INSTALLATION INSTRUCTIONS TURBOCHARGER SYSTEMS: 2004- Scion TC Manual Transmission Only P/N 15152 (No Catalytic Converter) Turbonetics, Inc. * 2255 Agate Court * Simi Valley, CA * 805-581-0333 * TurboneticsInc.
READ THIS FIRST: Study these instructions completely before proceeding. Engine and/or turbocharger damage may occur if any component within these instructions is improperly installed. Turbonetics, Inc or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation.
TORQUE RECOMMENDATION: When removing and re-installing factory fasteners, refer to the Toyota / Scion service manual for torque values. When installing fasteners included in this kit, refer to the following chart: Fastener Size 1/4" or 6mm 5/16” or 8mm 3/8” or 10mm NPT fittings Torque Torque (Pound-Feet) (Newton-Meters) 10 13 19 25 33 45 2-3 turns past finger tight TURBOCHARGER SYSTEM PARTS LIST: QTY P/N 1 1 1 1 11118 5-340 10781 10843 Turbocharger, E50 / Stg.
QTY P/N DESCRIPTION QTY P/N DESCRIPTION 1 3 ft. 1 4 8 2 30444-4 30827 31072-4 30275-200 30275-250 30275-300 Silicone 45’ Elbow, 2.50” Hose, Oil Drain – 5/8” Silicone Hose Coupling, 1.50” T-Bolt Clamp – 2.0” T-Bolt Clamp – 2.50” T-Bolt Clamp – 3.00” HOSES / CLAMPS PARTS LIST: 2 1 1 1 30128-4 30162-4 30172-4 21364 1 30380-4 Silicone Hose Coupling, 2.0” Silicone Hose Coupling, 3.0” Silicone Hose Coupling, 2.50” Silicone Hose Coupling, 2.50” x 6.50” long Silicone Hump Connector, 2.
P/N 11118 P/N 5-340 P/N 10843 P/N 10781 P/N 11124 P/N 21238 P/N 11126 P/N 21241 P/N 21240 P/N 21242 P/N 21239 60133 revG Page 5 of 38
P/N 21243 P/N 31040 P/N 21286 P/N 31080 60133 revG P/N 21279 P/N 60133 Page 6 of 38
Prepping the Vehicle for Turbo Kit Installation 1. Jack up the vehicle to a workable height and secure vehicle with jack stands. SEE FIGURE 1 FIGURE 1 2. Using a 10mm socket, remove undercarriage plastics splash guard. SEE FIGURE 2 & 3 FIGURE 2 FIGURE 3 Removing the Front Fascia 1. Using a 10mm socket, remove the bolt inside the fender well.
2. Using a small flat head screwdriver, carefully insert the screwdriver in the indented slot on the plastic trim clip and pry upwards. SEE FIGURES 6, 7, & 8 FIGURE 6 FIGURE 7 FIGURE 8 3. Remove front fasica by pulling it forward 4. Remove foam bumper reinforcement. SEE FIGURE 9 FIGURE 9 5. Remove plastic air dams on each side of the vehicle. Air dams are secured to the vehicle with the plastic trim clips that can easily be removed by using a flat head screwdriver.
FIGURE 10 Exhaust Disassembly 1. Unplug O2 sensor and remove the plastic securing ring that holds the wire to the radiator hose. SEE FIGURE 11 FIGURE 11 2. Remove the cosmetics plastic engine cover by unscrewing two 10mm nuts.
3. Remove the factory exhaust head shield by unscrewing the three 12mm bolts and one 12mm nut. SEE FIGURE 13 & 14 FIGURE 13 FIGURE 14 Note: Careful while removing the heat shield, it tends to get caught up with the O2 sensor and other things in the area. 4. Unscrew the O2 sensor with a 7/8” open end wrench or with a O2 sensor socket. SEE FIGURE 15 FIGURE 15 5. Using a 14mm socket, remove the stock catalytic converter support brackets.
6. Unbolt spring loaded bolts that connects the stock catalytic converter to the down pipe. SEE FIGURE 18 FIGURE 18 7. Save the exhaust crush ring gasket, this will be used when installing the new supplied down pipe. 8. Remove the five bolts that hold the stock exhaust manifolds to the head with a 12mm wrench. FIGURE 19 SEE FIGURE 19 Stock Intake Disassembly 1. Unplug the mass air sensor and remove the two Phillips screws that mounts the sensor to the factory air box.
2. Carefully lift the mass air sensor out of the factory air box and set it aside. You will be re-installing the sensor on a supplied intake pipe at a later time. 3. Remove the engine breather hose by pinching the tabs on the hose clamps with your finger or a pair of pliers and push the clamp away from the motor. SEE FIGURE 21 FIGURE 21 4. Loosen hose clamp that connects the intake tube to the air box. SEE FIGURE 22 FIGURE 22 5.
6. Remove the sensor that is mounted to the factory intake tube by inserting a small flat head screwdriver between the sensor bracket and the intake tube bracket. SEE FIGURE 24 FIGURE 24 7. Remove the factory air box by unbolting the three 10mm bolts inside. SEE FIGURE 25 FIGURE 25 8. Remove the factory cold air intake tube by unscrewing the Phillips screw that mounts the factory cold air intake tube to the body.
Fuel System Upgrade 1. Cut the vacuum hose that connects to the throttle body in half and install the supplied T-fitting in the orientation. SEE FIGURE 27 & 28 FIGURE 27 FIGURE 28 2. Unplug the four factory injectors by squeezing the tab on the side of the plugs and pulling upwards. 3. Disconnect the plug to the VVTi actuator by the passenger side of the fuel rail. 4. Unbolt both 12mm nuts that holds the fuel rail to the head. SEE FIGURE 29 FIGURE 29 5.
6. Remove stock fuel injectors from the fuel rail. Careful not to lose any of the o-rings when removing them. 7. Connect the new supplied injector pig tails to the factory harness by cutting the stock injector connector plugs off the factory harness. Cut wires around 2 ¾” from the edge of the connector, leaving enough wire length to connect the new plugs. SEE FIGURE 31 FIGURE 31 8. Crimp the new supplied connectors to the factory harness. Make sure the polarities are correct. FIGURE 32 & 33 SEE a.
9. Remove the o-rings from both the top and bottom of the stock injector and install them on the new supplied injectors (P/N 21382). SEE FIGURE 34, 35, & 36 FIGURE 34 FIGURE 35 STOCK STOCK SUPPLIED UPGRADE INJECTOR P/N #21382 SUPPLIED FIGURE 36 10. Slightly coat the outside of both o-rings with grease to ease installation of the injectors to the head and the rail. 11. Carefully insert the injector to the bungs on the head making sure the o-rings does not get kinked.
Installing Turbo Oiling System Turbo Oil Feed 1. Locate the oil sending unit on the driver’s side of the head. On top of the radiator hose connection. SEE FIGURE 37 FIGURE 37 2. Unplug the wires that are connected to the sensor and using a 24mm socket, remove the sensor from the head. 3. Re-tap the threaded hole using the supplied 1/8-27 NPT tap. Make sure you coat the tap with a lot of grease so no chips from the re-thread will enter the motor. 4.
Turbo Oil Drain 1. Using the supplied center punch (P/N #21273) and a hammer, punch a hole through the oil pan. Do not use a drill, by using a center punch, the material that bends over is used for threading. SEE FIGURE 39, 40, & 41 FIGURE 39 ~1.0” ~2.25” FIGURE 40 FIGURE 41 2. Coat the supplied 3/8” NPT tap (P/N #30809) with grease to insure no metal debris will enter the pan and tap the hole you just made.
3. Apply a small amount of high temp RTV to the threads of the supplied 3/8” NPT to 5/8” barb brass fitting (P/N #30133) and the threads in the oil pan as shown in the picture below. Thread the fitting into the pan and tighten. SEE FIGURES 43, 44, & 45 FIGURE 43 FIGURE 44 FITTING P/N #30133 FIGURE 45 Assembling the Turbo and Mounting it to the Manifold 1. Thread the four supplied M10x1.25 studs (P/N #30806) onto the turbo mounting pad on the manifold.
2. Slide the supplied turbo inlet gasket (P/N #30263) onto the four studs and mount turbocharger onto the manifold as shown in picture 47. 3. Secure the turbocharger to the manifold using the supplied flat washer (P/N #30804), lock washer (P/N #30805), and nut (P/N #30803), in those respective order. SEE FIGURE 47 FIGURE 47 4. Install the supplied oil drain flange (P/N #20259) to the turbocharger with a supplied oil drain gasket (P/N # 30141)in the middle.
FIGURE 49 FIGURE 50 FLANGE TO WASTEGATE DOWNPIPE P/N #21243 FLANGE TO FACTORY DOWNPIPE 2 FLANGE TO TURBO M8-1.25 x 20mm BOLT HIGH TEMP. RTV 9. Use five M8 flat washers (P/N #30589), four M8-1.25 x 25mm bolts (P/N #30739) and one M8-1.25 x 20mm (P/N #30700), mount the downpipe to the turbocharger. Hand tight all the bolts. SEE FIGURE 50 10.
Mounting the Turbo Assembly to the Engine 1. Bolt the turbo and manifold assembly onto the head. SEE FIGURE 52 & 53 FIGURE 52 FIGURE 53 2. Finger tight all five bolts that mount the manifold to the head. Make sure the factory exhaust gasket is reinstalled. 3. Slide the factory exhaust donut onto the new supplied downpipe. SEE FIGURE 54 FIGURE 54 4. Bolt the factory secondary downpipe to the new downpipe using the original spring loaded bolts finger tight only.
5. Using the original factory bolt, bolt the turbo downpipe support bracket to the side of the engine block. 6. Tighten the nuts that hold the manifold to the head first, and then tighten the bolt that support the turbo downpipe to the block and then the bolts that connect the secondary factory downpipe to the new supplied downpipe. 7. Apply a small amount of anti-seize to the threads of the factory O2 sensor and install the O2 sensor to the new turbo downpipe. 8.
FIGURE 59 Mounting Turbo Heat Shield 1. Wrap the supplied heat shield (P/N #31040) onto the turbine housing. SEE FIGURE 58 FIGURE 58 2. Using safety wires, secure the heat shield to the turbine housing. Mounting the Intercooler and Routing the Boost Tubes 1. Slide the intercooler (P/N #5-340) in place. The top mount of the intercooler should line up with the left side of the center core support reinforcement bar. 2. Bolt the intercooler to the center support bar using the supplied M10-1.
FIGURE 59 3. The bottom brackets of the intercooler should both line up with the existing mounting holes. When reinstalling the front fascia later, the factory bolts will bolt the intercooler to the core support. 4. Slide the supplied 6.50” long silicone hose (P/N #21364) on to pipe #21240. SEE FIGURE 60 & 61 5. Using a 2.50” (P/N #30172-4) silicone hose, connect the pipe to the intercooler, making sure the end with the 6.
FIGURE 62 FIGURE 63 PIPE P/N #21239 SIDE TO INTERCOOER FIGURE 64 7. Using the 45 degree silicone hose and two supplied 2.50” t-bolt clamps (P/N #30275-250), attach intercooler pipe assembly (P/N #21242) to the throttle body.
FIGURE 67 8. Install the supplied 2.50” silicone hump connector (P/N #30380-4) to the other end of the pipe that is connected to the throttle body, securing it with a 2.50” t-bolt clamp (P/N #30275-250). 9. Connect intercooler pipe assembly (P/N #21241) from the throttle body pipe to the pipe (P/N #21240) with the 6.50” long silicone hose. Secure pipes with the supplied 2.50” t-bolt clamps. SEE FIGURE 68 & 69 FIGURE 68 FIGURE 69 PIPE P/N #21241 SIDE TO THE 6.
FIGURE 72 11. Install the rubber o-ring (P/N #30468) into the groove of the blow off valve flange and install the Raptor blow off valve to the flange using the supplied ¼-20 x 5/8 serrated bolts (P/N #30248). Make sure the oring remains in its groove. Rotate the valve so it facing toward the front of the vehicle. Slide the supplied 1.50” diameter silicone hose (P/N #30172-4) onto the discharge of the valve. Secure using band clamps (P/N #30612). 12.
FIGURE 75 13. Install the supplied AEM Dry-Flow air filter (P/N #31080) to the other side of pipe assembly (P/N #21238). Re-install the factory mass air sensor on to machined flanged on the pipe. Bolt the sensor to the pipe using the supplied socked head allen bolts (P/N #31071). Don’t forget to plug the sensor. SEE FIGURE 76 & 77 FIGURE 76 FIGURE 77 PIPE P/N #21238 MASS AIR SENSOR FLANGE 14. Cut the supplied 5/8” hose (P/N #30827) to 11.0”.
FIGURE 80 Connecting the Signal Line to the Blow of Valve and Wastegate 1. Install 1/8”NPT to 5/32” barb fitting (P/N #30306) to the TOP port in the top cover of the blow off valve. Apply a small amount of thread sealant. SEE FIGURE 81 FIGURE 81 2. Cut the supplied 5/32” vacuum tubing (P/N #30542-BK) to length and connect the fitting on the blow off valve to the t-fitting by the throttle body. Next, connect the vacuum hose from the fitting on the turbo compressor housing to the fitting on the wastegate.
2. Replace the factory foam bumper bar back onto the reinforcement bar. SEE FIGURE 83 FIGURE 83 3. Replace the bottom plastic splash guard and front fascia. The factory bottom front fascia bolts will also secure the bottom intercooler brackets to vehicle.
Installing the UniChip PnP System 1. The factory ECU is located behind the glove box. Open the glove box and push on both sides toward the middle of the box and pull towards you slightly to release the box. SEE FIGURE 87, 88, & 89 FIGURE 87 FIGURE 88 PUSH FIGURE 89 PUSH 2. Rotate the glove box downwards to gain access to the hinge. Squeeze the plastic hinge together and push it away from the supporting rod for both sides.
3. Locate the factory ECU and unplug plugs #1, 3, and 5. SEE FIGURE 91, 92, & 93 FIGURE 91 FIGURE 92 5 4 FACTORY ECU 3 2 1 FIGURE 93 5 3 1 4. Using the supplied velcro, attached the Unichip PnP to the side of the factory ECU. Connect the harness from the Unichip PnP to the factory ECU and connect plug #1, 3, & 5 from the factory harness to the PnP unit.
FIGURE 96 TO FACTORY ECU UNICHIP PnP TO ECU HARNESS UNICHIP ECU UNICHIP PnP UNIT 5. Using the supplied plastic zip tires, zip tie the PnP wire harness together so it is out of the way of the glove box. SEE FIGURE 97 FIGURE 97 6. Secure the Unichip ECU to the flat tray beneath the OEM ECU.
FINAL CHECKLIST: • Review these instructions to make sure that all fasteners, clamps & electrical connections have been installed & torqued correctly. • Check that all hose routings are free of any kinks or near any hot or abrasive surfaces, that may cause wear over time. Adjust or reroute as necessary to provide adequate slack for engine movement. • Refill all fluids (oil & power steering) to factory recommended levels.
Turbonetics logo. The bottom port should be open. For the wastegate the fitting should be in the lower port furthest from the red Turbonetics logo. The upper port should be open. 3. Check for boost leak at or after MAF 4. Verify throttle body is operating properly 5. Ensure the O2 sensor extender provided from Turbonetics is installed on the second factory O2 sensor. The second O2 sensor is the one on the S pipe.
3. Turbo seal failed 4. Verify oil pressure Maximum boost limits on stock motor: 1. The stock 2AZ-FE has shown to be rather stout but it is not recommended boost pressure be increased above 8 PSI. However, there are reports of several customers running 9.5 PSI of boost with success while using the Spearco WIS part number 30993. A DIY instructional thread on Scion Tc installation of this system is posted on www.turboneticsownersclub.com in the Spearco Water Injection System Forum 2.
Warranty will not be granted for recurring damage, malfunction, or failure due to improper installation, misuse, unauthorized repair or alterations, or externally induced physical damage. Warranty is non-transferable and must be processed via the original purchaser from TURBONETICS. Remanufactured units, performance upgraded units, and O.E.M. replacement units are covered by a 90-day warranty or the O.E. warranty period.
