AVO Turboworld’s Bolt-on Instructions Manual

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 1 of 25
Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com
[e-mail]

AVOTurboworld Turbo system Fitting Instructions

for the 2001-2004 2.5-liter Subaru Impreza RS

Congratulations on purchasing AVO Turboworld’s Bolt-on Turbo Kit for the Subaru 2.5-liter RS. You are now
the proud owner of a turbosystem that draws on experience gained by not just 10 years of Subaru high
performance tuning, but more importantly 25 years of experience designing, manufacturing, installing and
modifying turbochargers.

Not only will this turbosystem greatly increase your engine’s power over stock, but it will also be user friendly
to drive and will remain so for many years of trouble free operation, with proper installation, servicing and
maintenance.

Contents

Chapter Page

Orientation 2

Tools and Consumables Required 6

Pre-Installation Preparations 7

Disassembly 8

Turbo Oil Return System 9

Turbocharger Assembly 9-10

Turbocharger Cooling + Lubrication 11-12

Turbocharger Intake System 13-14

Mechanical Systems Check 16

Engine Management Installation 17+18+19

Turbosystem Testing 20

Operation and Maintenance 21

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 2 of 25
Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com
[e-mail]

Orientation

Thank-you for choosing AVO Turboworld’s Subaru 2.5Ltr turbosystem! Many hundreds of hours
have been spent testing and developing this final turbocharger, with a large amount of work going
into ensuring the turbosystem seamlessly integrates with the stock engine, transmission and
electronics package. The end result is this complete package solution for turbocharging your
naturally aspirated Impreza RS.

But before grabbing a bunch of spanners and attacking your car take a moment to

STOP AND THINK

Read these supplied installation instructions thoroughly from start to finish – do you understand all
of the mechanical operations required? Are you sure that you can adequately complete all of the
mechanical operations required? Do you understand all of the terminology used in this installation
manual? Your installation skills will have a big effect on whether or not your new turbosystem will
perform to its full potential and give years of trouble free operation, without seriously damaging
either your engine or your wallet.

Prior to starting the installation, make sure that your car is in excellent mechanical condition and that
there are no outstanding faults or problems. This turbosystem has been designed to work only with
a car that is in a good state of repair. Pre-existing problems or faults can result in improper
operation and/or failure of your engine or turbosystem. This is your responsibility to ensure. No
matter how carefully we design our turbosystems, this is one area we have no control over and
cannot be held responsible.

This turbosystem is designed to run on high-octane unleaded fuel. Always use the highest grade of
fuel available in your area. This is essential for correct operation of your car and your new
turbosystem - failure to use high-octane fuel can result in engine damage. Prior to the installation of
this turbosystem ensure that you already have a full tank of high-octane fuel. If in doubt, drain the
fuel tank and refill with high-octane fuel.

Check all parts supplied with the Turbosystem prior to installation for the following;

a) Verify that all parts noted on the turbosystem kitting list have been supplied. Contact AVO

Turboworld or selling agent if any parts are missing.
b) Make sure that all parts are in good condition and have not been damaged during shipping, etc.
c) Take time to make sure you can identify the individual parts supplied to the relevant sections in the

attached fitting instructions.
d) Remember to fill out the attached warranty form and send it in to AVO Turboworld to activate your

product warranty.

AVO Turboworld is committed to constantly improving our range of products as well as our standard

of customer service. If during the course of installation you find any errors contained in our

instructions, or there are areas that could be improved to make installation easier, feel free to either

email us at [e-mail] or fax us at [phone] with your comments / suggestions.

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 3 of 25

Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com

[e-mail]

Kitting List

Note: Check this kit list before starting the install to make that you have all these parts.

1 x Exhaust & Turbo Charger

Assembly

1 x Fitting Instructions

1 x Front Pipe with Cat

PN: 2CJ92T01

25cm x Fire Sleeve

PN: 5Q9BBT01

1 x Oil Drain Fitting

PN: PBSPTC01

1 x Braided Oil Drain Hose

PN: ERZPCT01

1 x Oil Supply Fitting

PN: PBDZWC01

1 x Braided oil Supply Hose

PN: ER3FBT01

1 x Power Air Filter

PN: ENLEC001

1 x Steel Inlet Pipe

PN: 2BLOXT01

2 X 40/60 Hose Clamps

PN: MCF24C01

2” x 2” Blue Silicone Hose

PN: EMH25C01

1 x 32/50 Hose Clamp

PN: MCE04C01

1 x 38mm Blank off Plug

PN: FNFY7T01

6 x 30cm long Cable Tie

PN: KJXE7T01

1 x 12mm Plastic Straight

PM: 7JBM5S02

1 x 12mm Plastic T Piece

PN: 7JBM5S01

1 x 13mm Oil Breather Hose

PN: EN6MBT01

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 4 of 25

Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com

[e-mail]

1 x 5/16” Brass T Piece

PN: 7TJH4T01

4 x 10/16 Hose Clamps

PN: MCBP4C01

100cm High Press. Fuel Hose

PN: ES6H7T01

2 x 10/16 Hose Clamps

PN: MCBP4C01

46cm x5/16 Water Hose

PN:EN0H7T01

35cm x 5/16 Water Hose

PN:ENYH7T01

2 x 70/90 Hose Clamps

PN: MCK54C01

2” x 2 3/4” Blue Silicone Hose

PN:EMK05C01

1 x Intercooler Assembly

with a extra Injector

1 x Intercooler Air Scoop

PN:6H997T01

2 x 50/70 Hose Clamps

PN:MCS634C01

1 x Moulded Rubber Hose

PN: FNHE7C01

1 x 25/40 Hose Clamp

PN: MCDY4C01

1 x 31mm Blank off Plug

PN: FNEW7T01

1 x RH Intercooler Stay

PN: RBVTTT02

1 x LH Intercooler Stay

PN: RBXVTT01

4 x 8x1.25mm Nut

PN:1BEHUT01

4 x 8mm Spring Washer

PN:ABBHUT01

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 5 of 25

Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com

[e-mail]

4 x 8mm Flat washer

PN: ABBHUT01

4 x 8x1.25mm x 25mm Bolt

PN:ABEHUT25

2 x 8mm Spring Washer

PN: ABBHUT01

2 x 8x1mm x 25mm Bolt

PN:ABDHUT2525

4 x 10mmx 1.5mm Nut

PN:ABFJUT01

4 x 10 X 1.5mm x 40mm Bolt

PN:ABFJUT40

1 x 35/40 Hose Clamp

PN: MCDY4CO1

1 X Moulded Black Rubber

Hose

PN: FNEJ7CO1

1 x 32/50 Hose Clamp

PN: MCEO4CO1

1 X 100mm x 38mm Black Hose

PN: FNF67T01

300mm x4mm Vacuum Hose

PN: ENXD7T01

1 x 4mm Plastic T Piece

PN: 7JSD5501

1 x BOV Assembly

PN: S2A97G00A001A

1 x Injector Loom

PN:V299ST01

1 x SMT Computer

PN:91997X01

1 x SMT Computer Loom

PN: W199SX01

1 x Map Sensor

PN:9299SX01

1 x Computer Program

PN:

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 6 of 25

Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com

[e-mail]

Tools Required Consumables Required

Metric Combination Spanner Set New Engine Oil and Filter

Metric Socket Set Engine Coolant (For Topping Up Level)

Phillips point and Flat Blade Screwdriver Set High Temp O2 Sensor Safe Silicone Sealant

Putty Knife or Similar Subaru Oil Pan Silicone Sealer

Trolley Jack and 4 Axle Stands Aerosol Brake / Parts Cleaner or Similar

Vehicle Lift (If Available) WD40 Or Similar Penetrating Oil

Electric Hand Drill Electrical Insulation Tape

Drill Bit Assortment Kit Resin Core Electrical Solder

Multimeter 3mm Diameter Heat Shrink

Access to Gas welding set Subaru 2.5RS Owners Manual

Engine Oil Drain Pan Surgical Gloves or Similar

Soldering Iron Loc-tite Pipe Thread Sealant (or similar)

Side Cutting Pliers / Wire Strippers

Boost Pressure Gauge

Pre-Installation Preparations

1) Select a proper location for installation. You will need a hard flat paved surface in order to
safely jack up and support your car.

2) Disconnect Negative Battery Terminal.

3) Jack up front and rear of car. Support with axle stands. Refer to your Vehicle owners manual
for information on where to correctly place the jack and axle stands so as not to damage any
mechanical parts of your car.

4) Make sure the engine has cooled sufficiently for work to commence.

5) Drain all oil from the engine sump (oil pan) into a proper oil-drain pan.

NOTE!

Extreme caution must be exercised when working underneath your car. Under no circumstances
should you ever work under a unsupported/improperly supported car. Use only dedicated Automotive Axle
support stands. Serious injury/and or Death can result. Care must be taken when handling used engine oils,
avoid contact on unprotected skin. Ensure that all waste oils/solvents are disposed of in an environmentally
friendly approved manner.

Disassembly

Step 1 – Remove factory air-cleaner box and air intake pipes from the throttle body and inner

guard area. Take care when removing the oil system breather hoses to ensure that they are not
damaged or disconnected from the engine. Remove the factory air-cleaner box mounting brackets.

(Need picture of factory airbox and mounting brackets - Figs 1+2 )

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 7 of 25
Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com
[e-mail]

Step 2 – Remove and discard engine lifting/engine wiring harness-mounting bracket as shown in

(Fig 3+4) diagram.

Fig 3: Engine Lifting bracket and wiring

harness

Fig 4

Step 3 - Re-secure the wiring harnesses with plastic cable ties as shown in (Fig 5+6). This is to

make room for the turbocharger, which will fit in this area.

Fig 5: Use plastic cable ties to secure

harness.

Fig 6: Re-route wiring for turbo.

AVOTurboworld – For All Your Turbo Needs

Tel [phone] Page 8 of 25
Fax [phone] Created on 6/17/08 12:30 PM

www.avoturbo.com
[e-mail]

Step 4 – From underneath the car carefully un-plug and then remove the two oxygen sensors from

the factory Catalytic Converter/intermediate section (Fig 7). Spray both sensors with WD-40 to
assist with removal, as they can be difficult to remove. Take care not to damage the sensor body or
mounting threads during removal. Un-bolt and remove stock Catalytic Converter/Centre sectional
and discard.

Fig 7: Stock Catalytic Converters/center section

Step 5 – The air-conditioner receiver drier needs to be relocated to provide enough room for the

turbocharger assembly. Carefully push the receiver drier towards the engine bay firewall
approximately by one inch as shown in (Fig 7). Remove the high-pressure A/C line chassis rail­mounting clip and carefully bend the A/C pressure line in towards the Right Hand Suspension strut
tower. Refer to (Fig 8)

Caution! Be extremely careful when bending air conditioner hoses. Only bend hoses enough to
provide adequate clearance. Air conditioner systems contain gas at very high pressure. Over­stressing air conditioner lines can result in a discharge of high-pressure gas. Exposure to this can
result in serious injury.

Fig 8: Push receiver drier towards engine

bay firewall.

Fig 9: Push high-pressure A/C line in

against suspension strut.