INSTALLATION GUIDE

© ls1turbo.com.au 2007
 Ref: MDREV-02c

GEN-TT INTERCOOLED TWIN TURBO SYSTEM

INFORMATION AND INSTALLATION GUIDE

GEN-TT KIT PARTS/PACKING LIST

INTERCOOLER AND MANIFOLD PIPING
1 LHS Manifold Extension Assembly
1 RHS Manifold Extension Assembly
1 LHS Dump Pipe
1 RHS Dump Pipe
1 Intercooler Y Piece
1 Intercooler to Throttle Body Pipe
1 Intercooler Outlet Pipe
1 RHS Compressor Discharge
1 LHS Compressor Discharge
1 Intercooler Crossover Pipe

TURBOCHARGERS
2 Gen-TT KKR330 Turbocharger
2 Stainless Steel Turbocharger Gaskets

INTERCOOLER
1 Gen-TT Front Mount Intercooler

TURBOCHARGER BAGS
2 Gen-TT Turbocharger Heat Bag

SILICONE HOSE
1 100mm-75mm 90 Degree Reducer
3 50mm 90 Degree
2 50mm Straight (300mm long)
3 75mm Straight (200mm long)
2 25mm Straight (100mm long)

BLOW OFF VALVES

2 Gen-TT Blow Off Valve

HOSE CLAMPS
1 Size 64 (87-112) (3 supplied on LS2 due to MAF)
2 Size 40 (58-75)
7 Size 52 (77-95)
10 Size 28 (44-56)
4 Size 16 (23-38)

AIR FILTERS
2 63mm 90 Degree Rubber Elbow
2 Gen-TT Pod Filter

OIL WATER
1 Drain Kit

HARDWARE
8 8mm x 1.25mm Turbo Flange Nuts
8 8mm x 1.25mm x 35mm Turbo Flange Bolts
6 8mm x 1.25mm x 25mm Turbo Dump Pipe Bolts
2 8mm x 1.25mm x 25mm Intercooler Bolts (bottom)
2 8mm x 1.25mm Intercooler Nuts (bottom)
2 6mm Brass T-Piece
1 6mm 5 meter length rubber hose

TOOLS REQUIRED
Complete Metric Spanner set
Complete Metric Socket set
Complete Set of Phillips Heat/ Flat Head screw drivers
Adjustable spanner
Needle nose pliers
Full sized pliers
Metal Shears (Tin Snips)
Air/Electric Saw (preferred)
Electric Drill
Metric Drill bits
350mm Drill extension
1/8 inch BSP Tap (drill size 8.8mm)
1/2 inch BSP Tap (drill size 19mm)
Sharp Blade
Air/Electric Grinding Tool

CONSUMABLES REQUIRED
Tube High Temperature Neutral Cure Silicone
(Loctite 5699 Flange Sealant or similar)
Pipe and thread sealant compound
(Wurth Pipe Seal or similar)
Assorted cable ties/panduit straps
Electrical Insulation Tape
INSTALLATION
STEP 1
ENGINE BAY PREPARATION

Note: Attempting installation of Gen-TT assumes that the vehicle battery has already been located
outside the engine bay

- Disconnect battery (this assumes it is already re located to the boot)

- Remove front bar / head lights / fog lights
- Remove intrusion bar
- Remove standard air box / inlet tubing
- Remove engine covers
- Remove all ignition leads
- Remove RH side coil pack
- Remove Engine Oil dipstick
- Remove Headers / Cats

Note: With LS2 /L76/ VZ you will have to remove the coolant bottle from under the guard and fit
the supplied Gen TT LS2 overflow bottle

Note: Replace sparkplugs now for easy access

Recommended Spark Plugs for Gen-TT are NGK TR-6 at supplied plug gap

TRIMMING THE BODY

- Using a powered saw cut the required metal away from underneath the headlights to allow
fitment of the intercooler piping. This is shown in some detail in the diagrams
- Clean away any metal shavings before progressing with the installation

STEP 2
OIL SYSTEM
OIL FEED
- Identify the oil pressure fitting for the turbochargers in the oil feed/drain kit
- Remove the plate directly above the oil filter, and in the case of the LS1 HSV spec engine tap
the protruding tang with a 1/8th inch BSP tap. In the case of other/LS2 engines the pressure
housing can be tapped directly at the high point of the casting. Note the correct drill size is
8.8mm for the hole.
- Refit the pressure plate and tighten into position
- Using thread sealant screw the oil pressure fitting into the plate
- Route the oil pressure line up to the top of the fan shroud and then screw the tee piece and
individual turbocharger feed lines into position

OIL DRAIN

Note: The best way to put the drain holes in the sump is to remove it completely. However if you
choose to tap the sump in place please be aware you will need to drain the oil and change the
filter before starting the vehicle

- Drill both pilot holes into sump into the location specified in the photographs
- Drill 19mm sized holes into the sump. You then use a ½ inch BSP TAP to create the threaded
holes in the sump. You can use grease on the TAP to trap excess metal filings
- Clean inside the hole to pickup any excess filings and then plug the hole with some clean cloth
- Remove pictured fitting. Drill specified hole in the fitting and tap the fitting.
- Install ¾ inch oil drain fittings into the new tapped holes using thread sealant or similar.
- Now install the high temperature oil lines to the fittings and tighten hose clamps
- Run each oil drain line to the approximate position of each turbo, and ensure each end is
blocked to avoid oil contamination
STEP 3
INTERCOOLER SYSTEM

Note: US LHD Pontiac GTO has a specific intercooler pipe to allow spot light clearance. Please
refer the photographs for extra direction on fitment

- Cut the required hole under the RH side headlight (see pictures for measurement)
- Test fit the intercooler and find the central location on the car. Mark where holes need to
be drilled in the rad support to bolt the intercooler on. Some air con lines will need to be re
adjusted to fit the cooler. These are all easily bent aluminium lines. The power steering
‘cooler’ will need to be pushed back towards the radiator. There is plenty of room to play
with.
- The factory intrusion bar will locate the top of the intercooler.
- Fit the intercooler pipes and their associated silicone plumbing, making sure that all clamps
are tight. Only the main 4 inch to 3 inch silicone reducer on the throttle body can be left loose

STEP 4
EXHAUST MANIFOLDS

Note: The factory exhaust manifolds need to be swapped left to right

The factory manifold heat shields need to be removed
The factory pressed steel exhaust manifolds need to be used
Neutral Cure High Temperature Exhaust Silicone sealant must be used
Depending on the individual vehicle up to 3 mm may need to be ground from part of the right
hand engine mount to clear the reversed factory header

- Slide the LH manifold extension onto the manifold. Again using liberal amounts of high
temp silicon on the sealing surfaces. LH manifold extension has the spacer flange welded into
position, and is relieved to clear the inner chassis rail. With variations in body pressing
additional material may need to be removed from the spacer flange. Do this carefully using a
grinding disc. Minimum flange to chassis clearance is recommended at 5mm
- Fit the M8 Stainless nuts supplied along with HIGH temp Loctite to attach the manifold
extensions to the factory exhaust manifolds
- Tighten the nuts to ensure a solid fitment of the manifold extension to the manifold
- Remove excess silicon that squeezes out the side of the joint with an alcohol based solvent
- Repeat for the other side.
- Before installing the RH side manifold there are two rubber heater lines running above the
main air con line (RHD vehicles only). These will need to be re routed UNDER the air con
line that involves dumping the coolant. Alternatively (LHD vehicles) you can run some heat
shield sheath over the lines and use high temp zip ties to hold them to the air con line. There is
ample air gap between the manifold and the heater hoses and this step is carried out to ensure
durability.
- Now install the RH side exhaust manifold / extension as a whole. This can be a fiddly process
but is quite easy if you take your time. Torque the bolts up to manufactures specification.

Note: LHD Vehicles will require the air conditioning Right Hand side top air conditioner line to be
modified as shown in the MODIFY AIR CONDITIONER HOSE photograph

- Re install the DIP stick

STEP 5
FITTING THE TURBOCHARGERS
- Identify the oil drain fittings and bolt these with the supplied gaskets to the turbocharger

Note: All LHD vehicles have a different dump pipe arrangement that routes the dump pipe behind
the exhaust manifold to give adequate clearance to the LHD steering shaft assembly. Please
refer to the specific LHD fitment photographs for a visual representation
Note: With the turbochargers sitting in place on the vehicle each oil drain points partially towards
the nose of the vehicle rather than the sump. Take care not to put the oil drains on back to
front or installation problems will occur

- Sit each turbocharger in position noting that the LH turbocharger discharges directly down,
while the RH turbocharger discharges towards the inner guard
- Install metal base gasket between the turbocharger and the exhaust manifold
- Push the oil drain hose on at this stage and ensure that it runs freely and is kink free, this is
very important
- Push the turbocharger mounting nut/bolt assembly through each mounting hole in the flange,
but do not tighten yet
- Put each dump pipe into position and bolt to the back of the turbocharger
- With the dump pipes held away from the chassis rails using a metal bar or piece of wood, the
turbocharger can now be tightened into position to give it correct angularity. Note the
turbocharger can swivel on its base 2 – 3 degrees to provide correct clearance
- Once the correct position has been attained then securely tighten the turbo fastening hardware
- Coolant and oil feed lines can now be fitted to the turbochargers. Coolant feed for the
turbochargers are accessed from under the Throttle Body and can be Tee pieced for each
turbocharger
- Use the appropriate lines from the outside fittings to another T piece and run back to the
radiator (the line you took from under the throttle body runs to the radiator inlet you require.
- Fit all the oil / water lines to the turbo. Notice the turbocharger oil fittings have a small
restrictor hole in the top to allow easy identification. Avoid over tightening the fittings.
- Fit the compressor discharge pipe from the RHS turbo charger to behind the intercooler ready
to connect up to the intercooler crossover pipe.
- Install the RHS Blow Off Valve using the supplied silicone pipe.
- Connect the intercooler crossover pipe to the twin 2 inch to 3 inch ‘Y’ piece on the other end
of the cooler using the correct silicone and clamp sizes

STEP 6
MISCELLANEOUS

Note: With LS2 / L76 you will need to trim the silicon 4 to 3 inch 90deg bend. The MAF sits slightly
in side the TB to give extra clearance. The loom for the MAF will be unwrapped from the
main loom and then retaped to reach its new position

- LS2 powered vehicles need the supplied coolant bottle and bracket mounted in the position
shown on the opening page of this manual. A single bracket bolts into a factory location, and
the existing factory line can be used (shortened) by running it around behind the headlight to
the new coolant bottle, all the while keeping adequate clearance from the turbocharger
- All LS1 powered vehicles will require the PCM to be relocated in the cabin. This is a
relatively straightforward job with the PCM connectors pushing back through the main
firewall bung. In the case of a US car the PCM needs to be located in the LH kick panel,
which requires modification to the computer casing (the fins on top of the PCM need to be
ground back slightly). See photographs for more information
- In the case of an LS1 engine you will have to drill hole in the throttle body intercooler pipe to
accept the Air Intake Temperature Sensor. The wiring will have to be extended [Refer to
ELECTRICAL sub heading]
- Fit the coil pack back to the RH side and all leads back to the plugs.
- Fit the turbocharger dump pipes to the car (see pictures)
- Fit the air filters to the turbo chargers. Trimming of the rubber air filter elbows from the
turbochargers will be required. Take your time doing this for perfect fitment

Note: When fitting the air filter you need to make sure that the air filters are not compressed against
the body in any way shape or form. The air filters are designed to sit behind the headlights without
their shape being deformed in any way. Any compression of the air filters will cost you plenty of
power, so be very careful here!
- Fit the turbocharger heat bags and ensure the rear spring is in position at the rear of the heat
bag. Fitting the RHS heat bag correctly may require the intercooler pipe to be disconnected at
the throttle body
- Double check all hose clamps and fittings for tightness. (refer to no 41 re ‘Y’ piece clamps)
- Run the rubber lines for the Blow Off Valves from the vacuum feed from the back of the inlet
manifold. Two ‘T’ pieces will be required. *Note must be fed from the manifold.
- Now add new oil / oil filter / coolant and check for leaks.
- Check all hoses / oil lines for security and make sure nothing is touching the manifolds or
rubbing. (see photos for correctly mounted hoses etc)

STEP 7
EXHAUST SYSTEM

Note: These are hints for your exhaust installer

- When having your existing exhaust mated (or a new exhaust made) for the Gen-TT
Intercooled twin turbo system it is advisable for the exhaust builder to brace to dump pipes to
the bell housing bolts on each side to keep them from moving and/or vibrating during vehicle
operation
- It is also advisable to have metal ‘flex’ bellows after the dump pipes/catalytic converters to
give the exhaust system adequate durability

IMPORTANT TOPICS

ELECTRICAL
- LS1 Air Intake Temp Sensor wires will have to be lengthened
- LS1 Low coolant level wires will have to be lengthened to reach from the new PCM location
in the LH footwell area (it is part of the PCM loom) back to the coolant bottle. Alternatively
this connector can be ‘shorted out’ with a piece of insulated wire which will remove the dash
light, but also the low coolant warning

Note: Ensure that connections are soldered and properly insulated. Additional wiring may need to be
zip tied into place

LSX SERIES ENGINE BREATHER SYSTEM

Note: No engine breather hardware is supplied with the Gen-TT kit.

Recommended Gen-TT engine breather system is a professional catch can assembly with all of the
rocker cover breather and fresh air vent hoses attached to the catch can, which must then be vented to
the atmosphere. Replacing the oil filler cap with a filter style cap is also recommended, but can cause
cabin odours in the case of a high mileage engine.

It is possible to use plastic 90 degree fittings in each air cleaner elbow and route the rocker cover/valley
breathers to these elbows to evacuate crankcase gasses. This gives a sealed system. Refer optional
breather photographs for more information

IMPORTANT: For LS2/ Late LS1 where the engine breather system runs from the valley the
connection to the throttle body/inlet pipe MUST be disconnected to avoid pressurising the engine
oil sump. Failure to do may result in the engine oil dipstick being blown out and possible engine
damage.

LSX SERIES FUEL SYSTEM

Note: No engine fuel system hardware is supplied with the Gen-TT kit
Note: When retaining the standard tank and fuel bucket assembly never attempt full throttle
performance testing with less than a half tank of indicated fuel. Fuel surge in the factory fuel tank at
higher than stock acceleration rate can cause fuel starvation and possible engine damage

Recommended Gen-TT fuel system comprises 8 x 60lb/hour Siemens Deka High Impedance fuel
injectors, and a 255 litre/hour Walbro in-tank fuel pump

IMPORTANT: Never attempt to operate a Gen-TT equipped vehicle with less than 98 Octane
Premium Unleaded fuel (Australia/UK), or 93 Octane Premium Unleaded fuel (US/Middle East)
PHOTOGRAPHS
TRIMMING THE BODY

Body trimming required under RHS headlight

(Refer photograph RH Intercooler piping for more detail of section removed)

Note use of an air-saw to give a smooth finish

Trimming the edge of the intrusion bar is required

LH body trimming
OIL/WATER DRAIN/FEED

Oil feed fitting tapped into factory housing (LS2 pictured)

LHS Drill location for oil drain fitting

RHS Drill location for oil drain fitting (note proximity of Dipstick)

Fitting in sump and hose attached. Note smooth flowing bend and no kinks
Water line installation layout
INTERCOOLER

Intercooler installation finished and in place

Intercooler installation top view

Test fitting the intercooler pipe to check clearance

Intercooler Crossover pipe

Intercooler Y Piece

RH Intercooler piping
EXHAUST MANIFOLDS

Applying high temperature silicone to factory exhaust manifold

Silicone required on manifold spacer flange

Bolting the manifold extensions into place

Heat shielding trimmed and in position

FITTING THE TURBOCHARGERS

RH Completed Turbocharger Installation

LH Completed Turbocharger Installation

COMPLETED INSTALLATION GENERAL PICTURES

OPTIONAL BREATHER SYSTEM (ADEQUATE FOR ROAD USE)

NOT SUPPLIED AS PART OF GEN-TT KIT

Note rocker cover and valley breathers joined together with a tee piece
Rocker cover vents from each side of the engine can then be fed into each turbo
inlet with a 90 degree plastic fitting
RELOCATE PCM (LS1 ONLY)

Notice fins on the PCM lid have been ground away to allow kick panel refitting.
This mounting position is only required for LHD vehicles to avoid the pedal box
assembly

PCM wiring loom is run back through the standard rubber/plastic firewall
grommet before being sealed with silicone sealant to offer adequate weather
protection
LEFT HAND DRIVE SPECIFIC GEN-TT KIT MOUNTING PICTURES
MODIFY AIR CONDITIONING HOSE

The LHD Air-conditioning top aluminium line will interfere with the Left Hand
manifold extension and has to be modified in the manner shown. This example cost
$40 USD from a US air conditioning installer

Gen-TT Left Hand Drive Dump Pipe fits behind the exhaust manifold which no
longer requires the PCM to be relocated
Additional hole required for US spec intercooler pipe to clear the GTO spotlights
and allow a completely stock front end look
DISCLAIMER
It is extremely important that you check your local state and federal laws
regarding the legality of the Gen-TT for your individual vehicle.
Ls1turbo.com.au and Willall Racing accept no responsibility implied or
otherwise for any action or result of operation of a motor vehicle which is in
contravention of local laws.

Installation of a Gen-TT Intercooled Twin Turbocharger kit is only ever

recommended to be carried out by a qualified automotive technician that is
approved by Ls1turbo.com.au Willall Racing as a recognised fitting agent.