This article explains how to install a Zex dry nos kit on a 94-99 Toyota Celica GT (equiped 5SFE engine). It is very simple, but the instructions can get quite complicated, so these instructions walk you through the installation, thoroughly explaining each step. Reading the instructions that come with Zex Nitrous Kits completely is recommended, and this article should used as a supplement to the Zex Instructions....
Nitrous Basics
- Nitrous (nos)is not a fuel- if you run out of gas you cannot use nos as a fuel. All nitrous does is add oxygen, which in turn allows your engine to burn more fuel.
- Make sure your engine is in good operating condition (check for error codes, have a mechanic go over it if necessary). Nitrous puts a lot of stress on your engine, which leaves a small margin of error. Detonation with normal fuel is bad but not normally dangerous. Detonation while applying nitrous can destroy an engine.
- You will need special spark plugs to run nos. Typical plugs have a long ground which will heat up, and you will need to replace your plugs with a shorter ground plug. With a higher oxygen content you are more prone to detonation…which can be triggered by a factory spec plug. On my car I tried the stock replacement Bosch platinum +4's I had to quickly take them out and because they were very hot. I currently have the Zex Platinum cold 3 electrode spark plugs on my car. You may consider getting "short ground" spark plugs for daily driving (i.e. when you may consider using nitrous) and swapping in the factory-spec plugs when you're going on long distance driving (i.e. wont be using nitrous.)
- Another safety tip: When you are near redline DO NOT engage the NOS.
- You must use 92 octane gas no lower and no mixing. Higher-octane fuel has a slower burn preventing your engine from detonation due to the extra oxygen from nitrous.
- Make sure you check all the noslines after every bottle of nitrous. This is very easy to spot, just look for frost along the stainless steel nos lines.
- Read the Zex manual completely for kit specific safety tips.
Tools needed:
- battery powered drill with a number of different drill bits
- a soldering iron with flux and electrical solder (for wiring)
- wrenches: 7/16, 1/2, and 9/16; 2 of each
- flashlight
- hot glue gun or a really good epoxy glue (never know when you need it)
- 10mm socket and a ratchet
- a marker to mark drilling points
Recomended Preparations:
- new timing belt and water pump
- valves adjusted (valve lash)
- compression test
- diagnosis check
- use Magnecor KV85 wires and ZEX spark plugs
- A full tank of high/premium octane (92) gas
Step 1: Running the Main Line
I chose to locate the nitrous tank in the trunk. You may choose to locate your bottle elsewhere, the instructions should be very similar.
The kit comes with all the needed components for locating the tank in your trunk. Using the 15ft main nitrous line start with one end in the trunk. I ran the line through an existing hole under the spare tire up to the front of the car. You have the option of running the line through the interior of the car, which is much faster, however having the line under the car is safer and recommended by Zex. I zip-tied the nitrous line to the plastic bracket and followed the fuel line all the way to the engine (see image above). It helps to have someone grab the line when passing it up the port hole in your engine bay. For now leave, leave the line loose as there is quite a bit more to do =)
Step 2:Tank Brackets/Bottle Installation
The NOS bottle is comparable to a can of spray paint...it needs to be upright and tilted in the right direction to work correctly. The nitrous needs to freely flow through the main line, so you will need to mount the bottle in a position where the hose is always at the bottom corner of the bottle even during acceleration. Take note that the brackets are different sizes to mount the bottle correctly. The tall bracket goes on the nozzle end of the bottle while the small bracket goes on the butt-end of the bottle.
The tank brackets can be very difficult to install. I strongly recommend that you use 2 people for this step.
to mount the bracket you need to drill 4 holes in your trunk. Be aware of what you are drilling into and what is near before you start drilling and there shouldn't be a problem.
You really can mount the tank anywhere in the trunk. I mounted the bottle to the left of my CD Changer & Amp. If it is a concern you may want to find a stealth location elsewhere into the trunk, possibly behind or under the trunk molding (if the bottle will fit), or into the particle board covering the spare.
Step 3: Mounting The NMU (Nitrous Management unit)
You now need to find a place to mount the Zex Nitrous Management Unit (the sweet looking purple box.). The tubes that came with the package are way too short to mount the NMU anywhere but very close to the intake. I have an Injen intake which made it very easy to mount in the position in the pictures, however a stock intake may have trouble.
You can mount the NMU anywhere by simply buying longer stainless steel cables. The tube lines cost about 75 cents a foot and you will need 2 of 5' foot tubes.
Once you finish mounting the NMU you are ready to go to the next step.
Step 4: Finding your Fuel Regulator and Throttle sensor
Finding these two sensors is a bitch. This is why it took me so freaking long to install my nitrous kit....
| Fuel Regulator | |
 | Ok let's start with the fuel regulator. The fuel regulator looks like a mushroom top. If your car has a lot of mileage it will be rusted it will have one mini tube coming out if it. Compare it to the tube Zex give you...its smaller then that... Pop the stock tube off and follow the lines up to the intake those are where the 2 tubes are going to connect to. |
| Throttle Sensor | |
| The throttle sensor is located directly behind your actual throttle. It should be a plastic harness with 4 wires coming out of it (RED BLACK/WHITE BLUE/WHITE BROWN/BLACK WHITE). The throttle sensor wire is the BLACK/WHITE wire. This wire will connect the white wire on the Zex NMU so when you floor the pedal...the nitrous will activate. |  |
Step 5: Tube Installation
 | On the purple box (NMU) there are 2 tubes that you need to hook up. Find the vacuum hose which is connected to the fuel pressure regulator. Connect the "regulator" hose to the fuel pressure regulator. The second, "intake", hose goes to the intake manifold. |
Step: 6 Switch Mounting
Awww yeah...the nos switch...Everybody in New York is now telling me that nos is very illegal. I had no idea that NOS was illegal when I installed my nos...so I installed my switch in plain view. You may want to locate the switch in a slightly less obvious location. To install the switch on the dash all you need to do is pull off one of the blank tabs and hot glue the switch onto the tab.
Step 7: Wiring
There are 3 wires on the Zex NMU: red, white and black. The black wire is the ground so simply attach it to any part of the engine or chassis. The white wire connects to the throttle sensor. On my car it connects to the black/white wire right behind the throttle unit itself. Finally the red wire connects to the switch.
To wire the switch attach one wire to one prong of the switch (it doesn't matter which one). The other end needs to go to a constant 12v source, such as the battery.
Step 8:Installing the Nitrous Pin Nozzle
To install the nitrous nozzle you need a 7/16" hole in your intake. You want this about 6-18" from the throttle body. Take off your intake tube and drill a 7/16" hole, screw on the bulkhead fitting (mounting bracket). Make sure the intake is clean of loose metal form the drilling and replace the intake. The nozzle should fit perfectly into the fitting. It's a good idea to use LocTite, Yellow Formula 55 Thread Seal, TFE Paste with Teflon, or some form of thread sealant for the connections. People have had lines disconnect on them.
Step 9: Programming
When programming, disconnect the nitrous bottle or use an empty bottle.
- Turn your key to the "on" position without starting the car.
- Flip the switch to the "on" position. The light on the purple box (NMU) it should be bright red (if its not...reset it hitting the black button).
- From your engine bay...rev the car at full throttle for 10 seconds when that is done it should blink red, green, red, green over and over again.
- Turn the key and switch to the "off" position
- Turn switch to the "on" position. You should get a green light now
- Try to floor the pedal you should here a big click in side the NMU
...and your done =) fully installed.
Please read the instructions on to determine the boost you would like to give your car 55 65 or 75HP. I would say start with the lowest settings first and work your way up .
As for timing..rule of thumb is retard the timing 2 degrees for every 100 shot or 1 degree every 50 shot. ZEX includes a chart for this. Please observe the chart to and make the appropriate timing adjustment..
Finally double check your work...make sure you have the "cold" spark plugs installed, and have a full tank of 92 octane or higher gas.
Go have fun!!
Conclusion:
Overall rating 9
Installation: 8
Speed Enhancer: 9
Worth the price: 3
I recommend nos. It's a lot of money to invest, but its better then saving up for a turbo, intercooler and all that other complicated stuff. Nitrous provides enough speed when you really want to go... otherwise our 5SFE engines can do the rest on city street driving.
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