INSTALLATION MANUAL 6.1L SUPERCHARGER

 3.0L Reverse Revolution Twin Screw Supercharger INSTALLATION MANUAL: 2005‐2009 5.7L & 6.1L Dodge Charger, Challenger, Magnum, and Chrysler 300C Supercharger P/N: 004Z‐A05‐C001338‐A Page 1 of 101 Techco 3125 E. Coronado St, Anaheim, CA 92806 (714) 408‐9550 www.techcointl.com IF YOU ARE NOT EXPERIENCED IN THE AREA OF AUTOMOTIVE MECHANICS, WE STRONGLY ENCOURAGE YOU TO SEEK A CERTIFIED INSTALLATION CENTER OR AUTOMOTIVE MECHANIC FOR THE INSTALLATION OF THIS PRODUCT
Page 2 of 101 3.0L Reverse Revolution Twin Screw Supercharger Installation Manual for the 2005‐2009 5.7L & 6.1L Dodge Charger, Challenger, Magnum, and Chrysler 300C Supercharger We here at Techco would like to thank you for your purchase of the 3.0L Reverse Revolution Twin Screw Supercharger for the 2005‐2009 Dodge Charger, Challenger, Magnum, and Chrysler 300C with a 5.7L or 6.1L Engine. A lot of passion goes into each one of our products and we appreciate your business and hope you thoroughly enjoy your purchase. For your benefit please read this manual completely through before you start any work in order to familiarize yourself with the installation process of your Supercharger. Once you have read the installation manual please proceed to follow these step by step instructions for a fully functional product. Most of the questions that may come up should be answered in this manual; however, more questions may arise so please do not hesitate to call Techco at (714) 408‐9550 and speak with one of our experienced technical support staff. We want you to enjoy our products; so, we have trouble, with you having trouble. NOTE: Please retain all hardware removed from the vehicle tear down process. Much of it will be reused during the installation phase of your new Techco product. Please use caution during the installation of your product and please remember to use caution during the lifting and lowering of your vehicle as well as when your vehicle is in the air. If the vehicle is not properly placed on jack stands or on a lift serious injuries can occur. If for any reason you are unsure of what you are doing, stop and refer to this installation manual, call your local service center or the Techco facility directly. Again, thank you for choosing Techco and we hope your enjoy your product! Page 3 of 101 Recommended Tools To Be Used For SECTION 1: VEHICLE TEAR‐DOWN 3.0L Reverse Revolution Twin Screw Supercharger •
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Panel Puller Slotted Screw Driver 7mm 1/4” Drive Deep Well Socket 8mm 1/4” Drive Deep Well Socket 10mm 1/4” Drive Deep Well Socket 10mm Open Ended Wrench 13mm 3/8” Drive Deep Well Socket 15mm 3/8” Drive Deep Well Socket 15mm Open Ended Wrench T‐50 3/8” Drive Torx Bit 1/4” Drive Ratchet 6” Long 1/4” Drive Extension 12” Long 1/4” Drive Extension 3/8” Drive Ratchet 6” Long 3/8” Drive Extension 3/8” Drive Breaker Bar Fuel Line Removal Tool Constant Tension Band Hose Clamp Pliers or Regular Pliers Safety Glasses Hack Saw Table Vise Shop Towels or Rags Duct Tape Page 4 of 101 SECTION 1: VEHICLE TEAR‐DOWN 3.0L Reverse Revolution Twin Screw Supercharger 1. Disconnect the Negative Terminal from the Battery. 2. Raise and support the hood. 3. Disconnect the IAT Sensor Connector from the IAT Sensor located on the bend of the Intake Tube leading to the Throttle Body. (See Photo 1.1) 4. Loosen Hose Clamp mounting the Intake Tube to the Throttle Body. (See Photo 1.2) 5. Remove the Oil Breather Line attach between the Airbox and the Oil Filler Port from the Oil Filler Port. (See Photo 1.3) 6. Remove the Mounting Bolt the Airbox and then remove the Air Intake Assembly from the vehicle. (See Photos 1.3 & 1.4) 7. Remove the two Hood Latch Closeout Panels. (See Photo 1.5) Note: Use caution when removing the panel so as to not break the three retaining posts on the bottom each panel. 8. Remove the Eight Push Pin Fasteners from the top of the Front Fascia and remove the seven fasteners attaching the Front Fascia to Bumper Closeout Panel located under the vehicle. (See Photo 1.6) 9. Remove the three Push Pin Fasteners in each wheel well connecting the Front Fascia to the Wheel Arch Panel and remove the three Fasteners attaching the Wheel Arch Panel to Bumper Closeout Panel. (See Photo 1.7) 10. Remove the two remaining Mounting Bolts attaching the Bumper Closeout Panel to the vehicle and remove the Panel. 11. Pull the Wheel Arch away from the Front Fascia to gain access to and remove the Mounting Bolt from each front wheel well that attaches the Front Fascia to the Body. (See Photo 1.8) 12. Locate and remove the Mounting Bolt that attaches the top portion of the Front Fascia to the Body. (See Photo 1.9) 13. Carefully remove the two Front Side Blinker Assemblies from the vehicle, turn them sideways and place them in their mounting holes so that the Fascia can be removed. (See Photos 1.10 & 1.12) 14. With the help of another person carefully remove the Front Fascia from the body keeping in mind that there are two Wire Harnesses, one on each side that need to be disconnected from the Fascia before moving the away from the vehicle. (See Photos 1.11 & 1.12) Page 5 of 101 15. Remove the Front Bumper from the Chassis. (See Photo 1.13) WARNING: ANTIFREEZE IS A POISON; KEEP IT OUT OF REACH OF CHILDREN AND ANIMALS. Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, CALL 911 IMMEDIATELY. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Dispose of glycol based coolant properly; contact your government agency for location of collection center in your area. 16. Locate the Radiator Drain Valve and Drain Hose. With a container under the Drain Hose open the Valve and drain the Radiator. (See Photo 1.14) Note: There is about 15 Quarts of coolant in the entire system so use a container that holds at least that amount. Clean up any spilled coolant. 17. Remove the Nut Cap from each Wiper Arm to gain access to the Wiper Arm Mounting Nut, and then remove the Nut and Wiper Arm from the vehicle. (See Photo 1.15) Note: Make a note of the location of the Wiper Arms so that they can be reinstalled with the same orientation. 18. Remove the nine Push Pin Fasteners from the cowl then carefully remove the Cowl. (See Photo 1.15) Note: There are seven retaining clips attached to the bottom of the cowl just below the windshield. Use caution so as to not break any of these clips when removing the cowl. 19. Remove the four Retaining Bolts, PCM bracket, Electrical Connector fastened via push pin to the Passenger’s Side bottom, and Wiper Motor Harness attached via push pin fastener from the stock Chassis Brace and carefully remove the Brace from the vehicle. (See Photo 1.16) Note: The Wiper Motor has a rubber grommet that is attached to a bracket leading from the bottom of the tower brace to just below the wiper motor. The bracket is slotted towards the Engine so that the grommet can be slipped out when removing the Chassis Brace. 20. Remove the Vacuum Line from the front Driver’s Side of the Intake Manifold. (See Photo 1.17) 21. Disconnect the eight Fuel Injector Connectors by first moving the Red Locking Clip to the unlock position (towards the rear of the connector) then by pressing the release tab of the connector. (See Photo 1.18) 22. Disconnect the MAP Connector found on the back of the Intake Manifold by first moving the Red Locking Clip to the unlock position (towards the rear of the connector) then by pressing the release tab of the connector. (See Photo 1.19) 23. Disconnect the Throttle Body Connector by first moving the Red Locking Clip to the unlock position (towards the rear of the connector) then by pressing the release tab of the connector. The cut the Zip Tie from the Harness and the support on the Throttle Body. (See Photos 1.20 & 1.21) 24. Unplug the Vacuum Line from the Brake Booster. (See Photo 1.22) Page 6 of 101 NOTE: Use caution and rags when removing the Fuel Line as it is pressurized and fuel may spill. 25. Using a Fuel Line Removal Tool disconnect the Fuel Line from the Fuel Rail. (See Photos 1.23 & 1.24) 26. Remove the ten Intake Manifold Mounting Bolts from the Intake Manifold. (See Photo 1.25) Note: The each bolt has a plastic retainer so the bolt stays attached to the Intake Manifold. NOTE: Use extreme caution while lifting the Intake Manifold off of the Engine and ensure nothing falls into the now exposed Cylinder Head Ports. 27. With the aid of another person carefully lift the Intake Manifold from the vehicle. (See Photo 1.26) 28. Using Duct Tape, Tape the exposed Ports on the Cylinder Heads so that nothing can fall inside. (See Photo 1.27) 29. Remove the two Studs from the Water Pump Housing. (See Photos 1.28 & 1.29) 30. Using a Breaker Bar attached to the Belt Tensioner, release the tension on the Belt and remove it from the Engine. (See Photos 1.30 & 1.31) 31. Remove the Idler Pulley from the Engine. (See Photo 1.32) 32. Disconnect the Connector attached to the Radiator Dual Fan Assembly and remove the two Mounting Bolts attaching the Radiator Dual Fan Assembly to the chassis and remove the Fan Assembly down through the bottom of the vehicle. (See Photos 1.33 & 1.34) 33. Remove the Upper Radiator Hose that is attached to the Thermostat Housing. (See Photo 1.35) 34. Disconnect the harness from the Passenger’s Side Air Deflector and remove the two Push Pin Fasteners, one on the top and bottom of each and remove the Air Deflectors from the vehicle. (See Photo 1.36) 35. Disconnect the Transmission Radiator from the Engine Radiator and leave loose. (See Photo 1.37) Note: Do not disconnect any of Transmission Coolant Lines. 36. Remove the two upper Mounting Bolts attaching the Radiator to the chassis and four Radiator Support Brace Mounting Bolts attaching the Radiator Support Brace to the Chassis and remove the Brace and support the Radiator far enough away from the Engine to gain access to the Crank Pulley. (See Photos 1.38 ‐ 1.40) Note: Do not disconnect any Air Conditioning Coolant Lines. 37. Remove and save for later use the Stock Throttle Body, Hardware and Gasket. 38. Remove and save for later use the 10 Stock Intake Manifold Bolts. 39. Remove and save for later use the PCV Valve from the Passenger’s Side of the Stock Intake Manifold. Page 7 of 101 40. Remove and save for later use the Oil Filler Cap from the Driver’s Side of the Stock Intake Manifold. 41. Mark a line on each of the Air Deflectors that were removed during Step 34, 8” from the bottom. (See Photo 1.41) 42. Using Vise to hold the Air Deflector and a hacksaw; carefully cut the Air Deflectors as straight as possible along the length of the line drawn on each. Save the upper portion of each of the cut Air Deflectors for later use; discard the bottom section.(See Photo 1.41 & 1.42) Page 8 of 101 IAT Sensor Connector
IAT Sensor (Photo 1.1) Hose Clamp
(Photo 1.2) Page 9 of 101 Breather Line Bolt (Photo 1.3) Air Intake Assembly
(Photo 1.4) Page 10 of 101 Closeout Panel
(Photo 1.5) Fastener
Front Fascia
(Photo 1.6) Page 11 of 101 Front Fascia Wheel Arch Fastener
(Photo 1.7) Wheel Arch
Front Fascia (Photo 1.8) Bolt
Page 12 of 101 Body Bolt
Front Fascia
(Photo 1.9) Front Side Blinker
(Photo 1.10) Page 13 of 101 Front Fascia
(Photo 1.11) Harness
Front Side Blinker Front Fascia (Photo 1.12) Page 14 of 101 Bumper (Photo 1.13) Radiator Drain Valve
Drain Hose
(Photo 1.14) Page 15 of 101 Nut Cap
Cowl
Wiper Arm Nut Push Pin
(Photo 1.15)
Bolts Chassis Brace
Bolts
(Photo 1.16) Page 16 of 101 Vacuum Line
(Photo 1.17) Fuel Injector Connector
Red Locking Clip (Photo 1.18) Page 17 of 101 Red Locking Clip MAP Connector
(Photo 1.19) TB Connector
Red Locking Clip (Photo 1.20) Page 18 of 101 Zip Tie
(Photo 1.21) Vacuum Line
(Photo 1.22) Page 19 of 101 Fuel Line Removal Tool
(Photo 1.23) Fuel Line
Fuel Rail
(Photo 1.24) Page 20 of 101 Intake Manifold Bolt (Photo 1.25) (Photo 1.26) Page 21 of 101 (Photo 1.27) Stud
Water Pump Housing (Photo 1.28) Page 22 of 101 Water Pump Housing
Stud
(Photo 1.29) Breaker Bar Tensioner
(Photo 1.30) Page 23 of 101 Belt
(Photo 1.31) Idler Pulley
(Photo 1.32) Page 24 of 101 Bolt
Connector
(Photo 1.33) Dual Fan Assembly (Photo 1.34) Page 25 of 101 Upper Radiator Hose Thermostat Housing (Photo 1.35) Fastener
Air Deflector (Photo 1.36) Page 26 of 101 Transmission Radiator
Engine Radiator
(Photo 1.37) Bolt
(Photo 1.38) Page 27 of 101 Bolt
Support Brace (Photo 1.39) (Photo 1.40) Page 28 of 101 Air Deflector (bottom) Cut Line
Air Deflector (top)
8” From Bottom (Photo 1.41) Cut Line Air Deflector (top)
(Photo 1.42) Page 29 of 101 Recommended Tools To Be Used For SECTION 2: WIRING INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
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Small 2mm Blade Jeweler’s Screwdriver 26‐16AWG Wire Strippers Flush Cut Pliers Non‐Insulated Splice Crimpers Panel Puller Heat Gun Safety Glasses 3M Super 33+ Electrical Tape Page 30 of 101 SECTION 2: WIRING INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger NOTE: Steps 1 & 2 must be completed before the Radiator Dual Fan Assembly is reinstalled on the vehicle. There is very little clearance between the SC Crank Pulley and the Fan Connector and damage to the Radiator Dual Fan Assembly Harness will occur if steps 1 & 2 are not performed correctly. NOTE: When cutting Zip Ties use either a Zip Tie Gun or Flush Cutting Pliers only; this is to insure the zip tie end is cut flush with the Zip Tie Tensioner. Most other cutting devices will leave a sharp edge on the zip tie that will cause lacerations. 1. Remove the Lower Fan Harness from its Mounting Tab. (See Photo 2.1) 2. Using the supplied Zip Ties (000Z‐H07‐C000542); Zip Tie the Lower Fan Harness to the Twelve O’clock Support Brace. (See Photo 2.2) Note: While zip tying the Harness pull the wires as tight against the connector as they can safely be pulled without breaking. NOTE: Steps 3‐8 are for the extension of the Throttle Body section of the Engine Harness on vehicles equipped with a 6.1L Hemi Motor Only. The wiring on 5.7L Engine Harness is laid out differently and does not require the Throttle Body Extension Harness. NOTE: Use extreme caution when removing any terminal from a connector. It is better to damage the Stock Connector in order to remove a Terminal than to break the Terminal or Wire/Terminal Crimp Junction. 3. Using a 2mm Jeweler’s Screwdriver carefully remove the Blue TPA from the front of the Stock Throttle Body Connector to gain access to the Terminal Retaining Levers. (See Photo 2.3) 4. Using a 2mm Jeweler’s Screwdriver carefully lift the Terminal Retaining Lever found at each terminal inside of the connector and gently pull the Wire/Terminals out of the back of the connector. (See Photos 2.3‐2.6) Note: Sometimes it is necessary to push the wire/terminal in a little bit in order to relieve tension from the terminal retaining lever so that the lever can be lifted and the wire/terminal can be removed. NOTE: During shipping the Red TPA at the front of the supplied EPC Connector may get pushed in to the Locked Position. If this has happened carefully pull it out using the 2mm Jeweler’s Screwdriver to the Unlocked Position. (See Photos 2.9 & 2.10) Page 31 of 101 NOTE: The Terminal Position Numbers are marked on the back of the supplied EPC connector. (See Photo 2.8) 5. Carefully install the Wire/Terminals into the supplied EPC Connector (000Z‐E12‐C000900) in the following order. (See Photo 2.7 & 2.8) Note: The Terminals have a Tab on their bottom side. This Tab ensures the Terminal will only be inserted into the Connector in the proper orientation. On the Top Row (1‐3) the Tab faces Down and on the Bottom Row (4‐6) the Tab faces Up. Position 1: Brown Wire with an Orange Stripe Position 2: Pink Wire with a Yellow Stripe Position 3: Dark Blue Wire with a Gray Stripe Position 4: Brown Wire with a Dark Green Stripe Position 5: Dark Blue Wire with a Light Green Stripe Position 6: Brown Wire with a Dark Blue Stripe NOTE: Double check and make sure the wires are in their proper location otherwise the Throttle Body will not function properly. 6. Once the Wire/Terminals have be verified to be in the proper position and fully seated in the connector press the Red TPA into the Locked Position. (See Photos 2.9 & 2.10) 7. Connect the supplied Throttle Body Extension Harness (004Z‐E06‐C000874) to the newly install EPC Connector and press the Red Locking Clip forward into the Locked Position. (See Photo 2.11) 8. Rout the Throttle Body Extension Harness in the valley of the engine to the other side of the Water Pump Housing routing the harness under the Coolant Temperature Sensor Connector and along its harness length to the main engine harness and using the supplied Zip Ties (000Z‐H07‐C000542); Zip Tie the Throttle Body Extension Harness at this junction. (See Photo 2.12 & 2.13) Note: Only tighten this Zip Tie enough to lightly maintain the Throttle Body Extension Harness in this position. This zip tie will be fully tightened once the Super Charger has been installed and the Throttle Body Extension Harness has been connected to the Throttle Body at its new location. 9. Locate the Integrated Power Module in the Engine Bay mounted to the Passenger’s Wheel Well. (See Photo 2.14) NOTE: There are two models of the Integrated Power Modules found on the different year vehicles; (See Photos 2.15 & 2.16) to determine which IPM is applicable. Early Model IPMs have an External Computer attached to the front as seen in (Photo 2.15). Late Model IPMs have an internal computer and have a Plastic Plate attached to the front as seen in (Photo 2.16). 10. If installed disconnect or cut the Anchor Zip Tie attaching the Large Battery Cable of the IPM to the wheel well. (See Photo 2.17) Page 32 of 101 11. To remove the IPM from its hinged mount locate and release the three Locking Levers, then lift the IPM from its mount and position it so as to gain access to the connectors on the underside. (See Photos 2.18 & 2.19) Note: To release the three locking levers, push and hold them away from the IPM. They do not stay released so they have to be held in the release position. 12. EARLY MODEL IPM: Unlock the Red Locking Clip by pushing it towards the front end of the connector; then press the Release Tab on the back side of the connector to release the White Locking Lever and move the lever forward to disconnect the four Large Green, Gray, Black, & Blue Connectors and disconnect the Small Gray Connector to give access to the Large Blue Connector. (See Photos 2.20 & 2.21) LATE MODEL IPM: Disconnect the Medium Gray Connector found on the upper side of the IPM. (See Photo 2.22) 13. EARLY MODEL IPM: Remove the tape from the harness section leading from the Large Blue Connector to the harness junction giving access to the Wires leading to the Large Blue Connector. (See Photo 2.23) LATE MODEL IPM: Remove the tape from the harness section leading from the Medium Gray Connector to the harness junction giving access to the Wires leading to the Medium Gray Connector. (See Photo 2.24) NOTE: At this point the directions will apply to both the Early Model (Large Blue Connector) and Late Model (Medium Gray Connector) IPMs. Only one model needs to be shown in the photos. NOTE: BE SURE TO CUT ONLY THE 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE. On both model IPMs there are two Brown/White Wires; one 20AWG (Small Diameter) Brown/White Wire and one 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE. (See Photos 2.23 & 2.24) 14. Using the supplied Zip Ties (000Z‐H07‐C000542); Zip Tie the Looped Edge of the Fuse Holder of the supplied Intercooler Water Pump Harness (004Z‐E06‐C001086) to the main harness so that the edge of the Fuse Holder is at the junction where the removed tape begins. (See Photo 2.25) 15. Locate the 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE of the Connector. On early model IPMs cut the both the 16AWG Black Fuse Holder Wire and the 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE together at a point in the middle of the exposed harness and on the late model IPMs just cut the 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE at the same length as the 16AWG Black Fuse Holder Wire. (See Photo 2.25) 16. On early model IPMs strip both wires and on late model IPMs strip the 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE at the same point as the 16AWG Black Fuse Holder. (See Photo 2.26) 17. Place the supplied Heat Shrink (000Z‐E11‐C001097) over both the Black Fuse Holder Wire and the 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE previously cut that is attached to the main harness side. (See Photo 2.26) Page 33 of 101 18. Insert both stripped wires into the supplied Butt‐Splice (000Z‐E10‐C001096) and Crimp the splice onto the two wires. (See Photo 2.27) 19. Strip the 16AWG (LARGER DIAMETER) BROWN/WHITE WIRE that is attached to the Connector and insert it into the open end of the Butt‐Splice and Crimp the splice onto the single wire. (See Photo 2.28) 20. Slide the previously installed Heat Shrink up over the Butt‐Splice and using a heat source Shrink the Heat Shrink down around the Splice/Wire Junction. (See Photo 2.29) Note: Use caution when heating the Heat Shrink so as to not burn the surrounding wires. 21. Using 3M Super 33+ Electrical Tape, Tape the harness length from the Connector to the junction of the main harness. (See Photo 2.30) 22. Reconnect all previously disconnected connectors back up to the IPM making sure the White Locking Levers are locked into position and then lock the Red Locking Clips. Note: The IPM connector ports are color coded so they cannot be installed in the wrong location. 23. Rout the Intercooler Water Pump Harness along the main harness to the larger main harness installing Zip Ties where needed. Rout the main section of the Intercooler Water Pump Harness forward past the Washer Bottle following the Washer Motor Harness installing Zip Ties where needed and rout the Ground Wire along the main harness back to where the Main Ground Harness breaks away and install the terminal ring of the Intercooler Water Pump Harness Ground Wire on the Grounding Post underneath the vehicle Ground Harness. (See Photos 2.31‐2.33) Note: If the Intercooler Water Pump has already been installed connect the connector to the pump otherwise leave it hanging and it will be connected at a later point. 24. Reattach the IPM to its hinged mount, ensuring all three levers lock into place and the IPM is locked down and immobile. If the Anchor Zip Tie is being reused attach it at this point. 25. Install the supplied Air Charge Temperature Sensor Extension Harness (004Z‐E06‐C001271) onto the existing Inlet Air Temperature Sensor Harness that was disconnected during Section 1, Step 3 and slide the Red Locking Tab forward into the locked position. (See Photo 2.34) Note: Leave a few inches hanging out next to the Water Pump Housing and rout the rest of the Harness in the Valley of the Engine; it will be connected to its sensor once the Supercharger has been completely installed. 26. On vehicles equipped with the 6.1L engine only install the supplied Manifold Air Pressure Sensor Extension Harness (004Z‐E06‐C001270) on the existing Manifold Air Pressure Sensor Harness that was disconnected during Section 1, Step 22 and slide the Red Locking Tab forward into the locked position. (See Photo 2.35) Note: Leave this extension harness hanging behind the water lines that rise from the rear of the engine so that is does not get pinched when the supercharger is installed; it will be connected to its sensor once the Supercharger has been completely installed. Page 34 of 101 Driver’s Side H o o d Lower Fan Harness
Mounting Tab Lower Fan
(Photo 2.1) Driver’s Side H o o d Zip Tie
12 O’clock Brace
Lower Fan Harness Harness Pulled Tight (Photo 2.2) Page 35 of 101 TPA Removed
Stock Throttle Body Connector
(Photo 2.3) Wire/Terminal Being Removed
(Photo 2.4) 2mm Jeweler’s Screwdriver Page 36 of 101 Terminal Retaining Lever (Photo 2.5) Undamaged Wires/Terminals
(Photo 2.6) Page 37 of 101 Wire/Terminal Being Installed EPC Connector (Photo 2.7) BRN/ORN
PNK/YLW
DK BLU/GRY T a b T
a b T
a b T a b BRN/DK GRN (Photo 2.8) T
a b DK BLU/LT GRN
T
a b BRN/DK BLU
Page 38 of 101 TPA Unlocked
EPC Connector
(Photo 2.9) TPA Locked
EPC Connector
(Photo 2.10) Page 39 of 101 EPC Connector Clip Locked
TB Extension Harness
(Photo 2.11) EPC Connector TB Extension Harness Coolant Temp Sensor (Photo 2.12) Page 40 of 101 TB Extension Harness
Coolant Temp Sensor Snug (Not Tight) Zip Tie
(Photo 2.13) Passenger Wheel Well
Integrated Power Module (Photo 2.14) Page 41 of 101 Early Model Integrated Power Module
External Computer
(Photo 2.15) Late Model Integrated Power Module
Plastic Plate
(Photo 2.16) Page 42 of 101 Large Battery Cable
(Photo 2.17) Locking Lever
Locking Lever Locking Lever
(Photo 2.18) Page 43 of 101 (Photo 2.19) Large Blue Connector (Photo 2.20) Page 44 of 101 White Locking Lever
Red Locking Clip Release Tab
(Photo 2.21) Medium Gray Connector
(Photo 2.22) Page 45 of 101 16AWG (LARGE DIAMETER) BROWN/WHITE WIRE
20AWG (Small Diameter) Brown/White Wire
(Photo 2.23) 16AWG (LARGE DIAMETER) BROWN/WHITE WIRE
20AWG (Small Diameter) Brown/White Wire (Photo 2.24) Page 46 of 101 16AWG Black Fuse Holder Wire
Fuse Holder
16AWG (LARGE DIAMETER) BROWN/WHITE WIRE (Photo 2.25) Stripped Wires
Heat Shrink
(Photo 2.26) Page 47 of 101 Butt‐Splice
Black Fuse Holder & 16AWG (LARGE DIAMETER) BROWN/WHITE Wires Crimped Together
(Photo 2.27) All Three Wire Sections Crimped Together
(Photo 2.28) Page 48 of 101 Shrunk Heat Shrink (Photo 2.29) Taped Harness
(Photo 2.30) Page 49 of 101 All Connectors Reconnected
Grounding Post Intercooler Water Pump Harness
Harness Ground Wire (Photo 2.31) Intercooler Water Pump Harness
Uncut Zip Tie
(Photo 2.32) Page 50 of 101 Intercooler Water Pump Harness
Washer Bottle
Uncut Zip Tie
(Photo 2.33) Existing IAT Connector ACT Extension Harness
Water Pump Housing
(Photo 2.34) Page 51 of 101 Existing MAP Connector MAP Extension Harness (Photo 2.35) Page 52 of 101 Recommended Tools To Be Used For SECTION 3: SNOUT BRACE & SC CRANK PULLEY INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
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6mm 3/8” Drive Allen Bit 17mm 3/8” Drive Deep Well Socket 3/8” Drive Ratchet 3/8” Drive (75 Ft‐Lb) Toque Wrench 3/8” Drive Breaker Bar 22mm 1/2” Drive Deep Well Socket 1/2” Drive Ratchet 1/2” Drive 250 Ft‐Lb Torque Wrench 3.25” Diameter 5/16” Post Spanner Wrench or Chain Tong Wrench Drill Vacuum Red Loctite P/N 27131 Safety Glasses Page 53 of 101 SECTION 3: SNOUT BRACE & SC CRANK PULLEY INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger 1. Remove the Crank Damper Bolt. (See Photo 3.1) 2. Install the supplied Crank Drill Guide (004Z‐K01‐C001244) and New Crank Damper Bolt (000Z‐H02‐C000805) on the Crank and tighten the bolt so that the Drill Guide cannot move. (See Photo 3.2) Note: Make sure the bolt is tight so that the Drill Guide cannot move. NOTE: It is very important that the Crank Drill Guide DOES NOT MOVE while performing the next step. 3. Using the supplied #8 Drill Bit (000Z‐K05‐C001256); drill two holes to a depth of 14.5mm into the crankshaft (40.3mm from face of Tool). Once the proper depth has been achieved; remove the Drill Guide and Bolt. (See Photo 3.2) 4. Vacuum any debris from the newly drilled holes and crankshaft area. 5. Using the supplied Crank Damper Bolt (000Z‐H02‐C000805) and Hardened Washer (000Z‐H03‐C001179) install the Crank Pulley Adapter (004Z‐A01‐C001241) onto the crankshaft and torque the bolt to 130 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fastener. Note: While installing the Crank Pulley Adapter, ensure the dowel pins on the back of the adapter slide into the holes of the crankshaft that were previously drilled during step 3. 6. Install the supplied Tensioner Nut (000Z‐H01‐C001168) on the supplied Tensioner Bolt (000Z‐H02‐
C001025) and screw the Tensioner Bolt and Nut into the Snout Brace (004Z‐A05‐C001015) bottoming out the bolt. (See Photo 3.3) 7. Remove the existing bolt from the stock Idler Pulley that was previously removed from the engine during Section 1, Step 31 and install the Idler Pulley on the Snout Brace. (See Photo 3.3) 8. Install the supplied Lock Washer (000Z‐H03‐C001030) onto supplied Bolt (000Z‐H02‐C001026) and slide both into the top mounting hole of the Snout Brace. Next slide the Snout Brace Standoff (004Z‐A05‐C001023) over the bolt with the Flat Surface facing the Snout Brace. (See Photo 3.4) 9. Install the assembled Snout Brace onto the engine; lining up the Upper Mounting Bolt with the Upper Mounting Hole of the Water Pump Housing on the engine and the Idler Pulley being lined up with the Idler Pulley Mount. Start the bolt but do not tighten it. Be sure to use Red Loctite P/N 27131 on the fastener. (See Photos 3.4 & 3.5) 10. Install the supplied Lock Washer (000Z‐H03‐C001030) onto supplied Bolt (000Z‐H02‐C001029) and slide both into the idler pulley mounting hole. Start the bolt but do not tighten it. Be sure to use Red Loctite P/N 27131 on the fastener. (See Photo 3.6) Page 54 of 101 11. Install the supplied Lock Washer (000Z‐H03‐C001028) onto Bolt (000Z‐H02‐C000840) and slide both into the center mounting hole of the Snout Brace. Start the bolt but do not tighten it. Be sure to use Red Loctite P/N 27131 on the fastener. (See Photo 3.6) 12. Once the Snout Brace has been installed and all bolts started; Torque the three bolts to the following torque spec: TOP MOUNTING BOLT: 50 Ft‐Lbs MIDDLE MOUNTING BOLT: 12 Ft‐Lbs IDLER PULLEY MOUNTING BOLT: 50 Ft‐Lbs 13. Using a Breaker Bar attached to the Belt Tensioner, release the tension and install the stock Serpentine Belt on the Engine Pulleys. Refer to the photo for proper routing of the belt (See Photos 3.7) Page 55 of 101 Crank Damper Bolt
(Photo 3.1) Crank Drill Guide New Crank Damper Bolt Supplied #8 Drill Bit (Photo 3.2) Page 56 of 101 Snout Brace
Tensioner Bolt & Nut
Stock Idler Pulley (Photo 3.3) Upper Mounting Hole
Upper Mounting Bolt
Snout Brace Standoff
Idler Pulley Mount
(Photo 3.4) Page 57 of 101 (Photo 3.5) Upper Mounting Bolt
Center Mounting Bolt
Idler Pulley Bolt
(Photo 3.6) Page 58 of 101 Snout Brace
Stock Idler Pulley Belt Tensioner Serpentine Belt Installed (Photo 3.7)
Page 59 of 101 Recommended Tools To Be Used For SECTION 4: HEAT EXCHANGER INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
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13mm 3/8” Drive Deep Well Socket 3/8” Drive Ratchet 6” Long 3/8” Drive Extension 75 Ft‐Lb 3/8” Drive Torque Wrench 13mm Open Ended Wrench Drill 11/32 Drill Bit Constant Tension Band Hose Clamp Pliers or Regular Pliers Safety Glasses Sharpie Marker Page 60 of 101 SECTION 4: HEAT EXCHANGER INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger 1. Remove the Four Center Mounting Bolts from the bumper. (See Photo 4.1) 2. Install the four of the supplied Washers (000Z‐H03‐C001307) onto four of the supplied Mounting Bolts (000Z‐H02‐C001165) and install the New Mounting Bolts into the Four Center Holes of the Bumper so that 1/2” of the bolt is sticking out of the back side of the Bumper’s weld nut. 3. Install the four more of the supplied Washers (000Z‐H03‐C001307) onto each of the New Mounting Bolts. (See Photo 4.2) 4. Ensuring the Washers previously install during Step 3 do not fall off, install the Heat Exchanger Assembly (100A‐A10‐B000876) onto the four Mounting Bolts and torque the Bolts to 21 Ft‐Lbs pushing them further past the Bumper’s Weld Nut. (See Photos 4.3 & 4.4) 5. Install four more of the supplied Washers (000Z‐H03‐C001308) and four of the supplied Nylock Nuts (000Z‐H01‐C001166) onto the Mounting Bolts and tighten the Nylock Nuts securely. (See Photo 4.4) 6. Place the Water Pump Bracket (100Z‐A10‐C001046) over the Passenger’s Side of the Bumper and line up the edge of the bracket with the edge of the Bumper as shown in the photo. Using the Bracket as a template, mark the location of the hole on the top and bottom of the Bumper. (See Photo 4.5) 7. Use a center punch to make an indentation in the center of the marks so that the Drill Bit does not slip off of the mark then use an 11/32 Drill Bit to drill a 0.3437” hole through each of the two marked locations. 8. Using two of the supplied Bolts (000Z‐H02‐C001309), four of the supplied Washers (000Z‐H03‐C001308), and two of the supplied Nylock Nuts (000Z‐H01‐C001166) install the Water Pump Bracket onto the previously drilled Bumper and tighten the Nylock Nuts securely. (See Photo 4.6) Note: The Water Pump Bracket faces the rear of the vehicle and angles out towards the Passenger’s Front Tire. 9. Using two of the supplied Bolts (000Z‐H02‐C001309), four of the supplied Washers (000Z‐H03‐C001308), and two of the supplied Nylock Nuts (000Z‐H01‐C001166) install the Water Pump (100Z‐A10‐C001218) onto the Water Pump Bracket and tighten the Nylock Nuts securely. (See Photo 4.7) 10. If the Water Pump Harness (004Z‐E06‐C001086) has already been installed; connect the Water Pump Harness Connector to the Pump at this time. If the Water Pump Harness has not been installed see Section 2, Step 9 for the installation procedures. (See Photo 4.7) 11. Place the supplied piece of Polyester Mesh Sleeving (000Z‐H10‐C001235) over the supplied Heat Exchanger Outlet Hose (004Z‐A10‐C000898) and push it to the middle of the hose. Page 61 of 101 NOTE: Always wear Safety Glasses when installing Constant Tension Band Hose Clamps 12. Using one of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001310), install the Heat Exchanger Outlet Hose onto the Heat Exchanger Outlet (Driver’s Side) Port. (See Photo 4.8) 13. Rout the Heat Exchanger Outlet Hose around the Radiator Support Bracket, up along the inside of the Frame Rail, and into the engine compartment. Adjust the location of the previously installed Polyester Mesh Sleeving down the Outlet Hose until the hose is covered where it comes in contact with the AC lines and the Frame Rail. (See Photo 4.9 & 4.10) 14. Route one end of the supplied Recovery Tank‐Water Pump Hose (004Z‐A10‐C000895) behind the Passenger’s Headlight and down to the Water Pump. (See Photos 4.11 & 4.12) Note: The routing of this hose varies slightly between vehicle types. For Dodge applications (See Photo 4.10). For Chrysler applications (See Photo 4.12). 15. Using one of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001310), install the Recovery Tank‐Water Pump Hose onto the Water Pump Inlet (Vertical) Port. (See Photo 4.13) 16. Using two of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001310), install the Water Pump‐Heat Exchanger Hose (004Z‐A10‐C001160) between the Water Pump Outlet (Horizontal) Port and the Heat Exchanger Inlet (Passenger’s Side) Port. (See Photo 4.14)
Page 62 of 101 Stock Mounting Bolt Stock Mounting Bolt Stock Mounting Bolt Stock Mounting Bolt (Photo 4.1) Washer
New Mounting Bolt
(Photo 4.2) Page 63 of 101 Heat Exchanger Bracket
Heat Exchanger Heat Exchanger Bracket
Front Bumper
(Photo 4.3) Washer
Washer
Mounting Bolt Nylock Nut
Heat Exchanger Bracket
(Photo 4.4) Page 64 of 101 Water Pump Bracket Passenger’s Side Bumper
(Photo 4.5) Washer Water Pump Bracket Washer Nylock Nut
Mounting Bolt
Passenger’s Side Bumper
(Photo 4.6) Page 65 of 101 Water Pump Water Pump Bracket
Mounting Hardware Mounting Hardware Water Pump Harness
(Photo 4.7) CTB Hose Clamp Heat Exchanger Outlet Heat Exchanger Outlet Hose
(Photo 4.8) Page 66 of 101 Radiator Support Bracket
Frame Rail Heat Exchanger Outlet Hose
(Photo 4.9) Heat Exchanger Outlet Hose
A/C Lines & Frame Rail Polyester Mesh Sleeving
(Photo 4.10) Page 67 of 101 Recovery Tank‐Water Pump Hose
Passenger’s Headlight (Photo 4.11) Recovery Tank‐Water Pump Hose
Passenger’s Headlight
(Photo 4.12) Page 68 of 101 Recovery Tank‐Water Pump Hose CTB Hose Clamp
Water Pump Inlet Port (Photo 4.13) CTB Hose Clamp
Water Pump Outlet Water Pump‐Heat Exchanger Hose
(Photo 4.14) Page 69 of 101 Water Pump‐Heat Exchanger Hose
Heat Exchanger Inlet (Photo 4.15)
Page 70 of 101 Recommended Tools To Be Used For SECTION 5: SUPERCHARGER INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
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10mm 3/8” Drive Deep Well Socket 13mm 3/8” Drive Deep Well Socket 17mm 3/8” Drive Deep Well Socket 3/8” Drive Ratchet 12” Long 3/8” Drive Extension 4mm 3/8” Drive Allen Bit 5mm 3/8” Drive Allen Bit 8mm 3/8” Drive Allen Bit 17mm 3/8” Drive Deep Well Socket 17mm Open Ended Wrench 24mm Open Ended Wrench Safety Glasses Rubber Mallet Flashlight Zip Tie Gun or Flush Cut Pliers Constant Tension Band Hose Clamp Pliers or Regular Pliers Shop Towels or Rags Red Loctite P/N 27131 Page 71 of 101 SECTION 5: SUPERCHARGER INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger 1. Using the stock Hardware and Gasket previously removed during Section 1, Step 37; install the Stock Throttle Body onto the Supercharger Inlet Tube. Use a rubber mallet to gently tap the Throttle Body onto the alignment pins. See the photo for the proper orientation of the Zip Tie Mount. Torque the Bolts to 8.75 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 5.1) Note: Use care when installing the Throttle Body so as to not damage the Gasket. NOTE: Use extreme care when installing the Intake Manifold Gaskets so as to not cause any damage to either the Gasket or the Supercharger Intake Runners. 2. Using a panel puller carefully remove the four Push Pin Fasteners from the stock Intake Manifold. Using the stock Push Pin Fasteners install the supplied new 6.1L Intake Manifold Gaskets (000Z‐H16‐C001339) on the Supercharger Intake Runners. (See Photo 5.2) NOTE: Use extreme caution around the exposed Cylinder Head Ports and ensure that nothing falls into any exposed Port. 3. Remove the previously installed Duct Tape from the Cylinder Head Ports. Carefully clean any debris from the area. With the aid of a flashlight view each exposed Port to ensure that nothing has fallen inside. (See Photo 5.3) NOTE: On vehicles equipped with an automatic transmission the service tube may need to be moved out of the way. If this needs to be done LIFT, DO NOT SLIDE the Supercharger out of the way and moved the tube as needed. NOTE: Use extreme caution when installing the Supercharger so as to not damage the Intake Manifold Gaskets as well as ensuring that nothing falls into any exposed port. 4. With the aid of another person carefully LIFT the Supercharger onto the engine and LIFT, DO NOT SLIDE the Supercharger into place on top of the exposed Ports of the Cylinder Heads with the Snout resting in the Snout Brace. (See Photo 5.4) NOTE: Ensure the Supercharger is properly aligned before installing the mounting hardware. 5. Install the ten Stock Intake Manifold Bolts removed During Section 1, Step 38. Torque the Bolts to 10 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 5.5) Note: Start, but do not tighten any of the Manifold Bolts until all ten have been installed. Page 72 of 101 6. Using the two supplied Bolts (000Z‐H02‐C000763) and two supplied Washers (001A‐H01‐C000848) install the Snout Brace Clamp (004Z‐A05‐C001016) onto the Snout Brace coupling the Snout to the Brace. Torque the Bolts to 10 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 5.6) 7. Install the supplied Supercharger Belt (000Z‐A05‐C001255), first on the Supercharger Pulley then onto the supplied Supercharger Crank Pulley (004Z‐A05‐C001007). Using the three supplied Bolts (000Z‐H02‐C001243) and Washers (000Z‐H03‐C000641); pull the Supercharger Crank Pulley/Belt down to the Crank Pulley Adapter and install the Supercharger Crank Pulley/Belt. Torque the bolts to 55 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 5.7) 8. Connect the ACT Connector previously installed during Section 2, Step 25 onto the ACT Sensor on the Passenger’s Side Front Runner and push any excess harness length into the open area under the Supercharger. (See Photo 5.8) 9. Install the supplied Washer (000Z‐H03‐C001027) over the supplied Bolt (000Z‐H02‐C001026) and insert them into the supplied Supercharger Idler Pulley (004Z‐A05‐C001177), then slide the supplied Supercharger Idler Pulley Bushing (004A‐A05‐C001018) over the Bolt and down to the Pulley so that the smaller diameter section of the Bushing fits into the hole of the Idler Pulley. (See Photo 5.9) 10. Back the Tensioner Bolt and Nut out of the Snout Brace almost all of the way. Install the supplied T‐nut (004Z‐A05‐C001022) into the slot on the back of the Snout Brace and hold it in place while installing the now complete Supercharger Idler Pulley Assembly. Be sure to use Red Loctite P/N 27131 on the fastener. Note: The Supercharger Idler Pulley needs to be adjusted so tighten the Pulley Bolt so that it is snug but do not torque it at this time. 11. Tighten the Tensioner Bolt and Nut against the T‐Nut until the Supercharger Belt is sufficiently tight. (See Photo 5.10) NOTE: TO TEST THE TENSION ON THE SUPERCHARGER BELT, GRAB THE LONG SIDE AND TWIST IT. THE BELT SHOULD TWIST BETWEEN 40° AND 45°. 12. Torque the Supercharger Idler Pulley Bolt to 50 Ft‐Lbs. 13. Tighten the Nut on the Tensioner Bolt as tight as possible. 14. Torque the Tensioner Bolt to 40 Ft‐Lbs. 15. Using the two supplied Bolts (000Z‐H02‐C001306) and two supplied Washers (000Z‐H03‐C001164) attach the Inter Cooler Recovery Tank (100Z‐A10‐B001234) to the boss on the Passenger’s Side runner where the ACT sensor is located. Tighten the bolts securely. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 5.11) Page 73 of 101 NOTE: Always wear Safety Glasses when installing Constant Tension Band Hose Clamps 16. Using one of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001310), install the open end of the previously installed during Section 4, Step 15 Recovery Tank‐Water Pump Hose onto the Outlet Port of the Inter Cooler Recovery Tank. (See Photo 5.11) 17. Using one of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001310), install the open end of the previously installed during Section 4, Step 12 Heat Exchanger Outlet Hose onto the Intercooler Inlet Port of the Supercharger. (See Photo 5.11) 18. Connect the previously installed during Section 2, Step 8 Throttle Body Extension Harness to the Throttle Body. Be sure to install the Anchor Mount Zip Tie onto the mount on the Throttle Body and pull any slack out of the harness into the valley under the Supercharger, then tighten the zip tie that was left loose from Section 2, Step 8. (See Photos 2.13 & 5.11) Note: There should be about 1/4” of space between the Harness and the bottom of the Throttle Body. 19. Install the previously removed during Section 1, Step 40 Oil Filler Cap onto the Oil Filler Port on the Driver’s Side runner. (See Photo 5.11) 20. Install the Brake Booster Vacuum Hose (000Z‐H10‐C001098) between the Port on the Brake Booster and the Larger Port on the Driver’s Side of the Supercharger Inlet Tube. (See Photo 5.11) 21. Connect the Vehicle’s Hard Vacuum Line to the Smaller Port on the Driver’s Side of the Supercharger Inlet Tube. (See Photo 5.11) 22. Connect all 8 Fuel Injector Connectors; slide the Red Locking Tab “Forward” into the “Locked” Position. (See Photo 1.18) 23. Connect the MAP Connector previously installed during Section 2, Step 26 onto the MAP Sensor on the Driver’s Side rear runner; slide the Red Locking Tab “Forward” into the “Locked” Position. (See Photo 5.12) 24. Connect the Fuel Line Connector to the Fuel Line Port at the rear of the Passenger’s Side Fuel Rail. (See Photo 5.13) 25. Install the previously removed during Section 1, Step 39 PCV Valve into the port on the Passenger’s Side runner. Cut 2” of the supplied 1/2” ID Hose (000Z‐A02‐C000731) and install it on the PCV Valve, install the supplied 90° Barbed Fitting into this hose; using the remainder of the 1/2” ID Hose (000Z‐A02‐C000731) install it on the open end of the 90° Barbed Fitting and run the other end of the Hose to the Port on Passenger’s Side of the Supercharger Inlet Tube. (See Photos 5.14 & 5.15) 26. Using one of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001310), install the supplied Intercooler Outlet Hose (004Z‐A10‐C000894) between the Intercooler Outlet Port on the rear Passenger’s Side of the Supercharger and the Inlet Port of the Intercooler Recovery Tank. (See Photo 5.15) Page 74 of 101 27. Using one of the supplied Constant Tension Band (CTB) Hose Clamps (000Z‐H09‐C001317), connect the Intercooler Bleed Hose to the Inlet Bleed Port of the Intercooler Recovery Tank. (See Photo 5.16) 28. Reinstall the Radiator and Radiator Support Brace by raising them into position and installing the four Radiator Support Brace Mounting Bolts and two upper Mounting Bolts that were removed during Section 1, Step 36. Torque the Radiator Support Brace Bolts to 45 Ft‐Lbs and Torque the Upper Radiator Bolts to 9 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photos 1.38 & 1.39) 29. Reinstall the Transmission Radiator by pushing it into its mount, locking it into position. (See Photo 1.37) 30. Reattach the Upper Radiator Hose the Thermostat Housing. (See Photo 1.35) 31. Reinstall the Radiator Dual Fan Assembly using the two mounting bolts removed during Section 1, Step 32, and then connect the Dual Fan Connector to the Harness. Torque the Bolts to 4 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photos 1.33 & 1.34) Page 75 of 101 Stock Throttle Body SC Inlet Tube Zip Tie Mount
(Photo 5.1) Fastener
Fastener Gasket
Gasket Fastener
Fastener
(Photo 5.2) Page 76 of 101 Clean Ports
Clean Ports
(Photo 5.3) SC In Position
Snout In Position
(Photo 5.4) Page 77 of 101 Stock Bolt Installation
(Photo 5.5) Snout Brace and Bolts
(Photo 5.6) Page 78 of 101 SC Pulley SC Belt
SC Crank Pulley
(Photo 5.7) ACT Sensor
ACT Extension Harness
(Photo 5.8) Page 79 of 101 SC Idler Pulley Bushing SC Idler Pulley (Photo 5.9) Tension on SC Belt 40‐45° of Belt Twist Only
(Photo 5.10) Page 80 of 101 Oil Filler Cap
HE‐IC Hose
IC Recovery Tank
Vacuum Hoses
RC‐WP Hose TB Ext Harness
(Photo 5.11) MAP Extension Harness
(Photo 5.12) Page 81 of 101 Fuel Line
Fuel Rail (Photo 5.13) PCV Valve PCV Hose
(Photo 5.14) Page 82 of 101 IC‐RT Hose
PCV Fitting
(Photo 5.15) IC Bleed Hose IC Bleed Hose
IC Bleed Hose
(Photo 5.16) Page 83 of 101 Recommended Tools To Be Used For SECTION 6: SC COLD AIR KIT INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
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4mm 1/4” Drive Allen Bit 10mm 1/4” Drive Deep Well Socket 1/4” Drive Ratchet 6” Long 1/4” Drive Extension Pipe Tape or Pipe Dope 5/8” Open Ended Wrench 8mm Nut Driver or Slotted Screw Driver Page 84 of 101 SECTION 6: SC COLD AIR KIT INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger 1. Using three of the supplied Bolts (000Z‐H02‐C000763) and Washers (000Z‐H03‐C000764), install the Supercharger Venturi (004A‐A02‐C000890) in the Air Filter Shroud (004Z‐A02‐B000726). Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 6.1) Note: When installing the Venturi, ensure the threaded platform for the barbed fitting is facing the direction of the engine. 2. Using either Pipe Tape or Pipe Dope cover half of the threads of the supplied Barbed Fitting (000Z‐H10‐C001082). Install the Barbed Fitting into the hole in the Venturi until the Fitting is flush with the inside surface of the Venturi. (See Photo 6.2) Note: Do not tighten the Barbed Fitting so that it enters the airstream flowing through the Venturi. 3. Using one of the supplied Size 56 Hose Clamps (000Z‐H09‐C000871), install the Hump Hose onto the Venturi, ensuring the Hump Hose is fully seated against the lip. (See Photo 6.3) Note: Rotate the hose clamp so that the tension screw is not visible but is still accessible. Note: Use caution when installing the Air Filter Shroud so that the Power Steering Reservoir Lines and Harness do not get damaged. 4. Place one of the Size 56 Hose Clamps (000Z‐H09‐C000871) over the open end of the Hump Hose and install the Hump Hose/Venturi/Air Filter Shroud assembly in the vehicle making sure the Hump Hose fits around the opening of the Throttle Body and the Tab on the back of the Shroud fits into the groove of the Radiator Overflow Tank. Once installed tighten the Hose Clamp. (See Photo 6.4) Note: Rotate the hose clamp so that the tension screw is not visible but is still accessible. 5. Install the Push Pin Fastener (000Z‐H13‐C000808) into the mounting hole on the bottom of the shroud fastening it to the chassis. (See Photo 6.5) 6. Install the Airbox Mounting Bolt removed during Section 1, Step 6 in the mounting hole of the Air Filter Shroud. Be sure to use Red Loctite P/N 27131 on the fastener. (See Photo 6.6) 7. Using the Hose Clamp supplied with the Air Filter, install the Air Filter onto the Venturi and tighten the hose clamp. (See Photo 6.7) Note: Rotate the hose clamp so that the tension screw is not visible but is still accessible. 8. Install the Rubber Hose (000Z‐A02‐C000731) between the Barbed Fitting of the Venturi and the Barbed Fitting of the Supercharger next to the Oil Filler Port. (See Photo 6.8) Page 85 of 101 Bolt & Washer
Air Filter Shroud SC Venturi
(Photo 6.1) SC Venturi
Barbed Fitting
(Photo 6.2) Page 86 of 101 Hump Hose
Size 56 Hose Clamp
(Photo 6.3) Air Filter Shroud Tab
Radiator Overflow Tank
(Photo 6.4) Page 87 of 101 Push Pin
(Photo 6.5) Airbox Bolt (Photo 6.6) Page 88 of 101 Hose Clamp Air Filter
(Photo 6.7) Oil Filler Port
Oil Breather Hose
Barbed Fitting Barbed Fitting (Photo 6.8)
Page 89 of 101 Recommended Tools To Be Used For SECTION 7: SUPERCHARGER TUNE INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
None Required Page 90 of 101 SECTION 7: SUPERCHARGER TUNE INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger 1. Plug the Supercharger Tuned Diablo Predator (004Z‐E14‐C000958) into the Diagnostics Port of the vehicle, located under the Dash on the Driver’s Side. 2. Once the Predator has loaded and is on the Menu Screen, turn the Key to Run (Two Clicks) Note: DO NOT START THE ENGINE. 3. On the Menu Screen select “Performance Tune” and press the center round “Select Button”. 4. “Agree” to the disclaimer that appears on the screen by pressing the Select Button. 5. Select “Custom Tune” and press the Select Button. 6. Select the applicable Techco Tune and press the Select Button. 7. A description of the tune will be displayed on the screen; press the Select Button to select “Choose”. 8. Select “Install Tune” and press the Select Button. 9. When prompted; turn the Key “two clicks” to Off and then “two clicks” to Run. Note: DO NOT START THE ENGINE. 10. A description of the Installed Tune will be on the screen. Note: Do not unplug the Predator at this time. 11. Press the Select Button to “Reboot” 12. At the Main Menu select “Diagnostics” and press the Select Button. 13. Select “Trouble Codes” and press the Select Button. 14. Select “Clear Trouble Codes” and press the Select Button. 15. A “Faults Cleared” message will be shown. 16. Select “Close” and press the Select Button. 17. A “No Trouble Codes Found” message should be shown on the screen. If not, view and correct any trouble codes and then clear any remaining trouble codes. Page 91 of 101 18. Press the Escape Button all the way back to the Main Menu screen. 19. Turn the Key Off (two clicks) and unplug the Predator. Note: DO NOT START THE ENGINE. Page 92 of 101 Recommended Tools To Be Used For SECTION 8: FLUID FILL & ENGINE RUN 3.0L Reverse Revolution Twin Screw Supercharger •
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1/4” 3/8” Drive Allen Bit 17mm Open Ended Wrench 17mm 3/8” Drive Deep Well Socket 3/8” Drive Ratchet 3” Long 3/8” Drive Extension 3/8” Drive (75 Ft‐Lb) Toque Wrench Small Mirror Flashlight Safety Glasses Funnel Pipe Dope Mopar ® Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent (Between 14.7‐15.2 quarts for the Engine, about 4 quarts for the Intercooler) Shop Towels or Rags Page 93 of 101 SECTION 8: FLUID FILL & ENGINE RUN 3.0L Reverse Revolution Twin Screw Supercharger WARNING: ANTIFREEZE IS A POISON; KEEP IT OUT OF REACH OF CHILDREN AND ANIMALS. Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, CALL 911 IMMEDIATELY. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Dispose of glycol based coolant properly; contact your government agency for location of collection center in your area. Note: Do not mix Mopar® Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS‐9769) with any other type of antifreeze; doing so will reduce the corrosion protection and may result in premature water pump seal failure. 1. Make sure the drain on the bottom of the Radiator is closed. (See Photo 1.14) 2. Remove the Bleeder Plug from the front of the Water Pump Housing. (See Photo 8.1) Note: The Bleed Plug is located behind the Supercharger Snout Brace and is accessed through a hole in the Snout Brace below the Supercharger Pulley. 3. Remove the Overflow Reservoir Pressure Cap from the Overflow Reservoir. 4. Insert the Funnel into the opening of the Reservoir. Note: Use caution when filling the coolant system and avoid spilling any coolant. 5. Slowly fill the coolant system until fluid is seen at the Bleeder Plug Opening. Note: Because of the location of the Supercharger Snout Brace a mirror and flashlight will be needed in order to see the fluid at the Bleed Plug Opening. 6. Clean any spilled coolant. 7. Remove the Funnel, reinstall the Pressure Cap, coat the threads with Pipe Dope and reinstall the Bleeder Plug. NOTE: During normal driving, the coolant system will push air out of the engine and into the overflow bottle, dropping the level seen inside the bottle. If the engine overheats and pushes coolant into the overflow side of the coolant bottle, the coolant can only be sucked back into the cooling system if the pressure cap is left on the overflow reservoir. Removing the pressure cap will break the vacuum between the two bottle sections and the coolant will not return to cooling system. Page 94 of 101 8. Remove the cap from the Intercooler Recovery Tank. 9. Insert the Funnel into the opening of the Intercooler Recovery Tank. Note: Use caution when filling the Coolant System and avoid spilling any coolant. 10. Using the same coolant as the engine, slowly fill the Intercooler System until the fluid level stops dropping in the Recovery Tank. Note: At this point the engine will now be started in order to finish the bleeding process of the Engine Coolant System and the Supercharger Intercooler System. DO NOT REV THE ENGINE. 11. Make note of the Coolant Level of the Overflow Tank and then start the vehicle and let it slowly idle until the engine reaches operating temperatures. Note: DO NOT REV THE ENGINE. Note: WHILE INITIALLY FILLING THE INTERCOOLER RECOVERY TANK AIR POCKETS MAY FORM IN THE HOSE BETWEEN THE RECOVERY TANK AND THE WATER PUMP. IF THIS HAPPENS, THE WATER PUMP WILL NOT PUSH ANY FLUID THROUGH THE SYSTEM AND NO COOLANT FLOW WILL BE OBSERVED IN THE RECOVERY TANK. TO CORRECT THIS, MOVE THE HOSE BETWEEN THE RECOVERY TANK AND THE WATER PUMP VIGOROUSLY UNTIL ALL AIR POCKETS HAVE BEEN RELEASED AND COOLANT FLOW IS OBSERVED. 12. Return to the Intercooler Recovery Tank and continue to slowly fill the tank until all air leaves the system and there is a steady flow of water with no bubbles flowing out of the Recovery Tank Inlet into the Recovery Tank. Note: When the Intercooler System is properly bled the fluid level inside of the Recovery Tank should be just at the level of the Recovery Tank Inlet 13. Remove the Funnel from the Recovery Tank and install the Recovery Tank Cap ensuring that it is screwed on tightly. 14. By this time the engine should be at or close to operating temperatures of 192 to 199°F. Once the engine has been warmed up most of the trapped air in the Coolant System should have been pushed into the Recovery Tank. 15. Turn the engine off and allow it to cool. The coolant level in the Recovery Tank should be between the “MIN” and “MAX” lines. If it is not, adjust the fluid level accordingly. WARNING: DO NOT OPEN THE PRESSURE CAP ON THE OVERFLOW RESERVOIR WHILE THE ENGINE IS HOT. THE COOLANT IS EXTREMELY HOT AND SEVERE BURNS WILL OCCUR. Page 95 of 101 NOTE: DURING THE INITIAL RUNNING OF THE ENGINE AND AFTER THE FIRST DAY THE SUPERCHARGER BELT INITIALLY STRETCHES. THIS IS NORMAL; WHEN IT OCCURS, FOLLOW THE PROCEDURE BELOW. 1. Loosen the Nut on the Tensioner Bolt of the Snout Brace. 2. Loosen the Bolt on the Supercharger Idler Pulley. 3. Tighten the Tensioner Bolt of the Snout Brace. 4. Tighten the Nut on the Tensioner Bolt of the Snout Brace. 5. Torque the Supercharger Idler Pulley Bolt to 50 Ft‐Lbs. 6. Torque the Tensioner Bolt of the Snout Brace to 40 Ft‐Lbs. NOTE: TO TEST THE TENSION ON THE SUPERCHARGER BELT, GRAB THE LONG SIDE AND TWIST IT. THE BELT SHOULD TWIST BETWEEN 40° AND 45°. (SEE PHOTO 5.10) Page 96 of 101 Engine Coolant Bleed Port (Photo 8.1) Page 97 of 101 Recommended Tools To Be Used For SECTION 9: BODY WORK INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger •
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10mm 1/4” Drive Deep Well Socket 13mm 3/8” Drive Deep Well Socket 15mm 3/8” Drive Deep Well Socket 1/4” Drive Ratchet 12” Long 1/4” Drive Extension 3/8” Drive Ratchet 3/8” Drive (75 Ft‐Lb) Toque Wrench Safety Glasses Red Loctite P/N 27131 Page 98 of 101 SECTION 9: BODY WORK INSTALLATION 3.0L Reverse Revolution Twin Screw Supercharger 1. Using the Hardware removed during Section 1, Step 19; install the Chassis Brace, PCM bracket, Wiper Motor Rubber Mount, Electrical Connector fastened via push pin to the Passenger’s Side bottom, and Wiper Motor Connector attached via push pin fastener to the Driver’s Side bottom of the brace. Torque the bolt to 7 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 1.16) 2. Using the Hardware removed during Section 1, Step 18; Install the Cowl. (See Photo 1.15) 3. Using the Hardware removed during Section 1, Step 17; install the Wiper Arms and Nut Caps in the location noted during that step. Torque the bolt to 13 Ft‐Lbs. Be sure to use Red Loctite P/N 27131 on the fasteners. (See Photo 1.15) 4. Install the Front Bumper on the Chassis. (See Photo 1.13) 5. Using the Hardware removed during Section 1, Step 34; reinstall the modified Air Deflectors. Tuck the lip of the Air Deflectors on the outside edge behind the Heat Exchanger Bracket hardware to help keep them in place. Reinstall harness on the Passenger’s Side Air Deflector. (See Photo 1.36) 6. With the help of another person carefully install the Front Fascia onto the body keeping in mind that there are two Wire Harnesses, one on each side that need to be connected to the Fascia before placing the Fascia on the vehicle. (See Photos 1.11 & 1.12) 7. Once the Fascia has been pushed into place, install the two Front Side Blinker Assemblies. (See Photos 1.10 & 1.12) 8. Using the Hardware removed during Section 1, Step 12; install the Mounting Bolt that attaches the top portion of the Front Fascia to the Body on both sides. (See Photo 1.9) 9. Using the Hardware removed during Section 1, Step 11; Pull the Wheel Arch away from the Front Fascia to gain access to and install the Mounting Bolt from each front wheel well that attaches the Front Fascia to the Body. (See Photo 1.8) 10. Using the Hardware removed during Section 1, Step 10; install the two Mounting Bolts attaching the Bumper Closeout Panel to the vehicle. 11. Using the Hardware removed during Section 1, Step 9; install the three Push Pin Fasteners in each wheel well connecting the Front Fascia to the Wheel Arch Panel and install the three fasteners attaching the Wheel Arch Panel to Bumper Closeout Panel. (See Photo 1.7) 12. Using the Hardware removed during Section 1, Step 8; the Eight Push Pin Fasteners from the top of the Front Fascia and the seven fasteners attaching the Front Fascia to Bumper Closeout Panel. (See Photo 1.6) Page 99 of 101 13. Install the two Hood Latch Closeout Panels. (See Photo 1.5) Note: Use caution when installing the panels so as to not break the three retaining posts on the bottom each panel. NOTE: The CARB EO label is required to be installed on your vehicle to aid in passing the California SMOG Check program. 14. Install the provide CARB EO Label (004Z‐A13‐C001334) on the Radiator Support next to the Factory VECI Label. (See Photo 9.1) Page 100 of 101 CARB EO Label OEM VECI Label
(Photo 9.1) Page 101 of 101