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<p><font face="verdana" color="#1e90ff" size="5"><font color="#000000" size="2"><strong>UPDATES BY Derek-CEO:<br /></strong><br /><u>Tools you WILL need:<br /></u><br />- 24mm Box Wrench<br />- 8, 10,12 and 14mm box wrench&nbsp;and ratchet set<br />- Good heavy hammer<br />- To be continued<br /><br />Ok, due to the incredible support of all of you 7thgen people, i am going to start the DIY installation guide to installing the Stafford Fabrications Turbo Kit on a 2002 Civic.<br /><br />This DIY will show you how to go from Stock to Fast (stock is on the right side of the picture)<br /><br /><img alt="" src="/diyimages/10817comparison.jpg" border="0" /> <br />Ok, first of all, you have to take off your stock intake air box. It comes in 3 major pieces. First undo all of the bolts that hold the intake on (# 13, 16, 15) , and remove the hose clamp that hold the box to the throttlebody (#14) . Then remove the intake air temp. sensor (#11) and pull off the stock intake assembly. <br /><img alt="" src="/diyimages/13S5P01_B01.gif" border="0" /> <br /><br />Next, you must remove your stock exhaust manifold. First... disconnect both O2 sensors (#8). than you have the Head-manifold bolts/studs, and then you have to disconnect the support brace and the exhaust (# 11, 9, 19, 17, 10) . You may have to disconnect the heat shield. (# 12)<br /><img alt="" src="/diyimages/13S5P01_E04.gif" border="0" /> <br /><br />Next you will remove the stock fuel line. It disconnects at the fuel rail and the firewall. It just clips together. (#19)<br /><img alt="" src="/diyimages/13S5P01_B04.gif" border="0" /> &nbsp;<br /><br /><br />Ok, now for installing the turbo and manifold!<br /><br />Take the turbo and bolt it to the exhaust manifold (if its not already done). Bolt the downpipe to the wastegate housing, and then lower the turbo and manifold into the engine bay, and bolt it into place. it should look like this....</font> <br /><strong><img alt="" src="/diyimages/manifold_small_.JPG" border="0" /> &nbsp;<br /><br /></strong><font color="#000000" size="2">Here is the stock midpipe and the downpipe together<br /><br />***note the PERFECT fit***</font> <br /><img alt="" src="/diyimages/10817downpipe_and_midpipe.jpg" border="0" /> <br /><br /><font color="#000000" size="2">Alright, it is time to mount the Intercooler!!!<br /><br />Ok, first of all, take off your front bumper. There are some plastic push-in style connectors on the top and bottom of the bumper. Use a flat tip screwdriver to remove these. Then use a phillips screwdriver to remove the actual screws on the inside of the wheel well (you may want to turn your wheel all the way to the opposite side that you are working on). Once you have those removed, just pull on the end of the bumper and pull the rest of the clips loose (under the headlights). The bumper should be completely removed and put into a safe location.<br /><br /><br /><img alt="" src="/diyimages/13S5P01_B46.gif" border="0" /> <br /><br />Now, look underneath the car. The support for the radiator should have 2 holes in it. Slide the nutguides (looks like this ---&gt; nut--------------nut) under the radiator (over the support), line up the holes on the guide, then link up the holes on the intercooler, and use the bolts included to mount the intercooler.<br />Now stand back and marvel at you ingenuity.<br /><br />Here is the mounting holes <br /><img alt="" src="/diyimages/10817intercooler_mount_holes.jpg" border="0" /> <br /><br />and here is the nutrod<br /><img alt="" src="/diyimages/10817nutrod_3.jpg" border="0" /> <br /><br />here is where you insert the nutrod ( i know how it sounds, but thats how it goes)<br /><img alt="" src="/diyimages/10817nutrod_installing_.jpg" border="0" /> <br /><br />And this is what it should look like when you are done.<br /><img alt="" src="/diyimages/small4.jpg" border="0" /> <br /><br />Ok, now we can start the wiring. (as everyone cheers in the background)<br /><br />Ok, look at your fuel kit. Gaze in awe while you look at the colors of the wires. done gazing? good. The red wire is the 12v+ from the battery. The green is the signal wire from the ignition. And the Black is the ground. For the 12v+ (red) we recommend that you take it from the fusebox under the hood. as in the picture below. Also for the ground, you can use any ground on the body of the car. We recommend that you use ther ground that the battery terminal grounds to. <br /><br />*** Take off the battery terminals before the next step ***<br /><br />Unscrew the left screw that is painted red, insert the red wire (with proper connector), and tighten it back up.<br /><br /><img alt="" src="/diyimages/uhpic.jpg" border="0" /> <br /><br /><br />For the ignition wire, you can run it from anything that turns on when your key is in the "ON" position. We recommend that you drill a hole through your firewall into the drivers compartment, take the steering column cover off, and find the ignition connectors. <br />Remove these screws to take the cover off...<br /><br /><img alt="" src="/diyimages/7636Shroud.jpg" border="0" /> <br /><br />and it should look like this....<br /><br /><img alt="" src="/diyimages/7636Ignition_Harness.jpg" border="0" /> <br /><br />Tap into the black/yellow wire for the ignition wire, and run it through the hole in the firewall to the fuel kit. <br />(Thanks for the pics Smokie)<br /><br /><br />Now for the fuel lines. <br /><br />Look at the fuel Kit in this next picture. The Fuel in is on top, and the fuel out it on the bottom. Use the hoses and hose clamps provided to hook up the fuel lines, and use the bracket provided to secure the fuel kit (you have to drill a small hole and screw it into your firewall).</font> <br /><img alt="" src="/diyimages/10817fuel_kit_fuel_lines_.jpg" border="0" /> <br /><font color="#000000" size="2">The vaccume line for the boost guage and the FMU and the BOV comes from this line. It connects to the sensor by the MAP sensor right next to the throttle body, as shown in this picture<br /><img alt="" src="/diyimages/10817vaccume_line_2.jpg" border="0" /> <br />And since you are already there, remove the MAP sensor, and install the MAP sensor isolation valve and use the proper hardware included to install the sensor back into place<br /></font><img alt="" src="/diyimages/10817MAP_sensor.jpg" border="0" /> <br /><img alt="" src="/diyimages/fc297a82.jpg.orig.jpg" border="0" /> <br /><br /><font color="#000000" size="2">Oil lines<br /><br />Ok, first of all, you have to remove your oil pan. All you have to do to do this is....<br /><br />Drain all of your oil, remove all of the bolts/nuts from around your oil pan, and use a flathead screwdriver and gently pry the pan away from the block.<br /><br />Now that your pan is out of the car, drill the hole with the drill bit that matches the size of the oil drain line. Now, take it to a welder (of it you can weld) and have the drain line welded into place. Re-install your oil pan, and use the aeroquip line to hook the drain line from the turbo to the drain line on the pan.<br /><br />Here is the mark where you have to drill<br /><img alt="" src="/diyimages/10817drain_line_mark.jpg" border="0" /> <br />Here is the hole drilled<br /><img alt="" src="/diyimages/10817hole_in_oil_pan.jpg" border="0" /> <br />Here is the oil pan with the drain line installed<br /><img alt="" src="/diyimages/10817oil_drain_line.jpg" border="0" /> <br /><br />Now for the oil supply line, look at the back of your engine (from underneath) and you should see a little sensor above your oil filter. This is your oil pressure sensor. Remove this and replace it with the T fitting supplied, and screw the sensor into the fitting. On the other end of the fitting, screw your steel braided line (included) and run the line along side the engine, over your transmission, and into the fitting on the top of the turbo.<br /><br />Oil feed line<br /><img alt="" src="/diyimages/10817oil_feed.jpg" border="0" /> <br /><img alt="" src="/diyimages/10817oil_feed_line_turbo_side_.jpg" border="0" /> <br /><br />Now all your oil lines are hooked up. Before you test drive your car (after your done with everything else), double check these fitting to make sure they are tight.<br /><br />Install the intercooler piping. <br /><br />First of all, you will want to install the pipes that hook to the intercooler.<br />Since your bumper is off, look at the picture below and look where the intercooler piping goes from the engine bay to the outside of the car. The stock hole is too small, so you have to use something to bend a small amount of the body pinch out of the way. Just enough to fit the piping in there (not too much).<br /><br />Here is where you have to bend<br />Before<br /><img alt="" src="/diyimages/10817body_before_bending.jpg" border="0" />&nbsp;<br /><br />After (I would recommend painting any of the bare metal afterwards to avoid rust)<br /><img alt="" src="/diyimages/10817body_after_bending.jpg" border="0" />&nbsp;<br /><br /><img alt="" src="/diyimages/small1.jpg" border="0" /> <br /><br />Now put the pipes into place, and use the hose clamps and couplers on the intercooler side to hold them.<br /><br />Now you must install the pipe that goes from the turbo, to the LOWER intercooler pipe. (the only pipe i dont have a picture of). When you have that connected (will only go in 1 way), you will move on to the 90 degree bent pipe that hooks up to the UPPER intercooler pipe. Next you will install the bonnett onto the throttlebody. Then take the other 90 degree bent pipe and run it to the bonnett. (the 90 degree bends will be marked)<br /><br />Here is the bonnett<br /><img alt="" src="/diyimages/small6.jpg" border="0" /> <br /><br />Now all thats left is installing the air filter pipe. That is another unique pipe. it will also be marked. But it goes to the INTAKE part of the compressor housing on the turbo.<br /><br />here is a pic of the turbo, you can see the intake part on the side of it.<br /><img alt="" src="/diyimages/manifold_small_.JPG" border="0" /> &nbsp;<br /><br /><br />For the next installment, all thats left is showing you where the vaccume line is. If you already know where it is.... Happy Boosting!<br />If not, stay tuned. I will have more pictures.</font> </font></p>

03civict

Very well written and nice pics . Good stuff buddy.

Heiserb

awesomeeeee!