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Detailed Instructions On How To Install
The Greddy Blow Off Valve On A
1993 MR2 Turbo
TOOLS REQUIRED:
12mm 1/4 or 3/8 drive socket, or open end wrench
10mm 1/4 drive socket
1/4 drive ratchet handle
1/4 drive extension (I used two, 3 inch and 6 inch)
Not sure on the proper allen wrench size as it is metric
I used an SAE standard that seemed to fit OK, best guess
is about 4 or 5 mm hex. Same size fits both adjust screw
on BOV, and hold down screw on adapter.
10mm openend wrench
ADDITIONAL PARTS NEEDED:
GREDDY BOV ADAPTER KIT: BVS-11003 For MR2 E-SW20 3S-GTE engine
I purchased mine from CAP Cyberspace Automotive Performance
http://www.cyberauto.com
Talk to Stacey, she knows the proper Kit part number.
short 6 or 7 inch piece of black rubber hose 1/4 OD
Lubricone silicone lube or some type of silicone lub
for the O-ring so it doesn't rub raw up against the
seat of the air tube when re-installed.
INSTRUCTIONS:
First, it is easier to remove the entire air tube than it is to
mess with trying to pull the old BOV off and put the new one on
with the air tube in place, so first thing, get your 10mm socket
1/4 drive and small extension, and loosen the two end hose clamps
that hold the air tube, one on the turbo output, and the other on
the hose that comes off the intercooler input.
Then, loosen the small hose clamp that comes up to the side of the
stock BOV and pull the small hose off. This is the vacuum supply
hose that comes over from the side of the intake manifold.
Also loosen the return hose clamp the larger one that comes out
of the side of the stock BOV, and pull out the stock metal pipe.
NOTE: for those that have the large metal plate, with four bolts
that clamp the air tube to the head, you will need to
remove at least two of the bolts inorder to remove the air tube.
I removed this plate quite some time ago, as I see it as
nothing more than a big heat sink, sinking the heat the wrong
way, from the head back to the air tube, and you need as
little heat in that air tube as possible.
(What also works great in my case is that I also have the two
ten inch fans, one of which is right next to the air tube
sucking out heat at the rate of 670 CFM.)
I have been running mine with out this steel plate on the
air tube, for several years now, and have not seen any
ill effects from it at all.
NOTE: you will not need to reuse the oneway valve and the Tee and
the other small hoses that connect it.
Now finish loosening the air tube and pull the entire assembly out
so you can easily work on it.
Now using a 12mm socket or openend wrench, loosen the single bolt
that holds the stock BOV to the air tube. This will remove the
BOV from the air tube.
NOTE: be careful not to damage the O-ring, you will need it to
reinstall on the new Greddy BOV adapter plate.
Now carefully remove the O-ring from the stock BOV, and use some
silicone spray, or Kano Labs Lubricone to clean it and lub it before
putting it on the adapter plate.
Now place the O-ring on the new Greddy adapter plate.
Locate the odd looking stud bolt that has two different size
studs on either end, it is the only thing that looks like that
so it should be easy to find.
There is also only one place that it can go on the adapter plate
so with the O-ring in place on the adapter plate, position the
new adapter plate on the air tube and carefully press it down
then screw the (large end) stud down finger tight.
I found that pressing down on the adapter plate, seating the O-ring
and at the same time screw down on the stud helped.
One technique that may seat the stud better is to double nut the
top stud with another 6mm nut, and then tighten it down with a
10mm wrench. Since there are no torque specs given, then the
old calibrated wrist will have to do.
But be careful, remember this is aluminum.
You should now have the O-ring, and adapter plate screwed down
and seated on the air tube.
NOTE: it may look like the O-ring is not completely seated but
it should be OK, remember that there is only this one bolt
stud that is holding down the adapter, mine looks like it
is not 100% seated, but seals just fine.
You do not want to over torque the stud, as you are going into
aluminum, and could easily strip it out.
Next you want to place the gasket on the new adapter, and then place
the Greddy BOV on and using the allen head bolt and lock washer
and the other lock washer and the 6mm nut, screw down the BOV
onto the adapter plate.
At this point you can install the face sticker that comes with
the kit. This is a sticker that shows SOFT and HARD adjustment
for the adjusting screw on the BOV.
Simply peel the backing off the sticker, and then position it
so that it is right side up, and oriented properly and then
push it down on the face of the BOV.
Now using a 10mm wrench, and the allen wrench screw down the
nut and the allen head bolt and torque down, again you will have
to use your calibrated wrist, as no torque specs are given.
If any of you have a allen adapter torque wrench, first off
I would like to see that, and second I would suspect that the
nut and the bolt would be torqued to not much more than 3 or 4
foot pounds plus or minus a foot pound.
NOTE: when placed properly, the open end of the BOV, meaning
the discharge end of the BOV points to the drivers side
so make sure that you have it oriented properly.
NOTE: even though the Japanese instructions state that you should
connect the output of the BOV back into the intake as the
stock one was, this is your call.
I and I know others, have noticed no ill effects of having
the BOV vent to atmosphere. Although the sound may take a
little getting used to, I think it sounds really cool. :)
So this call is up to you.
What is interesting enough, is that even though the Greddy
Japanese instructions say to vent the output back to air intake
they provide in the kit of parts, a rubber cover cap that
fits just perfectly over where the stock metal pipe goes back
into the intake pipe.
Now as explained in the NOTE just above, the kit includes a rubber cap
that fits perfectly over the hole in the large intake rubber pipe
that goes into the intake of the turbo. So in my case, I removed the
stock metal pipe where it goes into the large rubber intake pipe
at the mouth of the turbo, by loosening the hose clamp on it, and
pull the metal pipe out of the side. Then using some Lubricone
or some silicone lubricant, (you will have to to make it slide on)
slide the rubber cap over the opening on the side of the large
intake pipe down near the mouth of the turbo.
Remember that this is the intake, and is not pressurized, so an
additional hose clamp on it is really not necessary.
The rubber cap provided has plenty of stretch in it, and fits nice
and tight over the opening.
If you choose to vent the output of the Greddy back to the intake
then leave this stock metal pipe in place and using the stock
short hose coupler, and two hose clamps, then couple the pipe up to
the Greddy BOV, and screw down and tighten the hose clamps.
At this point, check your work, and make sure that the Greddy BOV
is fitted nicely on the air tube, and that the bolts, nut, and stud
are all tighten down.
Now in my kit, the main air control adapter that is a small hose
to about a 12mm pipe type thread fitting, was not installed on the
BOV, so it is obvious on the BOV where it goes, there is no other
hole to install it. So I used a small piece of teflon pipe tape
wrap it around the fitting end, and screw it into the BOV.
Then using a 10mm openend wrench, tighten the fitting down.
NOTE: this is the only hose fitting you will need, the other
smaller hose fitting coming out of the other side of the
Greddy BOV is not used, and does NOT need to be plugged.
So now we are ready to reinstall the air tube, with your new
Greddy BOV installed.
Position the air tube in place and push it back into the two hoses.
Now check for position, and tighten down the hose clamps using a 10mm
socket.
For those of you that still have that metal plate that couples the
air tube to the head, if you still are using it, and I really don't
know why, then be sure to bolt it back up as part of the re-install.
Now check to make sure that the bottom end of the Greddy BOV is
not hitting the corner of the valve cover. If so then just loosen
the two hose clamps that hold the air tube on and push up on the
Greddy BOV a bit, and then while holding the BOV in place, tighten
down first the turbo hose clamp, and then the intercooler hose clamp.
This will ensure that the BOV doesn't bounce against the valve cover.
Now you are ready to hook up the one hose to the larger hose fitting
pointing towards the drivers side of the car.
I found that the piece of hose from the stock BOV just did not fit
properly on this fitting, so that is why I used a 6 or 7 inch piece
of small rubber hose and hooked it up.
Note that this is the hose that comes over from the side of the
intake manifold. This is the throttle close signal that the BOV
gets that tells it to open up and vent pressure when the throttle
is closed.
ADJUSTING THE BOV
-----------------
This is going to have to be a little trial and error session.
As I am running 16 psi of boost, then I currently have the center
adjusting screw on the BOV turned towards the hard side such that
as you count the threads left showing on the adjusting screw
there are 5 or 6 threads left showing. This so far seems to work OK
at 16 psi of boost. Now if you are not running 16 psi, then I would
suspect that you would have to adjust it more towards the
soft side and then have more threads showing on the adjustment screw.
Remember to loosen the 10mm nut on the adjustment screw when you
want to adjust it, and retighen it to lock it down in place.
You will need to make several partial, and full boost runs to finally
find the proper adjustment for the BOV, there are no specific
instructions in the Japanese instructions that come with the kit
as you can read below.
Otherwise you are done, again check your work, make sure that everything
is tighten down, expecially the hose clamps.
Below are the original Japanese instructions as translated by
Kiyoshi Muroi.
============================================================================
One of our Japanese managers here at NEC was kind enough to
translate word for word, the entire two page instruction set
that comes with the Greddy BOV kit.
Thanks to: Kiyoshi Muroi
NOTE: These instructions include a fully translated copy of the
Japanese instructions that come with the BOV kit.
The following are those instructions:
((Page 1))
Greddy Blow Off Valve Type-S
Adapter set instruction manual
Thank you for purchasing a Greddy Blow off valve Type S adapter set.
Please read this instruction manual and use for a long time.
About the instruction manual
----------------------------
IMPORTANT Please be sure to read it.
This instruction manual describes how to install this adapter set and
how to use it. Please be sure to read it and use it properly.
Please keep this manual during having this adapter set.
In this manual we denote these symbols:
WARNING: if you ignore the description denoted this, your life may
be in danger or you may be injured seriously.
CAUTION: if you ignor the description denoted this, you may be injured
or may damage something.
Adaption - the stock number : BVS-11003
Maker: Toyota
Car type: MR2
Car type ID: E-SW20
Car type year: start from Oct. 1989
Engine type ID: 3S-GTE
-CAUTION: This adapter set is designed to use on the car type
above. Please be sure not to use on another car type.
((Page 2))
-Before installation - IMPORTANT - Be sure to read it.
1. If you drive the car with this adapter on public roads, you
may be regulated by the officials.
This adapter set is exclusively for motor sports use.
If you drive the car with it on public roads, you should
contact DMV to confirm.
2. You should have this adapter set installed by the installation
authority. You should have special knowledge, technique, and
instruments in order to install it. You should have this
adapter set installed by the shop that is installation authority.
3. Before starting installation, be sure to do these below.
-Be sure to check the contents of this adapter set
-You should do installation indoors
-You should cover car body during installation.
-Be sure not to stick dust to parts or not to stain them
-During installation, you should take off the minus terminal of the car
battery
-You should cover the hole when you remove original parts from engine
-Be sure to follow the description when you fit up the blow off valve.
-Be sure to re-check all instruction steps after installation.
4. Be sure not to use the parts not included in this adapter set.
-We won't be responsible any defects, accidents, or damages
when you use improper parts.
((Page 3))
- Parts List -
- Blow off valve x 1
- Adapter x 1
- Bolt (exclusive for adapter) x 1
- Cover cap 30mm in diameter x 1
- stainless steel (SUS) cap bolt, 6mm in diameter, 15mm long x 1
- SUS spring washer, 6mm x 2
- Gasket x 1
- Nut, 6mm in diameter x 1
- Sticker plate x 1
- How to fit it
- Remove the original air by-pass valve (ABV) and O ring
- Fit up with the adapter with the bolt and the O ring (removed before)
then, fit up with blow off valve with the gasket.
- Refer to the figures below.
- CAUTION: be sure to cover the hole when you remove the original
parts so that dust shouldn't get into it. To stick dust may
cause engine trouble or damage.
(The bolow off valve and the other pipes may interfere with each other
when it occur, you may move them slightly in order not to interfere).
- Figures to install
<< Left Figure >> Before minor change of SW20. (Oct. 1989 - Sep. 1993)
<< Right Figure >> After minor change of SW20. (Oct. 1993 - )
((Page 4))
-WARNING: Be sure that an relief air from blow off valve shall return
to intake. If the relief air remain open to atmosphere,
engine may not work properly and may be stalled, and it
cause to be dangerous situation.
-WARNING: Be sure not to move the top adjust bolt of the blow off valve.
If you move the bolt, engine may not work properly because
of blow back air from the turbine and may be stalled, and it
cause to be dangerous situation.
-WARNING: If you want to install additional injector, be sure to
install at the position after this blow off valve
(that is between the blow off valve and the throttle valve)
- After installation - IMPORTANT - be sure to read it.
After installation be sure to check these instructions below
-CAUTION: Check to installation steps such as:
- how to fit up with every parts
- to fasten every bolts, nuts, and hose bands
- not to fail connection couplers or hoses.
-WARNING: Be sure about ventilation to start engine. Accelerate a little
to be sure every parts not to interfere each other.
Be careful so that exhaust gas may not affect your body.
Be sure to check engine works properly. If you find any anomalies when
you drive, you should stop on any safe area and contact the shop that
installed the valve.
- We take care of quality of this adapter set. We won't be responsible
for any troubles, accidents, or damages as a result of your lack
of caution.
--
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+ Marc L. Summers System Administrator +
+ 3100 N.E. Shute Road Hillsboro Oregon 97124 +
+ PH: 1-503-681-3338 FAX: 1-503-681-3304 +
+ Email: marcs@tdd.hbo.nec.com +
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