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GReddy Turbo Kit Installation Manual

Acura rsx type-s dc5 (k20a) t517z 8cm2
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GReddy Turbo Kit
2
Acura RSX Type-S DC5 (K20A)
T517Z 8cm

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Summary of Contents for GReddy Turbo Kit

  • Page 1 GReddy Turbo Kit Acura RSX Type-S DC5 (K20A) T517Z 8cm...
  • Page 2 • 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. • Use of GReddy Racing Spark Plugs ISO #7 or NGK plugs (colder than factory) is recommended with this kit.

  • Page 3: Parts List

    1. Parts List 1. Turbocharger T517Z 8cm P565 2. Turbo Exhaust Manifold (Cast Iron) Down Pipe Adapter (Cast Iron-Steel 60∅) Suction Pipe (Aluminum 60Ø) TZ suction flange (Aluminum 60Ø) Compression Pipe C-1 (Aluminum 50Ø) “ C-2 (Aluminum 60Ø) “ C-3 (Aluminum elbow No. 76 60Ø) Restrictor (Aluminum 43∅) 10.
  • Page 4 1. Parts List 28. Vacuum Hose (Blue) 5∅ x 200mm (for Actuator) 29. Rubber Hose 8Ø X 500mm (for Idle controller) 30. Rubber Hose 16Ø X 400mm (for Oil return) 31. Rubber Hose 19Ø X 190mm (for Blow by) 32. Silicone Hose 60Ø...
  • Page 5 1. Parts List 57. M6 X 10 P=1.0 B S/W F/W - (Down pipe heat shield) 58. M6 X 15 P=1.0 B S/W F/W - (Suction pipe & compression pipe bracket) 59. M6 X 15 P=1.0 B S/W F/W N (Suction pipe bracket) 60.
  • Page 6 1. Parts List 15-16...
  • Page 7 1. Parts List 28~31 33~34 35~40 50~51 57~67...
  • Page 8 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.

  • Page 9: Kit Installation

    3. Kit Installation 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.
  • Page 10 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 Oil Pressure Switch (1) Remove the Oil Pressure switch and Install the 3-way...
  • Page 11 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.
  • Page 12 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) Oil Return Installation (1) Install the provided oil return pipe to the turbocharger using the provided gasket and hardware as shown.
  • Page 13 (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:...
  • Page 14 (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.
  • Page 15 (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...
  • Page 16 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.
  • Page 17 (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.
  • Page 18 • 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. is not responsible for any damage to the vehicle’s electrical system caused by improper installation.
  • Page 19 Connector A Connector B Connector C Connector D Connector E (31P) (24P) (22P) (17P) (31P) 1 2 3 4 5 6 7 1 2 3 4 5 15 16 15 6 25 6 23 24 A19 A9 Connector Sensor adapter IN (W) Sensor adapter Out (G) Male Female 18-8 (PL/R)
  • Page 20 e-manage Factory ECU I/J Harness (18Pin) Wire Color Description ECU Pin # Color Code MAP IN (harness) White Green/Red Throttle Grey Red/Black INJ 1 INJ 1 Blue/Red Brown INJ 2 INJ 2 Orange/Red INJ 3 INJ 3 Yellow/Red Blue INJ 4 INJ 4 Purple/Red Yellow...
  • Page 21 • It is very important that you monitor the boost pressure, and make sure not to over boost. Over boosting can cause engine damage. • GReddy Performance Products, Inc. is not responsible for any engine damage caused by over boosting (increased boost), modification to the kit, and/or misuse of the product.

  • Page 22: Checking Error Codes

    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.
  • Page 23 Error Error description CODE Airflow Signal 1 Incorrect wiring or disconnected Airflow Signal 1 input error Airflow voltage Incorrect Airflow signal output wiring. output error No Injector Not receiving an injector signal for Additional Injection Map pulse from all Not receiving injector signal I/J CH-1 No Injector 1 pulse for Additional Injection Map Not receiving injector signal I/J CH-2...