GReddy Intercooler Kit User manual

GReddy Intercooler Kit

(Type 31)

2002-2003 Acura RSX Type-S

2 Parts List

(1) Intercooler (Type 31C) 1

(2) Intake pipe I-1 (50∅Aluminum) 1

(3) “ I-2 (50∅Aluminum) 1

(4) “ I-3 (50∅Aluminum) 1

(5) “ I-4 (60∅Aluminum) 1

(6) “ I-5 (60∅Aluminum) 1

(7)WasherTank 1

(8)WasherTankBracketA 1

(9)WasherTankBracketB 1

(10) Extension Harness 850mm 1

(11) Wire Connector Set (Male and Female) 8 set

(12) Hose 50∅x70mmStraight 3

(13) “ 60∅x70mmStraight 2

(14) “ 50∅- 60∅Reducer 1

(15) Hose band 50∅#32 7

(16) “ 60∅#36 5

(17)IntercoolerBracket 1

(18) Aluminum Spacer t=8mm 2

(19) Zip ties 150mm 5

(20) 8mm x 15mm P=1.25 Stainless B S/W F/W _ 2

(21) 8mm x 15mm P=1.25 Stainless B S/W F/W N 3

Parts List

1 2 3

4 5 6

7 8 9 10-11

12-13 14 15-16 17

18 19 20 – 23

2. Removal of Stock & Turbo Kit Parts

When removing the stock parts, make sure you read over the factory

repair manual for proper procedures.

2-1 Disconnect the negative side of the battery.

2-2 Remove the undercover, and the front bumper.

2-3 Remove the bumper support beam.

2-4 Remove the two horns.

2-5 Remove the wind shield washer tank.

2-6 Remove the Turbo Kit Air intake, suction pipe, the suction adapter, and the restictor.

(refer to the Turbo Kit Installation Manual)

2-7 Remove the Turbo Kit Compression Pipe C-2, and C-3.

(refer to the Turbo Kit Installation Manual)

3. Kit Installation

3-1 Body Modification

Cut the shaded area of the body at the left front

body as shown.

Spacer

Intercooler Installation

(1) Install the Intercooler bracket to the body with

the horn as shown using the provided spacer

between the horn bracket and I/C bracket.

(Parts used #: 17, 18, 21)

(2) Mount the Intercooler shown using provided

hardware. Secure the left side of the

intercooler (looking from the front of the

vehicle) to the bracket installed in the

previous step.

(3) Secure the right side of the intercooler to the

body as shown using the provided spacer

between the horn bracket and I/C bracket.

(Parts used #: 1, 18, 21,22)

(4) Position the intercooler so that it is mounted

straight before tightening the bolts.

3-3 Intercooler Piping Installation

(1) Install the I-1 to the C-1 (Aluminum elbow on

the turbo outlet) from the Turbo Kit. Secure

the I-1 pipe bracket to the engine harness

bracket as shown.

* Use the bolt supplied in the turbo kit that was

securing the compression pipe C-2.

(Parts used # 2, 12)

(2) Install the Intercooler pipe I-2 to the I-1 as

shown.

(Parts used # 3, 12)

(3) Install the I-3 pipe between I-2 and

intercooler inlet as shown.

(Parts Used #: 4, 12, 14)

(4) Install the I-4 to the intercooler outlet as

shown.

(Parts Used #: 5, 13)

(5) Install the Intercooler pipe I-5 to the I-4 as

shown. Secure the I-5 to the body. Modify

the splash guard where it contacts these

pipes.

(Parts Used #: 6, 13)

(6) Install the Compression pipe C-3 from the

turbo kit between the pipe I-5 and the

throttle body as shown. Reuse the hoses

and clamps from the turbo kit.

Blow by hose

To air assist

Control valve

3-4 Suction Pipe Installation

(1)Reinstall the Turbo Kit Suction Kit with out

the restrictor.

3-5 Windshield Washer Tank Installation

(1) Install the washer tank brackets A and B as

shown.

(Parts used # 8, 9)

(2) Install the two washer pumps to the

provided washer tank and install the tank on

to the bracket A and B as shown.

Extend the washer tank harness to reach

from the original tank location to the new

location. Refill the tank with washer fluid.

* Make sure not to reverse the positive and

negative wires.

* Make sure not the switch the front pump

and the rear pump connectors.

(Parts used # 7, 10, 11, 21)

3-6 Bumper Modification

(1) Cut the outlined area of the bumper to clear

the intercooler

* Cut the bumper little by little and test fit on

the vehicle. Trim the area the hits the

intercooler.

Starting the Engine

(1) Check all the pipe and hose connections, then reconnect the negative side of the battery.

(2) Start the engine. While idling, check for any air leeks.

(3) After inspection, reinstall the front bumper, under cover and other stock parts that was

removed.

Secure the bottom of the bumper with the intercooler bracket.

This completes the Intercooler Kit installation.

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