HKS 70020-AH015 Racing Suction Reloaded Intake Kit Installation Guide

HKS 70020-AH015 Racing Suction Reloaded Intake Kit

NOTICE

This manual assumes that you have and know how to use the tools and equipment necessary to safely perform service operations on your vehicle. This manual assumes that you are familiar with typical automotive systems and basic service and repair procedures. Do not attempt to carry out the operations shown in this manual unless these assumptions are correct. Always have access to a factory service manual. To avoid injury, follow the safety precautions contained in the factory service manual.

SAFETY PRECAUTIONS

WARNING

• To prevent electrical damage/burns/fires, always:
  • Disconnect the negative terminal of the battery before beginning installation.
  • When disconnecting wires/connectors, take extra care to avoid breaking/snapping the wires.

CAUTION

• Do not misuse this product.
  • Misuse of this product may lead to engine damage.
  • Misuse of this product may lead to loss of original function.
• Prior to installation, make sure the engine bay temperature has cooled to approximately 40℃/104°F
  • Failure to let the engine cool down properly can lead to severe burns.
• Insert clean rags into open piping to prevent contaminants from entering the pipes.
  • If neglected, contaminants in the piping can lead to engine damage.
  • Make sure that all of the parts listed in the Parts List are included in the kit.
  • Reference the factory service manual for the vehicle when removing factory parts.
  • Be careful when handling this product; avoid dropping or subjecting it to excessive impacts. Failure to do so may result in product damage or improper installation.
  • Use the proper tools when tightening nuts and bolts. If over-tightened, the bolts may become damaged.
  • Keep the removed factory parts in a safe place for ease of re-installation at a later date (if necessary).
  • Replace the filter element at regular intervals: (Recommended) Replace every 3,000~5,000km/2,000-3,200miles or every 3~6 months. Replacement filter elements are sold separately.
  • Do not wash the filter element as the filtration properties will be degraded.
  • However, there are certain conditions where, depending on dirt buildup, the filter may need to be replaced earlier than the above-recommended intervals.
  • If the vehicle and the product are not maintained properly as mentioned above, the product may not perform properly and the airflow meter sensor may not be able to detect the intake air volume accurately; it can lead to engine damage or other faulty conditions.

INSTALLATION PROCEDURE

REMOVAL OF FACTORY PARTS

1. Disconnect the negative terminal from the battery.

2. Remove the hose from the portion shown in Diagram 1.

3. Remove 2 clips and loosen the hose clamp to remove the air duct. (Dia.2)

4. Remove 2 bolts to remove the air duct bracket.(Dia.2)

5. Disconnect the connector from the airflow meter sensor. (Dia.3)

6. Remove the blow-by pipe from the air cleaner case. Remove the air cleaner case. (Dia.3)
   ADVICE:
   Remove the blow-off pipe while removing the air cleaner case from the throttle body.

7. Carefully remove the airflow meter sensor fromthe air cleaner case. (Dia.3)

INSTALLATION OF KIT PARTS

1. Install the supplied 10mm hose fitting and elbow. Wrap the threaded section with Teflon tape to prevent air leakage. (Dia.4)
   ADVICE:
   After tightening the hose fitting and elbow by hand, tighten them another one to two turns using the appropriate tools. (It is not necessary to tighten the fittings to the point where the nut touches the pipe.)

2. Assemble the airflow meter sensor as illustrated in Diagram 7. Ensure that the factory airflow meter sensor’s factory O-Ring is seated correctly, making sure it does not get pinched in the suction pipe. Tighten with the supplied M4 screws. Do not over-tighten. Tightening torque: 2.0~3.0 N-m (0.2~0.3 kg-m). (Dia.7)

3. Install joint hose 80mm to the filter assy. (Dia.5, Dia.7)

1. Check the direction of the air guide. Press and insert it into the joint hose. (Dia.5) Make sure not to leave any gaps between the filter assy and air guide. When intalling the hose fittings, wrap the threaded section with Teflon tape to prevent air leakage After tightening the hose fitting and elbow by hand, tighten them another one to two turns using the appropriate tools. (It is not necessary to tighten the fittings to the point where the nut touches the solenoid valve.)

• Temporarily install kit parts. (Dia.5, Dia.6, Dia.7, Dia.8) Make sure not to leave any space between air guide and suction pipe.

• Position the intake assembly on the vehicle avoiding unnecessary contact with other parts of the vehicle. Once the position is determined, secure the intake assembly to the vehicle using the supplied hose clamps and bolts. Do not over-tighten the clamps and bolts. (Dia.9)
  ADVICE: Use of proper tools can help avoid over-tightening of the hose clamps. (Screwdrivers are recommended. Do not use boxed wrenches since they tend to use more force.) If over-tightened, the filter assembly outlet may bend or become damaged. (Tightening torque: 2.0~3.0 N-m {0.2~0.3 kg-m})

• Reconnect the airflow meter sensor connector.

• Remove the engine cover. (Dia.10)

• Remove 2 Grommets. (Dia.11)

• Attach the sponge tape to the back side of the head louver. (Dia.12)

• Install the head louver. (Dia.12, Dia.14)

• ADVICE: For easier installation, remove the tab securing the purge joint, and relocate the purge joint. (Dia.13) (It’s not necessary to remove the purge joint.)
• Reconnect the cable to the negative terminal of the battery.

Confirmation After Installation

Check the following after the installation process is complete. （1）Check the following before starting the engine:

• Make sure pipes and hoses are routed and connected correctly.
• Make sure hose clamps are tightened.
• ake sure the negative cable terminal is securely connected to the battery.
• Make sure all bolts and nuts are tightened.
• Make sure all installed components do not come in contact with other parts.

（2）Start the engine and check the following:

• Make sure air is not leaking.
• Make sure the RPM rises smoothly when revving the engine 2-3 times while in neutral.
• Make sure the installed parts are not hitting each other.
• Make sure there are no idling issues.
• Make sure there are no loose parts once the engine is off.

MAINTENANCE

Proper daily maintenance of this product is necessary in order to maintain the safety, reliability, and function of this product. Maintenance is the responsibility of thedriver/owner.

• If work needs to be performed outside the scope of this manual, consult a professional.
• If the vehicle gets damaged, have the repairs performed by a professional.
• If you experience any abnormal noises, scents, or vibrations from the vehicle while driving, reference the vehicle’s Owner’s Manual.
• If this product is ever re-sold, please give this Instruction Manual to the new owner.
• When removing this product from the vehicle, please consult a professional.

PARTS LIST

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