Evo Upgrade Kit Installation Instructions

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Garrett Turbocharger Upgrade Kit for the Mitsubishi Evo XBill of Materials & PrecautionsPart Numbers: 788550-0001: GT3071R788550-0002: GT3076RApplication:2008 Mitsubishi Lancer Evolution XParts ListTools Needed Ratchet and metric sockets: 10, 12, 14, 17, 19, 22mm, 8mm 12pointItemDescriptionQty.1Turbocharger (GT3071R or GT3076R)12Compressor inlet elbow13Oil inlet fitting (banjo bolt)1 Torque wrench (lb-ft or N-m)4Oil drain line (with o-ring)1 Combination wrenches: 10, 12, 14, 17, 19mm5Water line1 Pliers for hose clamps (needlenose or similar)6Oil inlet spacer17O-ring for inlet elbow18Oil drain bolt (M8 x 1.25, 8mm 12-pt head) 29Oil drain gasket110Copper crush washer, M14411Copper crush washer, M12312Copper crush washer, M10213Actuator retaining ring114Bolt, turbine (stainless, M10 x 1.25 x 35)215Installation Instructions1 Socket extensions, various sizes Universal joint (“wobbly”) for socket extension Screwdrivers: flat blade and Phillips, various sizes Cutoff wheel or hacksaw for trimming steel heat shields & stud File or de-burring tool for steel heat shields & stud Ruler, scale or calipers (inch or metric) Floor jack and 2 jack stands rated for weight of vehicle, orvehicle lift NOTE: Bolt and fastener sizes may be different from onemodel year to the next depending on OE specifications.Different tools than those listed above may be required.Recommended Other Items Factory Service Manual & Owner’s Manual Safety glasses Anti-seize compoundPLEASE INSURE THAT THE PART NUMBER THAT HAS BEENRECEIVED WAS THE INTENDED PART NUMBER BEFOREBEGINNING INSTALLATION.See Honeywell Turbo Technologies’ return policy if the incorrect kithas been ordered.IMPORTANT INFORMATION - PLEASE READ CAREFULLYWe recommend that this Garrett product be installed by a qualified automotive technician. Ifyou have any doubts as to your ability to install this product, consult with a local automotiverepair company. Please be sure to carefully read all of the attached instructions prior tostarting the installation process. If you have any questions about the enclosed parts or theinstructions, call the distributor that you purchased the kit from for clarification.Prior to the Garrett product installation, be sure that the vehicle is parked on a level surfaceand the engine is cool. Engine fluids and components can be extremely hot following normalvehicle operation. Avoid direct contact of engine fluids or components with your skin whichmay cause personal injury.Document 737639-39 (Rev -)www.TurboByGarrett.com1

Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XPart Number: 788550-0001 or -0002IMPORTANT INFORMATION - PLEASE READ CAREFULLYReturn PolicyOnly unused and complete merchandise will be accepted for return subject to inspection andacceptance by Honeywell Turbo Technologies. No goods will be accepted without prior returnauthorization from Honeywell Turbo Technologies. No returns are accepted after thirty (30) daysfrom original ship date from Honeywell. All accepted returns are subject to a 20% restocking charge- NO EXCEPTIONS.Damaged ShipmentsThe customer must file a claim with the shipping company if goods arrive in a damaged condition.The customer must also notify the distributor from which the goods were purchased with pertinentinformation.Refused ShipmentsSending a shipment back to The Garrett Garage (or Honeywell) does not automatically give rise to acomplete refund or credit. Honeywell Turbo Technologies may, at its sole discretion require differentpayment means for any shipment refused and then reshipped. It is the customer’s responsibility tomake all arrangements with Honeywell Turbo Technologies for disposition of refused shipments.Shortage or Discrepancy ClaimShortage or Discrepancy claims must be reported within forty-eight (48) hours of receipt of goods tothe distributor from which the goods were purchased. The Honeywell distributor will determine thebest solution on how to address shortages or discrepancies.Limited WarrantyHoneywell Turbo Technologies warrants to the original purchaser of its Turbocharger Products thatsuch Turbocharger Products will, for a period of 1 year from date of shipment and subject to theLimitations on Warranty, be free from defects in materials and workmanship. For approved warrantyclaims Honeywell Turbo Technologies will, at its sole discretion, either credit the original purchaserin an amount equal to the original purchase price, or replace the applicable Turbocharger Productfree of charge, within 60 days of Honeywell Turbo Technologies’ approval. This is purchaser’s soleand exclusive remedy and provides the complete financial responsibility of Honeywell TurboTechnologies for a warranty claim. To be eligible for reimbursement, Customer must (a) submit allwarranty claims to Honeywell Turbo Technologies within 30 days of the discovery of the allegedTurbocharger Product defect; and (b) complete and return a Returned Material Authorization Form.Consumers are required to work through Honeywell’s distributors in order to process any warrantyclaims.When Honeywell Turbo Technologies requires the examination of a failed part, Honeywell TurboTechnologies will promptly notify Customer and will await receipt of the failed part before furtherprocessing the warranty claim. If Honeywell Turbo Technologies ultimately determines that thefailed part is covered under the Limited Warranty, Honeywell Turbo Technologies will reimburseCustomer for the actual cost of ground shipment for any part found to be defective.Document 737639-39 (Rev -)www.TurboByGarrett.com2

Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XPart Number: 788550-0001 or -0002IMPORTANT INFORMATION - PLEASE READ CAREFULLYLimitations on WarrantyThe Limited Warranty does not apply to any parts: (a) not used in accordance with Honeywell TurboTechnologies’ written instructions (b) for which no fault is found; (c) that have been modified in anymanner not specifically approved by Honeywell Turbo Technologies; (d) for which an inspectionindicates that reasonable and proper installation and/or preventative care and maintenance has notoccurred; (e) that have been subject to damage attributable to or caused by misuse, abuse orvandalism; mishandling, improper shipping or other transit related damage; acts of god orinsurrection; foreign object entry; any part not supplied by Honeywell Turbo Technologies; any repair,maintenance or service by anyone other than Honeywell Turbo Technologies; or any other acts thatare beyond Honeywell Turbo Technologies’ reasonable control; or (f) attributable to parts notsupplied by Honeywell Turbo Technologies. Honeywell Turbo Technologies expressly disclaims anyand all warranties relative to the foregoing circumstances.Honeywell Turbo Technologies shall not be liable to Customer under any circumstances forany special, incidental or consequential damages, including without limitation, damage to orloss of property other than for Turbocharger Products; damages incurred in installation,repair or replacement; lost profits, revenue or opportunity; loss of use; losses resulting fromor related to downtime of Turbocharger Products; the cost of replacement transportation,power, or compression; the cost of substitute products; or claims of third parties for suchdamages, howsoever caused, and whether based on warranty, contract, and/or tort (includingnegligence, strict liability or otherwise).The Limited Warranty is the only warranty made by Honeywell Turbo Technologies for any ofits turbochargers and related parts and/or services, and is in lieu of and excludes all otherwarranties, expressed or implied, including warranties of merchantability or fitness for aparticular purpose. Honeywell Turbo Technologies hereby disclaims all other warranties notexpressly set forth. Some jurisdictions do not allow for the exclusion of implied warranties, sothe above exclusions may not apply to you, however if implied warranties do apply they arelimited to the original purchaser and for a period of one (1) year from the date of shipment.Diagnosing Your VehicleDo not rely on diagnostic software without seeking the advice of an ASE certified mechanic.Diagnostic software should only be used as a general guideline to help you facilitate the repair ofyour car. If you experience or suspect any malfunction of vital safety equipment, such as your brakes,exhaust, motor, transmission, fuel delivery system, your car’s structural integrity or any otherpotentially life threatening malfunction, cease driving your vehicle immediately and seek professionalhelp. Always consult your owner’s manual.Vehicle Modification NoticeAny modifications to your car are AT YOUR OWN RISK. You should consult the owner’s manual andservice manual. You should also contact your car’s manufacturer to determine what effectsmodifications may have on your safety, warranty, performance, etc. Please also contact your localauthorities to determine whether your intended modifications will make your car illegal to drive onpublic roads. A vehicle modified by the use of competition parts may not meet the legal requirementfor use on public roads. It is your responsibility to comply with federal, state, and local laws prior todriving your vehicle on public roads.Document 737639-39 (Rev -)www.TurboByGarrett.com3

Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XPart Number: 788550-0001 or -0002IMPORTANT INFORMATION - PLEASE READ CAREFULLYOTHER PRECAUTIONSObserve all safety precautions and warnings contained in the installation instructions. Wear eye andear protection and appropriate protective clothing. When working under or around the vehicle supportit securely with jack stands. Use only the proper tools. Exercise extreme caution when working withflammable, corrosive, and hazardous liquids and materials.LEGAL INFORMATIONThe Garrett turbo kits are for use off the public roadways. Federal law restricts the removal ormodification of any part of a federally required emission control system on motor vehicles. Also,many states have enacted laws which prohibit tampering with or modifying emission or noise controlsystems. Vehicles which are not operated on public roadways may be exempt from certainregulations, however the buyer is strongly urged to check all applicable local and state laws and isultimately responsible for compliance with the applicable laws and regulations.Contact Information for QuestionsPlease contact the Honeywell distributor from which the equipment was purchased for any questionsregarding this Shipping/Returns/Cancellation Policy, for notifications to Honeywell TurboTechnologies, and for instructions on processing damaged shipments and authorized returns.Honeywell Turbo TechnologiesGarrett Independent AftermarketHoneywell International Inc.3201 W. Lomita Blvd.Torrance, CA 90505www.TurboByGarrett.comDocument 737639-39 (Rev -)www.TurboByGarrett.com4

Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XPart Number: 788550-0001 or -0002Installation InstructionsNOTE: 2 steel heat shields and one steel stud willneed to be trimmed as part of thisinstallation. See steps 35 & 48-50.TURBOCHARGER REMOVAL1.Uncover the vehicle’s battery, which islocated in the trunk. Disconnect the groundcable and secure it away from the terminal(10mm wrench or socket). See Fig. 1.Fig. 12.Locate the plastic engine compartmentcovers under the vehicle. Remove the rearmost center cover, shown outlined in yellowin Fig. 2. The cover is secured by roundplastic clips. Use a prying tool or a flat bladescrewdriver to pop out the center section ofthe clip, and then pull the clip out by hand(clips, flat blade screwdriver).Fig. 23.Then remove the passenger side front cover,which is secured by 2 bolts and plastic clips.This cover is shown outlined in Fig. 3, withbolt locations shown by arrows (2 bolts, clips,10mm socket, screwdriver).4.Drain the engine coolant by opening thedrain valve, which is now accessible on thepassenger’s side front of the radiator. Draininto a suitable container. Open the radiatorcap to speed the process (pliers).Document 737639-39 (Rev -)www.TurboByGarrett.comFig. 35

Part Number: 788550-0001 or -0002Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XInstallation Instructions5.Remove the upper plastic engine cover bypulling upwards until it pops off. See Fig. 4.Fig. 46.Remove the compressor outlet elbow hosescomplete with the adapter tube betweenthem. Remove the hose clamps at thelocations shown by arrows in Fig. 5. Theseparts will be reused (2 clamps, screwdriver).Fig. 57.Remove the compressor inlet hose, completewith rubber elbow and bypass valve. To doso, remove all 4 clamps at locations shown inFig. 6. These are:1.2.3.4.MAF sensor clampBypass valve clampBypass valve signal line clampTurbocharger inlet elbow clamp (outof sight)14These parts will be reused (4 clamps, Phillipsscrewdriver or 10mm socket, pliers).Document 737639-39 (Rev -)www.TurboByGarrett.com23Fig. 66

Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XPart Number: 788550-0001 or -0002Installation Instructions8.Remove the strut tower brace bar. There are3 nuts on each side of the car securing it tothe strut towers. These parts will be reused(6 nuts, 14mm socket). See Fig. 7.Fig. 79.Remove the cowl heat shield, located on thefirewall behind the cylinder head and underthe cowl overhang. These parts will bereused (3 bolts, 10mm socket). See Fig. 8.Fig. 810.Remove the heat shield covering the exhaustmanifold and downpipe. These parts will bereused (5 bolts, 10mm socket). Bolt locationsare shown by arrows in Fig. 9.Fig. 9Document 737639-39 (Rev -)www.TurboByGarrett.com7

Part Number: 788550-0001 or -0002Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XInstallation Instructions11.Remove the vacuum / emission hose fromthe black metal compressor outlet elbow andfrom the wastegate actuator. Tag this hosefor easy identification upon reassembly, andsecure the hose out of the way in the enginecompartment. These parts will be reused (2hose clamps, pliers). See Fig. 10.OUTLET ELBOWCLAMPCLAMPFig. 1012.Remove the black metal compressor outletelbow and its gasket, noting orientation ofthe gasket. These parts will be reused (2bolts, 12mm socket). See Fig. 11.TAB ON GASKETFig. 1113.From the driver’s side, find the steel bracketthat braces the compressor housing to theengine block. Remove this bracket, notingorientation. This part will be reused (2 bolts,17mm socket/wrench). See Fig. 12.14.Remove the cast aluminum inlet elbow fromthe compressor housing, along with itsgasket. The bolts will be reused but theelbow and gasket will not (3 bolts, 12mmsocket). See Fig. 12.ELBOWBRACKETFig. 12Document 737639-39 (Rev -)www.TurboByGarrett.com8

Part Number: 788550-0001 or -0002Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XInstallation Instructions15.16.Find the hard steel water line that connectsto the rear of the turbocharger’s centerhousing (facing firewall). Remove it, alongwith its banjo bolt, copper crush washers,and mounting bolt. Disconnect the rubberhose. These parts will be reused, except forthe crush washers. The hard line will betransferred to the Garrett turbocharger instep 31, using the original banjo bolt andnew copper crush washers supplied in kit (1banjo bolt, 1 bracket bolt, 1 clamp, pliers,10mm & 17mm sockets). See Fig. 13.WATER LINERUBBER HOSEFind the hard steel water line that connectsto the front of the turbocharger’s centerhousing (closest to engine block).See Fig. 14; turbocharger shown off ofvehicle for clarity. Remove the rubber hosethat connects to the hard line, but leave thehard line attached to the turbocharger fornow. The hard line will not be reused. Onlythe banjo bolt will be reused, with new M14copper crush washers supplied in kit (2clamps, pliers).WARNING: If raising vehicle is necessary,use a lift, or jack and jack stands, rated forweight of vehicle and follow manufacturer’srecommendations for lift points.17.Fig. 13From underneath the vehicle, remove thefront exhaust pipe (before catalyticconverter). Remove the 2 bolts with springsinto downpipe with 14mm socket on 12”(305mm) extension. Rear nuts are 19mm. Ifyou do not desire to remove the oxygensensor from the pipe, secure the pipe underthe car with zip-ties or wire, so that theoxygen sensor wire is not supporting theweight of the pipe (2 bolts, 2 nuts, 14mm &19mm sockets, extension). Fastener locationsshown by arrows in Fig. 15.Document 737639-39 (Rev -)www.TurboByGarrett.comFig. 14FRONT OF CARFig. 159

Part Number: 788550-0001 or -0002Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XInstallation Instructions18.From underneath the vehicle, remove theblack steel bracket that connects the turbineoutlet elbow (downpipe) to the engine block.This part will be reused (2 bolts, 14mmsocket). See Fig. 16.Fig. 1619.From underneath the vehicle, remove theheat shield attached to the top side of thetransfer case, behind and below theturbocharger. This part will be trimmed instep 49 and reused. Bolts fasten downwardinto transfer case (3 bolts, 10mm socket).See Fig. 17.HEAT SHIELDFig. 1720.Remove the heat shield above thepassenger-side inner driveshaft boot. Thispart will be trimmed in step 48 and reused (2bolts, 10mm socket). See Fig. 18.HEAT SHIELDFig. 18Document 737639-39 (Rev -)www.TurboByGarrett.com10

Part Number: 788550-0001 or -0002Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XInstallation Instructions21.22.23.24.From above the turbocharger, locate thelarge heat shield that covers the downpipe.There is a small heat shield that shares onehole with the large shield and also has itsown bolt. The shared bolt is on the undersideof the downpipe. Remove 3 bolts total to freeboth heat shields, note orientation andremove them. These parts will be reused (3bolts, 14mm socket). See Fig. 19. Theseshields can also be seen in Fig. 17.Remove the downpipe next. There are fourbolts and one nut securing it to the turbinehousing. The nut is installed on a stud that isthreaded into the downpipe. The downpipe,bolts, nut and washers will be reused. Thegasket may be reused. Penetrating oil maybe needed to loosen fasteners (4 bolts, 1 nut,14mm socket).Find the small steel bracket that connects theturbine housing to the engine block. Removethe bolt into the turbine housing. This bolt isaccessible from underneath the vehicle, andis visible between the passenger-sidedriveshaft and the oil pan. Leave the bracketattached to the engine block. This part will bereused (1 bolt, 14mm socket, extension, ujoint). See Fig. 20.SMALL SHIELDLARGE SHIELDFig. 19HALF-SHAFTBRACKET BOLTRemove the oil feed line (hard steel) fromthe engine block. Its banjo bolt installs intothe backside of the engine block (facingfirewall) on the passenger side, directlybelow the water pump. Remove boltssecuring the oil line to engine block andcompressor housing. These bolts passthrough 2 steel tabs on the oil line. Oil feedline will be reused along with banjo bolt andengine block support bolt. New M10 coppercrush washers are supplied in the kit (2 bolts,10mm wrench / socket). See Fig’s. 21 & 40.Document 737639-39 (Rev -)OIL PANwww.TurboByGarrett.comFig. 20BANJO BOLTFig. 2111

Garrett Turbocharger Upgrade Kit for Mitsubishi Evo XPart Number: 788550-0001 or -0002Installation Instructions25.26.27.Locate the turbocharger oil drain line. SeeFig. 22 (shown off of vehicle for clarity). Itdrains into the passenger side rear of engineblock, below oil feed banjo bolt. Removesingle bolt securing clamp to engine block.Remove bolt near middle of line securing it toengine block. Pull oil drain line out of blockbut leave attached to turbocharger. Ensurethe rubber o-ring is present and did notbreak and fall into oil pan. Clamp bolt will bereused. New oil drain line and o-ring includedin kit. Middle support bolt will not be reused(2 bolts, 10mm wrench/socket).From above the turbocharger, remove the 2bolts and 2 nuts securing the turbine housingto the exhaust manifold. These fastenersmay

2008 Mitsubishi Lancer Evolution X Parts List Tools Needed Item Description Qty. 1 Turbocharger (GT3071R or GT3076R)1 2 Compressor inlet elbow 1 3 Oil inlet fitting (banjo bolt) 1 4 Oil drain line (with o-ring) 1 5 Water line 1 6 Oil inlet spacer 1 7 O-ring for inlet elbow 1 8 Oil drain bolt (M8 x 1.25, 8mm 12-pt head) 2 9 Oil drain gasket 1

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