GReddy Intercooler Kit User manual

GReddy Intercooler Kit
(Type 31)
2002-2003 Acura RSX Type-S

2 Parts List
(1) Intercooler (Type 31C) 1
(2) Intake pipe I-1 (50∅Aluminum) 1
(3) “ I-2 (50∅Aluminum) 1
(4) “ I-3 (50∅Aluminum) 1
(5) “ I-4 (60∅Aluminum) 1
(6) “ I-5 (60∅Aluminum) 1
(7)WasherTank 1
(8)WasherTankBracketA 1
(9)WasherTankBracketB 1
(10) Extension Harness 850mm 1
(11) Wire Connector Set (Male and Female) 8 set
(12) Hose 50∅x70mmStraight 3
(13) “ 60∅x70mmStraight 2
(14) “ 50∅- 60∅Reducer 1
(15) Hose band 50∅#32 7
(16) “ 60∅#36 5
(17)IntercoolerBracket 1
(18) Aluminum Spacer t=8mm 2
(19) Zip ties 150mm 5
(20) 8mm x 15mm P=1.25 Stainless B S/W F/W _ 2
(21) 8mm x 15mm P=1.25 Stainless B S/W F/W N 3

Parts List
1 2 3
4 5 6
7 8 9 10-11
12-13 14 15-16 17
18 19 20 – 23

2. Removal of Stock & Turbo Kit Parts
When removing the stock parts, make sure you read over the factory
repair manual for proper procedures.
2-1 Disconnect the negative side of the battery.
2-2 Remove the undercover, and the front bumper.
2-3 Remove the bumper support beam.
2-4 Remove the two horns.
2-5 Remove the wind shield washer tank.
2-6 Remove the Turbo Kit Air intake, suction pipe, the suction adapter, and the restictor.
(refer to the Turbo Kit Installation Manual)
2-7 Remove the Turbo Kit Compression Pipe C-2, and C-3.
(refer to the Turbo Kit Installation Manual)
3. Kit Installation
3-1 Body Modification
Cut the shaded area of the body at the left front
body as shown.
Spacer
Intercooler Installation
(1) Install the Intercooler bracket to the body with
the horn as shown using the provided spacer
between the horn bracket and I/C bracket.
(Parts used #: 17, 18, 21)

(2) Mount the Intercooler shown using provided
hardware. Secure the left side of the
intercooler (looking from the front of the
vehicle) to the bracket installed in the
previous step.
(3) Secure the right side of the intercooler to the
body as shown using the provided spacer
between the horn bracket and I/C bracket.
(Parts used #: 1, 18, 21,22)
(4) Position the intercooler so that it is mounted
straight before tightening the bolts.
3-3 Intercooler Piping Installation
(1) Install the I-1 to the C-1 (Aluminum elbow on
the turbo outlet) from the Turbo Kit. Secure
the I-1 pipe bracket to the engine harness
bracket as shown.
* Use the bolt supplied in the turbo kit that was
securing the compression pipe C-2.
(Parts used # 2, 12)

(2) Install the Intercooler pipe I-2 to the I-1 as
shown.
(Parts used # 3, 12)
(3) Install the I-3 pipe between I-2 and
intercooler inlet as shown.
(Parts Used #: 4, 12, 14)
(4) Install the I-4 to the intercooler outlet as
shown.
(Parts Used #: 5, 13)
(5) Install the Intercooler pipe I-5 to the I-4 as
shown. Secure the I-5 to the body. Modify
the splash guard where it contacts these
pipes.
(Parts Used #: 6, 13)

(6) Install the Compression pipe C-3 from the
turbo kit between the pipe I-5 and the
throttle body as shown. Reuse the hoses
and clamps from the turbo kit.
Blow by hose
To air assist
Control valve
3-4 Suction Pipe Installation
(1)Reinstall the Turbo Kit Suction Kit with out
the restrictor.
3-5 Windshield Washer Tank Installation
(1) Install the washer tank brackets A and B as
shown.
(Parts used # 8, 9)
(2) Install the two washer pumps to the
provided washer tank and install the tank on
to the bracket A and B as shown.
Extend the washer tank harness to reach
from the original tank location to the new
location. Refill the tank with washer fluid.
* Make sure not to reverse the positive and
negative wires.
* Make sure not the switch the front pump
and the rear pump connectors.
(Parts used # 7, 10, 11, 21)

3-6 Bumper Modification
(1) Cut the outlined area of the bumper to clear
the intercooler
* Cut the bumper little by little and test fit on
the vehicle. Trim the area the hits the
intercooler.

Starting the Engine
(1) Check all the pipe and hose connections, then reconnect the negative side of the battery.
(2) Start the engine. While idling, check for any air leeks.
(3) After inspection, reinstall the front bumper, under cover and other stock parts that was
removed.
Secure the bottom of the bumper with the intercooler bracket.
This completes the Intercooler Kit installation.