Installation Instructions

Installation Instructions
Supercharger System
2002-3 Acura RSX-S
Race System Part #989-552 (not legal in California for use upon a highway)
440 Rutherford St. P.O. Box 847 Goleta, CA 93116
1-888-888-4079 • FAX 805-692-2523 • www.jacksonracing.com
1. SPECIAL NOTE:. If you do not have a shop
manual, buy one now! It is good to have
for any repairs now and in the future.
7. If the vehicle has over 15,000 miles on the
fuel filter, a new fuel filter will be required. A
new fuel filter is available at your local Honda
dealer. Always use genuine Honda parts.
2. TOOLS NEEDED: 10, 12, 13 (1/2”), 14, 17,
19mm socket and wrenches, phillips and
straight blade screwdrivers. A good soldering
devise and solder. Most of these tools are
available at your local hardware or auto parts
store.
8. VERY IMPORTANT! Remove negative battery cable. If you have a coded alarm on your
radio, retrieve the code before removing the
negative cable.
3. IF YOU ARE NOT A COMPETENT
MECHANIC, DO NOT ATTEMPT THIS
INSTALLATION!!
9. Put your car on jack stands. Never work
under a car that is not supported by jackstands or ramps.
4. READ THESE INSTRUCTIONS THOROUGHLY! Follow the instructions STEP-BYSTEP, and your installation will be trouble free.
If in doubt, CALL!! It is also suggested that as
you proceed through the installation you read
a few steps ahead so that you are sure to
catch all notes and hints.
REMOVAL OF STOCK PARTS
10. Remove your ECU & Immobilizer:
Remove the lower dash trim panel from below
the glove box. Remove the ECU assembly.
Remove the plastic trim panel from around the
steering column and remove the immobilizer
assembly from the ignition switch area.
Package the ECU, Immobilizer, Main Ignition
Key, and completed JR warranty card in the
enclosed shipping box with the Hondata label.
Ship complete box to Hondata. We suggest
using UPS or Fed Ex overnight delivery.
5. During this installation process, you will
reuse some parts or hardware and not reinstall others. It is recommended that you make
a space or box for those that you will reuse
and a separate space or box for those you will
not reinstall. In addition, you should save the
parts that will not get reused in case you ever
have reason to convert the engine back to
stock.
11. Remove the “IVTEC” plastic cover. Unplug
the Air Temperature (T/A) sensor harness from
the T/A sensor on the intake rubber hose. The
wire colors are green with a yellow stripe and
red with a yellow stripe.
6. Enclosed are a set of labels that we suggest
you use to label the electrical connectors that
you will be unplugging.
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Revised 10-2-03 REV 3
Supercharger Installation Instructions
remove the assembly from the car.
Air Injection Hose
15. Unplug the four electronic control plugs
from the throttle body. Apply labels to these
wiring harness plugs as you remove them.
The top plug nearest the valve cover is the
MAP (Manifold Absolute Pressure) sensor.
The MAP wire colors are Yellow/Red,
Green/Red, and Green/White. The solenoid
next to the MAP sensor is the Evap Solenoid
(Evaporative Control Solenoid). The wire colors for the Evap Solenoid are Yellow/Blue and
Black/Yellow. The plug on the front side of the
throttle body near the radiator is your TPS
(Throttle Position Sensor). The wire colors for
the TPS are Yellow/Blue, Green/Yellow, and
Red/Black. And lastly, the control on the bottom of your Throttle Body is the IAC (Idle Air
Control) valve. It is protected by a rubber boot.
Purge Valve Hose
Illustration 1
Power Brake Hose
12. Now, remove the large diameter rubber
hose between the air box and throttle body.
Loosen the clamp at the throttle body with a
Phillips head screwdriver and slide it off.
Illustration 2
13. Remove the valve cover vent hose from
the airbox. Remove the smaller hose the runs
from the Thermal valve near the head, to the
rubber intake hose. This is your Intake Air
Bypass Control or “Air Injection” supply hose.
It will be reconnected to the rubber intake
hose when the supercharger installation is
complete.
16. Unbolt the throttle body by removing the
two 12mm hex headed bolts and two nuts.
The bolts and nuts will not be reused. Pull the
throttle cables out of the retainer brackets on
the intake manifold and the Power Steering
pump and lay the the assembly out of the way.
17. Remove the two coolant hoses from the
Throttle Body. Be prepared for a small amount
of coolant to come out of the hoses. Install a
14. Remove the air box retaining bolts and
Purge Valve
MAP Sensor
Coolant Hoses
TPS Sensor
Coolant Ports
Illustration 3
Illustration 2
989-550 / 989-552
IAC Valve
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Revised 10-2-03 REV 3
Supercharger Installation Instructions
bolt or plug into the hoses to keep them from
leaking any large amounts of coolant.
instruction.
23. Push the two fuel hose retainer clips
inward and pull the fuel supply hose off of the
fuel rail. Always wear protective glasses as the
fuel system could still have pressure in the
hose.
Illustration 3
18. Disconnect the power brake hose from the
intake manifold. Illustration 1
19. Disconnect the Intake Air Bypass Control
(Air Injection) hose and Purge Valve hose from
the intake manifold and throttle body.
24. Remove the two 12mm headed nuts that
hold the fuel rail to the intake manifold.
Remove the fuel injectors and the rail as an
assembly and set aside on a clean towel.
Save your stock injectors and two phenolic
spacers. They will be replaced with high flow
injectors and thicker spacers.
Illustration 1
20. Disconnect the fuel injector harness from
the injectors and unbolt the ground lead on the
intake manifold. Unbolt the harness support
bracket near the front of the intake manifold
and lay the harness out of the way.
25. We now move under the car. Remove the
front lower splash shield to gain access to the
lower engine area. Remove the two lower
intake manifold support bracket bolts. Remove
the small clips that hold the fuel injector harness to the small support bracket. Remove the
upper bolt and complete support bracket from
the passenger side of the intake manifold. The
support on the intake manifold nearest the
transmission does not have to be removed
from the intake manifold. It can remain
attached to the intake manifold and will come
out of the engine compartment as an assembly.
21. Remove the small 90-degree PCV hose
from the intake manifold, near the power
steering pump, and from the PCV valve on the
engine. This hose will be replace with a longer
hose during the installation of the supercharg-
Illustration 4
26. From the top of the engine compartment,
remove intake manifold bolts and nuts. You
will need to remove the two intake manifold
studs before the intake manifold will come out
of the engine bay. You can remove the studs
using the “double nut” process or by using a
stud removal tool. The factory intake manifold
and hardware will not be reinstalled.
PCV Hose
er. You will be using one of the spring clamps
during the installation on the Air Injection
hose.
27. With the intake manifold removed perform
the following operations:
22. You will be working with the fuel system at
this point. Do not smoke or use fire or flame for
any reason while performing this procedure.
Remove the gas cap to relieve any fuel pressure then reinstall before moving to the next
989-550 / 989-552
28. With the drive belt still in place, loosen the
19mm nut holding the Power Steering pulley
on the power steering pump. You will be
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Revised 10-2-03 REV 3
Supercharger Installation Instructions
installing a new pulley later in the instructions.
Remove the throttle cable bracket from the top
of the power steering pump. It will not be
reused.
29. Loosen the spring loaded drive belt tensioner and remove the drive belt from the car.
It will not be reused.
engine is mounted in rubber and moves a lot.
Using a pair of cutters or a grinder, remove
these two tabs This will not harm the headlight
adjuster. Illustration 6
32. Remove the three, 17mm motor mount
fasteners and ground cable and remove the
passenger side motor mount. A floor jack will
be needed to move the engine while the
30. Remove the power steering pump
RESERVOIR from the bracket on the front of
the core support near the passenger side
headlight. Do not disconnect any hoses from
the power steering pump.
30. Remove the 10mm hex bolt that holds the
bracket to the core support. Bend the locator
tab horizontal (flat) and relocate the bracket
over to the next available hole (rearward 1”) in
the core support. Reattach the bracket using
the original bolt through the large existing hole
in the core support. Complete the installation
by installing a large O.D. fender washer and
flanged nut, supplied with your kit, to the bottom of the core support. Illustration 5
31. You will find two tabs on the back of the
passenger side headlight. These tabs are
Headlight Tabs
Illustration 6
mount is off.
33. Remove the two 12mm headed Power
Steering bolts and lift the power steering pump
out of the way. Remove the Power Steering
pulley and install the newly supplied Jackson
Racing Power Steering Pulley.
34. Jack the engine up slightly and remove the
automatic belt tensioner from the support
bracket. This tensioner and its (3) mounting
bolts will not be reused.
35. Remove the three alternator mounting
bolts, wiring, and small wire support bracket
and remove the alternator. The (3) mounting
bolts, wire support bracket, and the nut that
held it in place will not be reused.
Illustration 5
used to help guide a screwdriver into the
headlight adjuster. But these tabs can make
contact with our supercharger belt drive
assembly under extreme conditions as the
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36. This next step is easier to perform if you
jack the engine up slightly off of the lower subframe. From under the car, remove the (4) airconditioning compressor mounting bolts. You
will not be reusing the bottom mounting bolts.
Revised 10-2-03 REV 3
Supercharger Installation Instructions
Install the original upper mounting bolts in the
bottom A/C mounting holes. Install the (2) .5”
mounting spacers in between the A/C compressor and the lower A/C compressor mount.
Install (2) new 8 x 90mm upper bolts, with flat
and lock washers, through the A/C compressor and loosely thread them into the upper
mount. Drop the new A/C spacer plate with the
two cutaways onto these two new bolts.
Tighten all A/C mounting bolts at this time.
towards the hood latch. This hose will be connected to the top of the inlet casting at a later
37. Install the new lower alternator mounting
plate onto the original lower alternator mount
using (2) 8 x 20mm Allen head bolts. Install
this bracket so that the threaded holes of the
bracket are below the Allen head bolts.
Illustration 8
Illustration 7
Upper
Alternator
Mount
time. Clamp this hose with a “worm gear”
clamp provide in the kit.
40. Check the starter lead and rotate, if necessary, to a horizontal position below the
water pipe. Remove the small wiring support
bracket from the end of the starter. This will
allow clearance for the supercharger intake
Lower
Alternator
Mount
Illustration 7
38. Install the new upper alternator mount in
much the same way using an 8 x 40 Allen
head bolt. You will need to remove the 14mm
hex head bolt next to this mounting point first.
Install the small bracket with the threaded
area below the Allen head bolt. Reinstall the
alternator in its new location using a new 8 x
85mm upper mounting bolt with flat and lock
washers and two new 8 x 40mm lower bolts.
All hardware is supplied with the kit. Reattach
the wiring to the alternator. Illustration 8
39. Route a new 3/8” x 30” PCV hose from the
PCV valve across the front of the radiator area
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Illustration 9
manifold. If there is not clearance between the
manifold and starter lead and they touch significant damage to your engine, car or wire
harness could result. If you have milled your
cylinder head for racing this casting boss may
need to be ground down to allow clearance for
the supercharger intake manifold.Illustration
9
41. Install the new Jackson Racing
Supercharger intake manifold/supercharger
assembly and intake gasket at this time. The
Revised 10-2-03 REV 3
Supercharger Installation Instructions
long mounting bolts were installed in the
intake manifold when it was shipped to you.
But, just for reference, the long mounting bolts
will be an 8 x 75mm. The other two mounting
bolts will be 8 x 25mm. Torque all bolts to 16
foot pounds starting with the center lower bolt
and working outward in a circular pattern.
PS Spacer
42. Install a new 8 x 65mm bolt through the
P/S Mount
PCV Hose
Illustration 11
46. Thread the new Jackson Racing Power
Steering spacer, with the thick end onto the
mount, onto the 8 x 65 bolt and tighten
bolt/Power Steering pump/spacer assembly.
Illustration 11
Illustration 10
Alternator Spacer
new power steer mount. It will come from the
intake manifold side and point towards the
passenger side fender.
43. Install the new Jackson Racing Power
Steering/Tensioner mount to the original location for the automatic tensioner using three 8
x 30mm supplied. Illustration 10
44. Reinstall the motor mount at this time.
Reconnect the ground strap to the motor
mount at this time. You may have to rotate the
ground wire at the mount once you install the
belt drive assembly as the adjuster bolt travels
near the ground strap.
45. Install the Power Steering pump onto this
8 x 65mm bolt. Using the original lower mounting bolt, reattach the lower Power Steering
mount to the new tensioner mount.
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47. Install the 7 rib x 78.6” belt supplied in the
kit. Install the belt so that it travels from the top
of the crank pulley up to the power steering
pulley. From there it travels down to the supercharger pulley. It then travels down to the
alternator. Leave a large loop inward at this
point between the supercharger and the alternator and the point just under the power steering pulley. This is where the idlers will hold the
belt. From the alternator pulley it will turn back
towards the rear of the car and around the
water pump. From there it travels forward and
down to the air conditioning compressor and
then back to the crankshaft. Illustration 11
48. Find the shorter of the two billet aluminum
tensioner “scissors” brackets. It is called a
“scissors” bracket because the brackets slide
across each other like a pair of “scissors”. It
should have an adjuster bolt pivot held in
place by a 10mm-headed bolt on one side.
Install this “scissors” bracket to the Power
Revised 10-2-03 REV 3
Supercharger Installation Instructions
Steering/Tensioner mount while looping the
drive belt in front of the idler pulley. Loosely
install an 8 x 30mm bolt through the top hole
of the short bracket and thread it into the
upper spacer. Install the “scissors” bracket
using a 10 x 45mm countersunk bolt and
thread it into the lower boss on the Power
Steering/Tensioner mount. Be sure the drive
belt is in front and around the idler before tightening the 10 x 45mm bolt. Tighten using the
allen wrench provided with the kit.
49. Remove the previously installed 8 x 30mm
bolt from the top pivot point of the shorter of
the two tensioner “scissors” brackets. Pull the
drive belt up so that it is completely around all
the other pulleys. Pull all the excess belt into a
loop under the supercharger pulley and back
towards the other idler, above the alternator.
Install the longer of the two “scissors” brackets, with a 2” idler bolted in place, in front of
this loop. You will have to work the pulley/belt
arrangement into place between the alternator
8x30 Bolt
8x60 Bolt
Illustration 12
8x20 Bolt
and supercharger pulleys. Once the bracket
with idler are in front of the loop of belt, install
the bracket over the short bracket and reinstall
the 8 x 30mm bolt through the two mounting
plates and into the upper Power Steering
989-552
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pump spacer. Be sure the loop of drive belt is
in front of the 2” idler.
50. Install an 8 x 60mm bolt through the
adjuster bolt pivot and thread it into the threaded pivot of the longer “scissors” bracket. Install
a 8 x 20mm flanged bolt through the slot in the
outer “scissors” bracket and into the inner
“scissors” bracket. Illustration 12
51. Make sure the belt is correctly aligned on
the ribs and pulleys.
52. Adjust the alternator belt tension by loosening 8x30mm (12mm hex) upper pivot and
the 8x20mm (12mm hex) idler pinch bolt on
the outer scissor plate and adjusting with the
8x60mm (12mm hex) tensioner bolt. Tighten
until 45 lbs of belt tension is available. Further
belt tensioning will be required after the installation of your ECU upgrade.
53. Do not over tighten the belt as it will create
excess load on the idler bearings and shorten
belt life. But proper belt tension is vital during
the break-in period for this long belt. Always
check the belt tension from the longest “run” of
the belt between the crankshaft and the air
conditioning or between the crankshaft and
the power steering pump.
54. From under the car attach the new
Jackson Racing Intake manifold support
bracket from the original mounting position to
the mounting tab on the bottom of the intake
manifold. IMPORTANT!! - The 4 bolts holding the bracket on the bottom of the intake
manifold are only finger tight. Once everything is aligned remove each bolt individually, apply red loctite, and reinsert torqueing to 15 ft-lbs. Failure to do so could
result in the lose of these bolts and/or a
vacuum leak. There are two mounting blocks
that attach to the engine block. These mounting blocks will triangulate to the block and give
Revised 10-2-03 REV 3
Supercharger Installation Instructions
secure the fuel rail to the intake manifold in an
even pattern and torque to 12 ft lbs.
57. Reconnect the fuel supply hose to the fuel
rail fitting.
58. Reinstall the fuel injector wiring harness
onto the fuel injectors and reattach the ground
lead using a new 6x10mm ground bolt.
59. Reinstall the Intake Air Bypass Control (Air
Injection) hose from the thermal valve to the
fitting on the intake manifold near the valve
cover. Install one of the original spring clamps
from the PCV hose onto this “ABC” hose as it
did not have a clamp originally. But this hose
will see boost now and must have a clamp on
it.
60. Install a new Jackson Racing spacer to the
IAC valve on the bottom of the throttle body.
Remove the two Phillips screws and install the
spacer and gasket using the new 5 x 35mm
screws provided with the kit. Leave the original rubber gasket attached to the throttle body.
Illustration 13
better support to the intake manifold/supercharger assembly. You will be using an 8 x
40mm and a 10 x 40mm flanged bolt for the
lower mounting blocks and an 8 x 25mm bolt
and 8mm flanged nut for the upper mount.
Illustration 13
56. Reinstall the lower splash shield at this
time.
55. Install the high flow fuel injectors, into the
fuel rail and then install this complete assembly into the supercharger intake manifold. Be
sure to grease all seals before installation.
56. Install the two new thicker (.66”) phenolic
spacers and two new 8 x 35mm bolts to hold
the fuel rail to the intake manifold. Note: Be
VERY careful not to knock anything into the
fuel injector holes! Tighten the two bolts that
989-552
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61. Reconnect the Manifold Absolute Pressure
(MAP), Throttle Position Sensor (TPS) sensor,
Evap solenoid, and IAC valves. Check the
color-codes for proper connections.
62. Install the Throttle Body onto the new
Jackson Racing inlet casting using four new 8
x 35mm bolts. Check for full throttle and that
the throttle returns to the closed position. If
you have installed the Stage 1 Race Kit injectors they will move the fuel rail slightly from the
stock location. Using a pair of pliers, you will
need to gently bend the fuel inlet pipe slightly
to clear the throttle cables. Double check your
throttle and make sure it opens completely
and closes completely without any interference. Route the throttle cables over the top of
the valve cover, back towards the firewall, and
then forward onto the throttle body. They will
Revised 10-2-03 REV 3
Supercharger Installation Instructions
end up making a lazy “S” shape across the
valve cover. Make sure the throttle cables do
not make contact with any pulleys or belts.
Power Brake Hose
63. You will be installing a MAP Sensor spacer in the throttle body at this time. Remove the
phillips head screw and the MAP sensor from
the throttle body. Install the MAP sensor spacer with O ring into the throttle body. Reinstall
PCV Hose
Bypass Hose
Illustration 14
nect it to the small fitting next to the Power
Brake hose.
the MAP sensor into the spacer and complete
by installing a new 5mm screw through the
MAP sensor and spacer and thread it into the
throttle body. You will then connect a short
piece of vacuum hose from the spacer vacuum fitting to one of the vacuum nipples near
the fuel rail.
68. From the front of the car looking at the
engine compartment you will find the power
steering hose mounted to a large bracket at
the rear of the valve cover. Remove the 10mm
hex bolt and clamp on the right side of the
64. Reconnect the two coolant hoses to the
bottom of the throttle body.
65. Get the new hose that was routed from the
PCV valve along the front of the car. Connect
it to the inlet fitting on the top of the throttle
body inlet manifold. Illustration 14
66. Reconnect the Power Brake hose to the
fitting next to the PCV hose on the inlet casting.
Illustration 14
67. Route the new vacuum hose from the
bypass valve up to the inlet casting and con989-552
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New P/S Hose
Clamp location
Old P/S Hose
Clamp location
Illustration 15
mounting bracket. Carefully cut across the
grommet that is glued to the hose at this point
and remove the clamp grommet. Lift the
power steering hose from the main support
bracket and remove the main support bracket
from the passenger side of the valve cover.
Revised 10-2-03 REV 3
Supercharger Installation Instructions
Referring to the illustration, reinstall the grommet around the power steering hose near the
passenger side rear corner of the valve cover.
Install the previously removed round clamp
around this grommet and attach it using a .45”
spacer and 6x25mm bolt to the passenger
side rear corner of the valve cover in one of
the threaded holes already existing in the
valve cover. Illustration 15
69. Reinstall the airbox assembly and reconnect the air temperature sensor.
70. Reattach the negative ground to the negative battery terminal.
71. Reinstall your ECU and Immobilizer. Once
complete start your engine.
80. Recheck your fluid levels after you have
warmed the engine and let the engine cool
down.
RETENSION YOUR BELT AGAIN AT THIS
TIME. START YOUR RSX AND LET IT RUN
FOR 30 SECONDS. SHUT IT OFF AND
RETENSION THE BELT AGAIN. THIS SCENARIO SHOULD BE REPEATED 4 TIMES
TOTAL. THIS PROCEDURE WILL ALLOW
THE TENSION TO AVERAGE OUT OVER
THE WHOLE BELT RUN NOT JUST IN THE
AREA YOU ARE TENSIONING. THIS PROCEDURE WILL NEED TO BE FOLLOWED
WHEN A NEW BELT IS INSTALLED.
RECHECK THE BELT TENSION AT REGULAR INTERVALS FOR THE FIRST 100
MILES AS THE BELT WILL STRETCH DURING THIS PERIOD. THE BELT IS LIKE A
RUBBER BAND. A SHORT RUBBER BAND
DOES NOT STRETCH MUCH. BUT A LONG
RUBBER BAND WILL. THIS WIDE, LONG
BELT WILL STRETCH AND WILL REQUIRE
TENSION ADJUSTMENTS UNTIL IT STOPS
STRETCHING.
TIPS: Now that you have added substantial
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power to your RSX, here are some tips for
best performance, long life, and of course
more power.
Please, allow it to warm up for at least 3-5
miles before you start working the engine
hard. Longer in extremely cold conditions as it
will take a substantial amount of time to get
the oil warmed completely to operating temperature. Running an engine without the oil
being up to operating temperature is very hard
on your engine.
Installing a high performance intake will
improve air volume. In supercharged engines,
the easier the air flows in, the better power it
will make. The one thing you do not want to do
is make the supercharger have to pull hard to
get air.
Although the stock exhaust system is very
good, the Jackson Racing header and a good
cat-back system will help relieve any backpressure. In tests conducted by leading magazines the Jackson Racing Header (see
details and dyno on following page) made a
gain of 16 horsepower over the stock header
on average. The cleaner the exhaust gets out
of the engine, the better the good air will get
in. Keep in mind, in a supercharged engine, as
the air gets through the engine better, the
boost, in some cases, will actually go DOWN,
but the power will go UP! So, don’t be surprised if you start improving the intake air and
exhaust system and your boost actually starts
reading slightly lower than it did when it was all
stock.
Keep your cooling system in good shape.
Never run more than 50% anti-freeze coolant
to water ratio in the engine, if possible. Water
cools better than coolant but does not have
the high resistance to boiling or ability to resist
freezing. So, you must keep SOME antifreeze coolant in the engine. But try and run as
little as possible. It will keep the operating temperature lower allowing better power and
Revised 10-2-03 REV 3
Supercharger Installation Instructions
resistance to detonation.
If you have purchased our base RSX
Supercharger system we highly recommend
having the Jackson Racing/Hondata Stage 1
performance upgrade performed on your
stock ECU. See details and dyno on following
page.
Do not run a high performance camshaft with
a supercharger. Most high performance
camshafts depend on having both intake and
exhaust valves open at the same time to help
fill the cylinders. This, also, is counterproductive to superchargers. Anytime that both
valves are open at the same time the boost
goes out the exhaust port.
989-552
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Revised 10-2-03 REV 3
Supercharger Installation Instructions
RSX-S RACE HEADER
Part # 989-551
Superbike technology brought to the street! Jackson Racing
and Jardine Performance Products (Official supplier of
exhausts to Honda Racing's Superbike Team) have teamed
up to bring you the highest quality, most powerful exhaust
header for the RSX type S. Includes test pipe, hardware and
instructions. Not CARB exempt.
Features Include:
• Complete Stainless construction throughout including
CNC milled flanges
• 16 gauge US made Stainless steel tubing Tig welding
inside and outside of exhaust ports
• 4 phase tapered Primary tubes for high velocity
• True merged collector Significant horsepower and torque
gains throughout the powerband
Run 39 – All Stock -160 HP
Run 44 – DC Cold Air, DC Header (CARB Approved), DC Exhaust -173.9 HP
Run 45 – JR Race Header, DC Cold Air, DC Exhaust – 189.2 HP
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Revised 10-2-03 REV 3