Edelbrock 1501 Turbocharger Installation Instructions
Contents
1. M8 x 1 25 Nut Exhaust Manifold To Cylinder Head M8 Split Washer Exhaust Manifold To Cylinder Head Keihin Screw MAT Sensor Block Off Plate M10 x 1 5 Studs Exhaust Downpipe to Turbo Outlet Elbow M10 x 1 5 Flange Nut Exhaust Downpipe to Turbo Outlet Elbow M8 x 1 25 25mm Long Bolt Compressor Outlet Pipe to Intercooler Inlet Pipe 4 20 x 2 Hex Head Bolt Turbo Oil Drain Adapter Fitting Steel Oil Pan Socket Head Cap Screw M8 x 1 25 20mm Long Turbo Oil Drain Hose to Turbo Oil Drain Flange M8 Spring Washer Turbo Oil Drain Hose Mounting M8 Lock Washer Compressor Outlet Pipe to Intercooler Inlet Pipe M8 x 1 25 12 point Stainless Steel Nut Exhaust Manifold to Cylinder Head M6 x 1 0 12mm Long Serrated Flange Hex Head Bolt Compressor Inlet to Transaxle Brace Offset Camshaft Sprocket Keys 2 Advanced and 2 Retarded 2005 Edelbrock Corporation Page 2 of 11 Brochure 63 0219 Kit Contents Continued Hose Kit 01 Turbo Oil Drain Hose Assembly Ol Turbo Fuel Rail to Stock Fuel Rail Hose Assembly 01 Fuel Filter to Turbo Fuel Rail Fuel Hose Assembly Ol 2 Silicone Hose Coupling Compressor to Compressor Outlet Pipe 01 2 y2 3 Silicone Hose Coupling Compressor Inlet Pipe to Compressor O1 2 2 5 8 Silicone Hose Coupling Intake Manifold Inlet Pipe to Throttle Body Ol 2 Ya Silicone Hose Coupling Intercooler Outlet Pipe to Intake Manifold Inlet Pipe O2 2 Ys 2 Silicone Hose Couplings Int2. Remove the Oxygen Sensor from the factory lower exhaust header B Pipe and move to the side Disconnect the factory B Pipe from the Catalytic Converter inspect the donut gasket for wear If it is in good shape it may be re used Disconnect the B Pipe from the upper exhaust header Remove the lower intake manifold support bracket bolts at this time Remove the exhaust manifold heat shield and upper exhaust manifold If exhaust manifold gasket is not damaged re use Remove the air conditioning A C condenser fan and temporarily tie back its wiring harness with a supplied tie wrap Remove the A C line support bracket from under the radiator Save the 6mm nut and carefully remove the black plastic hose clip from the bracket Re install the hose clip on the supplied A C line bracket Use the supplied 6mm x 1 0 serrated flange hex bolt and the factory 6mm nut to install the Edelbrock A C line support bracket Remove the spark plug wire cover the spark plug wires and the wire clamps Remove the valve cover Removing the spark plugs will make it easier to turn the engine over in step 8 Remove the plastic Middle Timing belt cover See service manual for reference To simplify the timing belt adjustment turn the engine over to TDC on the number one cylinder closest to the belts The UP arrows on the stock cam sprockets should be up and the TDC marks aligned See Fig 1a Inspect the timing belt for cracks or oil or coolant soaking an
3. Refer to the Honda Factory Service Manual for torque values and sequence Lay out the Coolant Lines and Oil Feed Line in their approximate routing locations The Oil Feed Line the line with the 6AN female fitting should head down below the air conditioning condenser fan towards the driver s side then up along the driver s side of the condenser and towards the back of the engine taking care not to route the line in the way of any moving parts such as pulleys timing belts etc The coolant lines should be routed down toward the passenger side then up and toward the rear of the engine Factory Intake Manifold Removal a Relieve fuel pressure first by loosening the banjo bolt connecting the fuel line to the fuel filter Place a shop towel or rag over the wrench while loosening the banjo to soak up any fuel spray See Fig 4 When loosening or tightening the banjo bolt on the fuel filter can use a 19mm wrench of the hex of the fuel filter can to counteract the torque of loosening or tightening the banjo bolt This will prevent the fuel filter can and bracket from being improperly loaded during loosening or tightening at the banjo bolt Disconnect the fuel injector wiring harness from the bracket on the fuel rail and unplug the harness from the fuel injectors and purge valve Note the locations of each plug on the harness to prevent improper connection during re installation Disconnect the Throttle Position Sensor plug MAP Sensor plug and
4. Remove the stock throttle cable bracket bolts and install the supplied throttle cable bracket onto the Victor X manifold using the stock bolts Remove the stock fuel rail injectors purge valve fuel pressure regulator and install onto the Victor X manifold using the stock hardware Inspect all O Rings and Seals for wear replace if necessary In order to use the factory fuel pressure regulator on Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 6 of 11 Brochure 63 0219 Boost Gauge Adapter Fitting Boost Gauge Line Found in the Boost Gauge Box 3 16 Barb x 1 8 NPT Fuel Pressure Regulator Hose 14 NPT Street Elbow amp 10mm Barb x 1 4 NPT Power Brake Booster Hose 3 16 Barb x 1 8 NPT Cruise Control Vacuum Hose Mototron MAP Sensor Install Supplied Block Off Plate Here Not Pictured 1 4 Barb x 1 8 NPT Blow Off Valve Hose 8mm Barb x 1 4 NPT PVC Hose 9mm Barb x 1 4 NPT Purge Valve Hose 7mm Barb x 3 8 NPT Manifold Water Outlet 8 NPT Plug Fig 6c the Victor X intake manifold you will need to rotate it 180 so that the outlet is now pointing toward the valve cover Attach the Turbo Fuel Rail to Stock Fuel Rail hose assembly female end with the 180 bend to the driver s side of the turbo fuel rail Loop the hose under the Victor X intake manifold and attach the banjo end to the stock fuel rail using the stock banjo nut Use the new banjo sealing washers supplied in the kit A
5. Idle Air Control Motor plug Disconnect the purge line from the purge valve Disconnect the fuel return line from the steel chassis fuel line Disconnect the fuel line from the fuel filter Disconnect the coolant lines from the throttle body and manifold flange Disconnect the vacuum lines at the rear of the manifold The intake manifold support bracket does not need to be removed from the intake manifold It can be removed with the intake as an assembly since the lower bolts were removed previously Remove the throttle cable Remove the factory intake manifold nuts Remove the intake manifold assembly and set aside The intake manifold stud closest to the thermostat housing on the passenger side interferes with the intake flange when installing the intake manifold It is necessary to remove this stud to ease installation of the Victor X manifold Use two intake manifold nuts and jam them together to remove the stud See Fig 5 Set this stud aside Stuff the open intake ports in the cylinder head with paper towels to prevent any debris from entering the engine Thoroughly clean the gasket surface removing any remaining sealant or gasket material Oil Supply Line Installation F With the intake manifold removed there will be much more clearance to install the Oil Supply Adapter Remove the stock oil filter Replace Install the Oil Supply Sandwich Adapter in place of the stock oil filter Make sure the O Ring is facing toward the engine blo
6. housing using the two 8mm x 1 25 20mm long Socket Head Capscrews and the two 8mm spring washers Be sure the Turbo Oil Drain flange O Ring is in place A bit of grease on the O Ring helps to hold it in place The bend in the fitting at the turbo end should point toward the front of the vehicle Attach the female AN fitting to the Oil Drain Adapter on the oil pan Make sure the hose is not kinked Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 7 of 11 Brochure 63 0219 il Install the intercooler grommets into the holes in the lower radiator support as shown See Fig 9a Using a small amount of silicone based spray lubricant on the grommets will make installation easier Mount the intercooler by pressing the pins on the lower edge of intercooler into the grommets See Fig 9b Using the bolt removed from the horn attach the intercooler brace and horn to the center radiator support See Fig 9c Attach Compressor Outlet Pipe to the compressor outlet using the supplied silicone connector and the appropriate hose clamps The outlet of the compressor outlet pipe should face toward the driver s side of the vehicle See Fig 10a Attach the intercooler inlet pipe to the compressor outlet pipe using the three 8mm x 1 25 25mm long bolts O Ring Use a bit of grease on the O Ring to hold in place and the three 8mm split lockwashers See Fig 10b Attach the intercooler inlet pipe to the intercooler using a 2 1 4 to 2
7. length the 4 Red Silicone Hose and connect the wastegate to the fitting on the intake manifold inlet pipe specified in step 7 of the Compressor Inlet Outlet and Intercooler Plumbing Installation section Measure and cut to length the 1 4 Red Silicone Hose and connect the Blow Off Valve to the fitting on the intake manifold specified in Fig 6c 1 Note Whenever cutting wires do not cut next to the plug end Make sure to leave room for a new connection See Fig 15 Directly under the battery tray which was removed earlier is an oval shaped rubber grommet that supports and protects the factory wiring harness as it passes through the firewall Use a sharp blade to cut a round hole approximately 1 2 to 3 4 in diameter in the unused portion of the grommet 2 Working from under the dash carefully route the Edelbrock MotoTron 3 wire MAP sensor connector labeled MAP through the hole in the grommet Route the red power wire ring connector then the Charge Temp 2 wire connector black ground wire and the pink and red injector wires through the grommet as well 3 Attach the MAP sensor connector to the Edelbrock MotoTron MAP sensor installed into the Victor X intake manifold and attach the Charge Temp sensor connector to the sensor in the intake manifold inlet pipe 4 Using the supplied butt splice connectors connect the pink and red injector wires to the same colored wires on the auxiliary injector wire harness wh
8. needed move the location slightly to avoid any interference with the baffle Fig 2d 3 Using a center punch indent each drilling location to prevent the drill bit from walking Pre drill each hole with a 1 8 bit Secure the oil pan on a work bench or on a drill press and drill the outer bolt holes to Drill the center drain hole to 12 Deburr the holes and thoroughly clean the oil pan to remove metal shavings 4 Install the Oil Drain Adapter onto the oil pan using the two 4 20 x bolts We recommend using blue Loctite on the threads and the two 1 4 Stato Seal washers on the inside of the oil pan using the gasket on the outside of the pan See Fig 2d Torque the bolts to 6 8 ft Ibs 5 Apply liquid gasket to the oil pump to block and passenger side cover to block mating surfaces See Fig 2e Re install the oil pan Finger tighten nuts 1 6 See Fig 2e to hold the pan in place Install the Apply Liquid Gasket remaining bolts finger tight Tighten all nuts bolts to 8 9 ft lbs Start with nuts 1 6 and tighten the remaining bolts in a clockwise manner starting in the center and working your way out Oil Pump e 6 Reinstall the bellhousing cover and front and rear stiffening brackets Torque the bolts to factory service manual specifications Turbocharger Exhaust Manifold Assembly Installation 1 Remove the upper air conditioner condenser support bracket and air conditioner line bracket Using a zip tie o
9. silicone coupling and the appropriate hose clamps Attach the bracket on the intercooler inlet pipe to the factory tie down bracket location which was removed earlier using the factory bolt See Fig 10b Attach the intercooler outlet pipe to the intercooler with one of the 2 1 4 to 2 silicone couplings and the appropriate hose clamps Bolt the support bracket on the pipe to the inner fender using one of the factory lower airbox bolts See Fig 10c Install the Blow Off Valve onto the intake manifold inlet pipe Make sure the O Ring is properly seated on the Blow Off Valve flange Install the Blow Off Valve and V Band and tighten the V Itis located 4 Band Install the supplied banjo fitting onto the Blow Off Valve using the supplied sealing washers Install a 1 4 barb to 1 8 NPT fitting for wastegate actuator hose into the hole next to the blow off valve on the intake manifold inlet pipe See Fig 10 Install the CAT Charge Air Temp sensor in to the threaded fitting under the wastegate fitting on the intake manifold inlet pipe See Fig 11 Use thread sealant on the threads of the sensor Attach the intake manifold inlet pipe to the intercooler outlet pipe using the 2 1 4 silicone coupling and the appropriate hose clamps Attach the intake manifold inlet pipe to the throttle body using one of the 2 1 4 to 2 2 silicone couplings and the appropriate hose clamps Attach the intake manifold inlet pipe to the passenger
10. 2 The Edelbrock VTEC Pressure Switch Control Box needs to intercept the VTEC oil pressure signal Locate the VTEC pressure switch wire VTM It is a blue wire with a black stripe located at pin C10 See Fig 16 Cut the wire and strip only the end leading to ECU pin C10 Connect the purple wire from the Edelbrock VTEC pressure switch control box to the Stripped end Leave the other end the one leading to the engine compartment unconnected Cover the end of it with electrical tape to prevent it from making an accidental connection 13 Mount the Edelbrock MotoTron ECU and Edelbrock VTEC Pressure Switch Control box under the dash in a convenient location securing them with wire ties Using a heat gun shrink the insulation on the butt splice connectors Use a piece of heavy cardboard to shield carpeting and any nearby electrical tape or other components that could be damaged by heat Wrap the newly connected wiring with electrical tape to protect it and secure with tie wraps as necessary Reconnect the B amp C plugs to the factory ECU and reinstall the factory ECU Replace the passenger side kick panel Wire Slide Female Terminals Bumper Cover and Fender Liner Modification and Final Parts Re installation 1 On the inside of the front bumper cover a strip of material from the back side of the grill will need to be cut off to clear the intercooler Measure 34 from the mold parting line at each end of the grill and mark the measurement
11. Fitting O2 8mm Barb to NPT Adapter Fitting O1 3 8 Barb to NPT Male Adapter Fitting O1 Plug 02 Sensor Bung Second 02 Sensor Bung Catalog 1501 Rev 11 05 Page 3 of 11 2005 Edelbrock Corporation Brochure 63 0219 INSTALLATION INSTRUCTIONS Initial Parts Removal See factory service manual for procedures where noted 1 D S x00 Offset Camshaft Sprocket Keys Installation 1 on o u 10 11 T2 Begin by disconnecting the battery and draining the engine oil and coolant from the engine Remove the battery hold down using a 12mm wrench and remove the battery Disconnect any wiring attached to the battery tray and remove the tray Set aside This will provide access to the firewall for wiring later on Remove the front lower splash shield and front bumper cover as per the factory service manual procedure The front inner fender liners do not need to be removed You can allow the front inner fender liners to hang free remaining attached to the rear of the front wheel well openings Remove the stock intake tube and upper lower air box following the service manual instructions Save the air box mounting bolts and grommets These will be used to mount the compressor piping to the chassis Remove the lower radiator hose Remove the bolt holding the horn onto the center radiator support and move the horn to the side Remove the driver s side tie down bracket tow hook located behind the lower radiator support
12. Performer X Turbocharging System for 1999 2000 Honda Civic DOHC Vtec B16A2 Catalog 1501 INSTALLATION INSTRUCTIONS PLEASE study these instructions carefully before beginning this installation Most installations can be accomplished with common tools and procedures However you should be familiar with and comfortable working on your vehicle If you do not feel comfortable performing this installation it is recommended to have the installation completed by a qualified mechanic If you have any questions please call our Technical Hotline at 1 800 416 8628 7 00 am 5 00 pm Pacific Standard Time Monday through Friday or e mail us at edelbrock edelbrock com IMPORTANT NOTE Proper installation is the responsibility of the installer Improper installation may result in poor performance and engine or vehicle damage PLEASE complete and mail your warranty card Be sure to write the model number of this product in the Part ____ space THANK YOU Description The Edelbrock Performer X Turbocharging System is a complete Turbo Kit that gives 1999 2000 Honda Civic DOHC VTEC B16A2 owners a 70 80 horsepower increase from turbocharging The Garrett GT 28RS ball bearing turbo comes pre assembled as one unit with a Ni resist cast exhaust manifold and exhaust elbow and inlet oil and water lines for the simplest possible installation The system includes a high performance Victor X intake manifold with four additional injectors and a separate electronic co
13. See Fig 17a Measure 1 from the parting line at the center of the grill See Fig 17a Mark a line connecting the three measuring locations Using a cutoff wheel or other suitable tool cut along the marked out line Temporarily place bumper cover on the vehicle and check for clearance 2 Temporarily place each fender liner in place and mark area where interference with the intake piping occurs Trim out material as needed See Fig 17b 3 Install the fender liners and bumper cover following the Factory Service Manual instructions 4 Install the battery tray and battery Install the battery tie down and reconnect the battery cables 5 Fill the oil to the level recommended in the Final Checklist on page 11 and fill coolant to Factory Service Manual specifications Boost Gauge and Boost Gauge Mounting Pod Installation Follow the installation instructions included with the boost gauge and mounting pod for installation Note The boost gauge must be installed to allow you to properly monitor the amount of boost pressure If the boost reads higher than normal 6 8 psi for any reason do not drive the vehicle Running higher than recommended boost pressures on a stock engine could result in engine damage if driven repeatedly Contact our Tech Line at 800 416 8628 for assistance if overboost occurs Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 10 of 11 Brochure 63 0219 Final Checklist Note Do not start v
14. ash is not properly adjusted the increased temperatures created by the increased power output could accelerate valve seat wear and cause burnt valves If for any reason your engine has oil pressure that is below the acceptable service limits as specified in the Factory Service Manual this problem should be corrected before installing this turbocharger kit Note Check kit contents on the following page before starting your installation Oil Supply Sandwich Adapter The Oil Supply Sandwich Adapter included with this kit is designed to be installed on U S Domestic Market USDM B16 engines These engines feature an oil filter that mounts directly to the engine block Some J apanese Domestic Market DM B16 engines feature an oil cooler mounted between the oil filter and the engine block If your engine has an oil cooler you must use a different Oil Supply Sandwich Adapter It is Edelbrock part 22 1505 If you require the 22 1505 adapter please call the Edelbrock Tech Line at 1 800 416 8628 for assistance and ordering instructions After Installation Before Starting the Vehicle We recommend the use of a synthetic 10W30 motor oil Mobill was used in our testing Before starting the vehicle the oil drain hose should be disconnected from the oil pan and the engine should be turned over with the starter until oil is running out of the oil drain hose Note This may take one or two minutes of intermittent cranking for the oil system to be primed and for
15. cifications for your vehicle Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 1 of 11 Brochure 63 0219 Qy Kit Contents Description Individual Parts Ol Turbocharger Exhaust Manifold Exhaust Elbow Oil Water Line Assembly 01 Perfomer X Intake Manifold Turbo Fuel System Assembly Ol Oil Supply Sandwich Adapter Assembly Note A 12 allen wrench is required for installation of the adapter 01 Intercooler Ol Compressor Inlet Pipe Cast Aluminum Ol Compressor Outlet Pipe Cast Aluminum O1 Intercooler Inlet Pipe 01 Intercooler Outlet Pipe O1 Intake Manifold Inlet Pipe Ol Coolant Pipe Lower Radiator Re Routing O1 Exhaust Down Pipe Ol Air Filter Attachment Hose Clamps Assembly Q1 Blow Off Valve Assembly 01 Boost Gauge Plumbing Assembly 01 Boost Gauge Mounting Pod Pillar Mount O1 Gasket Intake Manifold Ol E O Sheet 01 E O Decal Wiring Kit Ol Auxiliary Engine Management Computer O1 VTEC Pressure Switch Control Box a1 Main Wiring Harness Ol Auxiliary Fuel Injector Wiring Harness O1 2 Bar MAP Sensor O1 CAT Sensor O8 Butt Splice Connectors Wiring O10 8 Tie Wraps Hardware Kit Ol Ol Ol Ol O7 O7 O7 a2 a3 a3 a4 a2 a2 a2 a4 Ol Ol a2 Catalog 1501 Rev 11 05 Throttle Cable Bracket Support Brace Compressor Inlet Pipe to Transaxle Air Conditioning Line Re Route Bracket MAT Sensor Block Off Plate M8 x 1 25 Stud Exhaust Manifold To Cylinder Head
16. ck and the threaded stud with hex opening is facing out Tighten with a Y2 Allen Wrench Make sure the blue fitting is facing toward the driver s side pointing upward slightly about the 10 o clock position Install a new oil filter Route the oil supply line to the sandwich adapter Using a light coat of oil on the threads tighten the female fitting onto the blue fitting on the sandwich adapter Victor X Manifold Installation 1 Note Use anti sieze or teflon paste on the threads of fittings before installing them into the intake manifold Install the vacuum fittings MotoTron MAP Sensor and supplied block off plate on the underside of the Victor X intake manifold See Fig 6a Install the water outlet fitting into the mounting flange Install the 1 8 NPT plug into the water outlet fitting See Fig 6b Refer to Fig 6c for Fitting Descriptions Remove the idle air control motor IAC from the factory intake manifold and install onto the Victor X intake manifold Remove the throttle body with MAP sensor attached and two throttle body studs from the factory intake manifold Using two nuts on the studs and jamming them will help get the studs out of the stock intake manifold See Fig 5 Install the two throttle body studs into the Victor X intake manifold one on the upper right bolt hole of the throttle body mounting flange and one on the lower left bolt hole Install the stock throttle body and gasket onto the Victor X manifold
17. d replace if necessary Refer to your service manual for complete replacement instructions Wipe up any oil or solvent that gets on the belt while you are working on it Keys as viewed when Loosen Do not remove the cam sprocket mounting bolts looking at the pulleys oes L i from the driver s side see ae Exhaust Intake Remove both cam sprocket mounting bolts and the cam sprockets Re a ui ooh ca Loosen Do not remove the belt tensioner mounting bolt Install the supplied offset keys and re install the cam sprockets See Fig 1b Hand tighten sprocket mounting bolts at this time Slip the timing belt back over the sprockets making sure the UP arrows and TDC marks are aligned These will be slightly offset due to the offset keys See Fig la Tighten sprocket mounting bolts to 40 ft lbs Rotate engine 5 6 revolutions counterclockwise when facing engine pulleys to seat the timing belt Tighten the tensioner mounting bolt to 40 ft lbs If you can twist the belt more than 90 by hand the belt is too loose If so check to see if the tensioner is stuck by loosening the mounting bolt and pulling up on the tensioner use a bent hanger or hook Replace the middle timing belt cover Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 4 of 11 Brochure 63 0219 13 Clean the valve cover seal surfaces on the head If the seal is not cracked or hardened it may be re used Press it into the receiver g
18. ehicle before completing this list Q Make sure that all fluids are at the recommended factory levels However the oil level should be kept at approximately 1 4 of the distance from the low to high marks on the dipstick to help oil drainback from the turbocharger Check oil level more often to make sure it does not run below the low mark on the dipstick See Fig 18 Note As stated above we recommend the use of a synthetic 10W30 motor oil Mobill was used in our testing Q Prime the turbocharger oil supply Before starting the vehicle the turbocharger oil drain hose should be disconnected from the oil pan and the engine should be turned over with starter until oil is running out of the oil drain hose This will ensure that the turbo is lubricated before initial start up This should be done with the spark plugs removed and the wiring harness plug disconnected from the Auxiliary Engine Management Computer Disconnecting the wiring harness from the Auxiliary Engine Management Computer will disable the ignition Note It may take one or two minutes of intermittent cranking for the oil system to be primed and for oil to reach the drain hose To keep from abusing the starter crank the engine in 20 30 second intervals until oil reaches the drain hose Once oil flow is established reconnect the turbocharger oil drain hose and Auxiliary Engine Management Computer Check the oil level again after priming the oil supply Q Make sure the oil drain hose has
19. ercooler Inlet Outlet Pipes to Intercooler O2 1 1 3 8 Silicone Hose Coupling Coolant Re Route Pipe Q 3ft 3 8 Cam Cover Breather Hose Q 7ft 1 4 Red Silicone Hose Wastegate amp Blow Off Valve Q 5ft 5 16 Purge PCV Hose Q 3ft 1 4 Fuel Hose Fuel Pressure Regulator Return Hose Clamp Kit 01 Hose Clamp 2 9 16 3 a4 Hose Clamps 2 1 16 3 O5 Hose Clamps 1 13 16 2 34 a2 Hose Clamps 1 9 16 2 1 2 a4 Hose Clamps 1 5 16 2 1 4 O2 Hose Clamps 5 16 I D Gasket Kit O1 Throttle Body to Intake Manifold Gasket 01 Turbo Outlet Elbow to Exhaust Down Pipe Gasket Ol MAT Sensor Block Off Plate Gasket 01 02 Sensor Bung Gasket Second 02 Sensor Bung Ol Oil Drain Adapter Fitting Gasket a2 Y4 Stato Seal Washer Turbo Oil Drain Adapter a4 12 3mm I D 16 2mm 0 D 1 5mm Thick Aluminum Crush Washer Fuel Banjo Fittings Ol Compressor Outlet Pipe to Intercooler Inlet Pipe O Ring O1 Turbocharger Oil Drain Flange O Ring Ol Inlet Air Temperature Sensor Grommet O2 Lower Intercooler Mount Grommets Fitting Kit 01 Turbo Oil Drain Adapter Fitting Ol 10mm Barb to NPT Adapter Fitting Ol 17mm Barb to 3 8 NPT Adapter Fitting O 2 3 16 Barb to 1 8 NPT Adapter Fitting 01 Y4 NPT to 1 4 NPT Female Street Elbow O2 1 8 NPT Pipe Plugs Q2 1 4 Barb to 1 8 NPT Adapter Fitting Q2 8mm Barb to 1 8 NPT Adapter Fitting O1 9mm Barb to NPT Adapter
20. ich should already be connected to the injectors Use a heat gun or blowdrier to shrink the butt splice connector insulation Use a piece of heavy cardboard to shield any nearby electrical tape or other components that could be damaged by heat NOTE DO NOT USE A LIGHTER OR OTHER OPEN FLAME IN THE ENGINE COMPARTMENT TO SHRINK THE SPLICE CONNECTOR INSULATION 5 Remove the engine compartment fuse box cover and use an 8mm socket to remove the screw holding the white power wire Connect the red power wire to this terminal using the stock screw 6 The black ground wire should be connected to the battery grounding strap on the shock tower Make sure this connection is clean and free of corrosion 7 Remove the passenger side kick panel to access the factory ECU Remove the ECU from its bracket Partially unwrap the wiring harness coming out of the factory ECU to have more room to work with the wiring Unplug the B 25 pin and C 31 pin plugs from the factory ECU 8 The Edelbrock MotoTron ECU modifies the VTEC switching RPM Locate the VTEC Signal wire on the wire side of the factory wiring harness at the ECU This is a green wire with a yellow stripe located in position B12 See Fig 16 Cut the wire and strip both ends The end leading to the engine compartment should be connected to the grey wire VTEC on the Edelbrock harness The end leading to pin B12 is connected to the red wire on the Edelbrock VTEC Pressure Switch Control Box The Edelbrock VTEC Pres
21. no kinks and that portions of the hose do not hang more than slightly lower than the drain fitting in the oil pan This can cause a back up of oil in the hose preventing proper draining of oil from the turbo housing This can result in small amounts of oil being drawn into the turbine housing causing oil smoke to be seen coming from the exhaust Q Along with synthetic oil we strongly recommend using a colder sparkplug in the engine In our Keep level testing we used Champion RC9MC4 sparkplugs stock 434 You may use any manufacturer s between plug that matches the stock plug configuration and is two to three heat ranges colder than stock Low and 1 4 Full Q Start the engine and check for any vacuum fuel or oil leaks Q Use only premium grade 91 octane or higher fuel with this turbo kit Lower grade fuel can Cause pre ignition knock and possible engine damage if used Ignition Timing You MUST reset your ignition timing BEFORE driving the vehicle Installation of offset camshaft sprocket keys will change the factory ignition timing Ideally you should check your timing upon first starting the engine Set your ignition timing to factory specifications for your vehicle Maintenence and Service Follow your regular factory recommended service intervals However we recommend changing the oil every 3000 miles as compared to the factory recommended 7500 miles Special Notice This Edelbrock part has received an Executive Orde
22. ntroller to add fuel and retard spark under boosted conditions The Edelbrock Exhaust manifold and elbow are designed for maximum flow and high velocity for quicker turbo spool up We have included an intercooler blow off valve windshield pillar mount boost gauge a turbo oil supply adapter and pre assembled Russell oil water and fuel lines to make this one of the most complete kits on the market Before Beginning This installation can be accomplished using common tools and procedures However one should have a basic knowledge of automotive repair and modification and be familiar with and comfortable working on this vehicle If you do not feel comfortable working on a large project such as this it is recommended to have the installation completed by a professional mechanic Keeping a 1999 2000 Honda Civic Si Service Manual on hand for reference is helpful REMEMBER WHEN WORKING AROUND GASOLINE DO NOT SMOKE AND KEEP ALL OPEN FLAMES SPARKS AND OTHER SOURCES OF IGNITION AWAY FROM THE WORK AREA Failure to do so can result in a FIRE or EXPLOSION Installing this turbocharger kit will substantially increase the power output of your engine Before installing this kit you should perform a compression test to ensure that your engine is in good condition Consult a Factory Service Manual for the proper compression test procedure and acceptable in service limits The valve lash should be properly adjusted If the valves are not properly seating or the valve l
23. oil to reach the drain hose To keep from abusing the starter crank the engine in 20 30 second intervals until oil reaches the drain hose This will ensure that the turbo is lubricated before the initial start up This should be done with the spark plugs removed and the wiring disconnected from the Auxiliary Engine Management Computer Disconnecting the wiring from the auxiliary computer will disable the ignition Along with synthetic oil we strongly recommend using a colder spark plug in the engine In our testing we used Champion RC9MC4 spark plugs Stock 434 You may use any manufacturer s plug that matches the stock plug configuration and is two to three heat ranges colder than stock The use of 91 octane fuel minimum is required with the use of this Performer X turbocharger kit The increased cylinder pressures created as a result of turbocharging can lead to detonation pinging if lower grade fuel is used The oil level should be kept at approximately 1 4 of the distance from the low to high marks on the dipstick to help oil drainback from the turbocharger Also using a high flow aftermarket exhaust in combination with the Performer X turbocharger kit is highly recommended Ignition Timing You MUST reset your ignition timing BEFORE driving the vehicle Installation of offset camshaft sprocket keys will change the factory ignition timing Ideally you should check your timing upon first starting the engine Set your ignition timing to factory spe
24. r number E O from the California Air Resources Board C A R B making it legal for street use on pollution controlled motor vehicles in all 50 states To assist you with emissions inspection we have included a silver fan shroud decal to verify that this part is a legal replacement part on the vehicle for which it is cataloged The adhesive backed decal should be affixed next to the existing emission and engine specification decal Do not cover your original equipment specification decal with the Edelbrock fan shroud decal Edelbrock Corporation 2700 California Street Torrance CA 90503 Tech Line 800 416 8628 E Mail edelbrock edelbrock com Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 11 of 11 Brochure 63 0219
25. r twine carefully flex the lines and condenser as far forward as possible and temporarily secure This will allow more clearance to place the turbocharger exhaust manifold assembly 2 Install the seven supplied 8mm x 1 25 studs into the exhaust manifold bolt holes Hand tighten only Note Do not reuse the factory exhaust bolts 3 The turbocharger exhaust manifold assembly must be installed from underneath the engine compartment This will require the vehicle being raised on jack stands or a lift WARNING MAKE SURE THE VEHICLE IS ON LEVEL GROUND AND SUPPORTED SECURELY BY J ACKSTANDS NEVER WORK UNDER A VEHICLE THAT IS SUPPORTED BY AJ ACK ONLY Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 5 of 11 Brochure 63 0219 Being careful not to damage the oil feed and coolant lines bring the turbo assembly up into position from underneath the vehicle Set turbo assembly in place using the stock exhaust gasket Note If the gasket is in good condition it may be re used The gasket should show no signs of leaking cracks missing pieces or burnt areas If the gasket is not in good condition it should be replaced Thoroughly clean flange of any old gasket material Using the supplied 8mm x 1 25 12 point nut on the center exhaust manifold stud See Fig 3 and the six Supplied 8mm x 1 25 6 point nuts attach the turbo assembly to the engine block You may need to bend the dipstick tube slightly to clear the exhaust manifold See Fig 3
26. roove in the cover and apply automotive sensor safe silicone to the eight corner edges on the head seal surface where the cam caps meet the head Allow to air dry for 10 minutes before installing the cover 14 Tighten the cover to 8 ft lbs in two or three steps See Fig 1c 15 You do not need to re install the spark plug wires and cover at this time Oil pan rail Fig 2c Oil Drain Adapter Installation Note Removal of the oil pan is required to install the turbo oil drain adapter 1 Remove the front and rear stiffening brackets connecting the block to the bell housing See Fig 2a Remove the bellhousing cover Using a 10mm socket remove the oil pan nuts and bolts and remove the oil pan If necessary gently tap on the oil pan with a rubber or plastic mallet to loosen the seal between the oil pan and the engine block Carefully remove and inspect the oil pan gasket If it is not cracked or torn it may be re used 2 The Oil Drain Adapter requires the oil pan to be drilled Mark the area to be drilled Center the drain hole below the third bolt hole from the driver s side on the front of the oil pan See Fig 2b 1 5 from the Oil Pan Rail See Fig 2c Using a scratch awl mark the center of each bolt hole 9 16 away from the center of the center drain hole so the distance between the bolt holes from center to center is 1 125 Fig 2c Make sure this location will not interfere with the oil baffle inside the pan If
27. side shock tower using one of the stock air box bolts Install a 1 4 barb to 1 8 NPT adapter fitting wastegate actuator hose into the intake manifold inlet pipe Install the Exhaust Down Pipe Thread the three 10mm x 1 5 studs into the exhaust elbow hand tight Making sure the exhaust down pipe gasket is in place install the exhaust down pipe onto the exhaust elbow using the provided 10mm x 1 5 flanged nuts Using the stock donut gasket if in good condition attach the exhaust down pipe using the factory bolts Attach the down pipe to the lower exhaust bracket using the factory bolts See Fig 12 Re install the factory O sensor Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 8 of 11 Brochure 63 0219 Connect o Coolant Line and Vacuum Hose Connections 1 Auxiliary Engine Management Computer Installation Install the supplied coolant hard pipe in place of the lower radiator hose using the supplied silicone couplings and hose clamps See Fig 13 Route one of the coolant lines from the turbo to the thermostat housing Cut to fit Connect the coolant line to the fitting on the side of the thermostat housing that originally connected a coolant line to the throttle body Route the other coolant line from the turbo to the throttle body coolant fitting Cut to fit Connect the line to the throttle body coolant fitting See Fig 14a amp 14b Use the supplied hose clamps to secure Measure and cut to
28. sure Switch Control Box is the small black box with black purple and red wires 9 The Edelbrock MotoTron ECU modifies the ignition signal to control the ignition timing Locate the Ignition Control wire ICM It is a yellow wire with a green stripe found at pin B13 See Fig 16 Cut the wire and strip both ends Connect the end leading to the engine compartment to the green black wire EST1 on the Edelbrock harness The end leading to pin B13 should be connected to the red wire CRANK on the Edelbrock harness Catalog 1501 2005 Edelbrock Corporation Rev 11 05 Page 9 of 11 Brochure 63 0219 10 The Edelbrock MotoTron ECU needs a switched 12 volt source Locate the Ignition Power wire IGP1 which is a yellow wire with a black stripe located at pin B1 See Fig 16 Cut the wire and strip the ends With a butt splice connector connect both ends to the purple wire KEYSWITCH on the Edelbrock harness 11 The Edelbrock MotoTron ECU and the Edelbrock VTEC pressure control switch both need to be grounded Locate the ground wire PG2 It is a heavy black wire found at pin B10 See Fig 16 Cut and strip both ends of the ground wire Connect one end of the ground wire to the black GROUND wire on the Edelbrock harness and the other end to the black wire on the Edelbrock VTEC pressure switch control box Reconnect both of these ends to eachother You may need more than one butt splice connector or make more than one connection to PG2 1
29. ttach the auxiliary fuel injector wiring harness to the auxiliary injectors 3 Using the supplied gasket install the Victor X manifold throttle body fuel system assembly onto the engine See Fig 7 Remember Remove the paper towels or rags before installing the intake manifold After placing the Victor X manifold onto the intake studs and hand tightening the studs you will have clearance to install the stud that was removed previously If desired this stud may be replaced with a 8mm x 1 25 25mm long bolt You may now tighten all intake nuts Follow the factory service manual for proper torque values and tightening sequence Re connect all factory sensors and vacuum hoses Re connect the factory fuel injector wiring harness to the stock fuel injectors and re attach the harness to the fuel rail bracket Re connect the stock throttle cable to the new bracket and following the factory service manual adjust the throttle cable for proper operation 4 Connect the Fuel Filter to Turbo Fuel rail hose assembly Connect the 90 banjo end to the fuel filter using the factory banjo bolt Use the new banjo sealing washers supplied in the kit Connect the 90 6 AN female end to the auxiliary fuel rail Using the supplied 4 SAE fuel hose connect the fuel pressure regulator outlet to the fuel return line using the stock hose clamps Compressor Inlet Outlet Intercooler Plumbing and Intercooler Installation 1 Press the Manifold Air Tempera
30. ture sensor grommet into the non threaded hole in the compressor inlet pipe Install a 3 8 barb x 1 4 NPT fitting into the threaded hole in the pipe Fit the Compressor Inlet Pipe to the compressor inlet using the supplied silicone coupling and clamps See Fig 8a Do not fully tighten Adjust the compressor Inlet pipe for alignment and using the Compressor Inlet Pipe support brace connect the support brace to the compressor inlet pipe using the 6mm x 1 0 12mm long bolt Hand tighten Find the ground wire bracket on the transaxle housing Remove the bolt that attaches the ground wire to the bracket and attach the support brace and ground wire to the bracket using this bolt See Fig 8b Tighten all nuts bolts and hose clamps Connect Air Filter Assembly to the compressor inlet pipe using the supplied silicone coupling and hose clamps 2 Cut the 3 8 hose to length and connect it to the fitting on the compressor inlet pipe on one end and to the valve cover breather port on the other end Remove the factory Manifold Air Temperature Sensor from the factory Air Inlet Pipe and install into the grommet in the Compressor Inlet Pipe The wiring for the manifold air temperature sensor MAT sensor plug needs to be separated from the wiring harness so that the MAT plug can reach the MAT sensor in the compressor inlet pipe Re wrap the harness with electrical tape Attach the plug to the MAT sensor 3 Attach the Oil Drain Hose Assembly to the turbo
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