GReddy Turbo Kit User manual

GReddy Turbo Kit
Acura RSX Type-S DC5 (K20A) T517Z 8cm2

Acura RSX Type-S DC5 (K20A) T517Z 8cm2
Installation Manual
Please read the entire manual before installing this kit.
Application:
Make Model Chassis Year
Acura RSX Type-S DC5 02~03
•This GReddy Turbo Kit Is designed only for the vehicles specified above.
•GReddy Front mount intercooler kit is recommended with this kit
•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. Ignition Harness (12P) 1
17. Sensor Adapter Type-AII US 1
18. Oil Pressure Hose SUS 600mm 1
19. “ Banjo Fitting male & female (small) 1set
20. “ Copper Washer 10∅(t=1.0mm) 2
21. “ Three Way Fitting 1
22. “ Union Fitting 1/8PT – 1/8 PT 1
23. “ Union Fitting 1/8PT – 1/8PF 90°1
24. Oil Return Flange tube 16∅(Turbo side) 1
25. “ Banjo Fitting male & female 16∅(Engine side) 1Set
26. “ Banjo Spacer t=16 1
27. “ Banjo Copper washer 15.5∅(t=1.0mm) 3

1. Parts List
28. Vacuum Hose (Blue) 5∅x 200mm (for Actuator) 1
29. Rubber Hose 8Ø X 500mm (for Idle controller) 1
30. Rubber Hose 16Ø X 400mm (for Oil return) 1
31. Rubber Hose 19Ø X 190mm (for Blow by) 1
32. Silicone Hose 60Ø x70mm 2
33. Reducer Hose 50Ø – 60Ø 1
34. Reducer Hose 60Ø – 70Ø 1
35. Hose band 8Ø Tridon #4 2
36. Hose band 16Ø Tridon #10 2
36. Hose band 19Ø Tridon #12 2
38. Hose band 50Ø Tridon #32 1
39. Hose band 60Ø Tridon #36 7
40. Hose band 70Ø Tridon #44 1
41. Gasket Turbo in 2
42. Gasket Turbo out 1
43. Gasket Turbine in 1
44. Gasket Turbine out 1
45. Gasket Down Pipe 1
46. Gasket Oil Return Flange Tube Small 1
47. Heat Shield Turbine 1
48. Heat Shield Down pipe 1
49. Thermo-cloth 100mm X 1000mm sheet 4
50. Zip ties 150mm 10
51. Zip ties 200mm 5
52. Three-way Vacuum Tee 10∅-6∅-10∅1
53. Suction pipe bracket 1
54. Oil return hose bracket 1
55. Airinx hose fitting 8∅-M18 1
56. Intake Air Temperature Grommet 1

1. Parts List
57. M6 X 10 P=1.0 B S/W F/W - (Down pipe heat shield) 2
58. M6 X 15 P=1.0 B S/W F/W - (Suction pipe & compression pipe bracket) 2
59. M6 X 15 P=1.0 B S/W F/W N (Suction pipe bracket) 1
60. M6 X 15 P=1.0 B S/W - - (Oil Return Bracket) 2
61. M8 X 15 P=1.25 B S/W F/W - (Turbine heat shield) 2
62. M8 X 30 P=1.25 B S/W F/W N (Compressor inlet) 2
63. M8 X 20 P=1.25 B S/W F/W - (Compressor outlet) 2
64. M8 X 30 P=1.25 B S/W - N (Exhaust manifold – Turbo in flange) 7
65. M8 X 75 P=1.25 B S/W - - (Turbine out) 2
66. M8 P=1.25 - - - N (Down pipe) 2
67. 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 26

1. Parts List
27 28~31 32 33~34 35~40
41 42 43 44 45
46 47 48 49 50~51
52 53 54 55 56
57~67

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 Remove 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 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.
3-4 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)

3-5 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.
(Parts used #2, 67)
3-6 Turbocharger Installation
(1) Wrap the thermo cloth the actuator as
shown.
* The heat off the manifold can damage
the actuator with out the thermo cloth.
(2) Install stud bolts on to the exhaust
manifold, then mount the turbocharger
to the manifold using provided gasket.
(Parts used #1,43,64)

3-7 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)
3-8 Oil Return Installation
(1) Install the provided oil return pipe
to the turbocharger using the provided
gasket and hardware as shown.
(Parts used #24, 46, 60)
(2) Remove the oil drain bolt and install the
provided oil return banjo bolt using
spacer and copper washers as shown.
(Parts used #25, 26, 27)
(3) Wrap the provided 16∅hose with thermo
cloth. Then Install the hose to connect
the oil return pipe from the turbo to the
oil return banjo fitting on the oil pan.
* Route the hose behind the intermediate
drive shaft as shown.
(Parts used #30, 36, 49)
(4) Install the Oil return hose bracket to the
block and secure the hose to the
bracket using provided zip ties as
shown.
(Parts used #50, 54)

(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: 20mm
Important!
With out this proper clearance, there is a
possibility of the return hose to fail and can
cause fire and damage the engine.
3-9 Compression Pipe Installation
(1) Install Compression pipe C-1 to the out-
let of the turbo using the provided
gasket and hardware.
(Parts used #6, 42, 63)
(2) Loosen the hose clamp on the Radiator
hose and rotate the hose so it comes up
slightly.

(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. Also, check the clearance
between the radiator hose and
compression pipes.
(Parts used #7, 8,32, 33,34, 38,39,
40,58)
(4) Cut the master power vacuum hose by
the intake manifold and install the 3-way
fitting. Connect the 5∅side to the
actuator with the provided 5∅hose.
* Secure all the vacuum hose with zip ties
to prevent the hose from coming off the
fitting.
(Parts used #28,50,52)
3-10 Intake Pipe Installation
Hose Adapter
Tabs
Main Body
(1) Remove the top bolt on the Airinx air
filter and remove the outer frame .
(Parts used #10)
(2) Install the provided hose adapter to the
inner frame of the Airinx.
(Parts used #11)
(3) Reinstall the outer frame and secure it
with the top bolt.
(4) Remove the rubber plug on the Airinx
and install the union fitting as shown.
(Parts used #55)

(5) Install the provided intake air
temperature sensor grommet to the
suction pipe S-1 as shown.
IAT Sensor
Grommet
(Parts used #4, 56)
(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
turbo kit. With out it, the system can
exceed the set boost level and can
damage the engine.
(7) Install the Airinx air filter and S-1.
Secure the suction pipe bracket to the
factory air cleaner box mounting point
as shown. S-1
Mounting point
* Make sure that the Airinx and the piping
does rub up on to the battery.
(Parts used #32,39,53,58,59)
(8) Connect the blow by tube from the valve
cover to the S-1 with the provided 18∅
hose and clamps. Also connect the air
assist control valve to Airinx using
provided 8∅hose and clamps.
Blow by hose
To air assist
Control valve
(Parts used #29,31,35,37)

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.
(Parts used #45, 48)
(3) Install the downpipe to the turbo using
provided gasket and hardware.
* Make sure that there is enough
clearance between the downpipe and
the oil pressure line.
(Parts used #3,44,64,65)
(4) Reinstall the catalytic converter and
reconnect the o2 sensor connectors.
* Reuse factory hardware to bolt the cat
back on but the bolts with springs will
require the provided nuts.
(Parts used #66)
•Heat Shield Installation
(1) Install the turbine housing heat shield on
to the downpipe using the provided M8 x
15mm bolts.
* Make sure that there is enough
clearance between the oil pressure line
and the power steering line.
(Parts used #47,61)

(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.
(2) Remove the injector clips off the rail,
and remove the injectors.
(3) Install the new injectors on to the rail.
* Lube the o-rings on the injectors and
make sure not to damage the o-ring
when installing them in to the rail.
(Parts used # 12)
(4) Replace the stud bolts and spacers that
holds the fuel rail down with the
provided stud bolts and spacers.
(5) Install the fuel rail assembly to the
intake manifold.
(6) Remove the injector wire cover and cut
the factory injector connectors. Cut the
provided injector harness to the same
length of the cut factory connectors.
(Parts used # 13)
Soldered.
Make sure the wires are properly
4. Tape up the exposed wires.
3.soldder the wires
2. Twist the two ends together.
1.Strip the wire ends.
How to Solder
(7) Solder the connectors to the harness
and connect them to the injectors.
Reconnect the ground wire back to the
manifold.

3-14 e-Manage Installation
(1) Remove the cover under the glove box to access the ECU and ECU harness.
(2) Install the Grey wire to the e-Manage I/J Harness (18Pin) connector as shown
below.
(3) Install the ignition harness wires in the e-Manage I/G Harness (12Pin) connector
as shown below.
* When inserting the wires in to the connectors, make sure that the direction of the
pins are correct and push them in all the way until they click in.
Grey
PL
/
W
BL/B O/B Y/W Y/B PL/B
BL/W O/W
IG Harness connector 12P
I/J Harness connector 18P
(4) Connect the I/J and I/G Harness to the factory ECU harness as shown in the
diagram on next page.
(Parts used #15, 16, 17)
Important
•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.
•It is recommended to solder all wires and use electrical tape or shrink warp
to insulate the wire connections.

8
6 4
2
73 7 9
10 13 115 6 18
4 23 222 2
25 6 29 31
1 2 3 4 5 6
8 10 4113 15 16
8 117 22
21 23 24
1 2 3 4 5 6 7 9
1
1 1
10 2
16
15 2 9 1
18 20 1
23 2
23 4 6 2
25 2
27 2
8 0 3
9
Connector E
(31P)
Connector D
(17P)
Connector C
(22P)
Connector B
(24P)
Connector
A
(31P)
B3 B5
A19 A9 B4
B2
A5
Connector
Sensor adapter IN (W)
Sensor adapter Out (G) Male Female
18-8 (PL/R)
18-3 (W)
18-10 (G) 18-7 (Y/R)
Splice
18-12 (B) 18-6 (O/R)
18-18 (B/R)
18-5 (BL/R)
12-5 (BL/W)
12-12 (BL/B)
12-4 (O/W)
12-11 (O/B)
12-10 (Y/W)
18-11 (BR)
12-9 (Y/B)
12-3 (PL/W)
12-8 (PL/B)
18-4 (GR)
18-13 (R)
Sensor adapter GND (B)
E26
A3
A10
A15
A27
A28
A29
A30
Color Code: W- White, G- Green, B- Black, BL - Blue, BR - Brown, R- Red, GR - Grey, PL - Purple, Y- Yellow, O- Orange

e-manage Factory ECU
Pin
# Wire Color Description ECU Pin # Color Code
3 White MAP IN A19(harness) Green/Red MAP
4 Grey Throttle A15 Red/Black TPS
5 Blue/Red INJ 1 B5 Brown INJ 1
6 Orange/Red INJ 2 B4 Red INJ 2
7 Yellow/Red INJ 3 B3 Blue INJ 3
8 Purple/Red INJ 4 B2 Yellow INJ 4
10 Green MAP
OUT
A19
(ECU side)
Green/Red MAP
11 Brown RPM E26 Blue NEP
12 Black GND A5 Black PG1
13 Red +B A3 Yellow/Black IGP1
18 Black/Red INJ GND A5 Black PG1
e-manage Factory ECU
Pin # Wire Color Description ECU Pin # Color Code
3 Purple/White IGT4 IN A27(ECU side) Brown IGPLS
4
4 Orange/White IGT2 IN A29(ECU side) Blue/Red IGPLS
2
5 Blue/White IGT1 IN A30(ECU side) Yellow/Green IGPLS1
8 Purple/Black IGT4
OUT
A27(Harness) Brown IGPLS
4
9 Yellow/Black IGT3
OUT
A28(Harness) White/Blue IGPLS
3
10 Yellow/White IGT3 IN A28(ECU side) White/Blue IGPLS
3
11 Orange/Black IGT2
OUT
A29(Harness) Blue/Red IGPLS
2
12 Blue/Black IGT1
OUT
A30(Harness) Yellow/Green IGPLS1
* Looking at harness side.
I/J Harness (18Pin)
* Looking at harness side.
IG Harness (12Pin)
Sensor Adapter Factory ECU
Wire Color Description ECU Pin # Color Code
White (male) KNK IN A9(Harness) Red/Blue KS
Green (female) KNK OUT A9(ECU side) Red/Blue KS
Black KNK GND A10
Green/Yellow SG2
Important !
Make sure the all the wire connections are correct. If they are connected
incorrectly, it can damage the e-Manage, ignition coils, and/or ECU.
(5) Reinstall the ECU back in its place, and secure the e-Manage next to the ECU.
* Avoid mounting the e-Manage unit in the area that would be exposed to direct
sun light, moisture, or near heater outlet