Automotive Manual PDF

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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Removal of Factory Intake
1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Unclip the six over center clamps, then remove the air cleaner lid.
3. Remove the air injection pump hose from the stock intake tube.
4. Remove the crank case vent hose from the stock intake tube.
5. Loosen the hose clamp at the throttle body, then remove the intake tube and filter.
6. Remove the solenoid from the lower air cleaner assembly.
7. Unclip the wire harness from the lower air cleaner assembly.
8. Unclip the vacuum hose from the rear of the lower air cleaner assembly.
9. Remove the three bolts that secure the lower air cleaner assembly.
10. Remove the lower air cleaner assembly.
11. Remove the stock rubber hose from the crank case vent on the cam cover and from the hard line.
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PREPARATION
1. Remove the EVAP hose, brake booster hose, PCV hose, vacuum hose, water bypass hoses, throttle cable, fuel lines, fuel injector connectors, IAC valve connector, TP sensor connector, MAP sensor connector, and EVAP canister purge valve connector from your current intake manifold and throttle body setup.
2. Remove the throttle body.
3. Remove the intake manifold brackets, intake manifold, and intake manifold gasket.
If adapting an Accord Euro R or 06 Civic Si intake manifold onto an 02-06 RSX/ITR or 02-05 Civic Si/CTR style head, continue to follow the remaining “PREPARATION” steps, otherwise skip to “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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Turbocharger: REMOVAL AND INSTALLATION
Turbocharger (Removal)
1. Open the hood.
2. Remove the engine cover.
3. Disconnect the charge air cooler inlet and outlet pipes.
4. Label and disconnect the intake air heater element electrical leads, intake air temperature (IAT) sensor electrical connector, manifold absolute temperature (MAP) sensor electrical connector and the pressure hoses.
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Step 1
Set parking brake on vehicle and disconnect the negative battery terminal.
Step 2
Remove flexible inlet hose from throttle body and air box by loosening two hose clamps. Disconnect the tube to the valve cover and the inlet air temperature sensor if applicable.
Step 3
Remove plastic cover on the left side of the throttle body. Unhook the throttle cable from the throttle body link-age, disconnect the throttle position sensor and vacuum hose from throttle body.
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At approximately 6,000 miles, I began noticing clutch slip at high 2nd gear loads. Over the next 1,500 miles, it got worse, until the clutch would break free in second and third under any hard acceleration.
At this time, Aprilia considers this a consumable item and doesn’t cover the clutch under warranty. Fortunately, at $160 list (I paid $144) for the entire clutch kit, it is reasonably priced. Even better, it is very easy to replace. Still, please ask your dealer to bring early clutch failure to the attention of Aprilia. If enough of us complain, maybe they’ll redesign it.
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Verify that the Brake System does not have any malfunctions. If the system is found to be malfunctioning verify that the malfunction will not interfere with the exchange process. Perform all necessary repairs prior to exchanging.
1. Verify that the vehicle engine is off.
2. Verify new and used fluid tank levels. Add new fluid or empty used as required.
3. Verify that all Switches and Attention Lights on the BFX control panel are OFF.
4. Connect red (positive) clamp on power cable to red (positive) terminal on vehicle battery.
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