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So Delicious !
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Discussion Starter #1 (Edited)
Well this is not really a how to, (but instructions are included)
and not sure if I'm allowed to, so here we go.

I'd like to THANK, Luke (Toolman) for reformating these
instructions to be easier on your eyes.
Thanks Again, Luke !

This is just my experience installing a zzp stage 3 turbo kit.
This may take a few days to complete, I am going to give the
instructions that came with the kit and I will add any thing good
or bad about the install.
I installed this on a 2007 G5 GT 2.4L AUTOMATIC
This kit is designed to run at 11psi on
stock engine. The waste gate is set to 6psi and you turn it up from there
with a manual boost controler. This kit will do more boost than 11psi,
I believe the stock fuel system can only support 12psi, I may be wrong
but taking chances by turning it up while stock.
The kit came with a HPT tune that was pig rich WOT,
it was like 10.0-1 AFR, but I'm sure they don't want to
be responsible for poping your motor.
Hence: why they say it needs to be dyno tuned.
I will say that this sure wakes my car up.
I wasn't looking to make mad power,
just a little bit more fun and I found it.


ZZP 2.4 Turbo Kit Instructions

Note: These instructions are intended for installers with previous turbo installation
experience. Some procedures will not be described in full detail. If you run into any
installation issues or have trouble comprehending any of the procedures, please contact
ZZPerformance or a qualified auto shop/technician to help you through the process.

1. Getting started: Remove the airbox ducting shown here.
zzpturbo01.jpg

2. Remove the MAF sensor from the airbox.
zzpturbo02.jpg

3. Remove the airbox lid and air filter.
zzpturbo03.jpg

4. Remove the lower half of the airbox.
zzpturbo04.jpg

5. Remove the passenger side headlight to access and remove the lower airbox ducting.
zzpturbo05.jpg

6. Remove the factory downpipe from the exhaust manifold and catback.
zzpturbo06.jpg

7. Remove the exhaust manifold from the engine.
zzpturbo07.jpg

8. Install the turbo oil feed fitting in the port shown below.
zzpturbo08.jpg
I read about a lot of people stripping out this allen headed plug.
I found out its 6mm and didn't strip it out.

9. Install the turbo manifold at this time.
zzpturbo09.jpg

10. Remove the oil pan and install the new turbo oil pan or weld the aluminum bung into the oil pan.
zzpturbo10.jpg

11. Install the turbocharger to the turbo manifold.
zzpturbo11.jpg
If you get the recirculated wastegate (dumps back into exhaust) you
need to put the downpipe up and wire it out of the way BEFORE you
install the turbo, or you will be doing it twice. I did. lol
Because it WILL NOT FIT after the turbo is installed.
Notice instructions make no mention of this. ??????

12. Install the oil drain hose as shown.
zzpturbo12.jpg
13. Install the 5-bolt turbo downpipe and Primary O2 sensor.
zzpturbo13.jpg
My downpipe has only 2 bolts, updated turbo flanges.
much better, than bolt together.

14. Recirculated wastegate dump tube shown below.
zzpturbo14.jpg
This is old style flanges, not what comes in my kit.

15. Install the wastegate at this time.
zzpturbo15.jpg
Again old style wastegate.

16. Install the turbo inlet coupler and discharge coupler as shown below.
zzpturbo16.jpg

17. Install the air filter tube in the fender-well as shown below.
zzpturbo17.jpg

18. Vent hose from the valve cover connects to the new intake tube.
zzpturbo18.jpg
This is where the v/c hose goes to.

19. Connect the vacuum T to the intake, evap hose, and vacuum hose.
zzpturbo19.jpg
I also didn't use the T they supplied,
looked like crap after install. :)

20. Non-intercooled charge tubing, intake tubing, and bypass valve configuration.
zzpturbo20.jpg
Where is the pics for the kit I bought with the intercooler ?

21. Typical boost controller mounting with additional line added for boost gauge:
zzpturbo21.jpg
zzpturbo22.jpg
Routing depends on the type of manual boost controler you have.
Mine is a Hallman Pro and only uses a hose to the side port and the
top port is open to the atmosphire.

Intercooler Installation

1. With the front bumper skin removed, install the front heat exchanger. The outer tabs slide
in behind the bumper support bolts and fasten with two additional nuts. The inner tabs bolt to
existing holes on the bottom of the bumper support. Wait until you are re-installing the bumper
skin before installing the inner bolts.
zzpintercooler1.jpg
I did this first thing a weekend before the install.
After I installed the intercooler and pump as instructed to do, I found out
the bumper will hit the cooler and needed to be ground down on the
back side to make clearence. In 4 places I needed to grind back about 1/4"
was my guess. Wrong answer, bumper still won't fit.
So I removed the coooler and reworked the brackets by expanding the top
holes and bending the side brackets to a different angle. By doing this I was
able to move the cooler back closer to the radiator. Just perfect and That
1/4' that I ground off is the exact amount of clearance I have now. Perfect.

2. Pump mounting in driver side fender-well is shown below.
zzpintercooler2.jpg
The intercooler pump pictured and the one in my kit are not the same.
My pump is much larger and would not fit where they wanted it. I got it close to there and then the hoses wouldn't fit right, the bumper wouldn't fit, nor the splash shield on the bottom. Re worked a different bracket and angle. Fits but had to buy different hose to finish this part of the install.
 

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So Delicious !
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5,263 Posts
Discussion Starter #2 (Edited)
3. Hose routing and filler T are shown below.
zzpintercooler3.jpg
Because my pump was much longer I had to put a 90 degree
bent hose where they show the clear hose, without the bend
it only wanted to kink the hose. This was my fix.
07 G5 GT TURBO BUILD 2010 009-1.jpg

4. Switched power to the pump can be obtained by connecting to the pink wire in the ABS harness.
zzpintercooler4.jpg
I don't hack into factory wiring harness. I ran a wire to the fuse box
and used an add-a-fuse circuit.



5. Tape up the wires to avoid connection issues.
zzpintercooler5.jpg
lol

6. Power and ground wires connected to the intercooler pump are shown below.
zzpintercooler6.jpg

7. Run the fill T up and next to the coolant bottle.
zzpintercooler7.jpg
They used the clear hose by the pump and black hose
for your fill tube. I wanted to know if the coolant was full,
so I used the clear hose for my fill tube.

8. Mount the intercooler, charge tubes, and blow off valve. Connect the intercooler hoses.
zzpintercooler8.jpg

9. Fill the intercooler system with a water/anti-freeze mix. Turn the key on to run the pump while
bleeding the air out of the system. It may take several minutes for most of the air to bleed out of
the system. Occasionally check the water level in the fill tube and add water as necessary.
10. Reinstall the bumper skin.
zzpintercooler9.jpg
Took about half an hour to finally bleed all the air out of the
intercooler and heat exchanger, poor system, but at least you
don't have to do this often. I also added some purple ice to
help with the cooling a little bit.

I expected to see "THE END"


These are just some pics to show how tight it is in there.
ZZPTK1- 003.JPG

ZZPTK1- 004.JPG

ZZPTK1- 005.JPG

ZZPTK1- 007.JPG

ZZPTK1- 008.JPG

I'll fill in more info tomorrow night
and write about MY EXPERIENCE.
 

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So Delicious !
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5,263 Posts
Discussion Starter #6

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ok i was about to say it didnt look like it in the how to but are you running b.p.v or b.o.v
 

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So Delicious !
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5,263 Posts
Discussion Starter #9 (Edited)
do u have a breather filter on the valve cover now? I dont know much about boost but i know alot of people seem to be doing catch cans...although u may not be running enough boost for that
No breather filter on the valve cover. The hose gets run down by the air filter
and hooks in there. I have seen no evidence of oil there yet.

ok i was about to say it didnt look like it in the how to but are you running b.p.v or b.o.v
BOV, a very quite one. You really can't tell from outside, my car is turbo'd.
I like it that way. lol
If you look in 9th pic on the second post, you'll see the red BOV.
 

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wow i didnt see that lol but ive debated putting one on mine but im gonna wait until i get a different turbo way on down the road dont wanna mess up the stock turbo. But good job on the install it looks really good.
 

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So Delicious !
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Discussion Starter #12
Updated some first post.

The instructions make it look so easy. How long did it take you to do the install?
Instructions are of not much use for the parts I recieved, all different.
about 4 hours to do the bumper, intercooler and pump one weekend.
about 8 hours total work the next weekend and monday, had to have welding
done, plus I had to play with stainless steel hoses while waiting, that took time.
If you knew what to expect and had acess to a lift and could do the welding
yourself, you could do it in a day.

I mean I installed this in my driveway....lol
 

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Updated some first post.


Instructions are of not much use for the parts I recieved, all different.
about 4 hours to do the bumper, intercooler and pump one weekend.
about 8 hours total work the next weekend and monday, had to have welding
done, plus I had to play with stainless steel hoses while waiting, that took time.
If you knew what to expect and had acess to a lift and could do the welding
yourself, you could do it in a day.

I mean I installed this in my driveway....lol
the true mechanic!
 

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It looks great, CherryGT, I take its probably a lot more fun to drive now. Actually kind of swaying me toward this option instead of the M62... according to ZZP, this kit could be installed on a 2.2 auto as well. I know some of the clearances on the auto are a bit tighter, from your experience, do you think the auto would be a lot more difficult to install? Also, did you go with the 2.5" or 3" exhaust option and did you go catted or catless?
 

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So Delicious !
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Discussion Starter #19
It looks great, CherryGT, I take its probably a lot more fun to drive now. Actually kind of swaying me toward this option instead of the M62... according to ZZP, this kit could be installed on a 2.2 auto as well. I know some of the clearances on the auto are a bit tighter, from your experience, do you think the auto would be a lot more difficult to install? Also, did you go with the 2.5" or 3" exhaust option and did you go catted or catless?
Way more fun !
For a 2.2 you need to find your own tuning.
I can't compare the install to a manual. IDK
It wasn't a difficult install if you can solve a few issues
that will arise, since instructions don't really help you.
I got the 3"catless down pipe, but I still have the MagnaFlow
catback which is only 2 1/2". (will be for sale in the near future)
I will be adding a 3" catback someday.
I have to say, that even at 6psi this turbo makes
Pontiac driving excitement come back !
 

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Thanks for the input, I wasn't too concerned with the tuning, I'll probably just have Trifecta work their magic for that part of things. Have you had any trouble code problems going catless?
 
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