Installing the Aem 50-150 Turbo Kit on Your Gr86: a Complete Step-by-step Guide

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The AEM 50-150 Turbo Kit is an excellent upgrade for your GR86, providing significant power and performance enhancements. In this guide, we will walk you through the entire installation process step-by-step, ensuring that you can complete the installation with confidence.

Tools and Materials Needed

Before starting the installation, make sure you have all the necessary tools and materials on hand. This will help streamline the process and prevent any interruptions.

  • AEM 50-150 Turbo Kit
  • Socket set
  • Wrench set
  • Torque wrench
  • Phillips and flathead screwdrivers
  • Vacuum line cutter
  • Electrical tape
  • Zip ties
  • Oil catch can (optional)
  • Safety glasses
  • Gloves

Preparing Your GR86

Before diving into the installation, it’s crucial to prepare your vehicle. Follow these steps to ensure a smooth installation.

  • Park your GR86 on a flat surface and engage the parking brake.
  • Disconnect the negative battery terminal to prevent electrical issues.
  • Remove any engine covers or components that may obstruct access to the turbo installation area.

Installing the Turbo Kit

Now that your GR86 is prepared, it’s time to install the AEM 50-150 Turbo Kit. Follow these steps closely.

Step 1: Remove the Stock Components

Begin by removing the stock intake system and exhaust manifold. This will create space for the turbo installation.

  • Loosen and remove the clamps securing the intake.
  • Unplug any sensors attached to the intake.
  • Remove the stock exhaust manifold by unbolting it from the engine block.

Step 2: Install the Turbo Manifold

With the stock components removed, you can now install the turbo manifold.

  • Align the turbo manifold with the engine block.
  • Secure it with the provided bolts, using a torque wrench to ensure proper tightness.
  • Double-check that all connections are secure.

Step 3: Attach the Turbocharger

Next, attach the turbocharger to the manifold.

  • Position the turbocharger onto the manifold.
  • Secure it with the provided hardware, ensuring a tight fit.
  • Connect the oil feed and return lines, making sure there are no leaks.

Step 4: Install the Intercooler

The intercooler is essential for cooling the air entering the engine. Follow these steps to install it.

  • Mount the intercooler in the designated location.
  • Connect the piping from the turbocharger to the intercooler.
  • Ensure all clamps are tight to prevent boost leaks.

Step 5: Reinstall the Intake System

With the turbo and intercooler installed, it’s time to reinstall the intake system.

  • Connect the new intake pipe to the turbocharger.
  • Secure it with clamps and ensure all sensors are reconnected.
  • Check for any loose connections or fittings.

Step 6: Install the Exhaust System

Now you can install the exhaust system, which is crucial for maximizing performance.

  • Attach the new exhaust components to the turbo outlet.
  • Secure all connections with the provided hardware.
  • Ensure there are no leaks in the exhaust system.

Step 7: Final Checks

Before starting your GR86, perform the following final checks.

  • Recheck all bolts and connections for tightness.
  • Reconnect the negative battery terminal.
  • Inspect the engine bay for any loose wires or components.

Testing Your Installation

After completing the installation, it’s vital to test the turbo kit to ensure everything is functioning correctly.

  • Start the engine and let it idle for a few minutes.
  • Check for any unusual noises or leaks.
  • Take the car for a test drive, monitoring boost levels and engine performance.

Troubleshooting Common Issues

If you encounter any issues during or after the installation, here are some common problems and solutions.

  • Boost Leaks: Check all connections and clamps to ensure they are secure.
  • Unusual Noises: Inspect the turbo and exhaust for any loose components.
  • Engine Warning Lights: Use an OBD-II scanner to check for error codes and troubleshoot accordingly.

Conclusion

Installing the AEM 50-150 Turbo Kit on your GR86 can significantly enhance your vehicle’s performance. By following this step-by-step guide, you can ensure a successful installation and enjoy the benefits of increased power and efficiency.