Page 1: Table Of Contents
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.
Page 2: Orientation
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.
Page 3 1 x 12mm Plastic T Piece 1 x 13mm Oil Breather Hose PM: 7JBM5S02 PN: 7JBM5S01 PN: EN6MBT01 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 3 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 4 1 x LH Intercooler Stay 4 x 8x1.25mm Nut 4 x 8mm Spring Washer PN: RBXVTT01 PN:1BEHUT01 PN:ABBHUT01 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 4 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 5 1 x SMT Computer Loom 1 x Map Sensor 1 x Computer Program PN: W199SX01 PN:9299SX01 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 5 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 6: Pre-Installation Preparations
Remove the factory air-cleaner box mounting brackets. (Need picture of factory airbox and mounting brackets - Figs 1+2 ) AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 6 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 7 Fig 5: Use plastic cable ties to secure Fig 6: Re-route wiring for turbo. harness. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 7 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 8 Fig 8: Push receiver drier towards engine Fig 9: Push high-pressure A/C line in bay firewall. against suspension strut. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 8 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 9 Fig 11: Loosen Banjo Power Steering bolt. Fig 12: Re-fit hose bracket facing downwards. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 9 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 10: Turbo Oil Return System
Damage to this “O” ring can result in oil system failure and serious engine damage. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 10 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 11: Turbocharger Assembly
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...
Page 12 Fig 17: Turbocharger up-pipe support Fig 18: Coat gasket with high-temp sealant. bracket Fig 19: Turbocharger sub-assembly AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 12 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 13 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 13 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 14: Turbocharger Cooling + Lubrication
(Continued) Do not re-fit the alternator. This will be done after the engine has been test run to check for oil leaks. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 14 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 15 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. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 15 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 16: Turbocharger Intake System
(Fig 29). Fig 27: Turbocharger intake breather hose. Fig 28 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 16 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 17 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).
Page 18 Remove fibreglass shroud and trim to allow adequate clearance. Fig 31 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 18 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 19: Mechanical Systems Check
(Step 7) for power steering oil. If required, top up with approved power steering fluid. Switch off Engine Disconnect Negative Battery Terminal AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 19 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 20: Engine Management Installation 17+18+19
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.
Page 21 1.0-1.4V KOEO O2 Sensor White Front O2 Sensor B134-22 0-1.0V KOEO AVO Fuel Cut Map Sensor Signal B136-5 2.4-4.8V KOEO AVO ECU 17 pin Connector (Wire Side View) INJ1 +12 V Trig1 E Temp TPS In Brown Blue Blue/ Blue/...
Page 22 NOTE: We no longer supply this version of the kit. The above diagram is for reference only for current owners of this older kit. AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 22 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 23 AVOTurboworld – For All Your Turbo Needs Tel +61 3 95844699 Page 23 of 25 Fax +61 3 95844008 Created on 6/17/08 12:30 PM www.avoturbo.com avo@avoturbo.com...
Page 24: Turbosystem Testing
Step 36 – AVO Turboworld recommends that fuel mixtures are verified using an air fuel ratio meter to check that the stock fuel pump and fuel system is operating correctly. Under full throttle the air fuel ratio should be 11.9 to 1_or around Lambda 0.82.
Page 25 Re-assemble all parts lubricating BOV brass piston with a light coating of transmission or sewing machine grade oil. NOTE! – If in any doubt contact AVO Turboworld prior to disassembly of your AVO Billet BOV AVO Turboworld Airfilter At 10,000 mile intervals (5000 miles for dusty / sandy operating conditions) remove your power filter element for servicing using the following procedure.