GReddy Turbo Kit 2003 Mazda RX-8 (13B-MSP) T618Z 10cm2 (Actuator Type) Emanage Ultimate
2003 Mazda RX-8 (13B-MSP)T618Z 10cm2 (Actuator Type) Installation Manual Please read the entire manual before installing this kit. Application: Make Mazda Model Chassis RX-8 Year LA-SE3P • This GReddy Turbo Kit is designed only for the vehicles specified above. • Premium grade gasoline (91 octane or higher) is required with this Kit. • Make sure that the vehicle is not equipped with any ECU upgrade chips. • This kit is designed for High Power 6 speed manual transmission Vehicle only.
1. Parts List 1. Turbocharger T618Z 10cm2 2. Exhaust Manifold Ductile Iron Cast 1 3. Downpipe Adapter Ductile Iron Cast 1 4. Intercooler Type 31C 1 5. Intercooler Bracket (Steel) 1 6. Suction Pipe S-1 (80∅-60∅ Aluminum) 1 7. S-2 (60∅ Aluminum with flange) 1 C-1 (50∅ Aluminum flange elbow ) 1 “ 8. Compression Pipe P380 1 9. “ C-2 (50∅ Aluminum) 1 10. “ C-3 (50∅ Aluminum) 1 11. “ C-4 (60∅ Aluminum elbow) 1 12. “ C-5 (60∅ Aluminum) 1 13.
36. Silicone Hose 50∅ - 60∅ Reducer 1 37. “ 80∅ x 80∅ Reducer 1 38. “ 80∅ - 90∅ Reducer 1 39. Hose Band 16∅ #10 2 40. “ 50∅ #32 5 41. “ 60∅ #36 8 42. “ 80∅ #48 4 43. “ 90∅ #56 1 44. Gasket Compressor Inlet (Part # 14465-54C00) 1 45. " Compressor Outlet 46. " Turbine Inlet 1 47. " Turbine Outlet 1 48. " Oil Return (Part # 14465-05U11) 1 TD Small 1 49. Intake Manifold Blocking Plate 1 50. Thermo Cloth 1 100mm x 250mm 51.
Part List 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24~26 27
28 29 30~32 33~35 36~38 39~43 44 45 46 47 48 49 50, 51 52, 53 54~56 57 58 59 60 61 62-66
2. Factory Parts Removal When removing the stock parts, please refer to the factory RX8 Workshop manual for proper procedures. 2-1 Factory Parts Removal 1. Remove the engine cover and the battery cover. Disconnect the negative terminal of the battery. 2. Remove the battery, battery box, and battery tray. 3. Drain the engine oil. 4. Remove the front strut bar, air cleaner box, air cleaner insulator and intake pipe. (RX8 Workshop Manual pages 01-13-2 ~ 01-13-6) 5.
3. Turbo Kit Installation 3-1 Intake Manifold Plate Installation 1. Remove the extension manifold (upper). Please refer to RX8 workshop manual pages 01-13-4 to 01-13-11. * Make sure to prevent any dirt or objects from entering the intake manifold. 2. Install the Intake Manifold Blocking Plate onto the manifold as shown in the picture. (Parts Used #49) 3. Apply silicone gasket to the manifold surface shown in the picture. Make sure the manifold is clean before installing.
3-3 Oil Pressure Line Installation 1. Remove the factory oil pressure switch at the left side of the rear rotor housing and install the Oil pressure line using the provided 3 way fitting, and straight fitting. Route the line to the right side of the engine (over the transmission) to connect to the turbo in the later step. * Apply Teflon tape on the PT thread in and to not over tighten the fitting. * Wrap the oil pressure line with the provided wire loom. 3-4 Turbocharger Install 1.
5. Connect the oil pressure line that was installed in the step 3-2 to the turbocharger. Install the turbocharger to the manifold using the provided gasket and hardware. (Parts Used #46, 66) 6. Reinstall the engine mount bracket and rubber, then remove the SST tool. 7. Install the suction pipe S-3 to the turbo inlet using the provided gasket and hardware. (Parts Used #7, 44, 65) 8. Replace the oil drain plug with the provided oil return fitting and copper washer. (Parts Used #28, 29) 9.
3-5 Intercooler Installation 1. Remove the auxiliary temp sensor on the bumper reinforcement, and rotate it 180°, then reinstall it back to the original mounting location. 2. Install the intercooler mounting bracket to the bumper reinforcement mounting bolt. Then install the intercooler to the bracket. *Adjust the bracket to mounting intercooler parallel. (Parts Used #4, 5, 64) 3. Remove the plastic part between the lower radiator hose and bracket. Bend the bracket up and secure it with zip ties as shown.
6. Secure C-5 bracket to the speed sensor harness bracket (LH). (Parts Used #11, 12, 13, 34, 35, 37, 41, 42, 56) 7. Reinstall the front stabilizer bar. 3-6 Airinx Installation 1. Install the suction pipe S-1 tot he S-2 using the provided hose and hose band. Secure the S-1 bracket with the ground wire mounted to the body. (Parts Used #6, 34, 41, 50) 2. Trim the shaded area of the factory air cleaner insulator as shown. 3. Remove the top housing and the filter of the Airinx by removing the top screw off.
4. Assemble the Airinx back together and hand tight the top screw. 5. Remove the factory Airflow meter off from the air cleaner box and install the Airflow mete to the provided air flow meter adapter. Install the Airinx and the adapter to suction Pipe S-1. * The O-ring on the Airflow meter will be reused. Apply some grease on the O-ring on the Airflow meter, and make sure not to damage when installing. (Parts Used #14, 17, 38, 42, 43, 62) Airflow Sensor 6.
2. Install the O2 sensor to the down pipe adapter and install the adapter to the Turbo using provided gasket and hardware. Connect the O2 sensor connector. (Parts Used #3, 47, 66) 3. Connect the Air Pump hose to the down pipe adapter. Bend the hose so that it will not contact the turbine housing. Re-use the stock gasket. (Parts Used #63) 4. Secure the Down Pipe Adapter to the transmission with the provided bracket. (Parts Used #20) 5.
3-8 e-manage Ultimate installation and vacuum hose connection for the actuator. 1. Remove the washer tank and drill a 1" hole on the fire wall. Make sure not to drill through any thing on the other side. There is a hump on the fire with a circle indentation behind the washer tank, which would be a perfect location to drill. Install a rubber grommet to protect the wire harness. 2. Remove the PCM cover and disconnect the Main harness from the PCM.
3-9 Bumper installation 1. Cut the under cover and the inner fender cover to clear the compression pipe. 2. Reinstall the front bumper.
Starting the Engine 1. Reinstall the battery tray, battery box, battery, and connect the positive terminal only. 2. Reinstall the front strut tower bar. 3. Refill the engine oil and inspect the hoses and wire connection, then connect the negative terminal of the battery. 4. Turn the ignition to “ON” position and confirm that the "ACTIVE" L.E.D. lights up GREEN. 5. Remove the ECM fuse and crank the engine to get oil pressure to the turbo.
