Import -AutoPerformance, Ltd                      8881 Dover Drive Maineville, OH 45039                                     Phone: 513 325-8421

 

 

Stage I Turbo Kit

Installation Manual

 

Thank you for purchasing the best turbo kit available for your car!

 

 

Please read this entire manual carefully before attempting installation of your new IAP turbo kit.  With proper installation and break in, your kit should provide you with years of dependable service and outstanding performance in your 1989-1998 240SX.

 

 

Should you require assistance installing your kit, please contact IAP at gofast@import-autoperformance.com or call us at 513-325-8421.

 

 

 

Please set aside 16-20 hours for installation if you are not familiar with auto mechanics, 12 hours if you are very comfortable with auto repair.

 

 

CAUTION: IAP recommends that you exercise a limit of 4000 RPMs during the first 500 miles after you complete your turbo kit install.  This will allow proper seating of the turbocharger bearings and journals and will allow your car’s ECU to adapt to your KA series engine being turbocharged.

 

 

 

 

 

Step 1:

Place vehicle in pre-designated work area and remove negative (-) battery cable using a 10mm socket.  After allowing the engine to cool to room temperature, use the included can of PB Blaster to spray the 10 mm bolts on all the heat shielding surrounding the stock exhaust manifold and midpipe.  Also apply Blaster to the large nut holding the front O2 sensor in the stock exhaust manifold.  Allow Blaster to penetrate for at least 30 minutes before trying to ‘break’ the bolts loose.  Exhaust system bolts can over time become seized, breaking the bolts off under pressure and causing you great headaches.  Be patient!

 

Step 2:

Remove the front O2 sensor from the stock exhaust manifold and then unplug it from its harness.  Remove the O2 sensor and place it aside for re-installation later.  Remove all heat shielding from exhaust manifold and midpipe.

 

Step 3:

Apply PB Blaster to the 3 bolts holding the midpipe to the stock exhaust manifold and the 8 nuts holding the stock exhaust manifold to the head.  Allow Blaster to sit on these items for 30 minutes before attempting to loosen them.

 

Step 4:

Remove stock exhaust manifold from vehicle.

 

Step 5:

Scrape old exhaust gaskets from head with a razor blade or suitable straight edge.

 

Step 6:

Remove entire air box assembly from the engine and lower fender well on the driver’s side of the vehicle.

 

Step 7:

Using a Sawzall or another type of reciprocating saw and a good metal blade, trim out a section of the driver’s side fender well to allow room for the intercooler piping and air cleaner installation (see photo below).

 

 

 

Step 8:

Drain engine oil from crankcase by removing oil drain plug on oil pan.  Remove oil filter from side of engine below intake runners to allow space for maneuvering hands/tools to oil pressure sending unit.

 

Step 9:

Remove factory oil pressure sending unit by unplugging sensor wire, then loosening unit with a small Crescent or other adjustable wrench.

 

Step 10:

Using included roll, cover the threads on the included brass ‘T’ fitting with one layer of white Teflon tape and thread ‘T’ fitting into included NPT to BPT thread adapter.  Tighten securely.  Thread adapter with ‘T’ fitting should now be threaded into factory oil pressure sending unit’s location.  Tighten securely.  You will now have 2 ports for oil pressure.  Coat the threads of your factory oil pressure sending unit with white Teflon tape and thread into port on ‘T’ fitting facing the passenger side tire.  Tighten securely.  Coat both ends of the included male-to-male NPT to -3 AN fitting with white Teflon tape.  Thread NPT side of male-to-male fitting into the brass ‘T’ fitting.  Tighten securely.  Thread one end of the oil supply line onto the other end of the male-to-male fitting.  Tighten securely.  Oil can now be routed to your turbocharger.  Route the oil supply line between intake runners 1 and 2 and over the engine valve cover letting it drape toward the location where the factory exhaust manifold resided.

 

Step 11:

Remove factory front bumper cover from vehicle.  Lift Intercooler up into front bumper area.  Using a Sawzall once again, trim out area shown in photo to allow placement of the intercooler (see photo). CAUTION: CHECK FITMENT FIRST!! YOU MAY NOT NEED TO TRIM IT AT ALL!

 

 

Step 12:

Mount IAP intercooler onto vehicle using 6mm bolts and your straight metal brackets (not included).  The bolts will thread into an existing factory-supplied location on each side of the vehicle between the front suspension members.  Intercooler is pre drilled in the area.  This screw is just for place holding, it is NOT a load-bearing fastener.

 

Step 13:

Feed oil return line up through the space between the A/C pump and engine mounts.  DO NOT let the oil return line rest against the power steering lines!  It WILL chew through them!!

 

Step 14:

Align included oil return flange HORIZONTALLY on the oil pan so you can look down the driver’s side of your engine and see it between the motor mount and A/C compressor.  Hold flange in place and drill oil pan with a 1/2” drill bit to allow oil to return to oil pan.  Align oil return flange and gasket with hole drilled and drill 2 3/8” holes that align with flange into the oil pan going through the pre drilled holes on the oil return flange and gasket.  Apply generous amount of included Permatex silicone sealant to outer edge of oil return flange to ensure a leak free fit.  Allow at LEAST 8 hours for the sealant to cure before refilling engine oil.

 

Step 15:

STOP!

Eat included Snickers bar and take a frustration break!  Snickers Satisfies!  See photo.

 

 

Step 16:

Measure oil return (-10 Aeroquip line) for length. The line should be as straight as possible to avoid oil burning. This is a gravity fed line, there is no pressure. Screw oil return line into oil return flange now mounted on oil pan.

 

Step 17:

Mount turbo to manifold with Copper form-a-gasket included, mount wastegate to flange on manifold, be sure to place gasket between each item (included).  Mount oil return ‘nipple’ to bottom of turbo, using gasket and some supplied silicone gasket material from oil flange installation.  The bolts on the turbo housing can be loosened to adjust the output of the turbo. It should point toward the ground.

 

Step 18:

Slide small diameter hose clamp onto open end of oil return line.  Line the inside of the line with motor oil and attach to the “nipple” on the bottom of the turbo.  It will be tight, this is normal.  Tighten clamp.  Place new Nissan exhaust gaskets on studs and install manifold/turbo/wastegate.  Tighten the nuts working from the outside to the inside, slowly tightening to ensure the manifold ‘seats’ properly against the head.

 

Step 19:

Slide all intercooler piping into place and attach using supplied silicone couplers and hose clamps.  The pipe with the two ‘nipples’ is to be attached to the Nissan inlets under and next to your throttle body (see photo).

 

 

 

Step 20:

Attach included hose from 1/8 NPT barb on intercooler piping to 1/8 NPT barb on wastegate.  Tie off with included ‘zip’ ties.  This must be secured!!  This is the boost controller.  Without a tight connection, the engine is in jeopardy!!

 

Step 21:

Remove the Intake Air temperature Sensor from the factory intake and attach it to your new IAP 3” Intake Pipe. Drill these holes by measuring the IAT sensor against the pipe. Reassemble the air intake system (see photo).

 

 

Step 22:

Reassemble your vehicle.

 

Step 23:

CONGRATULATIONS!  You’re done!

Drive for 500 miles before going above 4000 RPMs.  After that, feel free to lay down R compound at will!!

 

HAPPY MOTORING!