Weistec M156 Supercharger System

Transcription

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SL63
Weistec M156 Supercharger System
Installation Guide – Stage 1 / Stage 2
Phone 877-WEISTEC Fax 888-516-8219
www.weistec.com
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WARNING!
DO NOT HAVE YOUR ECU REPROGRAMMED ANYWHERE BUT AT WEISTEC FOR
THIS SUPERCHARGER. THE AMG 63 USES AN ELECTRONIC THROTTLE CONTROL
(ETC), WHICH IS CONTROLLED BY THE ENGINE CONTROL UNIT (ECU) AND THE
CALIBRATION INSIDE. A REFLASH DOES NOT PROPERLY RECALIBRATE THE
ENGINE MANAGEMENT SYSTEM; THIS CREATES A DANGEROUS SITUATION THAT
COULD RESULT IN A STUCK THROTTLE AND CAN LEAD TO INJURY OR DEATH.
WEISTEC FULLY REPROGRAMS THE ECU TO MERCEDES STANDARDS, AND
ENSURES THAT ALL ENGINE SAFETY CONTROLS ARE FULLY FUNCTIONAL.
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WARNING!
THE WEISTEC M156 SUPERCHARGER AND ACCOMPANYING PROGRAMMING
ARE DESIGNED AROUND THE USE OF 91 OCTANE FUEL OR HIGHER ONLY.
BEFORE YOU RUN YOUR MERCEDES WITH THE WEISTEC M156 SUPERCHARGER
INSTALLED EVEN ONCE, YOU MUST EITHER DRAIN THE FUEL TANK COMPLETELY
AND FILL IT UP WITH 91 OCTANE, OR BEGIN USING 91 OCTANE IN YOUR
MERCEDES TWO COMPLETE FILLUPS BEFORE INSTALLATION.
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WARNING!
IF YOU ARE NOT EXPERIENCED IN THE AREA OF
AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT
YOU REFER THIS INSTALLATION TO A CERTIFIED
INSTALLER OR TECHNICIAN.
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WARNING!
THE WEISTEC M156 SUPERCHARGER MUST BE FILLED WITH
160 mL OF PROVIDED OIL PRIOR TO ROTATION OF THE
COMPRESSOR SCREW SYSTEM OR YOUR WARRANTY WILL BE
VOIDED.
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WEISTEC M156 SUPERCHARGER
Installation Guide for MERCEDES AMG 63
Thank you for your purchase of the Weistec M156 Supercharger for the Mercedes AMG 63 with
the 6.3L motor. We appreciate your business, and we know you will enjoy your product.
For your benefit, please read the following instructions completely and thoroughly before
attempting to install the supercharger. Many questions we have received from customers
about the installation of our products that could have been easily solved by information listed
in the accompanying installation guide. We want you to enjoy the product in its fully functional
state, and reading this tutorial is the first step to getting you on your way to a more rare and
powerful Mercedes AMG.
PLEASE NOTE THAT IF YOU HAVE ANY AFTERMARKET POWERTRAIN PARTS ALREADY INSTALLED
ON YOUR VEHICLE, YOU MUST RETURN THE CAR TO STOCK STATUS – THIS INCLUDES PULLEYS,
PROGRAMMING, ETC.
THE CAR WILL NOT FUNCTION AND PARTS MAY NOT FIT PROPERLY IF OTHER AFTERMARKET
PARTS ARE INSTALLED.
We strongly urge that you also have at least one person to help you install the supercharger, as
the unit is heavy. You will soon be on your way to installing the World's First Supercharger for
the 6.3L!
Again, thank you for choosing Weistec Engineering!
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Table of Contents
Tools Required ............................................................................. Error! Bookmark not defined.
I.
Disassembly ..................................................................................................................... 2
II.
Bumper and Underbody Removal ............................................................................. 17
III.
Cradle Install and Air Tube Delete ............................................................................ 20
IV.
Weistec M156 Supercharger Installation................................................................. 32
V.
Power Steering Reservoir Relocation .......................... Error! Bookmark not defined.
VI.
Intercooler System Installation and Plumbing ....................................................... 39
VII.
Bumper and Underbody Installation ........................................................................ 47
VIII.
Supplementary Installation and Fluid Check .......................................................... 48
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Tools Required
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Hydraulic Jack or service lift
Jack Stands or transmission stand
1/4” Drive Ratchet
12" Long 1/4" Drive Extension
6.5mm 1/4” Drive Deep Well Socket
8mm 1/4” Drive Deep Well Socket
17mm 3.8" Drive Deep Well Socket
10mm Open End Wrench
1" Open End Wrench
8mm Ratcheting Wrench
3/8” Drive Ratchet
13mm 3/8" Drive Socket
Vice
17mm 3/8" Drive Deep Well Socket
19mm Heavy Duty Deep Well Socket
T-25 1/4" Drive Torx Bit
T‐30 1/4" or 3/8” Drive Torx Bit
E-8 3/8" Drive Reverse Torx Bit
E-10 3/8” Drive Reverse Torx Bit
E-14 3/8" Drive Reverse Torx Bit
Flat Head Screw Driver
Wire Cutter
Pushpin Removal Tool
6mm Drive Hex Bit
8mm Drive Hex Bit
Mechanics Rags
Vacuum
Painters Tape
Fluid evacuator
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Impact Gun (Optional)
Crimp Style clamp tool
5mm Drill bit
Drill
Grinder (Optional)
Torque Wrench
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I.
Disassembly
Before removing battery terminal, double check vehicle is in Park, and driver side window is
completely down.
1. Disconnect the Negative battery terminal by:
a. Swinging spare tire panel in truck upward to access battery.
b. Removing 2 T25 Torx Bit body screws.
c. Pulling top battery panel forward and sliding out.
2. Using 10mm Drive Socket, and 12" extension to remove batter ground strap. Raise and
support the hood.
3. Remove ECU by:
a. Removing right from rim and tire with 17mm heavy duty socket.
b. Removing inner wheel well using a 10mm Socket and 1/4" Drive Ratchet and
removing push pins with Push Pin Removal Tool.
c. Removing two 10mm nuts that hold ECU bracket using 10mm Socket and 1/4"
Drive Ratchet inside the fender.
d. Swinging ECU and Bracket out and unplugging chassis and engine harness from
ECU by sliding tabs.
e. Removing 4 T-27 bolts that hold bracket on ECU with a T-27 Torx Bit and 1/4"
Drive Ratchet.
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BEFORE MOVING ON, PLEASE FILL OUT THE VEHICLE INFORMATION/TUNE REQUEST FORM
AND MAIL THE ECU AND FORM TO 1701 E. EDINGER AVE. SUITE G4, SANTA ANA, CA 92705,
USA.
ELECTRONIC COMPONENTS SUCH AS THE ECU ARE VERY FRAGILE. PLEASE BE SURE TO
SECURELY PACK THE ECU WITH PROTECTIVE COVERING WHEN MAILING.
THE VEHICLE INFORMATION/TUNE REQUEST FORM IS INCLUDED WITH THE SUPERCHARGER
SYSTEM DOCUMENTATION, AND CAN ALSO BE FOUND AT http://weistec.com/support.html
4. Remove the air intake system from the vehicle by:
a. Removing plastic MAF clips.
b. Unplugging both MAF's.
c. Removing Mercedes engine cover.
d. Removing both air box inlet tubes.
e. Unplugging vacuum canister line.
f. Using Flat Head Screw Driver or 6.5mm Socket to loosen both Clamps.
g. Lifting the air box assemblies from the vehicle.
Place all removed parts in a safe location. Many parts will be reused.
5. Remove intake manifold by:
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a. Disconnecting Vacuum line from canister above the intake plenum.
b. Removing stock Y inlet from rear section of intake manifold. (Retaining clips on
both side of Y must be lifted upwards)
c. Unplugging all sensor clips, hoses, and fasteners and make wire harness free for
removal.
 8 injector clips
 Rear IAT Sensor clip
 Fuel pressure sensor clip
 2 throttle body clips (Front of manifold)
 1 map sensor clip (Front of manifold)
 1 Variable runner clip (Front of manifold)
 Air pump vacuum hose (Front of manifold, On solenoid side NOT
manifold side)
Variable Runner
TB 1
TB 2
MAP
d. Removing EVAP line from rear left valve cover and EVAP Silonoid.
e. Removing Variable Runner Solenoid from Intake Manifold and storing it for
reinstallation during final installation.
f. Removing PCV hose with T25 TORX Bit.
g. Removing 4 bolts for fuel rail removal.
h. Disconnecting fuel line using 14mm Open End Wrench and 17mm Open End
Wrench.
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Please be aware that the fuel system may retain fuel pressure that can be extremely
dangerous if removed suddenly. Proceed with caution.
Please be aware of dripping fuel that may get on parts that can be affected. Please cover fuel
line with a shop rag in this case.
i.
j.
k.
l.
Removing 10 T-45 Torx bolts from intake manifold.
Lifting intake manifold and setting on work bench.
Vacuuming area near ports to collect all trapped dust and debris.
Removing intake manifold gaskets and placing painters tape on runners.
6. Remove power steering reservoir and bracket by:
a. Removing all fluid with the use of a fluid evacuator.
b. Removing T-25 Torx bolt from reservoir tab.
c. Lifting up and disconnecting 2 lines from the front of the engine. (Remove hard
lines with reservoir.)
d. Use rags to reduce spillage.
e. Disconnecting retaining clip for air pump solenoid.
f. Removing 4 T-45 bolts and eliminate engine bracket.
7. Remove both rear engine hoist brackets by:
a. Removing 3 T-45 Torx bolts from right side of vehicle.
b. Cutting harness zip tie from bracket and removing bracket.
c. Inserting 2 T-45 Torx bolts to hold dipstick tube to head. (Same location)
d. Removing 3 T-45 Torx bolts from left side of vehicle.
e. Removing bracket.
8. Remove Throttle bodies by:
a. Placing intake manifold on clean work bench.
b. Removing map sensor with T-30 Torx Bit. (2 Bolts)
c. Detaching wire harness from the front of the intake manifold.
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d. Flipping manifold upside down, and removing 12 T-30 Torx bolts.
T-30
e. Inserting flat head screw driver between lower pan, and manifold plate and
gently prying to open.
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f. Pulling rubber wire bulk head through hole.
g. Using T-30 Torx bit, and removing 4 bolts per throttle body, and 2 metal wire
clamps.
h. Removing evaporative lines from each throttle body, as well as both horns by
unclipping from the side.
i. Bolting complete assembly back together to ensure safe storage.
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j.
Remove four airbox balls using a 10mm deep wall socket and 1/4" drive. (Store
in safe location, will be used soon)
f. At this point you will need to gather two (2) throttle bodies, two (2) throttle
body gaskets, one (1) throttle body harness, one (1) runner solenoid, one (1)
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map sensor, and one (1) IAT Sensor. These items will be reused on the
supercharger system.Removing plastic cover by turning 2 tabs 90 degrees and
lifting.
g. Removing ECU and cage with a T-30 Safety Torx Bit and a 3/8" ratchet.
Unplugging chassis and engine harness from ECU by sliding tabs.
Before removing battery terminal, double check vehicle is in Park, and driver side window is
completely down.
9. Disconnect the Negative battery terminal by:
d. Swinging spare tire panel in truck upward to access battery.
e. Removing 2 T25 Torx Bit body screws.
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f. Pulling top battery panel forward and sliding out.
10. Using 10mm Drive Socket, and 12" extension to remove batter ground strap. Raise and
support the hood.
11. Remove ECU by:
h. Removing right from rim and tire with 17mm heavy duty socket.
i. Removing inner wheel well using a 10mm Socket and 1/4" Drive Ratchet and
removing push pins with Push Pin Removal Tool.
j. Removing two 10mm nuts that hold ECU bracket using 10mm Socket and 1/4"
Drive Ratchet inside the fender.
k. Swinging ECU and Bracket out and unplugging chassis and engine harness from
ECU by sliding tabs.
l. Removing 4 T-27 bolts that hold bracket on ECU with a T-27 Torx Bit and 1/4"
Drive Ratchet.
BEFORE MOVING ON, PLEASE FILL OUT THE VEHICLE INFORMATION/TUNE REQUEST FORM
AND MAIL THE ECU AND FORM TO 1701 E. EDINGER AVE. SUITE G4, SANTA ANA, CA 92705,
USA.
ELECTRONIC COMPONENTS SUCH AS THE ECU ARE VERY FRAGILE. PLEASE BE SURE TO
SECURELY PACK THE ECU WITH PROTECTIVE COVERING WHEN MAILING.
www.weistec.com
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THE VEHICLE INFORMATION/TUNE REQUEST FORM IS INCLUDED WITH THE SUPERCHARGER
SYSTEM DOCUMENTATION, AND CAN ALSO BE FOUND AT http://weistec.com/support.html
12. Remove the air intake system from the vehicle by:
h. Removing plastic MAF clips.
i. Unplugging both MAF's.
j. Removing Mercedes engine cover.
k. Removing both air box inlet tubes.
l. Unplugging vacuum canister line.
m. Using Flat Head Screw Driver or 6.5mm Socket to loosen both Clamps.
n. Lifting the air box assemblies from the vehicle.
Place all removed parts in a safe location. Many parts will be reused.
13. Remove intake manifold by:
m. Disconnecting Vacuum line from canister above the intake plenum.
n. Removing stock Y inlet from rear section of intake manifold. (Retaining clips on
both side of Y must be lifted upwards)
o. Unplugging all sensor clips, hoses, and fasteners and make wire harness free for
removal.
 8 injector clips
 Rear IAT Sensor clip
 Fuel pressure sensor clip
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2 throttle body clips (Front of manifold)
1 map sensor clip (Front of manifold)
1 Variable runner clip (Front of manifold)
Air pump vacuum hose (Front of manifold, On solenoid side NOT
manifold side)
Variable Runner
TB 1
TB 2
MAP
p. Removing EVAP line from rear left valve cover and EVAP Silonoid.
q. Removing Variable Runner Solenoid from Intake Manifold and storing it for
reinstallation during final installation.
r. Removing PCV hose with T25 TORX Bit.
s. Removing 4 bolts for fuel rail removal.
t. Disconnecting fuel line using 14mm Open End Wrench and 17mm Open End
Wrench.
Please be aware that the fuel system may retain fuel pressure that can be extremely
dangerous if removed suddenly. Proceed with caution.
Please be aware of dripping fuel that may get on parts that can be affected. Please cover fuel
line with a shop rag in this case.
u. Removing 10 T-45 Torx bolts from intake manifold.
v. Lifting intake manifold and setting on work bench.
w. Vacuuming area near ports to collect all trapped dust and debris.
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x. Removing intake manifold gaskets and placing painters tape on runners.
14. Remove power steering reservoir and bracket by:
g. Removing all fluid with the use of a fluid evacuator.
h. Removing T-25 Torx bolt from reservoir tab.
i. Lifting up and disconnecting 2 lines from the front of the engine. (Remove hard
lines with reservoir.)
j. Use rags to reduce spillage.
k. Disconnecting retaining clip for air pump solenoid.
l. Removing 4 T-45 bolts and eliminate engine bracket.
15. Remove both rear engine hoist brackets by:
f. Removing 3 T-45 Torx bolts from right side of vehicle.
g. Cutting harness zip tie from bracket and removing bracket.
h. Inserting 2 T-45 Torx bolts to hold dipstick tube to head. (Same location)
i. Removing 3 T-45 Torx bolts from left side of vehicle.
j. Removing bracket.
16. Remove Throttle bodies by:
k. Placing intake manifold on clean work bench.
l. Removing map sensor with T-30 Torx Bit. (2 Bolts)
m. Detaching wire harness from the front of the intake manifold.
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n. Flipping manifold upside down, and removing 12 T-30 Torx bolts.
T-30
o. Inserting flat head screw driver between lower pan, and manifold plate and
gently prying to open.
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p. Pulling rubber wire bulk head through hole.
q. Using T-30 Torx bit, and removing 4 bolts per throttle body, and 2 metal wire
clamps.
r. Removing evaporative lines from each throttle body, as well as both horns by
unclipping from the side.
s. Bolting complete assembly back together to ensure safe storage.
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t. Remove four airbox balls using a 10mm deep wall socket and 1/4" drive. (Store
in safe location, will be used soon)
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At this point you will need to gather two (2) throttle bodies, two (2) throttle body gaskets,
one (1) throttle body harness, one (1) runner solenoid, one (1) map sensor, and one (1) IAT
Sensor. These items will be reused on the supercharger system.
II.
Bumper and Underbody Removal
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1. Safely place vehicle on vehicle hoist or stands.
2. Remove belly pan, and bumper shrouds by:
a. Using 8mm Socket and 1/4" Drive to remove complete underbody and set in a
safe location.
b. Using Push Pin Removal Tool, remove five pins from left and right side wheel
well and underbody. (Total varies on build date.)
c. Removing turn signal light on left and right side of bumper.
d. Using an 8mm Ratcheting Wrench, remove both bolts inside Signal hole.
e. Using 8mm Socket, 12" long 1/4" extension, and 1/4" Drive, remove top bumper
bolts between headlight mount and grill.
f. Removing grill support using 8mm Socket from radiator support.
g. Pulling both side grills from the bottom of the bumper to gain access.
h. Using 8mm Socket, 12" long 1/4" extension, and 1/4" Drive, remove bolt from
either side of lower grill in corner.
i. With the help of one more person, slide bumper forward and disconnect
headlight sprayers.
j. Setting bumper in a safe location.
k. Removing center oil cooler shroud
l. Removing oil cooler side mounts with a 10mm Socket and 1/4” Drive.
m. Shrouding and oil cooler side mounts (above) will be completely removed from
vehicle at this point.
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Oil cooler will be mounted to heat exchanger in steps ahead.
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III. Cradle Install and Air Tube Delete
1. Install Cradle assembly by:
a. Removing air pump valves using a T30 bit
b. Removing air pump tubes using an E10 bit.
c. Remove the indicated bolt from the left side air pump valve and drill through the
bolt hole with an 6mm drill bit.
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d. Remove the indicated bolt from the right side air pump valve and drill half way
through the hole from the bottom. Do not drill through the threads in the top
half of the air pump valve
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Keep Threads
Intact
e. Use a M6 x 1.0 tap to tap the threads from the bottom of the right side air valve.
f. Bolt air pump valves together, right side valve on top of the left side valve using
the included M6x1x30 Button head cap screw, as shown below
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g. Use a hack saw to cut off the mounting tab from the right side air valve shown
below
h. Bolt the air pump valves to the engine in the location where the left side air
valve was removed from and bolt the metal air tube back onto the left side air
valve
i. Connect the Air Tube and air valve vacuum lines
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j.
Use included hose and adapter fittings to connect the right side metal air tube to
the right side air valve in its new location. The Straight adapter bolts onto the
right side metal air tube and the Bent adapter bolts to the right side air valve.
Cut the included hose to proper length and use the included clamps on each end
of the hose.
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k. Clean block surface where existing power steering reservoir mounted.
l. Positioning the cradle in the front of the engine as shown
m. Insert one M8x1.25x25mm bolt through the left hole on top of the cradle and
partially thread them. Do not tighten the bolt yet
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Insert bolt into this hole. A bolt is not
used in the other hole to make
servicing the supercharger in the
future easier.
n. Bolt on Belt Wrap Idler using the M8x1.25x90mm bolts to the front of the cradle.
Partially thread them in.
Installation of
the belt wrap
idler is shown in
this illustration
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o. Tighten all three bolts using a 6mm hex bit starting with the top bolt then tighten
the front bolts. Torque to 20 ft-lbs
p. Removing existing serpentine belt using a 17mm 3/8" deep socket and a 3/8"
drive onto belt tensioner.
q. Removing all idlers pulleys, water pump pulley and the factory belt tensioner.
(Please view Belt Routing Diagram for further information on which pulleys are
replaced with new billet parts)
r. Installing all idler pulleys with retaining clip facing radiator in the locations
shown in the belt routing diagram below
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Belt Routing Diagram:
65mm Idler
65mm Idler
Grooved Idler
54mm Idler
Water Pump
Pulley
Tensioner
Idler
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a. Using supplied M8x22mm allen hex bolt and bearing washer on tensioner pulley
onto supplied Weistec High Rate Tensioner and M8x40mm allen hex bolts and
black bearing washers on the rest of the idlers. Install Weistec High Rate
Tensioner in place of the factory belt tensioner. Install Weistec Water Pump
Pulley using included hardware (Be sure to retain factory spacer on the idler
pulley above the crankshaft pictured below)
Do not forget
factory spacer
for this Idler
Make Sure All Idlers Are Installed With The Retaining Clip Facing the Radiator.
Stock Tensioner Idler:
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Billet Tensioner Idler Installed Using Supplied Washer and Bolt:
Installing included serpentine belt around newly added supercharger pulley.
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IV.
Weistec M156 Supercharger Installation
Always keep your work area clean for this process.
1. Install Supercharger System by:
a. Removing Supercharger from Box A and clean and dust or debris from system.
b. Removing runner cover tags, and all vacuum port plastic covers. Do NOT remove
throttle body covers.
c. Removing painters tape from ports and double check a clean surface.
d. Placing new (Included) intake manifold gaskets on head surface.
e. Clocking water manifold ports (Rear of Supercharger system) at a 10 o'clock and
2 o'clock position. (Do not tighten clamping bolts until you are sure water lines
will clear near firewall)
f. Installing the following vacuum lines before installation:
 Air pump vacuum line on lowest vacuum port for Stage 1 and Stage 2
vehicles, For Stage 3 the 1/8” port must be securely plugged or capped
 Long 3/8" EVAP line. (Keep coiled on top of supercharger unit)
 10" 1/2" brake boost line with crimp style clamp.
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g. Installing existing map sensor using 5mm Allen Bit.
Socket head allen bolts used for map sensor and PCV in rear Y inlet.
h. Unclipping injectors from existing fuel rails, and inserting into new fuel rails with
clips. (Be sure to use some lubrication to insert into fuel rails and supercharger,
failure to do so can result in damage to O rings)
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i.
Install the IAT (Intake Air Temperature) Sensor in the rear of the supercharger
system.
MAP Sensor
IAT Sensor
j.
With the help of a technician, lift supercharger system and carefully place it into
its position. Fitment should be very snug and clean. Be sure to lower the
Supercharger slowly as to not damage the gaskets.
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k. Using the included new stainless socket Allen bolts, insert all ten and tighten
snug. Torque bolts in a start pattern to 18-19 Lb. Ft. (25 Nm)
l.
Twisting existing brake booster line towards supercharger unit, and placing
included crimp style clamp on 1/2" brake booster hose and slide over existing
line. Adjust line and double check no bottle necks in line. Crimp clamp at this
point.
m. Installing new fuel rails and injectors onto supercharger unit buy using 4mm
Allen bit and 1/4" drive. Aluminum finish spacers will be used between manifold
and fuel rail.
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n. Running new fuel line crossover behind Y inlet. (45° end must be on right side of
vehicle)
o. Using 7/8" wrench, tight both fuel line ends.
p. Replacing existing harness zip ties with included zip ties. Cut excess and dispose.
Cut MAP sensor
plug here and
extend
q. Carefully cutting 3 wire map sensor wire about 1.5" away from plug and crimping
new extension. Use included heat shrink on all crimp joints and be sure to have
no wiring or metal showing through. Use 3/8" heat shrink over all three wires.
Clip plug in rear of Y inlet.
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New MAP Sensor
Plug Location
r. Clipping existing throttle body harness. (Two plugs)
s. Plugging in Variable Runner and Air Pump Solenoids to the engine harness.
Variable Runner Solenoid will have no vacuum lines connected to it. Air Pump
Solenoid will re-use factory vacuum lines for Stage 1 and Stage 2 cars. Stage 3
cars the solenoid will only be plugged into the engine harness. Cable ties
should be used to secure the solenoid in place.
Solenoid Cable
tied to harness
under air box
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t. Installing existing PCV line in rear section of Y Inlet using a 5mm Allen key.
Twisting hose can be necessary for proper seal.
Shown Above is the PCV hose correctly positioned for installation.
u. Installing existing airbox balls on included stand-off's using a 10mm open end
wrench, and a 10mm deep wall socket and 1/4" drive.
v. Running 3/8" EVAP hose along coil pack wiring harness and using crimp style
clamp onto EVAP solenoid. Use included zip ties to hold in place of existing EVAP
line.
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V.
Intercooler System Installation and Plumbing
1. Install Intercooler recovery tank by(Skip this Section if installing Weistec Trunk Ice
Tank, Refer to Trunk Tank Manual for hose routing):
a. Removing two existing timing cover bolts on right side using a T-30 Torx Bit and
3/8" drive.
Remove
b. Removing wire harness on right side.
c. Mounting tank using 5mm Allen Bit and 1/4" Drive against timing cover with
spacers.
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d. Installing lines onto reservoir and fastening included clamps with crimp style
clamp tool. (More pictures of this procedure below).
2. Install Water Pump by:
a. Using a 5mm Drill Bit and a Drill, drill two holes through bumper support.
1 1/4"
1/2"
b. Using two supplied body bolts, use a 10mm Socket and 1/4" Drive Ratchet to
screw in place.
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c. Mounting pump onto bracket by using a 12mm Open End Wrench to screw bolts
in place, and Using a 13mm Open End Wrench to install supplied M8 Serrated
nuts on back side of bracket.
3. Install Heat Exchanger by:
a. Cutting along white lines with an angle grinder to properly fit with heat
exchanger.
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b. Trimming around shrouding to properly fit oil lines.
Trim here with
Aviation snips
a. Installing metal brackets back onto vehicle and pushing oil cooler pins in top
grommets and shifting bottom grommets behind bracket to give the oil cooler a
more straight and flush mount. (This will leave room for the Heat Exchanger.)
b. Using a 5mm Drill Bit and a Drill, drill four holes on marks through bumper
support.
c. Using four included body bolts, use a 10mm Socket and 1/4" drive to screw in
place.
4. Install Intercooler hoses by:
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a. Placing included clamps on both ends of the short straight hose. Cut to length
approximately 11-12".
b. Placing included clamps on both ends of L-shaped molded hose and installing
from heat exchanger to the bottom o the recovery tank.
c. Placing included clamps on both ends of straight 3/4" hose and running from
water pump to the rear of the supercharger. (Be sure to tighten rear
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supercharger fitting at this point with a 1" Open End Wrench.)
Cut hose to length on supercharger side.
d. Placing included clamps on both ends of straight hose and installing from
intercooler reservoir to back side of supercharger system. Zip Tie water line to
radiator hose and keep clear of fan shroud. (Be sure to tighten water outlet nut
before moving forward with a 1" Open End Wrench)
Cut hose to length on supercharger side.
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Double Check all fitments of hoses and assure no bottle neck or kink in hose.
This will greatly reduce flow and performance of system. Also double check all
hoses are not lying against sharp objects.
5. Install Water Pump Wiring by:
a. Using 10mm Socket and 1/4" Drive, remove ground nut from left side wheel
well, and place included harness ground and retighten.
b.
c.
d.
e.
Running wire along body wiring up to fuse box.
Using zip ties from water pump along with body wiring.
Plugging harness and water pump together.
Run Blue switched line to open connector in fuse box.
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Run red power line to open connector in fuse box.
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VI.
Bumper and Underbody Installation
1. Install Bumper by:
a. Replugging all head light electrical clips.
b. Reinstalling bumper cover using an 8mm Socket, 12" Extension, 1/4" Drive and
8mm Ratcheting Wrench.
c. Reinstall grill support using a 8mm Socket and 1/4" Drive onto radiator support.
d. Lift car on hoist and reinstall underbody using an 8mm Socket and 1/4" Drive and
reinserting all push pins. (Ten total)
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VII. Supplementary Installation and Fluid Check
1. Install existing fuel line by:
a. Removing line from existing fuel rails with a 17mm Open End Wrench.
b. Installing onto new fuel rails using a 17mm Open End Wrench on the fuel rail
side, and install onto chassis side using a 17mm Open End Wrench and 14mm
Open End Wrench.
2. Install Throttle Bodies by:
a. Placing throttle bodies in vice.
b. Tapping existing hole with supplied 1/8" NPT Tap.
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c. using pipe sealant, place NPT plug into hole.
d. Removing protective film from throttle body inlets.
e. Placing included bolts into throttle body with existing gasket and fastening in star
formation on both sides.
f. Run existing throttle body wiring behind supercharger Y inlet and plug into both
throttle bodies.
3. Install factory air boxes by:
a.
b.
c.
d.
e.
Installing included black couplers and clamps on throttle body side.
Fastening clamps on throttle body side.
Freely placing existing air box couplers over coupler, install factory air boxes.
Fasten clamps on air box side.
Install air box inlets.
4. Install ECU by:
a. Inserting ECU into the fixture.
b. Clipping Chassis and engine harness and sliding clips to ensure proper plug in.
c. Reinstalling onto bracket and sliding in fender.
d. Gently bolting it down with 10mm Socket and 1/4" Drive Ratchet.
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5. Final assembly:
a. Plug in electrical connections for the Variable Runner Solenoid and Air Injection
Solenoid. Solenoids must be plugged in to prevent check engine lights and
other issues. Position solenoids in secure locations on the intake manifold and
use cable ties to hold them in place
b.
c.
d.
e.
f.
Add water into intercooler system and double check no leaks.
Reinstall battery ground using a 10mm Socket and 1/4" Drive.
Reinstall battery cover.
Check all vital fluids.
Turn Key to on position and add water into intercooler system until system is
fully bled and water is visibly circulating.
6. Fill supercharger with oil by:
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a. Removing plug on top of supercharger with a 5mm allen bit.
b. Filling supercharger unit with supplied oil.
Weistec Engineering recommends adding coolant / anti-freeze to the intercooler system if
climate temperatures reach freezing.
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7. Bleed Power Steering System by:
a. Making sure that power steering lines are properly routed, sloping down from
the reservoir to the power steering pump
b. Loosening Power Steering Reservoir Cap, wrapping a shop rag around the cap in
case of over flow.
c. Starting engine
d. Turning steering wheel from lock to lock 2 to 3 times.
e. Checking power steering fluid level, adding fluid if necessary
f. Repeating steps d and e until power steering system is functioning properly and
quietly
g. Tightening Power Steering Reservoir Cap
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Thank you from Weistec Engineering!
Always enjoy the added horsepower and torque of the M156 supercharger responsibly. Use
best judgment when driving, and remember to have fun!
NOTES:
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Weistec M156 Supercharger System

Transcription

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