gsr induction kit for citroen/peugeot 1.6 hdi

GSR INDUCTION KIT FOR CITROEN/PEUGEOT 1.6 HDI

INSTALLATION MANUAL

Thank you for buying one of our famous GSR induction kits. We appreciate and value each and every customer. Therefore we try to make our kits not only best performing kits on the market, but the best looking ones as well. However due to the fact that it is a fully handmade product, there might be some imperfections or cosmetic differences in between each kit. These might be: small dust particles trapped during the silicone shaping process; small scratch prints; colour shade differences; shape and thickness differences; and in some rare cases burnt marks on some hose areas (usually brown colour). These are only cosmetic and do not affect the performance of our product in any way.

Please note, that all kits are made about 1-2 cm (0.4-0.8 inch) longer that they should be. This is done because there are cars that had been involved in an accident and repaired incorrectly. Please make sure your kit is the correct length by test fitting it before final assembly. In case you need to trim its edge – use a sharp thin cutting knife and a clamp or Jubilee clip as a guide.

Finally, the filter provided is lubricated and ready to use. Additional lubrication is not required.

INSTALLATION

1. Remove the original air filter assembly:

1.1. Unscrew the 3 screws holding the top cover:

1.2. Once all 3 screws are undone, remove the top lid by tilting it up and lifting it away.

1.3. Remove the original panel air filter element:

1.4. Next unplug the air mass flow meter’s (MAF) connector:

1.5. Then, the lower intake pipe has to be unbolted from the turbo by using a 10mm spanner:

1.6. Once the bolt is removed, remove the build-in heater element by pressing the tabs.

After that, remove the plastic intake pipe by pulling in away at both ends:

1.7. Now both metal pin studs that hold the engine cover in place, have to be removed:

1.8. Once they’re undone, remove the complete air box assembly by gently lifting it out of the engine bay.

2. Remove the cold air feed box from behind the passenger headlight by prising the middle part upwards and pulling out the plastic rivet. Then slide the slider lock on top of cold air feed towards back of car. The air feed duct can now be removed along with its piping:

3. Now the mass air flow meter (MAF) has to be removed from its original piping by undoing the screws:

And removing it’s O-ring:

4. Next, using the Mass Air Flow Meter (MAF) as a connector, assemble the GSR induction kit as shown below:

5. Install jubilee clips (50-70mm) on both Mass Air Flow Meter’s sides to secure both GSR hoses on to it. Tighten the clips so that both hoses would hold firmly in place.

6. Next, install the bracket to support the induction kit at the back of engine. Remove the small M6 bolt next the fuel injector and replace it with a supplied longer replacement:

7. Fit the provided bracket on to this new bolt and tighten in place with supplied nut:

8. Place the complete induction kit into it’s place. Tighten it onto the turbo by using the supplied jubilee clip (50-70mm). Connect the heating element as required, depending on your car’s model:

8.1. For the 90bhp models, insert the metal part of the sensor into the small opening in the

GSR pipe and by using the supplied jubilee clip (16-25mm) slightly tighten it:

8.2. For the 110/112 bhp models that don’t have the metal sensor insert (as per below picture), use a provided black plastic adapter (16-22mm) to connect the sensor.

9. Insert the grey PVC air filter adapter into the GSR pipe and by using the provided heavy duty clamp (80-85mm) tighten it firmly.

10. Attach the loose end of bracket to the heavy duty clamp’s tightening bolt. Use a washer at both ends. Then tighten everything with a provided locknut (M8).

11. Next attach the cone air filter element to the grey PVC pipe and tighten it’s jubilee clip firmly.

12. Reinstall the metal studs to hold the engine cover in it’s place.

13. Reinstall the engine cover: