Stage 2 / Stage 3
& Items Required:
|Basic socket and wrench set||4x||3/8x1.5" turbo hardware|
|1x||High temp rtv||1x||
Shorter serpentine belt
|1x||Antiseize||grinder or metal
cutter for sway bar bracket (stage 2 headers only)
|1x||Brake clean and rag||16x||3/8x1" header bolts|
|2x||3/8 vacuum caps||1/4 vacuum hose|
Disconnect the negative battery cable
Remove the air filter box, air intake plumbing, headers, h-pipe (remove O2 sensors), 3/8 tube from the passenger valve cover to the throttle body, serpentine belt, smog pump and plumbing.
Do a test fit of both the drivers and passenger header to make sure there are no clearance issues (*Stage 2 headers will require trimming of the passenger sway bar mount.)
Clean the head surface with a gasket scraper and then rub some brake clean on to finish it off.
Take some high temp rtv and put a nice thin layer on the header flange surface and the head surface around the exhaust ports.
Let the rtv tack up for about 10 minutes.
Now carefully bring the header to the head surface and start 2 header bolts. One in the front and one in the back.
Now install the remaining header bolts and tighten down the bolts from the middle out. Do this both headers.
Install the crossover pipe with the included v-band clamps. The wastegate flange is always on the passenger side. Do NOT over tighten the v-band clamp or it will break!
Install your wastegate onto the crossover pipe and run a vacuum line to either the turbo or a the intake.
Put a 3/8 vacuum cap on the passenger valve cover and the throttle body.
Now loosely bolt up a t4 based turbo onto the passenger header. Just for mock up.
Install O2 sensors with some antiseize into downpipe and lower pipe behind the passenger header.
Put the 2 bolt clamp onto the front downpipe piece and leave it loose.
Now take the front half of the downpipe and loosely install it onto your exhaust housing with the supplied v-band clamp. You want it just loose enough that you can rotate the downpipe on the exhaust housing.
Now line up the front downpipe section with the rear downpipe section. Once you get it where the clearance is good snug down the v-band clamp on the exhaust housing and then slide the 2 bolt clamp back so it covers both side of the downpipe and tighten it down.
Remove the v-band clamp from the downpipe and remove the turbo.
Clean the t4 turbo mating surfaces with brake clean then apply a thin coat of high temp rtv to both mating surfaces.
Wait 10 minutes for the rtv to tack up.
Loosely bolt up the turbo to
the header. Install the downpipe with the v-band and tighten, Now fully
tighten down the turbo. 2010 pony down performance - all rights reserved
* pdp tips - Run a turbo oil drain line -10 or bigger, when using a high pressure oil pump a turbo inlet oil restrictor is required, Never clock your turbo inlet/outlet on the center section more than +/- 15 degrees.
2010 pony down performance - all rights reserved