Vortech 1994-2001 Acura Integra GSR User Manual

Acura 1.8L DOHC

Integra

Supercharger System

Installation Instructions

1994-2001 Model Years

50 State Smog Legal Per CARB EO #D-213-21

ENGINEERING, LLC

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

P/N: 4HC020-030 (Acura Integra LS) — v2.1 01/28/04

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

prior

to beginning the installation to determine if you

WARNING

Extreme care must be taken when driving a supercharged vehicle with the stock clutch. If clutch slippage is detected, discontinue hard use.Vortech recommends replacing the stock clutch with a higher capacity unit.

NOTE

Purchase one of the following fuel pressure optimizers. It may be necessary to compensate for the larger fuel injectors installed in this kit. (See “Trouble shooting” section for details.)

8F130-013 FUEL PRESSURE OPTIMIZER-BLUE 8F130-015 FUEL PRESSURE OPTIMIZER-RED 8F130-017 FUEL PRESSURE OPTIMIZER-PURPLE 8F130-018 FUEL PRESSURE OPTIMIZER-POLISH

2004 VORTECH ENGINEERING, LLC

or translated into another language in any form, by any means without written permission

of Vortech Engineering, LLC.

TABLE OF CONTENTS

FOREWORD.....................................................................................................................................ii

TABLE OF CONTENTS ....................................................................................................................iii

TOOL & SUPPLY REQUIREMENTS ................................................................................................iv

PARTS LIST - ACURA GSR..............................................................................................................v

PARTS LIST - ACURA INTEGRA LS ................................................................................................vi

PARTS LIST - ACURA TYPE R.........................................................................................................vii

1. PREPARATION/REMOVAL ..................................................................................................1

2. OIL FEED.............................................................................................................................1

3. OIL DRAIN ...........................................................................................................................2

4. FUEL PUMP INSTALLATION...............................................................................................3

5. FUEL INJECTOR INSTALLATION .......................................................................................4

6. FUEL MANAGEMENT (FMU) INSTALLATION ....................................................................5

7. MAP SENSOR BLEED ASSEMBLY INSTALLATION...........................................................6

8. POWER STEERING PLUMBING.........................................................................................7

9. MAIN BRACKET INSTALLATION.........................................................................................7

10. SUPERCHARGER MOUNTING PLATE INSTALLATION.....................................................8

11. SUPERCHARGER INSTALLATION.....................................................................................9

12. RADIATOR HOSE AND WATER NECK INSTALLATION .....................................................11

13. STANDARD KIT DISCHARGE DUCT INSTALLATION ........................................................12

14. AIR FILTER INSTALLATION ................................................................................................12

15. BYPASS VALVE INSTALLA TION..........................................................................................13

16. SUPERCHARGER DRIVE BELT INSTALLATION ...............................................................14

17. POWER STEERING PLUMBING/BLEEDING .....................................................................15

18. FINAL CHECK .....................................................................................................................16

19. TROUBLESHOOTING .........................................................................................................17

iii

28JAN04v2.1(Acura Integra LS (4HC..030v2.1))

P/N: 4HC020-030

1994-2001 1.8L DOHC ACURA INTEGRA

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH

Supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech

Engineering is not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech prior to using this product.

4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is

resolved.

5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000

miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with

original heat range plugs as specified by the manufacturer and retard timing from factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every at least 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 3/8” Swivel Head Ratchet

• 1/2" Socket and Drive Set: SAE & Metric

• 3/8" NPT Tap and Handle

• Adjustable Wrench

• Open End Wrenches: SAE & Metric

• Center Punch and a 5/8" Tapered Punch

• Springlock 5/16" Fuel Fitting Disconnect Tool

•5 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16" Drill Bits

• Hex Key Wrench Set

•Wire Strippers and Crimpers

• Utility Knife

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• New Spark Plugs

ACURA INTEGRA GSR 1.8L

ENGINEERING, LLC

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages

or damaged parts immediately.

PART # DESCRIPTION QTY PART # DESCRIPTION QTY

2E129-170 S/C,V-5 SQ G-TRIM CCW 1 4HC110-160 S/C MOUNTING PLATE ASSY 1

4HC010-160 MOUNTING PLATE, 1.8 GSR 1 7C080-056 8mm x 1.25 x 55mm HHD G5 BOLT 3 7K312-001 5/16" AN-WASHER 3 7A375-100 3/8-16 x 165 HXHD PCT. 3 7K375-040 3/8" AN960 FLAT WASHERS 3

4HC110-180 Assy, Honda Maps Bleed 1

4HC010-180 MAPS BLEED, HONDA 1 7C040-025 M4-.7 x 25mm HXHD CS PLTD 2 7U100-058 O-RING FUEL RAIL HONDA 1 7U030-046 5/32" VACUUM LINE .67' 7P062-187 1/16 NPT x 3/16 HOSE BARB 1 7U400-001 CHECK VALVE 1 7U100-055 TIE WRAP, 6" NYLON 2

4HC114-030 ASSY, S/C DRIVE, HONDA 1

8R101-000 PULLEY RETAINER ASSY, 4 RIB 1 2A034-370 S/C PULLEY 3.70" 4 GROOVE 1 2A044-520 BELT, K040520 HONDA HO S/C 1

4HC111-031 Mtng Brkt Asy, 1.8 INTEG PIN DRIVE 1

4HC011-021 MTNG BRKT, 1.8 GSR 1 4FG017-021 SPCR, LWR, ALT STY-PLT 2 7U250-022 DOWEL PIN, 1/4D x 3/4L 2 2D070-159 LARGE BEARING, EXTENDED DRIVE 2 7X100-025 WAVE WASHER-LARGE 1 7U100-084 SNAP RING, EXT DRV HOUSING 1 2D160-216 ASY, EXT DR HSNG TUBE, ACURA L 1 2D030-024 FLANGE, EXT TUBE END HONDA 1 7A312-075 5/16-18 x 3/4 HXCS GR5 ZINC 3 7K312-001 5/16 AN WASHER, PLATED 7 7A250-075 1/4-20 x 3/4 SHCS PLTD 5 4HC010-070 TENSIONER PLATE, HONDA, DOHC 1 7A250-101 1/4-20 x 1 HHCS, ZINC PLTD 4 7J006-093 6mm WASHER, PLATED 5 7A250-276 1/4-20 x 2.75" HHCS 1 7F250-020 1/4-20 HEX NUT 1 4FK116-021 IDLER PULLEY ASY. GEN II 1 7J312-000 5/16 FLAT WASHER-SAE 2 7A312-125 5/16-18 x 1-1/4 GR5 HXHD ZINC 1 4HC010-060 STUD, HONDA TENSIONER 1 7F312-018 5/16-18 NUT USS PLTD 2 7J312-875 5/16" WASHER, CUSTOM 1 4HC116-011 IDLER PULLEY ASY, HONDA 1 7C010-036 M10-1.25 x 35mm FLANGED 2 7J010-002 10mm WASHER, ZINC PLATED 2 2D170-226 ASY, DRIVE SHAFT, INTEGRA LS 1 4HC010-130 TOP PLATE, HONDA 1.6/1.8 1 7A312-525 5/16-18 x 5.25 HXCS GR8 ZINC 4 2D070-281 COUPLING, FLG, 3-PIN DRIVE 2 7U250-125 DOWEL PIN, 1/4D x 1.25L 6 2D070-260 COUPLING, DRIVE, COMPOSITE 1 7U100-070 KEY, 3/16 SQUARE x 7/8" LONG 2 7B375-075 3/8-24 x 3/4" GR8 HXHD BOLT 2 7J375-020 WASHER, 1.0 OD, .406 ID 2 2D030-051 HOUSING, COUPLING, EXT DRIVE SC 1 2D030-061 HOUSING, COUPLING, EXT DRIVE SH 1 7U312-101 DOWEL BUSHING, .312 x 1.00 2 2D030-026 SPACER, EXT DR HSNG, ACURA LS 1

4HC130-026 OIL FEED ASSY, HONDA 1

7P125-125 FTG, 1/8 NPT FEM x 1/8 BSPT MALE 1 7P125-034 1/8 NPT x 1 MALE x 2 FEM 1 7P125-027 -4 TO 1/8 NPT STRAIGHT 1 7P125-026 -4 TO 1/8 NPT 90° MALE 1 7P525-067 .500 CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4" HOSE BARB 2 7U030-026 1/4" OIL FEED HOSE 2.67' 7U100-055 TIE WRAP, 6” NYLON 5

4HC130-036 OIL DRAIN ASSY, HONDA 1

7U030-036 1/2" OIL DRAIN HOSE 1' 7R001-008 #8 STNLS HOSE CLAMP 2 7P375-042 MALE CONNECTOR 1 4HC100-010 TUBE NUT ASSY, HONDA 1

4HC238-048 FMU ASSY 1

6Z110-148 FUEL MGMT UNIT, 8:1 w/SPRING 1 7U030-016 1/4" FUEL LINE 1.25' 7R001-004 #4 HOSE CLAMPS 2 7U030-046 5/32" VACUUM LINE 1' 7P156-082 5/32 TEE 1

4HC110-040 POWER STEERING ASSY, 99-00 HONDA 1

7A250-104 1/4-20 x 1 BHCS SS 2 7C060-016 6mm BOLTS 2 7J006-093 6mm WASHER, PLATED 2 4HC010-040 FTG, HONDA PWR STR TOP 1 4HC010-050 FTG, HONDA PWR STR PUMP 1 4HC145-060 POWER STEERING LINE ASSY, HONDA 1 7U100-088 O-RING, -015 2

4HC110-140 SUPPLEMENT, PWR STR 1997 EAP 1

4HC010-140 FTG, GSR PWR STR TOP 1 4HC010-150 FTG, GSR PWR STR PUMP 1 7U100-013 O-RING, -013 1

4HC214-040 ASSY, GSR UPPER RADIATOR 1

4HC114-040 ASSY, GSR WATER NECK 1 7C060-020 BOLTS, M6 x 20mm 2 7U125-040 HOSE, GSR UPPER RAD. 1 7U031-016 5/16" FUEL HOSE 1.5'

4HC212-040 AIR DUCTING ASSY, GSR 1

7S275-200 2-3/4" x 2" SLEEVE 1 7S275-251 REDUCER, 2.75 TO 2.50 1 7R002-040 #40 STAINLESS HOSE CLAMP 1 7R002-044 #44 GOLDSEAL HOSE CLAMP 3 4HC112-040 DUCT, GSR DISCHARGE 1 8D001-001 BYPASS VALVE 1 8H040-075 1" AIR FILTER 1 7U034-016 1" GS HOSE 0.25' 7U030-046 5/32" VACUUM LINE 3' 7P156-082 5/32" TEE 1 7R002-016 #16 HOSE CLAMP 2 8H040-040 AIR FILTER, 3.5" FLG x 5.5L 1 7P375-008 ELBOW, 3/8" x 90° UNION 1 7U030-056 3/8" PCV HOSE 3'

4HC020-030 Instruction Manual 1 008123 Decal, Sprt Cmpct, S/C, White 2 008130 License Plate Frame, Vortech 1 008445 Ext. Drive Street Pkg Assy 1 8F001-270 Fuel Pump w/Filter, GSR IN-TANK 1 8F060-310 Fuel Injector, Honda, 310 CC/Min 4

Part No. 4HC218-030SQ

PARTS LIST

28JAN04v2.1(Acura Integra LS (4HC..030v2.1))

P/N: 4HC020-030

ACURA INTEGRA LS 1.8L

ENGINEERING, LLC

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages

or damaged parts immediately.

PART # DESCRIPTION QTY PART # DESCRIPTION QTY

4HC110-170 S/C,V-5 SQ G-TRIM CCW 1 4HC110-170 S/C MOUNTING PLATE ASSY 1

4HC010-170 MOUNTING PLATE, 1.8 LS 1 7C080-056 8mm x 1.25 x 55mm HHD G5 BOLT 3 7K312-001 5/16" AN-WASHER 3 7A375-100 3/8-16 x 165 HXHD PCT. 5 7K375-040 3/8" AN960 FLAT WASHERS 5 4HC010-200 MNTG BRKT BLOCK, INTEGRA LS 1

4HC110-180 ASSY, HONDA MAPS BLEED 1

4HC010-180 MAPS BLEED, HONDA 1 7C040-025 M4-.7 X 25mm HXHD CS PLTD 2 7U100-058 O-RING FUEL RAIL HONDA 1 7U030-046 5/32" VACUUM LINE .67' 7P062-187 1/16 NPT X 3/16 HOSE BARB 1 7U400-001 CHECK VALVE 1 7U100-055 TIE WRAP, 6" NYLON 2

4HC114-050 ASSY, S/C DRIVE, HONDA 1

8R101-000 PULLEY RETAINER ASSY, 4 RIB 1 2A034-370 S/C PULLEY 3.70" 4 GROOVE 1 2A044-525 BELT, K040525 HONDA 1

4HC111-031 MTNG BRKT ASY, 1.8 INTEG PIN DRIVE 1

4HC011-021 MTNG BRKT, 1.8 GSR 1 4FG017-021 SPCR, LWR, ALT STY-PLT 2 7U250-022 DOWEL PIN, 1/4D x 3/4L 2 2D070-159 LARGE BEARING, EXTENDED DRIVE 2 7X100-025 WAVE WASHER-LARGE 1 7U100-084 SNAP RING, EXT DRV HOUSING 1 2D160-216 ASY, EXT DR HSNG TUBE, ACURA L 1 2D030-024 FLANGE, EXT TUBE END HONDA 1 7A312-075 5/16-18 x 3/4 HXCS GR5 ZINC 3 7K312-001 5/16 AN WASHER, PLATED 7 7A250-075 1/4-20 X 3/4 SHCS PLTD 5 4HC010-070 TENSIONER PLATE, HONDA, DOHC 1 7A250-101 1/4-20 x 1 HHCS, ZINC PLTD 4 7J006-093 6mm WASHER, PLATED 5 7A250-276 1/4-20 x 2.75" SHCS 1 7F250-020 1/4-20 HEX NUT 1 4FK116-021 IDLER PULLEY ASY. GEN II 1 7J312-000 5/16 FLAT WASHER-SAE 2 7A312-125 5/16-18 X 1-1/4 GR5 HXHD ZINC 1 4HC010-060 STUD, HONDA TENSIONER 1 7F312-018 5/16-18 NUT USS PLTD 2 7J312-875 5/16" WASHER, CUSTOM 1 4HC116-011 IDLER PULLEY ASY, HONDA 1 7C010-036 M10-1.25 x 35mm FLANGED 2 7J010-002 10mm WASHER, ZINC PLATED 2 2D170-226 ASY, DRIVE SHAFT, INTEGRA LS 1 4HC010-130 TOP PLATE, HONDA 1.6/1.8 1 7A312-525 5/16-18 x 5.25 HXCS GR8 ZINC 4 2D070-281 COUPLING, FLG, 3-PIN DRIVE 2 7U250-125 DOWEL PIN, 1/4D x 1.25L 6 2D070-260 COUPLING, DRIVE, COMPOSITE 1 7U100-070 KEY, 3/16 SQUARE x 7/8 LONG 2 7B375-075 3/8-24 x 3/4" GR8 HXHD BOLT 2 7J375-020 WASHER, 1.0 OD, .406 ID 2 2D030-051 HOUSING, COUPLING, EXT DRIVE SC 1 2D030-061 HOUSING, COUPLING, EXT DRIVE SH 1 7U312-101 DOWEL BUSHING, .312 x 1.00 2 2D030-026 SPACER, EXT DR HSNG, ACURA LS 1

4HC130-026 OIL FEED ASSY, HONDA 1

4HC130-036 OIL DRAIN ASSY, HONDA 1

7U030-036 1/2" OIL DRAIN HOSE 1' 7R001-008 #8 STNLS HOSE CLAMP 2 7P375-042 MALE CONNECTOR 1 4HC100-010 TUBE NUT ASSY, HONDA 1

4HC238-068 FMU ASSY 1

6Z110-141 FUEL MGMT UNIT, 6:1 W/SPRING 1 7U030-016 1/4" FUEL LINE 1.25' 7R001-004 #4 HOSE CLAMPS 2 7U030-046 5/32" VACUUM LINE 1' 7P156-082 5/32 TEE 1

4HC110-040 POWER STEERING ASSY, 99-00 HONDA 1

4HC110-140 SUPPLEMENT, PWR STR 1997 EAP 1

4HC010-140 FTG, GSR PWR STR TOP 1 4HC010-150 FTG, GSR PWR STR PUMP 1 7U100-013 O-RING, -013 1

4HC214-060 ASSY, INTEGRA LS WATER NECK 1

4HC114-060 ASSY, INTEGRA LS WATER NECK 1 7C060-020 BOLTS, M6 x 20mm 2 7U125-040 HOSE, GSR UPPER RAD. 1 7U031-016 5/16" FUEL LINE 1.5'

4HC212-060 AIR DUCTING ASSY, INTEGRA LS 1

7S275-200 2-3/4" x 2" SLEEVE 1 7S275-251 REDUCER, 2.75 TO 2.50 1 7R002-040 #40 STAINLESS HOSE CLAMP 1 7R002-044 #44 GOLDSEAL HOSE CLAMP 3 4HC112-060 DUCT, INTEGRA LS DISCHARGE 1 8D001-001 BYPASS VALVE 1 8H040-075 1" AIR FILTER 1 7U034-016 1" GS HOSE 0.25' 7U030-046 5/32" VACUUM LINE 3' 7P156-082 5/32" TEE 1 7R002-016 #16 HOSE CLAMP 2 8H040-040 AIR FILTER, 3.5" FLG x 5.5L 1 7P375-008 ELBOW, 3/8" x 90° UNION 1 7U030-056 3/8" PCV HOSE 3'

4HC020-030 Instruction Manual 1

008123 DECAL, SPRT CMPCT, S/C, WHITE 2 008130 LICENSE PLATE FRAME, VORTECH 1 008445 EXT. DRIVE STREET PKG ASSY 1 8F001-270 FUEL PUMP W/FILTER, IN-TANK 1 8F060-310 FUEL INJECTOR, HONDA, 310 CC/MIN 4

Part No. 4HC218-060SQ

PARTS LIST

ACURA INTEGRA TYPE R 1.8L H.O.

ENGINEERING, LLC

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages

or damaged parts immediately.

PART # DESCRIPTION QTY PART # DESCRIPTION QTY

2E129-170 S/C,V-5 SQ G-TRIM CCW 1 4HC110-160 S/C MOUNTING PLATE ASSY 1