Cybernation Motorsports RSX Stage I Installation Guide
Contents
1. K K K K K K k K K k k K K k K K K K K K K 3 Down Pipe Dump Pipe Turbo Manifold Exhaust Manifold Waste Gate Note The Waste Gate Brand may vary due to availability and customer preference Air Fuel Gauge Boost Gauge 4 Layer Thermal Flex Couplers Throttle Body Hose silicon transition Cobra Fitting 90 Degree Set of Vacuum Lines 4 Oil Feed Line 12 1 8 Female Tee 10 Oil Return Line Oil Return Flange Hose Clamps 036 Large Clamps 56 10 Bulkhead Nut 10 Hose Fitting male 10 Hose Fitting female 1 8 Nipple Flare Rubber Grommet Turbo Bolts Fuel Rail Bolts amp Washers Wiring Diagram Tools and Equipment List EEEE NOTE tools listed what Cybernation Motorsports uses during installations Some tools may may not be substituted Some tools such as socket types are specific and required for the installation and will be labeled accordingly COPPER Screw Drivers Assorted Regular Assorted Phillips Pry Bar optional but makes life easier 1 r 3 Hammer Steel Rubber or Plastic Ratchet Set Ratchet Extensions 3 6 24 Sockets Metric2. Y UMOYS SE OU SYA BLY SE UMOYS 93 Aeg 22 20 YUHYSJEBY 7 UMOUS DIY 1 ORUM a PET 4 r sobu 389 BPISU Uses SE WAOYS noke nda EAU 23 yeay 2 AJIA OJU Be Aeg spis 79609557 JED BU 52 UMOYS noke 193 aps 24 apis 2 4 Jay dein lt By UMOYS NUM UEIPIEND MOJA XJ Jeo SE 123 7775 Aeg 25 JO Jeay keq poy UBAS PUN 3 UBIPIENS AMAS pay UIII ayy 3
3. WOY IULM GM S lt Z pay BY IND abuesseg JED y SE 193 APIS JOAUQ Aeg 26 Ja 29618 JO YULYS Aeq 13 UBIPIENS ay ama BBUEIC Boyds E Pay 3 UMOIG 22105 lt 24 oyu 7 anes PAY IND y UBS SE NOI 4 apis UMOJG Aeg 27 apis ade Jay LIM dein lt anoge Sy UMOYS AM UEIPIEND anja Jeo y SE UMOYS nda apis Aeg 28 apis 4 221 9 10 YULYS eey 2 y
4. 11 10 Before reinstalling the oil pan make sure to thoroughly clean any excess oil that may have accumulated on the journal with brake cleaner Any oil not cleaned off could cause the adhesive to not bond properly together which will cause oil to leak Apply Honda Bond to the oil pan and reinstall When reinstalling the oil pan make sure not to get Honda Bond on the oil pump NOTE If the Honda Bond applied to the oil pan has been sitting for more than 5 minutes do not install the oil pan Remove the Honda Bond thoroughly and reapply 11 Remove the O2 Sensors from the exhaust then remove the stock exhaust WARNING Take care not to damage the exhaust gaskets when removing the stock exhaust system from the motor You will reuse it for the installation Once the exhaust system has been removed inspect the gaskets for any sign of wear such as scaring tearing or deformity If any of these are seen in the inspection replace with a new one Note When removing the exhaust from the motor it is highly recommended that you use a 6 point closed ended wrench to prevent stripping of the nuts and bolts 12 Now that the exhaust is out of the way remove the Oil Pressure Sensor Replace with the 1 8 nipple and Brass T When installing brass T and the 1 8 nipple to the motor do not be alarmed if the nipple does not screw in very far before beginning to get tight This is normal Reconnect the oil sensor to the brass T This will leave one hole
5. 8mm shallow or deep throat socket ok 10mm deep throat socket REQUIRED 12mm deep throat socket REQUIRED 14mm shallow or deep throat socket ok 16mm deep throat socket REQUIRED 17mm deep throat socket REQUIRED 18mm deep throat socket REQUIRED 19mm deep throat socket REQUIRED 21mm deep throat socket REQUIRED 23mm deep throat socket REQUIRED Standard 9 16 7 16 34 Wrenches Metric NOTE all wrenches listed should be open and closed ended 10mm 6 or 12 point ok 12mm 6 or 12 point ok 14mm 6 point REQUIRED Standard 9 16 14 7 16 Car Jack and Jack Stands Drill Drill Bits 7 8 step up bit Substitute 7 8 metal drill bit Needle Nose Pliers Channel Locks Wire Cutters Crimpers Wire Strippers Soldering Iron Heat Shrink Substitute Electrical Tape Tie Straps Small Medium Large Torque Wrench recommended in conjunction with Service Manual 2 Adjustable Wrenches Stud Puller optional Oil Pan Seal Cutter optional Honda Bond Substitute Permatex Ultra Gray Brake Cleaner this stuff goes quick so make sure to get a few cans Additional Recommended Tools and Equipment The rest of this list includes tools that make the installation easier but are not required Car Lift Acura RSX Shop Manual Once can be obtained from helminc com Digi
6. Ul UMOYS SE ng ang Se UMOYS NOF 29 apis 4 yeay des 2 Y UMOYS SE PIY OUI PAY SYM 189 Se UMOYS NOF rang Aeg 30 Ode 9199 3 YULIYS pay PUN AY LIS 9910 E ayy pemo pay a4 PUN 3 OUUM UI BONS lt asim Ajeyewixosdde 34297 Se BY IND apis 2 55 4 31 Air Fuel Gauge Wiring Instructions These instructions are intended for the Autometer Ultra Light Gauges only 1 Tap A F Gauge RED wire to Guardian YELLOW wire 2 Tap A F Gauge BLACK wire to Guardian PINK wire 3 Tap A F Gauge PURPLE wire to Guardian WHITE with RED stripe wire 32 Congratulations You have finished the installation IMPORTANT PLEASE READ Before test driving your car ensure that a
7. available on the bottom for the Oil Feed Line which we will get to later Note Use Honda Bond when connecting the Brass T to the motor as well as the Oil Pressure Sensor and 1 8 nipples Ensure that no adhesive is put into the oil passageways Any clogs can and will cause insufficient oil pressure to reach the sensor and the turbo If this happens the turbo will fail from oil starvation 13 Loosen but do not remove the bolts on the turbo shown in figure 3 Figure 3 12 14 After the Bolts have been loosened connect the turbo to the turbo manifold using the provided hardware metal gasket and nuts but do not tighten fully until the turbo has been rotated Now that the turbo is connected loosely to the turbo manifold turn the turbo so that the position matches figure 4 The turbo should be roughly 1 2 to 2 from the exhaust Once the turbo has been properly clocked tighten the bolts mentioned in figure 3 as well as the turbo and turbo exhaust nuts Make sure that the bolts that connect the turbo and the manifold are very tight Tech Tip It is recommended that you install the Thermal Flex coupler to the turbo before mounting it to the motor It is much easier to tighten when it is out of the car Then install the 90 degree push lock vacuum fitting using Teflon tape in the hole indicated in Figure 4 by the red arrow and install the nylon vacuum line Figure 4 13 15 Connect the turbo to the Down Pipe Also make
8. cobra should be installed after the turbo and manifold have been installed Failure to do so will make installation of the turbo and manifold more difficult Install the waste gate and down pipe to the now mounted turbo manifold Tech Tip DO NOT install the waste gate and dump pipe before the turbo and manifold have been bolted up Installation before this will make the installation of the turbo and manifold much more difficult Install Dump Pipe to the Waste Gate Attach the Waste Gate to the turbo manifold Install a 90 degree push lock vacuum fitting to the side of the Waste Gate If your kit came with the Evolution waste gate you will notice 2 ports on the side where the fitting can be installed Use the bottom one Attach the vacuum line you installed onto the turbo to the 90 degree push lock vacuum fitting you just installed WARNING THIS 15 A CRITICAL PART OF THE INSTALLATION FAILURE TO INSTALL THIS VACUUM LINE WILL RESULT IN OVERBOOST WHICH CAN AND WILL CAUSE THE ENGINE TO FAIL WITHOUT THIS VACUUM LINE THE WASTE GATE WILL NOT WORK AND THE CAR WILL BOOST AS MUCH AS THE SYSTEM CAN PUSH WHICH IS 3015 40105 MAKE SURE THAT THE VACUUM LINE IS TO CLOSE OR TOUCHING THE TURBO MANIFOLD AND IS FREE OF OBSTRUCTIONS 15 26 Injector installation a b d e f 5 1 1 1 Remove both motor covers from the valve cover and intake manifold to allow access to the in
9. prevent the connector from locking in place Attach the new injectors to the fuel rail The injector clip connectors on the new 550cc injectors should be facing toward the rear of the car m Reinstall the fuel rail and new injectors using the stock spacers and washers and n bolts provided with the kit You must make sure that the fuel rail is flush and level to prevent leaks Most installations require about 6 washers per side along with the stock spacers Tech Tip Make sure that you reconnect the ground wire for the fuel rail This is a commonly missed step This will save you a lot of trouble shooting later on Attach the new injector clips to the 550cc injector plugs 16 27 Intercooler piping installation overview Refer to Figure 22 for routing information 28 Please note The u bends that come with the kit have extra length on them to accommodate aftermarket setups Depending on whether or not you have a stock or aftermarket bumper you may or may not have to cut the u bends for proper fitment 29 We have designed our kit so that the front bumper support does not have to be removed For installation center the intercooler under the bumper support rail with the tabs facing up The intercooler should be installed as far back as possible with out touching Mark the tabs that are welded onto the intercooler then drill and secure them to the bumper support Figure 22 Intercooler Piping From Turbo Instert Air Temperat
10. sure that you connect the Oil Feed Line using a 1 8 nipple flare and Oil Return Flange and male Oil Return Fitting before you install the assembly to the motor depending on the kit some oil return flanges will come with a gasket If your kit did come with a gasket do not use it Instead use Honda Bond for sealing The oil feed line uses a compression fitting No Honda Bond or Teflon tape is required You should now have what looks like in figure 5 Figure 5 16 17 18 19 With the turbo manifold and down pipe assembled bolt it up to the motor After installing the turbo reconnect the rear exhaust system along with the stock gaskets and reinstall the O2 sensors Note When installing the turbo manifold to the car you should use a 14mm 6 point closed ended wrench to prevent stripping of the nuts and bolts These bolts must be very tight to prevent them from coming loose Also do not forget to install the exhaust gasket If the current one is damaged then it must be replaced with a new one Connect the Oil Feed Line to the available hole on the Brass T using a 1 8 nipple flare Connect the Female 10 Push Lock fitting to the 10 Bulkhead and connect the Oil Return Line from the turbo to the oil pan Reinstall the Sub Frame using the reference points made before removal 14 20 21 22 23 24 25 Install the cobra fitting figure 6 onto the turbo Figure 6 Tech Tip Installation of the
11. Crbernation Motorspores RSX Stage Installation Guide We here at Cybernation Motorsports would like to congratulate you on your purchase of our RSX Stage Turbo Kit We have spent over a year developing this kit and we hope you enjoy it as much as we have enjoyed making it This manual was designed as a guide for mechanics to install this kit This is a Level 10 installation that requires special tools and a good understanding of automotive knowledge Cybernation Motorsports takes no responsibility for any problems or damaged that may or may not have been caused by errors in this manual or errors done during installation The Cybernation RSX Stage Kit is a High Performance aftermarket upgrade and is for off road use only This turbo kit like all others is not emissions legal Installation is done at the users own risk Before starting the installation please go to www cybernationmotorsports com for possible updates to this manual Parts List for K20A2 20 QTY PRODUCT DESCRIPTION See Cybernation Customized Turbo Intercooler Set of Intercooler Piping 2 U Bends 1 3 Long Intake Filter Cybernation 550cc Injectors Injector Clips w 8 plug contacts BOV blow off valve Note The Brand may vary due to availability and customer preference
12. jectors and fuel rail Remove the stock injector clips Remove the fuel rail Save the stock spacers as you will use them during the reinstallation of the fuel rail Remove the fuel rail studs with a stud puller Remove the stock injectors Make sure that none of the stock o rings are still in the injector cradles as well as in the fuel rail Each injector clip has a wire approximately 2 long going back to the harness wrapped in black rubber Either cut or push back the rubber as far as possible to the harness Cut the old injector clips Try to cut as close to the plug as possible This will save you the work of crimping on extension for the new plugs Strip the ends of the wires about 3 10 Feed the wires through the new injector clip Make sure to keep the same color wires on the same sides as the original injector plugs The Yellow and Black wire should be installed on the right side of the clip To determine the right side look at the injector clip with the female connection side face down and the release clip at the top Note The new metal contacts have to be crimped on with the wires through the plugs since they clip in backwards Crimp the new connectors to the stripped wire Then pull the wires back through the clip Note The new connectors have a longer piece of metal on one side than the other This side will go to the slit on the injector clip If it is not pulled through with them aligned it may damage the connector and
13. ll nuts and bolts are secure Also to make sure that you add oil back to your car Check for fuel leaks and oil leaks before driving the car When driving your car for the first time pay attention to the Air Fuel and Boost Gauges Drive your car at a slow pace check to make sure that the boost is not exceeding more then the recommended psi for your stage kit For stage 1 you want to be at around 7 to 8psi of boost Also make note of the Air Fuel gauge Make sure that the gauge stays in the green under acceleration You can progressively drive the car faster as you ensure everything is ok Stop boosting the car immediately if Air Fuel gauge does not read green while at wide open throttle and call Cybernation for help 33
14. ll the 7 8 hole in the oil pan as described in the next section The bulk head for the new oil return line assembly should be 34 8 Drill a hole using 7 8 step up drill bit in location shown in Figure 1 It is important that the oil return line is not drilled low If so the oil may not flow properly and the turbo could be damaged Figure 1 10 9 After drilling the hole insert bulkhead seen in figure 2 in the hole drilled in the previous step with the longer end on the inside of the pan Screw the nut and the washers hand tight Make a mark on the bolt about 1 8 after the nut Once the bolt has been marked remove the bolt and cut it along the mark that you have made Now that the bolt has been cut re insert the bolt and washers and nut You will need to apply Honda Bond if Honda Bond is not available Permatex Ultra Grey can be substituted between each plastic washer and the oil pan as well as the nut on the inside of the oil pan Tighten using 2 adjustable wrenches It is recommended to wait until the turbo and manifold and sub frame are reinstalled before attaching the 10 female push lock fitting for the oil return line When installing the 10 female push lock fitting use Honda Bond Make sure not to get any Honda Bond in the oil passage If the Oil Passage is block it will prevent oil flowing back into the oil pan which will damage the turbo Note Read directions on sealant for curing times Figure 2
15. tal Multi Meter sub 200 Air Tools Impact Gun Grinder Air Ratchet Bench Grinder w stone and wire wheel Digital Torque Wrench Parts Cleaner Drill Press Quarter Panel Blanket or Cover to prevent scratches Installation Guide 1 Disconnect the battery when performing this installation 2 Remove the Front Bumper 3 Put the car on an auto lift If one is not available then use a jack and jack stands If using jack stands use extreme caution and make sure that they are secure 4 Drain the oil from the car 5 Before removing the sub frame you must remember to make note of the sub frame alignment markers There is one marker indicated by 3 lines by the rear sub frame bolts Make a note of these in relation to the bolts to ensure that the re installation of the sub frame is straight To remove the sub frame removing the 4 bolts that hold it as well as the motor mount bolts in the front and the rear Note some cars have it in front of the rear sub frame bolt IN BETWEEN THE OIL PAN AND JOURNAL TO REMOVE IT Damage to the oil pan and or journal itself could cause oil leaks when put back together There are pry points you must use to remove the oil pan 7 Once the oil pan has been removed clean off the old Honda Bond being careful not to gouge the pan Do the same with the journal Manual Update Notice If your kit came with a steel braided oil return line and anodized fittings do not dri
16. ure Sensor Here Thermal Fien Couplers Intercooler Piping to Throttle Body Intercooler 17 Page Intentionally Left Blank This section covers the wiring of the system WARNING WHEN PERFORMING THIS SECTION OF THE INSTALLATION MAKE SURE THAT THE BATTERY IS DISCONNECTED 30 Remove the access panel on the side of the dash as indicated in figure 14 Figure 14 Side access panel 19 31 Remove the access panel from under the steering wheel the inside of the car 32 Remove the access panel from under the Glove Box 33 Note If installing a gauge pod insert the wiring for the boost gauge and air fuel gauge before feeding down through the dash Run all leads power wires and pressure line for the boost gauge for the gauges from top of the dash as indicated in Figure 14 With the side access panel removed feeding the wiring down through the dash is easier WARNING TAKE CARE NOT TO KINK THE PRESSURE LINE FOR THE BOOST GUAGE 34 Run the Boost Gauge pressure line from inside the car out to the engine bay and connect to a vacuum source The u shaped vacuum line in front of the valve cover will work fine 35 Connect the power and ground for the Boost Gauge to the location shown in the diagram below 20 Guardian Installation Note Disconnect battery when installing the Guardian Unit apis 4 10 yeay desm lt
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