In this phase, prior to even working on the vehicle, I will assemble and
dry-fit certain items in preparation to be mounted. We will also make some
modifications to allow fitment to the ZC engine.
| First you will want to grind off the "tabs"
on the bottom of the exhaust manifold. Be sure to test fit the
header before trying to mount the entire assembly (shown in next section). |
<picture to come> |
| Though it is optional and not necessary if you intend to use
just the stock 5 PSI boot, you can port (remove extra cast iron in
the manifold and turbo) the kit to make the air flow a bit smoother.
Shown in this photo is the ported turbo housing that exactly matches the
exhaust manifold. |
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| Next you will need to prep the turbo for installation into
the car. These are the parts required for the assembly of the oil
supply line that will come from the engine to cool and lubricate the
turbo.
Shown are parts:
11, 10, 9 |
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| This is the mounted oil supply line shown from the front of
the turbo housing. The oil supply line will be routed underneath the
manifold and around the drivers side of the vehicle. |
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| These are the parts required for the assembly of the oil
return line that will come from the turbo and return the oil to the oil
pan.
Shown are parts:
18, 14 (screws, washers, and oil return hose)
|
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| This is the mounted oil return line shown from the bottom of
the turbo. |
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| Be aware that there are TWO different types of
"studs" used to connect the turbo to the header. On the
left is the stud used for the down pipe (part #4) and there should be
three of these. The stud to the right is used for connecting the
turbo inlet to the exhaust manifold. |

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| These are the parts required for assembly of the exhaust
manifold to the turbo. Do NOT assemble this at this time as you
want to make sure the exhaust manifold will fit on the engine block first.
If you have already ported the manifold then you can insert the
"studs" into the manifold.
Shown are parts:
2, 44, 25, washers (lock) and nuts and turbo |
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| This is the completed turbo assembly. As you can see
it has the oil supply and return lines attached. It also had the
turbo outlet (part #3) attached to it along with the studs (and gasket,
washers and nuts) |
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