GReddy Turbo Kit 2003 Infiniti G35 Coupe (VQ35DE) Twin TD05-18G 8cm2
2003 Infiniti G35 Coupe (VQ35DE) Twin TD05-18G 8cm2 Installation Manual Please read the entire manual before installing this kit. Application: Make Infiniti Model G35 Coupe (6 speed MT) Chassis CPV35 Year 2003 • This GReddy Turbo Kit is designed only for the vehicles specified above. • GReddy Front mount intercooler kit is recommended with this kit • Premium grade gasoline (91 octane or higher) is required with this Kit. • Make sure that the vehicle is not equipped with any ECU upgrade chips.
1. Parts List 1. Turbocharger TD05-18G 8cm2 2. Wastegate (GReddy / Tial) 2 .45bar 2 3. Exhaust Manifold (Right Side) Ductile Iron Cast 1 4. Exhaust Manifold (Left Side) Ductile Iron Cast 1 5. Downpipe Adapter (Right Side) 1 6. Downpipe Adapter (Right Side) 1 7. Compression Pipe R C-1 (50∅ Aluminum Elbow No.6) 1 8. “ R C-2 (50∅ Aluminum) 1 9. “ R C-3 (50∅ Aluminum Elbow No.21) 1 10. “ L C-4 (50∅-70∅ Aluminum) 1 11. “ C-5 (50∅ Aluminum) 1 12.
30. Vacuum Hose 5∅ x 100mm (Blue) 1 31. 6∅ x 2000mm (Blue) 1 “ 32. Radiator Reserve Hose 7∅ x 10∅ x 790mm CR60° Tube 1 33. Rubber Hose 15∅ x 1140mm (Oil Return 440mm, Blow By 300mm, Power Steering 200mm) 1 34. Silicone Hose 50∅ x 70mm Straight 6 35. “ 80∅ x 80mm Straight 2 36. “ 60∅ - 70∅ Reducer 2 37. “ 60∅ - 80∅ Reducer 2 38. “ 70∅ - 80∅ Reducer 1 39. Hose Band 12∅ #8 4 40. “ 16∅ #10 9 41. “ 50∅ #32 12 42. “ 60∅ #36 4 43. “ 70∅ #44 5 44.
1. E-Manage (US-Z33) 1 62. “ Harrness 1 63. “ I/J Harness 1 64. “ RPM signal adapter 1 440cc 6 65. Injectors (with 4 aluminum fuel rail spacers) 66. M5 x 15mm Stainless P=0.8 B S/W F/W N 1 67. M6 x 15mm Stainless P=1.0 B S/W - 6 68. M6 x 15mm Stainless P=1.0 B S/W F/W N 5 69. M6 x 40mm Steel P=1.0 B 70. M8 x 15mm Stainless P=1.25 71. M8 x 20mm Stainless 72. M8 x 25mm Stainless 73. M8 x 30mm - - - - 1 B S/W - - 6 P=1.25 B S/W - - 2 P=1.
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2. Factory Parts Removal When removing the stock parts, make sure you read over the factory repair manual for proper procedures. 2-1 Disconnect the negative terminal of the battery. 2-2 Drain the engine oil, coolant and power steering fluid. 2-3 Disconnect the air flow meter. 2-4 Remove the Air cleaner assembly with airflow meter, intake tube, and breather hose. 2-5 Remove the Top Radiator Hose and the Water Pipe (Located above the Right Exhaust manifold).
3. Turbo Kit Installation Thermo Cloth Installation • Remove the bracket securing the fuel line right below the right side shock tower and disconnect the fuel line. Flip the connector so that the line points up and reconnect the line. Double wrap the fuel and evap Line using safety Wire. Leave the top bracket off and secure the bottom back on as shown.
• Wrap the Starter and the Main Engine harness right above the transmission bell housing. Important! Make sure that the main engine harness is properly wrapped and secured away from the manifold and the wastegate when they are installed. Caution! Without proper clearance and thermo wrapping the harness, it melt and cause a short in the electrical system or may catch on fire. Power Steering Line Installation 1. Remove the hose fitting off the power steering pump and install the provided fitting.
Oil Pressure Line Installation Install the oil pressure line to engine block using provided fittings. (Part Used #20, 21, 22, 23, 24) 600mm line is for the right side and 800mm line is for the left side. Exhaust Manifold Installation 1. Remove all factory exhaust manifold stud bolt off from the cylinder head. Install the provided M10 x 35mm stud bolts on to the cylinder head as shown. (Part Used #74) 2. Install the Exhaust Manifold using provided gasket and hardware.
Turbocharger Installation 1. Install the turbocharger on to the exhaust manifold installed in the previous step. * For the left side, remove the steering shaft joint before installing the turbo. * For the right side, remove the bolts holding the starter, and lower the starter before installing the turbo.
Wastegate Installation Install the provided banjo fitting on to the bottom port of the wastegate. (Top Port is used for boost controller) Install the wastegate using the provided gasket and hardware as shown. (Part Used #2, 73) * Left Side (Driver’s Side) Right Side (Passenger’s Side) Double check the clearance between the wastegate and the main engine harness on the right side (passenger side). Make sure that there is enough clearance to avoid the harness from getting to hot and melting.
Vacuum hose for Wastegate Installation Remove the factory engine cover. Locate the rubber plug on the intake manifold and remove it. Connect the 5∅ hose to the intake manifold and by using the three way fitting and connect the 6∅ hose to each of the wastegate fitting. (Part Used #30, 31, 59) Suction Pipe Installation 1. Install the Airinx air filter to the Suction pipe S-2 and S-4. (Part Used #14, 15, 16, 17, 18, 19, 33, 36, 37, 40, 42, 43, 44, 52, 53, 67) 2.
Compression Pipe Installation 1. Install the Air flow meter adapter on tot he air flow meter. 2. Install the Compression pipe C-1, C-2, C-3, C-4, C-5, and C-6 by using the provided hose and hose clamps as shown. Make sure to check all the clearance before securing the hose clamps. * When installing the airflow meter assembly, make sure not to reverse the flow.
Brake Check Valve Installation Install the provided check valve as shown. (Part Used #39, 46) Injectors Installation 1. Remove the upper intake manifold collector, fuel rail assembly with injectors and regulator. 2. Grind the top of the fuel rail as shown to clear the intake manifold. Make sure not to grind too much. Grind the part on the bracket that is raised down flat. Clean the rail thoroughly after grinding. 3. Install the 440cc injectors and reinstall the fuel rail using the provided spacer.
E-manage Installation Install the e-manage and the rpm adapter as shown in the diagram. Make sure to solder all connections except for the ones that are supplied with the male and female connectors. (Part Used #61, 62, 63, 64) Important! • Make sure you fully understand the diagram before attempting this installation. • Improper wiring can damage the ECM and the vehicle's electrical system. • GReddy Performance Product, Inc. will not be responsible for any damage caused by improper installation.
E-manage Installation
E-manage Installation e-manage I/J Harness (18Pin) Factory ECU Pin # Wire Color Description 3 White MAP IN ECU Pin # 51 Color Code Orange Airflow Meter (harness Side) 5 Blue/ Red INJ 1 23 Red/ Black INJ 1 6 Orange/ Red INJ 2 42 Black/ Red INJ 2 7 Yellow/ Red INJ 3 22 Red/ Yellow INJ 3 8 Purple/ Red INJ 4 41 White/ Red INJ 4 10 Green MAP OUT 51 (ECU side) Orange Airflow Meter 11 brown RPM RPM Adapter Brown 12 Black GND 116 Black/ Red ECM ground 13 Red
Starting the Engine 1. Refill the engine oil to factory spec. 2. Check all the hoses and wires connection, then reconnect the negative side of the battery. 3. Turn the ignition to “ON” position 2-3 times to get fuel pressure. Then, check the injectors and the fuel rail for any fuel leaks. * Repair any fuel leaks before starting the engine. Starting the engine with a fuel leak can cause fire in the engine compartment and can be very dangerous. 4.
e-manage Information • • • Important! The e-manage included in this kit is preprogrammed for the this turbo kit. Do not attempt to adjust any of the setting in the e-manage. Any adjustments made can cause damage to the e-manage, engine and the factory ECU. Important! As of 11/25/03 this kit is not a street legal kit. Please ignore the label on the e-manage. ACTIVE L.E.D. (2) When the ignition is turned on, it will illuminate and flash GREEN. (3) When it reaches to the A.A.V.
