Whipple 3.0L Ranger Supercharger Installation Guide

Transcription

Installation Manual: Lightning/Harley Supercharger System(R10)
Last Updated: August 2nd, 2006
Supercharger Installation Manual
Ford Lightning/Harley Truck 5.4L 16 Valve
1999-2004 Model Years
Engine: Ford 5.4L 16 Valve
Model Years: 1999-2004
Revision #9
June 6th, 2006
CALIFORNIA AIR RESCOURCE BOARD EXECUTIVE ORDER #D-231-24
Page 1 of 35
Table of Contents
Introduction.........................................................................................................3
Kit Components......................................................................................................................... 3
Supercharger Oil..................................................................................................................... 3
Recommended Tools................................................................................................................ 4
Pre-Installation Checklist ...................................................................................4
Supercharger Installation Instructions .............................................................5
Illustrated Installation Guide.................................................................................................... 6
Maintenance and Service .................................................................................28
Maintenance............................................................................................................................. 29
Servicing Your Supercharger ................................................................................................ 30
Post-Installation Checklist ...............................................................................31
Checklist Review ..................................................................................................................... 31
Symbol Key
Throughout this installation guide you will see the following symbols used:
NOTE
Used to indicate tips and information to aid in installation, maintenance, or use of the
supercharger.
!! CAUTION !!
Used to indicate precautions that must be taken to avoid damage to the
supercharger and associated components.
Ì WARNING!!
Used to indicate precautions that must be taken to avoid bodily injury as well as
damage to the supercharger and associated components.
Page 2 of 35
Introduction
This supercharger was created for the 5.4L Ford SVT Lightning and Ford Harley Truck, model years 1999-2004. It has
been designed and tested specifically for this application. Before beginning installation of this supercharger, first read
this section carefully then complete the Pre-Installation Checklist.
Kit Components
Before beginning installation, be sure you have identified all components of your Whipple 5.4L Lightning/Harley
Supercharger Kit. Check the supplied packing slip.
Supercharger Oil
As described in the Illustrated Installation Guide, the supercharger must be filled with oil prior to use. This
supercharger is shipped without oil inside. The oil is in a separate bottle supplied with your kit and you will be
instructed to add it in the Illustrated Installation Guide.
Warning label attached to Supercharger housing
!! CAUTION !!
Do not attempt to start the engine before adding the supplied Supercharger Oil to the
supercharger!
Tie Straps
These will be useful for securing the wiring harness away from the installation area as directed in the Illustrated
Installation Guide. They are inexpensive and will be very handy during installation.
Motor Oil
Motor oil will be useful as a lubricant and should be readily available during installation.
Adhesives and Chemicals
Thread locking chemicals such as Loctite #242 and #262 will be required during the installation. Some other helpful
chemicals is pipe thread sealant such as pipe Teflon and carbureted cleaner.
A Clean Blanket, Towel, or Tarp
This will be used to protect the supercharger, engine, and related components when the grinder is used during
installation.
Page 3 of 35
Vacuum
A vacuum is necessary to clean up any debris resulting from grinder use.
Clean Shop Towels
Use these to keep the installation area clean.
Recommended Tools
The following items are not included in this supercharger kit and it is strongly recommended that they're used for ease
of installation or maximum performance:
Fuel Pressure Gauge
As described in the Pre-Installation Checklist, a quality fuel pressure gauge is an important part of proper
supercharger operation. It is strongly recommended that a fuel pressure gauge is installed on the vehicle prior to
supercharger installation.
Fuel Line Removal Tool
You will need to remove the factory fuel line and fuel rail, this requires a special tool, contact your local parts store or
Ford parts dealer.
Torque Wrench
You will need a quality torque wrench to ensure proper tightening of bolts.
Pre-Installation Checklist
Before installing your Whipple Lightning Supercharger Kit, complete the following checklist.
!! CAUTION !!
Failure to complete the Pre-Installation Checklist may result in severe engine damage after
installation is complete.
1. If you purchased a complete Whipple/FRPP Lightning kit, ensure that you have used your FRPP flash tool
voucher and you have received your FRPP flash tool before you start your installation.
2. Verify Condition of Vehicle: Before the supercharger kit is installed, ensure the engine runs smoothly and that
the factory malfunction indicator light (MIL) is off. Only install the supercharger kit if the engine runs smoothly
and the MIL is off.
!! CAUTION !!
This product is intended for use only on stock, unmodified, well-maintained engines.
Installation on a worn-out or modified engine is not recommended without factory
computer and fuel system modifications.
3. Check Vehicle Fuel Pressure: Fuel pressure is critical to proper supercharger operation and must be checked
during wide-open-throttle operation when the fuel tank is 1/8th full. The fuel pressure should meet all factory
specifications.
4. Verify Fuel Octane: Ensure fuel of 91-octane or higher is in the vehicle fuel tank. If the octane grade is not
known, drain the fuel tank completely and fill to 1/8th with fuel of 91-octane or higher.
Page 4 of 35
!! CAUTION !!
Use only 91 octane fuel or higher. If fuel of less than 91-octane is present in the vehicle
fuel tank, the tank must be completely drained and refilled with 91 or higher octane to
1/8th of a tank.
5. Assess Cleanliness of Installation Area: Make sure your work area and the underhood area are free from
debris. This supercharger is a high-quality, close-tolerance compressor and must not be subjected to
contamination by dirt or any type of foreign material.
!! CAUTION !!
DO NOT remove the protective seal on the supercharger prior to installation. Foreign
material entering the supercharger will automatically void all warranties.
6. Identify Supercharger Kit Components: Before beginning installation, identify all the components of your
Whipple Supercharger Kit and ensure all items are present and undamaged.
7. Read Illustrated Installation Guide: Be sure to read through the Illustrated Installation Guide starting on
page 6 before beginning supercharger installation. Familiarize yourself with the components and tools you will
use and the procedures before you start for faster and easier installation.
Supercharger Installation Instructions
Vehicle: 1999-2004 Ford Lightning/Harley SC Upgrade Kit
Engine: 5.4L
Before you begin installing the Whipple Supercharger, make sure you have completed the Pre-Installation Checklist.
Be sure you have:
1.
2.
3.
4.
5.
6.
□
□
□
□
□
□
Verified the Condition of the Vehicle
Checked the Vehicle Fuel Pressure
Verified the Fuel Octane
Assessed the Cleanliness of the Installation Area
Identified the Supercharger Kit Components
Read and Understood the Illustrated Installation Guide
Have you completed all items in the Pre-Installation Checklist?
Page 5 of 35
NOTE
**NOTICE: Installation of Whipple Supercharger products signifies that you have read
this document and have agreed to the terms stated within.
It’s the purchaser’s responsibility to follow all installation instruction guidelines and
safety procedures supplied with the product as it’s received by the purchaser to
determine the compatibility of the product with the vehicle or the device the purchaser
intends to install the product on.
Whipple Superchargers assumes no responsibility for damages occurring from
accident, misuse, abuse, improper installation, improper operation, lack of
reasonable care, or all previously stated reasons resulting from incompatibility with
other manufacturer’s products.
There are no warranties expressed or implied for engine failure or damage to the
vehicle in any way, loss of use or inconvenience or labor reimbursement. This
includes merchantability and fitness.
Be sure you have read and understand the Introduction section and have completed the Pre-Installation Checklist,
then proceed to the Illustrated Installation Guide.
Illustrated Installation Guide
It is strongly recommended that you read through this guide before you begin installing the Whipple Supercharger.
1. Disconnect ground cable from battery.
2. Using an air hose, blow off any loose dirt or debris from engine compartment.
3. Fine the factory spigot for coolant draining on the factory heat exchanger (located on passenger side of HE) and
drain coolant from heat exchanger/intercooler system.
4. Find the factory coolant drain spigot located on the passenger side of the factory radiator. Drain coolant and store
for later use.
5. Remove factory intercooler water reservoir.
6. Disconnect the following factory electrical connectors:
Page 6 of 35
Mass Air Flow (MAF) sensor.
Inlet Air Temperature (IAT) sensor.
7. Remove factory air box cover and inlet air tube from throttle body. You will have to remove the following hoses:
IAC rubber hose feed from both the air inlet tube and 90 deg rubber fitting on IAC motor.
90 deg. Vacuum hose.
Driver side valve cover breather tube.
8. Remove factory lower air box from inner fender including the rubber inlet adapter.
9. Remove MAF sensor from air box cover.
10. Remove IAT sensor from lower air box.
11. Remove the factory throttle cable and cruise control cable from throttle body and anchor bracket.
12. Disconnect the following factory electrical connectors:
Throttle Position Sensor (TPS) (3-pin connector).
Idle Air Control (IAC) motor (2-pin connector).
Exhaust Gas Recirculation (EGR) solenoid (2-pin connector) (1=RD/YH, 2=BN/PK).
Differential Pressure Feedback EGR sensor (DPFE) (3-pin connector) (1=BN/LG, 2=GY/RD, 3=BN/WH).
Bypass boost solenoid (2-pin connector) (1=RD/YH, 2=LG/DG).
Manifold Air Pressure (MAP) sensor (3-pin connector) (1=BN/WH, 2=GY/RD, 3=DB/LG).
13. Remove factory throttle body from supercharger inlet adapter.
Page 7 of 35
Remove factory throttle bracket adapter from throttle body.
14. Remove EGR valve from engine.
Remove 90deg. hose from top of EGR valve.
Remove rubber hoses from EGR tube.
Remove vacuum lines (2) from EGR solenoid.
Remove EGR nut from factory exhaust manifold.
Remove EGR tubing/nut from EGR valve.
Remove EGR valve from supercharger inlet adapter.
15. Remove IAC motor from supercharger inlet adapter.
16. Remove vacuum lines from:
Supercharger inlet (passenger side) (2 reds, 1 black).
Page 8 of 35
Supercharger inlet (driver side) (EGR rubber hose, brake booster).
From supercharger bypass valve actuator.
17. Remove PCV vent hose from supercharger inlet adapter.
18. Remove power steering reservoir from thermostat housing by loosening the (1) bolt shown:
Remove power steering reservoir from support bracket. Support bracket from block does not have to be
removed although it can be by loosening the bolts and sliding bracket up.
Remove the factory upper radiator hose from engine.
Replace the factory thermostat with the supplied 160deg thermostat.
19. Remove supercharger belt by loosening the factory spring loaded tensioner:
Fish the belt around the fan blade or remove fan to pull belt off.
20. Remove intercooler hose feed and return hoses and bracket from supercharger mounting bolts (2 nuts).
Page 9 of 35
Remove hard IC lines from engine, they will not be utilized.
21. Remove EGR solenoid, Vent solenoid, Bypass boost solenoid bracket from driver side of supercharger.
22. Remove supercharger assembly from intercooler adapter housing by removing the 8 bolts.
23. Remove gasket from intercooler adapter housing.
24. Remove vacuum/boost line from intercooler adapter housing (1 black, 1 red)
25. Remove intercooler adapter housing from intake manifold.
26. Remove dows (2) from bottom side of intercooler adapter housing.
27. Inspect intercooler adapter housing adapter gasket, replace if damaged, re-utilize if it’s looks ok.
28. Remove intercooler feed/return 90deg hoses from inlet/discharge tubes.
29. Remove intercooler core from factory intercooler adapter housing by removing the (11) mounting bolts.
30. Remove carbon gasket from intercooler core mounting flange.
31. Mount intercooler core to new Whipple intercooler adapter housing:
Install intercooler core to new supplied intercooler adapter housing carbon gasket #1L3Z-9M436-AA.
Apply light amount of red Loctite #262 to threads of supplied (10) 5mm x 16mm socket head cap screws.
Use the supplied (10) 5mm x 16mm socket head cap screw and (10) 5mm AN washers.
Torque to 8 ft. pounds.
Reinstall factory 90deg rubber inlet/discharge hoses facing passenger side as was stock. Utilize factory
clamps.
Install supplied 5/8” barbed fittings into 90deg rubber inlet/discharge hose ends and secure with supplied
clamp.
Page 10 of 35
32. Install dows into Whipple intercooler adapter housing, tap into place with soft rubber hammer or equivalent.
33. SPARK PLUGS. This is the best time to install/replace the factory spark plugs. Install spark plugs (NGK BP7EFS)
with light amount of anit-seaze on threads (do not get on electrode). Torque to 25 ft. pounds.
34. Mount assembled intercooler adapter housing to factory intake manifold:
Reutilize factory steel stamped gasket between factory intake manifold and intercooler adapter housing.
Utilize the supplied (12) 10mm x 35mm socket head cap screws to secure adapter housing.
Connect factory vacuum/boost 90deg hose to 3/8” barb fitting.
Install supplied preformed 5/8” ID hose (Whipple PN#54201010) (Ford PN #U036 49602) to barb fittings
you installed in factory 90deg hoses. Secure hose to barb fittings using supplied pinch clamps. Route
hoses along passenger side of engine for later installation.
35. Rotate factory fuel PSI regulator nipple so that it faces directly back to the firewall.
36. Remove boost bypass solenoid from factory bracket.
37. Remove MAP sensor from factory bracket.
38. Install boost bypass solenoid to new supplied Whipple bracket, install by sliding into place.
Page 11 of 35
39. Install the MAP sensor to the new supplied Whipple bracket. Utilize the supplied (2) 10/32” x ½” socket head cap
screws and secure with the 10/32” nyloc jam nut.
40. Install new supplied boost bypass solenoid/MAP sensor bracket to driver side rear injector rail boss. Remove
factory bolt that secures the factory resistor, install the new bracket over the resistor and secure with factory bolt.
Plug in MAP sensor electrical connector to sensor.
Plug in boost bypass solenoid electrical connector.
41. Remove EGR solenoid from factory bracket.
42. Remove DPFE sensor from factory bracket.
Page 12 of 35
43. Install EGR/DPFE solenoid/sensor to new supplied bracket.
Utilize the supplied (3) 10/32” x ½” socket head cap screws to first secure the outer bolt for the EGR
solenoid. Secure with the supplied 10/32” nyloc nut on the backside.
Sandwich the DPFE sensor on top of the EGR solenoid and secure with the supplied 10/32” x ½” socket
head cap screw. Secure with the supplied 10/32” nyloc nut.
Install the supplied 10/32” x ½” socket head cap screw with the supplied .25” spacer behind the outer
DPFE mounting flange. Secure with the supplied 10/32” nyloc nut.
44. Remove factory spring loaded tensioner (from supercharger belt system).
You will need to remove the stop on the tensioner to gain more travel. Grind or file tensioner stop flat to
gain more travel. Re-install the belt tensioner. Torque to 20ft lbs
Page 13 of 35
45. Prepare cold air intake system:
Install IAT sensor into cold air intake by inserting and twisting until it locks in place.
(99-00 Models 90mm MAF included with kit) Install 90mm MAF sensor to air box and install the supplied
air filter billet venture on the inside of the air box, utilize the supplied (4) 6mm x 16m socket head cap
screws.
46. Install cold air intake system:
Apply light amount of grease/silicone into the factory rubber air filter box mounts.
Remove the factory cruise control motor mounting bolts from inner fender.
Install new cold air intake box by pushing dows thru the rubber grommets.
Feed the cruise control cable through the allocated round hole.
Install the supplied rubber grommet around cruise control cable (cut grommet so it slips over cable easy)
and slide up into the air box until it’s secure.
Page 14 of 35
Reinstall the cruise control motor (sandwich on top of the cold air intake box mounting flange) with the
factory bolts.
Install the new supplied high-flow air filter by sliding over the billet venturi and securing with the supplied
clamp.
Page 15 of 35
47. Install EGR/DPFE bracket to brake booster master cylinder stud and secure with supplied (1) 10mm nyloc nut.
Secure bracket to pre-installed bracket located on cold air intake box by installing the power steering
reservoir to the bracket. Utilize the factory power steering reservoir mounting bolts to secure.
Remove factory plastic wiring harness cover on driver side.
Cut small amount of electric tape from EGR solenoid and DPFE sensor loom so you can route wires
towards the driver side.
Cut to factory plastic wiring harness cover on driver side to clearance for the EGR solenoid and DPFE
sensor, approximately .50”H x 3.0” L rectangle notch.
Plug in the EGR solenoid electrical connector.
Plug in the DPFE electrical connector. Note: Some will need to slightly cut the factory plastic wire loom
cover to give the wires an extra 1-2”.
Page 16 of 35
o
Reinstall factory plastic wiring harness cover and secure with zip tie.
48. Vacuum/boost hose pre-routing.
Ì
WARNING!! Make sure to pre-install all rubber lines that go the
backside of the supercharger inlet, as access to these fittings later will be very difficult.
Locate the plastic/rubber vacuum hose junction just behind the battery. Remove the (2) black plastic lines
coming from the hose loom.
Install the supplied 7/32” x 24” line to the 7/32” barb behind the battery.
Route the 7/32” rubber vacuum lines around the back of the engine.
Install the 5/32” x 30” rubber hose to the bottom port facing forward on the boost bypass solenoid.
Remove the rubber 90deg 7/32” to 5/32” from the factory bypass actuator bottom port.
Install supplied 5/32” plastic hose coupler into factory rubber 90deg barb.
Install supplied 5/32” hose to plastic hose coupler.
Install factory rubber 90deg 7/32” to 5/32” fitting onto Whipple bypass valve actuator, install on the
passenger side port, facing down.
Install supplied 5/32” hose from the 7/32” to 5/32” rubber 90deg fitting and route to middle nipple facing
forward (counting the top that faces up) boost bypass solenoid.
Page 17 of 35
Install supplied 7/32” x 36” rubber hose to bottom/inside port of Whipple bypass actuator (facing up) and
route to front/driver side of engine for later installation into air inlet.
BOOST BYPASS SCHEMATIC
5/32" x 14"
7/32" x 25"
Goes to factory
vac. line
Goes to 7/32
fitting on
7/32" x 4" supercharger
intake
Goes to
7/32
fitting on
air tube
Top port
Upper
side port
7/32" x 36"
Boost
bypass
solenoid
Lower
side port
5/32" x 18"
5/32" 30"
Bypass
actuator
Inside port
Goes to factory
vac. line
Outside port
Reducer
elbow from
vehicle
Remove the factory rubber boot from the PCV tube.
Install the supplied 3/8” x 20” rubber hose with 90deg rubber fitting onto factory PCV tube and route to
backside/driver side of engine.
Page 18 of 35
49. Install the 3/8” rubber hose you pre-routed from the PCV valve to the Whipple SC inlet 90deg 3/8” barbed fitting.
PCV VALVE SCHEMATIC
3/8" vac. hose 30" long
Goes to 3/8" 90deg fitting
on supercharger intake
Goes to factory
PCV
50. Vacuum/boost hose routing:
Install the factory 3/8” rubber 90deg hose on the 3/8” straight barb fitting on the Whipple intercooler
adapter housing to the factory fuel PSI regulator nipple.
Page 19 of 35
51. Mount factory IAC motor to bottom side of Whipple supercharger inlet housing using the supplied gasket
PN#E83Z-9F670-A and the supplied (2) 6mm x 20mm hex head bolts.
52. Install the supplied o-rings to bypass valve. Apply heavy amount of lubricant such as engine oil or grease.
53. Install supplied gasket to intercooler housing to supercharger mounting flange, you may use a small amount of
gasket cinch to help keep the gasket from moving from it’s location. You may also use anerobic sealant, Permatex
#510 or Loctite #518 for sealing if a gasket is not available.
54. Install Whipple supercharger assembly to intercooler housing by sliding over the Whipple bypass valve orings.
Secure supercharger using the supplied (2) 8mm x 25mm (back holes) and (2) 8mm x 30mm (front holes)
6-point hex bolts. Torque to 25 ft. pounds.
Ì WARNING!!
Verify that the intercooler inlet/outlet hoses do not interfere with the bypass actuator
arm. If so, reposition hose so that there is no possible interference.
Page 20 of 35
55. Mount EGR valve to Whipple supercharger inlet utilizing the supplied (2) 8mm x 30mm socket head cap screws.
Route the supplied 5/32” x 8” rubber hose from the EGR solenoid top port to the top of the EGR valve port.
Install factory 3/8” rubber hose from brake booster to Whipple SC inlet 3/8” barbed straight fitting (front fitting).
56. Install the supplied 3/8” plastic hose coupler and rubber 90deg fitting into factory 3/8” rubber hose coming from the
EVAP service port (green fitting) to the Whipple SC inlet 3/8” straight fitting (middle fitting).
EGR SOLENOID SCHEMATIC
5/32" x 12"
5/32" x 22"
5/32" x 2"
Goes to factory Evap .
Goes to 5/32" 90deg
fitting on supercharger
intake.
5/32" x 5"
Goes to EGR valve
EGR solenoid
Page 21 of 35
57. Install the supplied 5/32” x rubber hose from the 7/32” to 5/32” tee to the top port (faces up) of the boost bypass
solenoid.
58. Install the supplied EGR tube from the factory exhaust manifold to the EGR valve. Reinstall the factory lines from
the DPFE sensor.
59. Install the factory throttle body.
Utilize the supplied gasket PN#.
Utilize the factory bolts (4) to secure throttle body (use dual thread bolts on bottom) and torque to 15 ft.
pounds.
Install factory throttle cable bracket to bottom bolts of throttle body, utilize factory nuts to secure bracket.
Torque nuts (2) to 15 ft. pounds.
60. Extend the factory TPS and IAC wires. Use the supplied wires and butt connect/heat shrink wires or solder/heat
shrink wires.
61. Plug in the TPS sensor and IAC connectors.
62. Install the 90deg air inlet tube from the factory MAF to the throttle body using the supplied hump hose to the
throttle body and the hose to the MAF. Secure with supplied hose clamps.
63. Install breather hose from driver side valve cover breather to the 5/8” barb fitting on the plastic SC inlet.
Page 22 of 35
64. Install the supplied u-bend 5/8” hose from the IAC motor boss to the 5/8”” barb fitting on the plastic SC inlet.
65. Review the supplied componets for the front support system. The idea of the front support is to hold the drive
snout from pulling down, it’s very important that the mid-piece is meeting the bottom of the drive snout and in line
with the lower support piece.
TOP COLLAR
MID-PIECE
LOWER
SUPPORT
Page 23 of 35
66. For proper installation, install the lower support and mid-piece so it’s sitting flush on the Ford front idler plate.
Install the (3) 8mm x 20mm hex head (with flange), but leave loose for the time being.
67. Install the top collar. Slowly tighten the top (2) 6mm x 18mm socket head allen bolts which will pull the mid-piece
up and secure to the front drive snout. It’s critical that it stays parallel to the lower support bracket.
Page 24 of 35
68. Now that the top collar and mid-piece are secure, push the lower support down so it’s flush with the factory idler
plate.
69. Once it’s flush, tighten the hex head flanged 8mm bolts, torque to 20ft/lbs.
70. Now install the radiator hose, this must be cut and shortened so the front support is not resting against hose. To
shorten, cut just after the 90deg radius from the thermostat housing.
Page 25 of 35
71. Once the radiator hose is in place, use a large set of channel locks to bend the factory radiator hose support
bracket back towards the engine. This will help keep the hose away from the front support.
72. Reinstall factory belt (note that it is easier to install the belt over the SC pulley guards and then slide over the
smooth idlers).
73. Reinstall factory intercooler water reservoir.
74. Install factory intercooler water reservoir inlet/outlet hoses to previously installed (#1811) intercooler hoses by
cutting the #1811 hose to fit. Utilize the supplied 5/8” barb and clamps to secure hose.
75. Re fill engine coolant system and i/c cooling (50/50 mix) system.
76. The battery cable can now be re connected.
77. Install the supplied C.A.R.B. 50-state emissions sticker in a visible location on the factory radiator shroud. To
properly install, use a light abrasive material such as scotch-brite to scuff the mounting area. Clean the area off
and install the sticker.
Page 26 of 35
78. Fill the new s/c compressor with oil per supplied instructions.
Make sure the SC is sitting square/flat.
Remove -4AN allen plug and fill SC with WHIPPLE SC OIL ONLY!!
Fill to the middle of the sight glass. NOTE: The W140AX compressor takes a maximum of 5.8 fl/oz.
Reinstall -4AN allen plug.
NOTE: After running the SC, the oil level will lower due to oil filling the bearings. The proper level should
be between the bottom of the sight glass and the middle.
Change SC oil every 100,000 miles and only use WHIPPLE SC OIL ONLY!!
!! CAUTION !!
Severe damage to the compressor will occur if you overfill the supercharger front gear
case.
WHIPPLE SC OIL LEVEL
Fill to center of oil sight glass. 5.8 fl/oz. or 155cc.
DO NOT OVERFILL, WILL VOID WARRANTY!!
OIL FILL P LUG
M AXIM UM OIL LEVEL
OIL LEVEL OP ERATING RANGE
M INIM UM OIL LEVEL
!! CAUTION !!
case.
79. Start engine and check for any fuel or coolant leaks. Top off engine coolant and intercooler coolant tanks while
engine is running.
Page 27 of 35
80.
Ì WARNING!!
Verify the bypass actuator is working properly. To monitor, look at the bypass arm when the
motor is not running. Start engine and verify that the actuator arm has opened. This arm will be extended when
the engine is above 1” of vacuum (boost) and will be open when there is more than 1” of engine vacuum.
CLOSED
OPEN
Page 28 of 35
Maintenance and Service
Be sure to follow the maintenance and service recommendations below to optimize the life and performance of your
Whipple-supercharged Lightning/Harley.
Maintenance
For best performance and continued reliability it is essential to adhere to the following guidelines:
1. Use only premium grade fuel (91-octane or higher).
2. Always listen for any sign of spark knock or pinging. If present, discontinue use immediately and consult your
vehicle owner’s manual.
3. Do not overfill the supercharger front gear case.
!! CAUTION !!
case.
4. Do not operate the vehicle at large throttle opening if the MIL lamp is on steadily. This indicates an electronic
engine control malfunction: reduce throttle opening and consult your vehicle dealer.
!! CAUTION !! TUNER KITS
When installing the Whipple SC, the vehicle’s stock computer program is not accurate
for the new SC and failure to recalibrate properly may cause serious damage to the
engine and/or drivetrain.
!! CAUTION !! COMPLETE KITS WITH FRPP FLASH TOOL
When installing the Whipple SC, modifying the supplied flash calibration may cause
serious damage to the engine and/or drive-train.
BYPASS ACTUATOR ROUTING
Page 29 of 35
Ì WARNING!! For systems that remove Ford factory boost solenoid system ONLY
1. If you remove the factory Ford boost solenoid system, then it is very important to re-route the bypass
actuator properly. Incorrect routing can result in supercharger failure which will not be warrantied!
2. Locate the actuator on the passenger rear side of supercharger.
3. Disconnect the hose to the bottom port of actuator and leave this port open, do not cap.
4. Route a dedicated boost line from intake manifold, above or below intercooler to top port of actuator.
Secure lines with tie wraps.
Route to 7/32" dedicated
boost line (above or
below IC)
TOP
PORT
Leave bottom port open
to atmosphere (DO NOT
PLUG)
BOTTOM
PORT
BYPASS ACTUATOR TESTING
TOP
PORT
Leave bottom port open
to atmosphere (DO NOT
PLUG)
1. Move actuator arm into actuator .
2. Plug top port with finger while actuator is
pressed in.
3. Let go of actuator arm while finger is still on
top port.
4. If actuator is good , actuator arm will stay in
the same position until you remove your
finger. If bad, it will come back to it’s relaxed
position.
IF BAD, REPLACE IMMEDIATELY
Page 30 of 35
BOTTOM
PORT
Servicing Your Supercharger
It is recommended that the following items be inspected at normal service intervals:
1. Check the supercharger oil level at every engine oil change. Add Whipple SC oil to the supercharger if
required.
2. Check the supercharger/accessory drive belt. Adjust or replace as required.
3. Change the oil in the supercharger every 100,000 miles. Use Whipple SC oil only.
4. Test the bypass actuator every 10,000 miles.
5. HIGH HP trucks with Ford boost solenoid removed should inspect the actuator every 5,000 miles.
Follow these guidelines to properly maintain your WhippleSupercharged Lightning/Harley.
Post-Installation Checklist
After installing the Whipple supercharger kit it is essential that the following checklist be completed.
!! CAUTION !!
Failure to complete the Post-Installation Checklist may result in severe engine damage.
1. Review Maintenance and Service Recommendations: Read through the section and familiarize yourself with
the steps you must take to ensure your Whipple-supercharged truck/SUV will continue to operate with
optimum performance.
2. Verify Fuel Octane: When you re-fuel your truck/SUV, ensure you use fuel of 91-octane or higher. It will always
be beneficial to run 92-94 octane when available.
!! CAUTION !!
Use only 91-octane fuel or higher. If fuel of less than 91-octane is present in the vehicle
fuel tank, the tank must be completely drained and refilled with 91 or higher octane to
1/8th of a tank.
3. Check Vehicle Fuel Pressure: Fuel pressure is critical to proper supercharger operation and must be checked
during wide-open-throttle operation when the fuel tank is 1/8th full. Fuel pressure should meet all factory
specifications.
Checklist Review
Page 31 of 35
Have you completed the Post-Installation Checklist? Be sure you have:
1.
□
Reviewed the Maintenance and Service Recommendations
2.
□
Verified the Fuel Octane
3.
□
Checked the Vehicle Fuel Pressure
Have you completed all items in the Post-Installation Checklist?
NOTE
There are no warranties expressed or implied for engine failure or damage to the vehicle in any way
during supercharger installation or use.
If you have completed the Post-Installation Checklist, you have successfully installed your Whipple Lightning/Harley
Supercharger Kit.
Congratulations! Your supercharger installation is now complete.
Important information
PULLEY SIZE VS. BOOST
SC Pulley
7.5" Crank (stock)
Boost
Ratio
9.0 Crank
Boost
Ratio
10.0
2.14
14.5
2.57
3.50"
11.5
2.31
16.5
2.77
3.25"
13.5
2.50
18.5
3.00
3.00"
15.5
2.73
21.0
3.27
2.75"
17.5
3.00
23.0
3.60
2.50"
Boost measurements are made at 5000rpm.
Compressor RPM = (Crank pulley/SC pulley)*Engine RPM
BOOST LEVELS
All Whipple kits are shipped with 11.5psi pulleys for stock engines. Additional pulley’s are available for higher boost
levels. With proper PCM calibration, the factory engine has proven to withstand 15psi before detonation on 91-octane
fuel. With additional modifications, 17psi is achievable on 91 octane but must have a custom calibration for the octane
level. Vehicles that run 93-94 octane can run 17psi before detonation with proper tuning. The Whipple Supercharger
has the ability to produce over 700RWHP but additional modifications are needed to achieve such power levels.
With stock engines, the Whipple/Ford Racing flash tool has been calibrated for 91 octane and the supplied 3.385” SC
pulley. This will produce approximately 11.5psi at sea level. Stock engines may run 3.25” SC pulley’s (12.5psi) to
temperatures of 0 degree’s Fahrenheit, any cooler will result in a lean and potentially damaging effect. Stock engines
may run a 3.00” SC pulley (13.5psi) down to 40 degree’s Fahrenheit, any cooler will result in a lean and potentially
damaging effect. Please note that increased performance may shorten the transmission life and may need upgrading
when running smaller than the 3.385” SC pulleys.
FUEL SYSTEM
The factory fuel system (flow only) is ok and needs no additional changes for boost levels up to 15psi. The factory fuel
system including the pump and injectors are adequate for 15psi on stock engines. Engines that run more than 15psi
Page 32 of 35
or are heavily modified need larger injectors and more fuel flow. Whipple Superchargers recommends going to 60lb
fuel injectors (available from Whipple).
“TUNER KITS” FACTORY PCM CALIBRATION
If you have a “TUNER KIT” (no computer or fuel system included), then you must have your factory PCM tuned by a
professional tuner. This includes fueling, spark, transmission as well as many other functions. You must contact your
preferred tuning specialist for a custom tune, failure to do so may lead to severe power-train damage.
AIR FUEL RATIO
Air fuel ratio is the measurement of the amount of air and fuel being burned during the combustion process. There are
currently many different air fuel-monitoring systems and accuracy is not always guaranteed. Wide band oxygen
sensors vary over time and deteriorate with uses of leaded gasoline. Whipple only uses Horiba wide band analyzers
and UEGO 6-wire sensors, the most accurate available. Our sensors are checked after every use and transfer
functions are changed every time so make sure you’re using an accurate meter.
Whipple has found that 12.6:1 is approx. the best a/f for power. Be very careful though, too lean of an air fuel ratio
increase cylinder temps and increase the chance of detonation, which is detrimental to engine life. Under high boost
applications such as 13-15PSI, Whipple recommends 12:25:1. For levels above 15psi, you should never run leaner
than 12.25:1 unless you’re using 100+ octane and are monitoring detonation/knock. Race gas setups can run 12.6:1
up to 21psi. Once again, this is based with a very accurate a/f meter so this should only be used as a rule of thumb
because most meters will vary.
SPARK PLUGS
Factory spark plugs are acceptable for up to 10psi. Any boost level beyond 10 should only be run with Denso Iridium
NGK plugs, which offer superior performance. We recommend a Denso Iridium IT20 (stock gapping) for 14-20psi and
the Denso Iridium IT22 (stock gapping) for boost levels over 20psi. Whipple also recommends the NGK BP7EFS
plugs gapped to .035” which will help prevent detonation.
ENGINE COOLANT
For boost levels above 15psi, Whipple recommends running a 75/25 mix of distilled water and coolant vs. the factory
50/50. We also recommend 1-2 bottles of Red Line Water Wetter coolant additive. This will reduce air bubble
insulation, which increases overall engine temp.
INTERCOOLER COOLANT AND COOLERS
The factory intercooler system is very well designed and Whipple saw no increased benefits from any changes below
13psi of boost. For systems that run more than 13psi, Whipple recommends changing the 50/50 factory ratio to 75/25
distilled water and factory Ford coolant. We also recommend 1 bottle of Red Line Water Wetter coolant additive. If
you are running above 15psi, a higher capacity heat exchanger such as Fluidyne’s is a good choice as well as a larger
capacity reservoir and electric fan kit. This will have a higher capacity to maintain low discharge temperatures. When
going to larger capacity heat exchangers and reservoirs, you should install one extra bottle of Red Line Water Wetter
(2 total).
THROTTLE BODY
Increased bore mono blades such as Billet Flow’s and Accufabs do have beneficial changes. In all cases, the large
mono blade throttle bodies will have a significant throttle response increase at all given throttle positions and therefore
will fill to most as increased power. Before 450hp, gains are very little in overall power output. After 450 hp, you begin
to see an increasing performance gain, approx. 5hp @ 500hp and becomes significantly important at levels above
550hp.
FUEL LEVEL
Never operate at WOT when the vehicle fuel levels are below a ¼ tank. Low fuel levels could cause the fuel pump to
cavitate and you’ll have fuel flow spikes resulting in lean conditions and consequently detonation.
Page 33 of 35
LIMITED WARRANTY
All merchandise manufactured by Whipple Industries has a limited warranty against defects in workmanship and
materials to the original purchaser of the Whipple Supercharger System for one calendar year from Whipple Industries
ship date. The limited warranty must be signed, dated and returned to Whipple Industries within 30 days of the
Whipple Industries ship date and must be accompanied by a copy of the original sales invoice. This warranty is nontransferable.
If an item is suspected of being defective, return it to Whipple Industries for inspection after obtaining the proper
Return Authorization Number. If an item is determined to be defective, we will repair or replace it at our discretion
within a period of one year from the shipping date on your invoice.
Whipple Industries Inc. limited warranty specifially does not apply to products which have been (a) modified or altered
in any way, (b) subjected to adverse conditions suach as misuse, neglect, accident, improper installation or
adjustment, dirt, or other contaminants, water, corrosion or faulty repair; or (c) used in other than those specifically
recommended by Whipple Industries Inc. All products designed for off-road use are considered racing parts and carry
no warranty, either expressed or implied, as we have no control over how they are used.
On warranty items, repair/replacements will be limited to parts manufactured by Whipple Industries and will not include
claims for labor or inconvenience. All other merchandise distributed by Whipple Industries is warranted in accordance
with the respective manufacturer's own terms of warranty. This warranty is expressly made in lieu of any and all other
warranties expressed or implied, including the warranties of merchantability and fitness.
Whipple Industries will not be responsible for any other expenses incurred by the customer under the terms of this
warranty, nor shall it be responsible for any damages either consequential, special, contingent, expenses or injury
arising directly or indirectly from the use of these products.
Whipple Industries reserves the right to determine whether the terms of the warranty, set out above, have been
properly complied with. In the event that the terms are not complied with, Whipple Industries shall be under no
obligation to honor this warranty. By signing this form, you understand and agree to the terms above.
NAME (Print)
ADDRESS
SIGNATURE
CITY
DATE
PHONE
SC SERIAL #
EMAIL
(Found on compressor bearing plate)
(Optional)
VIN #
Page 34 of 35
STATE
ZIP
CONGRATULATIONS
Your new Whipple Supercharger is engineered to significantly increase your engines power across
a broad range of RPM’s. It is Whipple’s goal to improve your driving experience for many miles
and years to come.
Whipple Superchargers operate as an air pump and contain internal rotors that are driven by the
engine’s crankshaft and serpentine belts. The supercharger compresses outside air and channels
it into the engine’s intake ports. Because of their design, superchargers may generate some
additional noise over the standard, normally aspirated induction system.
At idle, you may hear a medium-pitch rattle from the supercharger main housing. This will diminish
at about 400-500 rpm above idle.
You may also experience a muffled high-pitched whine during acceleration. This is caused by the
pumping action of the supercharger compressing air and only occurs during boost conditions. It is
inaudible during part-throttle acceleration.
These are normal noises associated with any supercharger and have no effect on supercharger
performance or engine durability.
Your supercharger is warranted by Whipple Superchargers. Note that Whipple Superchargers will
not authorize any warranty repair work or supercharger replacement for normal noises.
Page 35 of 35

Whipple 3.0L Ranger Supercharger Installation Guide

Transcription

Similar documents

import tuner - Vortech Superchargers

frs_brz_sheet

MUSTANG SUPERCHARGER KIT

Atlantis Energy Systems Inc.

generic superchargers

2005 Sea Doo RXP Supercharger Removal

the mk3`s two.slow nickname is well earned, but bahn brenner aims

2016 Tahoe Suburban Brochure - Specialty Vehicle Engineering

6.4 dodge - Kenne Bell

detective skills