: Step 5-A: Remove the air filter from CAI. Use socket or flat head screw driver. Step 5-B: Remove the CAI tube and remove Mass Airflow Meter from CAI. Use hands and screwdriver or hex key as necessary.

9 Step 5 Undercar Dissasembly (cont.): Step 5-C: Remove the underbody plastics. Use flat blade & Phillips screw drivers as well as 10MM socket as necessary. Step 5-D: Chisel out staked portion of passenger side axle nut to allow nut to turn. Then remove pass. side axle nut. Use large hammer and punch and drift and 30MM 12 point socket. Step 5-E: Remove the 2 nuts and 1 bolt securing the bottom of the hub assy. to the passenger side lower control arm. Use 17MM socket and breaker bar. Step 5-F: Remove the axle from the hub. It may be necessary To hammer on the end of the axle to push it out Through the hub. Be careful to use a large brass drift and not to damage the threads. Use large hammer and drift. Step 5-G: Remove the 2 nuts and securing the passenger Side drive axle to the support collar. Use 14MM socket and/or wrench.

10 Step 5 Undercar Dissasembly (cont.): Step 5-H: Remove the Passenger side drive axle. *Note gear oil will pour out from the trans. At this Time so it may be wise to drain the gear oil first. Step 6 Exhaust Manifold Removal: Step 6-A: Remove the bolts securing the coil packs and Then remove coil packs Use 10MM socket. Step 6-B: Remove the 2 nuts securing the crankcase breather Tube Use 10MM socket. Step 6-C: Remove the 2 breather hoses from the valve cover Use hands or needle nose pliers. After Removal Step 6-D: Remove all remaining nuts and bolts around the perimeter of the valve cover. Use 10MM socket.

11 Step 6 Exhaust Manifold Removal (cont.): Step 6-E: Remove valve cover. Lift up at the rear driver s side corner first to separate the oil feed tube from the cylinder head, then push back away from the front of the vehicle to get the studs for the breather tube clear before lifting up. Use hands and a screw driver or small prying device As needed. Step 6-F: Cover the exposed valvetrain with clean rags to prevent foreign objects or debris from falling in. Use 10MM socket. Step 6-G: Remove the 5 bolts securing the exhaust manifold heat shield. (some bolts are more easily accessed from below the vehicle). Once the bolts are removed leave the heat shield in place it is not removed yet. Use 12MM ratcheting flex head wrench. Step 6-H: Remove the 2 bolts securing the exhaust center Pipe to the exhaust manifold. Use 14MM deep socket and extension. 6-H 6-I Step 6-I: Remove the 2 bolts securing the exhaust center Pipe to the muffler assy. Use 14MM deep socket and 14MM wrench. Step 6-J: Unplug the 2 O2 sensor connectors located inside The passenger side footwell behind the carpet on the center console. Use Hands or needle node pliers if necessary

12 Step 6 Exhaust Manifold Removal (cont.): Step 6-K: Push both O2 sensor connector wires and grommets out through the floorboard of the car. Use Hands Step 6-L: Pry the 2 hangers off the exhaust center pipe (it may Be necessary to use some WD-40 or soap and water Solution to loosen them) and then remove the exhaust center pipe. Be careful not to damage the O2 sensors or O2 sensor wires. Use hands or prybar Step 6-M: Remove the nuts securing the firewall heatshield. 2 Nuts are up top by the head and the rest are below. Once nuts are removed remove the heatshield. Use 10MM flex head ratcheting wrench Step 6-M: Remove exhaust manifold heat shield. Use hands Step 6-O: Remove exhaust manifold Support bracket. Use 14MM socket and/or wrench `

13 Step 6 Exhaust Manifold Removal (cont.): Step 6-P: Remove the bolts and nuts securing the exhaust manifold to the cylinder head and remove the exhaust manifold*. Use 14mm socket, swivel and a long extension. *Note Exhaust manifold can be left in the car to be removed more easily at the end of section 7 Step 7 Final Undercar Dissasembly: Step 7-A: Remove the bolts securing the Drive axle support hoop. Use 14MM socket. Step 7-B: Remove the center support bolt for the rear motor mount. It is accessed through the drivers side wheel well. Use 17MM socket and extension. Step 7-C: Remove the center support bolt for the front motor mount. Use 14MM socket and 14MM wrench. Step 7-D: Remove the 2 bolts securing the front motor mount. Then remove front motor mount. Use 14MM socket.

14 Step 7 Final Undercar Dissasembly: Step 7- E: Remove the bolts securing the front motor mount bracket. Use 14MM wrench or socket. Step 7- F: Remove the bolts securing the rear motor mount and rear of the center crossmember. Pull the motor mount up so the studs are clear of the holes. Use 14MM deep socket. Step 7- G: Remove the bolts securing the front of the center crossmember. Use 14MM wrench or socket. Step 7- H: Swing the center crossmember to the drivers side so it is out of the way. Step 7- I: You should now have full access to the back of the engine.

15 Step 8 Oil System Preparation: Step 8-A: Remove the oil pan drain plug and drain all oil. Use 14MM wrench. Step 8-B: Remove oil pan bolts and nuts and Oil Filter. Use 10MM deep socket and extension. Use oil filter wrench for filter. Step 8-C: Remove oil pan by inserting a flat wedge between the pan and the bottom of the block being careful not to gouge the block or bend the pan. Use a flat wedge such as a wide blade paint scraper and a hammer. Step 8-D: Remove the oil pan and clean the pan and mating surfaces of the pan and block. Use scraper, wire brush, rags and brake clean. Step 8-E: Drill hole in oil pan for return line. Use ¾ drill bit or hole saw.

16 Step 8 Oil System Preparation (cont): Step 8-F: Using the oil return fitting for a template mark the 3 drill locations for the fitting. Then remove the fitting and drill out the holes Use?/? drill bit. Although we had it welded this oil pan is a good example of a proper return line fitting location Step 8-G: Clean the oil pan and return line fitting thoroughly with brake clean Use brake clean and rags. Step 8-H: Clean the oil pan and return line fitting thoroughly with brake clean Use brake and clean rags. Step 8-I: Coat the return line fitting with silicone sealant as shown and install to oil pan. Use a?? /MM socket. Step 8-J: Lay a bead of silicone sealant on the mating surface of the oil pan. Use silicone sealant.

17 Step 8 Oil System Preparation (cont): Step 8-K: Reinstall the oil pan using original bolts and nuts. Use 10MM deep socket and extension. Step 8-L: Clean the turbo and oil return fitting for the turbo. Attach the oil return line fitting with the 2 provided countersunk bolts. Use 7/32 allen head wrench or socket. Step 8-M: Remove the oil pressure sender from the oil filter housing. Use crecent wrench. Step 8-N: Wrap the threads of both oil adapters and the oil pressure sender with Teflon tape as shown.. Use Teflon Tape and hands. Oil Pressure splitter Oil Feed Fitting Oil Pressure sender Step 8-N: Install the oil pressure splitter. Be careful not to Over-tighten it as brass is a soft metal and can break. Use crecent wrench. Step 8-O: Install the oil feed fitting and then braided turbo oil feed line. Use crecent wrench. Step 8-P: Install the oil feed pressure sender. Use crecent wrench.

18 Step 9 Turbo Installation: Step 9-A: Swing the bottom of the engine forward, make sure the Exhaust manifold gasket is in place and lift the turbo assembly up into position on the back of the engine from below. Slide it onto the studs and start a bolt or nut to hold it in place. Then install the additional nuts and bolts. Use 14MM flex head ratcheting wrench and 14MM socket with swivel and extension. Original Location Note: It may be necessary to relocate the studs from the outer 2 upper bolt positions. If so please relocate it as shown in the picture to the right New Location Step 9-B: Connect the vacuum line from the fitting on the compressor housing to the fitting on the wastegate actuator. If you wish to install a boost controller it will need to be installed in the middle of this line Step 9-C: Re-install the valve cover. Follow steps 6F 6A. in reverse order. Use tools as described in steps. Step 9-D: Remove the safety clip from around the stock fuel line. Use hand. Step 9-E: Squeeze the release tabs and pull off the stock fuel line. Use hand.

19 Step 9 Turbo Installation (cont): Step 9-F: Remove the 2 12MM bolts securing the fuel rail Use 12MM socket and ratchet. Step 9-G: Remove the fuel rail and remove injectors from fuel rail by gently rocking them back and forth while pulling. Step 9-H: Check the SF fuel rail to ensure all connectors are tight and properly sealed. Ensure there is no debris inside the fuel rail. Make sure the fuel hose barb is facing as shown in the picture. Lubricate injector O-rings with a small amount of fuel and insert into the fuel rail as shown. Use hands or an adjustable crescent wrench if needed. Step 9-I: Insert the mounting bolts into the fuel rail holes and then Install the new fuel rail and tighten the two bolts gradually in even steps. Use 12MM socket and ratchet. Step 9-J: Re-connect the injector connectors and the camshaft position sensor. Step 9-K: Re-install the firewall heat shield and the valve cover. Make sure the valve cover gasket is soft and pliable, if not it should be replaced to prevent oil leaks Use 10MM socket and wrench. Step 9-K: Re-install mounts and crossmember. Reverse the steps 7I 7A Use tool described.

20 Step 10 Piping Installation: Step 10-A: Locate the Discharge Pipe 1 Turbo side. Use hands Step 10-B: Bent the A/C lines slightly as shown. Use hands Step 10-C: Place 2 coupler and 2 clamps on turbo outlet and Insert Discharge Pipe 1 Turbo side as shown. Use hands Note: Do not tighten clamps until instructed to do so. Step 10-D: Place 2.25 coupler and 2 clamps on pipe as shown. Use hands Step 10-E: Insert Discharge Pipe 2 Midpipe into the coupler as shown. Place a 2.25 coupler on the bottom end Use hands

21 Step 10 Piping Installation (cont): Step 10-F: Bend forward center tow hook down slightly. Use prybar. Step 10-G: Bend power steering cooler lines back against air conditioning condenser. Step 10-H: Insert intercooler mounting tabs as shown. It should line up with the inner hole when properly aligned Step 10-I: Mount intercooler to lower front crossmember using the mounting tabs, bolts and washers that were provided as shown Step 10-J: Place a 2.25 coupler on the inlet side of the intercooler and Insert Discharge Pipe 3 Intercooler side into the coupler from the intercooler and the coupler from Discharge pipe 2 as shown.

22 Step 10 Piping Installation (cont): Step 10-K: Place a 2.5 coupler on the outlet side of the intercooler and Insert Delivery Pipe 1 Intercooler side into the coupler from the intercooler. Attach another 2.5 coupler to the top side of the pipe as well. Step 10-L: Install the Mass Airflow Meter (MAF) in the mounting location on Delivery pipe 2 throttle body side. Please be careful to install it facing the correct direction as the orientation of the MAF is critical to proper vehicle operation. Then attach the 2.75 coupler to the throttle body and to the Delivery pipe number 2 and install delivery pipe number 2 to the throttle body and delivery pipe number 1 as shown. Step 10-M: Place the short 2.5 coupler on the end of the Air Inlet Pipe 3 turbo side. Step 10-N: Place the Air Inlet Pipe 3 turbo side on the turbo air inlet. Place a 2.5 coupler on the front end of the pipe. Step 10-O: Place the Air Inlet Pipe 2 mid pipe in the coupler from Air Inlet Pipe 3. Place a 2.5 coupler on the front/upper end of the pipe.

23 Step 10 Piping Installation (cont): Step 10-P: Place the Air Inlet Pipe 1 filter side in the coupler from Air Inlet Pipe 2. Place the air filter on the front/upper end of the pipe. Step 10 Piping Installation (cont): Step 10-Q: Now that all pipes are in place make sure that all pipes are located in the proper position and not hitting anything. Beginning with the turbo outlet, proceed to position and tighten all the couplers one at a time. Use flat bladed screw driver or appropriate size nut driver.

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