1999-2000 Honda Civic Si

Transcription

Honda
1.6L DO
H
Superc
C
h
a
rger Sy Civic Si
Installa
stem
tion In
structi
1999-2
0
ons
0
50 Stat
0 Mod
e Sm
og Leg
al Per C
el Year
s
ARB E.O
. #D-21
3-21
®
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 v3.0
01/19/04
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.
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.
© 2004 VORTECH ENGINEERING, LLC
All rights reserved. No part 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, LLC.
P/N: 4HC020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
19JAN04 99-00Honda Civic Si(4HC v3.0)
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 INSTALLATION.................................................................................................................................7
11.
AFTERCOOLER INSTALLATION....................................................................................................................................9
A. RESERVOIR INSTALLATION......................................................................................................................................10
B. AFTERCOOLER WATER PUMP WIRING AND INSTALLATION.........................................................................12
C. WATER COOLER INSTALLATION.............................................................................................................................12
D. AFTERCOOLER INSTALLATION..............................................................................................................................13
E. SURGE TANK INSTALLATION...................................................................................................................................15
12.
STANDARD KIT DISCHARGE DUCT INSTALLATION...............................................................................................15
13.
AIR INLET DUCT INSTALLATION..................................................................................................................................15
14.
STANDARD BYPASS VALVE INSTALLATION..............................................................................................................16
15.
SUPERCHARGER DRIVE BELT INSTALLATION..........................................................................................................17
16.
POWER STEERING PLUMBING/BLEEDING...............................................................................................................18
17.
FINAL CHECK.....................................................................................................................................................................18
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
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or
damaged parts immediately.
PART #
DESC
QTY
PART #
2E129-120
S/C,V-5 SQ CCW ’99-’00 1.6 DOHC Honda
1
4HC110-020
4HC010-022
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
ASSY, S/C DRIVE, HONDA 1.6 DOHC HO
8R101-000
Pulley Retainer Assy, 4 Rib
2A034-370
S/C Pulley 3.70” 4 Groove
2A044-520
Belt, K040520 HON HO S/C
2A044-335Belt, K040335 HON Pwr Str
1
1
1
1
1
4HC111-041
4HC011-011
7U250-022
2D070-159
7X100-025
7U100-084
7A312-075
7K312-001
4HC010-130
7A250-075
4HC010-070
7A250-101
7J006-093
7A250-276
7F250-020
4FK116-021
7J312-000
7A312-125
4HC010-060
7F312-018
7J312-875
2D030-024
4HC116-011
7C010-036
7J010-002
2D170-228
2D160-218
2D030-051
2D030-061
2D070-281
7U250-125
1
1
2
2
1
1
3
3
1
5
1
4
5
1
1
1
2
1
1
2
1
1
1
2
2
1
1
1
1
2
6
Mounting Bracket Assy
Mtg Brkt, HON 1.6 DOHC
Dowel Pin, Ø1/4” x 3/4” L
Lg Bearing, Extended Drive
Wave Washer - Large
Snap Ring, Ext Drv Housing
5/16-18 x 3/4 HXCS G5 Zinc
5/16 AN-Washer, Plated
Top Plate, Honda 1.6 /1.8
1/4-20 x 3/4” SHCS Pltd
Tensioner Plate, Honda DOHC
1/4-20 x 1” HHCS, Zinc Pltd
6mm Washer, Plated
1/4-20- x 2.75 HHCS
1/4-20 Hex Nut
Idler Pulley Assy, Gen II
5/16 Fender Washer, SAE
5/16-18 x 1-1/4 GR5 HXHD Zinc
STUD, Honda Tensioner
5/16-18 Nut USS Pltd
5/16 Washer Custom
Flange, Ext Tube End Honda
Idler Pulley Assy, Honda
M10 x 1.25 x 35mm Flanged
10mm Washer, Zinc Plated
Assy, Drve Shft, Civic, Pin Dr
Tube HSG Asy, 99 Civic, Pin Dr
Housing, Coupling, Ext Drive SC
Housing, Coupling, Ext Drive SH
Coupling, Flg, 3-Pin Drive
Dowel Pin, Ø1/4” x 1.25” L
DESC
v
QTY
7B375-075
7J375-020
7U100-070
2D070-260
7A312-550
7U312-125
3/8-24 x 3/4” GR8 HXHD Bolt
Washer, 1.0 OD, .406 ID
Key, 3/16” Square x 7/8” Long
Coupling, Drive, Composite
5/16-18 x 5.50 SHCS Zinc
Dowel Bushing, .312 x 1.25”
3
2
2
1
4
2
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
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
FUEL PUMP, ’99-’00 HONDA
8F101-310
Fuel Pump Rail Assy, Honda
5W001-019
12-10 GA Solderless Connector
5W001-014
Fuse Holder 10 GA Wire
5W001-015
Fuse, Blade Type 20 amp
5W001-042
12-10 GA 3/16” Ring Terminal
5W001-001
16-14 Wire Tap
5W001-011
16-14 GA Eyelet .25” Hole
8F010-110
Fuel Pump Hangar
7E010-075
#12 x 3/4” Sheet Metal Screw
7U314-001
#8 Lord Mount
7F008-032
8-32 Hex Lock Nut
7J008-001
#8 Flat Washer
8F001-200
Corvette Fuel Pump 200 in Line 3/8”
008340 Fuel Pump Decal, T-Rex
7P312-008
T-Rex - 5/16 Barb
7U031-018
5/16 Fuel Hose High Press
7R001-004
#4 Hose Clamp
7P312-005
5/16 Fem Fuel Steel
7P312-007
5/16 Male Fuel Al.
7U100-044
7U100-055
5W001-021
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
1
2
2
2
1
1
1
2
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
P/N: 4HC020-010
1999-2000 HONDA CIVIC Si STD., cont’d.
PARTS LIST
PART #
DESC
QTY
PART #
DESC
4HC112-010
AIR INTAKE ASSY, ’99-’00 HONDA
4HC012-011 3-1/2” 90 Plastic Elbow
4FA012-011
3-1/2” 90 Plastic Elbow
8D001-001Bypass Valve
7P750-100
1” Barb to 3/4 NPT Plastic Fitting
7U034-016
1” GS Hose
7U034-016
1” GS Hose
7U030-046
5/32” Vacuum Line
7P156-082
5/32 TEE
7R002-016
#16 Hose Clamp
7U035-001
“3-1/2” Flex Hose
7R002-052
#52 Goldseal Hose Clamp
7S350-200
3-1/2 X 2 Sleeve
7R002-056
7U100-061
7P375-008
Elbow Union Eub
7U030-056
3/8 PCV Hose
5W001-012
18-22 GA Butt Connectors
5W022-030
Wire, Red 22
5W022-040
Wire, Green 22
8H040-040
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
1
1
3
1
1
1
1
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
P/N: 4HC020-010
vi
QTY
1999-2000 HONDA CIVIC Si H.O.
PARTS LIST
PART #
DESC
QTY
PART #
2E129-120
S/C,V-5 SQ CCW ’99-’00 1.6 DOHC Honda
1
4HC110-020
4HC010-022
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
ASSY, S/C DRIVE, HONDA 1.6 DOHC HO
8R101-000
Pulley Retainer Assy, 4 Rib
2A034-333
S/C Pulley 3.33” 4 Groove
2A044-514
Belt, K040514 HON HO S/C
2A044-335Belt, K040335 HON Pwr Str
1
1
1
1
1
4HC111-041
4HC011-011
7U250-022
2D070-159
7X100-025
7U100-084
7A312-075
7K312-001
4HC010-130
7A250-075
4HC010-070
7A250-101
7J006-093
7A250-276
7F250-020
4FK116-021
7J312-000
7A312-125
4HC010-060
7F312-018
7J312-875
2D030-024
4HC116-011
7C010-036
7J010-002
2D170-228
2D160-218
2D030-051
2D030-061
2D070-281
7U250-125
1
1
2
2
1
1
3
3
1
5
1
4
5
1
1
1
2
1
1
2
1
1
1
2
2
1
1
1
1
2
6
Mounting Bracket Assy
Mtg Brkt, HON 1.6 DOHC
Dowel Pin, Ø1/4” x 3/4” L
Lg Bearing, Extended Drive
Wave Washer - Large
Snap Ring, Ext Drv Housing
5/16-18 x 3/4 HXCS G5 Zinc
5/16 AN-Washer, Plated
Top Plate, Honda 1.6 /1.8
1/4-20 x 3/4” SHCS Pltd
Tensioner Plate, Honda DOHC
1/4-20 x 1” HHCS, Zinc Pltd
6mm Washer, Plated
1/4-20- x 2.75 HHCS
1/4-20 Hex Nut
Idler Pulley Assy, Gen II
5/16 Fender Washer, SAE
5/16-18 x 1-1/4 GR5 HXHD Zinc
STUD, Honda Tensioner
5/16-18 Nut USS Pltd
5/16 Washer Custom
Flange, Ext Tube End Honda
Idler Pulley Assy, Honda
M10 x 1.25 x 35mm Flanged
10mm Washer, Zinc Plated
Assy, Drve Shft, Civic, Pin Dr
Tube HSG Asy, 99 Civic, Pin Dr
Housing, Coupling, Ext Drive SC
Housing, Coupling, Ext Drive SH
Coupling, Flg, 3-Pin Drive
Dowel Pin, Ø1/4” x 1.25” L
DESC
QTY
7B375-075
7J375-020
7U100-070
2D070-260
7A312-550
7U312-125
3/8-24 x 3/4” GR8 HXHD Bolt
Washer, 1.0 OD, .406 ID
Key, 3/16” Square x 7/8” Long
Coupling, Drive, Composite
5/16-18 x 5.50 SHCS Zinc
Dowel Bushing, .312 x 1.25”
3
2
2
1
4
2
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
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
FUEL PUMP, ’99-’00 HONDA
8F101-310
Fuel Pump Rail Assy, Honda
5W001-019
12-10 GA Solderless Connector
5W001-014
5W001-015
5W001-042
12-10 GA 3/16” Ring Terminal
5W001-001
16-14 Wire Tap
5W001-011
16-14 GA Eyelet .25” Hole
8F010-110
Fuel Pump Hangar
7E010-075
#12 x 3/4” Sheet Metal Screw
7U314-001
#8 Lord Mount
7F008-032
8-32 Hex Lock Nut
7J008-001
#8 Flat Washer
8F001-200
Corvette Fuel Pump 200 in Line 3/8”
008340 Fuel Pump Decal, T-Rex
7P312-008
T-Rex - 5/16 Barb
7U031-018
5/16 Fuel Hose High Press
7R001-004
#4 Hose Clamp
7P312-005
5/16 Fem Fuel Steel
7P312-007
5/16 Male Fuel Al.
7U100-044
7U100-055
5W001-021
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
1
2
2
2
1
1
1
2
vii
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
P/N: 4HC020-010
1999-2000 HONDA CIVIC Si H.O., cont’d.
PARTS LIST
PART #
DESC
8N301-090
QTY
PWRCLR ASSY, ’99-’00 HONDA 1.6 DOHC
4HC112-030
AIR DISCHARGE ASSY,
’99-’00 HONDA AFTERCOOLER
7S275-200
2-3/4 x 2 Sleeve
7R002-044
#44 Goldseal Hose Clp
7S275-251
2.75- 2.5 I.D. Sleeve
7R002-040
#40 Stnls Hose Clp
7P100-100
1” NPT x 1” Barb Plastic Fitting
PART #
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
QTY
4HC112-010
AIR INTAKE ASSY, ’99-’00 HONDA
4HC012-011 3-1/2” 90 Plastic Elbow
4FA012-011 3-1/2” 90 Plastic Elbow
8D001-001Bypass Valve
7P750-100
1” Barb to 3/4 NPT Plastic Fitting
7U034-016
1” GS Hose
7U034-016
1” GS Hose
7U030-046
5/32” Vacuum Line
7P156-082
5/32 TEE
7R002-016
#16 Hose Clamp
7U035-001
“3-1/2” Flex Hose
7R002-052
7S350-200
3-1/2 x 2 Sleeve
7R002-056
7U100-061
7P375-008
Elbow Union Eub
7U030-056
3/8 PCV Hose
5W001-012 18-22 GA Butt Connectors
5W022-030 Wire, Red 22
5W022-040 Wire, Green 22
8H040-040
Air Filter
1
1
3
1
1
1
8N101-090
P/N: 4HC020-010
DESC
1
viii
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 re-attach 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.
3/4”
1”
Fig. 3-a
Note: This method of rolling over the lip of
the hole and tapping it works very well
if carefully done and should cause no
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.
OIL DRAIN
TUBE
E.
4.
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
2
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 subframe.
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
ATTACH TO MANIFOLD VACUUM
FUEL PRESSURE REGULATOR
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 INSTALLATION
A. Remove the top four transmission-to-bell housing
bolts and the bracket that the ground strap is attached to.
B. Remove the bracket and grommet securing the top
of the radiator to the vehicle. Install the supplied
bracket and original grommet in the original bracket.
(See Fig. 10-a.)
C. Install the supplied 8mm stud with a .70” spacer in
the rear most hole.
D. 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.
E.
NOTE: The lower radiator hose should be routed on
the engine side of the mounting plate.
Fig. 10-a
Remove the 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.
7
P/N: 4HC020-010
10. SUPERCHARGER INSTALLATION, cont’d.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
Install into the supercharger gear case the supplied
Ø5/16 x 1.25” alignment dowels. (Slight heating of
the gear case may be necessary to make the installation of the dowel pins easier.)
Align the four hole pattern on the mounting bracket
making sure that the larger diameter holes are
aligned with the alignment dowels. (See Fig. 10‑b.)
Tap the mounting plate so that the mounting plate
is flush with the gear case and the alignment dowels
are running through the plate.
Align the counter bores in the black coupler housing with the alignment dowels passing through the
mounting plate. Lightly tap the housing until it is
flush with the mounting bracket (See Fig. 10-c.)
Loosely insert the three 12mm bolts through the
washers and the mounting plate into the supercharger. Do not tighten. (See Fig. 10-c.)
Apply a thin layer of grease on the inside diameter
of the steel supercharger drive coupling containing
three Ø1/4” dowel pins. Install the supplied key and
drive coupling onto the supercharger input shaft.
Heat may also be necessary to install the coupling
onto the shaft. (A propane torch will make this easier
if needed.) Verify the coupling is bottomed out on
the shaft. Secure the coupling with the supplied
Ø1.0” washer and 3/8-24 x .75” HXHD screw. Use a
light thread-lock compound. (See Fig. 10-c.)
Install the supplied composite ring onto the threepin coupler located on the supercharger input shaft.
(See Fig. 10-d.)
Lower the supercharger and mounting plate into
the engine compartment. Align the four lower
holes in the mounting plate with the four holes in
the transmission bell housing while aligning the
six-hole composite ring on the supercharger with
the three-pin coupling on the installed drive shaft
assembly. Connect them together. Verify that each
set of pins is inserted into the raised bosses on their
corresponding side of the composite ring. Align the
holes so that one side of the pins alternate with
the opposite side of pins. Slide the two assemblies
together until a positive stop is felt and the couplers
are flush with the composite drive coupling ring.
(See Fig. 10-e, 10-f.)
With the mounting plate positioned on the transmission, install each of the three supplied 8mm bolts
through a washer, the mounting plate and a spacer.
Note the spacer thickness. The two .85” spacers go
on the front two bolts while the two .70” spacers
go on the rear bolt and stud. (The spacers must be
installed between the bellhousing and the mounting plate.) Do not tighten.
Loosely install the supplied 8mm nut and washer
onto the stud.
Align the black anodized coupler housings and se-
ALIGNMENT DOWELS
Fig. 10-b
DRIVE
COUPLING
12mm SCREWS
COUPLER
HOUSING
Fig. 10-c
COMPOSITE RING
Fig. 10-d
PINS ALIGN
INTO HOLES
WITH RAISED
BOSSES
Fig. 10-e
P/N: 4HC020-010
8
cure them to the supercharger gear case using the
supplied 5/16-18 x 5.5” HXHD screws with washers.
Snug the screws at this time.
Fig. 10-f
OIL FILTER FEED
(7P375-095)
1/8 NPT MALE
90° (7P125-111)
1/8 NPT TO 1/4"
HOSE BARB 90°
(7P125-037)
FROM
SUPERCHARGER
VOLUTE
DISCHARGE
FILTERED ENGINE OIL
3/8" COPPER
WASHER
(7J375-024)
2 PLACES
FLOW
1/4" I.D.
HOSE
AIR CHECK VALVE
(7P125-110)
V-2 AIR ASSIST
ADAPTER
TO SUPERCHARGER
(7P375-105) GEARCASE OIL FEED
14.5
STEPLESS
CLAMP
1/8 NPT TO 1/4" HOSE (7R004-003)
2 PLACES
BARB (7P125-036)
V-5 HONDA AIR ASSIST ASSEMBLY
Fig. 10-g
Fig. 10-h
Fig. 10-i
9
P/N: 4HC020-010
N. Tighten the supplied 8mm screws securing the
mounting plate to the engine.
O. Tighten the 12mm bolts running through the mounting plate.
P. Route the free end of the oil feed hose to the supercharger and attach. The oil feed assembly should be
checked/plumbed per Fig. 10-g.
Q. 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.
R. Tighten the oil drain tube nut in the oil pan fitting.
Tighten the oil drain hose clamp.
S. Provide 1/2” clearance from the supercharger to the
radiator fan support by cutting the support. A small
bladed saw such as a hacksaw blade works well for
this step. (See Fig. 10-i.)
For non-aftercooled, standard supercharger kit installation, skip step 11
and proceed with step 12.
11. AFTERCOOLER INSTALLATION
A. Reservoir Installation
1.
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. 11-a and 11-b. Use the supplied washer
on each side.
2.
Using the reservoir mounting bracket as a template, drill a 1/4” hole and insert and tighten
the third mounting bolt.
3.
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.
4.Bolt the reservoir mounting bracket to the reservoir using 1/2” long bolts. (See Fig. 11‑d.)
5.
Remove the passenger side turn signal wires
from the grommet in the fender well. Re-route
them around the front of the fender well and
re-attach.
6.
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. 11-i for system
plumbing).
Fig. 11-a / Air filter and elbow
shown will be installed later
Fig. 11-b / Air filter and elbow
shown will be installed later
P/N: 4HC020-010
10
11. 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. 11-c.
8.
Install clamps on each end of the hose mender
installed in step 11-A-6.
Fig. 11-c
Fig. 11-d
Fig. 11-e
11
P/N: 4HC020-010
B. Aftercooler Water Pump Wiring And Installation
1.
Mount the aftercooler pump relay in the location shown in Fig. 11-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. 11-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. 11-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. 11-f
(+) WATER PUMP
(GREEN WIRE ON
HELLA PUMP)
86
87
87A
GROUND
85
TO BLACK WIRE
WITH YELLOW
STRIPE FROM
COIL
30
12 VOLT (+)
RELAY
Fig. 11-g
P/N: 4HC020-010
12
C. Water Cooler Installation
1.
Using the supplied hardware, loosely attach
one supplied bracket to each side of the water
cooler as per Fig. 11-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. 11-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:
4.
5.
6.
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 con-
Fig. 11-h
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.
13
P/N: 4HC020-010
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)
COOLED CHARGE AIR
TO TEE INSERTED IN RADIATOR OVERFLOW
HOSE NEAR RESERVOIR CAP
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
SURGE TANK
(8N156-050)
ER
OW
FL
AT
W
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)
1/2" SOCKET HEAD CAP
SCREW (7A250-050)
SUPERCHARGER
DISCHARGE
3/4" HOSE (7U038-000)
CUT TO FIT 3 PLACES
WATER
RESERVOIR
MOUNTING
BRACKET
(4HC010-110)
HONDA WATER COOLER
MOUNTING
BRACKET (4HC010-100)
WATER
RESERVOIR
(8N055-030)
1" NPT HOLE NOT
USED. HOLE SHOULD
BE BLIND OR PLUGGED
TOP OF TANK
WATER COOLER
(8N006-010)
90° MOLDED HOSE ELBOW
(7U030-065 (CONNECTS
FITTING ON BOTTOM OF
TANK TO INLET OF WATER PUMP)
WATER
PUMP
CLAMP
(8N010-080)
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. 11-i
P/N: 4HC020-010
14
E.
Surge Tank Installation
1.
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.
2.Bolt the surge tank mounting tab to the surge
tank using the supplied 1/4-20 x 1/2” bolts and
washers.
3.
Connect the hose from the top of the reservoir
to the bottom of the surge tank and secure
with nylon clamp.
4.
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.
5.Bolt surge tank to passenger side strut tower
using the supplied 6mm bolt and washer. (see
Fig. 11-j)
6.
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.
7.
Remove the cap from the surge tank and fill
the system with 25% coolant/75% water mix.
Fig. 11-j
FOR AFTERCOOLED SUPERCHARGER KIT INSTALLATION,
SKIP STEP 12 AND PROCEED TO STEP 13.
12.
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.
13.
THROTTLE
BODY
STANDARD KIT DISCHARGE DUCT INSTALLATION
BYPASS
VALVE
Fig. 12-a / Std discharge
duct orientation
SUPERCHARGER
DISCHARGE
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. 13-a).
Fig. 13-a / Aftercooled bypass valve
installed (standard kit similar)
15
P/N: 4HC020-010
13.
AIR INLET DUCT INSTALLATION, cont’d.
B. Install the supplied air filter on the remaining 90°
elbow (does not have any drilled holes). (See Fig.
13-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.
13-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. 13-b / Aftercooler water tank not
shown for clarity
NOTE: Do not attempt to operate nonaftercooled vehicles without the inlet
restrictor installed. The vehicle may
detonate on pump gas.
Fig. 13-c / Standard kit inlet
restrictor installation
14.BYPASS VALVE INSTALLATION
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.
P/N: 4HC020-010
16
Fig. 14-a
15.
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. 15-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. 15-c.)
F. Install the grooved idler pulley onto the machined
idler stud. Using thread-locker, tighten the 5/16”nut
and washer. (See Fig. 15-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. 15-c).
Fig. 15-a
Fig. 15-b
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.
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. 15-c
17
P/N: 4HC020-010
16.
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. 16-a). Rotate the 90° fitting for
the best hose routing and tighten fitting (see Fig.
16-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. 16-a
Caution:The Honda Shop Manual recom-
mends using only Honda Power Steering Fluid -V or S as any other fluid can cause poor performance and increased wear.
Fig. 16-b
17.
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.
P/N: 4HC020-010
18
17.
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.
19
Fig. 17-a / Aftercooled kit
Fig. 17-b / Standard kit
P/N: 4HC020-010
®
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

1999-2000 Honda Civic Si

Transcription

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