Weistec M113K Supercharger System

Transcription

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Weistec M113K Supercharger System
Installation Guide
Phone 877-WEISTEC Fax 888-516-8219
www.weistec.com
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WARNING!
DO NOT HAVE YOUR ECU REPROGRAMMED ANYWHERE BUT AT WEISTEC FOR
THIS SUPERCHARGER. THE AMG 55 USES AN ELECTRONIC THROTTLE CONTROL
(ETC), WHICH IS CONTROLLED BY THE ENGINE CONTROL UNIT (ECU) AND THE
CALIBRATION INSIDE. A REFLASH DOES NOT PROPERLY RECALIBRATE THE
ENGINE MANAGEMENT SYSTEM; THIS CREATES A DANGEROUS SITUATION THAT
COULD RESULT IN A STUCK THROTTLE AND CAN LEAD TO INJURY OR DEATH.
WEISTEC FULLY REPROGRAMS THE ECU TO MERCEDES STANDARDS, AND
ENSURES THAT ALL ENGINE SAFETY CONTROLS ARE FULLY FUNCTIONAL.
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WARNING!
THE WEISTEC M113K SUPERCHARGER AND ACCOMPANYING PROGRAMMING
ARE DESIGNED AROUND THE USE OF 91 OCTANE FUEL OR HIGHER ONLY.
BEFORE YOU RUN YOUR MERCEDES WITH THE WEISTEC M113K SUPERCHARGER
INSTALLED EVEN ONCE, YOU MUST EITHER DRAIN THE FUEL TANK COMPLETELY
AND FILL IT UP WITH 91 OCTANE, OR BEGIN USING 91 OCTANE IN YOUR
MERCEDES TWO COMPLETE FILLUPS BEFORE INSTALLATION.
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WARNING!
IF YOU ARE NOT EXPERIENCED IN THE AREA OF
AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT
YOU REFER THIS INSTALLATION TO A CERTIFIED
INSTALLER OR TECHNICIAN.
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WARNING!
THE WEISTEC M113K SUPERCHARGER MUST BE FILLED WITH
160 mL OF PROVIDED OIL PRIOR TO ROTATION OF THE
COMPRESSOR SCREW SYSTEM OR YOUR WARRANTY WILL BE
VOIDED.
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WEISTEC M113K SUPERCHARGER
Installation Guide for MERCEDES AMG 55
Thank you for your purchase of the Weistec M113K Supercharger for the Mercedes AMG 55
with the 5.5L Kompressor motor. We appreciate your business, and we know you will enjoy
your product.
For your benefit, please read the following instructions completely and thoroughly before
attempting to install the supercharger. Many questions we have received from customers
about the installation of our products that could have been easily solved by information listed
in the accompanying installation guide. We want you to enjoy the product in its fully functional
state, and reading this tutorial is the first step to getting you on your way to a more rare and
powerful Mercedes AMG.
PLEASE NOTE THAT IF YOU HAVE ANY AFTERMARKET POWERTRAIN PARTS ALREADY INSTALLED
ON YOUR VEHICLE, YOU MUST RETURN THE CAR TO STOCK STATUS – THIS INCLUDES PULLEYS,
PROGRAMMING, ETC.
THE CAR WILL NOT FUNCTION AND PARTS MAY NOT FIT PROPERLY IF OTHER AFTERMARKET
PARTS ARE INSTALLED.
We strongly urge that you also have at least one person to help you install the supercharger, as
the unit is heavy. You will soon be on your way to installing the World's First Supercharger
Upgrade for the 5.5L Kompressor!
Again, thank you for choosing Weistec Engineering!
www.weistec.com
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Table of Contents
Tools Required ............................................................................. Error! Bookmark not defined.
I.
Disassembly ..................................................................................................................... 2
II.
M113K Supercharger System Assembly ................................................................... 18
III.
M113K FEAD System Install ........................................................................................ 22
IV.
M113K Supercharger Assembly Install .................................................................... 24
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Tools Required
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Hydraulic Jack or service lift
Jack Stands or transmission stand
1/4” Drive Ratchet
12" Long 1/4" Drive Extension
6.5mm 1/4” Drive Deep Well Socket
8mm 1/4” Drive Deep Well Socket
17mm 3.8" Drive Deep Well Socket
10mm Open End Wrench
1" Open End Wrench
8mm Ratcheting Wrench
3/8” Drive Ratchet
13mm 3/8" Drive Socket
Vice
17mm 3/8" Drive Deep Well Socket
19mm Heavy Duty Deep Well Socket
T-25 1/4" Drive Torx Bit
T‐30 1/4" or 3/8” Drive Torx Bit
E-8 3/8" Drive Reverse Torx Bit
E-14 3/8" Drive Reverse Torx Bit
Flat Head Screw Driver
Wire Cutter
Pushpin Removal Tool
6mm Drive Hex Bit
8mm Drive Hex Bit
Mechanics Rags
Vacuum
Painters Tape
Fluid evacuator
Impact Gun (Optional)
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Crimp Style clamp tool
5mm Drill bit
Drill
Grinder (Optional)
Torque Wrench
Ultra Black RTV Silicone
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I.
Disassembly
Before removing battery terminal, double check vehicle is in Park, and driver side window is
completely down.
1. Disconnect the Negative battery terminal by:
a. Swinging spare tire panel in truck upward to access battery.
b. Pulling top battery panel forward and sliding out.
2. Using 10mm Drive Socket, and 12" extension to remove batter ground strap. Raise and
support the hood.
3. Remove ECU by:
a. Removing engine bay liner in the upper corner of the engine bay by turning the
two plastic screws ¼ counter-clockwise
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b. Sliding the two plastic locks to the unlock position and lifting out the ECU/Fuse
Box cover
c. Removing ECU by unlocking the grey locks on the connectors, unplugging the
harness plugs, and removing the ECU from the car.
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BEFORE MOVING ON, PLEASE FILL OUT THE VEHICLE INFORMATION/TUNE REQUEST FORM
AND MAIL THE ECU AND FORM TO 1701 E. EDINGER AVE. SUITE G4, SANTA ANA, CA 92705,
USA.
ELECTRONIC COMPONENTS SUCH AS THE ECU ARE VERY FRAGILE. PLEASE BE SURE TO
SECURELY PACK THE ECU WITH PROTECTIVE COVERING WHEN MAILING.
THE VEHICLE INFORMATION/TUNE REQUEST FORM IS INCLUDED WITH THE SUPERCHARGER
SYSTEM DOCUMENTATION, AND CAN ALSO BE FOUND AT http://weistec.com/support.html
4. Remove the air intake system from the vehicle by:
a. Gently pulling up on the Mercedes engine cover
b. Removing both air box inlet tubes.
c. Using Flat Head Screw Driver or 6.5mm Socket to loosen Clamps on the inlet Y
and air boxes.
d. Lifting the air box assemblies from the vehicle.
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5. Remove AMG manifolds by:
a. Using Flat Head Screw Driver or 6.5mm Socket to loosen Clamps on the
supercharger outlet
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b. Removing all 7 screws from each AMG Manifold
c. Removing AMG Manifolds from the engine bay
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6. Remove Throttle Body and EVAP Lines by:
a. Unplugging Throttle body harness.
b. Removing all 4 throttle body bolts using a T-30 Torx Bit.
c. Disconnecting Throttle Body EVAP line.
d. Removing Throttle Body from vehicle and placing it somewhere clean and safe.
e. Removing EVAP line from Right Valve Cover.
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f. Removing EVAP line from Left Valve Cover.
7. Remove Fuel Rails and Injectors by:
Please be aware that the fuel system may retain fuel pressure that can be extremely
dangerous if removed suddenly. Proceed with caution.
Please be aware of dripping fuel may get on parts that can be affected. Please cover fuel
line with a shop rag in this case.
a. Removing 4 bolts for fuel rail removal.
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b. Disconnecting fuel line using 17mm Open End Wrench.
c. Unplugging all 8 fuel injectors.
d. Lifting up on the fuel rails to remove them along with the injectors
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8. Remove Air Valves by:
a. Disconnecting vacuum lines and air lines from both of the air valves
b. Unbolting Air Valves from the intake manifold runners and placing them
somewhere clean and safe as they will be reused.
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9. Remove Supercharger by:
a. Removing Supercharger Belt
b. Removing Intercooler water line bracket
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c. Disconnecting rubber intercooler water lines from the hard lines
d. Removing Intake manifold bolts
e. Removing EVAP Solenoid line by unbolting it from the right Valve cover and
disconnecting both ends.
f. Unplugging all sensor clips, hoses, and fasteners and make Supercharger free for
removal.
 Supercharger Clutch clip
 Rear IAT Sensor clip
 Bypass Valve harness from engine harness
 1 map sensor clip (Left side of supercharger outlet)
g. Removing Supercharger assembly from engine bay and placing it on a clean work
bench
h. Vacuuming and cleaning engine valley and intake ports.
i. Using painter’s tape to seal intake ports until the Weistec M113K Supercharger
system is bolted onto the engine.
10. Remove Bypass Valve by:
a. Removing MAP Sensor by removing two screws
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b. Removing IAT Sensor by carefully unclipping it
c. Removing all screws that attach the Intercooler to the supercharger
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d. Gently prying the intercooler and supercharger apart
e. Removing Bypass Valve rubber gasket and 4 Bypass Valve Bolts
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f. Placing Bypass Valve on a clean workbench as it will be reused.
11. Remove Factory Supercharger Belt Tensioner by:
a. Removing Tensioner pulley
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b. Removing Tensioner bolts
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II.
M113K Supercharger System Assembly
1. Install IAT Sensor by:
a. Installing IAT Sensor into Intake Manifold in the location shown below. Make
sure to lubricate the O-Ring to prevent damage during installation
2. Install MAP Sensor by:
a. Pressing in MAP Sensor in the location shown below and bolt in using original
bolts. Use Blue Loctite on the bolts and make sure to lubricate the O-Ring.
3. Install Bypass Valve by:
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a. Trimming Bypass Valve rubber cover as shown below. Some early models do not
have the rubber cover. If your Bypass Valve does not have the cover, skip this
step.
b. Lubricating included Bypass O-Ring and positioning it in the groove as shown
below.
c. Bolting on Bypass valve using original hardware.
d. Pressing on included Bypass Coupler and loosely fitting on two included 6080mm European hose clamps
4. Install Inlet Manifold by:
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a. Cleaning then applying Black RTV Silicone to Inlet Manifold as shown below.
b. Mounting Inlet Manifold onto Supercharger inlet making sure the Bypass Coupler
properly attaches to Inlet Manifold. Be sure to install the Inlet Manifold as
shown below to avoid smearing the Black Silicone RTV applied in the previous
step. Line up the top of the Inlet Manifold so that is touching the Supercharger
inlet. Then press the back of the Inlet Manifold down so that it is properly
seating in the Bypass Coupler as well as mated with the Supercharger Inlet
It is highly important that care be taken with this step to ensure there are no
vacuum leaks.
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c. Bolting on Inlet Manifold using 4 included M8x1.25x25 bolts, Torque to 40 Nm.
One of the bolts must be bolted from the opening of the Inlet Manifold as shown
below.
d. Wiping away excess silicone
e. Position and tighten the two 60-80mm European hose clamps on bypass valve
coupler
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III. Weistec M113K FEAD System Install
1. Install M113K FEAD System by:
a. Tapping the indicated hole using an M8x1.25 Tap.
b. Bolting on the M113K FEAD Bracket using the included bolts as shown below.
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c. Bolting on included 8 Rib Belt Tensioner Assembly using included M10x1.5x80
bolt and M10 washer. Make sure tensioner is aligned so that the alignment peg
is fully inserted into the alignment hole on the FEAD Bracket.
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IV.
Weistec M113K Supercharger Assembly Install
1. Install Supercharger Assembly by:
a. Pressing on included ¾” 90 degree molded heater hose onto barbed fittings at
back of the Supercharger System using one clamp on each hose. Make sure that
the hoses are aligned so that they will be pointing to the left side of the engine
bay.
b. Removing painters tape from intake ports on the cylinder heads
c. Placing on included M113K Intake Manifold Gaskets
d. Lowering Supercharger Assembly onto engine with the ¾” hoses routed to the
left side of the engine bay, making the assembly is properly seated and no lines
or wiring are pinched.
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e. Bolting down the Supercharger Assembly with the included M8x1.25x25 bolts,
Torque to 40 Nm
2. Connect All Electrical Connections by:
a. Connecting MAP Sensor
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b. Connecting IAT Sensor
c. Connecting all 8 Fuel Injectors – There are two options, one is to use the plug
and play injector clips. The other is to cut off the factory injector clips and wire
in the EV6 Female Pigtails (Polarity does not matter) using a soldering iron and
heat shrink to cover the solder joints.
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d. Connecting Bypass Harness to Engine Harness
3. Install Air Valves by:
a. Pressing in left and right Air Valves and bolting them to the manifold using the
original bolts and included gaskets
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b. Connecting 1/8 inch vacuum lines. Be sure to have the filters installed in the
proper direction
c. Pressing on M113K Air Tube
d. Trimming Air Pump hose and pressing it onto the barbed fitting installed in the
M113K Air Tube
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4. Connect Fuel Lines by:
a. Routing fuel line under the Inlet Manifold between the Bypass Valve and the
Supercharger unit. Make sure the side with the 90 degree –AN fitting is on the
left side of the engine
b. Screwing on hose fittings to the fittings on the fuel rails
c. Screwing on factory fuel line to the right side fuel rail fitting.
5. Connect Emissions Lines by:
a. Fitting the OEM hose shown below to the left side valve cover and connecting it
to the middle vacuum port on the Inlet Manifold
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b. Fitting the OEM hose shown below to the right side valve cover and connecting it
to the vacuum port on the right side of the Inlet Manifold
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c. Removing the OEM hose shown below from the factory air box. If the plastic
barbed coupler comes off in the OEM hose, remove it. Press in the included
brass barbed fitting and install an included clamp.
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d. Pressing on the included -10 hose section onto the other end of the brass barbed
fitting and installing an included clamp
e. Pressing the OEM hose onto the port on the right valve cover and routing the
hose as shown below. The other end of the hose will be pressed and clamped
onto the M113K Intake Tube
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f. Disassembling the factory EVAP Solenoid hard line as shown below
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g. Installing the Factory EVAP Solenoid hard line as shown below. One end
connects the OEM solenoid vacuum line with an included 3/8 clamp.
h. Pressing and clamping on the included 3/8 EVAP hose to EVAP hard line
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i.
Routing 3/8 EVAP line behind the Inlet Manifold and connecting it to the 3/8
vacuum port on the left side of the Inlet Manifold as shown below.
j.
Connecting 1/8” Air Valve vacuum line to the 1/8” vacuum port on the left side
of the Inlet Manifold, routing it under the left side fuel rail and connecting it to
the Air Valve Solenoid line that has the blue filter.
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6. Install Throttle Body by:
a. Holding the Throttle Body in a vice and tapping the hole using the included 1/8”
NPT Tap as shown below
b. Screwing in the included 1/8” NPT Stainless Plug using pipe sealant.
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c. Screwing in included 1/8” NPT Stainless Plug into Inlet Elbow. Use Teflon Tape to
ensure a proper seal
d. Pressing Inlet Elbow Gasket into the gasket groove on the Inlet Manifold
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e. Bolting on Inlet Elbow using included 4 M6x1x20 Socket Head Screws torque to
16 Nm
f. For 74mm Throttle Body: Positioning Throttle body gasket in the gasket groove
on the Inlet Elbow the bolting on the 74mm Throttle Body Throttle Body using
included M6x1x30 button head screws as shown below. Torque to 16 Nm.
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g. For 82mm Throttle Body: Applying Black RTV Silicone to the Inlet Elbow and
bolting on the 82mm Throttle Body using included M6x1x30 button head screws
as shown below. Torque to 16 Nm.
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7. Connect Intercooler Plumbing by:
a. Pressing the 5/8 barb side of the included 5/8 to ¾ Barb Couplers into the factory
intercooler lines and clamping them with the included 5/8 clamps as shown
below.
b. Running the ¾ Intercooler lines towards the front of the engine
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c. Pressing the ¾ Intercooler lines onto the ¾ sides of the barb couplers and
clamping them on with the included ¾ clamps as shown below
8. Install Intake by:
a. For 74mm Throttle Body: Fitting the smaller side of included silicone coupler
onto the throttle body and clamping it on using the provided 70-90mm European
style hose clamp as shown below
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b. For 82mm Throttle Body: Fitting the included silicone coupler onto the throttle
body and clamping it on using the provided SAE No.60 hose clamp
c. Pressing in M113K Intake tube and clamping it on using the included SAE No.60
hose clamp
d. Pressing the -10 hose onto the vacuum port on the M113K Intake Tube and
clamping it on using the included 5/8” hose clamp
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e. Fitting Weistec Air Filter onto the M113K Intake Tube and clamping it on using
the included SAE NO.60 clamp
9. Fill Supercharger With Oil by:
a. Removing plug on top of supercharger with a 5mm allen bit.
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b. Filling Supercharger unit with supplied oil
c. Reinstalling plug on top of supercharger using Black RTV Silicone
10. Install Supercharger Belt by:
a. Using a 3/8 drive ratchet to pull back on the tensioner and routing the included 8
Rib Supercharger Belt per the routing diagram shown below.
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Thank you from Weistec Engineering!
Always enjoy the added horsepower and torque of the M113K supercharger responsibly. Use
best judgment when driving, and remember to have fun!
NOTES:
www.weistec.com
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Weistec M113K Supercharger System

Transcription

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