Edelbrock Victor Open Track Turbocharging System for 1996-2000 Honda Civic DOHC Vtec B16A2

Catalog #1509

INSTALLATION INSTRUCTIONS

PLEASE study these instructions carefully before beginning this installation. Most installations can be accomplished with common tools and procedures. However, you should be familiar with and comfortable working on your vehicle. If you do not feel comfortable performing this installation, it is recommended to have the installation completed by a qualified mechanic. If you have any questions, please call our Technical

Hotline at: 1-800-416-8628, 7:00 am - 5:00 pm, Pacific Standard Time, Monday through Friday or e-mail us at [email protected].

IMPORTANT NOTE: Proper installation is the responsibility of the installer.

Improper installation may result in poor performance and engine or vehicle damage.

PLEASE complete and mail your warranty card. Be sure to write the model number of this product in the "Part #____" space. THANK YOU.

Description: The Edelbrock Performer X Open Track Turbocharging System is intended for high boost pressure, off-highway applications in conjunction with user provided and tuned engine management.

The Part #1509 kit with the Garrett GT-28RS ball-bearing turbocharger can provide boost pressures of up to 28 PSIG (Pressure reading at boost gauge) on a modified B16A engine. The kit comes with all of components needed for the mechanical installation of the turbocharger system including a pre-assembled turbocharger-exhaust manifold-outlet elbow assembly with hoses installed; air to air intercooler; Tial blow-off valve; Victor X intake manifold; and all of the required fasteners, fittings, hoses, gaskets, and piping. No engine management is provided. An engine fitted with this kit using the stock un-modified engine management will not function properly and damage to the engine will occur.

Before Beginning: Someone who has a basic knowledge of automobile repair and modification and is familiar with and comfortable with working on their vehicle can accomplish the mechanical installation of this kit using common tools and procedures. However, successful operation of the engine with this turbocharger kit requires a working knowledge of the set-up and tuning of an engine management system. The required modifications to your engine and fuel delivery system are dependent on the boost pressure and power output you desire to run. For boost levels above 8 PSIG, aftermarket pistons, connecting rods, and valves are required to assure engine durability. High boost pressures and power output will also require an aftermarket high-volume fuel pump such as Edelbrock #17938 (190 liter/hr) or #17936 (255 liter/hr). Customer tunable engine management packages are available from multiple manufacturers such as: AEM, Hondata, Motec, F.A.S.T., Accel DFI, Apex, etc., and will be available from Edelbrock MotoTron in the near future.

WARNING: WHEN WORKING AROUND GASOLINE OR OIL, WORK IN A WELL VENTILATED AREA,

AND KEEP ALL OPEN FLAMES, SPARKS AND OTHER SOURCES OF IGNITION AWAY FROM THE WORK AREA.

FALURE TO DO SO CAN RESULT IN A FIRE OR EXPLOSION.

WARNING: WHEN RAISING A VEHICLE, MAKE SURE THE VEHICLE IS ON LEVEL GROUND AND SUPPORTED

SECURELY BY JACKSTANDS. NEVER WORK UNDER A VEHICLE THAT IS SUPPORTED BY A JACK ONLY!

Oil Supply Sandwich Adapter: The Oil Supply Sandwich Adapter included with this kit is designed to be installed on U.S. Domestic Market

(USDM) B16 engines. These engines feature an oil filter that mounts directly to the engine block. Some Japanese Domestic Market (JDM) B16 engines feature an oil cooler mounted between the oil filter and the engine block. If your engine has an oil cooler, you must use a different Oil

Supply Sandwich Adapter. It is Edelbrock part #22-1505. If you require the #22-1505 adapter, please call the Edelbrock Tech-Line at

1-800-416-8628 for assistance and ordering instructions.

After Installation, Before Starting the Vehicle:

We recommend the use of a synthetic 10W30 motor oil. Mobil1 was used in our testing. Before starting the vehicle, the oil drain hose should be disconnected from the oil pan and the engine should be turned over with the starter until oil is running out of the oil drain hose (Note: This may take one or two minutes of intermittent cranking for the oil system to be primed and for oil to reach the drain hose. To keep from damaging the starter, crank the engine in 20-30 second intervals, until oil reaches the drain hose). This will ensure that the turbo is lubricated before the initial start-up. This should be done with the spark plugs removed and the wiring disconnected from the Auxiliary Engine Management Computer.

Disconnecting the wiring from the auxiliary computer will disable the ignition. Along with synthetic oil, we strongly recommend using a colder spark plug in the engine.

Catalog #1509

Rev. 11/05 - RS/mc Page 1 of 10

©2005 Edelbrock Corporation

Brochure #63-0320

Kit Contents

Qty.

Description

Individual Parts

❑ 1

Turbocharger / Exhaust Manifold / Exhaust Elbow / Oil-Water Line Assembly

❑ 1

Victor X Intake Manifold

❑ 1

Oil Supply Sandwich Adapter Assembly (Note: A ½” allen wrench is required for installation of the adapter)

❑ 1

Intercooler

❑ 1

Compressor Inlet Pipe, Cast Aluminum

❑ 1

Compressor Outlet Pipe, Cast Aluminum

❑ 1

Intercooler Inlet Pipe

❑ 1

Intercooler Outlet Pipe

❑ 1

Intake Manifold Inlet Pipe

❑ 1

Coolant Pipe (Lower Radiator Re-Routing)

❑ 1

Exhaust Down Pipe

❑ 1

Air Filter / Attachment Hose / Clamps Assembly

❑ 1

Blow Off Valve Assembly

❑ 1

Gasket, Intake Manifold

Hardware Kit

❑ 1

Throttle Cable Bracket

❑ 1

Support Brace (Compressor Inlet Pipe to Transaxle)

❑ 1

Air Conditioning Line Re-Route Bracket

❑ 1

MAT Sensor Block Off Plate

❑ 7

M8 x 1.25 Stud (Exhaust Manifold To Cylinder Head)

❑ 7

M8 x 1.25 Nut (Exhaust Manifold To Cylinder Head)

❑ 7

M8 Split Washer (Exhaust Manifold To Cylinder Head)

❑ 2

Keihin Screw (MAT Sensor Block Off Plate)

❑ 3

M10 x 1.5 Studs (Exhaust Downpipe to Turbo Outlet Elbow)

❑ 3

M10 x 1.5 Flange Nut (Exhaust Downpipe to Turbo Outlet Elbow)

❑ 4

M8 x 1.25, 25mm Long Bolt (Compressor Outlet Pipe to Intercooler Inlet Pipe)

❑ 2

¼-20 x ½” Hex Head Bolt (Turbo Oil Drain Adapter Fitting, Steel Oil Pan)

❑ 2

Socket Head Cap Screw, M8 x 1.25, 20mm Long (Turbo Oil Drain Hose to Turbo Oil Drain Flange)

❑ 2

M8 Spring Washer (Turbo Oil Drain Hose Mounting)

❑ 4

M8 Lock Washer (Compressor Outlet Pipe to Intercooler Inlet Pipe)

❑ 1

M8 x 1.25, 12-point Stainless Steel Nut (Exhaust Manifold to Cylinder Head)

❑ 1

M6 x 1.0, 12mm Long, Serrated Flange Hex Head Bolt (Compressor Inlet to Transaxle Brace)

Hose Kit

❑ 1

Turbo Oil Drain Hose Assembly

❑ 1

2” Silicone Hose Coupling (Compressor to Compressor Outlet Pipe)

❑ 1

2 ½” - 3” Silicone Hose Coupling (Compressor Inlet Pipe to Compressor)

❑ 1

2 ½ - 2 5/8” Silicone Hose Coupling (Intake Manifold Inlet Pipe to Throttle Body)

❑ 1

2 ¼” Silicone Hose Coupling (Intercooler Outlet Pipe to Intake Manifold Inlet Pipe)

❑ 2

2 ¼” - 2 ½” Silicone Hose Couplings (Intercooler Inlet/Outlet Pipes to Intercooler)

❑ 2

1 ¼ - 1 3/8” Silicone Hose Coupling (Coolant Re-Route Pipe)

❑ 3ft. 3/8” Cam Cover Breather Hose

❑ 7ft ¼” Red Silicone Hose, Wastegate & Blow-Off Valve

❑ 5ft. 5/16” Purge / PCV Hose

❑ 3ft ¼” Fuel Hose, Fuel Pressure Regulator Return

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©2005 Edelbrock Corporation

Brochure #63-0320

Qty.

Description

Hose Clamp Kit

❑ 1

Hose Clamp, 2 9/16” - 3 ½”

❑ 4

Hose Clamps, 2 1/16” - 3”

❑ 5

Hose Clamps, 1 13/16” - 2 ¾”

❑ 2

Hose Clamps, 1 9/16” - 2 ½”

❑ 4

Hose Clamps, 1 5/16” - 2 ¼”

❑ 2

Hose Clamps, 5/16” I.D.

Kit Contents (Continued)

Gasket Kit

❑ 1

Throttle Body to Intake Manifold Gasket

❑ 1

Turbo Outlet Elbow to Exhaust Down Pipe Gasket

❑ 1

MAT Sensor Block Off Plate Gasket

❑ 1

O

2

Sensor Bung Gasket (Second O

2

Sensor Bung)

❑ 1

Oil Drain Adapter Fitting Gasket

❑ 2

¼” Stato Seal Washer (Turbo Oil Drain Adapter)

❑ 4

12.3mm I.D. / 16.2mm O.D. / 1.5mm Thick, Aluminum Crush Washer (Fuel Banjo Fittings)

❑ 1

Compressor Outlet Pipe to Intercooler Inlet Pipe O-Ring

❑ 1

Turbocharger Oil Drain Flange O-Ring

❑ 1

Inlet Air Temperature Sensor Grommet

❑ 2

Lower Intercooler Mount Grommets

Fitting Kit

❑ 1

Turbo Oil Drain Adapter Fitting

❑ 1

10mm Barb to ¼”NPT Adapter Fitting

❑ 1

17mm Barb to 3/8”NPT Adapter Fitting

❑ 2

3/16” Barb to 1/8”NPT Adapter Fitting

❑ 1

¼”NPT to ¼”NPT Female Street Elbow

❑ 2

1/8”NPT Pipe Plugs

❑ 2

¼” Barb to 1/8”NPT Adapter Fitting

❑ 2

8mm Barb to 1/8”NPT Adapter Fitting

❑ 1

9mm Barb to ¼”NPT Adapter Fitting

❑ 2

8mm Barb to ¼”NPT Adapter Fitting

❑ 1

3/8” Barb to ¼”NPT Male Adapter Fitting

❑ 1

Plug, O

2

Sensor Bung (Second O

2

Sensor Bung)

Catalog #1509

Rev. 11/05 - RS/mc Page 3 of 10

©2005 Edelbrock Corporation

Brochure #63-0320

INSTALLATION INSTRUCTIONS

Initial Parts Removal (See factory service manual for procedures where noted)

1.

Begin by disconnecting the battery and draining the engine oil and coolant from the engine. Remove the battery hold down using a 12mm wrench and remove the battery. Disconnect any wiring attached to the battery tray, and remove the tray. Set aside. (This will provide access to the firewall for wiring later on.)

2.

Remove the front lower splash shield and front bumper cover, as per the factory service manual procedure. The front inner fender liners do not need to be removed. You can allow the front inner fender liners to hang free, remaining attached to the rear of the front wheel well openings. Remove the stock intake tube and upper/lower air box following the service manual instructions. Save the air box mounting bolts and grommets. These will be used to mount the compressor piping to the chassis.

3.

Remove the lower radiator hose.

4.

Remove the bolt holding the horn onto the center radiator support and move the horn to the side.

5.

Remove the driver’s side tie down bracket (tow hook) located behind the lower radiator support.

6.

Remove the Oxygen Sensor from the factory lower exhaust header (B-Pipe), and move to the side. Disconnect the factory B-Pipe from the

Catalytic Converter, inspect the donut gasket for wear. If it is in good shape, it may be re-used. Disconnect the B-Pipe from the upper exhaust header. Remove the lower intake manifold support bracket bolts at this time. Remove the exhaust manifold heat shield and upper exhaust manifold. If exhaust manifold gasket is not damaged, re-use.

7.

Remove the air conditioning (A/C) condenser fan and temporarily tie back its wiring harness with a supplied tie wrap.

8.

Remove the A/C line support bracket from under the radiator. Save the 6mm nut and carefully remove the black plastic hose clip from the bracket. Re-install the hose clip on the supplied A/C line bracket. Use the supplied 6mm x 1.0 serrated flange hex bolt and the factory 6mm nut to install the Edelbrock A/C line support bracket.

Oil pan rail

1.125”

1.50”

Use 1/4-20 x

1/2” bolts &

Stato-Seal washers

Fig. 1a

Locate between 3rd

& 4th bolt hole from driver side

Fig. 1b Fig. 1c

Keep clear of baffle

Fig. 1d

Oil Drain Adapter Installation (Note: Removal of the oil pan is required to install the turbo oil drain adapter)

1.

Remove the front and rear stiffening brackets connecting the block to the bell housing (See Fig. 1a). Remove the bellhousing cover. Using a 10mm socket, remove the oil pan nuts and bolts and remove the oil pan. If necessary, gently tap on the oil pan with a rubber or plastic mallet to loosen the seal between the oil pan and the engine block. Carefully remove and inspect the oil pan gasket. If it is not cracked or torn, it may be re-used.

2.

The Oil Drain Adapter requires the oil pan to be drilled. Mark the area to be drilled. Center the drain hole below the third bolt hole from the driver’s side on the front of the oil pan (See Fig. 1b), 1.5” from the Oil

Pan Rail (See Fig. 1c). Using a scratch awl, mark the center of each bolt hole 9/16” away from the center of the center drain hole so the distance between the bolt holes, from center to center, is 1.125” (Fig. 1c). Make sure this location will not interfere with the oil baffle inside the pan. If needed, move the location slightly to avoid any interference with the baffle (Fig. 1d).

5

1

Apply Liquid Gasket

Oil Pump

3

6 4

3.

Using a center punch, indent each drilling location to prevent the drill bit from walking. Pre-drill each hole with a 1/8” bit. Secure the oil pan on a work bench or on a drill press, and drill the outer bolt holes to ¼”. Drill the center drain hole to ½”. Deburr the holes and thoroughly clean the oil pan to remove metal shavings.

2

Fig. 1e

4.

Install the Oil Drain Adapter onto the oil pan using the two ¼-20 x ½” bolts (We recommend using blue Loctite on the threads) and the two

¼” Stato-Seal washers on the inside of the oil pan, using the gasket on the outside of the pan (See Fig. 1d). Torque the bolts to 6-8 ft/lbs.

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©2005 Edelbrock Corporation

Brochure #63-0320

5.

Apply liquid gasket to the oil pump to block, and passenger side cover to block mating surfaces (See Fig. 1e). Re-install the oil pan. Finger tighten nuts 1-6 (See Fig. 1e) to hold the pan in place. Install the remaining bolts finger tight. Tighten all nuts/bolts to 8-9 ft/lbs. Start with nuts 1-6, and tighten the remaining bolts in a clockwise manner, starting in the center and working your way out.

6.

Re-install the bellhousing cover and front and rear stiffening brackets. Torque the bolts to factory service manual specifications.

Turbocharger / Exhaust Manifold Assembly Installation

1.

Remove the upper air conditioner condenser support bracket and air conditioner line bracket. Using a zip-tie or twine, carefully flex the lines and condenser as far forward as possible and temporarily secure.

This will allow more clearance to place the turbocharger/exhaust manifold assembly.

2.

Install the seven supplied 8mm x 1.25 studs into the exhaust manifold bolt holes. Hand tighten only.

Note: Do not reuse the factory exhaust bolts.

3.

The turbocharger/exhaust manifold assembly must be installed from underneath the engine compartment. This will require the vehicle being raised on jack stands or a lift.

(WARNING: MAKE SURE THE VEHICLE IS ON LEVEL GROUND AND SUPPORTED

SECURELY BY JACKSTANDS. NEVER WORK UNDER A VEHICLE THAT IS SUPPORTED

BY A JACK ONLY!)

Dipstick Tube

12-Point Nut

Fig. 2

4.

Being careful not to damage the oil feed and coolant lines, bring the turbo assembly up into position from underneath the vehicle. Set turbo assembly in place using the stock exhaust gasket.

(Note: If the gasket is in good condition, it may be re-used. The gasket should show no signs of leaking, cracks, missing pieces, or burnt areas. If the gasket is not in good condition, it should be replaced. Thoroughly clean flange of any old gasket material). Using the supplied 8mm x 1.25 12-point nut on the center exhaust manifold stud (See Fig. 2), and the six supplied 8mm x 1.25 6-point nuts, attach the turbo assembly to the engine block. You may need to bend the dipstick tube slightly to clear the exhaust manifold

(See Fig. 2). Refer to the Honda Factory Service Manual for torque values and sequence.

5.

Lay out the Coolant Lines and Oil Feed Line in their approximate routing locations. The Oil Feed Line (the line with the 6AN female fitting) should head down below the air conditioning condenser fan, towards the driver’s side, then up along the driver’s side of the condenser and towards the back of the engine, taking care not to route the line in the way of any moving parts (such as: pulleys, timing belts, etc.). The coolant lines should be routed down toward the passenger side, then up and toward the rear of the engine.

Factory Intake Manifold Removal

1.

Relieve fuel pressure first by loosening the banjo bolt connecting the fuel line to the fuel filter. Place a shop towel or rag over the wrench while loosening the banjo to soak up any fuel spray (See Fig. 3). When loosening or tightening the banjo bolt on the fuel filter can, use a

19mm wrench of the hex of the fuel filter can to counteract the torque of loosening or tightening the banjo bolt. This will prevent the fuel filter can and bracket from being improperly loaded during loosening or tightening at the banjo bolt.

2.

Disconnect the fuel injector wiring harness from the bracket on the fuel rail and unplug the harness from the fuel injectors and purge valve (Note the locations of each plug on the harness to prevent improper connection during re-installation). Disconnect the Throttle Position Sensor plug, MAP

Sensor plug, and Idle Air Control Motor plug. Disconnect the purge line from the purge valve.

Disconnect the fuel return line from the steel chassis fuel line. Disconnect the fuel line from the fuel filter. Disconnect the coolant lines from the throttle body and manifold flange. Disconnect the vacuum lines at the rear of the manifold. The intake manifold support bracket does not need to be removed from the intake manifold. It can be removed with the intake as an assembly since the lower bolts were removed previously. Remove the throttle cable. Remove the factory intake manifold nuts. Remove the intake manifold assembly and set aside.

Fig. 3

3.

The intake manifold stud closest to the thermostat housing, on the passenger side, interferes with the intake flange when installing the intake manifold. It is necessary to remove this stud to ease installation of the Victor X manifold. Use two intake manifold nuts, and jam them together to remove the stud

(See Fig. 4). Set this stud aside.

4.

Stuff the open intake ports in the cylinder head with paper towels to prevent any debris from entering the engine. Thoroughly clean the gasket surface removing any remaining sealant or gasket material.

Fig. 4

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Rev. 11/05 - RS/mc Page 5 of 10

©2005 Edelbrock Corporation

Brochure #63-0320

Oil Supply Line Installation

1.

With the intake manifold removed, there will be much more clearance to install the Oil Supply Adapter. Remove the stock oil filter (Replace).

Install the Oil Supply Sandwich Adapter in place of the stock oil filter. Make sure the O-Ring is facing toward the engine block, and the threaded stud with ½” hex opening is facing out. Tighten with a ½” Allen Wrench. Make sure the blue fitting is facing toward the driver’s side, pointing upward slightly, about the 10 o’clock position. Install a new oil filter. Route the oil supply line to the sandwich adapter. Using a light coat of oil on the threads, tighten the female fitting onto the blue fitting on the sandwich adapter.

Victor X Manifold Installation

1.

(Note: Use anti-sieze or teflon paste on the threads of fittings before installing them into the intake manifold). Install the vacuum fittings and supplied block-off plate on the underside of the Victor X intake manifold (See Fig. 5a). Install the water outlet fitting into the mounting flange.

Install the 1/8” NPT plug into the water outlet fitting (See Fig. 5b). (Refer to Fig. 5c for Fitting Descriptions).

#1 #2 #3 #4 #5 #6 #7 #8

Fig. 5a

#9

#10

Fig. 5b

#1

#2

#3

#4

#5

#6

Boost Gauge Adapter Fitting (Boost Gauge Line,

Found in the Boost Gauge Box)

3/16” Barb x 1/8” NPT (Fuel Pressure Regulator

Hose)

1/4” NPT Street Elbow & 10mm Barb x 1/4” NPT

(Power Brake Booster Hose)

3/16” Barb x 1/8” NPT (Cruise Control Vacuum Hose)

Install Supplied Block-Off Plate Here (Not Pictured)

1/4” Barb x 1/8” NPT (Blow-Off Valve Hose)

#7

#8

8mm Barb x 1/4” NPT (PVC Hose)

9mm Barb x 1/4” NPT (Purge Valve Hose)

#9

17mm Barb x 3/8” NPT (Manifold Water Outlet)

#10

1/8” NPT Plug

Fig. 5c

2.

Remove the idle air control motor (IAC) from the factory intake manifold and install onto the Victor X intake manifold. Remove the throttle body (with MAP sensor attached), and two throttle body studs from the factory intake manifold. Using two nuts on the studs, and jamming them, will help get the studs out of the stock intake manifold (See Fig 4). Install the two throttle body studs into the Victor X intake manifold, one on the upper right bolt hole of the throttle body mounting flange and one on the lower left bolt hole. Install the stock throttle body and gasket onto the Victor X manifold. Remove the stock throttle cable bracket bolts, and install the supplied throttle cable bracket onto the Victor

X manifold using the stock bolts. The Victor X manifold is compatible with all stock replacement fuel injectors and fuel rails. Our part #4796

(Honda injectors) or part #4797 (Bosch-style injector) hard anodized fuel rails have a much high flow capacity than the stock fuel rail. In order to use the factory fuel pressure regulator on the Victor X intake manifold, you will need to rotate it 180° so that the outlet is now pointing toward the valve cover.

3.

Using the supplied gasket, install the Victor X manifold / throttle body / assembly onto the engine (See Fig. 6). (Remove the paper towels or rags before installing the intake manifold). After placing the Victor X manifold onto the intake studs and hand tightening the nuts, you will have clearance to install the stud that was removed previously. If desired, this stud may be replaced with a 8mm x 1.25, 25mm long bolt.

You may now tighten all intake nuts. Follow the factory service manual for proper torque values and tightening sequence. Re-connect all factory sensors and vacuum hoses. Re-connect the factory fuel injector wiring harness to the fuel injectors, and re-attach the harness to the fuel rail bracket. Re-connect the stock throttle cable to the new bracket and following the factory service manual, adjust the throttle cable for proper operation.

Fig. 6

Compressor Inlet / Outlet, Intercooler Plumbing, and Intercooler Installation

1.

Press the Manifold Air Temperature sensor grommet into the non-threaded hole in the compressor inlet pipe. Install a 3/8” barb x ¼” NPT fitting into the threaded hole in the pipe. Fit the Compressor Inlet Pipe to the compressor inlet using the supplied silicone coupling and clamps

(See Fig. 7a). Do not fully tighten. Adjust the compressor Inlet pipe for alignment, and using the Compressor Inlet Pipe support brace, connect the support brace to the compressor inlet pipe using the 6mm x 1.0 (12mm long) bolt. Hand tighten. Find the ground wire bracket on the transaxle housing. Remove the bolt that attaches the ground wire to the bracket and attach the support brace and ground wire to the bracket using this bolt

(See Fig. 7b). Tighten all nuts/bolts and hose clamps. Connect Air Filter Assembly to the compressor inlet pipe using the supplied silicone coupling and hose clamps.

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©2005 Edelbrock Corporation

Brochure #63-0320

2.

Cut the 3/8” hose to length and connect it to the fitting on the compressor inlet pipe on one end and to the valve cover breather port on the other end.

Remove the factory Manifold Air Temperature Sensor from the factory Air Inlet Pipe and install into the grommet in the Compressor Inlet Pipe. The wiring for the manifold air temperature sensor (MAT sensor) plug needs to be separated from the wiring harness so that the MAT plug can reach the MAT sensor in the compressor inlet pipe. Re-wrap the harness with electrical tape. Attach the plug to the MAT sensor.

Fig. 7a

Fig. 7b

3.

Attach the Oil Drain Hose Assembly to the turbo housing using the two 8mm x 1.25 (20mm long) Socket Head Capscrews and the two 8mm spring washers. Be sure the Turbo Oil Drain flange O-Ring is in place. (A bit of grease on the O-Ring helps to hold it in place). The bend in the fitting at the turbo end should point toward the front of the vehicle. Attach the female AN fitting to the Oil Drain Adapter on the oil pan.

Make sure the hose is not kinked.

4.

Install the intercooler grommets into the holes in the lower radiator support as shown (See Fig. 8a). Using a small amount of silicone-based spray lubricant on the grommets will make installation easier. Mount the intercooler by pressing the pins on the lower edge of intercooler into the grommets (See Fig. 8b). Using the bolt removed from the horn, attach the intercooler brace and horn to the center radiator support

(See Fig. 8c).

Install Grommets Here

Fig. 8a

Fig. 8b Fig. 8c

5.

Attach Compressor Outlet Pipe to the compressor outlet using the supplied silicone connector and the appropriate hose clamps. The outlet of the compressor outlet pipe should face toward the driver’s side of the vehicle

(See Fig. 9a). Attach the intercooler inlet pipe to the compressor outlet pipe using the three 8mm x 1.25 (25mm long) bolts, O-Ring (Use a bit of grease on the O-Ring to hold in place), and the three 8mm split lockwashers

(See Fig. 9b). Attach the intercooler inlet pipe to the intercooler using a 2 ¼” to 2 ½” silicone coupling and the appropriate hose clamps. Attach the bracket on the intercooler inlet pipe to the factory tie-down bracket location (which was removed earlier) using the factory bolt

(See Fig. 9b). Attach the intercooler outlet pipe to the intercooler with one of the 2 ¼” to 2 ½” silicone couplings and the appropriate hose clamps. Bolt the support bracket on the pipe to the inner fender using one of the factory lower airbox bolts

(See

Fig. 9c).

Bracket attaches to the factory tie-down bracket location

Fig. 9a Fig. 9b Fig. 9c

6.

Install the Blow-Off Valve onto the intake manifold inlet pipe. Make sure the O-Ring is properly seated on the Blow-Off Valve flange. Install the Blow-Off Valve and V-Band and tighten the V-Band. Install the supplied banjo fitting onto the Blow-Off Valve using the supplied sealing washers. Install a 1/4” barb to 1/8” NPT fitting (for wastegate actuator hose) into the hole next to the blow-off valve on the intake manifold inlet pipe (See Fig. 9). Install 3/8 NPT pipe plug under the wastegate fitting on the intake manifold inlet pipe (See Fig. 10).

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©2005 Edelbrock Corporation

Brochure #63-0320

7.

Attach the intake manifold inlet pipe to the intercooler outlet pipe using the 2 ¼” silicone coupling and the appropriate hose clamps. Attach the intake manifold inlet pipe to the throttle body using one of the 2 ¼” to 2 ½” silicone couplings and the appropriate hose clamps. Attach the intake manifold inlet pipe to the passenger side shock tower using one of the stock air box bolts.

8.

Install a ¼” barb to 1/8”NPT adapter fitting (wastegate actuator hose) into the intake manifold inlet pipe.

9.

Install the Exhaust Down-Pipe.

Thread the three

10mm x 1.5 studs into the exhaust elbow, hand tight.

Making sure the exhaust down-pipe gasket is in place, install the exhaust down-pipe onto the exhaust elbow using the provided 10mm x 1.5 flanged nuts.

Using the stock donut gasket (if in good condition), attach the exhaust down-pipe using the factory bolts.

Attach the down pipe to the lower exhaust bracket using the factory bolts (See Fig. 11). Re-install the factory O2 sensor.

Fig. 10

10. You must use an exhaust system with little or no back pressure to achieve maximum turbo boost.

Fig. 11

Coolant Line and Vacuum Hose Connections

1.

Install the supplied coolant hard pipe in place of the lower radiator hose, using the supplied silicone couplings and hose clamps

(See Fig.

12).

2.

Route one of the coolant lines from the turbo to the thermostat housing. Cut to fit. Connect the coolant line to the fitting on the side of the thermostat housing that originally connected a coolant line to the throttle body. Route the other coolant line from the turbo to the throttle body coolant fitting. Cut to fit. Connect the line to the throttle body coolant fitting

(See Fig. 13a & 13b). Use the supplied hose clamps to secure.

3.

Measure and cut to length the ¼” Red Silicone Hose and connect the wastegate to the fitting on the intake manifold inlet pipe specified in step 7 of the “Compressor Inlet/Outlet and Intercooler Plumbing Installation” section. Measure and cut to length the ¼” Red Silicone Hose and connect the Blow-Off Valve to the fitting on the intake manifold specified in Fig. 5c.

View from under the vehicle.

Connect one line here

Connect other line here

(Picture taken with intake manifold off)

Coolant

Hardpipe

Fig. 12 Fig. 13a Fig. 13b

Bumper Cover and Fender Liner Modification and Final Parts Re-installation

1.

On the inside of the front bumper cover, a strip of material from the back side of the grill will need to be cut off to clear the intercooler.

Measure ¾” from the mold parting line at each end of the grill and mark the measurement (See Fig. 14a). Measure 1½” from the parting line at the center of the grill (See Fig. 14a). Mark a line connecting the three measuring locations. Using a cutoff wheel or other suitable tool, cut along the marked out line. Temporarily place bumper cover on the vehicle and check for clearance.

2.

Temporarily place each fender liner in place and mark area where interference with the intake piping occurs.

Trim out material as needed (See Fig. 14b).

3.

Install the fender liners and bumper cover following the

Factory Service Manual instructions.

4.

Install the battery tray and battery. Install the battery tie down and reconnect the battery cables.

5.

Fill the oil to the level recommended in the

“Final

Checklist” on page 10, and fill coolant to Factory

Service Manual specifications.

Parting Line

Measure 3/4”

Measure 1-1/2” Fig. 14a

Cut as Required.

Repeat on

Driver Side

Fig. 14b

Catalog #1509

Rev. 11/05 - RS/mc Page 8 of 10

©2005 Edelbrock Corporation

Brochure #63-0320

Final Checklist (Note: Do not start vehicle before completing this list.)

❑ Make sure that all fluids are at the recommended factory levels. However, the oil level should be kept at approximately 1/4 of the distance from the low to high marks on the dipstick to help oil drainback from the turbocharger. Check oil level more often to make sure it does not run below the low mark on the dipstick (See Fig. 15). (Note: As stated above, we recommend the use of a synthetic 10W30 motor oil.

Mobil1 was used in our testing.)

❑ Prime the turbocharger oil supply. Before starting the vehicle, the turbocharger oil drain hose should be disconnected from the oil pan and the engine should be turned over with starter until oil is running out of the oil drain hose. This will ensure that the turbo is lubricated before initial start-up. This should be done with the spark plugs removed and the wiring harness plug disconnected from the Auxiliary Engine Management Computer.

Disconnecting the wiring harness from the Auxiliary Engine Management Computer will disable the ignition

(Note: It may take one or two minutes of intermittent cranking for the oil system to be primed and for oil to reach the drain hose. To keep from abusing the starter, crank the engine in 20-30 second intervals, until oil reaches the drain hose.).

Once oil flow is established, reconnect the turbocharger oil drain hose and Auxiliary Engine Management Computer. Check the oil level again after priming the oil supply.

Keep level between

Low and

1/4 Full

High

Mark

Low

Mark

Fig. 15

❑ Make sure the oil drain hose has no kinks, and that portions of the hose do not hang more than slightly lower than the drain fitting in the oil pan. This can cause a back-up of oil in the hose, preventing proper draining of oil from the turbo housing. This can result in small amounts of oil being drawn into the turbine housing, causing oil smoke in the exhaust.

❑ Along with synthetic oil, we strongly recommend using a colder sparkplug in the engine. In our testing, we used Champion RC9MC4 sparkplugs (stock #434). You may use any manufacturer’s plug that matches the stock plug configuration and is two to three heat ranges colder than stock.

❑ Start the engine and check for any vacuum, fuel, or oil leaks.

❑ Use only premium grade 91 octane (or higher) fuel with this turbo kit. Lower grade fuel can cause pre-ignition (knock), and possible engine damage, if used.

Maintenence and Service

Follow your regular factory recommended service intervals. However, we recommend changing the oil every 3000 miles, as compared to the factory recommended 7500 miles.

Catalog #1509

Rev. 11/05 - RS/mc

Edelbrock Corporation • 2700 California Street • Torrance, CA 90503

Tech-Line: 800-416-8628 • E-Mail: [email protected]

Page 9 of 10

©2005 Edelbrock Corporation

Brochure #63-0320