PWR TWIN-TURBO KIT by wxr16887

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									              INSTALLATION AND INSTRUCTION GUIDE
                                            FOR
                                     FAIRLADY Z (Z33)
                           VQ35DE(2002.08~2004.09)



 Contents                                                                    Page
        1.    Before Installing (pg 2)                                         2
        2.    Attention (pg 2)                                                 2
        3.    Content List                                                    3-4
        4.    Figure of KIT (Sketch Map)                                      5-6
        5.    Removal of Factory OEM Parts                                    7-9
        6.    Installation of Exhaust Manifold                                 9
        7.    Installation of Turbocharger                                   10 - 11
        8.    Removal and Installation of Oil Pan                            11 - 13
        9.    Power-steering Cooler Relocation                               13 - 14
        10.    Installation of Intercooler and Removal of Reservoir Tank     14 - 15
        11.    Installation of Injectors                                       15
        12.    Installation of Piping and Air Filter                         15 - 19
        13.    Installation of Fuel Pump and Regulator                       19 - 20
        14.    Vacuum Hose Routing and Actuator                              21 - 22
        15.    After the Installation                                          23
        16.    Turbo Vehicle Requirements                                      24


      Issued on 1St December, 2003         COPY AND REPRODUCTION FORBIDDEN
      Revised on 11th April, 2005


Z33 TWIN-TURBO KIT
                                              1
1. Before Installing

      Read this installation guide in it’s entirety before beginning the installation.
      Fit and remove factory OEM parts following the factory service manual and this guide.
      This product has been designed for installation on factory spec vehicles.
      We do not guarantee the function, performance and safety of this TWIN-TURBO KIT if installed in a vehicle other
       than specified.
      We accept no responsibility for the damage that may result if any components in this kit are modified, dismantled
       or installed in a vehicle or engine other than specified.
      This guide and the components are subject to be change without notice.
      Keep this guide filed in a safe place, readily accessible at any time.
      If the engine check light turns on after installation, please check all connections to ensure proper reinstallation of
       factory sensors and connectors.
      The power and heat created by the engine increases by use of the Power Enterprise Twin Turbo Kit.          Because of
       this we highly suggest you raise the heat value of the spark plug.       (Recommended value is NGK No.7 or No.8)
      Use unleaded high-octane gasoline ONLY.
      Use a high grade engine oil designed for turbo applications (10W40 and 15W50)


2. Attention

      This kit was designed to be installed only in the Z33, NISSAN FAIRLADY 350Z (VQ35DE) engine.
      Handle the TWIN-TURBO KIT components carefully.             Do not drop or subject to strong shocks or damage may
       occur.
      Ask a trained service technician to install this kit.
      Confirm the contents of this turbo kit following the KIT components list (Page3-4)
      Re-use the original OEM bolts and nuts that are not included in this turbo kit.
      It dangerous to modify any part of this turbo kit as the components in and around the turbo kit may possibly be
       damaged resulting in an unsafe condition.
      Some slight modifications to the vehicle may be required for installation of this turbo kit.
      Disconnect the minus (-) terminal on the battery prior to the installation.
      Tighten the bolts and nuts to factory torque specs with the proper tools.
      Keep connectors and couplings away from oils and other contaminants.           Promptly clean parts if they come into
       contact with contaminants.
      Keep the pipes and turbochargers away from any dust or other contaminants that may damage the rotating
       assembly.   Failure to do so may cause irreparable damage to parts or engine.
      When working with the fuel system, do so in a well ventilated area to avoid a hazardous environment. *Promptly
       contact the shop you purchased this Power Enterprise TWIN-TURBO KIT if the model of your vehicle is not the
       one specified to this turbo kit.




Z33 TWIN-TURBO KIT
                                                               2
3.   Content List.

        No.                           Part Description          Quantity                Details
         1       PE1420 Turbocharger                               1       Separative Actuator, Left Side
         2       PE1420 Turbocharger                               1       Separative Actuator, Right Side
         3       Exhaust Manifold                                  1       Left Side
         4       Exhaust Manifold                                  1       Right Side
         5       Exhaust Outlet Pipe                               1       Left Side
         6       Exhaust Outlet Pipe                               1       Right Side
         7       Oil Return Outlet Pipe                            1       Left Side
         8       Oil Return Outlet Pipe                            1       Right Side
         9       Oil Return Inlet Pipe for Oil Pan                 2
         10      Turbo Oil Feed Line                               1       Length = 1100mm, Left Side
         11      Turbo Oil Feed Line                               1       Length = 650mm, Right Side
         12      Turbo Oil Feed Line Banjo Bolt                    2
         13      Turbo Oil Feed Pressure Block Assembly            1       PT1/8 Including Nipples
         14      High Capacity Aluminum Oil Pan                    1
         15      Oil Return Hose φ15                               2       Length = 320
         16      Turbo, Exhaust Manifold Gasket                    2
         17      Turbo Outlet Gasket                               2
         18      Oil Return Gasket                                 4
         19      Intake Pipe                                       1       Left Side
         20      Intake Pipe                                       1       Right Side
         21      Air Filter Adapter                                1       Left Side
         22      Air Filter Adapter                                1       Right Side
         23      Turbo Compressor Outlet Pipe                      1
         24      Turbo Compressor Outlet Pipe                      1
         25      Intercooler Piping                                1       Turbo side of Intercooler
         26      Intercooler Piping                                1       Turbo side of Intercooler
         27      Piping to Intercooler                             1       2 Into 1 Piping, IN
         28      Piping from Intercooler                           1       Φ70mm – φ80mm, OUT
         29      Piping to Throttle Body                           1       φ80mm Piping
         30      Intercooler Assembly                              1
         31      Intercooler Mounting Bracket                      1       Upper Side
         32      Intercooler Mounting Bracket                      2       Lower Side
         33      Power-steering Cooler Relocation Bracket          2       Left Side
         34      Power-steering Cooler Relocation, Joint Pipe      2       φ10mm Hard Pipe
         35      Power-steering Cooler Relocation Hose             2       φ9mm x 900mm
         36      Reservoir Tank Bracket                            1       L Type, Short
         37      Reservoir Tank Bracket                            1       L Type, Long
         38      Reservoir Tank Hose                               1       φ8mm Length = 1000mm
         39      Air Impulse II Filter, S                          2
         40      Air Impulse II Gasket                             2
         41      Silicone Hose φ6 Actuator side                    1       Length = 2000mm
         42      Silicone Hose φ45                                 4       Intercooler Piping, Turbo Side
         43      Silicone Hose φ50                                 2       Air Impulse II Intake Piping
         44      Silicone Hose φ70                                 2       Intercooler IN & OUT
         45      Silicone Hose φ80                                 2       Throttle Body Piping
         46      Hose Band φ6-15                                   6
Z33 TWIN-TURBO KIT
                                                            3
     47    Hose Band φ11-φ18                               4    Power Steering Hose
     48    Hose Band φ14-φ27                               6
     49    Hose Band φ33-φ57                               8    For φ45mm Piping
     50    Hose Band φ40-φ63                               4    For φ50mm Piping
     51    Hose Band φ59-φ82                               4    For φ70mm Piping
     52    Hose Band φ65-φ89                               4    For φ80mm Piping
     53    Turbo Compressor IN side Gasket                 2
     54    Turbo Compressor OUT side Gasket                2
     55    Blowby Hose φ15                                 1
     56    Blowby Joint Pipe Straight                      1    φ16
     57    Blind Cap Surge Tank side                       1    φ10
     58    Three-way T splitter                            1    φ6-φ6-φ6
     59    High Capacity Injectors                         6    Color, O-ring Assembly
     60    255L/H Fuel Pump                                1
     61    Fuel Pressure Regulator                         1
     62    Fuel Pressure Regulator Block                   1    Including Fuel Tube
     63    Fuel Pressure Regulator, Fuel Return Hose       1    φ8 Length = 500mm
     64    Fuel Pressure Regulator, Vacuum Hose            1    φ4 Length = 4000mm
     65    Heat Wrap                                       1    100mm x 1000mm
     66    Wire                                            1    Length = 1000mm
     67    Stud Bolt M19 SUS EX Manifold                   11   Length = 38mm
     68    Stud Bolt M19 SUS EX Manifold                   3    Length = 32mm
     69    Stud Bolt M8 SUS                                13   Length = 35mm
     70    Bolt M8 SUS L=20                                5
     71    Flange Nut M10 SUS                              11
     72    Nut M10 SUS                                     3
     73    Nut M8 SUS                                      13
     74    Drain Plug, Oil Pan                             1
     75    Copper Washer Drain Plug, Banjo Bolt            5    φ12mm
     76    Cap Bolt M6 Oil Pan                             3    Length = 60mm
     77    Cap Bolt M6 Oil Pan                             7    Length = 20mm
     78    Flange Bolt M8 Uni-chrome L=12mm                12
     79    Bolt M6 Uni-chrome                              2    Length = 8mm
     80    Bolt M6 Uni-chrome                              6    Length = 12mm
     81    Bolt M6 Uni-chrome                              7    Length = 15mm
     82    Bolt M6 Uni-chrome                              12   Length = 18mm
     83    Self Tapping Screws                             2    Length = 15mm
     84    Nut M6 Uni-chrome                               6
     85    Zip Tie                                         15   Length = 100mm
     86    Zip Tie                                         15   Length = 150mm
     87    Zip Tie                                         8    Length = 200mm
     88    Zip Tie                                         3    Length = 300mm
     89    Fuel Return, Assembly                           1    Including 90°
     90    Corrugated tube                                 1




Z33 TWIN-TURBO KIT
                                                       4
4. Figure of KIT (Sketch)




Z33 TWIN-TURBO KIT
                            5
4. Figure of KIT (Sketch)




Z33 TWIN-TURBO KIT
                            6
5. Removal of Factory OEM Parts                *Follow the service manual.

5-1. Removal of Air Filter Assembly (Fig 1.)

(1)   Disconnect the minus terminal on the battery.
(2)   Confirm engine is cool to the touch and coolant temps are low enough to handle. Remove the undercover and
      drain the radiator of fluids.
(3)   Drain the engine of oil.
(4)   Remove the air duct and the resonator (1 and 2)
                                                                         (5)     Remove the holder and the air
                                                                                 cleaner element (4 and 5)
                                                                         (6)     Take off the air duct on the air
                                                                                 intake side (No.6), and remove the
                                                                                 air cleaner case (No.7) with the air
                                                                                 flow meter together.
                                                                         (7)     Remove the two grommets (No.8)
                                                                                 from the engine bay.
                                                                         (8)     Remove the air flow meter (No.3)
                                                                                 from the air cleaner case (No.7)
                                                                                 Take care not to lose the O-ring.




5-2 Removal of the Injector (Fig 2 & 3)

                                                                  (1)   Open the fuel tank cap to reduce the
                                                                        internal pressure of the fuel tank.
                                                                  (2)   Remove the strut tower bar and the
                                                                        plastic engine cover.
                                                                  (3)   Remove the canister purge valve, the
                                                                        electronic-control      throttle body and
                                                                        bracket (No.1, 2, 3. Fig 2)
                                                                  (4)   Remove the upper intake manifold (No.4.
                                                                        Fig 2)
                                                                  (5)   Remove the cover (No.5. Fig 2) and the
                                                                        lower intake manifold (No.6. Fig 2.)
                                                                        After removal, take care to protect the
                                                                        intake manifold from any dust and other
                                                                        contaminants.



 Z33 TWIN-TURBO KIT
                                                        7
                                                                       (6)     Remove the four fuel rail bolts (No.2. Fig
                                                                               3) and four insulators (No.3. Fig 3)
                                                                       (7)     Disconnect the injector clips (No.4. Fig 3)
                                                                               and     then   remove   the six injectors
                                                                               themselves.     When removing the fuel
                                                                               injectors, be careful as the fuel rails may
                                                                               be pressurized with gasoline and a
                                                                               hazardous spill may occur.
                                                                       (8)     Seal the injector holes in the intake
                                                                               manifold side with a cloth in order to
                                                                               protect it from dust.
                                                                       (9)     Remove two bolts and take off the fuel
                                                                               line Bracket (No.6. Fig 3) of the right
                                                                               side member.




5-3 Removal of the Exhaust Manifold (Fig 4)

(1)   Disconnect the exhaust Y pipe (2-1 pipe.)
(2)   Remove the catalyst heat shield around the lower side of the transmission, and then both the left and right rear
      O2 sensors (No. 3 and No. 4.)
(3)   Remove the catalytic converters. (No. 1 and No. 2.)
                                                                         (4)    Take off the front O2 sensor (7 and 10.)
                                                                         (5)    Remove the exhaust manifold heat
                                                                                shields (No. 5 and No. 8.)
                                                                         (6)    Remove the exhaust manifolds. (No. 6
                                                                                and No. 9.)
                                                                         (7)    Remove the exhaust manifold gaskets
                                                                                and remove all twelve stud bolts (No.
                                                                                11.)
                                                                         (8)    Center the steering wheel straight and
                                                                                put a matching mark on the upper and
                                                                                lower steering shafts as a guide for
                                                                                later reinstallation. Remove steering
                                                                                shaft.




NOTE: DO NOT TURN THE STEERING WHEEL AFTER TAKING OFF THE SHAFT. DAMAGE TO STEERING
ANGLE SENSOR MAY OCCUR!
 Z33 TWIN-TURBO KIT
                                                            8
5-4 Removal of the Water Pipe and Reservoir Tank (Fig 5)
(1)   Take off the radiator upper hose and water bypass hose (No. 1 and No. 2.)
(2)   Remove the heater and rear water bypass hose (No. 3 and No. 4.)
                                                                              (3)   Take off the harness blanket off the
                                                                                    water pipe (No. 5.)
                                                                              (4)   Take off the two bolts (No.8) and the
                                                                                    water pipe. At this time, do not hurt
                                                                                    O-ring (No.6.)
                                                                              (5)   Remove the right front reservoir tank,
                                                                                    the     reservoir   tank     blanket   and
                                                                                    reservoir hose.




5-5 Removal of the Bumper Cover

(1)   Take off six clips on the front of the bumper, the three bolts on the upper part of each fender.
(2)   Take off the three bolts on both the left and right of the lower section of the bumper. Remove the bumper cover.
(3)   Take off the right front tire and the right inner fender liner.
(4)   Remove the OEM horn and the ambient temperature sensor.


6. Installation of Exhaust Manifold (Fig 6 – 9)

                                                                        (1)   Insert three stud bolts (Part No.68) into
                                                                              (Holes Marked A, Fig 6, Passengers Side) the
                                                                              cylinder head.     Insert the longer threaded
                                                                              side of the studs into the head.
                                                                        (2)   Insert 11 stud bolts (Part No.67) into the
                                                                              remaining locations of the head.             The
                                                                              lengths of the threads should be equal on
                                                                              both sides.


(3)   Fit two stud bolts (Part No.69) into outlet of left exhaust manifold (Holes Marked A, Fig 7, Drivers Side)
(4)   Use the flange nuts (Part No.71) to fix the left exhaust manifold (Part No. 3, Drivers Side), reuse the stock OEM
      exhaust gasket.


 Z33 TWIN-TURBO KIT
                                                             9
(5)   Insert one stud bolt (No.69) into outlet of right exhaust manifold (Holes Marked A, Fig 8, Passenger Side).
      Insert the shorter threaded part of the stud into the flange of the exhaust manifold.
(6)   Reusing the OEM gasket, install the right exhaust manifold (Part No.4, Passenger Side) onto stud bolts (Part
      No.67, No.68) installed in step (1) with flange nuts (Part No.71)
                                                     (7)   Bend the outside-rear corner of the heat shields located on
                                                           both the left and right engine mounts down towards the
                                                           mount.
                                                     (8)   Take off the fuel line bracket (No.1) on the passenger side
                                                           behind the shock tower (Fig 9). Bend the fuel line up (No.
                                                           2) and away from the exhaust manifold.         Take care to
                                                           gradually bend the fuel line while avoiding kinking the line.
                                                     (9)   Insulate the modified fuel line (Step 8) and the vacuum
                                                           hose above it from heat using the heat wrap (Part No.65)
                                                           and wire (Part No.66.) Do not use entire sheet as you will
                                                           need the remaining portion in another step.
                                                     (10) Using a zip tie, fasten the insulated fuel line and
                                                                    vacuum hose to the vehicle body.




 Z33 TWIN-TURBO KIT
                                                           10
7. Installation of Turbocharger

7-1 Installation of Turbocharger (Passenger) (Fig 10 – 12)

(1)   Remove the actuator from the passenger turbocharger assembly (Part No.2.) Do not lose the bolts or snap rings
      as you must reuse them.
(2)   Fit five stud bolts (Part. No.69) into turbocharger exhaust housing.
(3)   Use the turbo and exhaust manifold gasket (Part No.16) and temporarily install the turbocharger with bolts
      (Part No.70) and nuts (Part No.73.) Use three bolts and one nut.




(4)   Install the actuator temporarily and check whether the actuator rod touches the compressor housing or the
      engine mount (Fig 10). If it touches, please grind the engine mount using a suitable tool in order to keep a
      minimum clearance of 2 mm.
(5)   Fasten the turbocharger and the actuator tightly and install the actuator snap ring.
(6)   Check clearance of the turbocharger and the heat shield (Fig 11) modified in “Installation of Exhaust Manifold,
      step 7.”
(7)   Fit one stud bolt (Part No.67) into the right outlet pipe.
(8)   Install the right outlet pipe (Part No.6) and turbo outlet gasket (Part No.17) to the turbocharger using five nuts
      (Part No.73.)
(9)   Install the steering shaft, matching the markings you made.
                                                     (10) Install the OEM catalytic converter, the gasket and the right
                                                          O2 sensor x 2, reusing the original bolts and nuts.
                                                     (11) Cover the turbo side of the right oil inlet line (Part No.11, Fig
                                                          12) with the heat wrap in order to insulate from heat.
                                                     (12) Connect the right inlet line (Part No.11) to the turbocharger
                                                          using the oil banjo bolt (Part No.12) and two copper washers
                                                          (Part No.75.) Assemble the oil inlet line aiming it toward
                                                          the compressor side and the lower front part of the car.
                                                     (13) Put the oil return gasket (Part No.18) into the right oil return
                                                          pipe (Part No.8), and install it with two bolts (Part No.78.)


 Z33 TWIN-TURBO KIT
                                                            11
7-2 Installation of Turbocharger (Driver) (Fig 13 – 14)

                                                          (1)    Fit five stud bolts (No.69) into EX housing of the left
                                                                 Turbocharger Assembly.
                                                          (2)    Cover the turbo side of the left oil inlet hose with the heat
                                                                 sheet in order to insulate from heat.
                                                          (3)    Referring to Picture 2-1, install the left oil inlet
                                                                 hose(No.10) with the oil banjo bolt (No.12) and two copper
                                                                 washers (No.75) as putting toward the compressor
                                                                 housing.
                                                          (4)    Put the turbo and EX manifold gasket (No.16) in, and
                                                                 install Turbocharger temporally with bolts (No.70) and
                                                                 nuts (No.73.) Use two bolts and two nuts.
                                                          (5)    Check whether if Turbocharger compressor in the picture
                                                                 2-2 touches the engine mount. If it touches, modify the
                                                                 engine mount with a sander and adjust to keep a
                                                                 clearance more than 1 mm.
                                                          (6)    Fasten Turbocharger itself tight.
                                                          (7)    As in the picture 2-1, make sure that the oil inlet hose goes
                                                                 above the actuator rod and toward the front part of the
                                                                 engine mount. Assemble the oil inlet hose not touching
                                                                 the actuator rod, and fasten the hose with the wrap band.
(8)   Fit one stud bolt (No.67) into the left outlet pipe (No.5.)
(9)   Install the left outlet pipe (No.5) and the turbo outlet gasket (No.17) to Turbocharger using five nuts (N0.73.)
(10) Install the genuine catalyst and the gasket and the left O2 sensor x 2 reusing the genuine bolts and nuts.
(11) Install the genuine catalyst blanket and the exhaust front tube (in the picture 2-1) reusing the genuine bolts and
      nuts.
(12) Cover the starter harness with the heat sheet in order to insulate from heat.
(13) Put the oil return gasket (No.18) in the left oil return pipe (No.7), install it with two bolts (No.78)
(14) Seal the IN and OUT side of left and right Turbocharger with a cloth or taping in order to prevent it from dust.


8. Installation of the Oil Pan

(1)   Take off ten bolts of the genuine oil pan, and remove the oil pan using the seal cutter. Be careful not to hurt the
      surface you install the oil pan.
(2)   Using tools such as a scraper, get rid of the liquid gasket sticking to the surface you install the oil pan.
(3)   Take off the genuine oil pressure sensor on the front side of the oil element.
(4)   Put two oil return pipe (No.9) and the oil return gasket (No.18) in the big capacity aluminum oil pan, and install
      them with four bolts (No.78.) The left and right oil return pipe are both same. Install the pipe toward the rear
      side as you see in the picture 3-1 and 3-2.


 Z33 TWIN-TURBO KIT
                                                                12
(5)   Clean the surface you install the oil pan, and paint the liquid gasket on the surface you install the big capacity
      aluminum oil pan without any gap or break. Pain it a little more because the oil may leak if you paint it less.
(6)   Using ten cap bolts (No.76 and 77), install the big capacity aluminum oil pan. Tighten the bolts in diagonal.
      Refer to the finished picture 3-3 of completion.
(7)   Fit the drain bolt (No.74) and the copper washer (No.75) to the big capacity aluminum oil pan. Pour the engine
      oil one hour after installing of the oil pan.
                                                                                                             (8)     Connect
                                                                                                                   the      oil
                                                                                                                         return
                                                                                                                   hose φ15
                                                                                                                   (No.15) to
                                                                                                                   the     left
                                                                                                                   and right
                                                                                                                   oil return
                                                                                                                   pipe with
      four hose bands (No.48.) If the hose is too long, cut it not to make it folded and bended.


                                                                                                                   (9)    Take
                                                                                                                          AN4
                                                                                                                         nipple
                                                                                                                     x 2 off
                                                                                                                     the oil




      pressure block Assembly (No.13), and assemble PT1/8 nipple to the oil pressure block.
(10) As in the picture 3-4, install the oil pressure block to the genuine oil pressure sensor, making sure that the
      genuine oil pressure sensor is above the oil pressure block.
(11) Assemble AN4 nipple x 2 to the oil pressure block.
(12) Connect the right oil inlet hose to the right side of AN4 nipple, and the left oil inlet hose to the front side of AN4
      nipple. Install them making sure that the hoses do not twist and touch the body. Fasten the oil inlet hose to
      Part A in the picture 3-4 with a wrap band, keeping the oil inlet hose off the genuine stabilizer.
(13) After checking the clearance and twist of the oil inlet hose, install the coupling of the genuine oil pressure sensor
      and the alternate blanket.




 Z33 TWIN-TURBO KIT
                                                            13
9. Taking off, Removal and Installation of the Power-steering Cooler

                                                (1)   Extract      the   power-steering   fluid   inside    of   the   genuine
                                                      power-steering tank.
                                                (2)   As in the picture 4-1, take off the joint pipe, which is in the lower
                                                      side of the power-steering tank, and No.1, 2, 3 and 4 in the picture
                                                      of the power-steering hose with the stay altogether. Do not take
                                                      off the power-steering hose in the lower side of the power-steering
                                                      hose.
                                                (3)   Remove the power-steering cooler itself.
                                                (4)   Take two parts of the stay off the power-steering itself, and leave
                                                      the power-steering only.
                                                (5)   At the place of the reinforcement in the picture 4-2, make a 4 mm
                                                      hole and modify it at two parts.




(6)   Assemble two pieces of power-steering cooler stay type L (No.33) to the power-steering cooler itself with a wrap
      band, and install them with two tapping vises (No.83) following the picture 4-3.
(7)   Following the picture 4-4, install two power-steering joint pipes (No.34) and two power-steering hoses (N0.35)
      using four hose bands (No.47). Put the hose along the frame through the hole the genuine pipes laid, and
      connect it to the power-steering cooler itself. If the hose is too long, cut it shorter to connect.
(8)   Fasten the installed power-steering hose with a wrap band.
(9)   As in the picture 4-5, put the genuine horn not to touch the intercooler, and bend the stay backward and modify
      it to install the hose.
(10) Pour the power-steering fluid into the genuine power-steering tank.


10. Installation of the Intercooler and Removal of the Reservoir Tank

                                                                                                                       (1)   Ta
                                                                                                                             ke
                                                                                                                             th
                                                                                                                              e
                                                                                                                             ha

 Z33 TWIN-TURBO KIT
                                                              14
      rness of the vehicle in the front of the radiator core support and the ambient temperature sensor off the core
      support. As in the picture 5-1, fasten them backward with wrap bands.
(2)   Cut nails on the Part A of the radiator core support in the picture 5-2 and 5-3.
(3)   As in the picture 5-3, cut the Part B of the radiator core support in order to keep it off the intercooler.
                                          (4)   Install the upper part of intercooler stay (No.31) temporally with the
                                                center bolts of the bonnet catch.
                                          (5)   Install the intercooler assembly (No.30) to the upper of the intercooler
                                                stay temporally using one bolt (No.81.)
                                          (6)   Install two pieces of the intercooler stay lower side (No.32) temporally
                                                using four bolts (No.81), as in the picture 5-4.
                                          (7)   Tighten the bolts, checking the position and the clearance of the

                                                                                    intercooler.
                                                                              (8)   If the clearance the left OUT pipe of the
                                                                                    intercooler side tank has is narrow,
                                                                                    sharpen the reinforcement on the Part
                                                                                    A I the picture 5-5.
                                                                              (9)   Cut the Part A in the picture 5-6 and
                                                                                    the radiator core support to get the
                                                                                    piping through.        Modify the piping
      according to the intercooler IN side (No.27.) Work it after protecting the right intercooler side tank from dust.
(10) Remove the reservoir tank itself, the stay including two bolts and the reservoir tank hose.
(11) Using the reservoir tank type L short (No.36) and the reservoir tank stay type L long (No.37), fasten the
      reservoir tank itself to the genuine bolt part and the harness lock part, as in the picture 5-7, applying bolts
      (No.81) and nuts (No.84.)
                                                        (12) Fasten the long stay type L and the reservoir tank itself
                                                             certainly using wrap bands.
                                                        (13) Using the reservoir tank hose (No.38), install the reservoir
                                                             tank and the radiator together. If the hose too long, cut to
                                                             adjust it.
                                                        (14) Supply the cooling water up to the regulation quantity.




11. Installation of the Injector




 Z33 TWIN-TURBO KIT
                                                              15
                                                                                                                     (1)   Put
                                                                                                                           six
                                                                                                                            of
                                                                                                                           the




      injector spacer top spacers indicated as C (in the picture 6-1) into the injector holder of the intake manifold.
(2)   Leaving the injector top collar of Part B and the O-ring of the Part A assembled; apply the lubrication liquid to
      the O-ring. And then install six of the big capacity injector (No.59) to the delivery pipe. Do not use the
      genuine injector clips.
(3)   Put four of the insulators in the bolt part of the delivery pipe, install the delivery pipe Assembly to the intake
      manifold not to hurt the injector O-ring (following the picture 6-2 to complete to install.)
(4)   Assemble the couplings with the injectors; install the intake manifold collector of lower side and the cover.
(5)   Install the intake manifold collector of the upper side, electronic-control throttle body, the canister purge and the
      water line.


12. Installation of the Piping and the Air Cleaner.
* Check whether if the inside of the pipe contains dust prior to the installation. If it does, clean it well.
(1)   Take off the harness stay of Part A in the picture 7-1 and the oil level gauge lock of Part B.
(2)   Remove the air conditioner tube stay in the lower pressure side as in the picture 7-2.
(3)   Take off the harness stay fastened on the back side of the alternator by removing two bolts.
                                                                                (4)   Bend the air conditioner pipe of the
                                                                                      Part A as in the picture 7-3 toward
                                                                                      inner, and modify to get the suction
                                                                                      pipe   through.         Bend   the   air
                                                                                      conditioner      pipe    slowly      and
                                                                                      carefully.




(5)   Install the suction pipe type L (No.19) using the turbo compressor IN side gasket (No.53) and two the flange nuts
      (No.78.)   If the suction pipe L side touches the installation part of the air conditioner pipe, modify the
     installation part of the air conditioner pipe by tools such as a sander. At this time, sharpen and modify careful
 Z33 TWIN-TURBO KIT
                                                            16
      to the air conditioner pipe itself.
(6)   Cover the Part A in the picture 7-4 of the suction pipe L side with the heat sheet in order to insulate from the
      heat of EX manifold.
(7)   Install the turbo air out pipe type L (No.23) using the turbo compressor OUT gasket (No.54) and three of the
      bolts (No.80.)
(8)   Bend the body side of the air conditioner pipe toward the engine side, and leave the air conditioner hose with no
      burden.
(9)   Make sure that the clearance of the suction pipe and the air conditioner pipe (the high-pressure side.) If no,
      bend and modify the air conditioner pipe to keep the clearance.
(10) As keeping the Part A in the picture 7-6 off the body, install the suction pipe R side (No.20) using the turbo
      compressor gasket (No.20) and two of the flange bolts (No.78.)
                                                           (11) If the water hose and the vehicle harness is close to
                                                                 EX manifold, insulate them from heat by covering the
                                                                 heat sheet.
                                                           (12) Install the turbo air out pipe type R (No.24) using the
                                                                 turbo compressor OUT gasket (No.54) and three of
                                                                 bolts (No.80), as keeping the Part B in the picture 7-6
                                                                 off the brake line. If the Part B touches, bend the
                                                                 brake line to keep away.
                                                           (13) Dent the water pipe of the Part A in the picture 7-7 by
                                                                 tools such a hammer, and modify it to keep it off the
                                                                 turbo air out pipe R side.




(14) Install the modified water pipe. When the installation, install it not to hurt the O-ring using bolts at two
      places.
(15) Install the heater hose and the water hose to the water pipe.
(16) Install the genuine blowby hose to the suction pipe R side. Cover up the surge tank side with the blind mask.
(17) Assemble the blowby hose φ15 (No.55) and the blowby joint pipe (No.56) to the blowby hose of the suction pipe L
      side, using two of the hose bands (No.48.)
(18) Connect the genuine blowby hose L side and the blowby joint pipe together.




 Z33 TWIN-TURBO KIT
                                                          17
(19) Install the air cleaner gasket (No.40) and the air cleaner adapter R side (No.22) to the air cleaner (No.39) using
     four of bolts (No.82.) Be sure that the longer side is the air cleaner adapter R side.
                                                                                                                 (20) Us
                                                                                                                      in
                                                                                                                       g
                                                                                                                      th
                                                                                                                       e
                                                                                                                       si
                                                                                                                       li
                                                                                                                      co
                                                                                                                       n
                                                                                                                       e
                                                                                                                       h
     ose φ50 (No.43) and two of the hose bands (No.50), install the air cleaner Assembly as in the picture 7-8. Make
     it sure that the piping can run through between the air cleaner and the radiator upper hose, as Part A in the
     picture 7-8. You do not fasten the air cleaner R side Assembly with any parts.
(21) Install the air cleaner gasket (No.40) and the Air cleaner adapter L side (No.21) to the air cleaner (No.39) using
     four of the bolts (No.82.) Be sure that the shorter side is the air cleaner adapter L side.
(22) Remove the vehicle harness lock on your side from the left strut. Put the vehicle harness lock around lower side
     of the air cleaner. Fasten it with the provided warp bands in order to keep it off the air cleaner and the suction
     pipe.
(23) Using the silicone hose φ 50 (No.43) and two of the hose bands (No.50), install the air cleaner Assembly as in the
     picture 7-9. Keep the clearance between the air cleaner and the radiator due to make the piping run through
     the genuine air cleaner duct hole, as the Part A in the picture 7-9. Check whether if the high-pressure side pipe
     of the air conditioner (the Part B in the picture 7-9) touches the suction pipe and the air cleaner. If it touches,
     bend the air conditioner pipe in order to make them apart. You do not fasten the air cleaner L side Assembly
     with any parts.
                                                                                                               (24) Inst
                                                                                                                      all
                                                                                                                     the
                                                                                                                     pipi
                                                                                                                      ng
                                                                                                                    inte
                                                                                                                     rco
                                                                                                                     oler
                                                                                                                      IN
                                                                                                                    side
     (No.27) to the intercooler Assembly temporally using the silicone hose φ70 (No.44) and two of hose bands
     (No.51.)
(25) Install the piping air out pipe R side (No.26) to the piping on the R side temporally using two of the silicone hose
     φ45 (No.42) and four of the hose band. At this time, install it carefully not to crush the radiator upper hose.
 Z33 TWIN-TURBO KIT
                                                      18
      Refer to the picture 7-11 when installing the piping.
(26) Install the piping sir out pipe L side (No.25) to the piping of the L side using two silicone hose φ45 (No.42) and
      four hose bands (No.49). Fasten the piping and the radiator hose with warp bands as the Part A in the picture
      7-10 in order to keep them off the stabilizer.
(27) As you confirm clearance and positions of each part, tighten the hose band you installed temporally.
                                                                                                                 (28) Let
                                                                                                                         the
                                                                                                                      pipi
                                                                                                                         ng
                                                                                                                     inte
                                                                                                                         rco
                                                                                                                      oler
                                                                                                                      OU
                                                                                                                          T
                                                                                                                     side
                                                                                                                      (No
      .28) run through the genuine air cleaner duct, and install it temporally using the silicone hose (No.44) and two
      hose bands (No.51.)     See the picture 7-12 as reference.     Confirm that it doesn’t touch the reinforcement
      blanket.


(29) Install the genuine air flow meter to the flange part of the piping intercooler OUT side, putting its coupling part
      toward outside. To install, use four bolts (No.82) and nuts (No.84).
(30) Bend the oil level gauge toward inside in order to keep it away from the piping.
(31) Using two silicone hoses (No.45) and four hose bands (No.52), install the piping throttle (No.29) to the genuine
      air flow meter as you see the picture 7-13.
(32) Making sure that you have clearance enough and positions right of each part, tighten the hose band you installed
      temporally. Besides that, insert the coupling of the genuine air flow meter.


13. Installation of the Fuel Pump and the Regulator.

(1)   Take off the interior cover behind the right seat, and then remove the cover of the fuel tank fastened with clips at
      four places and the fuel harness.
(2)   After confirming that the thermal pressure stays low, disconnect the quick connector and take off six bolts of the
      fuel pump retainer.
(3)   Lift the fuel pump Assembly up, take off the clip of the transfer hose and remove the fuel pump case Assembly.
      Remove it without bending the fuel gauge.
                                                                                                                   (4)     D
                                                                                                                           i
                                                                                                                           s
                                                                                                                           c


 Z33 TWIN-TURBO KIT
                                                            19
       onnect two terminals of the fuel gauge and take the pump case to pieces. Take off the clips on the lower side,
       and remove the genuine fuel pump and the insulator. You do not use the insulator.




(5)   At the point in the picture 8-1, make a hole of φ14. After modifying, finish it without any burr.
(6)   Take off the genuine fuel filter off the genuine pump, and assemble 255L/H fuel pump (No.60). Install the filter
       lock ring using the provided parts.
(7)   As the same as the genuine pump, connect 255L/H fuel pump and the coupling. You do not use the insulator.
(8)   Please install the fuel return bolt(89) as in picture8-2.(be sure that the copper washer would come on the upper
       part as a picture), tighten the return nipple ofφ9 and return block. If you tightened the return bolt and nut too
       tight, it could damage the surface of the case. Attach it so that fuel would not leak.
(9)   Please be sure that spring inside the fuel filter is at the center.
(10) Put two springs in, assemble the pump case.
(11) Connect the terminals, and confirm that the pump case slides up and down.
(12) Put the O-ring in; install the fuel pump retainer with six bolts after installing the transfer hose. Install it
      without bending the fuel gauge.
(13) Make a cut with a tool like a cutter to a fuel tube and get it apart from the one touch connector as in picture8-4.
      Remove the O ring also. (Please be careful not to cut one touch connector when you make a cut in the fuel tube.)
(14) Make a cut to the fuel pipe and remove the fuel tube. Remove the O ring also.(If you bend the fuel pipe a little,
      work can be done comfortably.)
(15) Attach fuel hose(63) to the fuel pipe and tight up with the hose band(46). Please insert the fuel hose deep to the
      fuel pipe so that the fuel hose won’t go off. Don’t cut the fuel hose.


                                                                                                                     (16)
                                                                                                                   Apply
                                                                                                                      the
                                                                                                                   lubric
                                                                                                                   ant to
                                                                                                                   the O
                                                                                                                     ring
      of the regulator ASSY(61) and use two bolts(79) to attach it to the regulator block Assembly(62)as in picture8-5.
      Also tighten the φ9 nipples too.
(17) Put the regulator at the position as in picture 8-6, piping the fuel hose as a picture and bind each part with a hose
      band(46).Please connect the fuel hose from fuel pipe to the φ9 nipples of the regulator block and from φ9
      nipples to the quick connector.(Cut the fuel hose at the suitable length when you connect it. Please fix the
      regulator with wrap band to keep regulator away from the body of the vehicle.)
(18) Install the regulator return hose and return bolt reasonably with using the hose bands (No.46.)
(19) Please protect with the corrugated tube (No.90) where.the part that fuel hose would touch the body
(20) Make a cut in a rubber part of the fuel tank cover so that the vacuume hose could pass through.(Please don’t
      crash the vacuume hose.
(21) Please install the fuel pump harness. Don’t attach the fuel tank cover.
 Z33 TWIN-TURBO KIT
                                                          20
14. Laying the Vacuum Hose and the Actuator

14-4 Laying and Installation of the Vacuum hose

                                                                                                                 (1)    Ta
                                                                                                                           k
                                                                                                                           e
                                                                                                                        th
                                                                                                                           e
                                                                                                                           g
                                                                                                                           e
                                                                                                                           n
                                                                                                                        ui
                                                                                                                           n
      e blind cap off the Part A in the picture 9-1, and install the vacuum hose (No.64.) Install it without cutting it.
(2)   Put the vacuum hose through the Part B in the picture 9-1. Be careful not to crash the hose.
(3)   As in the picture 9-2, put the vacuum hose into the room by cutting the vehicle harness rubber boots behind ABS.
      When cutting the boots, be careful not to hurt the vehicle harness itself. Do not crash the vacuum hose.
(4)   Take the genuine side step cover in the inner side, the front cover, and the rubber packing to remove the floor
      carpet.
(5)   Lift the right rear interior up a little, and take off the carpet.
                                                                                                                 (6)    As
                                                                                                                        in
                                                                                                                       the
                                                                                                                       pict
                                                                                                                       ure
                                                                                                                       9-3,
                                                                                                                       inst


 Z33 TWIN-TURBO KIT
                                                              21
      all the vacuum hose. Fasten it with wrap bands not to block driving, and install it as it stays in the inner side
      of the front cover.
(7)   Install the vacuum hose along the side step, and put it through the rear interior to above the fuel tank as in the
      picture 9-4. Fasten it with wrap bands as protecting it from crashing.
(8)   Install the vacuum hose to the pressure regulator. If the hose too long, cut it to adjust.
(9)   Put the carpet as it was, and install the rear interior, the side step, the front cover and the rubber packing.
      Make sure that the vacuum hose does not go to the inside of the room.


14-2 Installation of the Actuator

                                                                                                                (1)   Inse
                                                                                                                           rt
                                                                                                                         the
                                                                                                                         silic
                                                                                                                         one
                                                                                                                      hose
                                                                                                                         φ6
                                                                                                                      (No.
                                                                                                                          41)
                                                                                                                         into
      the right actuator’s nipple, and fasten it with wrap bands.
(2)   Along the oil inlet hose right side, bind the water pipe and the oil inlet hose left side together with wrap band as
      you seen in the picture 9-5.
(3)   Using the three-way joint (No.58), cut and install the silicone hose in the proper length as in the picture 9-6.
(4)   Insert the rest of the silicone hose into the left actuator’s nipple, and fasten it with a wrap band. Cut one
      ending of the hose in the proper length and install it to the three-way joint.
(5)   Insert the rest of the silicone hose into the rest nipple part of the three-way joint, and connect it from the
      direction of the left strut to the nipple of the piping (φ80.) If the hose too long, cut it to install. Fasten the
      nipple part with a wrap band.
(6)   To prevent the silicone hose from playing, fasten each part with wrap bands. Cover the hose around the turbo
      with the heat sheet to insulate from heat.




 Z33 TWIN-TURBO KIT
                                                            22
15 After Installtion

(1)   Replenish engine oil. Because the oil pan has big capacity, pour one litter more than usual.
(2)   Replenish radiator cooling water. Bleed air of certain amount before you start the engine.
(3)   Check any slack of each part.
(4)   Check any part not installed. If any, look over the installation again.
(5)   Check the clearance of each part. Check especially Turbocharger, EX manifold and other parts which are
      possible to have heat.
(6)   Use left wrap bands to bind hoses and cords not to play.
(7)   Start the engine, and check leaking of oil, water, fuel and exhaust gas. Check also any smell, sound, touch and
      leak.
(8)   Stop the engine, and check the amount of engine oil and power-steering oil. If low, replenish them. Spin the
      steering to left and right some times and bleed air. Take off the radiator cap, replenish cooling water and bleed
      air one more time.
(9)   Start the engine again, and check leaking of fuel around the fuel regulator. If no, install the rear cover.
(10) At last, finish to install the engine cover, the strut tower bar, the bumper and the under cover. Good job!




 Z33 TWIN-TURBO KIT
                                                           23
16 Attentions for Turbo Type                 *Read this page certainly!!

(1)   By use of this PWR TWIN TURBO KIT, the calorific value of the engine increases. You need to raise the heat
      value of the ignition plug. (Recommended heat value is NGK racing plug No.8.)
(2)   Use unleaded high-octane gasoline. .(Please use the best grade high octane gasoline.)
(3)   Use engine oil for a turbocharged engine, such as 10W40 and 15W50.
(4)   The boost pressure of this PWR TWIN TURBO KIT is set from 0.3K to 0.35K. It depends on the engine and the
      muffler. There is no problem for fuel setting if the boost pressure is up to 0.5K, but the endurance of the normal
      engine may be extremely lost.       Consider that the normal engine of VQ35 engine is limited to 420ps
      approximately.    It depends on the vehicle and the conditions of its use.
(5)   We accept no responsibility the damage of the engine or KIT, troubles, or claims you have when you raise the
      boost pressure.
(6)   You need to strengthen the engine when you raise the boost pressure.
(7)   Because of the installation of Turbo, the calorific value increases. Depending on the conditions of driving, you
      may need the oil cooler and the big capacity radiator.
(8)   Make sure one more time that you install the steering shaft surely.
(9)   This product is designed only for racing vehicles. You may not be able to have warranty of car suppliers.
(10) This product is designed for racing vehicles. Use it correctly under the Road Traffic Law.
(11) After the installation, drive carefully because the power characteristics of the engine changes sharply.
(12) For the protection of Turbocharger, idle the engine for a while to fully cool down the turbocharger.
(13) You may have a lack of the capacity of the clutch because of the installation of this product. We recommend to
      exchange the strengthened product.
(14) This KIT is for normal ECU only. It could cause a damage to engines if you use tuned ECU. We accept no
      responsibility to any claims from using tuned ECU.
(15) This KIT correspond to normal mufflers. If you use straight catalyzer or sports muffler that is sufficient in
      exhaust discharge, boost pressure may raise. We accept no responsibility about that.
(16) We accept no responsibility about accident and injury caused from attaching this KIT.




                                                                Power Enterprise Co., Ltd.
                                                                307 Nakajima Fuji-shi, Shizuoka-ken
                                                                416-0907 JAPAN


                                                                TEL: 0545-66-0707
                                                                FAX: 0545-66-0708
                                                                URL: http://www.power-enterprise.co.jp




 Z33 TWIN-TURBO KIT
                                                           24

								
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