AVO Turboworld's Bolt-on User manual

AVOTurboworld – For All Your Turbo Needs
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AVOTurboworld Turbo system Fitting Instructions
for the 2001-2004 2.5-liter Subaru Impreza RS
Congratulations on purchasing AVO Turboworld’s Bolt-on Turbo Kit for the Subaru 2.5-liter RS. You are now
the proud owner of a turbosystem that draws on experience gained by not just 10 years of Subaru high
performance tuning, but more importantly 25 years of experience designing, manufacturing, installing and
modifying turbochargers.
Not only will this turbosystem greatly increase your engine’s power over stock, but it will also be user friendly
to drive and will remain so for many years of trouble free operation, with proper installation, servicing and
maintenance.
Contents
Chapter Page
Orientation 2
Tools and Consumables Required 6
Pre-Installation Preparations 7
Disassembly 8
Turbo Oil Return System 9
Turbocharger Assembly 9-10
Turbocharger Cooling + Lubrication 11-12
Turbocharger Intake System 13-14
Mechanical Systems Check 16
Engine Management Installation 17+18+19
Turbosystem Testing 20
Operation and Maintenance 21

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Orientation
Thank-you for choosing AVO Turboworld’s Subaru 2.5Ltr turbosystem! Many hundreds of hours
have been spent testing and developing this final turbocharger, with a large amount of work going
into ensuring the turbosystem seamlessly integrates with the stock engine, transmission and
electronics package. The end result is this complete package solution for turbocharging your
naturally aspirated Impreza RS.
But before grabbing a bunch of spanners and attacking your car take a moment to
STOP AND THINK
Read these supplied installation instructions thoroughly from start to finish – do you understand all
of the mechanical operations required? Are you sure that you can adequately complete all of the
mechanical operations required? Do you understand all of the terminology used in this installation
manual? Your installation skills will have a big effect on whether or not your new turbosystem will
perform to its full potential and give years of trouble free operation, without seriously damaging
either your engine or your wallet.
Prior to starting the installation, make sure that your car is in excellent mechanical condition and that
there are no outstanding faults or problems. This turbosystem has been designed to work only with
a car that is in a good state of repair. Pre-existing problems or faults can result in improper
operation and/or failure of your engine or turbosystem. This is your responsibility to ensure. No
matter how carefully we design our turbosystems, this is one area we have no control over and
cannot be held responsible.
This turbosystem is designed to run on high-octane unleaded fuel. Always use the highest grade of
fuel available in your area. This is essential for correct operation of your car and your new
turbosystem - failure to use high-octane fuel can result in engine damage. Prior to the installation of
this turbosystem ensure that you already have a full tank of high-octane fuel. If in doubt, drain the
fuel tank and refill with high-octane fuel.
Check all parts supplied with the Turbosystem prior to installation for the following;
a) Verify that all parts noted on the turbosystem kitting list have been supplied. Contact AVO
Turboworld or selling agent if any parts are missing.
b) Make sure that all parts are in good condition and have not been damaged during shipping, etc.
c) Take time to make sure you can identify the individual parts supplied to the relevant sections in the
attached fitting instructions.
d) Remember to fill out the attached warranty form and send it in to AVO Turboworld to activate your
product warranty.
AVO Turboworld is committed to constantly improving our range of products as well as our standard
of customer service. If during the course of installation you find any errors contained in our
instructions, or there are areas that could be improved to make installation easier, feel free to either
email us at [email protected] or fax us at [phone] with your comments / suggestions.

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Kitting List
Note: Check this kit list before starting the install to make that you have all these parts.
1 x Exhaust & Turbo Charger
Assembly
1 x Fitting Instructions
1 x Front Pipe with Cat
PN: 2CJ92T01
25cm x Fire Sleeve
PN: 5Q9BBT01
1 x Oil Drain Fitting
PN: PBSPTC01
1 x Braided Oil Drain Hose
PN: ERZPCT01
1 x Oil Supply Fitting
PN: PBDZWC01
1 x Braided oil Supply Hose
PN: ER3FBT01
1 x Power Air Filter
PN: ENLEC001
1 x Steel Inlet Pipe
PN: 2BLOXT01
2 X 40/60 Hose Clamps
PN: MCF24C01
2” x 2” Blue Silicone Hose
PN: EMH25C01
1 x 32/50 Hose Clamp
PN: MCE04C01
1 x 38mm Blank off Plug
PN: FNFY7T01
6 x 30cm long Cable Tie
PN: KJXE7T01
1 x 12mm Plastic Straight
PM: 7JBM5S02
1 x 12mm Plastic T Piece
PN: 7JBM5S01
1 x 13mm Oil Breather Hose
PN: EN6MBT01

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1 x 5/16” Brass T Piece
PN: 7TJH4T01
4 x 10/16 Hose Clamps
PN: MCBP4C01
100cm High Press. Fuel Hose
PN: ES6H7T01
2 x 10/16 Hose Clamps
PN: MCBP4C01
46cm x5/16 Water Hose
PN:EN0H7T01
35cm x 5/16 Water Hose
PN:ENYH7T01
2 x 70/90 Hose Clamps
PN: MCK54C01
2” x 2 3/4” Blue Silicone Hose
PN:EMK05C01
1 x Intercooler Assembly
with a extra Injector
1 x Intercooler Air Scoop
PN:6H997T01
2 x 50/70 Hose Clamps
PN:MCS634C01
1 x Moulded Rubber Hose
PN: FNHE7C01
1 x 25/40 Hose Clamp
PN: MCDY4C01
1 x 31mm Blank off Plug
PN: FNEW7T01
1 x RH Intercooler Stay
PN: RBVTTT02
1 x LH Intercooler Stay
PN: RBXVTT01
4 x 8x1.25mm Nut
PN:1BEHUT01
4 x 8mm Spring Washer
PN:ABBHUT01

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4 x 8mm Flat washer
PN: ABBHUT01
4 x 8x1.25mm x 25mm Bolt
PN:ABEHUT25
2 x 8mm Spring Washer
PN: ABBHUT01
2 x 8x1mm x 25mm Bolt
PN:ABDHUT2525
4 x 10mmx 1.5mm Nut
PN:ABFJUT01
4 x 10 X 1.5mm x 40mm Bolt
PN:ABFJUT40
1 x 35/40 Hose Clamp
PN: MCDY4CO1
1 X Moulded Black Rubber
Hose
PN: FNEJ7CO1
1 x 32/50 Hose Clamp
PN: MCEO4CO1
1 X 100mm x 38mm Black Hose
PN: FNF67T01
300mm x4mm Vacuum Hose
PN: ENXD7T01
1 x 4mm Plastic T Piece
PN: 7JSD5501
1 x BOV Assembly
PN: S2A97G00A001A
1 x Injector Loom
PN:V299ST01
1 x SMT Computer
PN:91997X01
1 x SMT Computer Loom
PN: W199SX01
1 x Map Sensor
PN:9299SX01
1 x Computer Program
PN:

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Tools Required Consumables Required
Metric Combination Spanner Set New Engine Oil and Filter
Metric Socket Set Engine Coolant (For Topping Up Level)
Phillips point and Flat Blade Screwdriver Set High Temp O2 Sensor Safe Silicone Sealant
Putty Knife or Similar Subaru Oil Pan Silicone Sealer
Trolley Jack and 4 Axle Stands Aerosol Brake / Parts Cleaner or Similar
Vehicle Lift (If Available) WD40 Or Similar Penetrating Oil
Electric Hand Drill Electrical Insulation Tape
Drill Bit Assortment Kit Resin Core Electrical Solder
Multimeter 3mm Diameter Heat Shrink
Access to Gas welding set Subaru 2.5RS Owners Manual
Engine Oil Drain Pan Surgical Gloves or Similar
Soldering Iron Loc-tite Pipe Thread Sealant (or similar)
Side Cutting Pliers / Wire Strippers
Boost Pressure Gauge
Pre-Installation Preparations
1) Select a proper location for installation. You will need a hard flat paved surface in order to
safely jack up and support your car.
2) Disconnect Negative Battery Terminal.
3) Jack up front and rear of car. Support with axle stands. Refer to your Vehicle owners manual
for information on where to correctly place the jack and axle stands so as not to damage any
mechanical parts of your car.
4) Make sure the engine has cooled sufficiently for work to commence.
5) Drain all oil from the engine sump (oil pan) into a proper oil-drain pan.
NOTE! Extreme caution must be exercised when working underneath your car. Under no circumstances
should you ever work under a unsupported/improperly supported car. Use only dedicated Automotive Axle
support stands. Serious injury/and or Death can result. Care must be taken when handling used engine oils,
avoid contact on unprotected skin. Ensure that all waste oils/solvents are disposed of in an environmentally
friendly approved manner.
Disassembly
Step 1 – Remove factory air-cleaner box and air intake pipes from the throttle body and inner
guard area. Take care when removing the oil system breather hoses to ensure that they are not
damaged or disconnected from the engine. Remove the factory air-cleaner box mounting brackets.
(Need picture of factory airbox and mounting brackets - Figs 1+2 )

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Step 2 – Remove and discard engine lifting/engine wiring harness-mounting bracket as shown in
(Fig 3+4) diagram.
Fig 3: Engine Lifting bracket and wiring
harness
Fig 4
Step 3 - Re-secure the wiring harnesses with plastic cable ties as shown in (Fig 5+6). This is to
make room for the turbocharger, which will fit in this area.
Fig 5: Use plastic cable ties to secure
harness.
Fig 6: Re-route wiring for turbo.

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Step 4 – From underneath the car carefully un-plug and then remove the two oxygen sensors from
the factory Catalytic Converter/intermediate section (Fig 7). Spray both sensors with WD-40 to
assist with removal, as they can be difficult to remove. Take care not to damage the sensor body or
mounting threads during removal. Un-bolt and remove stock Catalytic Converter/Centre sectional
and discard.
Fig 7: Stock Catalytic Converters/center section
Step 5 – The air-conditioner receiver drier needs to be relocated to provide enough room for the
turbocharger assembly. Carefully push the receiver drier towards the engine bay firewall
approximately by one inch as shown in (Fig 7). Remove the high-pressure A/C line chassis rail-
mounting clip and carefully bend the A/C pressure line in towards the Right Hand Suspension strut
tower. Refer to (Fig 8)
Caution! Be extremely careful when bending air conditioner hoses. Only bend hoses enough to
provide adequate clearance. Air conditioner systems contain gas at very high pressure. Over-
stressing air conditioner lines can result in a discharge of high-pressure gas. Exposure to this can
result in serious injury.
Fig 8: Push receiver drier towards engine
bay firewall.
Fig 9: Push high-pressure A/C line in
against suspension strut.

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Step 6 – Remove Cruise control actuator assembly
From its stock mounting point at the front of the Right Hand suspension strut tower. Disconnect
vacuum hose from intake manifold, electrical connector and cruise control cable from throttle
butterfly. Take note of actuator adjustment. Keep cruise control actuator in a safe place for re-fitting
at a later stage. (Fig 10)
Fig 10: Cruise control actuator
Step 7 – Remove Power steering hose mounting clamps from the side of the intake manifold.
Loosen 17mm Banjo nut for the power steering discharge pipe (Fig 11). Loosen only enough to
allow movement of the pipe fitting. Wrap rag or paper towel around fitting to catch any fluid that may
leak out. Remove and refit rear power steering mounting clamp to the power steering pipes so that it
is facing downwards (opposite to original position) (Fig 12) while carefully rotating the high
pressure power steering hose downwards. This is to allow enough clearance for the Turbo intake
pipe. Re-tighten the power steering banjo bolt.
Fig 11: Loosen Banjo Power Steering bolt.
Fig 12: Re-fit hose bracket facing
downwards.

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Step 8 – Remove the engine accessory drive belt cover from above the power steering pump and
alternator. Remove alternator belt and then remove alternator assembly. This is done to gain access
to the stock oil pressure switch. Wrap insulation tape around alternator wiring harness connections
so that there is no risk of short circuits, etc.
Step 9 – Drain engine oil (if you have not already done this step). Mark Oil Pan for position of turbo
oil drain fitting. (Fig 13) Remove oil level dipstick from the engine and start removing all engine oil
Sump Pan bolts. The rear oil pan bolts are accessed through holes in the suspension cross-
member. (Fig 14) Use a putty knife or similar and carefully pry between oil pan and engine block
and separate oil pan from cylinder block. Once the oil pan is loose from the engine block the engine
oil pick-up needs to be unbolted to allow removal of the sump pan. Be careful not to lose the oil
pick-up sealing “O” Ring.
Fig 13: Mark the position of the oil drain on
oil pan.
Fig 14: Access hole for rear oil.
Turbo Oil Return System
Step 10 – Drill marked hole in engine oil pan with a 13mm diameter drill bit. Using a gas welding set
braze the turbocharger lower oil drain fitting (PN: PBSPTC01) to the oil pan. Once this fitting is
welded into the sump, pressure test the weld to ensure that it will not leak once it is refitted to the
engine.
Use putty knife or scraper blade to clean the old oil pan sealant, check the sealing surface of the oil
pan for any damage sustained when removing oil pan from engine. Repair as required. Carry out
the same procedure for the sealing surface on the engine block. Using aerosol parts/brake cleaner,
thoroughly clean all metal shavings / debris from the inside of the oil pan and engine block sealing
surface. Clean all traces of oil/grease from the sealing surfaces of both the engine oil pan and the
engine block.
NOTE! It is very important that all traces of metal shavings are cleaned from the oil pan before fitting
to engine. Even the smallest metal shavings or pieces of sump sealant could potentially cause
serious engine damage.
Apply a good coating of Loctite pipe thread sealant to the turbo lower oil drain fitting (PN:
PBSPTC01) and screw fitting into engine oil pan. Do not over tighten fitting.
Step 11 – Apply a bead of Subaru oil pan sealer to the sealing surface of the oil pan. Refitting of
the oil pan is the reverse process of removal. Be sure to re-install the engine oil pickup at the same
time.
NOTE! It is very important that the engine oil pickup “O” ring is not damaged during installation.
Damage to this “O” ring can result in oil system failure and serious engine damage.

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Wipe off any excess oil pan sealer with paper towels or rags.
Step 12 – Disconnect wiring connector from stock oil pressure switch and carefully un-screw from
the engine block. Apply a small amount of Loctite pipe sealant to the threads of the supplied AVO
turbo oil feed adaptor fitting (PN: PBDZWC01) and screw into engine block. Carefully tighten
adaptor fitting so that the stock oil pressure switch can be installed in the 12 o’clock position (Fig
15). Install stock oil pressure switch. Use a spanner to support oil pressure adaptor fitting while
tightening stock oil pressure switch.
NOTE! Do not over tighten adaptor fitting or stock oil pressure switch, fitting or switch may break off
as a result.
Fig 15
Turbo Charger Assembly
Step 13 – The turbocharger comes pre-assembled to simplify installation, but always double check
and inspect to ensure bolted joints, oil and water fittings are tight before fitting the turbocharger to
the engine(Fig 16).
Fig 16: Turbocharger sub-assembly

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Step 14 - The turbocharger subassembly including turbocharger up-pipe is installed from
underneath the vehicle. Carefully feed the turbocharger subassembly up through the space behind
the RH cylinder head. Loosely install turbocharger up-pipe mounting bracket (Fig 17) to hold
turbocharger in place.
Coat stock 2 bolt stainless steel exhaust gasket with high temperature sealant and fit in the flange
joint between stock exhaust headers and the new turbocharger up-pipe (Fig 17+18). Using two of
the supplied exhaust bolts and nuts, hand tighten the exhaust flange joint. At the other end of the
turbo catalytic converter pipe, coat the existing exhaust gasket with high temperature sealant and
bolt up using the supplied exhaust bolts (Fig 18).
Fig 17: Turbocharger up-pipe support
bracket
Fig 18: Coat gasket with high-temp sealant.
Fig 19: Turbocharger sub-assembly

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Turbocharger Assembly
Step 15 – Coat turbo outlet flange with high temperature sealant. There is no need for a gasket
between the turbo outlet and the turbo catalytic converter pipe. Fit the turbo catalytic converter pipe
to the turbocharger and bolt up hand tight using the supplied copper nuts and stainless steel
washers (Fig 18). Install turbo catalytic converter pipe to transmission casing mounting bracket (Fig
19) using the original retaining bolt. Install only finger tight.
Fig 19
Fig 20
At the other end of the turbo catalytic converter pipe, coat the existing exhaust gasket with high
temperature sealant and bolt up using the supplied exhaust bolts (Fig 20).
Step 16 - Tighten all nuts and bolts previously only installed by hand. Check alignment of exhaust
pipes to ensure that there is adequate clearance with surrounding components. You need to tighten
the turbocharger up-pipe mounting bracket (Fig 17), turbocharger up-pipe to stock exhaust header
flange (Fig 18), the turbocharger outlet flange to catalytic converter pipe (Fig 19), catalytic converter
pipe support bracket (Fig 20) and finally the catalytic converter pipe to stock exhaust system joint
(Fig 18).
Step 17 – Re-install previously removed front and rear Oxygen sensors. Secure front oxygen
sensor harness with plastic cable ties to ensure that wiring harnesses don’t touch the turbo up-pipe
or catalytic converter pipe.

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Turbocharger Cooling + Lubrication
Step 18 – Route the turbocharger oil drain hose down past the back of the RH cylinder head, (Fig
15+12) and then between the RH exhaust manifold and RH engine mount. Connect oil drain hose
to fitting previously welded into oil pan and tighten hose fitting. Do not over tighten.
NOTE! When fitting the turbocharger oil drain hose, care should be taken to ensure that the drain
hose does not touch the turbocharger up pipe and RH exhaust manifold. It should also be well clear of
the RH front driveshaft. Failure to do so can result in engine oil leakage and is a potentially serious
fire risk.
Step 19 – Route braided turbocharger oil supply hose (PN: ER3FBT01) under intake manifold past
the back of the power steering pump (Fig 20). Screw fitting into the oil pressure switch adaptor and
carefully tighten fitting. Don’t over tighten fitting!
Route braided turbocharger oil supply hose from under the intake manifold and pass it down
underneath the front of the turbocharger compressor housing. Attach hose fitting to turbocharger oil
supply and carefully tighten (Fig 21).
NOTE! Pay attention that the turbocharger oil supply hose is well clear of any rotating engine parts
and does not touch hot exhaust parts. Carefully check to ensure that they are not twisted, kinked or
will chafe on sharp engine parts. Failure to do so can result in a high-pressure engine oil leakage and
is a potential serious fire risk.
Fig 21: Direction of turbocharger oil feed
pipe.
Fig 22: Route turbocharger oil feed under
front of compressor cover.
Step 19 – (Continued) Do not re-fit the alternator. This will be done after the engine has been
test run to check for oil leaks.

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Turbocharger Cooling + Lubrication
Step 20 – The turbocharger has two different length hoses for its water cooling circuit. The longest
turbocharger cooling hose, 460mm (18 Inches) long connects to the stock engine block coolant
crossover pipe (Fig 23). The remaining turbocharger cooling hose, 350mm (13.75 Inches) long
connects to the stock throttle body heater hose at the throttle position sensor side of the throttle
body (Fig 24).
Route the turbocharger cooling hoses from the turbocharger to the throttle body and the engine
block coolant crossover pipe. Route turbocharger coolant hoses along the same path as the
turbocharger oil supply hose. Cable tie coolant hoses securely.
NOTE! Pay attention that turbocharger cooling hoses are well clear of any rotating engine parts and
does not touch hot exhaust parts. Carefully check to ensure that it is not twisted, kinked or will chafe
on sharp engine parts. Failure to do so can result in coolant loss and potential damage to the engine
or turbocharger.
Remove the stock rubber coolant pipe that fits between the throttle body and the engine coolant
crossover pipe and discard. Using supplied hose clamps (Item 33), attach turbocharger cooling
hoses. Tighten hose clamps. If this is done quickly there is no need to drain the engine of coolant.
Fig 23: Engine block coolant crossover
pipe.
Fig 24: Throttle body heater hose
connection.
Top up engine coolant level (if required) and pressure test for any coolant leaks at the throttle body,
engine block crossover pipe or the turbocharger banjo bolts.

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Turbocharger Air Intake System
Step 21 – Fit the 2.25” silicone hose joiner (Item 78) to the turbocharger compressor cover inlet
(Fig 25). Use the two supplied hose clamps (Item 79). Fit the metal turbocharger intake pipe
noting that the blow-off valve return fitting faces upwards. Fit air filter and air filter mounting bracket.
Tighten all mounting bolts and clamps (Fig 26).
Fig 25
Fig 26: Air filter mounted.
Step 22 – Fit the short black breather hose and one of the supplied plastic 12mm T pieces (PN:
7JBM5S01)to the turbocharger air intake pipe breather fitting (Fig 27). Plug one end of this T piece
into the factory PCV valve connector hose. The remaining end of this T piece plugs into the other
supplied plastic 12mm T piece (Fig 28). The two ends of this last T piece is used to join the
passenger side and drivers side cam cover breather vent ports. Use the supplied long black plastic
breather hose (Item 76) along with the supplied 12mm straight plastic hose joiner (Item 75).
Route this long plastic breather hose from the stock drivers side cam cover breather hose to the
other side of the engine (Fig 29).
Fig 27: Turbocharger intake breather hose.
Fig 28

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Turbocharger Air Intake System
Step 23 – Fit turbocharger discharge hose to the turbocharger compressor cover, the end with the
115 degree bend is the turbocharger end (Fig 29). Fit supplied clamps but don’t tighten as yet.
Spray hose connections with WD-40 which will assist with sliding the hose connections on.
Fit the supplied 2.75” silicone hose joiner (PN:EMK05C01)to the intercooler discharge. Fit intercooler
discharge and loosely clamp to throttle body using the supplied hose clamps (Item 86).
Fit other end of turbocharger discharge hose to intercooler, this is the end with the 90 degree bend.
Check to make sure that the compressor discharge hose is not kinked or twisted.
Using supplied mounting nuts and bolts (Item 89+90+91) and fit RH and LH intercooler mounting
brackets (Item 99+100) to the intercooler and inlet manifold (Fig 30). Re-use the rubber mounting
bushes and sleeves from the stock airbox mounting brackets and bolt down the intercooler.
Fig 29
Fig 30
Step 24 – Fit supplied AVO Turboworld sequential blow-off valve (Item 95) to intercooler (Fig 29)
using supplied short rubber hose joiner (Item 93) and hose clamps (Item 94). Connect blow-off
valve vent return to turbocharger intake pipe using supplied short rubber hose joiner (PN: FNF67T01)
using supplied hose clamps (Item 98).
Connect blow-off valve vacuum hose (Item 96) to the spare vacuum fitting on the stock intake
manifold (Fig 27).
Turbocharger Air Intake System
Step 25 - Remove RH inner fender plastic liner panel. Position cruise control actuator inside of
inner fender area (Fig 31). Fit up cruise control actuator as shown, mark holes through stock
mounting bracket and drill two new 6mm mounting holes. Use supplied 6mm bolts and nuts to
attach cruise control actuator to inner fender area.
NOTE! Use care when drilling the inner fender so as not to drill through wiring looms and other engine
bay accessories. Check carefully before drilling holes. Always use approved eye protection when
drilling.
Cut cruise control wiring connector and extend wiring loom. Ensure all electrical joints are soldered
and properly insulated. Reconnect to vehicle wiring harness.

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Run vacuum hose from intake manifold through inner fender and re-connect to cruise control
actuator. Pass cruise control actuator cable through inner fender and re-connect to the throttle
butterfly. Secure cruise control wiring loom, vacuum cable and actuator cable with plastic tie cables.
Step 26 – Remove the blanking plate from underneath the stock hood scoop. Fit the supplied
Fibreglass Intercooler Scoop Shroud (Item 83) to the underside of the stock hood (Fig 31). Fit
supplied rubber seal to intercooler hood shroud (Item 84).
Check installed height of intercooler hood shroud and seal by slowly closing the hood. If there is
insufficient clearance, do not slam hood shut. Remove fibreglass shroud and trim to allow adequate
clearance.
Fig 31

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Mechanical Systems Check
Step 27 – Refill engine with engine oil and fit new oil filter. Check to ensure that all oil and coolant
connections are tight. Make sure that there are no loose hoses, pipes or cables near rotating
engine accessories.
Re-Connect Negative Battery Terminal.
Have assistant start engine, while the engine is running, check and inspect the following items for
coolant, oil and exhaust leaks.
NOTE! Exercise extreme caution when working around the engine while it is running. Always
maintain safe distance from hot exhausts and rotating engine parts and accessories. Be aware of
loose items of clothing, neckties and jewellery. Always switch off engine prior to attempting any sort
of mechanical work or adjustments.
Step 18 – Turbocharger oil drain hose and oil pan fitting.
Step 19 – Turbocharger oil supply feed hose at turbocharger and engine block.
Step 14 – Turbocharger exhaust up-pipe to stock exhaust header flange.
Step 15 – Turbocharger to catalytic converter pipe and stock exhaust system.
Step 16 – Oxygen Sensors.
Step 20 – Turbocharger cooling hose connections at throttle body, engine block and turbocharger.
Switch off Engine
Step 28 – Repair any oil, coolant or exhaust leaks as required. Check engine oil level and engine
coolant level. Top up as required.
Step 29 – Re-install alternator and alternator belt. Re-tension alternator belt. Adjust belt tension
until strong thumb pressure deflects the alternator drive belt by approx 0.5”. Don’t over tighten.
Refit accessory drive belt cover.
Step 30 – Restart engine and turn steering wheel from lock to lock. Check and inspect power
steering hose banjo (Step 7) for power steering oil. If required, top up with approved power steering
fluid.
Switch off Engine
Disconnect Negative Battery Terminal

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Engine Management Installation
Step 31 – Pull back carpet from passenger side front foot well to expose alloy footplate for stock
engine control computer. Remove alloy footplate, disconnect wiring harness from stock engine
control computer (Fig 32) and remove engine computer from foot well.
The additional AVO Turboworld engine control computer fits alongside the stock engine control
computer.
Fig 32
Step 32 – The attached wiring diagram for installation of the AVO engine control computer. All
wiring joints must be soldered and insulated with heat shrink and high quality electricians tape.
Do not use add-on crimp connectors for building a bridge harness as they give unreliable
connections and can result in erratic operation.
NOTE! Some model cars have wiring colours that are different from what is marked on the attached
wiring diagram. Use pin position references for connection. Always verify with volt meter that the
correct circuits are being connected to avoid damage to the AVO / Stock engine control unit and stock
electrical system. If in doubt consult AVO Turboworld or seek advice of a professional auto
electrician.
Step 33 – Run supplied vacuum hose from AVO engine control unit to inlet manifold through the
engine bay firewall. Tee into the stock fuel pressure regulator vacuum hose.
NOTE! The vacuum hose connection between the intake manifold and the AVO Engine control unit is
very important for correct operation of the turbosystem. Check to make sure that this vacuum hose is
not twisted, kinked, disconnected, blocked or connected to the wrong manifold fitting prior to starting
engine.
Step 34 – Install supplied AVO fuel cut defender as per supplied wiring diagram.