Ball-bearing turbochargerInstallation guideAVO350 PN: S1104M06A350AAVO380 PN: S1104M06A380AAVO420 PN: S1104M06A420AAVO450 PN: S1104M06A450AAVO500 PN: S1104M06A500AAVO550 PN: S1104M06A550A

Applied Models:2005-2009 Legacy GT, Outback XT2008+ Impreza WRX2009+ Forester XT

You are now the proud owner of a highly tested and proven AVOturboworld-designedTurbocharger upgrade unit. You will find our suggested installation procedures for theturbocharger below. Please follow these instructions to ensure a successful installation of yournew AVOturboworld upgrade part.

Note: Check this kitting list before starting the install.

Turbocharger assembly Oil supply line PCST4C01 Oil supply banjo bolt CBVKTC012x 11x16mm Copper Washers AQUK4A01

Compressor gasket GP1AA001

Oil drain fitting PBTPTC02 Oil drain gasket GPTOAA01 2x Oil drain bolts BBVHUA13 3-bolt gasket 44022AA150

3 x 10x1.25mm Copper Nut ACTTA001 5-bolt outlet flange gasket 44022AA180 Water supply fitting OBUMTC02 Water supply fitting OBUMTC04

2x water fitting banjo CBUNTC014x 14x20mm Copper Washer AQVN4A01

A) OrientationBefore grabbing your tools and taking apart your car, take a moment to

STOP AND THINKAVOturboworld’s Ball Bearing Turbocharger kit is a serious performance upgrade part, and is designed to suitcars that already have a high level of modification. DO NOT attempt to fit our 450 and larger turbochargerupgrades unless your car has an upgraded fuel pump and higher-flow fuel injectors installed. All turbochargerupgrades require some form of programmable engine management. We highly recommend that you have enginemanagement calibration done by tuning professionals on a proper dyno.

Read these supplied installation instructions thoroughly from start to finish before starting the install. Do youunderstand all of the mechanical operations required? Are you sure that you can adequately complete all of themechanical operations required? Do you understand all of the terminology used in this installation manual?Your installation skills will have a big effect on whether or not your new AVOturboworld part will perform to its fullpotential and give years of trouble free operation, without seriously damaging either your engine or your wallet.

Prior to the installation, make sure that your car is in excellent mechanical condition and that there are nooutstanding faults or problems. This turbocharger has been designed to work only with a car that is in good stateof repair. Pre-existing problems or faults can result in improper operation and/or failure of your engine. This isyour responsibility to ensure. No matter how carefully we design our parts, this is one area we have no controlover and cannot be held responsible.Always use the highest grade of fuel available in your area. This is essential for correct operation of your car andyour new Upgrade parts. Failure to use high-octane fuel can result in engine damage.

B) Check all parts supplied with the AVO LGT Turbocharger prior to installation for thefollowing;1) Verify that all parts noted on the fitting list have been supplied. Contact AVOturboworld or the original point of

purchase if any parts are missing.2) Make sure that all parts are in good condition and have not been damaged during shipping etc.3) Take time to make sure you can identify the individual parts supplied to the relevant sections in the attached

fitting instructions.4) AVOturboworld is committed to constantly improving our range of products as well as our standard of

customer service. If during the course of installation you find any errors contained in our instructions, or thereare areas that could be improved to make installation easier, feel free to either email us at avo@avoturbo.comor fax us on +613 95844008 with your comments / suggestions.

C) Tools Required Consumables RequiredMetric Socket/ Ratchets, Extensions, Wrenches WD-40 or SimilarFlat Blade / Phillips Head Screw DriverCombination PliersAxle Stands

D) Pre-Installation Preparations5) Select a proper location for installation. You will need a hard, level paved surface in order to safely jack up

and support your car.6) There should be a visual check over the vehicles condition7) Before commencing work on the vehicle you should note any faults.8) Disconnect the Negative Battery Terminal9) Jack up the front of the car, then place the axle stands in the proper locations to provide support. Refer to

your Vehicle owner’s manual for information on where to correctly place the jack and axle stands so as not todamage any mechanical parts of your car.

10) Make sure the engine has cooled sufficiently for work to commence.11) Drain the engine coolant from the radiator.

NOTE! Extreme caution must be exercised when working underneath your car. Under no circumstances shouldyou ever work under an un-supported/improperly supported car. Use only dedicated Automotive Axle supportstands. Serious injury/and or death can result if you do not follow these procedures!

Installation

First remove the air box as this will ease the installation process.Next remove the engine engine cover. You will need to remove the 4press-in retaining clips from the plastic upper engine cover. Removal ofthese clips requires a 1/2 turn counter-clockwise while applying very lightpressure with a Phillips head screwdriver. Once the centre pin pops upthe clip can be removed. Remove the plastic engine cover.

You will need to remove the factory TMIC next. Start by removing thehoses from the BOV. First remove thevacuum line (the smaller line at the top ofthe BOV).Next remove the recirculation hose fromthe BOV. Grip the ends of the factoryspring clip together and pull it off gently.

Remove the 12mm bolts holding the intercooler to the mounting brackets.

Loosen the throttle body hose clamp on the intake manifold side of thehose. This is so you can easily pull the TMIC off when you are ready.

Remove the two 12mm nuts and bolts connecting the intercooler to theturbocharger. Take care not to drop the nuts into the engine area.

Remove the intercooler. You will need to pull it up and off the throttlebody. Inspect the intercooler while it is off, and if it has any oil in it, put itup on its side so that it can drain out.

Place a clean rag over the turbocharger compressor outlet, so thatforeign materials do not enter the turbo while you are removing it.

Remove heat shielding from the turbocharger (if it is OEM). There is six10mm bolts holding it on. Some can be difficult to reach.

You will now need to remove two bolts and three 14mm nuts from thefront pipe. Next remove the 14mm bolt that mounts the front pipe to thetransmission.

Remove the two center flange bolts, then the 12mm bolt, and finally the14mm nuts. You should now be able to remove the front pipe completely.

Remove the boost controllervacuum line, then remove theturbocharger oil supply line.(Note: you will not need to keep theold boost line or oil supply line)

You will need to get at the up-pipenext. To do this, you will need toremove the engine undercover.Once you remove all the plasticpop-its and various bolts, it willcome right off.

Next you will be removing the up-pipe. Spray the three 14mm boltsholding the up-pipe to the turbocharger liberally with some CRC or otherlubricant, as they will likely be quite tough to remove.You do not need to remove the turbocharger support brackets, but it isadvised to loosen the bolts on them a bit to help when you are adjustingthe fitment of the new turbocharger.

Loosen the inlet hose clamp at the turbocharger inlet side.

Remove the bolt that holds theinlet pipe onto the intakemanifold. Pull the inlet pipeforward 1 to 2 inches till it is off ofthe turbocharger.

To remove the turbocharger just pull it straight up and out. It will pop rightoff of the oil drain line. Leave that line where it is on the engine.

The factory up-pipe on 2005-2006 Subaru Legacy models is fitted with acatalytic converter. This catalytic converter is not the most reliable, andcan break apart, throwing debris into the turbocharger. For this reasonwe suggest replacing the catted up-pipe with a flex-section catless up-pipe. Newer models do not have this catted up-pipe, probably becauseof reliability concerns.

Fit the new 3-bolt gasket to the up-pipe. You can use a bit of high-tempsilicone gasket to help with the seal.

Perform a visual check of the AVO turbocharger before the installation.Check that the turbo orientation is the same as the turbocharger that youpulled off of the car. Make sure that there is some pre-load on the solidboost actuator.

Remove the outside water banjo bolt from the AVO turbocharger, this willbe placed back on later.

Before fitting the turbocharger to the car, lubricate the oil drain tube (atthe bottom of the turbocharger) with some CRC or other oil. This willmake it much easier to slide the turbocharger in. Slide the turbochargerin at an angle.

There are a few things to consider as you are aligning the turbochargerup.

1. The alignment of the oil drain.

Use a bent driver, or a tool that looks a lot like a dentists pick, to help pullthe inlet tube over the compressor inlet.One tip to fitting the inlet tube is to remove the inlet tube clamp from theinlet tube and rest it on the compressor cover inlet. Then fit the inlet tubeto the compressor inlet. You can then easily slide the clamp onto the inlettube from this point.

If you are still running the factory TGV valves, you will that it is a tight fitbetween the turbocharger compressor cover and the TGV’s. If it is tootight, you will need to loosen off the up-pipe bolts and the turbo supportbrackets, push the turbocharger towards the back of the car, and thentighten the bolts up again.

Fit the 3 copper nuts to the stud bolts and tighten them down.

Tighten the three 14mm copper nuts down, then tighten down the mountsupport brackets. Check that the turbo is sitting flat on the up-pipe faceas you are tightening the nuts down.

Fit the water line back up to the turbo. Tighten it up carefully, do not overtighten the water line, as it may easily strip.

Check the water banjo on the other side is tight.

Check to see the clearance between the transmission and the turbocompressor cover. Note: if it is touching the turbo, then the turboorientation is incorrect. You will need to remove the turbo and re-adjustthe orientation.

Tighten up the clamp on the intake pipe.

Fit the braided oil line to the turbo and the supply line. Do not overtighten! The supplied oil supply line is actually two pieces, the Oil Lineitself and an adapter fitting that goes onto the stock oil supply hard line.

You need to remove that adapterfrom the oil line, and screw thatonto the hard line. Once it is onsecurely, thread the oil supply lineonto the adapter. Now place thebanjo bolt fitting on the oil line,and bolt it to the turbocharger.

Re-fit the front pipe. Note: The AVO turbocharger will not work with astock front pipe due to its superior divided wastegate design.Make sure to use the supplied gasket.

Bolt the center pipe up to the front pipe. Make sure all bolts are torquedup properly. Re-fit the turbo heat shield. Depending on the design of thefront pipe used, you may need to trim the heat shield for a proper fit.

Fit the new turbocharger compressor gasket to the turbocharger. Checkthe TMIC before fitting it, making sure it is clean of any foreign objects.

Fit the TMIC to the turbocharger.Start by fitting it to the throttle body side first. Get it fully fitted into thethrottle body, loosely tighten the clamp down, then fit it to the turbo side.Keep the bolts holding the turbo to the intercooler loose, as it takes a bitof adjusting for a perfect fit.

Fit the TMIC to the turbocharger.Start by fitting it to the throttle body side first. Get it fully fitted into thethrottle body, loosely tighten the clamp down, then fit it to the turbo side.Keep the bolts holding the turbo to the intercooler loose, as it takes a bitof adjusting for a perfect fit. Line the intercooler up till it is square, andtest fit the engine cover if your car has one.Start tightening up the turbo side bolts first, then the mounting bolt nearthe BOV.

Tighten up the clamp on the throttle body to the TMIC fully.

Fit the BOV back to the TMIC. Torque the two bolts down carefully.Replace the hoses to the BOV.

Fit the engine cover back on to the vehicle, and make sure to fit theengine undercover as well. Check all hoses, fittings, and other parts tomake sure that they have been torqued down correctly and there is noleaks possible.

G) Post Start Inspection

Step 1 – Start Engine and Check the following items• Inspect Turbo Oil Feed pipe to check for any oil leakage from both the cylinder head banjo bolt and

turbocharger oil feed banjo bolt. Repair if required• Inspect Turbocharger Oil drain hose for any signs of oil leakage at the oil sump or turbocharger flanges.

Make sure that the oil drain hose is not blocked.• Purge all air from cooling system and make sure that there is no vapour lock in the stock cooling system.• Inspect Turbocharger Coolant hose connections for any signs of coolant leakage. Repair as required.

Step 2 – Test turbo boost pressure – AVOturboworld strongly recommends the use of a chassis dyno forchecking or setting turbo boost pressure. If Chassis Dyno is not available, please take note of the following:

NOTE! Exercise Extreme Caution when carrying out the following procedures on Public roads. Always use anassistant to watch and record boost readings. Do not attempt to operate car and watch boost gauge at same time.Observe posted speed limits, prevailing road conditions and the amount of road traffic. Allow more than enoughroad space to safely complete procedure. Failure to do so could result in serious injury or death either to you,passengers or other road users.

• Reach an engine speed of 2000Rpm in 3rd Gear• Apply full throttle and accelerate the engine to 5000Rpm• Have an assistant record peak boost pressure reached.• Immediately abort the boost pressure test if your boost pressure goes higher than the desired amount of

boost pressure by a large amount. Re-check all hose connections and proceed directly to Step 3 and/orthe Troubleshooting section.

NOTE! Operation of your engine at boost pressures higher than what your engine is capable of handling for evenshort periods of time is not recommended. Serious damage to the engine or to the Turbocharger system mayresult from too much boost pressure.

Step 3 – Additional boost pressure adjustment. (If Not Required Jump to Step 4) If Peak boost pressure islower or higher than the desired amount, perform the following steps.

NOTE! Allow Engine to cool completely before attempting to re-adjust boost actuator. Serious burns / injury mayresult from trying to work on a hot engine / turbocharger assembly.

• Remove upper heatshield from the turbocharger.• Remove Retaining Clip from Turbocharger Actuator Link Rod. step 25• If Peak Boost Pressure is LOWER than required decrease the length of the actuator Link Rod.• If Peak Boost Pressure is HIGHER than required increase the length of the actuator Link Rod.• Adjust length of actuator link rod by steps of only ONE turn. Always Test boost pressure before making

adjustments of more than one turn at a time.• Follow instructions outlined in STEP 2.

Step 4 – Re-Fit Turbocharger upper heatshield cover. Installation Complete!

Note: After completion and removing your tools, double check for leaks and any loose fittings. Correct ifnecessary. In order to maintain the reliability of your AVOturboworld upgrade part, you should inspect allcomponents during the recommended engine servicing schedules; and rectify or replace any damagedcomponents as necessary.

Job Done-Enjoy your car!NOTE! – If in any doubt over the operation or installation of your parts contact

AVOTurboworld, or your selling dealer for advice and assistance

in troubleshooting your questions.