Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Installation of this kit requires modifications to the front bumper and removal of the bumper reinforcement. Please check with the owner of the vehicle before installing this kit.2. Removal of Stock Parts Please refer to the factory service manual for the proper removal of stock parts. 2-1 Disconnect the negative terminal of the battery. 2-2 Remove the under carriage cover. 2-3 Remove the front bumper. 2-4 Remove the bumper reinforcement (this will not be reinstalled). 2-5 Remove the stock Intercooler piping. 2-6 Remove the power steering oil cooler. 3. KIT INSTALLATION 3-1 Mount the Intercooler (1) Mount the top bracket of the Intercooler to the horn bracket using the stock bolt. (Parts used #1) (2) Mount the bottom bracket to the radiator core support lower. (Parts used #17) 3-2 Intake Pipe installation (1) Install the intake pipes I-1, I-2 from the turbo outlet side stock piping to the Intercooler. (Parts used #2, 6, 11)

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INSTALLATION INSTRUCTIONS 1. REMOVE AIRBOX SCOOP – - Remove two plastic body clips with Phillips head screwdriver Gently pull scoop away from airbox 2. REMOVE AIRBOX MAF Sensor – Disconnect MAF sensor plug and loosen hose clamp – - Remove 10mm bolt connecting airbox to bracket Remove entire airbox and MAF assembly by gently pulling up and away from the factory rubber intake pipe Remove BPV (Turbo Bypass Valve) return hose from IC to BPV Remove BPV from rubber intake pipe and completely disconnect BPV vacuum line – - 3. – - – - REMOVE RUBBER INTAKE PIPE FROM TURBO Loosen hose clamp from intake pipe to turbo Remove boost solenoid hose from intake pipe (leave connected to solenoid) Remove crank case vent line (take off completely) Pull intake pipe away 4. REMOVE MAF SENSOR FROM STOCK AIRBOX AND INSTALL TO HARMAN INTAKE PIPE. BE CAREFUL NOT TO PINCH OR DAMAGE THE RUBBER O-RING ON THE MAF SENSOR. Use supplied 4mm bolt with lock washer and washer to attach MAF sensor to intake pipe. DO NOT OVERTIGHTEN. 5. INSTALL 3.00” TO 2.75” SILICONE REDUCER TO TURBO WITH SUPPLIED CLAMP. Small side goes to the turbo. 6. INSTALL HM INTAKE PIPE TO SILICONE REDUCER WITH CLAMP CONNECT MAF SENSOR PLUG TO MAF SENSOR 7. This is the most common problem when installing the intake. Don’t forget to plug in the MAF sensor before turning the ignition. Failure to do so will cause a CEL. 8. INSTALL CONE FILTER USING SUPPLIED HOSE CLAMP 9. INSTALL BPV

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1) Remove air duct, battery cover, battery, lower battery tray and silver wiring harness bracket that is mounted with two bolts to
the battery tray. 2) Remove bypass valve along with both tubes connected to it. 3) Remove air intake box and tube. 4) At this point you can now install the air filter fan shield using the supplied M8 bolts. If you are using an OEM or Aftermarket intercooler pipe that still utilizes the mount on the battery tray remove the bolt and install the fan shield with the spacer in between the shield and intercooler pipe tab, tighten it down with the supplied longer M8 bolt. If you are using an Aftermarket intercooler pipe that doesn’t have the mount you will need to use the supplied longer spacer to space the fan shield away from the battery correctly. Refer to picture below. 5) Remove the backing from the battery tray and stick it into place. Then you can set the battery on it and install the battery cables at the angles shown. 6) You can now lay the battery into position and tie it down using the supplied tie down. This can be done using the OEM hook locations. You may have to remove some of the wire tie downs to allow the cables to move with the battery. 7) Install the turbo to intake custom silicone coupler onto the turbo, leave the clamps loose at this time. This coupler is to be routed underneath the fuel lines and engine harness. Be sure to completely seat the coupler onto the turbo. Install the intake pipe and filter leaving the clamps loose for further adjustment. 9) Now at this time get the tube that connected the bypass valve to the intercooler piping and cut 1 in. off of one end as shown below*. The end that you cut goes to on the bypass valve, the other end to the intake.

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Turn OFF the ignition. Remove the air cleaner outlet duct. Remove the air intake pipe from the turbocharger. Disconnect the electrical connector (2) from the boost pressure sensor (3). Remove the nut (4) retaining the boost pressure sensor bracket and the coolant tube. Lift the coolant tube (1) off of the stud and move it out of the way. 7. Remove the boost pressure sensor (2) and the bracket (1) from the intake manifold. 8. Remove the bracket from the sensor. 9. Inspect the boost pressure sensor seal for damage and replace as necessary. INSTALLATION PROCEDURE 1. Position the bracket (1) over the sensor (2). 2. Install the boost pressure sensor into the intake manifold and guide the bracket over the stud. 3. Position the coolant tube (1) over the stud. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the retaining bolt (4). Tighten Tighten the bolt to 9 N.m (80 lb in). 5. Connect the electrical connector (2) to the boost pressure sensor (3). 6. Install the air intake pipe to the turbocharger. 7. Install the air cleaner outlet duct.

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AIR INDUCTION SYSTEM CARBURETED Air Intake System The air intake system used on carbureted vehicles supplies fresh, filtered, temperature-controlled air to the carburetor. System consists of an air cleaner, air intake pipe, carburetor, intake manifold and intake air control system. The intake air control system maintains a uniform air temperature inside the air cleaner. Carburetor receives fresh air, controlled within a narrow temperature range, regardless of outside temperature. Carburetor Carburetor is a 2-barrel downdraft fixed venturi type. Carburetor consists of 3 layers, a choke valve and air horn make up the top layer; the venturi, float chamber, accelerator pump, actuator, and choke housing make up the middle layer; and the primary and secondary throttle valves, secondary diaphragm, and pilot screw are part of the throttle body, or bottom layer of the carburetor. FUEL INJECTION