99HondaCivicSI(4HC V2.0)

Transcription

Honda
1.6L DO
H
C Civic
Superc
Installa harger Sys
tem
tio
1999-2 n Instruc
tions
000 Mo
del
Si
Years*
*Lega
l
in Cali
fornia
only fo
r racin
g vehic
les wh
ich ma
y neve
r be us
ed upo
n a hig
hway.
®
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: 4HC020-010
©2001 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
18APR01 V2.0 (99 Honda Civic SI (4HC V2.0))
FOREWORD
Proper installation of this supercharger kit requires general automotive mechanic knowledge and
experience. Please browse through each step of this instruction manual prior to beginning the
installation to determine if you should refer the job to a professional installer/technician. Please
call Vortech Engineering for installers in your area.
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.
© 2001 VORTECH ENGINEERING, INC.
All rights reserved. No parts of this publication may be reproduced, transmitted, transcribed,
or translated into another language in any form, by any means without written permission
of Vortech Engineering, Inc.
P/N: 4HC020-010
ii
Table Of Contents
FOREWORD ..................................................................................................................................... ii
TABLE OF CONTENTS .................................................................................................................... iii
TOOL & SUPPLY REQUIREMENTS ................................................................................................ iv
PARTS LIST-1999-2000 HONDA CIVIC Si-STANDARD .................................................................. v
PARTS LIST-1999-2000 HONDA CIVIC Si-AFTERCOOLED (H.O.) ................................................ vii
1.
PREPARATION/REMOVAL .................................................................................................. 1
2.
OIL FEED ............................................................................................................................. 1
3.
OIL DRAIN ........................................................................................................................... 2
4.
FUEL PUMP WIRING AND INSTALLATION ........................................................................ 2
5.
FUEL MANAGEMENT UNIT (FMU) INSTALLATION ........................................................... 4
6.
MAP SENSOR BLEED ASSEMBLY INSTALLATION ........................................................... 5
7.
RADIATOR RESERVOIR RELOCATION ............................................................................. 6
8.
POWER STEERING PLUMBING ........................................................................................ 6
9.
MAIN BRACKET INSTALLATION ........................................................................................ 7
10.
SUPERCHARGER MOUNTING PLATE INSTALLATION .................................................... 7
11.
SUPERCHARGER INSTALLATION ..................................................................................... 8
12.
AFTERCOOLER INSTALLATION ........................................................................................ 9
A. RESERVOIR INSTALLATION ........................................................................................ 9
B. AFTERCOOLER WATER PUMP WIRING AND INSTALLATION ................................... 11
C. WATER COOLER INSTALLATION ................................................................................. 12
D. AFTERCOOLER INSTALLATION ................................................................................... 13
E. SURGE TANK INSTALLATION ....................................................................................... 14
13.
STANDARD KIT DISCHARGE DUCT INSTALLATION ........................................................ 14
14.
AIR INLET DUCT INSTALLATION ....................................................................................... 15
15.
STANDARD BYPASS VALVE INSTALLATION .................................................................... 15
16.
SUPERCHARGER DRIVE BELT INSTALLATION ............................................................... 16
17.
POWER STEERING PLUMBING/BLEEDING ..................................................................... 17
18.
FINAL CHECK ...................................................................................................................... 17
iii
P/N: 4HC020-010
1999-2000
HONDA CIVIC Si
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 92 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
P/N: 4HC020-010
iv
1999-2000 HONDA CIVIC Si STD.
Part No. 4HC218-010SQ
®
PARTS LIST
ENGINEERING, INC.
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report
any shortages or damaged parts immediately.
PART #
DESC
2E129-120
S/C,V-5 SQ CCW ’99-’00 1.6 DOHC HONDA
QTY
1
4HC110-020
4HC010-020
4HC010-090
2A017-700
2A017-854
7F008-020
7C080-070
7K312-001
7J012-092
7A312-125
7C080-080
7C012-025
4HC010-080
7U100-061
4HC010-120
7U031-016
S/C MOUNTING PLATE ASSY
Mounting Plate
Pilot, HON Mtg Brkt
Spacer, Long
Spacer, Short
M8 x 1.25 Nut
8mm x 1.25 x 70MM HHD G5 Bolt
5/16” AN-Washer
M12 Washer
5/16”-18 x 1 1/4 HXHD
M8X1.25 x 80mm Stud
M12-1.75 x 25mm HXHD Pltd.
TAB, Honda Rad. Mount
Grommet 3/8 I.D. 5/8 Flange
Brkt, Rad Res Honda
5/16” Fuel Line
1
1
1
2
2
1
3
8
3
4
1
3
1
1
1
4’
4HC110-010
4HC010-010
7C040-025
7U100-058
7U030-046
7P062-187
7U400-001
7U100-055
ASSY, HONDA MAPS BLEED
MAPS Bleed, Honda
M4-.7 x 25mm HXHD CS Pltd
O-ring Fuel Rail Honda
5/32” Vacuum Line
1/16 NPT x 3/16 Hose Barb
Check Valve
Tie Wrap, 6” Nylon
1
1
2
1
1’
1
1
2
4HC114-020
8R101-000
2A034-370
2A044-520
2A044-335
ASSY, S/C DRIVE, HONDA 1.6 DOHC HO
Pulley Retainer Assy, 4 Rib
S/C Pulley 3.70” 4 Groove
Belt, K040520 HON HO S/C
Belt, K040335 HON Pwr Str
1
1
1
1
1
4HC111-011
4HC011-011
7U250-022
2D170-222
2D070-159
7X100-025
7U100-084
2D160-212
2D030-024
7A312-075
7K312-001
4HC010-030
7A250-075
4HC010-070
7A250-101
7J006-093
7A250-276
7F250-020
4FH116-021
7J312-000
7A312-175
4HC010-060
7F312-018
7J312-875
4HC116-011
7C010-036
7S010-002
MOUNTING BRACKET ASSY
Mtg Brkt, HON 1.6 DOHC
Dowel Pin, Oversize
Assy, Ext. Drive Shaft
Bearing
Preload Spring
Snap Ring
Assy, Ext Drive Tube ’99-’00 Honda
Flange, Ext Tube End HON
5/16-18 x 3/4 HXCSG5P
5/16 AN-Washer
Top Plate, Honda 1.6 DOHC
1/4-20 x 3/4” SHCS Pltd
Tensioner Plate, Honda 1.6 DOHC
1/4-20 x 1” HHCS
6mm Washer, Plated
1/4-20- x 2.75 HHD
1/4-20 Nut
Idler Pulley Assy
5/16 Fender Washer SAE
5/16-18 x 1.75 HHD Bolt
STUD, Honda Tensioner
5/16-18 Nut
5/16 Washer HD
Idler Pulley, Assy, Honda
M10 x 1.25 x 35mm HHCSG8P
10mm Washer, Zinc Plated
1
1
2
1
2
1
1
1
1
3
3
1
5
1
4
5
1
1
1
2
1
1
2
1
1
2
2
v
PART #
DESC
4HC130-026
7P125-125
7P125-034
7P125-027
7P125-026
7P525-067
7P250-066
7U030-026
7U100-055
OIL FEED ASSY, HONDA 1.6 DOHC
Ftg, 1/8 NPT Fem x 1/8 BSPT Male
1/8 NPT x 1 Male x 2 Fem
-4 TO 1/8 NPT Straight
-4 TO 1/8 NPT 90° Male
.500 Crimp Ferrules
#4 Swivel x 1/4” Hose Barb
1/4” Oil Feed Hose
QTY
1
1
1
1
1
2
2
2.67’
5
4HC130-036
7U030-036
7R001-008
7P375-042
4HC100-010
OIL DRAIN ASSY, HONDA 1.6 DOHC
1/2” Oil Drain Hose
#8 Stnls Hose Clamp
Male Connector
Tube Nut Assy, Honda
1
1’
2
1
1
4HC238-078
6Z110-140
7U030-016
7R001-004
7U030-046
7P156-082
FMU ASSY, ’99-’00 HONDA
Fuel Mgmt Unit, 6:1 w/Spring
1/4” Fuel Line
#4 Hose Clamps
5/32” Vacuum Line
5/32 TEE
1
1
1.25’
2
1’
1
4HC101-001
8F101-310
5W001-019
5W001-014
5W001-015
5W001-042
5W001-001
5W001-011
8F010-110
7E010-075
7U314-001
7F008-032
7J008-001
8F001-200
008340
7P312-008
7U031-018
7R001-004
7P312-005
7P312-007
7U100-044
7U100-055
5W001-021
FUEL PUMP, ’99-’00 HONDA
Fuel Pump Rail Assy, Honda
12-10 GA Solderless Connector
Fuse Holder 10 GA Wire
Fuse, Blade Type 20 amp
12-10 GA 3/16” Ring Terminal
16-14 Wire Tap
16-14 GA Eyelet .25” Hole
Fuel Pump Hangar
#12 x 3/4” Sheet Metal Screw
#8 Lord Mount
8-32 Hex Lock Nut
#8 Flat Washer
Corvette Fuel Pump 200 in Line 3/8”
Fuel Pump Decal, T-Rex
T-Rex - 5/16 Barb
5/16 Fuel Hose High Press
#4 Hose Clamp
5/16 Fem Fuel Steel
5/16 Male Fuel Al.
1/2” Wire Loom
1
1
1
1
1
2
1
1
2
4
4
8
8
1
1
1
4’
4
1
1
10
10
3’
4HC110-040
7A250-104
7C060-016
7J006-093
4HC010-040
4HC010-050
4HC145-060
7U100-088
POWER STEERING ASSY, ’99-’00 HONDA
1/4-20 x 1 BHCS SS
6mm Bolts
6mm Washer, Plated
Ftg, HON Pwr Str Top
Ftg, HON Pwr Str Pump
Power Steering Line Assy, Honda
O-ring, -015
1
2
2
2
1
1
1
2
P/N: 4HC020-010
1999-2000 HONDA CIVIC Si STD., cont’d.
®
PARTS LIST
ENGINEERING, INC.
IMPORTANT: Before beginning installation, verify that all parts are included in the kit.
Report any shortages or damaged parts immediately.
PART #
DESC
QTY
PART #
4HC112-010
4HC012-011
4FA012-011
8D001-001
7P750-100
7U034-016
7U034-016
7U030-046
7P156-082
7R002-016
7U035-001
7R002-052
7S350-200
7R002-056
7U100-061
7P375-008
7U030-056
5W001-012
5W022-030
5W022-040
8H040-040
AIR INTAKE ASSY, ’99-’00 HONDA
3-1/2” 90 Plastic Elbow
Bypass Valve
1” Barb to 3/4 NPT Plastic Fitting
1” GS Hose
1” GS Hose
5/32” Vacuum Line
5/32 TEE
#16 Hose Clamp
“3-1/2” Flex Hose
#52 Goldseal Hose Clamp
3-1/2 X 2 Sleeve
Elbow Union Eub
3/8 PCV Hose
18-22 GA Butt Connectors
Wire, Red 22
Wire, Green 22
Air Filter
1
1
1
1
1
.2 FT
.3 FT
3 FT
1
4
.75 FT
2
1
2
2
1
2.5 FT
4
1.25 FT
1.25 FT
1
4HC112-020
7S275-200
7R002-044
7S275-251
7R002-040
4HC012-020
4HC010-187
AIR DISCHARGE ASSY. ‘99-00 HONDA
2-3/4 x 2” Sleeve
2.75 - 2.5 I.D. Sleeve
#40 Stnls Hose Clamp
Honda Discharge Duct Std
Restrictor, Inlet 1.6 Std
1
1
3
1
1
1
1
P/N: 4HC020-010
vi
DESC
QTY
1999-2000 HONDA CIVIC Si H.O.
®
PARTS LIST
ENGINEERING, INC.
PART #
DESC
2E129-120
S/C,V-5 SQ CCW ’99-’00 1.6 DOHC HONDA
QTY
1
4HC110-020
4HC010-020
4HC010-090
2A017-700
2A017-854
7F008-020
7C080-070
7K312-001
7J012-092
7A312-125
7C080-080
7C012-025
4HC010-080
7U100-061
4HC010-120
7U031-016
S/C MOUNTING PLATE ASSY
Mounting Plate
Pilot, HON Mtg Brkt
Spacer, Long
Spacer, Short
M8 x 1.25 Nut
8mmX1.25x70MM HHD G5 Bolt
5/16” AN-Washer
M12 Washer
5/16”-18 x 1 1/4 HXHD
M8X1.25 x 80mm Stud
M12-1.75 x 25mm HXHD Pltd.
TAB, Honda Rad. Mount
Brkt, Rad Res Honda
5/16” Fuel Line
1
1
1
2
2
1
3
8
3
4
1
3
1
1
1
4’
4HC110-010
4HC010-010
7C040-025
7U100-058
7U030-046
7P062-187
7U400-001
7U100-055
ASSY, HONDA MAPS BLEED
MAPS Bleed, Honda
M4-.7 x 25mm HXHD CS Pltd
O-ring Fuel Rail Honda
5/32” Vacuum Line
1/16 NPT x 3/16 Hose Barb
Check Valve
1
1
2
1
1’
1
1
2
4HC114-010
8R101-000
2A034-333
2A044-514
2A044-335
ASSY, S/C DRIVE, HONDA 1.6 DOHC HO
Pulley Retainer Assy, 4 Rib
S/C Pulley 3.33” 4 Groove
Belt, K040514 HON HO S/C
Belt, K040335 HON Pwr Str
1
1
1
1
1
4HC111-011
4HC011-011
7U250-022
2D170-222
2D070-159
7X100-025
7U100-084
2D160-212
2D030-024
7A312-075
7K312-001
4HC010-030
7A250-075
4HC010-070
7A250-101
7J006-093
7A250-276
7F250-020
4FH116-021
7J312-000
7A312-175
4HC010-060
7F312-018
7J312-875
4HC116-011
7C010-036
7C010-002
MOUNTING BRACKET ASSY
Mtg Brkt, HON 1.6 DOHC
Dowel Pin, Oversize
Assy, Ext. Drive Shaft
Bearing
Preload Spring
Snap Ring
Assy, Ext Drive Tube ’99-’00 Honda
Flange, Ext Tube End HON
5/16-18 x 3/4 HXCSG5P
5/16 AN-Washer
Top Plate, Honda 1.6 DOHC
1/4-20 x 3/4” SHCS Pltd
Tensioner Plate, Honda 1.6 DOHC
1/4-20 x 1” HHCS
6mm Washer, Plated
1/4-20 x 2.75 HHD
1/4-20 Nut
Idler Pulley Assy
5/16 Fender Washer SAE
5/16-18 x 1.75 HHD Bolt
STUD, Honda Tensioner
5/16-18 Nut
5/16 Washer HD
Idler Pulley, Assy, Honda
M10 x 1.25 x 35mm HHCS G8P
10mm Washer, Zinc Plated
1
1
2
1
2
1
1
1
1
3
3
1
5
1
4
5
1
1
1
2
1
1
2
1
1
2
2
vii
PART #
DESC
4HC130-026
7P125-125
7P125-034
7P125-027
7P125-026
7P525-067
7P250-066
7U030-026
7U100-055
OIL FEED ASSY, HONDA 1.6 DOHC
Ftg, 1/8 NPT Fem X 1/8 BSPT Male
1/8 NPT x 1 Malex 2 Fem
-4 TO 1/8 NPT Straight
-4 TO 1/8 NPT 90° Male
.500 Crimp Ferrules
#4 Swivel x 1/4” Hose Barb
1/4” Oil Feed Hose
QTY
1
1
1
1
1
2
2
2.67’
5
4HC130-036
7U030-036
7R001-008
7P375-042
4HC100-010
OIL DRAIN ASSY, HONDA 1.6 DOHC
1/2” Oil Drain Hose
#8 Stnls Hose Clamp
Male Connector
Tube Nut Assy, Honda
1
1’
2
1
1
4HC238-078
6Z110-137
7U030-016
7R001-004
7U030-046
7P156-082
FMU ASSY, ’99-’00 HONDA
Fuel Mgmt Unit, 10:1 Std
1/4” Fuel Line
#4 Hose Clamps
5/32” Vacuum Line
5/32 TEE
1
1
1.25’
2
1’
1
4HC101-001
8F101-310
5W001-019
5W001-014
5W001-015
5W001-042
5W001-001
5W001-011
8F010-110
7E010-075
7U314-001
7F008-032
7J008-001
8F001-200
008340
7P312-008
7U031-018
7R001-004
7P312-005
7P312-007
7U100-044
7U100-055
5W001-021
FUEL PUMP, ’99-’00 HONDA
Fuel Pump Rail Assy, Honda
12-10 GA Solderless Connector
12-10 GA 3/16” Ring Terminal
16-14 Wire Tap
16-14 GA Eyelet .25” Hole
Fuel Pump Hangar
#12 x 3/4” Sheet Metal Screw
#8 Lord Mount
8-32 Hex Lock Nut
#8 Flat Washer
Corvette Fuel Pump 200 in Line 3/8”
Fuel Pump Decal, T-Rex
T-Rex - 5/16 Barb
5/16 Fuel Hose High Press
#4 Hose Clamp
5/16 Fem Fuel Steel
5/16 Male Fuel Al.
1/2” Wire Loom
1
1
1
1
1
2
1
1
2
4
4
8
8
1
1
1
4’
4
1
1
10
10
3’
4HC110-040
7A250-104
7C060-016
7J006-093
4HC010-040
4HC010-050
4HC145-060
7U100-088
POWER STEERING ASSY, ’99-’00 HONDA
1/4-20 X 1 BHCS SS
6mm Bolts
6mm Washer, Plated
Ftg, HON Pwr Str Top
Ftg, HON Pwr Str Pump
Power Steering Line Assy, Honda
O-ring, -015
1
2
2
2
1
1
1
2
P/N: 4HC020-010
1999-2000 HONDA CIVIC Si H.O., cont’d.
®
PARTS LIST
ENGINEERING, INC.
PART #
DESC
8N301-090
PWRCLR ASSY, ’99-’00 HONDA 1.6 DOHC
4HC112-030
QTY
AIR DISCHARGE ASSY,
’99-’00 HONDA AFTERCOOLER
2-3/4 x 2 Sleeve
#44 Goldseal Hose Clp
2.75- 2.5 I.D. Sleeve
#40 Stnls Hose Clp
1” NPT x 1” Barb Plastic Fitting
1
1
3
1
1
1
8N101-090
PWR CLR WELDED ASSY. ’99-’00 HON 1.6
1
8N106-090
8N006-010
4HC010-100
7A250-074
7F250-021
7J250-001
WATER CLR MTG ASSY, ’99-’00 HONDA
Water Cooler
Brkt, Honda Water Cooler
1/4-20 HHD, 3/4 Long
1/4-20 Nylock Nut
1/4 Flat Washer
1
1
2
8
8
16
8N107-090
8F001-402
8N010-080
5W001-009
5W001-010
5W001-040
5W001-017
5W014-030
5W001-014
5W001-011
5W001-015
5W001-009
8F101-510
WATER PUMP MTG ASSY, ’99-’00 HONDA
Pump, Hella Water
Adel Clamp
16-14GA Male Slide, Insulated
16-14GA Female Slide, Insulated
12-10GA Female Slide
3/8” Ring Terminal 12GA
14 GA Strd Wire, Black
16-14GA Eyelet .25” Hole
16-14GA Male Slide
H2O Pump Wiring Assy, Honda
1
1
1
2
2
2
1
3’
1
2
1
1
1
8N105-090
8N055-030
7P100-120
4HC010-110
7A250-050
7A250-074
7J006-093
7U038-000
7U030-065
7R007-001
7P500-026
7P500-078
7U038-012
7U038-150
7P375-075
7F250-021
7S250-150
WATER TANK MTG ASSY, ’99-’00 HONDA
Reservoir
1” NPT Pipe Plug
Brkt. Reservoir. HONDA. Pass
1/4-20 SHD, 1/2 Long
1/4-20 HHD, 3/4 Long, Pltd
1/4 Washer
3/4” Heater Hose (cut to fit)
3/4” Hose (tank-pump)
Nylon Clamp 1-1/8”
1/2 NPT to 3/4 Hose 90° Barb
1/2 NPT to 3/4 Hose Barb
3/4” 90° Hose 4 x 12”
3/4” 150° Hose
3/4” Hose Mender
1/4” Nylock Nuts
1/4” Fender Washer
1
1
1
1
2
3
8
11’
1
14
5
3
2
1
2
3
1
8N104-090
7C060-016
7J006-093
7P312-082
7U031-016
7U100-055
7U100-044
8N056-060
8N056-050
7P312-125
7A250-050
8N010-090
ASSY, SURGE TANK HONDA
M6 x 1.00 x 16 HXHD
6mm Washer, Plated
5/16” Male Barb TEE
5/16” Hose
6” Tie Wrap
4” Tie Wrap
Surge Tank
Cap
5/16” Barb, 1/8” NPT
1/4-20 SHCS, 1/2” Long
Mtg Tab
1
1
1
1
1.25’
10
5
1
1
1
1
1
7S275-200
7R002-044
7S275-251
7R002-040
7P100-100
P/N: 4HC020-010
PART #
1
4HC112-010
4HC012-011
4FA012-011
8D001-001
7P750-100
7U034-016
7U034-016
7U030-046
7P156-082
7R002-016
7U035-001
7R002-052
7S350-200
7R002-056
7U100-061
7P375-008
7U030-056
5W001-012
5W022-030
5W022-040
8H040-040
viii
DESC
AIR INTAKE ASSY, ’99-’00 HONDA
Bypass Valve
1” Barb to 3/4 NPT Plastic Fitting
1” GS Hose
1” GS Hose
5/32” Vacuum Line
5/32 TEE
#16 Hose Clamp
“3-1/2” Flex Hose
3-1/2 x 2 Sleeve
Elbow Union Eub
3/8 PCV Hose
18-22 GA Butt Connectors
Wire, Red 22
Wire, Green 22
Air Filter
QTY
1
1
1
1
1
.2’
.3’
3’
1
4
.75’
2
1
2
2
1
2.5’
4
1.25’
1.25’
1
1.
PREPARATION/REMOVAL
A. Disconnect the negative cable at the battery.
B. Remove the plastic pan underneath the radiator
and set aside.
C. For aftercooled vehicles, remove the front bumper
cover and driver’s side headlight. (This step is
not required but aids in the installation of the
supercharger kit).
D. Remove the air box and all of the inlet ducting up
to, but not including, the throttle body.
E. Remove the air temperature sensor from the inlet
duct and set aside.
F. Remove the valve cover breather hose.
G. Remove the power steering belt, pump and
mounting brackets.
H. Remove the A/C drive belt and belt tensioner. It
is necessary to remove and set aside the two
bolts holding the lower driver’s side engine mount
to the frame so that the belt can be removed
between the engine mount and the frame.
I. Remove the coolant reservoir and bracket.
2.
OIL FEED
A. Remove the oil filter.
B. Remove the oil pressure sender from rear of
engine block near the oil filter.
C. Install the 1/8” BSPT male to 1/8” NPT female
adapter in the engine block. Leave the TEE
pointed upward. Install the 1/8” NPT x #4 straight
fitting in the top of the TEE pointed slightly
towards the passenger’s side of the engine.
Install the oil pressure sender in the TEE and reattach the electrical plug (see Fig. 2-a).
D. Temporarily cover one end of the oil feed line and
protect it from debris until connecting it to the
supercharger.
E. Connect the open end of the oil feed line to the #4
fitting. Use tie wraps to secure the line and
protect it from kinking, abrasion, and high heat
areas.
F. Install new oil filter.
1
Fig. 2-a
P/N: 4HC020-010
3.
OIL DRAIN
A. To provide an oil drain for the supercharger, it is
necessary to make a hole in the front of the oil
pan. Locate and center punch the hole per Fig.
3-a. This hole should be 3/4” from bottom of oil
pan lip and centered between the stiffening ribs.
Note:
Upon breaking through the oil pan, oil
may drain out of the newly formed hole.
Some oil may be drained from the pan
if the oil continues to flow.
B. Remove the paint around the hole.
C. Use a small center punch to perforate the pan
and expand the hole. Switch to a larger diameter
punch and expand the hole further to approximately ø9/16”.
D. Tap the hole with a 3/8” NPT to approximately
1/2” deep or until the supplied drain fitting can be
started. Pack the flutes of the tap with heavy
grease to hold chips.
Note:
FUEL PUMP WIRING AND INSTALLATION
A. Mount the supplied fuel pump relay in the location shown in Fig. 4-a using the supplied sheet
metal screw.
B. Feed the yellow wire from relay terminal #85
through the passenger’s side firewall (the grommet is located behind the battery) and route
behind the glove box.
C. Open the glove box completely. (Sides of glove
box door must be pushed towards each other so
that door can fully open).
D. Locate the PGM-FI relay located to right of the
glove box. (See Fig. 4-b.) Use the supplied
wiretap to connect the yellow wire from the
auxiliary fuel pump relay (terminal #85) to terminal #4 on PGM-FI relay (yellow wire with green
stripe).
P/N: 4HC020-010
1”
Fig. 3-a
This method of rolling over the lip of
the hole and tapping it works very well
if carefully done and should cause no
problems.
E. Thoroughly clean the threaded area. Apply a
small amount of silicone sealer to the new threads.
Apply more sealer to the 3/8” NPT x 1/2” inverted
flare fitting and secure in the hole. Make sure that
a seal is formed all around the fitting.
F. Thread the tube nut and 1/2” aluminum tube into
the inverted flare fitting by hand. Do not tighten
until the supercharger drain hose has been connected.
G. Temporarily cover the end of the oil drain tube to
keep out debris.
H. Drain the engine oil and refill with fresh oil.
4.
3/4”
2
OIL DRAIN
TUBE
OIL PAN
Fig. 3-b / View from passenger side.
FUEL PUMP RELAY
Fig. 4-a
4.
FUEL PUMP WIRING AND INSTALLATION, cont’d
E. Connect the red 12-gauge wire from terminal #30
to the supplied fuse holder using the supplied
butt connector. Install a yellow ring terminal on
the other end of the fuse holder and bolt to one of
the two fuse box power supply wires at the front
of the fuse box (see Fig. 4-a).
F. Run the black wire from terminal #86 on the fuel
pump relay to the battery cable chassis ground.
G. With the long red 12 gauge wire connected to the
fuel pump relay terminal #87, route the free end
across the engine bay and alongside the fuel
lines to the area near the fuel tank. Secure as
necessary to avoid heat and sharp edges.
H. Install the supplied adel clamps and lord mounts
on the fuel pump and attach the two fuel pump
mounting brackets as shown in Fig. 4-c.
I. Using Figs. 4-c and 4-d for approximate location,
drill four holes in the bottom of the frame rail and
mount the fuel pump to the vehicle using the
supplied #12 x 3/4” sheet metal screws. The
pump inlet (inlet side is opposite from electrical
connections) must point toward the front of the
vehicle.
J. Install the supplied quick disconnect fittings in
both ends of the supplied 5/16” fuel line and
tighten the supplied hose clamps. Separate the
fuel line at the quick disconnect fitting in front of
the gas tank and attach supplied fittings to their
respective locations. Measure the hose and cut
so that line from fuel tank is connected to the inlet
of the pump. Route the remaining hose to the
pump outlet. Try to make the bends as large as
possible, so as to avoid kinking the hose. Secure
the hoses using tie wraps and tighten all of the
hose clamps.
K. Attach the previously routed red wire to the
positive terminal of the fuel pump using the
yellow ring terminal connector.
L. Using two yellow ring terminal connectors and
the black 12-gauge wire, connect the ground
terminal of the fuel pump to the ground on the
vehicle sub-frame.
Fig. 4-b
Fig. 4-c
Fig. 4-d
3
P/N: 4HC020-010
5.
FUEL MANAGEMENT UNIT (FMU) INSTALLATION
A. Using the FMU mounting bracket as a template,
mark and drill two holes in the firewall using Fig.
5-a as a reference for location. Mount the FMU as
per photo.
B. Attach the supplied 1/4” hose to the 90° barb
fitting on the Vortech FMU and tighten the suppled
clamp.
C. Disconnect the factory fuel regulator return line
from the bottom of the fuel regulator and connect
to the straight fitting on the bottom of the FMU
using the original clamp.
D. Attach the free end of the 1/4” hose (that was
previously installed on the FMU) to the bottom of
the fuel regulator and tighten the supplied clamp.
E. Using the supplied 5/32” vacuum line and TEE
connect the 90° fitting on top of the FMU to the
manifold vacuum line connected to the fuel regulator as shown in Fig. 5-a.
Fig. 5-a
FUEL PRESSURE
REGULATOR
ATTACH TO MANIFOLD
VACUUM
F.M.U.
IN
OUT
VEHICLES STOCK
RETURN LINE
(TO TANK)
Fig. 5-b
P/N: 4HC020-010
4
6.
MAP SENSOR BLEED ASSEMBLY INSTALLATION
A. Remove the two screws securing the Manifold
Air Pressure (MAP) sensor on top of the intake
manifold.
B. Insert the supplied MAP sensor bleed assembly
with the bleed hole positioned next to the intake
manifold. The bleed hole must be down (see Fig.
6-b).
C. Use the original O-ring between the fitting and
the intake. Use the supplied O-ring between the
MAP sensor and the fitting.
D. Install the supplied 4mm bolts (see Fig. 6-a). Do
not over-tighten the fasteners.
NOTE: The discharge side of the check valve
should be left disconnected and vented
to atmosphere as shown in Fig. 6-a.
Fig. 6-a
SUPPLIED
M4 X 25MM BOLT,
2 PLACES
1/16 NPT - 3/16" BARB FITTING
MAP SENSOR
SUPPLIED O-RING
5/32" HOSE
BLEED HOLE MUST
BE DOWN TOWARD
THROTTLE BODY
FITTING, MAP SENSOR
FACTORY O-RING
THROTTLE BODY
CHECK VALVE
CHECK VALVE
FLOW DIRECTION
Fig. 6-b
5
P/N: 4HC020-010
7.
RADIATOR RESERVOIR RELOCATION
A. Remove the rear most top and bottom bolts from
the bracket holding the electrical plugs on the
passenger side strut tower.
B. Position the supplied bracket per Fig. 7-a and
reinstall the hardware.
C. Fit the reservoir to the bracket with the cap
installed.
D. Run the supplied 5/16” hose from the radiator fill
neck to the radiator reservoir cap.
E. Remove the factory vent tube/water line assembly from the valve cover breather. This assembly
will no longer be used.
F. Replace the hose running from the bottom of the
throttle body to the engine block with a piece of
the supplied 5/16” hose. Secure with the factory
clamps.
Fig. 7-a
Passenger strut tower as viewed
from the driver’s side of the vehicle
8.
POWER STEERING PLUMBING
A. Lightly coat the O-ring on the supplied power
steering pump fitting with Honda power steering
fluid and insert into the power steering pump.
Rotate fitting until the bolt holes line up with the
pump. Secure the fitting to the power steering
pump using the supplied 6mm bolts and washers.
B. Attach the straight fitting end of the supplied
power steering hose to the just installed power
steering pump fitting and tighten.
Fig. 8-a
P/N: 4HC020-010
6
9.
MAIN BRACKET INSTALLATION
A. Lower the supplied cast aluminum mounting
bracket assembly in front of the engine and push
tightly against the exhaust manifold. Lower the
power steering pump between the mounting
bracket and the vehicle frame.
B. Install the two shortest factory power steering
bracket bolts and the two supplied 10mm bolts in
each of the four mounting holes in the supplied
mounting bracket. Tighten to 33 ft/lbs (44 N-m). If
necessary, the A/C bracket can be lowered for
bolt access.
C. Loosely install the power steering pump using
the original bolts and tensioner screw.
D. Install the supplied 2.25” idler pulley to the mounting bracket. Make sure that the spacer between
the two idler pulley bearings slides over the
mounting bracket pilot, secure using the supplied 5/16 x 1- 1/4” bolt and 5/16 washer (see Fig.
9-a).
Fig. 9-a
Fig. 9-b
10. SUPERCHARGER MOUNTING PLATE INSTALLATION
A. Remove the top four transmission-to-bell housing bolts and the bracket that the ground strap is
attached to.
B. Install the supplied 8mm stud with a .70” spacer
in the rear most hole.
C. Relocate the ground strap (minus bracket). The
ground strap may be refastened to the transmission with one of the bracket bolts just removed if
the hole in the ground wire lug end terminal is
opened up.
NOTE: The lower radiator hose should be routed
on the engine side of the mounting plate.
D. Position the mounting plate on transmission.
Install each of the three supplied 8mm bolts
through a washer, the mounting plate and a
spacer. Note spacer thickness! The two .85”
INSTALL STUD & .70”
SPACER IN THIS POSITION
.70” SPACER
.85” SPACER
7
Fig. 10-a
SUPERCHARGER
PILOT
P/N: 4HC020-010
10. SUPERCHARGER MOUNTING PLATE INSTALLATION, cont’d.
spacers go on the front two bolts while the two
.70” spacers go on the rear bolt and stud. (The
spacer must be installed between the bell-housing and mounting plate.) Do not tighten.
E. Loosely install the supplied 8mm nut and washer
onto the stud.
F. Line up the mounting plate so the drive-shaft (as
seen through the large hole in the mounting
plate) is centered in the drive-shaft housing.
Tighten the four mounging plate fasteners. (See
Fig. 10-a.)
G. Remove the bracket and grommet securing the
top of the radiator to the vehicle. Install the
supplied bracket and original grommet in the
original location. (See Fig. 10-b).
Fig. 10-b
SUPPLIED BRACKET
11. SUPERCHARGER INSTALLATION
A. Remove plastic drain fitting cap and
install the supplied 1/2” oil drain hose
onto the barb fitting on the bottom of
the supercharger and secure with the
supplied #8 hose clamp.
B. Verify that the spline on the end of the
supercharger input shaft is liberally
coated with anti-seize lubricant.
C. Carefully slide supercharger input
shaft into the end of extended drive
shaft.
OIL FILTER FEED
(7P375-095)
1/8 NPT MALE
90° (7P125-111)
1/8 NPT TO 1/4"
HOSE BARB 90°
(7P125-037)
FILTERED ENGINE OIL
FLOW
3/8" COPPER
WASHER
(7J375-024)
2 PLACES
1/4" I.D.
HOSE
1/8 NPT TO 1/4" HOSE
AIR CHECK VALVE BARB (7P125-036)
(7P125-110)
V-2 AIR ASSIST
ADAPTER
(7P375-105)
V-5 HONDA AIR ASSIST ASSEMBLY
TO SUPERCHARGER
GEARCASE OIL FEED
NOTE: Once the splines on the supercharger
and the input shaft are lined up they
should slide easily together. DO NOT
FORCE SPLINES!
Fig. 11-a
D. Loosely insert each of the four 5/16 x 1-1/4” bolts
through a washer, the extended drive tube flange
and the supercharger mounting plate into the
supercharger. (See Fig. 11-b.) Do not tighten.
E. Loosely insert the three 12mm bolts through the
washers and the mounting plate and into the
supercharger. Do not tighten.
F. Tighten the four 5/16” bolts first. Then tighten the
remaining 12mm bolts.
Fig. 11-b
P/N: 4HC020-010
FROM
SUPERCHARGER
VOLUTE
DISCHARGE
8
14.5
STEPLESS
CLAMP
(7R004-003)
2 PLACES
11. SUPERCHARGER INSTALLATION, cont’d.
G. Route the free end of the oil feed hose to the
supercharger and attach. The oil feed assembly
should be checked/plumbed per Fig. 11-a.
H. Attach the free end of the oil drain hose to the
previously installed oil drain tube. Make sure that
the oil drain hose and tube are constantly slanting down towards the oil pan. If the drain hose
gets kinked, routed uphill or is otherwise restricted, supercharger damage may occur.
I. Tighten the oil drain tube nut in oil pan fitting.
Tighten the oil drain hose clamps.
J. Provide 1/2” clearance from the supercharger to
the radiator fan support by cutting the support
(see Fig. 11-c). A small bladed saw such as a
hacksaw blade works well for this step.
Fig. 11-c
FOR NON-AFTERCOOLED, STANDARD SUPERCHARGER KIT INSTALLATION, SKIP STEP 12 AND PROCEED WITH STEP 13.
12. AFTERCOOLER INSTALLATION
A. Reservoir Installation
1.
2.
3.
4.
5.
6.
Using two of the supplied 1/4” x 3/4” long
bolts, insert through the passenger side
fender well underneath the headlight. Install the reservoir mounting bracket and
tighten as shown in Figs. 12-a and 12-b.
Use the supplied washer on each side.
Using the reservoir mounting bracket as a
template, drill a 1/4” hole and insert and
tighten the third mounting bolt.
Using thread sealant, install a 1/2” NPT 90°
hose barb fitting in the top of the reservoir so
that it will point away from the frame rail
when the reservoir is installed.
Bolt the reservoir mounting bracket to the
reservoir using 1/2” long bolts. (See Fig.
12-d.)
Remove the passenger side turn signal wires
from the grommet in the fender well. Reroute them around the front of the fender
well and re-attach.
Using the two supplied 4x12” 90° molded
hoses, cut about 2” from each of the short
legs and connect the short legs with the
supplied hose mender and clamps (see Fig.
12-i for system plumbing).
Fig. 12-a / Air filter and elbow
shown will be installed later
Fig. 12-b / Air filter and elbow
shown will be installed later
9
P/N: 4HC020-010
12. AFTERCOOLER INSTALLATION, cont’d.
7.
From outside the vehicle, insert the hose
through the fender well grommet as shown
in Fig. 12-e. Trim as necessary, then attach
and clamp the end of the hose to the top of
the reservoir as shown in Fig. 12-c.
8.
Install clamps on each end of the hose
mender installed in step 12-A-6.
Fig. 12-c
Fig. 12-d
Fig. 12-e
P/N: 4HC020-010
10
B. Aftercooler Water Pump Wiring And
Installation
1.
Mount the aftercooler pump relay in the
location shown in Fig. 12-f using the supplied sheet metal screw.
2.
Connect the yellow wire from terminal #85
to the black wire with yellow stripe running
from the coil using the supplied wiretap.
3.
Run the black wire from terminal #86 on the
aftercooler pump relay to the battery chassis ground located on the passenger side
strut tower in front of the fuse box.
4.
Connect the red 12-gauge wire from terminal #30 on the aftercooler pump relay to the
fuse holder using the supplied butt connector. Install a yellow ring terminal on the other
end of the fuse holder and bolt to one of the
two fuse box power supply wires at the front
of the fuse box (see Fig. 12-f).
5.
Install the supplied water pump clamp on
the water pump. Insert a 1/2” long screw
through the clamp and tighten in the position shown in Fig. 12-c. The pump outlet
should poing toward the driver’s side of the
vehicle with room to route the hose in front
of the radiator core support.
6.
Use the supplied black wire, ring terminal
and slide connectors to extend the water
pump ground wire (brown wire on Hella
pump) to the same grounding location used
for the water pump and fuel pump relay
grounds.
7.
Route the red wire from the aftercooler relay
terminal #87 to the water pump. Using the
supplied male and female slide connectors,
attach the red wire to the positive wire on
the water pump (green wire on Hella pump).
8.
Using thread sealant, install a 1/2” NPT 90°
hose barb fitting in the bottom of the
aftercooler reservoir so that it points towards the water pump inlet.
9.
Loosen the water pump clamp bolt and
connect the pump inlet to the bottom reservoir fitting with the supplied 90° hose. Secure the hose with nylon clamps on both
ends. Tighten the water pump clamp.
NOTE: Double check that all
wires are connected to
the proper relay lugs.
AFTERCOOLER
PUMP RELAY
Fig. 12-f
(+) WATER PUMP
(GREEN WIRE ON
HELLA PUMP)
86
87
87A
GROUND
30
85
TO BLACK WIRE
WITH YELLOW
STRIPE FROM
COIL
12 VOLT (+)
RELAY
Fig. 12-g
11
P/N: 4HC020-010
C. Water Cooler Installation
1.
Using the supplied hardware, loosely attach
one supplied bracket to each side of the
water cooler as per Fig. 12-h. Using sealant,
insert the 90° fittings into the inlet and outlet
of the water cooler and point them towards
the passenger’s side of the vehicle. (See
Fig. 12-i.)
2.
With water cooler inlet and outlet pointed up,
insert bolts through the brackets into the
existing holes at the lowest mounting point
in the vehicle’s radiator core support.
3.
Tighten the bolts securing the bracket to the
water cooler. Tighten the bolts securing the
brackets to the core support.
CAUTION: In the following step, use extreme care when drilling
through the core support. If
the drill bit slips or goes
through the hole too far it will
damage the radiator or the
A/C condenser.
4.
5.
6.
Using the brackets as a guide, drill a 1/4”
hole on each side of the water cooler. Insert
the supplied 1/4” bolts through the brackets
and into core support on each side of the
water cooler.
Connect the outlet of the water pump to the
far side of the water cooler with 3/4” hose.
Clamp each end.
Route the 3/4” hose from the remaining
fitting on the water cooler, in front of the
radiator, next to the passenger side upper
engine mount, under the hoses and wiring
and next to the throttle body.
D. Aftercooler Installation
1.
Locate the coolant hose that connects to the
throttle body. Remove the metal tube assembly and all connected hoses. Install the
supplied 1/4” hose and clamps between the
thermostat housing and the throttle body.
2.
Using sealant, install the supplied 90° fitting
into the 1/2” NPT hole in the aftercooler core
nearest the air outlet. Install the supplied
straight fitting in the remaining hole. Connect the hose previously routed near the
throttle body, to the 90° fitting installed in the
aftercooler.
3.
Install the supplied 150° hose elbow onto
the straight fitting on the aftercooler so that
the free end will be routed near the distributor.
P/N: 4HC020-010
12
Fig. 12-h
D. Aftercooler Installation, cont’d.
4.
Install the aftercooler core assembly between
the supercharger discharge and the throttle
body. The 2-3/4” to 2-1/2” reducer sleeve should
be placed between the supercharger and the
aftercooler. Tighten the clamps on the sleeves.
5.
Carefully verify that the aftercooler has sufficient clearance to the throttle arm throughout its
full range of motion.
6.
Install the 1” plastic barbed fitting in aftercooler
inlet duct 1” NPT hole.
7.
Verify that all hoses are routed smoothly and
without kinks.
POWER COOLER ASSEMBLY
(8N101-090)
TO TEE INSERTED IN RADIATOR OVERFLOW
HOSE NEAR RESERVOIR CAP
COOLED CHARGE AIR
90° 1/2” NPT TO 3/4” HOSE BARB
(7P500-026) 6 PLACES. 90° FITTING
POINTING DOWN
6MM BOLT AND WASHER
(SECURES SURGE TANK
TO FENDERWELL)
1/2” NPT TO 3/4” HOSE BARB
97P500-078 2 PLACES
WATER
FLOW
SURGE TANK
(8N156-050)
150° MOLDED HOSE
ELBOW (7U038-150)
TO BYPASS
VALVE INLET
3/4" HOSE MENDER (7P375-075)
2 PLACES
WATER FLOW
90° MOLDED HOSE
ELBOW (7U038-012)
SUPERCHARGER DISCHARGE
3/4" HOSE (7U038-000)
CUT TO FIT 3 PLACES
1/2" SOCKET HEAD CAP
SCREW (7A250-050)
WATER PUMP
CLAMP
(8N010-080)
WATER
RESERVOIR
MOUNTING
BRACKET
(4HC010-110)
WATER
RESERVOIR
(8N055-030)
1" NPT HOLE NOT
USED. HOLE SHOULD
BE BLIND OR PLUGGED
HONDA WATER COOLER
MOUNTING
BRACKET (4HC010-100)
WATER COOLER
(8N006-010)
TOP OF TANK
90° MOLDED HOSE ELBOW
(7U030-065 (CONNECTS
FITTING ON BOTTOM OF
TANK TO INLET OF WATER PUMP)
WATER FLOW
WATER PUMP (8F001-402)
1/2" SOCKET HEAD CAP SCREW (7A250-050)
(INSTALL THROUGH ADEL CLAMP AND INTO WATER TANK TO HOLD WATER PUMP)
Fig. 12-i
13
P/N: 4HC020-010
E. Surge Tank Installation
1.
2.
3.
4.
5.
6.
7.
Using thread sealant, install a 1/2” NPT to
3/4” hose barb straight fitting into the front
and side of the surge tank (see Fig. 12-j).
Insert straight fitting into the side of the
surge tank. Insert 1/8” NPT X 5/16 barb
fitting into the front of the surge tank.
Bolt the surge tank mounting tab to the
surge tank using the supplied 1/4-20 x 1/2”
bolts and washers.
Connect the hose from the top of the reservoir to the bottom of the surge tank and
secure with nylon clamp.
Connect the hose previously installed on
the air outlet side of aftercooler core to the
top of the surge tank and secure with a nylon
clamp.
Bolt surge tank to passenger side strut
tower using the supplied 6mm bolt and
washer. (see Fig. 12-j)
Cut the 5/16” line between the radiator and
the reservoir and install the supplied TEE.
Connect the barb fitting on the surge tank to
the TEE with the supplied 5/16” hose.
Remove the cap from the surge tank and fill
the system with 25% coolant/75% water
mix.
Fig. 12-j
FOR AFTERCOOLED SUPERCHARGER KIT INSTALLATION,
SKIP STEP 13 AND PROCEED TO STEP 14.
13.
A. Loosely install the supplied sleeves on both ends
of the supplied plastic discharge duct. The 2-3/4”
to 2-1/2” reducer sleeve should be placed on the
supercharger.
B. Put the discharge duct into position and slide the
sleeves onto the supercharger and the throttle
body.
C. Tighten the hose clamps on both ends of the
discharge duct.
14.
THROTTLE
BODY
STANDARD KIT DISCHARGE DUCT INSTALLATION
AIR INLET DUCT INSTALLATION
A. Install the supplied 1” plastic barbed fitting, two
grommets, the air temperature sensor and the
3/8” barbed elbow into their respective inlet duct
holes (see Fig. 14-a).
Fig. 14-a / Aftercooled bypass valve
installed (standard kit similar)
P/N: 4HC020-010
14
BYPASS
VALVE
Fig. 13-a / Std discharge
duct orientation
SUPERCHARGER
DISCHARGE
14.
AIR INLET DUCT INSTALLATION
B. Install the supplied air filter on the remaining 90°
elbow (does not have any drilled holes). (See
Fig. 14-b.) From below, insert elbow through
hole in fender-well. Attach 3 1/2” sleeve to the
protruding part of the elbow and tighten clamp.
C. For standard non-aftercooled kits, insert the supplied aluminum ring into the sleeve so that it sits
flat on the top of the plastic elbow just inserted.
(See Fig. 14-c.)
D. Install the elbow with holes into the sleeve with
the 1” barb nearest the supercharger. Orient the
lower elbow for maximum air filter and elbow
clearance and tighten #56 clamps.
E. Connect the supplied 3/8” hose from the valve
cover breather barb to the inlet duct 3/8” barb
previously installed.
F. Lengthen the air temp sensor plug wires using
the supplied butt connectors and wire and connect to sensor.
G. Install the supplied 3-1/2” flex hose with two #52
clamps between the supercharger and the air
inlet elbow.
H. Tighten all hose clamps.
Fig. 14-b / Aftercooler water tank not
shown for clarity
90° ELBOW
HOSE CLAMP
CONNECTING
SLEEVE
RESTRICTOR
HOSE CLAMP
NOTE: Do not attempt to operate nonaftercooled vehicles without the
inlet restrictor installed. The vehicle
may detonate on pump gas.
AIR FILTER
HOSE
CLAMP
90° ELBOW
Fig. 14-c / Standard kit inlet
restrictor installation
15.
BYPASS VALVE INSTALLATION
5/32” HOSE
A. Use the supplied 1” hose to connect the bypass
valve inlet to the 1” barb on the supercharger
discharge tube/duct. (See Fig. 14-a.)
B. Connect the bypass valve outlet to the air inlet
duct with the supplied hose.
C. Tighten hose clamps on each connection.
D. Using supplied 5/32” vacuum line and TEE, connect barb on bypass valve to manifold vacuum.
Use the manifold vacuum line connected to the
fuel regulator.
15
BYPASS VALVE
SUPERCHARGER
DISCHARGE TUBE
AIR INLET DUCT
Fig. 15-a
P/N: 4HC020-010
16.
SUPERCHARGER DRIVE BELT INSTALLATION
A. Insert the keyway into the extended drive input
shaft and install the pulley. Using thread-locker,
install the 3/8-24 bolt through the washer and
retainer and into the input shaft. The pulley
retainer bolt will be tightened after the supercharger belt is installed.
NOTE: Do not hammer or pry on the supercharger pulley. Heat gently with a propane torch if required for easier installation.
B. Install the supercharger drive belt. Once the belt
is fully routed except for going around the supercharger pulley, start the belt on the supercharger
pulley and use a ratchet on the harmonic damper
bolt to manually rotate engine until the belt is on
and centered. (See Fig. 16-a.)
C. Tighten the input shaft bolt as much as possible
until belt slippage occurs. Grab the belt on each
side of the supercharger pulley with one hand
and squeeze together. Tighten the input shaft
bolt to 35 ft.lbs.
D. Install the supplied power steering pump belt.
Using the factory tensioner screw snug the power
steering belt. Tighten both power steering pump
mounting bolts.
E. Install mounting bracket top plate. Center on
dowel pins and tighten the five socket head cap
screws. Verify that the plate is fully seated on
mounting surface. (See Fig. 16-c.)
F. Install the grooved idler pulley onto the machined
idler stud. Using thread-locker, tighten the 5/16”
nut and washer. (See Fig. 16-b.)
G. Insert stud through mounting bracket side plate
and start the thick washer and 5/16” nut.
H. Attach the side plate to the top plate and to the
mounting bracket using four 1” bolts and washers. (See Fig. 16-c).
NOTE: If the side plate does not sit flat on the
lowest mounting boss, use the supplied
1-1/4” bolt and spacer. Insert the spacer
between the mounting boss and the side
plate.
Fig. 16-a
Fig. 16-b
I.
Thread a 1/4” nut onto the long 1/4” tensioner bolt
and thread the bolt into the side plate.
J. Press down firmly on the tensioner idler and
thread 1/4” bolt into the side plate until it touches
the tensioner stud. Tighten 5/16” nut on outside of
tensioner stud. Tighten the jam nut on the 1/4”
tensioner bolt.
K. Reinstall and tighten the two lower engine mount
to frame bolts.
Fig. 16-c
P/N: 4HC020-010
16
17.
POWER STEERING PLUMBING/BLEEDING
A. Install the supplied power steering belt in the
stock location.
B. Loosely attach the power steering pressure hose
to the remaining power steering fitting. With the
original O-ring installed (replacement supplied)
slide the original power steering fitting into the
other end of the fitting.
C. Install the fitting in the receiver in the mounting
bracket top plate. Secure using the supplied
1/4-20 cap screws (see Fig. 17-a). Rotate the 90°
fitting for the best hose routing and tighten fitting
(see Fig. 17-b).
D. Reattach the factory power steering return hose
to the power steering pump with the original
clamp.
E. Fill the power steering reservoir to the upper level
line. Bleed the system by starting the engine and
running it at a fast idle while turning the steering
wheel lock to lock several times. Recheck the
fluid level.
Fig. 17-a
Caution: The Honda Shop Manual recommends using only Honda Power
Steering Fluid -V or S as any other
fluid can cause poor performance
and increased wear.
Fig. 17-b
18.
FINAL CHECK
A. Reinstall the headlight, front bumper and splash
guard removed in step 1.
B. Reconnect battery.
C. Make sure that all oil drain and oil feed fittings are
connected and tight and that the engine is filled
with factory specified oil.
D. Make sure that the radiator and reservoir are full.
E. Verify that the power steering reservoir is at “full
cold” level.
F. Insert the supplied 20 amp fuse(s) into the fuel
and aftercooler water pump fuse holder if so
equipped.
G. While listening to area near auxiliary fuel pump,
key ignition on and verify fuel pump operation.
Fuel pump should operate for a short time and
then turn off. Cycle the fuel pump several times
by turning ignition on and then off. Check all fuel
system hose connections for leakage.
17
P/N: 4HC020-010
18.
FINAL CHECK, cont’d.
H. (Aftercooled kits only.) With key on, make sure
aftercooler water pump (if equipped) is operating
and that water is flowing through the surge tank.
Fill as necessary. If water is not flowing, remove
aftercooler supply hose (attached to water cooler)
and lower until water flows out of the hose. This
should prime the pump. Reconnect hose to
aftercooler. Verify water flow. Do not run the
water pump for extended periods (30 seconds or
more) without water flow. Fill the aftercooler
surge tank frequently until the level stabilizes.
I. With engine running turn steering wheel in both
directions. Check power steering hose connections for leakage.
J. For off-road and high RPM use, the ignition
timing should be set to 12° BTDC by following the
procedure in the Honda Shop Manual. For emissions legality, a boost retard ignition may be
installed or the timing should be set to the bottom
of the factory specs. In all cases, if detonation is
detected, discontinue hard use until the problem
is fixed.
K. Belt slippage is usually accompanied by a squealing noise at high RPM and a leveling off or
fluctuating boost pressure. If belt slippage occurs, tighten tensioner as follows:
1. Turn the engine off.
2. Loosen the 5/16 nut on the outside of the belt
tensioner plate until the tensioner stud is just
loose. Loosen the jam nut on the tensioner
bolt.
3. Thread in the tensioner bolt until the idler
moves 1/4”.
4. Tighten the nut securing the idler stud. Tighten
the jam nut on the tensioner bolt.
5. Test drive the vehicle and repeat steps until
belt slippage is eliminated.
L. Periodically, verify that the supercharger pulley
bolt is tight. Also verify that the belt is not slipping
under boost.
M. Read the STREET SUPERCHARGER SYSTEM
OWNER'S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty
(30) days of purchasing your supercharger system.
Fig. 18-a / Aftercooled kit
Fig. 18-b / Standard kit
®
ENGINEERING, INC.
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: 4HC020-010

99HondaCivicSI(4HC V2.0)

Transcription

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