Corvette Stage X Twin Turbo Installation. Please read the entire instructions as we ve made many changes.

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1 Corvette Stage X Twin Turbo Installation Please read the entire instructions as we ve made many changes. Disconnect battery. Remove plastic fuel rail covers over the valve cover. Remove Air Box in front of MAF. Remove complete air intake system from Throttle-body forward, save MAF meter. Remove spark plugs re gap to.035, save for reinstall. Suggested spark plug replacement for most applications would be NGK TR6 gapped Remove complete center section of exhaust (H-pipe and catalytic converters). If converters are to be used cut exhaust pipes in front of catalytic. See photo On newer models removal of the pre cats is necessary and the main converters must be move back about 3. We cut the stock exhaust pipe using a cut off saw then weld it back together. If not retaining the stock converters it s recommended to use a Corsa SS X-Pipe asm with the addition of 1-4 length of 2 ½ Stainless tube and 2-2 ½ stainless band clamps to complete the assembly. (Items not provided) Remove exhaust Manifolds and oil dip stick and tube. Remove front bumper cover and lower inner fender well extensions. Remove brake cooling ducts. Remove horns and electric air pump. ( On the X kit we don t reinstall the air pump) We have reinstalled it along with the EGR tubes on the manifold and if your planning on doing so contact us and we can supply pictures and fittings needed. Remove low pressure power steering hose from rack to reservoir. 1

2 Remove air conditioning line from compressor. (Be sure to evacuate the system before removing the line). Install supplied air condition manifold on the back of the compressor. 2

3 The upper line needs to be routed towards the rear of the engine between the turbo and block, be sure to position the fire sleeve so it is protecting the hose where it passes by the exhaust housing. Also insure upon final assembly that this hose is routed between the block and the dipstick tube. The lower hose installs on the bottom of the a/c manifold. It goes forward and attaches to the condenser. The routing of this hose goes initially to the rear and wraps down below the motor mount and then along the oil pan rail and out under the steering rack. 3

4 Installation of turbo oil drain fittings. When drilling pan you can use a shop vacuum to suck up all shavings while drilling, we also use grease on the drill bit. Use Grease in each flute of the tap will help hold shavings to the tap. On 2000 model year and up the oil pan is 2-piece design. The bottom cover can be removed during this process and tap area thoroughly cleaned. When reinstalling the pan cover fasteners, torque to 10 Nm. Install all fittings with a Teflon tape type thread sealer. Driver s side is 7/8 down from pan rail and 5 3/8 forward of oil filter boss, mark spot and drill 45/64 hole and tap ½ NPT pipe thread and install fitting. See photo Passenger side is 7/8 down from pan rail and 9-5/8 from bell housing, follow the same procedure from drivers side for drilling hole and tapping ½ NPT pipe. See photo 4

5 Remove left engine mount and modify as per photo, this must be done to clear the larger T4 compressor housing. The easiest way to accomplish this is with a simple 3 hole saw from your local hardware store. Make sure the mount is secure in a vise or equivalent before drilling. 5

6 Turbo charger preparation/installation. The passenger side engine cradle must be modified as shown. We use a die grinder with an aluminum cutting bit. The installation can be accomplished with out doing this step but it is very difficult to assemble. 6

7 On a few of the installs we ve done the R.S. turbo did contact the frame where a support plate is welded. If this is noticed on your install, the frame can be dented slightly with a pry bar or hammer. You can also grind some of the weld on the frame or grind the compressor cover. The turbo manifolds will be installed using factory bolts and gaskets. Preassemble the passenger side manifold/turbo combination using the provided studs and nuts using a thin bead of Loc-tite ulta copper sealant on the flanges. The oil feed fitting is preinstalled in the turbo in the position they need to be. Install the 34-3an oil feed line to the turbo with the line being fed slightly forward away from the exhaust side. Install 1 2 silicone couple and clamp into place on the compressor discharge. At this point the assembly can be installed as a unit from the top. Remove the passenger coil pack and valve cover this is easier if you remove the plastic shroud from around the battery first. With a little patience it will drop right in and can be bolted into place. 7

8 Locate (1) 2 ¾ silicone 45 elbows & 2 #44 clamps. Install silicone elbow with the short leg toward the compressor cover on passenger side turbo pointing 45 (horizontal to the ground) to right of car. 8

9 If you re doing the install with the engine installed in the engine bay, lay the first piece of 3 intake ducting (The left side ducting is in 3 parts) in the bay before installing the turbo as it will not be able to be installed unless you remove the alternator and power steering. Make sure a silicone 3 X 2 ½ coupler is fastened on the end of the pipe. The end that is 2 ¾ is fastened to the compressor inlet when the turbo is installed. At this time drop the Driver side manifold down from the top and let the rear turbo discharge hang in opening behind the engine cradle. Apply a thin bead of Loc-tite Ultra Copper RTV to the exhaust manifold and install driver s side turbocharger using the studs and 3/8 loc-nuts (provided). Attach the 13-3an turbo oil feed line directing the line slightly forward and down away form the exhaust housing. Install silicone elbow on driver s side turbo pointing 75 (toward steering column) up & left of car. Pull up the Turbo assembly and attach the manifold using the stock bolts and gaskets. 9

10 Install the pipe and clamps that was previously laid bay like shown below but do not tighten yet. Remove the oil transfer cover located above the oil filter that holds the temperature sensor. Drill 5/16 hole opposite of the sending unit and tap to 1/8 npt. Install the brass run tee with the two steel -3an oil feed line fitting already installed. The oil restrictors are already installed it the fittings. Route and install the oil feed line to the installed oil supply fitting installed in the previous step. The oil feed line is routed in front of the oil pan. The driver s side is self explanatory. 10

11 Install 4 extension wires onto oil temperature harness and plug into sending unit. This can simply be done but cutting the harness approx. 2 from the Packard connector and splicing in the 4 extensions using the supplied crimp type Butt connectors. Install the oil drain assemblies. Use the hardware and gaskets provided, try to use no silicone as it can plug up the drain exit. Verify a smooth drain transition to the fittings in the oil pan. If needed to insure a smooth drain transition, the center section can be rotated by loosening up turbine housing and compressor cover bolts. Install the driver s side using a 4 section of drain hose as shown below. 11

12 Install 5 ½ drain hose and clamps on passenger side and again verify smooth drain transition. Wiring on starter will have to be wrapped and moved to clear turbo housing. You will need to loosen the 13mm nut on the starter and reposition the connections away from the turbine housing See Photo 12

13 Now is a good time to wrap all wiring etc as shown with heat shielding to prevent damage from the heat of the turbochargers and down pipes. Locate exhaust down pipes and heat wrap and 4 #36 clamps. Wrap exhaust pipes from mounting flange to the support TAB and use #36 clamps to secure wrap. We supply the heat wrap but talking with installers they don t use it much. Install the down pipes using 5 bolts per side (provided) with a thin bead of RTV. We find a combination of a 5/16 combination wrench, a 11/32 6 point ¼ drive swivel socket and some patience and all will go well. If using the stock converters, insure the slip fit tubes provided are installed before installation. Be sure to use anti-seize on the bolts and wastegate dump tubes. The passenger side top bolts are easiest to install from top, leave all the bolts loose until all are started. Once both down pipes are installed you can now install the provided waste gates. From TTi the wastegates are installed with the 9-10 psi springs, change if required. All the flanges are designed to use RTV and not gaskets. Also preinstall the 1/8 NPT to hose barb fitting into the bottom most port on the wastegate. Using the provided bolts (½ are standard and ½ are metric) and slip fit tubes assemble each side (valve seat towards the down pipe) as shown below in the pics. Use a bit of patience when tweaking and rotating the wastegate flanges to align the bolt holes and again do not tighten until all fasteners have been started. 13

14 Once the down pipes are tight, slide the couplers back so that they mate to converters and tack weld in place and remove catalytic converter and weld all the way around and reinstall pipes. Use the stock bolts to fasten to undercarriage. Install 02 sensors and plug. Be sure wires DO NOT rub on exhaust pipes. This step may or may not be required. We have found if you have the external Power Steering cooler you can tweak the attachment brackets and relocate to clear turbo plumbing. 14

15 If required, install power steering adapter fitting into steering box. Install new power steering hose from steering box to reservoir and tighten fitting and hose clamp, refill reservoir. Before you can mount the intercooler, remove plastic radiator shroud from in front of radiator and discard. Save the outside air temperature sensor for reinstall later. Locate the front mount intercooler and install (2) 2 1/2 silicone hoses and clamps. Position the cooler as low as possible while still being able to slip the compressor discharge pipes into the inter cooler hose just above the front radiator support (see photo. Using the intercooler mounting bracket as a template, mark the holes while an assistant holds the cooler in position as described above. Drill the support where marked and use the (2) 2 X 5/16 bolts and hardware to install. Don t over tighter as the support is hollow. 15

16 Locate (2) 2 x 3 silicone hose couplers & 4 #32 clamps, Install the couplers onto the turbo outlets of each turbo, tighten clamps to secure to turbo, slide remaining clamps onto hoses Locate the 6 Intercooler hot pipes, pipe #1, #2, & #3 is passenger side (RS) (shown in pic from top to bottom). Install pipe #1 into passenger side turbo hose coupler. Attach Pipe #2 as shown below into #1 and down to lower radiator area. 16

17 Install pipe #3 onto R.S. of intercooler & through hole in brake ducting panel. Do not tighten. Attach the other end to pipe #2 as shown (Note Pipe #3 no longer contains a BOV) Locate Pipes #4 & #5 & 6, they are drivers side (LS) pipes and labeled top to bottom. 17

18 Locate (1) 2 x 3 silicone coupler & (2) #32 clamps, install onto pipe #4 locate pipe #4, install into driver side (L.S.) turbo, Position pipe so it exits between the engine cradle and the frame under steering linkage. Locate pipe #6, install onto end of #5 pipe making sure # 5 pipe is routed under the sway bar. (See photo) install 2 hose onto # 5 pipe, tighten clamp. Next install # 6 pipe into the intercooler. Insure all pipes are aligned and won t contact anything. Tighten all remaining hose clamps. 18

19 Below are the two pipes used for the compressor inlet ducting on the passenger side. The smaller pipe with the 2.75 end installs into the silicone elbow previously installed on the compressor inlet. Sometimes it s easier to install if the tube is slightly ovaled in a vise to help clear the A/C compressor fitting. Locate 3 R.S. air inlet pipe, the pipe is routed through the brake cooling duct hole over the steering linkage. Before installing the pipe review the pictures below. Using a suitable tool remove the excess material as shown so the pipe will sit flush against the frame. Once removed use black spray paint to cover any exposed metal. 19

20 The second pipe is installed from the 3 outlet of the first pipe through the brake duct hole. See photo below. Once the pipe is in place and the mounting tab is in the 12 o clock position, drill ¼ hole fasten using hardware provided. Install K&N Air filter. 20

21 Locate the two remaining 3 compressor inlet ducting. The first pipe was installed when the turbo/manifold was installed. The middle pipe is routed above the engine cradle and below the steering rack and attached to the pipe installed earlier.(see photo below) Remove the rack/pinion bolt and pry up on the rack to insert the pipe. You need to twist the pipe to install it. Route it to the pipe that is fastened to the compressor inlet and snug the clamp. Fasten the pipe to the engine cradle using the threaded hole already there. Be sure the pipe doesn t rub on the balancer. If your vehicle is equipped with a Power steering cooler you must first unbolt the cooler and trim off the bottom right mounting tab as the pipe travels through that point. After installing the intermediate pipe, reinstall the modified cooler using the left mount bolt and a zip tie on the right hand side to the power steering rack. 21

22 Install 3 pipe #3 onto the center pipe coupler and position through the brake duct hole (some trimming may be required) using the bracket on the pipe, mark and drill a hole it the radiator cradle, align and fasten. Tighten all clamps from turbo compressor housing to filter. Once again check the ducting to be sure in isn t rubbing on the chassis, steering or sway bar and final tighten all clamps. Install K&N filter. Locate horns, you will need to drill a ¼ hole in passenger side front frame 3 from end of tube, mount horns as seen in photo using ¼ x 1 ½ bolts and nut, plug in horns. 22

23 On the stage X system we do not install the A.I.R. tubes or reinstall Air Pump. Codes to be disabled by tuner. If require, install the A.I.R pump as shown below and contact TTI for fittings etc to connect the A.I.R. system. Install the front fascia and other plastic panels removed prior to installion, note some plastic panels will need some minor trimming to reinstall. Install tie wrap mounts using the supplied sheet metal screws to the metal frame inline with the 5 holes located in the bottom of the front fascia. Using zip ties thread them through the tie wrap mounts installed and then through the adjacent hole in the front fascia. When all 5 are installed, gradually tighten each curling up the front fascia creating a nice airflow entry into the front intercooler. Locate the drain holes in the front of each leg of the radiator cradle. This will be the new attachment point for the spring loaded center air deflector. Trim the top portion of the stock air deflector to clear the intercooler and use 3/8 sheet metal screws to attach the deflector to the cradle. (Note install in pic is slightly different than described). 23

24 Locate 8x6 heat shields, this will need to be installed between passenger exhaust manifold & turbo outlet pipe, once installed bend around pipe & it will stay in place. Reinstall the dip stick tube, some bending and modification on the tube is necessary. Install spark plugs gapped to If running more that 5 psi its recommend to use NGK TR6 plugs Install coil packs and spark plug wires. 24

25 Remove hose from throttle body and install vacuum caps on throttle body & clamp. Remove hose from valve cover side and install vacuum cap. Install vacuum log into brake booster hose. (See photo) cut the factory hose and slip the barb log into the hose. There is no need to clamp this hose. Install BOV, we now use the new tial 50 mm valve mounted directly to the outlet tank of the intercooler. Using vacuum hose provided install one end to by-pass valve and the other end to the fitting on the vacuum log. For a boost source for the wastegates, route a single hose from the log to the L.S. waste gate, tee from there to the R.S. waste gate. If your using a boost controller follow there instructions from here. 25

26 We have changed the crankcase breather to a PH special, it simply will replace the stock oil fill cap. No trimming necessary. Now is a good time to install injectors. This turbo system is sold as system only. It can be run on a stock engine with proper tuning and fuel system (injectors and boost-apump). Boost should be kept below 5 psi. On modified engine with forged internals we ve seen over 850rwhp. Install a 3.5 silicone coupler over the end of the MAF and 2 clamps. Note the Direction of airflow on the MAF denoted by an arrow. Install the top airflow closeout panel as shown below under the stock radiator hold down. Some slight trimming may be needed, especially with an aftermarket radiator. Connect MAF meter to K&N tube using 3 ½ hose and 2 #56 clamps be sure to point MAF plug up. Install 3 ½ hose onto MAF. Slide the assembly onto the MAF and then onto throttle body, tighten all clamps. Install air temp sensor into K&N air tube, plug in air temp sensor and MAF. 26

27 ENJOY!! 27