GReddy Turbo Kit User manual

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 Model Chassis Year
Honda Civic EP3 EP3 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.
•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.
Important
•This installation should only be performed by a trained specialist who is very
familiar with the automobile’s mechanical, electrical and fuel management
system.
•If installed by an untrained person, it may cause damage to the kit as well as
the vehicle.
•GReddy Performance Products Inc. is not responsible for any damage to
the vehicle’s electrical system caused by improper installation.

1. Parts List
1. Turbocharger T517Z 8cm2P565 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∅) 1
10. Airinx AY-MB (Blue filter) 1
11. Airinx Adapter (M60) 1
12. Fuel Injector 440cc (w/spacerx2, stud bolt x2 o-ringx8) 4
13. “ Connector Harness 4
14. e-Manage 1
15. I/J Harness (18P) 1
16. Sensor Adapter Type-AII US 1
17. Oil Pressure Hose SUS 600mm 1
18. “ Banjo Fitting male & female (small) 1set
19. “ Copper Washer 10∅(t=1.0mm) 2
20. “ Three Way Fitting 1
21. “ Union Fitting 1/8PT – 1/8 PT 1
22. “ Union Fitting 1/8PT – 1/8PF 90°1
23. Oil Return Flange tube 16∅(Turbo side) 1
24. “ Banjo Fitting male & female 16∅(Engine side) 1Set
25. “ Banjo Spacer t=16 1
26. “ Banjo Copper washer 15.5∅(t=1.0mm) 3

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. Hose band 70Ø Tridon #44 1
40. Gasket Turbo in 2
41. Gasket Turbo in 1
42. Gasket Turbine in 1
43. Gasket Turbine out 1
44. Gasket Down Pipe 1
45. Gasket Oil Return Flange Tube Small 1
46. Heat Shield Turbine 1
47. Heat Shield Down pipe 1
48. Thermo-cloth 100mm X 1000mm sheet 4
49. Zip ties 150mm 10
50. Zip ties 200mm 5
51. Three-way Vacuum Tee 10∅-6∅-10∅1
52. Suction pipe bracket 1
53. Oil return hose bracket 1
54. Airinx hose fitting 8∅-M18 1
55. Intake Air Temperature Grommet 1

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. M8 X 75 P=1.25 B S/W - - (Turbine out) 2
65. M8 P=1.25 - - - N (Down pipe) 2
66. M10 X 45 P=1.25 B S/W F/W N (Ex. Manifold) 3

1. Parts 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 25

1. Parts List
26 27~30 31 32~33 34~39
40 41 42 43 44
45 46 47 48 49~50
51 52 53 54 55
56~66

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.
2-6 Remove the Air cleaner assembly with intake tube, breather hose and Intake
temperature sensor.
2-7 Disconnect the primary and secondary O2 sensor and remover the catalytic
converter.
2-8 Remover the VTEC solenoid valve assembly.
2-9 Remove the exhaust system heat shield and manifold.
2-10 Remove the heat shield plate (bottom of the firewall) and the intermediate drive
shaft heat shield.

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
Power Steering Hose
Engine Harness
(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) Wrap the thermo cloth to the engine
harness and the heater hoses by the
fire wall.

3-3 Oil Pressure Line Installation
Install the 3-way
fitting to the block
first.
3-way fitting
PF
PT
PT
PT
Oil Pressure Switch
(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)
(2) Install the oil pressure switch to the 3-
way fitting and reinstall the VTEC
solenoid assembly with the modified
heat shield.
* Make sure that the heat shield does not
hit the oil pressure switch.
Check
(3) Reconnect the oil pressure switch
harness and the crank sensor.
(4) Connect the oil pressure line to the
installed union fitting.
(Parts used #18)
3-4 Exhaust Manifold Installation
(1) Install three stud bolt on to the cylinder
head as shown.
(Parts used #67)