Nissan R35 GTR Intercooler Pipe Kit w/ Cold Air Intake Installation Instructions 1. Disconnect the negative terminal on the battery that is located at the passenger firewall side. 2. Remove both front driver and passenger side front wheels.
3. Remove all 12 plastic clips and 1 Phillip head screw on top side of fender wheel well. 4. (Optional) Remove the driver side wheel well splash guard fender. 5. Repeat step 3 and 4 to remove the passenger side wheel well splash guard fender.
6. Remove the front under side air splitter by removing all 14 x 10mm, 2 x 12mm bolts, and 2 plastic clips. 7. Remove the fender s Side Marker Lights by pushing in the clip. Disconnect the electrical connector. Repeat the same procedure on the other side of the car. Optional: Using some masking tape and tape off the fender and bumper line section to prevent any scratching when removing the front bumper
8. Remove 3 x 10mm screws on the underside of the driver and passenger side front wheel fenders 9. Remove the hood latch cover by removing all 8 plastic clips. 10. Remove all 6 upper front bumper plastic clips
11. (Optional) For clearance to access the turbo to IC pipe Remove all 8 x 10mm bolts and remove the front underside Air Splitter Center Skid Plate. 12. Remove the plastic clip on OEM air box inlet on driver side, and then remove the inlet. Repeat same procedure on passenger side. 13. Optional: For ease of removing front bumper (preserving the paint) and installing pipe kits, it is recommended to have a 2 nd installer present for assistance.
14. Remove the OE front fascia/bumper. 15. Remove the passenger side OEM oil cooler air duct by removing 4 plastic clips. 16. Remove the passenger side OEM oil cooler air duct bracket by removing 4 x 10mm bolts.
17. Remove the passenger side OEM oil cooler by removing the 4 x 10mm bolts. DO NOT DISCONNECT the oil lines from the cooler. 18. Disconnect the recirculation hose and vacuum source hose from OEM BPV on both driver and passenger side. 19. Remove two 12mm bolts that attach the OEM BPV on both driver and passenger side.
20. Loosen both hose clamps on the coupler that are connecting the air-box to turbo inlet. Then remove the 10mm bolt on side of air box. Repeat same procedures on the other side. 21. Remove wire harness bracket on both driver and passenger side by removing the 12 mm bolt. 22. Remove air boxes on both driver and passenger side.
23. Remove the driver side air temperature sensor and its harness on the OE Throttle body pipe. 24. Loosen all the driver side OE clamps from TB to IC with an 8mm ratchet or flat head screw driver.
25. Remove the driver side OE BPV recirculation hose from the BPV to Turbo. 26. Remove 3 x 12mm bolts for the center piece of OE IC to TB pipe under the driver side fender wheel well.
27. Remove driver side all 3 pieces (2 x metal, 1 x rubber pipes) of the IC to TB OE pipes 28. Remove the driver side Turbo to IC connector pipe by removing the 12mm bolt, wire harness anchor, 29. 2 x 8mm clamps holding the rubber coupler to the IC. Then repeat step 23 to 28 on the passenger side of the car.
30. Install the removable inserts into the intake pipes. 31. Remove both MAF sensors from OEM air boxes and reinstall both sensors on to Synapse Engineering intake pipes. Reuse the 7mm bolts to fasten the sensors on the intake pipes. 32. Install the 45 degree silicone couplers and clamps on both driver and passenger side, but do not tighten the clamps yet.
33. Install the passenger side intake pipe onto silicone coupler that is already on the turbo inlet. 34. For driver side intake pipe, remove driver side power steering reservoir lower bolt, then line up the driver side intake bracket bolt hole to the same hole. Fasten the 10mm bolt onto the bracket but do not tighten yet. 35. Install air filter onto intake pipe on both driver and passenger side, but do not tighten filter clamp yet. Then adjust the intakes and filters assembly to allow proper clearance in order to prevent the intake assemblies physically contacting their surroundings.
36. Tighten all components for the GTR intake assembly on both driver and passenger sides. 37. Install a 2.75 straight coupler onto the passenger side throttle body, and then install the KIT0000047.1 (Pass. Upper IC to TB Pipe). Place the Gap Spacer (provided) between the pipe bracket and the strut tower bolt hole, then fasten the 10mm bolt (provided). 38. Install a 2.75 to 2.5 Reducer coupler onto the passenger side Intercooler outlet side.
39. Install a 2.75 straight coupler onto the KIT0000047.1 pipe, and then install KIT0000048.1 (Pass. Lower IC to TB Pipe). Connect the other end of the pipe to the coupler from the previous step. Line up the pipe bracket to the proper bolt hole as indicated in the above (right side) picture. Note: Notice that the Passenger side IC to TB Lower Pipe has a slight bend on the Upper Pipe connecting side. 40. Preinstall a 2.25 to 2 Reducer Coupler onto the turbo discharge. Preinstall a 2.75 to 2.25 Reducer Coupler onto the Intercooler inlet side.
41. Install the KIT0000049.1 (Pass Side Turbo to IC Pipe) according to the steps as depicted in the above 3 pictures. Repeat steps 36 to 40 for the driver s side Intercooler Pipe kit install. 42. Place the adapter O-ring on the inlet side of the BOV. Make sure the O-ring sits flat in the BOV before installing onto the pipe.
43. Install the Synchronic Blow-Off-Valves onto the IC to TB Upper Pipes on both driver and passenger side. Then install the BOV Discharge Recirculation Pipes onto the recirculation inlet (circled in the above picture) on the turbo. Use the 1.25 couplers & clamps provided. Cut and re-size the 1.25 couplers if necessary.
44. Measure about 7 inches in length of Boost Connect hose and cut 2 equal length pieces. Connect the 2 pieces of hose to Y connector. Then Cut approximately 5 inches of Boost Connect hose and push that into the collector side of the Y connector. 45. Push the other end of the cut Boost Connect hose into the OEM vacuum hose that was connected to the OEM By-Pass-Valve. Try to push it approximately 2 inches into the OEM vacuum hose. Then slide the OE hose clamp back to ensure tight fit. 46. Connect the MAF sensors to driver and passenger side s Intake Pipes
47. Install and connect the pressure sensors to the undersides of driver and passenger IC to Throttle Body Pipes. 48. Check all pipe kit components and ensure all bolts and clamps are tighten. 49. Reinstall the passenger side oil cooler assembly and check that the oil lines are still connected and have not sustained any damages throughout the installation process.
50. Reinstall the OE front fascia/bumper and driver/passenger side markers. 51. Reinstall the Air Splitter Center Skit Plate if it was previously removed. 52. Reinstall the OE Front Air Splitter.
53. Reinstall the OE Hood Latch Cover 54. Reinstall driver and passenger sides wheel well splash guard fenders if they were removed. Driver & Passenger side Install Complete