Turbo Systems.pdf

Turbo Systems

Installation Instructions

Acura Integra /

Honda Civic

Disclaimer: The product described herein are for off-road use only and are not intended for installation on emissions

controlled vehicles.

2255 Agate Court Simi Valley, CA 93065 Tel. 805.581.0333 Fax: 805.584.1913

www.turboneticsinc.com

Part No. 60108-rev.b

Turbo Kit Installation Instructions No. 60108-rev.b

IMPORTANT, READ THIS FIRST : Study these instructions completely before proceeding.

Engine and/or turbocharger damage may occur if any component within these instructions

is improperly installed. Turbonetics, Inc. or any of its distributors cannot be held responsible for

damages as a result of negligent or improper installation. This complete turbocharger system can

be installed using common tools and automotive procedures, but installer must have a thorough

knowledge of automotive engine operation and feel comfortable working on the vehicle. If in

doubt, consult a knowledgeable turbo installer or Turbonetics tech support specialist with any

questions.

Although this turbo system has been designed to use existing emissions controls (including

catalytic converter), check local laws regarding aftermarket modification to emission controlled

vehicles. Remove the turbocharger kit from its carton and inspect for any obvious physical

damage. All kit components are thoroughly inspected and carefully packaged prior to shipment

from the factory. If any shipping damage is evident, contact your supplier and request that they

process a claim with the shipper involved. Be sure to review the Turbo System Parts List to verify

that you have all necessary kit components to proceed. If any components in the parts list are

missing, contact Turbonetics, Inc. Customer Service department.

Before proceeding, it is recommended to have the following items:

• Honda / Acura service / repair manual

• A large table / bench nearby

• Standard selection of automotive tools

• Plenty of adjacent available workspace

• The ability to lift the vehicle (at least a foot or two off the ground)

• Replacement oil pan gasket or RTV sealant, oil filter and engine coolant

• NPT thread sealant tape

Removing the Factory Exhaust Manifold and Downpipe

Begin by removing the following:

1.) Exhaust manifold and A-pipe to the catalytic converter. Save the hardware used to

mount the manifold to the head and the hardware that mount the A-pipe to the

catalytic converter.

a. Remove the oxygen sensor from the exhaust manifold, using great care not

to damage it.

b. Remove the exhaust donut gasket found at the end of the factory A-pipe.

2.) Air box and intake pipe. Completely remove the intake system from the throttle body

all the way to the box located in the fender well.

3.) Remove the bumper cover to expose the area under the bumper.

4.) Remove the plastic skirt located directly under the engine and attached to the

bumper cover.

**Tip: Keep an empty box on hand to keep the hardware removed. Some of these will be reused

when installing the turbo kit.

Once the exhaust manifold has been removed, locate the air conditioning compressor line. Take

note of all of the brackets that maintain a fixed position for this line. Removing these brackets will

make it free from constraint and allow you to pull it back to have more room when installing the

turbo and manifold. You can use cable / zip ties to keep the a/c lines secured.

2255 Agate Court Simi Valley, CA 93065 Tel. 805.581.0333 Fax: 805.584.1913

www.turboneticsinc.com

Mounting the Turbocharger to the Manifold and Downpipe

Orientating the Turbocharger

The arrows in figure 1 and 2 point to the areas of a turbocharger which keep the center section in

a fixed position.

1.) Loosen the bolts until the compressor housing, bearing housing, and turbine housing

will rotate freely in relation to one another.

2.) Attach the turbo to the manifold with the supplied hardware and gasket as shown in

figure 3 and mount the assembly onto the head using the factory gasket. You will

find on some applications that it is easier to drop the turbo in first, then bolt on the

manifold, then bolt the turbo to the manifold.

3.) Rotate the center section of the turbocharger so that the oil drain is facing

downwards. Keep in mind that the oil drain is a gravity drain system, and the drain

fitting should be pointed as near to vertical as possible. If this is not done, the oil will

not drain out of the turbocharger properly, and it may blow oil past the seals.

4.) Rotate the polished compressor housing so that the discharge is pointed down to

where the intercooler piping will be mounted.

5.) Tighten the turbine housing and compressor housing bolts

Turbine Housing

Turbine Housing Clamps

Turbine Housing Bolts

Figure 1

Compressor Housing Clamps

Compressor Housing

Compressor Housing Bolts

Figure 2

2255 Agate Court Simi Valley, CA 93065 Tel. 805.581.0333 Fax: 805.584.1913

www.turboneticsinc.com

Mounting the Turbocharger to the Manifold

1.) Thread the four supplied M10x1.25 – 42mm long studs into the threaded holes on the

turbo mounting flanges of the manifold (as shown in figure 3)

2.) With the manifold facing upwards (pointed side of the exhaust manifold flange facing

upwards) install the turbo to the manifold with the compressor housing facing toward the

left hand side (passenger side) (as shown in figure 4)

3.) Tighten the turbo to the manifold using the supplied nuts and washers

Figure 3

Figure 4

Mounting the Wastegate to the Manifold

1.) Thread the two supplied M8x1.25 – 30mm long stud into the threaded holes on the

wastegate mounting flange of the manifold (as shown in figure 5)

2.) With the manifold facing upwards (pointed side of the exhaust manifold flange facing

upwards) install the wastegate to the manifold with the wastegate discharge flange facing

toward the right hand side (driver’s side) (as shown in figure 6)

3.) Tighten the wastegate to the manifold using the supplied nuts and washers

Figure 5

Figure 6

2255 Agate Court Simi Valley, CA 93065 Tel. 805.581.0333 Fax: 805.584.1913

www.turboneticsinc.com

Installing the Downpipe

1.) Install the factory donut gasket onto the end of the downpipe.

2.) With the turbo / manifold combination in place, install the downpipe onto the turbine

housing using the provided hardware and to the catalytic converter using the factory

hardware.

3.) Install the wastegate dump tube into the open port on the downpipe, rotating it as you

press it in if necessary (the fitment should be snug).

**Tip: You may want to keep all of the fasteners loosely installed until all of the components

are in place. This will make installing all of the components easier. Tighten all of the

hardware only after everything is in place.

When mounting the turbo to the manifold and mounting the downpipe onto the turbo, use a thin

layer of high-temperature gray silicone, or Permatex Copper Coat as a sealant. Though all

flanges are well-machined, flat surfaces, the silicone will further cover any exhaust leaks that may

slip by.

Figure 7

2255 Agate Court Simi Valley, CA 93065 Tel. 805.581.0333 Fax: 805.584.1913

www.turboneticsinc.com

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