GReddy Turbo Kit Installation manual

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GReddy Turbo Kit Installation manual | Manualzz

GReddy Turbo Kit

Honda Civic Si EP3 (K20A) T517Z 8cm

2

Honda Civic Si EP3 (K20A) T517Z 8cm

2

Installation Manual

Please read the entire manual before installing this kit.

Application:

Make Model Chassis Year

Honda Civic EP3 EP3 02~03

GReddy Front mount intercooler kit is recommended with this kit.

(Please check with your GReddy Authorized dealer for availability)

• Premium grade gasoline (92 octane or higher) is required with this Kit.

• Make sure that the vehicle is not equipped with any ECU upgrade chips. is recommended with this kit.

Important

• This installation should only be performed by a trained specialist who is very familiar with the automobile’s mechanical, electrical and fuel management system.

• If installed by an untrained person, it may cause damage to the kit as well as the vehicle.

• GReddy Performance Products Inc. is not responsible for any damage to the vehicle’s electrical system caused by improper installation.

1. Parts List

1. Turbocharger T517Z 8cm

2

P565

2. Turbo Exhaust Manifold (Cast Iron)

3, Down Pipe Adapter (Cast Iron-Steel 60

∅)

4. Suction Pipe

5. TZ suction flange

(Aluminum 60Ø)

(Aluminum 60Ø)

6. Compression Pipe C-1 (Aluminum 50Ø)

7. “ C-2 (Aluminum 60Ø)

8. “

9. Restrictor

C-3 (Aluminum elbow No. 76 60Ø)

(Aluminum 43

10. Airinx AY-MB (Blue filter)

∅)

12. Fuel Injector 440cc (w/spacerx2, stud bolt x2 o-ringx8)

13. “ Connector Harness

14. e-Manage

15. I/J Harness (18P)

19.

16. Sensor Adapter Type-AII US

17. Oil Pressure Hose SUS 600mm

18. “ Banjo Fitting male & female (small)

“ Copper Washer 10

∅ (t=1.0mm)

20. “ Three Way Fitting

21. “ Union Fitting 1/8PT – 1/8 PT

22. “ Union Fitting 1/8PT – 1/8PF 90

23. Oil Return Flange tube

°

16

∅ (Turbo side)

24. “ Banjo Fitting male & female 16

∅ (Engine side)

25. “ Banjo Spacer t=16

26. “ Banjo Copper washer 15.5

∅ (t=1.0mm)

4

4

1

1

1

1

1set

2

1

1

1

1

1Set

1

3

1

1

1

1

1

1

1

1

1

1

1. Parts List

27. Vacuum Hose (Blue) 5

∅ x 200mm (for Actuator)

28. Rubber Hose

29. Rubber Hose

30. Rubber Hose

31. Silicone Hose

8Ø X 500mm (for Idle controller)

16Ø X 400mm (for Oil return)

19Ø X 190mm (for Blow by)

60Ø x70mm

32. Reducer Hose 50Ø – 60Ø

33. Reducer Hose 60Ø – 70Ø

34. Hose band

35. Hose band

8Ø Tridon #4

16Ø Tridon #10

36. Hose band

37. Hose band

38. Hose band

39. Hose band

40. Gasket Turbo in

41. Gasket Turbo in

42. Gasket Turbine in

43. Gasket Turbine out

19Ø Tridon #12

50Ø Tridon #32

60Ø Tridon #36

70Ø Tridon #44

44. Gasket Down Pipe

45. Gasket Oil Return Flange Tube Small

46. Heat Shield Turbine

47. Heat Shield Down pipe

1

1

1

1

48. Thermo-cloth 100mm X 1000mm sheet

Zip 10

50. Zip ties 200mm

51. Three-way Vacuum Tee 10

∅-6∅-10∅

4

5

1

1

1

52. Suction pipe bracket

53. Oil return hose bracket

54. Airinx hose fitting 8

∅-M18

55. Intake Air Temperature Grommet

1

1

1

2

1

7

1

2

1

1

1

1

1

1

2

1

1

2

2

1. Parts List

56. M6 X 10 P=1.0

57. M6 X 15 P=1.0

58. M6 X 15 P=1.0

59. M6 X 15 P=1.0

B S/W F/W -

(Down pipe heat shield)

2

B S/W F/W -

(Suction pipe & compression pipe bracket)

2

B S/W F/W N

(Suction pipe bracket)

B S/W - -

(Oil Return Bracket)

1

2

60. M8 X 15 P=1.25 B S/W F/W -

(Turbine heat shield)

61. M8 X 30 P=1.25 B S/W F/W N

(Compressor inlet)

2

2

62. M8 X 20 P=1.25 B S/W F/W -

(Compressor outlet)

2

63. M8 X 30 P=1.25 B S/W - N

(Exhaust manifold – Turbo in flange)

7

64. M8 X 75 P=1.25 B S/W - -

(Turbine out)

65. M8 P=1.25

66. M10 X 45 P=1.25

- - - N

(Down pipe)

B S/W F/W N

(Ex. Manifold)

2

2

3

1. Parts List

1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

16 17 18 19 20

21 22 23 24 25

1. Parts List

40 41 42 43 44

51 52 53 54 55

56~66

2. Removal of Stock Parts

When removing the stock parts, make sure you read over the factory repair manual for proper procedures.

2-1 Disconnect the negative terminal of the battery.

2-2 Release the fuel pressure in the fuel system by loosening the fuel pulsation damper on top of the fuel rail. (see factory repair manual for detail procedure).

2-3 Drain the engine oil.

2-4 Remove the front strut bar and it’s brackets.

2-5 Remove the engine cover.

2-6 Remove the Air cleaner assembly with intake tube, breather hose and Intake temperature sensor.

2-7 Disconnect the primary and secondary O2 sensor and remover the catalytic converter.

2-8 Remover the VTEC solenoid valve assembly.

2-9 Remove the exhaust system heat shield and manifold.

2-10 Remove the heat shield plate (bottom of the firewall) and the intermediate drive shaft heat shield.

3. Kit Installation

3-1 Factory heat shield modification

(1) Heat shield plate modification

Trim the shaded area on the heat shield plate that was removed as shown.

(2) VTEC Solenoid Valve Assembly heat shield Modification.

Trim the shaded area on the heat shield that was removed as shown.

3-2 Thermo Cloth Installation

(1) Disconnect the Crank sensor and Oil

Pressure Sensor connector and wrap

the thermo cloth to the harness as shown.

(2) Wrap the thermo cloth to the power

steering line by the fire wall.

(3) Wrap the thermo cloth to the engine harness and the heater hoses by the fire wall.

Power Steering Hose

Engine Harness

3-3 Oil Pressure Line Installation

(1) Remove the Oil Pressure switch and install the union fitting and 3-way fitting on to the block.

* Use Teflon tape on the thread.

* Point the 3-way fitting outlet where the oil pressure switch is going to be installed to 2 o’clock.

(Parts used #21,22,23)

(2) Install the oil pressure switch to the 3- way fitting and reinstall the VTEC solenoid assembly with the modified heat shield.

* Make sure that the heat shield does not hit the oil pressure switch.

(3) Reconnect the oil pressure switch

harness and the crank sensor.

(4) Connect the oil pressure line to the installed union fitting.

(Parts used #18)

3-4 Exhaust Manifold Installation

(1) Install three stud bolt on to the cylinder

head as shown.

(Parts used #67)

Oil Pressure Switch

Install the 3-way

fitting to the block

first.

PT PT

PT

3-way fitting

Check

PF

(2) Install the exhaust manifold using the factory gasket.

* Use a new exhaust manifold gasket.

* Use factory nuts on the top side of the flange.

(Parts used #2, 67)

Installation

(1) Wrap the thermo cloth the actuator as shown.

* The heat off the manifold can damage the actuator with out the thermo cloth.

(2) Install stud bolts on to the exhaust manifold, then mount the turbocharger to the manifold using provided gasket.

(Parts used #1,43,64)

3-6 Oil Pressure Line Connection

(1) Connect the oil pressure line that was installed in step 3-4 to the turbo using banjo fitting and copper washers. As shown.

* Point the banjo fitting towards the firewall.

(Parts used #19,20)

Return

(1) Install the provided oil return pipe to the turbocharger using the provided gasket and hardware as shown.

(Parts used #24, 46, 60)

(2) Remove the oil drain bolt and install the provided oil return banjo bolt using spacer and copper washers as shown.

(Parts used #25, 26, 27)

(3) Wrap the provided 16

∅hose with thermo cloth. Then Install the hose to connect the oil return pipe from the turbo to the oil return banjo fitting on the oil pan.

* Route the hose behind the intermediate drive shaft as shown.

(Parts used #30, 36, 49)

(4) Install the Oil return hose bracket to the block and secure the hose to the bracket using provided zip ties as shown.

(Parts used #50, 54)

(5) Modify the drive shaft heat shield by cutting the shaded area in the picture to prevent the hose from rubbing up on the shield.

• Reinstall the heat shield and make sure there are enough clearance between the hose and the shield and the drive shaft.

* Oil return hose to heat shield: 10mm

* Oil return hose to drive shaft: 20mm

Important!

With out this proper clearance, there is a possibility of the return hose to fail and can cause fire and damage the engine.

3-8 Compression Pipe Installation

(1) Install Compression pipe C-1 to the out let of the turbo using provided gasket and hardware.

(Parts used #6, 42, 63)

(2) Loosen the hose clamp on the Radiator hose and rotate the hose so it comes up slightly.

(3) Install compression pipe C-2, and C-3 between C-1 and throttle body. Using provided hose and clamps.

* Secure the bracket on C-2 to the factory air cleaner box mounting point.

* Make sure that the compression pipes does not interfere with shifter linkage movement. Also, check the clearance between the radiator hose and compression pipes.

(Parts used #7, 8,32, 33,34, 38,39,

40,58)

(4) Cut the master power vacuum hose by the intake manifold and install the 3-way fitting. Connect the 5

∅ side to the actuator with the provided 5

∅ hose.

* Secure all the vacuum hose with zip ties to prevent the hose from coming off the fitting.

(Parts used #28,50,52)

3-9 Intake Pipe Installation

(1) Remove the top bolt on the Airinx air filter and remove the outer frame.

(Parts used #10)

(2) Install the provided hose adapter to the inner frame of the Airinx.

(Parts used #11)

(3) Reinstall the outer frame and secure it with the top bolt.

(4) Remove the rubber plug on the Airinx and install the union fitting as shown.

(Parts used #55)

(5) Install the provided intake air temperature sensor grommet to the suction pipe S-1 as shown.

(Parts used #4, 56)

Grommet

IAT Sensor

Main Body

Tab

Hose Adapter

(6) Install stud bolts on to the inlet of the turbo, and install suction adapter using provided gasket and restrictor.

(Parts used #5,9,41,62)

Important!

The restrictor must be used with this turbo kit. With out it, the system can exceed the set boost level and can damage the engine.

(7) Install the Airinx air filter and S-1.

Secure the suction pipe bracket to the factory air cleaner box mounting point as shown.

* Make sure that the Airinx and the piping does rub up on to the battery.

(Parts used #32,39,53,58,59)

(8) Connect the blow by tube from the valve cover to the S-1 with the provided 18

∅ hose and clamps. Also connect the Air assist control valve to Airinx using provided 8

∅ hose and clamps.

(Parts used #29,31,35,37)

3-10 Down Pipe Installation

(1) Install three stud bolt on the turbine housing as shown.

(Parts used #64)

S-1

Mounting point

Blow by hose

To air assist

Control valve

(2) Check the fitment of the downpipe heat shield and install gasket on the catalytic converter end of the downpipe.

* The heat shield will be reinstalled later once the downpipe is installed.

(Parts used #45, 48)

(3) Install the downpipe to the turbo using provided gasket and hardware.

* Make sure that there are enough clearance between the downpipe and the oil pressure line.

(Parts used #3,44,64,65)

(4) Reinstall the catalytic converter and reconnect the o2 sensor connectors.

* Reuse factory hardware to bolt the cat back on but the bolt with spring will require the provided nuts.

(Parts used #66)

Heat Shield Installation

(1) Install the turbine housing heat shield on to the downpipe using the provided M8 x

15mm bolts.

* Make sure that there are enough clearance between the oil pressure line and the power steering line.

(Parts used #47,61)

(2) Install the down pipe heat shield on to the downpipe using the provided M6 x

10mm bolts.

(Parts used #48,57)

3-12 Fuel Injectors Installation

(1) Disconnect the fuel injector connectors and ground wire on the fuel delivery tube and remove the fuel delivery tube.

* When removing the rail, use a rag to absorb the fuel that leaks out from the rail and hose.

(2) Remove the injector clips off the rail, and remove the injectors.

(3) Install the new injectors on to the rail.

* Lube the o-rings on the injectors and make sure not to damage the o-ring when installing them in to the rail.

(Parts used # 12)

(4) Replace the stud bolts and spacers that holds the fuel rail down with the provided stud bolts and spacers.

(5) Install the fuel rail assembly to the intake manifold.

(6) Remove the injector wire cover and cut the factory injector connectors. Cut the provided injector harness to the same length of the cut factory connectors.

(Parts used # 13)

(7) Solder the connectors to the harness and connect them to the injectors.

Reconnect the ground wire back to the manifold.

How to Solder

1.Strip the wire ends.

3.soldder the wires

Make sure the wires are properly

Soldered.

2. Twist the two ends together.

4. Tape up the exposed wires.

Installation

(1) Remove the cover under the glove box to access the ECU and ECU harness.

(2) Install the Grey wire to the e-Manage I/J Harness (18Pin) connector as shown below.

(3) Connect the I/J Harness to the factory ECU harness as shown in the diagram on next page.

(Parts used #15, 16, 17)

Important

• This installation should only be performed by a trained specialist who is very familiar with the automobile’s electrical and fuel management system.

• GReddy Performance Products Inc. is not responsible for any damage to the vehicle’s electrical system caused by improper installation.

• It is recommended to solder all wires and use electrical tape or shrink warp to insulate the wire connections.

Connector A

(31P)

Connector B

(24P)

1 2 3 4 5 6 7

1 1 2

2 3 2 4

15 16

25 2 6

9

1 2 3 4 5

2 2

2 8 0

8 10

17 8

6 7

Connector C

(22P)

Connector D

(17P)

Connector E

(31P)

2

3

4

10

22 2 2 4

13

6 7 8 9

29 31

18-12 (B)

18-18 (B/R)

A5

B2

B3

B4

B5

18-8 (PL/R)

18-7 (Y/R)

18-6 (O/R)

18-5 (B/R)

スフ

18-10 (G)

18-3 (W)

18-9 (PL)

SLC (BR)

SLC (LB)

18-11 (BR)

18-4 (GR)

18-13 (R)

SLC (R)

SLC (PL)

SLC (B)

A10 A3 A15

A18

A19

E26

Color Code: W - White, G - Green, B - Black, BL - Blue, BR - Brown, R - Red, GR - Grey, PL - Purple, Y - Yellow, O - Orange,

LB - Light Blue

I/J Harness (18Pin)

Pin

#

Wire Color Description ECU Pin # Color Code

* Looking at harness side.

3

4

White

Grey

7

8

5

6

Blue/Red

Orange/Red

Yello w/Red

Purpl e/Red

9

Purpl e

10

Green

11

Brown

12

Black

13

Red

18

Black/Red

MAP IN A19

(h arness)

Green/Red

MAP

Throttle A15

Red/Black

TPS

INJ 1

INJ 2

INJ 3

INJ 4

B5

B4

B3

B2

Brown

Red

Blue

Yellow

INJ 1

INJ 2

INJ 3

INJ 4

PLS SLC

Purple

MAP

OUT

A19

(ECU side)

Green/Red

RPM E26

GND A5

Blue

Black

MAP

NEP

PG1

+B A3

Yellow/Black

IGP1

INJ GND A5

Black

PG1

Sens or Adapte

Wire Color r Factory ECU

Description ECU Pin # Color Code

Blue (Male) SPD IN A18

(Harness)

White/Green

VSS

Brown

(ECU side)

White/Green

VSS

Purple (Male) PLS e-Manage 18-9 Purple

IGP1

Black

GND A10

Green/Yellow

SG2

Important !

Make sure the all the wire connections are correct. If they are connected incorrectly, it can damage the e-Manage and/or the ECU.

(5) Reinstall the ECU back in its place, and secure the e-Manage next to the ECU.

* Avoid mounting the e-Manage unit in the area that would be exposed to direct sun light, mo isture, or near heater outlet

3-15 Starting the Engine

(1) Refill the engine oil to factory spec.

(2) Check all the hoses and wires ne then recon nect the n egative sid e of the battery.

(3) Tun the ignition to “ON” positio 3 get fuel pressure. Then, check the injectors and the fuel rail for any fuel leaks.

* Repair any fuel leaks before starting the engine. Starting the engine with a

fuel leak can cause fire in the engin e compartme nt and can be very dangerous.

(4) Remove the ECM fuse and cra nk the engin e to get oil pre ssure to the turbo.

(Until the oil light on the dash turns off) Check for any oil leaks, then reinstall the fuse and start the engine.

(5) While idling, check for any oil, coolant, or air leeks.

(6) After inspection, reinstall the under cover and other stock parts that was remove d. setting. This turbo kit is preset to boost between 0.6kg/cm

2 e turbo-actuator to 0.5kg/cm

2

.

It is very important that you monitor the boost pressure, and make sure not to over boost. Over boosting can cause engine damage.

This completes the Turbo Kit installation.

Important!

It is very important that you monitor the boost pressure, and make sure

not to over boost. Over boosting can cause engine damage.

GReddy Performance Products, Inc. is not responsible for any engine

damage caused by over boosting (increased boost), modification to the kit, and/or misuse of the product. NO WARRANTY is offered.

Due to lack of control over proper installation and use of this product,

NO WARRANTY is offered for t his kit.

e-manage Information

Important!

The e-manage included in this kit is preprogrammed for the this turbo kit.

Do not attempt to adjust any of the setting in the e-manage.

If any adjustment made can cause damage to the e-manage, engine and

the factory ECU.

Important!

As of 5/25/03 this kit is not a street legal kit. Please ignore the label on the

e-manage.



ACTIVE L.E.D.

• When the ignition is turned on

, it will illumin ate and flash GREEN.

• When it reaches to the A.A.V. setting RPM range, it will illuminate and flash

ORANGE.

When an error is detected it will flash RED.



INTE

RACTION L.E.D.

This will illuminate when there is a connection with PC.

Ch ecking Error Codes

When the unit is powered up and if there are any errors, the ACTIVE L.E.D will turn “RED” from “GREEN”, and begin to flash.

If this happens shut the engine off and turn the ignition switch to “ON” position to go to Self Troubleshooting Mode. While in the Self

Troubleshooting Mode, the L.E.D. will show the error code. Turn off the ignition. Check the error code in the chart below and fix the problem. The error code will show until the error is corrected.

Checking Error Code Chart

CODE

32

33

34

40

41

42

43

44

49

51

52

53

54

57

23

24

31

11

15

20

21

22

Error

Airflow Signal 1 input error

Airflow voltage output error

No Injector pulse from all

Error description

Incorrect wiring or disconnected Airflow Signal 1

Incorrect Airflow signal output wiring.

No Injec tor 1 pulse

No Injector 2 pulse

No Injector 3 puls e

No Injector 4 pulse

Not receiving an injector signal for

Additional Injection Map

Not receiving injector signal I/J CH-1 for Additional Injection Map

Not receiving injector signal I/J CH-2 for Additional Injection Map

Not receiving injector signal I/J CH-3 for Additional Injection Map

Not receiving injector signal I/J CH-4 for Additional Injection Map

Incorrect Injector 1 pulse

Incorrect Injector 2 pulse

Incorrect Injector 3 pulse

Incorrect Injector 4 pulse

Improper order of

Ignition input signal

No Ignition Signal 1 pulse

No Ignition Signal 2 pulse

No Ignition Signal 3 pulse

No Ignition Signal 4 pulse

Incorrect I/J CH-1 wire to e-Manage unit

Incorrect I/J CH-2 wire to e-Manage unit

Incorrect I/J CH-3 wire to e-Manage unit

Incorrect I/J CH-4 wire to e-Manage unit

Incorrect wiring order of the ignition signal wires.

Not receiving the ignition signal to IG CH-1

Not receiving the ignition signal to IG CH-2

Not receiving the ignition signal to IG CH-3

Not receiving the ignition signal to IG CH-4

No Ignition pulse

Not receiving the ignition signal to an y of the channels

Incorrect Ignition 1 pulse

Incorrect Ignition 2 pulse

Incorrect Ignition 3 pulse

Incorrect Ignition 4 pulse

JP2 + 12V error

Incorrect IG CH-1 wire to e-Manage unit

Incorrect IG CH-2 wire to e-Manage unit

Incorrect IG CH-3 wire to e-Manage unit

Incorrect IG CH-4 wire to e-Manage unit

Incorrect Jumper setting (JP2)

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