GReddy Turbo Kit Honda Civic Si EP3 (K20A) T517Z 8cm2
Honda Civic Si EP3 (K20A) T517Z 8cm2 Installation Manual Please read the entire manual before installing this kit. Application: Make Honda Model Civic EP3 Chassis EP3 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. (Please check with your GReddy Authorized dealer for availability) • Premium grade gasoline (92 octane or higher) is required with this Kit.
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 27. Vacuum Hose (Blue) 5∅ x 200mm (for Actuator) 1 28. Rubber Hose 8Ø X 500mm (for Idle controller) 1 29. Rubber Hose 16Ø X 400mm (for Oil return) 1 30. Rubber Hose 19Ø X 190mm (for Blow by) 1 31. Silicone Hose 60Ø x70mm 2 32. Reducer Hose 50Ø – 60Ø 1 33. Reducer Hose 60Ø – 70Ø 1 34. Hose band 8Ø Tridon #4 2 35. Hose band 16Ø Tridon #10 2 36. Hose band 19Ø Tridon #12 2 37. Hose band 50Ø Tridon #32 1 38. Hose band 60Ø Tridon #36 7 39.
1. Parts List 56. M6 X 10 P=1.0 B S/W F/W - (Down pipe heat shield) 2 57. M6 X 15 P=1.0 B S/W F/W - (Suction pipe & compression pipe bracket) 2 58. M6 X 15 P=1.0 B S/W F/W N (Suction pipe bracket) 1 59. M6 X 15 P=1.0 B S/W - (Oil Return Bracket) 2 60. M8 X 15 P=1.25 B S/W F/W - (Turbine heat shield) 2 61. M8 X 30 P=1.25 B S/W F/W N (Compressor inlet) 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.
1.
1.
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 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) Oil Pressure Switch Install the 3-way fitting to the block first.
(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) 3-5 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. (2) Install stud bolts on to the exhaust manifold, then mount the turbocharger to the manifold using provided gasket.
3-7 Oil Return Installation (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.
• 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.
(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) Main Body Tab (2) Install the provided hose adapter to the inner frame of the Airinx.
(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.
(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.
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.
3-13 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) 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.
Connector A (31P) 1 2 3 4 10 11 12 23 23 24 5 6 15 16 25 26 Connector B (24P) 9 7 18 19 20 21 27 28 29 30 1 2 3 4 5 8 10 17 18 B2 A5 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 18-8 (PL/R) 18-12 (B) 18-7 (Y/R) 18-18 (B/R) 18-6 (O/R) ｽﾌ 18-5 (B/R) 18-10 (G) 18-3 (W) 18-9 (PL) SLC (BR) 18-11 (BR) SLC (LB) 18-4 (GR) 18-13 (R) SLC (PL) SLC (R) SLC (B) A10 A3 A15 A19 A18 E26
I/J Harness (18Pin) * Looking at harness side.
3-15 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) Tun 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. 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 illuminate and flash GREEN. • When it reaches to the A.A.V.
Checking Error Code Chart 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.
