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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.
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

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.
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)

 

This is the mounted oil return line shown from the bottom of the turbo.
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.

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

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)
   
 
All content copyright David Moore 2000, 2001