GReddy Turbo Kit User manual

GReddy Turbo Kit
96-98 Nissan 240SX S14 (KA24DE) TD06-20G 8cm2

96-98 Nissan 240SX S14 (KA24DE) TD06-20G 8cm2
Installation Manual
Please read the entire manual before installing this kit.
Application:
Make Model Chassis Year
Nissan 240SX S14 96-98
•This GReddy Turbo Kit is designed only for the vehicles specified above.
•GReddy Front mount intercooler kit is recommended with this kit
•Premium grade gasoline (92 octane or higher) is required with this Kit.
•Make sure that the vehicle is not equipped with any ECU upgrade chips.
•Use of GReddy Racing Spark Plugs ISO #7 or NGK plugs (colder than factory) is
recommended with this kit.
Important
1. This installation should only be performed by a trained specialist who is
very familiar with the automobile’s mechanical, electrical and fuel
management system.
2. If installed by an untrained person, it may cause damage to the kit as
well as the vehicle.
3. GReddy Performance Products Inc. is not responsible for any damage to
the vehicle’s electrical system caused by improper installation.

1. Parts list
1. Turbocharger TD06-20G 8cm2 P380 1
2. Exhaust manifold (Cast Ductile Iron) 1
3. Downpipe (60∅steel) 1
4. Compression Pipe C-1 (50∅Aluminum) 1
5. “ C-2 (50∅Aluminum) 1
6. “ C-3 (60∅Aluminum) 1
7. Suction Pipe (80∅Aluminum) 1
8. Airinx AY-M Blue Filter 1
9.AirinxAdapter 1
10.Oil Pressure Line 1200mm 1
11.Oil Pressure Fitting 3-way 1/8PT 1
12. “ 1/8PT – 1/8PT 1
13. “ 1/8PT – 1/8PF 1
14.Oil Pressure Banjo Fitting Small (Male & Female) 1set
15.Copper Washer 10∅(t=1.0) 2
16.Oil Return Flange Pipe 19∅1
17.Oil Return Pipe 19∅(Weld-on Type) 1
18.Oil Return Spacer 15∅-7∅10mm 1
19.Hose 5∅1500mm 1
20. “ 16∅1120mm (Breather 240mm, Blow-by 480mm. Power steering 400mm) 1
21. “ 19∅320mm 1
22.Silicone Hose 50∅Straight 2
23. “ 80∅Straight (60mm) 1
24. “ 50∅-60∅Reducer 1
25. “ 60∅-70∅Reducer 1
26. “ 70∅-80∅Reducer 1
27.Hose band 16∅#10 4
28.Hose band 19∅#12 2
29.Hose band 50∅#32 5
30.Hose band 60∅#36 2
31.Hose band 70∅#44 2
32.Hose band 80∅#48 3

1. Parts list
33.Compression Pipe C-3 Bracket 1
34.Heatshield Bracket A 1
35.Heatshield Bracket B 1
36.Heatshield 1
37.Restricter 80∅-42∅1
38.Gasket Exhaust Manifold 1set
39.“TurboInlet 1
40. “ Turbo Outlet 1
41.“OilReturn 1
42.Thermo Cloth 1000mm 3
43.Vacuum fitting 5∅-1/8PT 2
44.3-Way vacuum fitting 1
45.ZipTies 150mm 10
46.e-Manage 1
47.e-Manage Harness 1
48.Injectors 370cc (Top Feed Type) 4
49.Injector Harness harness, wire connector, insulator 4set
50.FuelRailAssembly 1set
51.Fuel Rail Spacer 38.5mm 2
52.Fuel Regulator Adapter Fitting 1
53.Fuel Rail Fitting 1
54. M5x10mm StainlessCap P=0.8 B - - - 2
55. M6x15mm Stainless P=1.0 B - - N 7
56. M6x25mm Stainless P=1.0 B - - N 1
57. M6 Stainless S/W F/W 10
58. M8x55mm Stainless Cap P=1.25 B - F/W - 2
59. M10x20mm Stainless P=1.5 B S/W - - 3
60. M10x35mm Stainless Stud P=1.25 – 1.25 B - - - 1
61. M10x45mm Stainless Stud P=1.25 – 1.50 B - - - 5
62. M10 Stainless P=1.25 S/W - N 15

1 2 3
4 5 6
7 8 9
10 11 12 - 13 14

15 16 17 18
19 – 21 22- 26 27 - 32
33 34 35
36 37 38 - 40
41 42 43 44

45 46 47
48 50 51
52 53 54–62

2. Removal of Stock Parts
When removing the stock parts, make sure you read over the
factory repair manual for proper procedures.
2-1 Disconnect the negative terminal of the battery.
2-2 Drain the engine oil and power steering fluid.
2-2 Disconnect the air flow meter.
2-4 Remove the Air cleaner assembly with airflow meter, intake tube, breather hose
and Intake temperature sensor.
2-5 Disconnect the primary and secondary O2 sensor and remover the catalytic
converter.
2-6 Remove the exhaust manifold.
2-7 Remove oil pan (Please refer to the factory service manual for detail instructions
for removing the oil pan.)
2-8 Remove the fuel rail assembly with injectors and regulator.

3. Kit Installation
3-1 Oil pan modification
1. Clean the oil pan.
2. Install the oil return pipe using the
provided spacer as shown.
3. Mark the oil pan to drill out for the
19mm hole.
4. Remove the oil return pipe and drill out
Spacer
the marked hole.
5. Reinstall the oil return pipe and weld
the pipe to the oil pan.
6. Clean the welded area and paint to
prevent rusting.
7. Reinstall the oil pan on to the engine.
(Parts used #17, 18, 51, 52)
3-2 Thermo Cloth Installation
1. Wrap the AC line, O2 sensor wire with
the provided thermo cloth.
(Parts used #42)
3-3 Replace Power Steering Hose
1. Cut the provided 16∅hose to 400mm
and wrap it with thermo cloth.
2. Replace the power steering hose with
this hose.
(Parts used #20, 27, 42)
3-4 Replace Stud Bolt
1. Remove the bottom stud bolt on the #3
port on the cylinder head and replace it
with the provided stud bolt.
(Parts used #54)

3-5 Exhaust Manifold Installation
1. Install the exhaust manifold with the
provided gaskets and hardware.
(Parts used #2, 38, 56)
3-6 Turbo Installation
1. Install the oil return pipe to the turbo
using provided gasket and hardware.
(Parts used #1, 16, 41, 50, 52)
2. Install the turbo assembly to the
manifold
(Parts used #39, 55, 56)

3-6 Oil Pressure Line Installation
1. In stall the oil pressure fitting to the
block. Install the three way fitting
between the block and the factory oil
pressure sensor.
(Parts used #10, 11, 12, 13)
2. Install the Oil Pressure line to the three
way fitting and route the line under the
engine by the sub-frame as shown.
3. Install the banjo fitting to the pressure
line and connect the line to the
turbocharger as shown.
(Parts used #14, 15)

3-7 Oil Return Line Installation
1. Wrap the oil return hose with the
provided thermo cloth and install the
hose from the turbocharger to the oil
pan.
(Parts used #21, 28, 42)
3-8 Down Pipe Installation
1. Install the downpipe to the turbocharger
as show using provided gasket and
hardware.
(Parts used #3, 40, 53)
2. Install provided stud bolt and secure
the down pipe to the transmission
housing as shown.
(Parts used #55)

3-9 Catalytic Converter Installation
1. Install the factory catalytic converter to
the down pipe.
3-10 Heatshield Installation
1. Install the heat shield to the
turbocharger as shown.
(Parts used #34, 45, 36, 50, 50)
3-11 Compression Pipe Installation
1. Install C-1, C-2 to turbo out let.
(Parts used #4, 5, 22, 29, 51, 52)
2. Install C-3 from C-2 to throttle body in
let. Secure the pipe to the radiator fan
shroud as shown.
(Parts used #6, 20, 24, 25, 27, 29, 30, 31)
3. Install the vacuum line for the actuator
with a 3way tee from the fuel pressure
regulator to the actuator.
(Parts used #19, 43)

3-12 Suction Pipe Installation
1. Install the Airinx adapter on to the Airinx
filter housing.
(Parts used #8, 9)
2. Install the S-1 to the turbo inlet and
install the Airinx assembly to the S-1 as
shown.
(Parts used #7, 23, 26, 31, 32, 37)
3. Install the blow-by, and idle control
valve hose to the C-3 and S-1 as
shown.
(Parts used #19, 20, 28, 44, 45)
3-13 Injector and Fuel rail Installation
1. Cut the factory injector harness and
install the provided injector harness.
(Parts used # 49)
2. Install the Fuel Regulator fitting and fuel
rail fitting on to the rail using the
provided o –rings.
(Parts used #50, 52, 53)
3. Install the factory fuel regulator to the
fitting on the new rail with provided
hardware.
(Parts used #54)
4. Install the factory fuel regulator to the
fitting on the new rail with provided
hardware.
(Parts used #54)
5. Install the provided injectors with the
new fuel rail assembly.
(Parts used #48)

3-14 E-manage Installation
1. Wire in the E-manage to the factory ECU.
Important! Make sure to solder all the wires in except for the wires that has male
and female connectors. (Parts used # 46, 47)
102 104 3 47  61
107 109 106 43
Ar
White
I
Brown
#3
Yellow
/Red
#1
Blue
/Red
+B
Red
Ar
Green
#2
Orange
/Red
#4
Purple
/Red
#E
Black
/Red
E
Black
Code Description E-manage Color ECU pin #
+B +12V ignition power Red 61
E ECU ground Black 43
Ar Air Flow Meter Signal Green & White 47
I RPM Signal Brown 3
#1 Injector #1 Signal Blue/Red 102
#2 Injector #2 Signal Orange/Red 107
#3 Injector #3 Signal Yellow/Red 104
#4 Injector #4 Signal Purple/Red 109
#E Injector Ground Black/Red 106

3-15 Starting the Engine
(1) Refill the engine oil to factory spec.
(2) Check all the hoses and wires connection, then reconnect the negative side of the
battery.
(3) Turn the ignition to “ON” position 2-3 times to get fuel pressure. Then, check the
injectors and the fuel rail for any fuel leaks.
*Repair any fuel leaks before starting the engine. Starting the engine with a
fuel leak can cause fire in the engine compartment and can be very
dangerous.
(4) Remove the ECM fuse and crank the engine to get oil pressure to the turbo. (Until
the oil light on the dash turns off) Check for any oil leaks, then reinstall the fuse and
start the engine.
(5) While idling, check for any oil, coolant, or air leeks.
(6) After inspection, reinstall the under cover and other stock parts that was removed.
(7) On the initial run, be sure to have a boost gauge to check the turbo-actuator setting.
This turbo kit is preset to boost between 0.6kg/cm2 to 0.6kg/cm2.
It is very important that you monitor the boost pressure, and make sure not to over
boost. Over boosting can cause engine damage.
This completes the Turbo Kit installation.
Important!
•It is very important that you monitor the boost pressure, and make sure not to
over boost. Over boosting can cause engine damage.
•GReddy Performance Products, Inc. is not responsible for any engine damage
caused by over boosting (increased boost), modification to the kit, and/or
misuse of the product. NO WARRANTY is offered.
•Due to lack of control over proper installation and use of this product,
NO WARRANTY is offered for this kit.

e-manage Information
Important!
•The e-manage included in this kit is preprogrammed for the this turbo kit.
•Do not attempt to adjust any of the setting in the e-manage.
•Any adjustments made can cause damage to the e-manage, engine and the
factory ECU.
Important!
As of 5/25/03 this kit is not a street legal kit. Please ignore the label on the
e-manage.
ACTIVE L.E.D.
3 When the ignition is turned on, it will illuminate and flash GREEN.
4 When it reaches to the A.A.V. setting RPM range, it will illuminate and flash ORANGE.
5 When an error is detected it will flash RED.
INTERACTION L.E.D.
3 This will illuminate when there is a connection with PC.
Checking Error Codes
When the unit is powered up and if there are any errors, the ACTIVE L.E.D will turn
“RED” from “GREEN”, and begin to flash.
If this happens shut the engine off and turn the ignition switch to “ON”
position to go to Self Troubleshooting Mode. While in the Self
Troubleshooting Mode, the L.E.D. will show the error code. Turn off the
ignition. Check the error code in the chart below and fix the problem.
The error code will show until the error is corrected.

Checking Error Code Chart
Incorrect wiring or disconnected Airflow Signal 1
Airflow Signal 1
input error
Airflow voltage
output error
No Injector
pulse from all
No Injector 1 pulse
No Injector 2 pulse
No Injector 3 pulse
No Injector 4 pulse
Incorrect Airflow signal output wiring.
Not receiving an injector signal for
Additional Injection Map
Not receiving injector signal I/J CH-1
for Additional Injection Map
Not receiving injector signal I/J CH-2
for Additional Injection Map
Not receiving injector signal I/J CH-3
for Additional Injection Map
Not receiving injector signal I/J CH-4
for Additional Injection Map
CODE
11
15
20
21
22
23
24
31
32
33
34
40
41
42
43
44
49
51
52
53
54
57
Improper order of
Ignition input signal
Error Error description
Incorrect Injector 1
pulse
Incorrect Injector 2
pulse
Incorrect Injector 3
pulse
Incorrect Injector 4
pulse
Incorrect wiring order of the ignition signal wires.
Incorrect I/J CH-1 wire to e-Manage unit
Incorrect I/J CH-2 wire to e-Manage unit
Incorrect I/J CH-3 wire to e-Manage unit
Incorrect I/J CH-4 wire to e-Manage unit
No Ignition Signal 1
pulse
No Ignition Signal 2
pulse
No Ignition Signal 3
pulse
No Ignition Signal 4
pulse
Not receiving the ignition signal to IG CH-1
Not receiving the ignition signal to IG CH-2
Not receiving the ignition signal to IG CH-3
Not receiving the ignition signal to IG CH-4
Incorrect Ignition 1
pulse
Incorrect Ignition 2
pulse
Incorrect Ignition 3
pulse
Incorrect Ignition 4
pulse
No Ignition pulse
JP2 + 12V
error
Incorrect IG CH-1 wire to e-Manage unit
Incorrect IG CH-2 wire to e-Manage unit
Incorrect IG CH-3 wire to e-Manage unit
Incorrect IG CH-4 wire to e-Manage unit
Incorrect Jumper setting (JP2)
Not receiving the ignition signal
to any of the channels