1. PEUGEOT 206 INSTALLATION 99’— 05’ 206 1.6 TU5JP4
1. Remove the air intake system
1.Remove all parts of the air cleaner,
intake hose and blow-by hose .
2. Remove the exhaust system.
1.Remove the power steering belt.
2.Remove the power steering pump.
3.Remove the alternator and
alternator mounting bracket.
4.Remove the down pipe and second
O2 sensor.
5.Remove the exhaust manifold heat
shield.
6.Remove the exhaust manifold and
primary O2 sensor.
3. Installation of turbo assembly
1.Install the primary O2 sensor into
turbo assembly.
2.Install the turbo assembly on the
cylinder head making sure that all
bolts or nuts are secure.
3.Make sure that actuator is free
and clear and moves without binding.
4.Reinstall the alternator mounting bracket
and alternator.
5.Reinstall the power steering pump.
6.Reinstall the drive belt. .
steering pump
air intake hose Ex
ex. manifold
air cleaner
turbo assembly
primary O2 sensor

2. 4.Installing oil return fitting 1.Remove the oil filter and filter
mounting assembly.
2.The oil pressure sending unit is
attached to the assembly and
needs to be removed from assembly
for installation in a new location..
3.Remove the oil relief O ring
oil filter and oil filter mounting
adapter from assembly.
4. Install the oil filter mounting adapter into the now exposed oil filter mounting location on the block and
install new oil filter included in kit.
5. Install oil relief O ring into oil
return fitting assembly included with this kit.
6. Install oil return assembly to oil relief hole using one bolt .
oil return fitting assembly
5. Install the oil return hose.
1.Install the oil return hose between
turbo oil outlet and oil return fitting.
2.Using the hose clamps included
in the kit, secure the oil return hose.
6. Installing of oil supply system
Locate plug in front of head as shown in
in photo. Remove plug and proceed.
1.Install (T) fitting adaptor into engine
head.
2.Install brass (T) connector into (T)
fitting adapter and install oil pressure
sending unit into (T) fitting.
3.Install oil line fitting in the side of the
(T) fitting.
4.Connect stainless oil line to oil line
fitting.
5.Bring oil line around to turbo and
connect to oil inlet of turbo.
oil return hose
(T) fitting adapter
oil sending
to turbo
(T) fitting

3. down pipe
7. Installation of the down pipe
1.Reinstall second O2 sensor in the
down pipe.
2.Install the down pipe with gasket to
the turbo exhaust outlet.
3.Connect down pipe to
exhaust system with gasket.
second O2 sensor
8. Installation of water cooling system
1. install the new heater hose included in
the kit. between water inlet and water
(T) fitting the other end to heater.
2.Locate the heater water outlet hose, cut
in half in an easy to reach location
Insert the (T) fitting supplied into each
half of the hose and secure with hose
clamps supplied.
3.Connect the stainless water lines
supplied to the (T) fittings and then
feed both lines to the turbo. connect the
water lines to either of the water
connections of the turbo. .
to heater
to turbo
(T) fitting
from engine

4. 9. Installing the intercooler system
1. Installing the intercooler first fit
the charge piping to compressor outlet
and around to intercooler inlet. Then
locate position of intercooler mounting
to correspond with charge piping.
2.See photograph to locate chassis
position to mount intercooler.
intercooler
fix chassis
10. Install and connect charge piping
1.Refer to photos and drawing for
flow layout.
2.Note corresponding numbers on
charge piping.
A. Flow of charge air is in the direction
of the arrow on the charge pipes.
3. Install blow off valve on intercooler
as shown.
A. There is an adjustment screw on top
of B.O.V. for sooner or later release
of pressure.
IP201 2
to throttle
from turbo
BOV 1
11. Installation of air intake system
1.Install one end of the air intake
hose to the compressor inlet, and
the other end to the air filter Install the blow-by hose to the
quick connector and to the air
intake hose.
blow-by hose
air filter
check valve
air intake hose

5. IP201
12. Fuel system installation
1.If you are using the 2 extra injector
fuel system mount the Ip201 interface
between charge pipe and throttle
body.
A Disconnect the factory fuel rail from the
nipple and install rail adapter. .
B. Using the stainless fuel line included
connect one end of the Ip201 injector
interface and the other end to the
fuel rail adapter. ( please refer to figure 2 )
4. Install the ICU401 injection control unit
as shown in the following pages of this
instruction. ( please refer to page 14)
fuel line
to IP201
fuel rail
rail adapter
13. MAP sensor
1.Connect MAP sensor wiring to the
ECU. ( please refer to figure 4 )
MAP-5
Your installation should now be complete. Prior to setting car on ground take
a moment to check all lines hoses fitting etc. At this time refill radiator and
engine oil. check for any leaks.
If everything looks good connect battery and start motor. Let it run for a
few minutes. Turn off motor and check for leaks.
After running engine and car is still lifted it is recommended to change oil
and filter to make sure any loose material is removed.
Installation should now be complete lower car and enjoy.
Turbo specialties.