Evolution Powersports Maverick R P47-400 Turbocharger Upgrade System

Parts Included in Paragon 47-400 Turbo Upgrade System

Specifications

Required Parts (Sold Separately)

• EVP or other Full Turbo Back Exhaust System

Steps to Sending in Your Turbocharger

• Wash turbocharger with heat shields removed but exhaust on.
• Remove wastegate and hardware before sending.
• Tape/plug the coolant & oil passages on the turbocharger.

Installation Steps

Step 1: Remove Heat Shields

Remove the two-part heat shields around the turbocharger. This requires removing 1 hose clamp, (2) 10mm screws underneath, and (4) screws on top by the valve cover.

Refer to Figure 1 and Figure 2 for visual guidance.

Step 2: Disconnect Sensors

Unplug the O2 sensor from the engine harness. If running a "shocker" (likely referring to a specific accessory or setup), unplug the actuator plug as well.

Refer to Figure 3 for visual guidance.

Step 3: Remove Downpipe Heat Shield

Remove the heat shield located on the downpipe using (3) 10mm screws.

Refer to Figure 4 for visual guidance.

Step 4: Remove Downpipe

Remove the (4) exhaust springs holding the downpipe to the muffler. Loosen the V-band clamp holding the downpipe onto the turbocharger. Use a 13mm socket. If the V-band is stuck, lightly tap it. Do not bend the clamp. Remove the downpipe.

Refer to Figure 5 for visual guidance.

Step 5: Remove Charge Tube and Intake Components

Remove the turbocharger to intercooler charge tube using (2) 11mm nuts. If you have a rising rate setup, remove the vacuum line. Remove the intake tube, valve cover breather (if not running a catch can), and either the OEM airbox or high-flow intake.

Refer to Figure 6 and Figure 7 for visual guidance.

Step 6: Disconnect Electronic Wastegate

Unplug the electronic wastegate connector. It has (2) tabs, one on top and one on the bottom. Press both tabs together to release and remove the connector.

Refer to Figure 8 for visual guidance.

Step 7: Remove Flex Jointer V-Band Clamps

Remove both V-band clamps holding the flex jointer from the header to the turbocharger. Note the orientation of these clamps. Use a 10mm socket.

Refer to Figure 9 and Figure 10 for visual guidance.

Step 8: Prepare Coolant System

Remove the cap from the coolant reservoir. Pinch off all coolant lines going to and from the engine. There are a total of 5 clamps: two going to the head, lines running up to the radiator and intercooler (located by the plenum), a large hose by the temperature sensor, and a hose between the firewall and plenum.

Refer to Figure 11 and Figure 12 for visual guidance.

Step 9: Remove Wastegate Rod Nut

Carefully remove the 10mm nut holding the wastegate rod to the flapper. Remove the nut, washer, and inner sleeve. Apply PB Blaster and let it sit.

Refer to Figure 15 for visual guidance.

Step 10: Remove Wastegate Bracket

Remove (2) 8mm screws holding the wastegate bracket onto the turbocharger.

Refer to Figure 16 for visual guidance.

Step 11: Remove Turbocharger Mounting Screws and Wastegate Bracket

Remove (2) 10mm turbocharger mounting screws on the bottom. Remove the wastegate bracket and rod.

Refer to Figure 17 for visual guidance.

Step 12: Drain Coolant from Turbocharger

Place a catch pan underneath the vehicle. With the wastegate bracket removed, you can access the coolant drain plug on the turbocharger. Use a 17mm socket to slowly remove the plug and copper washer.

Refer to Figure 18 and Figure 19 for visual guidance.

Step 13: Remove Header Top Screws

Remove (4) 10mm screws on the top of the header.

Refer to Figure 20 for visual guidance.

Step 14: Loosen Header Pinch Plate Screws

Loosen the bottom pinch plate screws holding the header to the block. You may need to indent the heat shield to access the screw.

Refer to Figure 21 for visual guidance.

Step 15: Remove Top Turbocharger Screws

Remove the (2) top 10mm turbocharger screws.

Refer to Figure 22 for visual guidance.

Step 16: Remove Turbocharger

Wiggle the turbocharger off the (2) locating pins while lifting the header up slightly. You do NOT need to remove the header. There is a pipe between the header and turbocharger.

Refer to Figure 23 for visual guidance.

Step 17: Check Compensator and Gaskets

Keep the compensator and (2) gaskets. If they are torn or bent, you must get new ones.

Refer to Figure 24 for visual guidance.

Step 18: Clean Mounting Location and Replace Gasket

Clean up the turbocharger mounting location and gasket. Remove the old gasket and replace it with the supplied gasket. Ensure the compensator tube is seated at the bottom of the exhaust manifold or turbocharger. If not, remove, clean, and reinstall. Sometimes they can get pinched sideways.

Refer to Figure 25 for visual guidance.

Step 19: Install Coolant Plug

Install the coolant plug and sealing washer into the turbocharger. Torque to 22 ft-lb. This is the part you will be sending to Evolution Powersports.

Refer to Figure 26 for visual guidance.

Step 19b: Retain Hardware

You will keep all mounting hardware and wastegate hardware. DO NOT SEND THIS WITH YOUR TURBOCHARGER!

Refer to Figure 27 for visual guidance.

Figure 28: Inlet/Outlet Identification

Note: Please tape over both coolant and oil inlet/outlet ports. The image shows the turbocharger with labels for: Oil Inlet, Coolant Outlet, Coolant Inlet, Locating Hole (x2), and Oil Outlet.

Step 20: Install Wastegate Bracket and Rod

Install the wastegate bracket and (2) 8mm screws onto the turbocharger. Install the wastegate rod with sleeve, washer, and nut onto the wastegate flap. You will notice the wastegate flap will not be fully closed; this is normal.

Refer to Figure 29 for visual guidance.

Step 21: Reinstall Header and Gasket

Remove the header and inspect the gasket. If torn, replace it. Reinstall the header into the pinch plate. Install the new turbocharger gasket if you have not already done so.

Refer to Figure 30 for visual guidance.

Step 22: Install New Turbocharger

Install the new turbocharger, fully assembled with the compensator and gaskets. Install (2) turbo mounting screws loosely.

Refer to Figure 31 for visual guidance.

Step 23: Orient Compensator Gaskets

Spin the compensator gaskets so the tabs are facing the wastegate actuator. If not clocked correctly, the V-band clamps will be clocked incorrectly.

Refer to Figure 32 for visual guidance.

Step 24: Torque Clamping Plate Screws

Torque the bottom (3) screws on the clamping plate to 18 ft-lb in sequence.

Refer to Figure 33 for visual guidance.

Step 25: Install Compensator V-Band Clamps

Install the compensator V-band clamps and hand tighten them for now. Ensure the gasket tab is in the opening of the V-band.

Refer to Figure 34 for visual guidance.

Step 26: Torque Exhaust Manifold Screws

Torque the upper exhaust manifold screws to 18 ft-lb in sequence. Note the difference between the "NEW" and "USED" tightening sequences.

Refer to Figure 35 (NEW EXHAUST MANIFOLD) and Figure 36 (REUSED EXHAUST MANIFOLD) for visual guidance.

Step 27: Torque Turbocharger Screws

Torque the (4) turbocharger screws to 18 ft-lb in sequence.

Refer to Figure 37 for visual guidance.

Step 28: Torque Compensator V-Band Clamps

Torque the compensator V-band clamps to 80 in-lb.

Final Reassembly Steps

• Remove all the coolant clamps on all hoses.
• Reinstall the HFI intake tube.
• Reinstall charge tube from intercooler to turbocharger.
• Reinstall exhaust and all heat shields.
• Check oil levels; you may have to add a little.
• Add coolant, heat cycle the engine so the thermostat opens to top off coolant.

Map Sensor Installation

Step 1: Install Primary MAP Sensor

Locate the MAP sensor on the top of the plenum. Remove the electrical connector. Use a T-30 socket to remove the screw. Remove the OEM MAP sensor. Install dielectric grease on the supplied 4-bar MAP sensor O-ring. Install the new sensor into the plenum and plug in the electrical connector.

Refer to Figure 38 for visual guidance.

Step 2: Install Secondary MAP Sensor

Locate the second MAP sensor on the inside of the throttle body. Remove the charge tube. Unplug the electrical connector. Use a T-30 socket to remove the screw. Remove the OEM MAP sensor. Install dielectric grease on the supplied 4-bar MAP sensor O-ring. Install the supplied MAP sensor harness to the OEM harness and MAP sensor.

Refer to Figure 39 for visual guidance.

Fuel Injector Installation

Step 1: Prepare Injector Ports

Spray all injector ports and the plenum with brake cleaner and compressed air. Ensure no debris falls into the injector ports. Remove (2) 8mm screws.

Refer to Figure 40 for visual guidance.

Step 2: Disconnect Fuel Line

Carefully push down and remove the blue safety clip on the fuel quick connector. Do not break it. Press down on the top black connector and remove the fuel hose from the fuel rail.

Refer to Figure 41 for visual guidance.

Step 3: Remove Fuel Rail and Injectors

Remove the fuel rail with injectors attached. Flip the fuel rail 180 degrees. Unclip all injector electrical connectors.

Refer to Figure 42 for visual guidance.

Step 4: Install New Injectors

ONLY remove the (3) secondary injector clips. Remove the old injectors and clean the O-rings. Install the (3) supplied 1000cc injectors. Use dielectric grease on the O-rings.

Refer to Figure 43 for visual guidance.

Step 5: Reinstall Components

Reinstall all other parts in reverse order. No injector adapters are needed.

Spark Plug Installation

Step 1: Remove Wind Dam

Remove the bed and intercooler / radiator wind dam.

Refer to Figure 44 for visual guidance.

Step 2: Remove Charge Tubes

Remove both charge tubes from the intercooler using an 11mm socket.

Refer to Figure 45 and Figure 46 for visual guidance.

Step 3: Remove Coolant Reservoir Screw

Remove the (1) coolant reservoir mounting screw using a 10mm socket.

Refer to Figure 47 for visual guidance.

Step 4: Relocate Coolant Reservoir

Remove the coolant reservoir and bungee it up to the cage.

Refer to Figure 48 for visual guidance.

Step 5: Remove Intercooler Tray Screws

Remove (6) intercooler tray screws using a 10mm socket.

Refer to Figure 49 for visual guidance.

Step 6: Remove Intercooler

Tilt the back of the intercooler upwards, unplug (2) intercooler fan connectors. Remove the intercooler from the vehicle.

Refer to Figure 50 for visual guidance.

Step 7: Access Valve Cover and Remove Spark Plugs

With the intercooler removed, you can now access the valve cover. Unplug (3) coil pack connectors, remove (3) T-30 screws, and remove the (3) coils. Use a 14mm socket to loosen the spark plugs. Use a magnet to remove the plugs.

Refer to Figure 51, Figure 52, Figure 53, and Figure 54 for visual guidance.

Step 8: Install New Spark Plugs

Apply a small amount of anti-seize to the threads of the new plugs. Install the plugs into the head using a magnet. Torque the plugs to 124 in-lb (14 Nm).

Step 9: Final Reassembly

Once complete, reinstall the vehicle in reverse order.

Important Notes and Disclaimer

Thank you for choosing Evolution Powersports products. If you require further assistance, please call our Tech Support at (715) 247-3862.

Note: This product is exempt from the emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code §§ 27156 and 38391]. This product is sold only for use in connection with EPA certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/that purchase this product represent and warrant that the product is purchased only in connection with EPA -certified, emission-regulations-exempt and noise-regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.