FITTING INSTRUCTIONS FOR XRT300 AND XRT350 BA XR6 … · XRT300 AND XRT350 BA XR6 TURBO UPGRADE KIT...

XRT300 AND XRT350 BA XR6 TURBO UPGRADE KIT FITTING

INSTRUCTIONS

The use of ‘NFU’ (No Further use) and ‘REUSE’ (Re Use) relates to the

individual parts storage when performing the upgrade.

Also note that all bolt sizes relate to the spanner required.

1. Unpack box and position parts for easy access.

2. Place vehicle on hoist.

3. Remove battery terminals from battery using a 10mm ring/open ender,

remove battery clamp then pull battery straight up (tight fit) and place the

clamp with the Pulse battery (REUSE). Remove battery tray (unscrewing

large self taper) and place in an area designated for parts that have no further

use (NFU).

4. Remove four (4) black plastic screw slips from front of radiator garnish and

panel, place in a container for later use (REUSE).

5. Remove two (2) top plastic grille clips and then remove panel (REUSE).

6. Remove fourteen (14) x 7mm screws and plastic clips from black plastic

undertray, along with one Phillips head screw from each plastic inner guard

(screws support the undertray at the bumper end – front) (REUSE).

7. Remove black plastic undertray (REUSE).

8. (We recommend two (2) people for bumper removal with one (1) person per

side of the bumper). Each person to pull sharply at the side of the front

bumper pulling bar away from the guard.

9. Once the bumper sides are free, move to the front of the vehicle and pull the

bumper assembly foreword. It should slide off quite easily to reveal two

driving light electrical clips that must be unsecured. Bumper can now be

removed and stored away from vehicle (REUSE).

10. Remove plastic ‘egg shell from behind bumper using 10mm socket.

11. Remove driver’s side headlight. a) from the underside of the vehicle, remove

indicator globe and leave hanging. b) Using a 10mm socket, remove headlight

and place with front bumper. (REUSE).

12. Unclip headlight wiring (3 clips)

13. Undo 7mm hose clamp from air box. Unclip air filter box, remove filter and

then using an 8mm socket, remove (3) bolts and air filter box. (NFU)

14. Remove factory cold air snorkel using Philips head screwdriver (2).

15. Unscrew and disconnect all intercooler piping from top of engine and at sides

of radiator, remove Blow Off Valve hose (the one that goes back to the inlet

manifold). Remove all rubber hose clamps for REUSE.

16. Working at the front of the vehicle using a 12mm spanner, undo four (4)

12mm bolts that hold the intercooler in place (REUSE), ensure all hoses and

spring clips are also undone (REUSE). Unclip wiring harness from intercooler

bracket.

17. Using a 12mm spanner, remove horns and horn bracket and disconnect wiring

(1 x 12mm nut) (REUSE). Remove steel intercooler bracket from passenger

side (NFU)

18. Undo 2 x 8mm bolts holding power steering oil cooler mounted underside of

factory intercooler.

19. Remove steel intercooler brackets from passenger side (NFU).

20. Remove intercooler (NFU).

21. Remove aluminium intercooler pipe that is situated on the underside of the

battery area. The initial step is to disconnect the sensor wire followed by the

sensor itself (10mm spanner), remove bolt situated on the underside and

between the battery box and support panel (NFU).

22. Pull alloy pipe forwards and immediately replace the earth wires back into

their original position using the same bolt.

23. Disconnect throttle body connectors.

24. Remove four (4) 5mm throttle body cap screws with a ball type Allen key,

and pull throttle body upwards with care not to damage gasket (REUSE).

25. Using an 8mm socket (or for speedy removal, an air ratchet), unbolt two

manifold brackets (between manifold and head), remove dipstick followed by

the dipstick tube. (REUSE).

26. INLET MANIFOLD. Remove 14 x 6mm inlet manifold bolts using 3/8” ball

type Allen key socket (REUSE).

27. Disconnect MAP sensor connector from area close to throttle body, remove

brake booster line from rear of manifold, likewise the fuel pressure vacuum

line, and LIFT off the inlet manifold noting a reusable metal gasket. Place

tape or a rag over the inlet manifold base. (NFU).

28. Place manifold on bench where the MAP sensor and brass brake booster (rear

of manifold) fittings are to be removed and replaced with PNs: NPT-S10MM

(T-piece), NPH-50 (Short Hose), and ???? (T-piece), for fitment to Cobra

Plenum PN: NPP 002 (REUSE). Also fit carbon canister purge line and PVC

hose.

29. While at bench, equip manifold with Cobra PN: NPT 005 throttle body

adaptor.

30. Using a 8.5mm drill (or 11/32”), drill the front most and rear most holes in the

factory manifold base – use either a short 3/8” air drill or right angle air drill –

ensuring absolute straightness and that no material makes its way into the

manifold base.

31. Using a 8mm (or 11/32”) socket 3/8” drive ratchet and a 6” extension bar and

ratchet, remove the two screws holding the original throttle body bracket to

the inlet manifold base. Discard bracket and replace bolts.

32. Position Cobra battery Tray PN: NPB-B 009, on the left (passenger) side,

locating ‘lug’ into existing rail holes. Note that these may need to be tapped

into place using a plastic hammer. Once battery tray is positioned firmly in

place, use an 8mm drill bit to drill through battery tray mounting hole through

inner guard, and then push PN: NPB-825 (Bolt) and PN: NPB-B014 (Washer)

through from the underside, position PN: NPM-8 (13mm Nut & Bolt) and

tighten.

33. Place Pulse battery on tray (with the terminals on the high side of the tray) and

refit using factory clamp with PN: NPB-M8150 (Bolt) and PN: NPB-B014

(Washer).

34. NOTE: EXCLUSIVE TO XRT350: Remove and replace fuel injectors using

PN: NP 17108 (Injectors). The procedure consists of disconnecting six (6)

injector clips, six (6) plugs and four (4) 10mm bolts using a 10mm socket.

35. Drill two (2) 8.5mm holes in radiator support panel while taking care not to

damage wiring on underside of panel (driver’s side).

36. Remove rubber mounts and bosses from factory intercooler and place these on

the two top Cobra intercooler bosses. Position the two remaining mounts

through bumper iron base using PN: NPM 8 (M8 nuts).

37. INTERCOOLER FITMENT. Prior to placing intercooler in its final position,

ensure that existing wiring on the underside of the driver’s side radiator

support panel is unclipped to ensure no damage occurs. Once intercooler has

been slid into position, restore wiring to original position and re-clip.

38. Use four factory intercooler nuts to contain the two newly drilled top end

threads (12 & 13mm).

39. Replace power oil cooler to original position.

40. Using factory hose clamp (not spring clamp) from factory intercooler tubing,

place the lower factory intercooler hose over intercooler inlet and tighten hose

clamp.

41. Cut threaded bolts protruding through intercooler mounts.

42. Using PN: NPB 004 (Intercooler Hose), feed it from the passenger side of the

engine bay (white dot end to intercooler), underneath the headlight and place

over the intercooler outlet (rubber grease may be used for easier fitment) –

once again using a factory clamp.

43. Apply NPH-S012 (Heat Shrink-wrap) over the battery earth lead terminal.

Using supplied cable tie, position battery terminal to existing driver’s side

wiring harness.

44. Remove fuse box lid, undo a 12mm nut, and while holding the main battery

feed cable, unclip wiring harness from inner guard and engine crossmember

and undo main starter motor power feed.

45. Following along a similar line to Instruction 37, using NPB-C010 (Cables),

reconnect and then position wiring on passenger side using available holes,

then refit fuse box lid.

46. Extend throttle body and boost pressure sensor wiring using PN: NPL-E013

(Loom Extension). Cut wiring at approximately 50mm back from the

connector. Join corresponding wires to Loom Extension using solder and

shrink wrap. Then slide PVC sleeve towards the connector to cover exposed

wires at the other end of the loom. Slide 8mm shrink wrap over the PVC

sleeve and join corresponding wires into factory loom. Once this is done, slide

the sleeve 8mm back over the joins.

47. Remove factory thermostat housing, and replace with PN: NPT-005

(Thermostat Housing); adding a dab of silicon sealant to parting surfaces.

Note that for a superior job; neatly trim 20mm off the thermostat end of

existing radiator hose to facilitate rotation for best fitment. Top up coolant as

required.

48. PN: NPP-002 (Inlet Manifold). Fit factory studs to the front and rearmost

manifold flange holes. Position factory throttle body on front of manifold

using factory gasket and bolts. (Replace gasket if damaged).

49. Position PVC and canister lines under manifold base.

50. Using remaining PN: NPS-M8 (Studs), position in factory inlet manifold base

(outer side), refit original steel manifold gasket and place Cobra manifold in

position.

51. Using eight (8) PN: MPM-8 (Nuts), and six (6) original cap screw bolts,

employ a 3/8” drive 6mm Allen key ball socket and tighten as required. Note

that the rearmost manifold bolt is more easily accessed from under the

vehicle.

52. Refit manifold braces into original positions, and prior to refitting dipstick

tube, slightly exaggerate original bend (for clearance) while taking extreme

care not to kink. Replace dipstick.

53. Place factory throttle body rubber onto throttle body. Ensure that you do not

confuse this rubber with the turbo inlet pipe rubber.

54. Position PN: NPT-005 (Reducer) into rubber throttle body adapter, place

intercooler hose in position and tighten using factory hose clamps.

55. Connect throttle body and turbo pressure sensor wiring.

56. Remove rocker cover oil filler cap and PVC hose (also disconnect hose at

other end, and turn the hose end for end), remove all 5mm Allen headed

screws from rocker cover garnish to allow its removal. Remove six (6) rubber

coil holders for positioning on PN: NPR 001 (Rocker Cover Garnish).

57. Fit Cobra rocker garnish panel. When positioning factory Allen headed

screws, pull these down in stages. Note: As Cobra rocker garnish is of a

thicker higher quality material than factory unit, it will appear that the factory

screws are in fact too short. This is not the case, however do not over-tighten

screws to compensate.

58. Re-fit oil filler cap and replace ‘turned’ PVC hose, adding PN: NPO-B 011

(Rubber Breather Hose). Push onto rocker cover breather and direct hose

under the manifold, along the front of the cylinder head, while cable tying to

steel pipes.

59. Assemble PN: NPI 003 (Air Intake Pipe) and PN: RE-0870 (K&N pod filter),

sliding small end of intake pipe through from the inside of air box.

60. Remove driver’s side front mudguard bolt, and rotate radiator hose spring clip

to allow air box to sit flush.

61. Position PN: NPA 008 (Air Box) and in the process allow assembled intake

pipe and filter to rest in their ‘natural position’. Do not force air box into

position.

62. Once assembly is in position with intake pipe positioned on turbocharger,

tighten hose clamp.

63. Clip air box under fuse box lid clip carefully so as to a) not break cold air box

nor b) fuse box clip. Refit front mudguard bolt into position through air box

hole, fit PN: P3 1006 (Brass Fitting) to air intake pipe and fit PN: NPO-B011

(Breather Hose) to brass fitting.