Automotive Manual PDF

Preparation for Installation
1. Make sure that there are no metal chips or other debris inside the manifold. Check that all bolts will run freely into any tapped holes.
2. Note that while this manifold makes provision for all vacuum lines and other brackets or parts that attached to the stock manifold, the vacuum ports originally on the front side of the manifold have been moved to the back for a cleaner appearance. This will require the use of longer vacuum hoses in some cases.
3. Disconnect battery and drain coolant.
4. Mark and identify all hoses and valves.
5. Check the condition of all hoses, gaskets and o-rings. Replace as needed. Use a new intake gasket. Honda #17105-P72-004.
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Relieving fuel pressure
a) Remove the fuel fill cap.
b) On models equipped with a 6mm service bolt. (illustrated below) If your vehicle is not equipped with a 6mm service bolt, then proceed to step c.
i) Use a box end wrench on the 6mm service bolt on top of the fuel filter or fuel rail, while holding the special banjo bolt with another wrench.
ii) Place a rag or shop towel over the 6mm service bolt.
iii) Slowly loosen the 6mm service bolt one complete turn.
iv) Leave service bolt loose until all pressure has been relieved.
v) Tighten service bolt to 10 lbf-ft.
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The installation of the supplied high pressure fuel pump requires removing and reinstalling the fuel tank. An automotive lift makes this job much easier. The fuel tank can be removed with the car on jack-stands, provided you have the car high enough, and an assistant ready to help you. Our recommendation is to use an automotive lift, as it is much easier. Even if you are doing this super charger installation yourself you may want to consider taking the car to your shop and have your technician install the complete fuel system which consists of the fuel pump, fuel lines, fuel filter, fuel pressure regulator as well as some minor wiring changes to the fuel system. With the new high pressure fuel system in place you will be able to drive the car home to continue the balance of the installation.
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TO START:
1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Depress the locking clip on the mass air sensor electrical connection, and then separate the mass air sensor electrical connection.
3. Loosen the hose clamp that retains the stock intake tube to the resonator, and then remove the tube from the resonator as shown.
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Someone who has a basic knowledge of automobile repair and modification and is familiar with and comfortable with working on their vehicle can accomplish the mechanical installation of this kit using common tools and procedures. However, this kit is designed to allow you to custom fit the fuel lines and components to your application, and will require that you cut hoses to fit and drill holes for fuel pressure regulator mounting, junction blocks, etc. If you do not feel comfortable with any of the steps listed below, please consult a qualified professional installer. Make sure to read the instructions provided with the supplied fuel rail and fuel pressure regulator. These will be referenced throughout this instruction sheet.
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Someone who has a basic knowledge of automobile repair and modification and is familiar with and comfortable with working on their vehicle can accomplish the mechanical installation of this kit using common tools and procedures. However, this kit is designed to allow you to custom fit the fuel lines and components to your application, and will require that you cut hoses to fit and drill holes for fuel pressure regulator mounting, junction blocks, etc. If you do not feel comfortable with any of the steps listed below, please consult a qualified professional installer. Make sure to read the instructions provided with the supplied fuel rail and fuel pressure regulator. These will be referenced throughout this instruction sheet.
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The 2004 to 2006 GTO fuel system uses a method that is referred to as a “return side jet” to fill the fuel pump canister. This means the fuel from the fuel pressure regulator return is being used to create the high velocity jet that fills the pump canister. The pump itself, like most modern fuel systems, actually pumps the fuel out of the canister to the engine and the jet refills the canister. This means that if you are using all or almost all of the fuel that the pump can deliver, there is little or no fuel returned to the canister by the pressure regulator. Since there is nothing left to drive the jet, the jet is not able to refill the canister and the pump will eventually run dry. For this reason it is even more important to have a pump capable of delivering more fuel than is needed on the GTO.
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System Components/Operation System Description Electronic Control Unit (E.C.U) Coolant Temperature Sensor Fuel Pump Air Flow Sensor Intake Air Temperature Sensor Fuel Pressure Regulator Fuel Injectors Throttle Switch Fuel Filters Oxygen Sensor Ignition System Idle Stabilization Crankcase Emission Control / Vent-Libe Heating Element Evaporative Emission System Checking / Adjusting Throttle Valve Throttle Switch (Adjusting) Throttle Switch (Wiring and E.C.U Check) Coolant Temperature Sensor Air Flow Sensor / Intake Air Temperature Sensor Fuel Injectors (Spray Pattern, Quantity)
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