Turbocharging Honda Civic D16Y8.pdf

Performer X Turbocharging System

for 1996-2000 Honda Civic D16Y8

Catalog #1500

INSTALLATION INSTRUCTIONS

PLEASE study these instructions carefully before installing your Edelbrock Performer X Turbocharging System for Honda Civic D16Y8.

If you have any questions or problems, do not hesitate to contact our Technical Hotline at: 1-800-416-8628, from 7am-5pm

Monday-Friday, Pacific Standard Time or via e-mail at: Edelbrock@Edelbrock.com. Please complete and mail your warranty card.

Description: The Edelbrock Performer X Turbocharging System is a complete Turbo Kit that gives 1996-2000 Honda Civic SOHC

VTEC D16Y8 owners a 60-70 horsepower increase from turbocharging. The Garrett T-28 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 Performer X intake manifold with four additional injectors and a separate

electronic controller 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, o-ring sealed compressor flanges, 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 1996-2000 Honda Civic 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 lash 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).

After Installation, Before Starting the Vehicle:

We recommend the use of a synthetic 10W30 motor oil. Mobil1 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 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 Turbo-Link box. Disconnecting the wiring

from the Turbo-Link box 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.

Rev. 10/03

Page 1 of 13

Catalog #1500

Brochure #63-0187

Kit Contents

Qty.

Description

Turbocharger / Exhaust Manifold / Exhaust Elbow / Oil-Water Line Assembly

Perfomer X Intake Manifold / Turbo Fuel System Assembly

Oil Supply Sandwich Adapter Assembly

Intercooler

Compressor Inlet Pipe

Compressor Inlet Pipe Support Brace

Compressor Outlet Pipe

Intercooler Inlet Pipe

Intercooler Outlet Pipe

Intake Manifold Inlet Pipe

Exhaust Down Pipe

Air Filter / Attachment Hose / Clamps Assembly

Blow Off Valve Assembly

Boost Gauge / Plumbing Assembly

Boost Gauge Mounting Pod (Pillar Mount)

Auxiliary Engine Management Computer

Main Wiring Harness

Auxiliary Fuel Injector Wiring Harness

Fuse Wiring Harness and Fuse.

VTEC Resistor Wire

MAP Sensor Resistor Wire

Ring Connectors, Wiring

Butt Splice Connectors, Wiring

Turbo Oil Drain Adapter Fitting

Turbo Oil Drain Hose Assembly

Turbo Fuel Rail to Stock Fuel Rail Hose Assembly

Fuel Filter to Turbo Fuel Rail Fuel Hose Assembly

2 ¼” Silicone Hose Couplings

2 ¼” - 2 ½” Silicone Hose Couplings

5/32” I.D. Vacuum Hose

5ft.

3ft.

Rev. 10/03

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Catalog #1500

Brochure #63-0187

Kit Contents (Continued)

7ft.

3/8” Cam Cover Breather Hose

¼” Red Silicone Hose, Wastegate & Blow-Off Valve

5/16” Fuel Injector Air Supply / Purge / PVC Hose

¼” Fuel Hose, Fuel Pressure Regulator Return

Hose Clamps, 1 13/16” - 2 ¾”, 9/16” Wide Band

Hose Clamps, 2 1/16” - 3”, 9/16” Wide Band

Hose Clamps, 5/16” I.D.

10mm x 1.5 Studs (Exhaust Downpipe to Turbo Outlet Elbow)

8mm x 1.25, 1.31” Long Stud (Compressor Inlet Pipe Mounting)

¼-20 x 5/8” Hex Head Bolt (Turbo Oil Drain Adapter Fitting)

6mm x 1.0-12mm Long Hex Bolt (Support Brace to Compressor Inlet Pipe)

Socket Head Cap Screw, 6mm x 1.0, 20mm Long (Compressor Outlet Pipe to Turbo Mounting)

Socket Head Cap Screw, 8mm x 1.25, 20mm Long (Turbo Oil Drain Hose to Turbo Mounting)

8mm x 1.25 Nylon Locking Nut (Compressor Inlet Pipe Mounting)

10mm x 1.5 Flange Nut (Exhaust Downpipe to Turbo Outlet Elbow)

8mm Spring Washer (Turbo Oil Drain Hose Mounting)

6mm Spring Washer (Compressor Outlet Pipe Mounting)

8mm Flat Washer (Compressor Inlet Pipe Mounting)

12.3mm I.D. / 16.2mm O.D. / 1.5mm Thick Aluminum Crush Washer (Fuel Banjo Fittings)

¼” Stato Seal Washer (Turbo Oil Drain Adapter)

Intake Manifold Gasket

Turbo Outlet Elbow to Exhaust Down Pipe Gasket

Oil Drain Adapter Fitting Gasket

O-Ring, Compressor Inlet Pipe to Compressor Inlet Flange

O-Ring, Turbocharger Oil Drain Flange

O-Ring, Compressor Outlet Flange to Compressor Outlet Pipe

10mm Barb to ¼”NPT Adapter Fitting (Intake Manifold Fitting Kit)

17mm Barb to 3/8”NPT Adapter Fitting (Intake Manifold Fitting Kit)

3/16” Barb to 1/8”NPT Adapter Fitting (Intake Manifold Fitting Kit)

¼” Barb to ¼”NPT Female Street Elbow (Intake Manifold Fitting Kit)

1/8”NPT Pipe Plugs (Intake Manifold Fitting Kit)

¼” Barb to 1/8”NPT Adapter Fitting (Intake Manifold Fitting Kit)

8mm Barb to 1/8”NPT Adapter Fitting (Intake Manifold Fitting Kit)

9mm Barb to ¼”NPT Adapter Fitting (Intake Manifold Fitting Kit)

Lee Plug .093” Diameter (Intake Manifold Fitting Kit)

¼”NPT Pipe Plug

#3 Plastic Vacuum Tee, 5/32” Diameter

8mm Barb to ¼”NPT Adapter Fitting

3/8” Barb to ¼”NPT Male Adapter Fitting

Check Valve, Fuel Injector Air Supply Hose

Inlet Air Temperature Sensor Grommet

Lower Intercooler Mount Grommets

8” Tie Wraps

E.O. Sheet

E.O. Decal

5ft.

3ft.

Rev. 10/03

Page 3 of 13

Catalog #1500

Brochure #63-0187

INSTALLATION INSTRUCTIONS

Initial Parts Removal and Intercooler Installation (See factory service manual for procedures where noted)

1. 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.)

2. 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.

3. Remove the bolt holding the horn onto the center radiator support and move the horn to the side.

4. Remove the driver’s side tie down bracket located behind the lower radiator support.

5. 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.

6. Install the intercooler grommets into the holes in the lower radiator support as shown (See Fig. 1a). 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. 1b). Using the bolt removed from the horn, attach the intercooler brace

and horn to the center radiator support (See Fig. 1c).

Install Grommets Here

Fig. 1a

Fig. 1b

Fig. 1c

Oil Drain Adapter Installation (Note: Removal of the oil pan is required to install the turbo oil drain adapter)

1. Remove the transaxle to oil pan braces using a 12mm wrench on the smaller bolts, and a 14mm wrench on the larger bolts

(See Fig. 2). Remove the bellhousing cover using a 12mm wrench (See Fig. 2) . Using a 10mm socket, remove the oil pan

bolts and remove the oil pan. If necessary, gently tap on the oil pan with a rubber or plastic mallet to loosen the seals 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 drivers side on the front of the oil pan (See Fig. 3a) , 1.5” from the Oil Pan Rail (See Fig. 3b) . 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 from center to center

is 1.125” as shown in Fig. 3b .

Remember to

remove this

cover before

removing the

oil pan

Driver Side of Pan

Bolt Holes:

1 2 3

1.125”

1.500”

Fig. 2

Fig. 3a

Fig. 3b

Rev. 10/03

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Catalog #1500

Brochure #63-0187

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 ¼”. Drill the center drain hole

to ½”. Deburr the holes and thoroughly clean the oil pan to remove any metal

shavings.

4. Install the Oil Drain Adapter onto the oil pan using the two ¼-20 x 5/8” bolts

(We recommend using blue Loctite on the threads) and the two ¼” Stato-Seal

washers on the inside of the oil pan, using the gasket on the outside of the pan

(See Fig. 4a & 4b). Torque the bolts to 6-8 ft/lbs.

5. Reinstall the oil pan. Finger tighten nuts 1-6 (See Fig. 4c) to hold the pan in

place. Install the remaining bolts finger tight. Tighten all nuts/bolts to 8-9 ft/lbs,

starting with nuts 1-6, and tightening the remaining bolts in a clockwise

manner, starting in the center and working your way out.

6. Reinstall the belhousing cover. Torque bolts to 17 ft/lbs.

7. Reinstall the transaxle to the oil pan braces. Make sure the braces line up flush

with both the oil pan and the transaxle before tightening the bolts. These braces

are an integral part of the engine / transaxle structure and if they are not aligned

properly before the bolts are tightened, this will put undue structural stress on

the engine / transaxle.

¼-20 x 5/8” Bolts

and Stato-Seal Washers

Fig. 4a

Fig. 4b

Turbocharger / Exhaust Manifold Assembly Installation

1. Remove the upper air conditioner condenser support bracket and

air conditioner line bracket. Using a zip-tie or twine, carefully flex

the lines and condenser as far forward as possible and temporarily

secure. This will allow more clearance to place the turbo / exhaust

manifold assembly (See Fig. 5).

2. Being careful not to damage the oil feed and coolant lines, set turbo

assembly in place using the stock exhaust gasket (See Fig. 5).

( Note: If the gasket is in good condition, it may be reused. 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 old gasket material). Using

the stock nuts, attach the turbo assembly to the engine block.

Note: Holding the turbo assembly about ¼”-½” away from the

engine block while starting the nuts onto the studs provides

clearance to get the nuts started. Refer to the Honda Factory

Service Manual for torque values and sequence.

3. 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 drivers side, then up along the drivers 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.

Fig. 4c

Tie back to provide

extra clearance

Fig. 5

Rev. 10/03

Page 5 of 13

Catalog #1500

Brochure #63-0187

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