GReddy Turbo Kit

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

electrical and fuel management system. . 2.96-98 Nissan 240SX S14 (KA24DE) TD06-20G 8cm2 Installation Manual Please read the entire manual before installing this kit. GReddy Performance Products Inc. If installed by an untrained person. is not responsible for any damage to the vehicle’s electrical system caused by improper installation. Application: Make Nissan Model 240SX Chassis S14 Year 96-98 ! ! ! ! ! This GReddy Turbo Kit is designed only for the vehicles specified above. Important 1. This installation should only be performed by a trained specialist who is very familiar with the automobile’s mechanical. Make sure that the vehicle is not equipped with any ECU upgrade chips. it may cause damage to the kit as well as the vehicle. Use of GReddy Racing Spark Plugs ISO #7 or NGK plugs (colder than factory) is recommended with this kit. 3. GReddy Front mount intercooler kit is recommended with this kit Premium grade gasoline (92 octane or higher) is required with this Kit.

Parts list 1. Silicone Hose 50" Straight 23. 8. Copper Washer 10" (t=1. Oil Return Flange Pipe 19" 17. “ 60"-70" Reducer 26. Oil Return Pipe 19" (Weld-on Type) 18. Hose band 28. “ 1/8PT – 1/8PT 13. Blow-by 480mm. 5. Oil Pressure Line 1200mm 11. 9. “ 1/8PT – 1/8PF 14. “ 19" 320mm 22. Turbocharger 2. Hose band 29. Hose 5" 1500mm 20. Hose band 30.0) 16.1. 6. Compression Pipe “ “ Suction Pipe Airinx AY-M Airinx Adapter TD06-20G 8cm2 P380 (Cast Ductile Iron) (60" steel) C-1 C-2 C-3 (50" Aluminum) (50" Aluminum) (60" Aluminum) (80" Aluminum) Blue Filter 1 1 1 1 1 1 1 1 1 1 1 1 1 1set 2 1 1 1 1 1 1 2 1 1 1 1 4 2 5 2 2 3 10. “ 80" Straight (60mm) 24. Oil Return Spacer 15"-7" 10mm 19. Exhaust manifold 3. “ 16" 1120mm (Breather 240mm. Hose band 16" 19" 50" 60" 70" 80" #10 #12 #32 #36 #44 #48 . 7. “ 70"-80" Reducer 27. Power steering 400mm) 21. Downpipe 4. “ 50"-60" Reducer 25. Hose band 32. Oil Pressure Fitting 3-way 1/8PT 12. Hose band 31. Oil Pressure Banjo Fitting Small (Male & Female) 15.

Compression Pipe C-3 Bracket 34. e-Manage 47. M5x10mm Stainless Cap M6x15mm Stainless M6x25mm Stainless M6 Stainless M8x55mm Stainless Cap P=0.50 B M10 Stainless P=1.25 B M10x20mm Stainless P=1. Injectors 370cc (Top Feed Type) 49. 55. insulator 50.25 – 1.0 B B B S/W F/W F/W S/W N N N 1 1 1 1 1 1set 1 1 1 3 2 1 10 1 1 4 4set 1set 2 1 1 2 7 1 10 2 3 1 5 15 P=1.25 B M10x45mm Stainless Stud P=1. Parts list 33.1. “ Oil Return 42. Thermo Cloth 1000mm 43. Heatshield 37.1/8PT 44. Heatshield Bracket B 36. 56. Restricter 80" -42" 38. Vacuum fitting 5" .8 P=1. “ Turbo Inlet 40. 59. Injector Harness harness.0 P=1. 58. Fuel Rail Spacer 38. 61. 62. Fuel Rail Assembly 51. 60. “ Turbo Outlet 41. Zip Ties 150mm 46. Fuel Rail Fitting 54.5mm 52.25 – 1. Heatshield Bracket A 35.5 B S/W M10x35mm Stainless Stud P=1. 57.25 . 3-Way vacuum fitting 45. e-Manage Harness 48. Gasket Exhaust Manifold 39. Fuel Regulator Adapter Fitting 53. wire connector.

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

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 .

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

2. 27. (Parts used #20. Cut the provided 16" hose to 400mm and wrap it with thermo cloth. Wrap the AC line. Reinstall the oil return pipe and weld the pipe to the oil pan. Reinstall the oil pan on to the engine. Clean the oil pan. 5. O2 sensor wire with the provided thermo cloth. Clean the welded area and paint to prevent rusting. 7. 3. Replace the power steering hose with this hose. 6. Install the oil return pipe using the provided spacer as shown. (Parts used #17. Remove the bottom stud bolt on the #3 port on the cylinder head and replace it with the provided stud bolt. 51. Mark the oil pan to drill out for the 19mm hole. Kit Installation 3-1 Oil pan modification 1. 2. (Parts used #42) 3-3 Replace Power Steering Hose 1.3. 4. Remove the oil return pipe and drill out the marked hole. (Parts used #54) Spacer . 18. 52) 3-2 Thermo Cloth Installation 1. 42) 3-4 Replace Stud Bolt 1.

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

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

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

5. 20. (Parts used #34. Install the factory catalytic converter to the down pipe. 52) 2. C-2 to turbo out let. (Parts used #19. 30. (Parts used #6. Install C-1. (Parts used #4. 31) 3. 25.3-9 Catalytic Converter Installation 1. 27. 29. 22. 24. 43) . 3-10 Heatshield Installation 1. 29. 36. 45. 50) 3-11 Compression Pipe Installation 1. Install the heat shield to the turbocharger as shown. Secure the pipe to the radiator fan shroud as shown. Install the vacuum line for the actuator with a 3way tee from the fuel pressure regulator to the actuator. Install C-3 from C-2 to throttle body in let. 51. 50.

52. Install the Airinx adapter on to the Airinx filter housing. (Parts used #8. Install the provided injectors with the new fuel rail assembly. (Parts used #50. Install the factory fuel regulator to the fitting on the new rail with provided hardware. 26.3-12 Suction Pipe Installation 1. Install the Fuel Regulator fitting and fuel rail fitting on to the rail using the provided o –rings. (Parts used #48) . 53) 3. 9) 2. 23. Cut the factory injector harness and install the provided injector harness. and idle control valve hose to the C-3 and S-1 as shown. 44. 45) 3-13 Injector and Fuel rail Installation 1. Install the blow-by. (Parts used #54) 5. Install the factory fuel regulator to the fitting on the new rail with provided hardware. Install the S-1 to the turbo inlet and install the Airinx assembly to the S-1 as shown. 32. 31. (Parts used #19. (Parts used #54) 4. (Parts used #7. 28. (Parts used # 49) 2. 37) 3. 20.

Wire in the E-manage to the factory ECU.3-14 E-manage Installation 1. 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 #1 Blue /Red #3 Yellow /Red I Brown Ar White Ar Green +B Red #2 Orange /Red #4 Purple /Red #E Black /Red E Black 107 109 106 43 Code +B E Ar I #1 #2 #3 #4 #E Description +12V ignition power ECU ground Air Flow Meter Signal RPM Signal Injector #1 Signal Injector #2 Signal Injector #3 Signal Injector #4 Signal Injector Ground E-manage Color Red Black Green & White Brown Blue/Red Orange/Red Yellow/Red Purple/Red Black/Red ECU pin # 61 43 47 3 102 107 104 109 106 .

then reconnect the negative side of the battery. (Until the oil light on the dash turns off) Check for any oil leaks. and make sure not to over boost. GReddy Performance Products. (7) On the initial run. (2) Check all the hoses and wires connection. coolant. ! ! . It is very important that you monitor the boost pressure. check the injectors and the fuel rail for any fuel leaks. Important! ! It is very important that you monitor the boost pressure. Due to lack of control over proper installation and use of this product. NO WARRANTY is offered for this kit. This turbo kit is preset to boost between 0. (5) While idling. check for any oil. be sure to have a boost gauge to check the turbo-actuator setting. Starting the engine with a fuel leak can cause fire in the engine compartment and can be very dangerous. Over boosting can cause engine damage. Inc.6kg/cm2 to 0. This completes the Turbo Kit installation. Over boosting can cause engine damage. NO WARRANTY is offered. or air leeks. is not responsible for any engine damage caused by over boosting (increased boost). (6) After inspection. and/or misuse of the product. then reinstall the fuse and start the engine.6kg/cm2 . reinstall the under cover and other stock parts that was removed. * Repair any fuel leaks before starting the engine. Then. and make sure not to over boost. (4) Remove the ECM fuse and crank the engine to get oil pressure to the turbo.3-15 Starting the Engine (1) Refill the engine oil to factory spec. (3) Turn the ignition to “ON” position 2-3 times to get fuel pressure. modification to the kit.

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

Checking Error Code Chart CODE Error 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 Injector 1 pulse Incorrect Injector 2 pulse Incorrect Injector 3 pulse Incorrect Injector 4 pulse Improper order of Ignition input signal No Ignition Signal 1 pulse No Ignition Signal 2 pulse No Ignition Signal 3 pulse No Ignition Signal 4 pulse No Ignition pulse Incorrect Ignition 1 pulse Incorrect Ignition 2 pulse Incorrect Ignition 3 pulse Incorrect Ignition 4 pulse JP2 + 12V error Error description Incorrect wiring or disconnected Airflow Signal 1 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 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 Incorrect wiring order of the ignition signal wires. 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 Not receiving the ignition signal to any of the channels 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) 11 15 20 21 22 23 24 31 32 33 34 40 41 42 43 44 49 51 52 53 54 57 .

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