LT1 Impala SS
Turbo System Installation Instructions
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Disconnect battery negative cable.
Remove factory plastic cover over motor.
Remove air intake ducting from throttle body to mass air meter.
Remove air temperature sensor from ducting. Save for re-installation.
Unplug (4) O2 sensors, 2 in front of converters and 2 in rear of converters.
Remove converters from vehicle and remove O2 sensors from the converter pipe.
Remove L.S. exhaust manifold (driver side).
Remove one way air valve from driver’s side manifold.
Carefully bend brake lines out of ABS box towards inner fender panel to clear new exhaust manifold and turbo. Drain oil.
Mark spot on pan at the third bolt from the rear of the pan on the drivers side. 2” down from third bolt drill a 1/4” pilot hole in pan.
Use a 37/64” hole tap and install 3/8” pipe fitting pointing forward. Put silicone around fitting at pan.
Install turbo exhaust manifold using Felpro gasket and (6) stainless bolts (3/8 X 1”). Tighten manifold and safety wire bolts.
Install turbo drain with 1/2” pipe by 5/8” hose barb.
Install oil pressure fitting onto turbo.
Remove 1/4” plug in block above oil filter and cooler adapter.
Install 1/4” pipe fitting supplied with kit. Install #4 90 degree swivel at about the 1 o’clock position. Install #4 hose onto 90 degree fitting and tighten. Be sure hose is routed behind head and away from exhaust.
Install turbo using (4) 3/8” X 1/4” bolts with gasket and lock nuts.
Install oil pressure line onto turbo and oil pan. Tighten clamps.
Install 3” downpipe onto turbo using (4) 3/8” X 1” bolts and gasket. Be sure exhaust pipe is positioned away from steering.
Install one way valve onto 3′ downpipe pointing forward. Connect 10” piece of silicon hose to valve and to coupler. Tighten clamps.
Install heat shield onto turbo.
Remove torque converter shield.
Locate passenger side of crossover pipe with the wastegate mount, and install wastegate onto pipe using (2) 5/16” X 1/4”bolts, lock-nuts, and gasket. Be sure wastegate points down.
Install pipe with wastegate onto passenger manifold using original gasket and nuts. Do not tighten yet.
Install drivers side crossover onto passenger side pipe and onto drivers side manifold using (3) 3/8” X 1&1/4” bolts and lock nuts. Tighten all crossover bolts.
Install oxygen sensor into passenger side crossover and plug in.
Install Y pipe onto downpipe and install drivers side converter using (2) 3/8” X 1&1/2” bolts provided. Do not tighten yet.
Locate 2&1/2” passenger converter pipe and wastegate pipe. Install wastegate pipe into 2&1/2” converter pipe and install into Y pipe and into passenger converter rear. Install 2&3/8” X 1&1/2” bolts into passenger converter rear.
Install wastegate pipe onto wastegate using 2&5/6” X 1” bolt and gasket. Make sure pipe is straight across under converter making sure everything is level and not rubbing anywhere. Install 2&1/2” clamps on front of both converters and on downpipe. Tighten clamps, converter bolts, and wastegate bolts. Install remaining (3) oxygen sensors, tighten and plug in.
Install 90 degree fittings onto boost side of wastegate and onto turbo vacuum hose from turbo to wastegate. Be sure hose does not rub on exhaust.
Locate torque converter shield. You will have to modify this to fir. Trim a little at a time until it fits around 2&1/2’ pipe. You should have about 1/4” clearance when done.
Remove bolts that hold transmission cooler and pull away from AC condenser about 2”. Locate 2 long nuts and (4) 5/16” bolts and washers. Install intercooler in front of AC condenser using 10mm bolt on hood latch on passenger front. Install (1) 5/16” X 3/4” bolt and washer through lower core support and through intercooler lower mount. Use 1 washer and long nut and tighten.
Install transmission cooler onto long nut, with 5/16” X 3/4” bolt. Use other long nut to hold the other end of the transmission cooler.
Remove inner lower fender well in front of drivers tire. Install (2) 2&1/2” hoses onto intercooler. Install 2&1/2” J pipe onto intercooler lower hose so that the J pipe goes around the core support and points back. Install 2&1/2” hose on end of J pipe. Install 2&1/2” S pipe onto end of J pipe. Position S pipe so it is between the fans on the radiator pointing up. Install 2&1/2” hose on end of S pie. Install 4” hose on throttle body. Install 2” intercooler pipe onto intercooler top and on 2” compressor pipe. Tighten all clamps on 2” and 2&1/2” pipes.
Locate lower inner fender well. You will have to trim it to fit around the pipes before you install it.
Install 2&3/4” hose onto turbo inlet. Install 3’ inlet tube and 3” rubber elbow on mass air meter.
Install 3/8” pipe to 1/2” hose fitting onto chrome pipe. Rotate pipe so the fitting is at the 7 o’clock position.
Remove factory breather hose from valve cover to throttle body plug, with supplied 1/2’ vacuum plug and clamp. Install 40” breather hose from valve cover fitting to chrome air inlet fitting.
Install air temperature sensor into 3’ rubber elbow. You will have to extend the wires to the sensor, with supplied wire and butt connectors and split loom.
Locate the small vacuum hose that you removed from the factory air inlet tubing. Install this in the small hole in the bottom of the 3’ rubber elbow.
Install fuel pump.
System now comes with programmable fueler system. Install throttle body plate with injectors between steps ___ & ____. Follow instructions on programming unit.