Tools and Materials Needed for the Turbosmart S600 Install

Before you begin, gather all necessary tools and replacement parts. Having everything organized will prevent delays and ensure a smooth installation. Beyond the basic hand tools, you’ll need specific items to handle the turbo system’s demands.

  • Turbosmart S600 Turbo Kit – Includes turbocharger, wastegate, blow-off valve, and all mounting hardware
  • Socket set (metric, ¼-inch and ⅜-inch drive) with extensions
  • Combination wrenches (10mm to 22mm)
  • Screwdrivers – flathead and Phillips
  • Torque wrench – ⅜-inch drive, range 10–80 ft-lb
  • Intercooler piping kit – compatible with IS300, includes couplers and T-bolt clamps
  • Silicone vacuum lines – various diameters for wastegate and BOV
  • Oil feed line (braided stainless steel) and oil drain line with gaskets
  • New exhaust manifold gaskets and turbo-to-manifold gasket
  • High-temperature engine oil (10W-40 or per your climate)
  • Engine coolant – Toyota Long Life or equivalent
  • Jack stands and a hydraulic floor jack
  • Shop rags, safety glasses, and latex gloves
  • Threadlocker (medium strength) and anti-seize compound
  • Multimeter for checking electrical connections
  • Booster pump or coolant filler funnel to purge air from cooling system

Optional but recommended: an air compressor with blow gun to clean threads, a flexible magnet for dropped bolts, and a digital angle gauge for precise wastegate alignment.

Preparation Steps

Proper preparation prevents mistakes and ensures safety. The IS300 engine bay is tight, so take time to set up your workspace.

Vehicle Setup

  1. Park the car on a level concrete surface. Engage the parking brake.
  2. Place jack stands under the front frame rails after raising the front with a hydraulic jack. Do not rely on the factory scissor jack.
  3. Allow the engine to cool completely – at least 2 hours after last driven. The exhaust manifold and turbo components get extremely hot.

Electrical & Fluid Precautions

  1. Disconnect the negative battery terminal. This prevents short circuits and resetting the ECU for a cleaner start after installation.
  2. Remove the front bumper. The IS300’s bumper cover is held by screws under the headlights, fender well tabs, and along the lower grille. Unclip the fog light connectors if equipped.
  3. Drain the engine oil: remove the drain plug and oil filter. Replace the old filter with a new one (OEM or high-flow performance filter). Install the drain plug with a new crush washer.
  4. Drain the coolant: open the radiator cap, then loosen the drain petcock on the passenger side of the radiator. Also disconnect the lower radiator hose at the engine block to fully empty the block. Be environmentally responsible with fluid disposal.

Workspace Organization

  • Lay out the Turbosmart S600 kit components and identify each piece against the installation manual.
  • Label the factory electrical connectors and vacuum hoses with masking tape and a marker before removing them.
  • Have a clean tray or magnetic mat ready for small bolts.

Removing the Stock Components

With the car prepared, remove the factory intake, exhaust manifold, and all associated hardware. Work methodically to avoid damaging surrounding parts.

Step 1: Remove the Stock Intake System

  • Unbolt the air filter box from the inner fender. Disconnect the mass air flow (MAF) sensor connector.
  • Remove the intake resonator (located behind the passenger headlight).
  • Take out the entire intake tube leading to the throttle body. Set aside the rubber coupler.

Step 2: Disconnect Exhaust Manifold and Turbo

  • Unbolt the front exhaust pipe from the manifold – three 14mm bolts.
  • Remove the heat shield covering the stock exhaust manifold (if equipped).
  • Unbolt the manifold from the cylinder head. The IS300 uses a two-piece manifold; loosen the bolts in reverse order of tightening (from the center outward).
  • Lift the manifold and disconnected stock turbo (if present) out of the engine bay. Note: many IS300s did not come factory turbocharged; this step assumes you are replacing an aftermarket turbo or starting with a naturally aspirated engine after installing a turbo-specific oil pan.

Step 3: Remove Interfering Hoses and Lines

  • Disconnect the coolant hoses from the throttle body (the IS300 uses coolant to heat the throttle plate). Cap the openings to prevent spills.
  • Remove the vacuum lines that will be replaced by the new kit – specifically the lines to the stock boost control solenoid.
  • Take off any wiring harness brackets attached to the intake manifold or engine cover.

Note: If you are installing this kit on a previously non-turbo IS300, you must also replace the oil pan with a turbo-compatible unit that has a drilled and tapped oil return line port, or install an aftermarket oil return adapter between the oil pan and block. Refer to Turbosmart’s technical support for specific oil pan recommendations.

Installing the Turbosmart S600 Turbo Kit

The heart of the upgrade – now mount the turbo and all its supporting systems. Follow torque specs precisely to avoid leaks or turbo failure.

Step 4: Install the Exhaust Manifold and Turbo

  • Clean the cylinder head mating surface of any old gasket material. Use a plastic scraper to avoid scoring aluminum.
  • Apply a thin coat of anti-seize to the manifold studs, then thread on the new manifold gasket.
  • Position the Turbosmart S600 turbo onto the manifold. Ensure the turbo’s oil drain port faces downward (toward the oil pan).
  • Torque the manifold bolts to 25 ft-lb in a cross-pattern, then retorque to 35 ft-lb after three heat cycles.
  • Install the turbo-to-manifold bolts with threadlocker. Torque to 35 ft-lb.

Step 5: Connect Oil Feed and Drain Lines

  • Attach the oil feed line to the turbo’s oil inlet port (typically 4AN fitting). Route the line to the engine block oil pressure sender location (remove the sender and use a T-fitting).
  • Seal the drain line to the oil pan: use a new gasket and tighten to 12 ft-lb. Do not overtighten – the aluminum flange can crack.
  • Install the coolant lines to the turbo’s water jacket. The Turbosmart S600 uses a water-cooled center cartridge – connect one line to the engine’s coolant return and the other to the heater hose circuit. Use constant-tension spring clamps.

Step 6: Mount the Intercooler and Charge Pipes

  • Position the intercooler in front of the radiator. Most aftermarket kits use the lower bumper mount points. Secure with rubber-lined brackets to avoid vibration.
  • Route the charge pipe from the turbo outlet to the intercooler inlet (hot side). Then from the intercooler outlet to the throttle body (cold side).
  • Tighten all T-bolt clamps to 50 in-lb. Check clearance to the radiator shroud and fan – you may need to trim the shroud slightly.
  • Attach the blow-off valve (BOV) to the charge pipe. The Turbosmart BOV included with the S600 kit is a vent-to-atmosphere type; it works best when the MAF sensor is relocated to the cold side pipe. Alternatively, use a recirculating setup if you prefer.

Step 7: Install the Intake System

  • Fit the air filter (included) onto the turbo’s compressor inlet. Use a silicone hose and clamp.
  • Mount the MAF sensor on the cold side of the intercooler before the throttle body. This requires fabricating a short section of pipe with a MAF flange, or using an adapter. Relocating the MAF is a common mod for greater airflow readings.
  • Route the recirculation hose from the BOV to the intake pipe after the MAF (if using recirc).

Electrical Connections

Proper wiring ensures the wastegate, BOV, and any provided boost controller work reliably.

Step 8: Wastegate Actuator

  • Connect the wastegate actuator lever to the turbo’s flapper door. Adjust the rod so that the door is fully closed at rest, with 2-3mm of preload on the spring.
  • Connect a vacuum line from the compressor housing boost reference port to the bottom port of the wastegate.
  • If using the Turbosmart boost controller (sold separately), wire the solenoid according to the diagram: 12V from ignition-switched source, ground, and signal wire to the ECU (for 3-port EBC).

Step 9: Vacuum Lines and Sensors

  • Route a vacuum line from the intake manifold (tap a port after the throttle plate) to the blow-off valve reference port.
  • Connect the fuel pressure regulator (if aftermarket) to the manifold vacuum. The stock IS300 uses a vacuum-referenced FPR.
  • Plug any unused vacuum ports on the intake manifold with silicone caps.
  • Reconnect the engine coolant temperature sensor, knock sensors, and any other connectors you had to unplug earlier. Confirm all connectors latch securely.

Step 10: Battery and Voltage Check

Reconnect the negative battery terminal. Use a multimeter to verify the battery voltage (should be 12.5V+) and the alternator output (14.0V-14.5V at idle). Low voltage can cause the boost controller or wideband O2 sensor to malfunction.

Final Steps – Reassembly and Fluid Fill

After all mechanical and electrical work, prepare the car to run.

Step 11: Reassemble Front End

  • Install the front bumper cover. Ensure all clips and screws are tight. Cut a small section of the lower grille if the intercooler protrudes slightly.
  • Reinstall the headlights, side markers, and any removed under-tray panels.
  • Reattach the MAF sensor connector and any fog light wiring.

Step 12: Refill Fluids

  • Add fresh engine oil. The IS300 holds about 5.5 quarts with filter. Fill slowly and check the dipstick.
  • Fill coolant: pour a 50/50 mix of ethylene glycol and distilled water through the radiator neck. Use a coolant funnel to bleed air – run the engine with the cap off until the thermostat opens (about 195°F). Top off as needed.
  • Check power steering fluid and brake fluid levels.

Step 13: Final Torque Check

Double-torque the following critical fasteners:

  • Exhaust manifold bolts: 35 ft-lb
  • Turbo-to-manifold bolts: 35 ft-lb
  • Oil drain flange bolts: 12 ft-lb
  • Intercooler piping clamps: 50 in-lb
  • Wastegate lock nut: tighten with threadlocker

Testing the Installation

Now comes the moment of truth. A careful test ensures no leaks, no odd noises, and proper function.

Cold Start and Leak Check

  • Prime the oil system: pull the fuel pump fuse and crank the engine for 10 seconds. This allows oil pressure to build before the engine starts.
  • Replace the fuse and start the engine. Let it idle for 5 minutes.
  • Inspect for oil leaks around the feed and drain lines. Also check coolant hoses for weeping.
  • Listen for exhaust leaks at the manifold gasket – a ticking noise that changes with rpm indicates a leak. Tighten manifold bolts slightly if needed.

Drive Test and Boost Observation

  • Take the car for a gentle drive. Keep boost below 5 psi for the first 100 miles to let components seat.
  • Monitor boost pressure with a gauge (or data log). The Turbosmart S600 should hit target boost between 2800-3500 rpm depending on wastegate spring.
  • Listen for BOV operation: a sharp psshh sound at shift or throttle lift confirms proper function.
  • Check that the car does not go into limp mode. If it does, inspect the MAF signal and vacuum lines.

Data Logging and Fine-Tuning

Use a wideband O2 sensor and a tuning tool (e.g., ECUTek, Haltech, or a flash tune for the IS300’s stock ECU) to adjust fuel and ignition timing. Silicone Intakes offers base maps for the IS300 with the S600 kit, but professional dyno tuning is strongly recommended.

Tuning and ECU Considerations

The stock IS300 ECU is not boost-ready. Adding a turbo requires fuel and timing changes. Key points:

  • Fuel system upgrades: Install 550cc or larger injectors and a Walbro 255 lph or higher fuel pump. The stock injectors max out around 280 hp.
  • MAP sensor: Add a 3-bar or 4-bar MAP sensor if using a standalone ECU. For stock ECU flash tuning, use a piggyback like the Aristo GTE ECU with a MAP sensor adapter.
  • Ignition timing: Reduce timing under boost to prevent knock. Aim for 12-15 degrees at peak torque, ramping to 18-20 at high rpm.
  • Professional tuning: Seek a shop experienced with the IS300 and GE engine. Driftmotion is one well-known resource for 2JZ-GE turbo setups.

Common Pitfalls and How to Avoid Them

  • Oil drain too small or kinked: Use a -10AN or larger drain line with a gentle slope. A kinked return line will cause smoke and turbo seal failure.
  • Insufficient clearance: The S600 turbo sits close to the firewall. Check that the downpipe does not contact the steering shaft. You may need to dent the downpipe or use a flex section.
  • Boost creep: If boost exceeds the wastegate setting, ensure the wastegate port on the turbine housing is adequately sized. Some users need to port the wastegate hole for better bypass flow.
  • Vacuum leaks: Use high-quality silicone hoses. Small leaks cause erratic boost, lean mixtures, and idle problems. Pressure test the system to 20 psi.

Performance Expectations

With proper tuning and supporting mods (intercooler, exhaust, fuel system), the Turbosmart S600 kit on a 2JZ-GE IS300 produces 350-400 wheel horsepower on pump gas (93 octane) at 12-15 psi. With ethanol and higher boost (20+ psi), over 450 whp is achievable while still running reliable oil and coolant temperatures. Expect a spool of 3200-3600 rpm to full boost, with a broad power band through 7200 rpm.

The car will feel dramatically faster – the S600 turbo’s billet compressor wheel reduces lag compared to older journal-bearing turbos. Combined with the improved wastegate control from Turbosmart’s design, you get consistent boost without spikes.

Conclusion

Installing the Turbosmart S600 Turbo Kit on your IS300 is a rewarding project that transforms the car’s character. This step-by-step guide covers every phase from preparation to testing. Remember to take your time, use a torque wrench, and never rush the tuning process. A well-installed kit delivers reliable power for thousands of miles. If you encounter problems, consult the Turbosmart installation manuals and join dedicated IS300 forums for community advice. With patience and attention to detail, you’ll enjoy a turbocharged IS300 that outperforms stock models in every way.