GReddy Turbo Kit User manual

GReddy Turbo Kit
05-on SCION TC TD05-18G 8cm2

05-on SCION TC TD05-18G 8cm2
Installation Manual
Please read the entire manual before installing this kit.
Application:
Make Model Chassis Year
SCION TC 05-on
• This GReddy Turbo Kit is designed onl for the vehicles specified above.
• Premium grade gasoline (92 octane or higher) is required with this Kit.
• Use of GReddy Racing Spark Plugs ISO 7 or NGK plugs (colder than factor ) is
recommended with this kit.
• This Turbo Kit DOES NOT include a fuel control system. It is mandator to
purchase a fuel control s stem as installing the turbo kit alone will cause engine
damage due to extreme lean conditions.
• It is recommended to purchase either the tC Turbo e-Manage Kit or the tC Turbo
e-Manage Ultimate Kit. These kits include 440cc injectors and the control unit is
loaded with a program, made specificall for this application. Please contact an
Authorized GRedd Dealer for purchasing information.
• Scion tC turbo kit e-Manage Kit part number: TC440EMK
• Scion tC turbo kit e-Manage Ultimate Kit part number: TC440EUK
Important
1. This installation should onl be performed b a trained specialist who is
ver familiar with the automobile’s mechanical, electrical and fuel
management s stem.
2. If installed b an untrained person, it ma cause damage to the kit as
well as the vehicle.
3. GRedd Performance Products Inc. is not responsible for an damage to
the vehicle’s electrical s stem caused b improper installation.

1. Parts list
1. Turbocharger TD05-18G 8cm2 P560mmHg 1
2. Exhaust manifold (Stainless) 1
3. Down pipe 1 (Cast Ductile Iron) 1
4. Down pipe 2 (60φ steel) 1
5. Intercooler (TYPE 31) 1
6. Suction Pipe S-1 (80φ Aluminum) 1
7. Compression Pipe C-1 (50φ Aluminum) 1
8. “ C-2 (50φ Aluminum) 1
9. “ C-3 (60φ Aluminum) 1
10. “ C-4 (60φ Aluminum) 1
11. “ C-5 (60φ Aluminum) 1
12. Airinx AY-M (Blue Filter) 1
13. Airinx Adapter Hose (M70) 1
14. Airinx Adapter (INX-1020) 1
15. Oil Pressure Line 400mm 1
16. Oil Pressure Fitting 1/8PT-M10 P1.25 1
17. “ Copper Washer 10φ (t=1.0) 1
18. “ 3-wa 1/8PT 1
19. “ 1/8PT – 1/8PT 1
20. “ 1/8PT – 1/8PF 1
21. Oil Return Flange Pipe 16φ (turbo) 1
22. Oil Return Pipe 16φ (engine) (Weld-on T pe) 1
23. Hose 5φ 1000mm 1
24. “ 16φ 300mm ( Blow-b .) 1
25. “ 16φ 350mm ( Oil Return .) 1
26. Silicone Hose 50φ Straight (70mm) 2
27. “ 60φ Straight (70mm) 3
28. “ 80φ Straight (80mm) 1
29. “ 50φ-60φ Reducer 1
30. “ 60φ-65φ Reducer 1
31. “ 70φ-80φ Reducer 1
32. Hose band 10φ #5 4
33. Hose band 16φ #10 4
34. Hose band 50φ #32 5
35. Hose band 60φ #36 8
36. Hose band 65φ #40 2
37. Hose band 70φ #44 2
38. Hose band 80φ #48 3
39. Gasket Turbo Inlet （TD05） 1

40. “ Turbo Outlet （TD05） 1
41. “ Down pipe (60φTriangle) 1
42. “ Oil Return （TD05） 1
43. Heat shield 1
44. Thermo Cloth 1000mm １
45. Zip Ties 150mm 10
46. 3-Wa vacuum fitting 10φ-5φ-10φ 1
47. One wa Valve 1
48. Intercooler Bracket 1
49. Airinx Bracket 1
50. Heat shield Bracket 1
51. M4x10mm Stainless Cap P=0.7 B - - - 2
52. M6x15mm Stainless P=1.0 B S/W - - 2
53. M6x15mm Stainless P=1.0 B S/W F/W - 3
54. M6x20mm Stainless P=1.0 B S/W F/W N 1
55. M8x35mm Stainless P=1.25 B - F/W N 3
56. M8x30mm Stainless Stud P=1.25 B S/W - N 5
57. M8x38mm Stainless Stud P=1.25 B S/W F/W - 1
58. M8 Stainless P=1.25 - - - N 2
59. M10 x25mm Stainless P=1.5 B S/W - N 3

１ ２ ３ ４ ５
６ ７ ８ ９ １０
１１ １２ １３ １４ １５
１６ １７ １８ １９ ２０

２１ ２２ ２３～２５ ２６～２８ ２９～３１
３２～３８ ３９ ４０ ４１ ４２
４３ ４４ ４５ ４６ ４７
４８ ４９ ５０ ５１～５９

2. Removal of Stock Parts
Please refer to the OE repair manual for removing stock parts.
2-1 Disconnect the negative terminal of the batter .
2-2 Drain the engine oil.
2-3 Disconnect the air flow meter.
2-4 Remove the Air cleaner assembl with airflow meter, intake tube.
2-5 Disconnect the primar O2 sensor and remove the exhaust manifold
2-6 Remove oil pan (Please refer to the factor service manual for detail instructions
for removing the oil pan.)
3. Kit Installation
3-1 Oil pan modification
1. Clean the oil pan.
2. Use the diagram to the right for welding
the oil return pipe to the oil pan.
3. Mark the oil pan to drill out for the
16mm hole.
4. Install the oil return pipe and weld
the pipe to the oil pan as the diagram
shows.
5. Clean the welded area and paint to
prevent rusting.
6. Reinstall the oil pan on to the engine.
(Parts used #22.)
45
4545
45°
°°
°
30mm
30mm30mm
30mm
20mm
20mm20mm
20mm
16
1616
16φ
φφ
φ

3-2 Thermo Cloth Installation
Wrap the AC line and surrounding
wire harnesses with the provided
thermo wrap.
(Parts used #44)
3-3 Turbocharger Assembly
1. Install the oil return flange tube to the
turbocharger using the provided
gasket.
(Parts used #1, 21, 39, 52)
2. Install stud bolts to the exhaust
housing and install the down pipe
adapter with provided gasket.
(Parts used #3,40,56)
3. Mount the turbocharger to the
manifold using the provided gasket
and bolts.
(Parts used #2, 3,39, 55,57)
4. Install the down pipe adapter1 to
the down pipe adapter2 with
provided gasket and hardware.
(Parts used #4,41,59)
3-4 Turbocharger Assembly Installation
Install the turbocharger assembl
with the provided gaskets.
※ Use stock bolts and exhaust manifold
gasket.

3-5 Front exhaust pipe Installation
Install the factor front exhaust pipe to
the down pipe.
※ Use stock bolts and exhaust gasket.
3-6 Oil Return Connection
. Wrap the oil return hose with the
provided thermo cloth and install the
hose from the turbocharger to the oil
pan.
(Parts used #25, 33, 44)
3-7 Oil Pressure Line Connection
1. Remove the factor oil pressure
switch then install the oil pressure
union and the three wa fitting as
shown.
(Parts used #18, 19, 20)
※Appl Teflon tape to the PT side
of the union fitting.
2. Connect the oil pressure line from the
turbo to the three wa fitting.
(Parts used #15,16,17.)
※Install the oil pressure line to the
turbocharger using oil pressure
fitting, 1/8pt-M10 P1.25and
copper washers.
CAUTION
Improper connection of the oil pressure line
can damage the turbocharger. Take caution to
prevent teflon tape from entering the oil lines.

3-8 Intercooler Core Installation
Mount the intercooler core as shown. Secure the top bracket to the hood latch
assembl and the bottom bracket to the sub-frame.
(Parts Used #5, 48, 54)
3-9 Suction Pipe Installation
1. Remove the Airflow Sensor from the
stock air box and install onto provided
Airinx adapter. Take caution to install in
the proper direction. Use stock bolts.
(Parts used #12)
2. Install the Airinx adapter on to the
Airinx Air filter.
(Parts used #12,13,14)
3. Install the S-1 pipe to the turbo inlet
and the Airinx assembl to the S-
1 pipe
as shown.
(Parts used #6,28,31,37,38)
4. .Connect the blow b tube from the
valve cover to the S-1 pipe with the
provided 16φ hose and clamps
(Parts used #24, 33)

3-10 Compression Pipe Installation
1. Install the Compression pipes C-1, C-2
from the turbo outlet to the Intercooler.
(Parts used #7,8,26,30,34,35)
.
2. Install the Compression pipes C-3, C-4 ,C-5 from the Intercooler to the throttle bod .
(Parts used #9,10,11,27,30,35,36)
3-10 Heat shield Installation
Install the heat shield to the
alternator as shown.
(Parts used #43, 50, 36, 50, 53)

3
33
3-
--
-12 V
12 V12 V
12 Va
aa
acuum
cuumcuum
cuum line Installation
line Installation line Installation
line Installation
Cut the brake booster vacuum hose b
the intake manifold and install the
3-wa fitting. Connect the 5φ side to
the actuator with the provided 5φ
hose.
*Secure all the vacuum hoses
with zip ties to prevent the hose
from disconnecting.
(Parts used #23,45,46)
3-13 Starting the Engine
1. Refill the engine oil to factor spec.
2. Check all the hoses and wires connection, then reconnect the negative side of the
batter .
3. Turn the ignition to “ON” position 2-3 times to get fuel pressure. Then, check the
injectors and the fuel rail for an 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 an oil leaks, then reinstall the fuse and
start the engine.
5. While idling, check for an oil, coolant, or air leaks.
6. After inspection, reinstall the under cover and other stock parts that was removed.
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.