Turbochargers are a type of forced-induction intake system that make use of impellers to compress air and force it into the combustion chamber of the engine. A twin turbocharger system makes use of two turbochargers instead of a single unit to create more boost pressure. Installation of a twin turbocharger is not much more complicated than a single unit setup. The installation process is still very difficult and time-consuming, usually requiring between 20 and 40 hours of labor. It is highly recommended that a complete turbocharger installation kit is purchased to avoid having to buy each part separately.
Disconnect the negative battery cable. Wait five minutes for the back-up capacitors to discharge before moving on. Disconnect the lower radiator hose and allow all of the engine coolant to flow out into a drain pan. Remove the oil pan drain bolt and allow all of the engine oil to drain into a drain pan.
Remove factory installed hardware, including the hood, front and rear inner fenders, bumper bar, front wheels, engine cover, air filter assembly, intake tube, mass air flow sensor, throttle body, engine oil cooler, ambient air temperature sensor, radiator cover, exhaust manifolds, exhaust downpipe, left-hand water galley plug, oil filter and fuel injectors. Disconnect the clutch line from the master cylinder and disconnect the left-hand steering shaft.
Install the water take-off adapter into the water-galley opening and connect the outer water hose to the adapter. Install the exhaust manifold heat shields. Install the exhaust manifold mounting studs. Install boost sensing hoses for both turbocharger wastegates. Connect the oil supply hose to the oil inlet port on turbocharger using a banjo bolt. Install rear turbo studs, oil drain and the water supply adapter on the turbochargers. Bolt the left-hand and right-hand side turbochargers to their respective exhaust manifolds. Connect both wastegates to both turbocharger outlet pipes. Install the boost hose banjo and filter plug to both turbochargers. Connect the outlet pipes to both turbochargers. Install the oxygen sensors into the outlet pipes. Connect both boost sensing hoses to the respective wastegates. Install the oil filter. Bolt both exhaust manifolds (with attached turbochargers) to the engine. Connect boost hoses to 90-degree barb fitting on both turbocharger compressor housing outlets. Install both compressor entry ducts to the turbocharger compressor housings.
Attach both air entry hoses to both compressor air entry ducts using silicone hose clamps. Feed the air entry ducts rearward into the silicon air entry hoses and secure them with silicone hose clamps. Attach the blow-off valve joiner ducts to the entry hoses using standard hose clamps. Install the compressor discharge hoses. Install the intercooler inlet hoses to the discharge ducts. Install the blow-off valves and valve outlet ducts. Install your air filter element to the joiner duct. Install both the turbocharger oil inlet hoses and outer water hoses. Reconnect the steering shaft. Remove the intake manifold and connect all vacuum hoses. Reinstall the manifold. Install high-flow fuel injectors and rails. Install the return oil line check valve. Install the exhaust intermediate pipe to the outlet pipe.
Refill all engine fluids. Check all connections for leaks. Disconnect the ignition coil(s). "Start" the engine for 10-second bursts five times to prime the fuel and oil systems. Reconnect the ignition coil(s) and start the engine.
