GReddy Turbo Kit User manual

―１―
GReddy Turbo Kit
HONDA S2000 AP2 (2004-2005 F22C) T518Z 8cm
2

―２―
HONDA S2000 AP2 (F22C) T518Z 8cm
2
Installation Manual
Please read the entire manual before installing this kit.
Application:
Make Model Chassis
Year
HONDA S2000 AP2
04～
～～
～05
• 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 ECM upgrade chips.
• Use of GReddy Racing Spark Plugs ISO #8 or NGK plugs (colder than factory) is recommended
with this kit.
※ The following parts are necessary for proper installation of the kit.
Honda Genuine Parts:
・Part Name Gasket, Exhaust manifold P/# 18115-PCX-004 Quantity １
・Part Name Gasket, Silencer P/# 16705-PD1-003 Quantity １
・Part Name Sealing Washer P/# 90428-PD6-003 Quantity １
Important
• This installation should only be performed by a t
rained 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.
• This kit is for off-road use vehicle only which may never be driven on a public highway

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１
１１
１．
．．
． Parts List
１．Turbocharger Ｔ５１８Ｚ－１０ｃｍ
２
Ｐ５５５ １
２．Exhaust Manifold （ＳＵＳ４２．７φ） １
３．Downpipe （Steel ６０φ） １
４．Intercooler Spec-V T-28C １
５．Suction Pipe Ｓ－１ （Aluminum ６０φ） １
６．Compression Tube Ｃ－１ （Aluminum ５０φ） １
７． 〃 Ｃ－２ （Aluminum ６０φ） １
８． 〃 Ｃ－３ （Aluminum ６０φ） １
９． 〃 Ｃ－４ （Aluminum ６０φ） １
１０． 〃 Ｃ－５ （Aluminum ７０φ） １
１１．Injectors（S2000 Use only 550cc×4、O-ring Large×8、O-ring Small×4、Spacer×5）１ｓｅ
１２．Injector Harness ４
１３．Fuel Pump Kit （Walbro 255lph, S2000 pump kit) １
１4．E-manage Ultimate （ＴＫ US--ＡＰ2）１
１5． 〃 Plug-in harness Ｈ－８ (AP2 Specific) １
１6．ＡＩＲＩＮＸ ＡＹ－ＭＢ １
１7． 〃 Hose Adapter Ｍ６０ １
１8．Air Diversion Panel （Aluminum ＝１．０） １
19．Oil Filter Relocation Kit Engine Block Attachment １
20． 〃 Oil filter Attachment １
21． 〃 Center Union Ｍ２０ Ｐ１．５－ＡＮ１０ （For Block side）１
22． 〃 Center Union ３/４ＵＮＦ１６－ＡＮ１０ （For Filter side）１
23． 〃 Side Union ＡＮ１０ ２
24． 〃 O ring（For attachment）１
25． 〃 O ring（For Center Union）２
26． 〃 O ring（For Side Union）２
27． 〃 Oil Line Hose Ａ ４５°－ ４５°19５㎜ １
28． 〃 〃Ｂ４５°－90°270 ㎜１
29． 〃 １/８ＰＴ Plug Union ４
30． 〃 Ｍ１４ plug bolt （O ring attachment）１
31． 〃 Corrugated Tube ３００㎜ １
32． 〃 GReddy Oil Filter ＯＸ－０２ １
33． 〃 Stay １

―４―
34．Oil Pressure Hose ＳＵＳ ４００㎜ １
35． 〃 Union fitting １/８ＰＦ－Ｍ１０ Ｐ１．２５ １
36． 〃 Union fitting １/８ＰＴ－１/８ＰＴ １
37． 〃 ９０°Union fitting １/８ＰＴ－１/８ＰＦ １
38. 〃 3 Way Fitting １
39． 〃 Copper Washer １０．５φ×１８×１．０ １
40．Oil Return Flange Tube １６φ １
41． 〃 Hose Union １６φ－Ｍ１４ Ｐ１．５ １
42． 〃 Copper Washer １４φ×１９×２．０ １
43．Vacuum Hose ４φ×１２００㎜ (Actuator, Pressure sensor, Air solenoid) １
44．Rubber Hose ７．５φ×３００㎜ (Water Line) １
45． 〃 １２φ×４３０㎜ (Blow-by) １
46． 〃 １５φ×３４０㎜ (Oil return) １
47． 〃 １８φ×４００㎜ (Air-pump) １
48．Silicone Hose 5０φ×７０㎜ 1
49．〃６０φ×７０㎜ 2
50． 〃 ７０φ×７０㎜ １
51． 〃 ５０φ－６０φ Reducer １
52． 〃 ６０φ－７０φ Reducer １
53．Hose Band ８φ Tridon ＃４ ２
54． 〃 １２φ Tridon ＃８ ２
55． 〃 １５φ Tridon ＃１０ ２
56． 〃 １９φ Tridon ＃１２ ３
57． 〃 ５０φ Tridon ＃３２ 3
58． 〃 ６０φ Tridon ＃３６ 7
59． 〃 ７０φ Tridon ＃４４ ３
60．Gasket Turbo ＩＮ １
61． 〃 Turbo ＯＵＴ １
62． 〃 Suction Tube Flange １
63． 〃 Compression Tube Flange １
64． 〃 Downpipe （Ring ６５φ） １
65． 〃 Oil return Gasket １

―５―
66．Bracket Intercooler １
67． 〃 Air pump １
68． 〃 Vacuum Tank １
69． 〃 Air Diversion Panel １
70． *No longer used in this kit*
71． 〃 Pressure Sensor １
72．Pressure Sensor Adapter １
73．Hose Union ５φ－１/８ＰＴ １
74．１９φHose Union １
75．Rubber Mount ２
76．Clip ３
77．Air Duct ５０φ×１０００㎜ １
78．Thermo Cloth １００×１０００㎜ ２
79．Zip Tie １００㎜（Black）１０
80．Zip Tie ２００㎜（Black）１０
81．Ｍ４×１８㎜ P0.7 ＋Head B －－ N (Pressure Sensor) ２
82．Ｍ５×１２㎜ P0.8 ＋Head B －－ N (Sec. Air Solenoid Valve) １
83．Ｍ６×１５㎜ P1.0 Stainless B S/W －－
(Oil filter re-locater stay)
２
84．Ｍ６×１５㎜ P1.0 Stainless B S/W F/W －
(Oil Return, Baffle plate stay)
3
85．*No longer used in this kit*
86．Ｍ６×２５㎜ P1.0 Stainless B S/W F/W －
(Pressure Sensor Stay)
2
87．Ｍ６Flange Nut Ｐ1.0 Steel
(Rubber Mount)
２
88．Ｍ８×１５㎜ P1.25 Stainless B S/W －－
(Oil filter re-locater stay)
２
89．Ｍ８×１５㎜ P1.25 Stainless B S/W F/W N
(Air pump, I/C, I/C stay, C-4)
６
90．Ｍ８×20 ㎜P1.25 Stainless B S/W F/W －
(Turbine Compressor IN/OUT
４
91．Ｍ８×30 ㎜P1.25 Stainless Stud B S/W －N
(Turbine Exhaust IN/OUT)
９
92．Ｍ１０×２０㎜ P1.25 Stainless B S/W F/W N
(Downpipe Stay)
１

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Parts List
１２３４
５６７８９
１０ １１ １２ １３ 14
15 16 17 18 19

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20 ２１ ２２ ２３ ２４
２５ ２６ 27, 28 29
30 31 32 33 34
35, 36 37 38 39 4０
4１4２4３4４-47 48-50

―８―
５1, 52 ５3-59 60 61 62
63 64 65 66 67
No longer in use
68 69 70 71 72
73 74 75 76 77
78 79, 80 81-92

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2. Removal of Stock Parts
When removing the stock parts, make sure you read over the factory
repair manual for the proper procedures
.
2-1 Disconnect the battery. Write down the radio presets and be sure to have the code
for the factory radio.
2-2 Relieve the fuel pressure in the fuel system. (see factory repair manual for detail
procedure).
2-3 Drain the engine oil.
2-4 Remove the Air cleaner assembly with intake tube, and breather hose.
2-5 Remove the exhaust manifold and heat shields.
2-6 Remove the two engine under covers and the front bumper.

―１０―
3. Kit Installation
3-1 Turbo Installation
(1) Before installing the turbo charger, make sure to
insulate the surrounding components with the
provided thermo cloth. Since the area around
the exhaust manifold will get very hot, it is
important to insulate the surrounding components
to prevent fire/heat damage.
(2) Install the #91 studs on the exhaust housing.
Install the #35 union with #39 brass washer on the
top side of the turbo as shown.
〈Parts used: 35, 39, 91〉
(3) Install the #91 studs onto the exhaust manifold,
then attach the turbo to the manifold. Be sure to
use the provided gasket between the turbo and
manifold #60.
〈Parts used: 1, 2，60，91〉
(4) Unclip the plug going to the Vtec Solenoid as
shown by the arrow in the image. Temporarily
remove the OEM intake support bracket that is
attached to the passenger side of the chassis.
Pass the turbocharger assembly through this
space from the front of the engine towards its
destination. Be cautious not to damage the
turbocharger or any engine parts during this
process, as it is a close fit.
(5) Use the new OEM exhaust manifold gasket when
installing the turbocharger assembly onto the
motor.
(6) Tighten the exhaust turbocharger assembly onto
the cylinder head using the OEM nuts.
(7) Install #40 oil return tube with #65 gasket on the
bottom side of the turbo with the provided #84
bolts as shown in section 3- 3.
〈Parts used: 40，65，84〉
№35
Do not install oil
return yet
№91

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3-2 Oil Pressure Switch
(1) Remove the factory oil pressure switch. Install #36
union into the #38 three way fitting. Proceed to
install into the block where the oil pressure switch
was located.
*Be sure to use Teflon tape on each side of the
union.
〈Parts used: 36，38〉
(2) Install the factory oil pressure switch to the part of
the three wayfitting facing the front of the car.
※ Install the ９ ０° fitting #37 facing upwards as
shown.
※ Be sure to use Teflon tape on the ９０°fitting (3
way fitting side ONLY) and on the oil pressure
switch. 〈Parts used: 37〉
3-3 Oil Filter relocation
(1) Install Unions #21 & #23 into Oil Block adapter
#19. Make sure to use the provided O rings #25 &
#26 on the unions and #24 on the adapter. Install
union plugs #29 into the adapter as shown.
※ Lubricate the o-ring and the thread to prevent any
cross threading and damaging the o-ring.
※ Apply Teflon tape on the 1/8PT plugs and make
sure not to over torque.
〈Parts used: 19, 21, 23, 24, 25, 26, 29〉
(2) Install the adapter as shown. The #23 union
should be facing in the 7 o’clock position, tighten
the #21 union so the adapter is secured in this
position.
※ Lubricate the O-ring and the thread to prevent any
cross threading and damaging the o-ring.
№38
№36
№37
Oil press sensor
№29
№21，25 №23，26
№24

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(3) Install #29 union plugs in the 2 locations in
adapter #20 as shown. Install union #22 with O
ring #25 and union #23 with O ring #26 in the
adapter as shown. Install plug bolt #30 as shown.
※ Lubricate the o-ring and the thread to prevent any
cross threading and damaging the o-ring.
※ Apply Teflon tape on the 1/8PT plugs and make
sure not to over torque.
〈Parts used: 20，22，23，25，26，29，30〉
(4) Attach bracket #33 to the adapter using bolts #88.
Attach the oil filter to the adapter, be sure to use a
little oil on the filter seal.
※ Lubricate the O-ring on the filter.
〈Parts used: 32，33，88〉
(5)
(5)(5)
(5) Attach the filter adapter to the passenger side
shock tower using the provided M6 bolts #83.
〈Parts used: 83〉
№23，26
№22，25
№30
№29
№29

―１３―
(6) Connect oil hoses #27 (A) & #28 (B).
･ Oil line hose Agoes between the center unions.
Where the 90 degree fitting is on the filter side,
and the 45 degree fitting on the engine side.
･ Oil line hose B goes between the side unions.
Where the 45 degree fittings are on each side.
※ Use the corrugated tube (#31) to cover any part of
the oil lines that might make contact with any part
of the chassis or the other oil line.
※ Refer to the Images to reference where each end
of the hoses should go.
〈Parts used: 27, 28，31〉
Optional Sensor Installation Instructions
Engine Block side Oil filter side
･ Sections Ａ、Ｂ、Ｅ （１／８ＰＴ）・・・able to measure oil temperature and oil pressure.
･ Section Ｃ（１／８ＰＴ） ・・・ The electrical type warning meter temperature
sensor fits here.
･ Section Ｄ（Ｍ１４×Ｐ１．５） ・・・Mechanical type temperature sensor fits here.
A
AA
A
B
BB
B
E
EE
E
D
DD
D
C
CC
C

―１４―
3-4 Oil Feed Line installation
(1) Install the #34 oil feed line as shown, connecting
one end to the ９０°fitting from the oil pressure
switch and the other to the union on the top side
of the turbo. Bend the line to make room for the
compression pipe on the turbo. Be careful not to
kink the line. Be sure that the oil line does not
make contact with any other parts.
〈Parts used: #34〉
(2) Remove the factory oil drain bolt and crush
washer. Using #41 Union and #42 brass washer,
install where the factory oil drain bolt was located.
〈Parts used: 41, 42〉
(3) Cover the #46 １５φhose with thermo cloth (#78)
and connect it from the oil return flange pipe to the
oil return union on the oil pan. Use #55 hose
bands on each end to secure the hose from
leaking oil.
〈Parts used: 46，55, 78〉
3-5 Downpipe Installation
(1) Disconnect and remove the O2 sensor from the
factor exhaust manifold and install onto the
provided downpipe. Install the #64 downpipe
gasket on the end of the downpipe, which
connects to the catalytic converter.
〈Parts used: 3，64〉
№41
№34
№64
Sensor
№46

―１５―
(2) Install the downpipe to the turbine housing using
#61 turbine gasket, secure with provided nuts and
lock washers.
※ Use factory spring bolts to attach the downpipe to
the catalytic converter.
〈Parts used: 61〉
(3) Use the factory exhaust manifold bracket to
support the downpipe.
※ Use the factory bolt on the transmission side, use
#92 nut/bolt to secure the downpipe to the
bracket.
〈Parts used: 92〉
3-6 Vacuum Piping
(1) Remove the breather/coolant pipe. Have a towel
or rag ready to catch the coolant that will spill out
from the port below the throttle body.
(2) Use #44 ８ φ hose to connect the coolant
passages as shown. Secure the ends with the
provided #53 hose clamps.
〈Parts used:44，53〉
Factory
EX
Bracket
Breather/Water
Pipe Assy.
№29

―１６―
(3) Remove the secondary air control solenoid valve
hoses from the hard lines and take note which
hose goes to which hard line. Attach the
secondary air control solenoid valve to the
provided bracket #68 using the provided M5
nut/bolt #82, then install the bracket onto the
chassis cross bar using the OEMbolt.
〈Parts used: 68，82〉
(4) Connect the ５φ hose routed under the fuel pipe
to the vacuum tank IN side 【Ａ】 (hose with check
valve). Also connect the lower ５φ pipe to the
air control solenoid valve 【Ｂ】 using the provided
hose（７００㎜ cut）.
※ Make sure the hoses are secured to prevent them
from touching the engine belts.
〈Parts used: 43，80〉
(5) Secure the hoses with cable ties.
① 【Ａ】 ５φ hose at the upper pipe and check
valve.
② Intake Manifold and lower ５φ pipe.
〈Parts used: 80〉
№68
Sec. Air Control Valve
Ａ
ＡＡ
Ａ
Ｂ
ＢＢ
Ｂ
Ｃ
ＣＣ
Ｃ

―１７―
3-7 Intercooler Installation
(1) Attach bracket #66 to the radiator support as
shown using the existing hole and the provided
hardware #89.
※ Longer side of the bracket attaches to the radiator
support.
〈Parts used: 66，89〉
(2) Intercooler mounting.
Left and Right Mounting Brackets Use the existing hole on the underside of the frame as shown for
the intercooler mounting brackets. Use the provided nuts/bolts #89 to secure the intercooler in place.
Bottom Mounting Bracket Intercooler and bottom
mounting bracket. Use provided nuts/bolts #89 to
secure the intercooler to the bracket.
〈Parts used: ４，89〉
Right Side
Right SideRight Side
Right Side Left Side
Left SideLeft Side
Left Side
Bottom Side
Bottom SideBottom Side
Bottom Side
№66

―１８―
3-8 Air Pump Relocation
(1) Remove the lower mounting bolt from the air
pump, place the #67 bracket as shown. Use the
factory bolt in the same location it was taken to
secure the bracket down. Use the provided #89
nuts and bolts to relocate the pump towards the
front of the car, mounting it to the end of the #67
mounting bracket as shown.
〈Parts used: 67，89〉
(2) The air pump IN hose is the upper hose and the
OUT hose is the lower hose. Unclip the stay on
both hoses and position the IN hose so it sits
directly below the OUT hose as shown. Remove
the original stay that was holding the IN hose to
make room for the intercooler piping. Re-clip the
OUT hose once the IN hose is positioned below it.
3-9 Suction Pipe Installation
(1) Install the #75 rubber vibration mount onto the
factory intake mounting bracket as shown.
〈Parts used: 75〉
№75
№67
IN
IN

―１９―
(2) Install suction pipe S-1 to the compressor housing
using the provided #62 gasket. Be sure that the
bracket on the pipe is positioned onto the rubber
vibration mount previously installed. Secure S-1 at
the compressor housing with the provided #90
hardware. Secure S-1 at the bracket and vibration
mount with the provided #87 nut.
〈Parts used: ５，62，87，90〉
Install the １２φoil resistant hose #45 from the valve
cover breather nipple to the nipple on the S-1 suction
pipe. Use provided hose clamps #54 to secure both
ends of the hose.
〈Parts used: 45，54〉
※ Install the provided １９φhose (#47) to the air
pump OUT hose using union #74. Secure the
other end of the hose to the suction pipe S-1. Use
provided #56 hose clamps to secure both ends of
the hose, as well as the end of the air pump OUT
hose (3 hose clamps used total).
〈Parts used: 47，56，74〉
№45
№47
№74
Zip Tie here
S-1
Rubber
Mount

―２０―
3-10 Intercooler Piping
(1) Install #75 rubber vibration mount to the factory
hole on the chassis as shown.
〈Parts used: 75〉
(2) Install hose fitting ５ φ － １ /８ Ｐ Ｔ #73 to
compression pipe C-1.
※ Be sure to use Teflon tape on the threads of the
hose fitting.
〈Parts used: 6,73〉
(3) Cut provided vacuum hose to 200mm and route it
between the actuator and C-1 and secure the
hose with zip-ties.
〈Parts used: 43，80〉
(4) Install Compression tube C-1, C-2, C-3 from turbo to
intercooler inlet as shown. Use C-1 Gasket #63.
Compression Tube Ｃ－
Ｃ－Ｃ－
Ｃ－２
２２
２
Using the provided #87 flange nut, secure the
tube to the vibration rubber stub as shown.
Compression Tube Ｃ－
Ｃ－Ｃ－
Ｃ－３
３３
３
The shorter straight side is intercooler side.
〈Parts used No.6,7,8,48,49,51,57,58,63,87,90〉
№73
№75
C-2
C-1
C-2
C-3
C-2
C-3
Secure
here