GReddy Turbo Kit Acura RSX Type-S DC5 (K20A) T517Z 8cm2
Acura RSX Type-S DC5 (K20A) T517Z 8cm2 Installation Manual Please read the entire manual before installing this kit. Application: Make Acura Model RSX Type-S Chassis DC5 Year 02~03 • This GReddy Turbo Kit Is designed only for the vehicles specified above. • GReddy Front mount intercooler kit is recommended with this kit • 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.
1. Parts List 1. Turbocharger T517Z 8cm2 P565 1 2. Turbo Exhaust Manifold (Cast Iron) 1 3, Down Pipe Adapter (Cast Iron-Steel 60∅) 1 4. Suction Pipe (Aluminum 60Ø) 1 5. TZ suction flange (Aluminum 60Ø) 1 6. Compression Pipe C-1 (Aluminum 50Ø) 1 7. “ C-2 (Aluminum 60Ø) 1 8. “ C-3 (Aluminum elbow No. 76 60Ø) 1 9. Restrictor (Aluminum 43∅) 10. Airinx AY-MB (Blue filter) 1 1 11. Airinx Adapter (M60) 1 12. Fuel Injector 440cc (w/spacerx2, stud bolt x2 o-ringx8) 4 13.
1. Parts List 28. Vacuum Hose (Blue) 5∅ x 200mm (for Actuator) 1 29. Rubber Hose 8Ø X 500mm (for Idle controller) 1 30. Rubber Hose 16Ø X 400mm (for Oil return) 1 31. Rubber Hose 19Ø X 190mm (for Blow by) 1 32. Silicone Hose 60Ø x70mm 2 33. Reducer Hose 50Ø – 60Ø 1 34. Reducer Hose 60Ø – 70Ø 1 35. Hose band 8Ø Tridon #4 2 36. Hose band 16Ø Tridon #10 2 36. Hose band 19Ø Tridon #12 2 38. Hose band 50Ø Tridon #32 1 39. Hose band 60Ø Tridon #36 7 40.
1. Parts List 57. M6 X 10 P=1.0 B S/W F/W - (Down pipe heat shield) 2 58. M6 X 15 P=1.0 B S/W F/W - (Suction pipe & compression pipe bracket) 2 59. M6 X 15 P=1.0 B S/W F/W N (Suction pipe bracket) 1 60. M6 X 15 P=1.0 B S/W - (Oil Return Bracket) 2 61. M8 X 15 P=1.25 B S/W F/W - (Turbine heat shield) 2 62. M8 X 30 P=1.25 B S/W F/W N (Compressor inlet) 2 63. M8 X 20 P=1.25 B S/W F/W - (Compressor outlet) 2 64. M8 X 30 P=1.25 B S/W - N (Exhaust manifold – Turbo in flange) 7 65.
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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.
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.
3-3 3-4 Power Steering Line Modification Remove the power steering bracket off the line and valve cover. Bend the Power steering line so that the line routes closer towards the shock tower. Make sure not to kink or break the line. 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.
3-5 Exhaust Manifold Installation (1) Install three stud bolts on to the cylinder head as shown. (Parts used #67) (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) 3-6 Turbocharger Installation (1) Wrap the thermo cloth the actuator as shown. * The heat off the manifold can damage the actuator with out the thermo cloth.
3-7 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) 3-8 Oil Return Installation (1) Install the provided oil return pipe to the turbocharger using the provided gasket and hardware as shown.
(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) 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.
(5) Install the provided intake air temperature sensor grommet to the suction pipe S-1 as shown. (Parts used #4, 56) Grommet IAT Sensor (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.
3-11 Down Pipe Installation (1) Install three stud bolt on the turbine housing as shown. (Parts used #64) (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 is enough clearance between the downpipe and the oil pressure line.
(2) Install the down pipe heat shield on to the downpipe using the provided M6 x 10mm bolts. (Parts used #48,57) 3-13 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.
3-14 e-Manage 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) Install the ignition harness wires in the e-Manage I/G Harness (12Pin) connector as shown below. * When inserting the wires in to the connectors, make sure that the direction of the pins are correct and push them in all the way until they click in.
Connector A (31P) 1 2 3 4 5 6 15 16 10 11 12 23 23 24 25 26 A5 Connector B (24P) 9 7 18 19 20 21 27 28 29 30 A19 A9 1 2 3 4 5 8 10 17 18 B2 Connector C (22P) Connector D (17P) Connector E (31P) 6 7 2 3 4 13 14 15 16 10 21 22 23 24 22 23 24 13 8 9 6 7 15 16 25 26 18 29 B3 B5 B4 Connector Sensor adapter IN (W) Sensor adapter Out (G) Male Female 18-8 (PL/R) 18-3 (W) 18-10 (G) 18-7 (Y/R) 18-12 (B) Splice 18-6 (O/R) 18-18 (B/R) 18-5 (BL/R) 12-5 (BL/W) 12-12 (BL/B) 12-4 (O/W
I/J Harness (18Pin) e-manage Pin # Wire Color Description 3 White MAP IN 4 Grey 5 Color Code A19(harness) Green/Red MAP Throttle A15 Red/Black TPS Blue/Red INJ 1 B5 Brown INJ 1 6 Orange/Red INJ 2 B4 Red INJ 2 7 Yellow/Red INJ 3 B3 Blue INJ 3 8 Purple/Red INJ 4 B2 Yellow INJ 4 Green MAP OUT A19 Green/Red MAP 10 * Looking at harness side.
3-16 Starting the Engine (1) Refill the engine oil to factory spec. (2) Check all the hoses and wires connection, then reconnect the negative side of the battery. (3) Turn the ignition to “ON” position 2-3 times to 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 engine compartment and can be very dangerous.
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. Any adjustments 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 illuminate and flash GREEN. • When it reaches to the A.A.V.
CODE 11 15 20 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.
