Turbonetics P-N 15152 User Manual

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.com

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. This
complete turbocharger system can be installed using common tools and automotive procedures, but installer must
have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle. If in
doubt, contact Turbonetics’ technical support staff at 805-581-0333, between the hours of 8:00AM and 5:00PM
PST, Monday through Friday.

Remove the turbocharger system from its carton and inspect for any obvious physical damage. All kit
components are thoroughly inspected and carefully packaged prior to shipment from the factory. If any shipping
damage is evident, contact your supplier and request that they process a claim with the shipper involved. Be sure
to review the parts list on page 3 to verify that you have all necessary system components to proceed. If any
components in the parts list are missing, contact Turbonetics’ customer service staff.

Although this turbocharger system has been designed to use many of the factory emissions controls, it is not
currently “smog” legal in California, and therefore recommended for “off road” use only. In other states, check
local laws regarding aftermarket modification to emission controlled vehicles.

The information contained in this publication was accurate and in effect at the time the publication was approved
for printing and is subject to change without notice or liability. Turbonetics reserves the right to revise the
information presented herein or to discontinue the production of parts described at any time.

SAFETY REQUIREMENTS: It is recommended to follow these precautions.

• Always wear safety glasses & gloves.

• Turn the ignition switch to the OFF position & disconnect the battery.

• Always use properly rated jack stands when working under the vehicle.

• Prevent unexpected vehicle movement by using wheel chocks and/or parking brake.

• Operate the vehicle only in well ventilated areas.

• Do not smoke or use flammable items near or around the vehicle’s fuel system.

• Keep hands, clothing and other objects away from moving parts when engine is running.

SUPPLIES: It is recommended to have the following items before beginning installation.

• Toyota factory service manual, for your model year Scion TC

• A large table or bench, and plenty of adjacent available workspace

• Standard selection of automotive tools, primarily metric sizes

• An assortment of “zip ties” and/or thin-gauge steel wire

• The ability to securely lift the vehicle at least a few feet off the ground

• High temp. automotive RTV sealant

• NPT thread sealant

• Replacement engine oil and oil filter

• Hammer

60133 revG Page 2 of 38

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 10 13
5/16” or 8mm 19 25
3/8” or 10mm 33 45

NPT fittings 2-3 turns past finger tight

TURBOCHARGER SYSTEM PARTS LIST:

QTY P/N DESCRIPTION P/N 15152

1 11118 Turbocharger, E50 / Stg.2 / Ball Bearing X
1 5-340 Air to Air Intercooler, Spearco X
1 10781 Wastegate, Evolution X
1 10843 Blow-off Valve, Raptor X

1 11124 Hardware Kit, Nuts / Bolts / Fittings / Misc. X
1 11126 Hardware Kit, Fuel Components X

1 21239 Tube, Turbocharger to Intercooler X
1 21240 Tube, Intercooler to Throttle Body – 1 X
1 21241 Tube, Intercooler to Throttle Body – 2 X
1 21242 Tube, Intercooler to Throttle Body – 3 X
1 21238 Tube, Air filter to Turbocharger X
1 21243 Tube, Exhaust, Downpipe X

1 21279 Manifold, Exhaust X
1 31040 Heat Shield, Tangential T3 housing X
1 31080 Air Filter, AEM Dry-Flow, 3.0” Inlet X
1 21286 Fuel Controller, UniChip X
1 60133 Install Instructions X

Torque

(Pound-Feet)

Torque

(Newton-Meters)

60133 revG Page 3 of 38

QTY P/N DESCRIPTION QTY P/N DESCRIPTION

HOSES / CLAMPS PARTS LIST:

2 30128-4 Silicone Hose Coupling, 2.0”
1 30162-4 Silicone Hose Coupling, 3.0”
1 30172-4 Silicone Hose Coupling, 2.50”
1 21364 Silicone Hose Coupling, 2.50”

x 6.50” long

1 30380-4 Silicone Hump Connector,

2.50”

HARDWARE KIT# 11124 (NUTS / BOLTS / FITTINGS) PARTS LIST:

1 30133 Fitting, 3/8” NPT x 5/8” Hose,

Straight

4 30306 Fitting, 1/8” NPT x 5/32” Hose,

Straight

4 30307 Fitting, 1/8” NPT x 5/32” Hose,

Elbow
1 30544 Fitting, 1/8” NPT x -3, Straight
1 30551 Fitting, 1/8” NPT x -3, Elbow
1 30562 Fitting, 1/8” NPT, M x M x F
1 30244 Fitting, ½” NPT x 5/8” Hose,

Straight
1 31068 Fitting, Hose Tee - Nylon
2 30570 Hex Bolt, 5/16 -18 x 1.0" Lg.
4 30739 Hex Bolt, M8-1.25 x 25mm Lg.
3 30700 Hex Bolt, M8-1.25 x 20mm Lg.
2 30248 Hex Bolt, 1/4-20 x 5/8” Lg.
1 31003 Hex Bolt, M10-1.25 x 40mm Lg.
2 31071 Screw, M4-0.7 x 10mm, BHCS
9 30589 Flat Washer, 5/16” or M8
6 30804 Flat Washer, M10
1 30591 Flat Washer, 1/4" or M6
9 30593 Lock Washer, 5/16” or M8

HARDWARE KIT #11126 (FUEL COMP’TS) PARTS LIST:

4 21382 Fuel Injector, Upgrade

1 30444-4 Silicone 45’ Elbow, 2.50”

3 ft. 30827 Hose, Oil Drain – 5/8”

1 31072-4 Silicone Hose Coupling, 1.50”
4 30275-200 T-Bolt Clamp – 2.0”
8 30275-250 T-Bolt Clamp – 2.50”
2 30275-300 T-Bolt Clamp – 3.00”

5 30805 Lock Washer, M10
1 30586 Hex Nut, Nylon Lock
2 30653 Hex Nut, M8
5 30803 Hex Nut, M10-1.25
4 30806 Stud, M10-1.25 x 42mm Lg.
2 30860 Stud, M8-1.25 x 30mm Lg.
1 30862 Hex Plug for O2 Bung, M18-1.5
1 31067 Mount, Vibration Damping – Blk.
1 20259 Flange, Oil Drain – ½” NPT
1 21273 Tool, Center Punch
1 21376 O2 Sensor Ext. Boss
1 30808 Tap, 1/8 NPT
1 30809 Tap, 3/8 NPT
1 20142 Gasket, Wastegate
1 30468 O-Ring, Blow off Valve
2 30612 Clamp, Hose, Liner Style #020
4 30817 Clamp, Hose, Worm Drive, 5/8”
1 31014 Oil Supply Hose, -3 x 12”
1 31007 Heat Shield Wrap – 1.5” Wide x

7.5” Long

12 30542-

BK

4 31079 Pig Tail Harness, Fuel Injector

Hose, Vacuum, Silicone – 5/32”

60133 revG Page 4 of 38

P/N 11118 P/N 5-340 P/N 10781

P/N 10843 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 21279

P/N 21286 P/N 31080 P/N 60133

60133 revG 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. SEE FIGURE 4 & 5
FIGURE 4 FIGURE 5

60133 revG Page 7 of 38

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. SEE FIGURE 10

60133 revG Page 8 of 38

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. SEE FIGURE 12

FIGURE 12

60133 revG Page 9 of 38

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. SEE FIGURE 16 & 17

FIGURE 16 FIGURE 17

60133 revG Page 10 of 38

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. SEE
FIGURE 19

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. SEE FIGURE 20

FIGURE 20

60133 revG Page 11 of 38

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. Remove the factory intake tube that connects to the throttle body by pinching the tabs on the hose clamp
with a pair of pliers. SEE FIGURE 23

FIGURE 23

60133 revG Page 12 of 38