Transcript
ADVANCED MOTORSPORT SOLUTIONS
VR6 Supercharger System Golf III and Jetta III VR6 Installation Manual Model Year 1994-1999.5
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ADVANCED MOTORSPORT SOLUTIONS Index 1.0 1.1 1.2 1.3 1.4
Parts List Required Tools Required Standard Parts Required Misc. Shop Supplies Safety Precautions
2.0 2.1 2.2 2.3 2.4
Vehicle Pre-Requisites Compression Test Leak-down Test Engine Bay Preparation Installation Overview
3.0
Installation
4.0
Finial Checks
5.0 5.1
Maintenance and Belt Tension Interval Troubleshooting
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ADVANCED MOTORSPORT SOLUTIONS 1.0
Parts List
See Packing List inside carton box 1.1
Required Tools
Phillips Screwdriver Set Flat Tip Screwdriver Set Torx T-15 Driver 5mm Allen Bit 3/8” Drive 6mm Allen Bit 3/8” Drive 8mm Spline Driver Metric Wrenches Metric Sockets 1/4”Drive Metric Sockets 3/8 Drive Ratchet 3/8” Drive Ratchet 1/4” Drive Extension Set 1/4” Drive Extension Set 3/8” Drive Torque Wrench 3/8” Drive Center Punch (Automatic) or Regular with Hammer
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ADVANCED MOTORSPORT SOLUTIONS 1.1
Required Tools Continued
Air or Electric Drill Tap set 8mmx1.25 Normal, & Bottoming 17/64 Drill bit with Stop 1 ½“Hole saw and mandrel Flat File Round File Grease Pencil Metric Tape Measure Diagonal Cutter Pliers Regular Pliers Circlip Pliers Puller for A/C Clutch or Gear Puller Hydraulic Jack and Stands or Shop Lift 1.2
Required Standard Parts
Intake Manifold Gasket Upper Intake Manifold Gasket Lower Oil Pan Gasket Oil Filter Oil Drain Plug Washer
021 133 227 J 021 133 227 H 021 133 609 B See Dealer Variance with production date N 013 849 2
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ADVANCED MOTORSPORT SOLUTIONS 6 Quarts Engine Oil 1.3
Locally Available
Required Misc. Shop Supplies
Qty Required 3 Standard Thread ¼-20 Bolts or Screws (Used to Remove A/C Clutch Plate) 1 Metric Bolt 8x1.25 x 35mm (Used To De-Tension Belt Tensioner) Tube of Blue Loctite Thread locker 242 Tube of Teflon Based Pipe Thread Sealant Masking Tape Masking Paper Primer Paint Enamel (Black) Factory Approved Shop Repair Manual
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ADVANCED MOTORSPORT SOLUTIONS 1.4
Safety Precautions
Working safely is very important. Many components are under pressure, or require a great deal of pressure to remove. Always take care and proceed with caution. After reading this complete installation manual if you have any doubts regarding any of the procedures we recommend the installation to be performed by a trained technician or AMS authorized Dealer. Below you will find a list of recommended safety basics when working on the vehicle. • Disconnect the vehicles battery • Always wear Eye and or Ear Protection when Drilling, Cutting, Grinding, Welding, Brazing, or working with any part of the fuel system, Air Condition System. • Never Work under any vehicle supported by a jack • Wear Latex gloves when working with or near any automotive liquids (Ex. Gasoline, Engine Oil, Brake Fluid, Coolant, Power Steering Fluid Etc.) many of these items have been known to cause cancer and other health related problems. 2.0
Vehicle Pre-Requisites
Vehicle must be in perfect working order before the installation takes place. We recommend a full safety check to be performed on the vehicle. Covering Braking, Steering, Suspension, Engine, Transmission, Clutch, Wheels, Tires, Lightning, Horn, Etc.
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ADVANCED MOTORSPORT SOLUTIONS 2.1
Compression Test
A compression test must also be performed to acquire engine condition. The test must be performed with the Main engine harness connector removed. Also while cranking the engine over, the throttle must be held in the wide-open position. Compression should be between 185-195 Psi 2.2
Leak-down Test
A leak-down test must be performed to acquire engine condition. The test must be performed with a regulated and dried shop air supply. Leak-down results must not indicate 15% or higher. If high leakdown results are found the engine must be disassembled to determine the problem. After the problem is corrected and all break-in limits are met, the Installation may take place. 2.3
Engine Bay Preparation
Engine bay preparation is recommended on an older vehicle if so required. Engine bay must be clean before the installation takes place. Caution must be taken when washing the engine bay due to electrical components and water being retained in the spark plug galleys. After washing the engine bay be sure to dry the area with shop air or by using rags. Be sure no water is in the spark plug galleys when starting the engine or damage can occur due to the shorting of the ignition system. A degreaser can be used as necessary on affected areas. Many are available commercially.
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ADVANCED MOTORSPORT SOLUTIONS 2.4
Installation Overview
The installation of the ADVANCED Supercharger System must be taken with care in order to ensure a healthy reliable vehicle. We took great care in developing the system for this engine family and expect you to also follow in the same manner during “the final phase” the installation. A faulty installation can cause many possible problems (Ex. engine failure, supercharger failure etc.) That is why a great degree of care must be taken during this conversion process. On the next few pages we will cover the steps involved during the installation. • • • • • • • • • • • • • • •
Obtain Radio code from customer Warm up engine and perform compression and Leak-down tests. While engine is warm drain engine oil and remove oil filter. Disconnect Battery Remove Cooling Fan Guard Remove Complete Air Cleaner housing Mark passages for Oil Return Line With template and Drill, Clean, and Paint Remove Upper and Lower Intake manifolds Remove Serpentine Belt Tensioner and Belt Remove Alternator Remove A/C Compressor (Do not disconnect A/C Hoses) Machine A/C Compressor Clutch Pulley 1mm thick sides Reinstall A/C Compressor Install Alternator with Idler Bracket Install Oil Supply Adapter and Feed Line
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ADVANCED MOTORSPORT SOLUTIONS 2.4 Continued • • • • • • • • • • • • • • • • • • • • •
Install Intake Manifolds Install Supercharger Bracket onto Cylinder Head Mark Hole Drill and Tap Drain Engine Oil and Replace Filter Remove Oil Pan and Clean Mark Hole for Oil Return Adapter with template Drill hole in pan and Weld Adapter onto pan Clean and paint Oil pan Reinstall oil Pan Install New Serpentine belt Install oil return line on Supercharger Mount Supercharger to bracket Tension Belt and Torque Supercharger mounting bolts Install Check valve for EVAP line at manifold Install Air Filter Install Intake Charge Pipe and Secure Clamps Route Hose for Crankcase Ventilation to Air Filter Remove Motronic Control Unit (ECU) and install new PowerProm in the ECU Fill Engine With oil Be ready to disarm alarm system if so equipped Connect Battery Start Engine
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ADVANCED MOTORSPORT SOLUTIONS • Check For and leaks (Fuel, Oil, Air) 2.4 Continued • • • •
Let Cooling fan Cycle Test Drive Vehicle Carefully Set Clock Decode Radio
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ADVANCED MOTORSPORT SOLUTIONS 3.0
Installation
3.1
Warm up engine and perform compression and leak-down test.
3.2
While engine is warm drain Engine Oil and Change Oil Filter. (Replace Drain Plug Washer)
3.3
Obtain Radio Code from Customer (if equipped with factory radio or coded type unit)
3.4
Disconnect Negative (-) Battery Terminal
3.5
Remove Cooling Fan Guard
• Remove (3) Bolts for Guard 3.6 • • • • • • •
Removal of Air Cleaner Box
Loosen Clamp for Mass Air Flow sensor (MAF) and pull off air tube. Loosen Clamp for Secondary Air Pump feed and pull off tube. Disconnect 4-Pin Connector at MAF. Release (2) Latches for Air Box Lid and remove Lid. Release (2) O-ring type mounting bands from the bottom half of the Air Cleaner Box. Remove lower half of the Air Cleaner Box. Release (2) Latches for MAF on Air Box Lid and carefully pull out the MAF sensor (Dropping the MAF sensor may cause damage to the sensor). Set MAF sensor aside.
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ADVANCED MOTORSPORT SOLUTIONS 3.7 • • • • • • • • • • • • • •
Oil Return Line Preparation
Cover Air Intake and Secondary Air Tubes with Plastic Bags. Remove (2) Plastic-retaining clips to gain access to studs. Using Template (A) provided place over studs and mark top of sheet metal with grease pencil. Drill with hole saw and finish opening to match template. Raise Vehicle on lift. Remove Plastic Cover from bottom of Frame Rail. Using Template (B) provided fit to bottom of front rail and mark with grease pencil. Drill with hole saw and finish opening to match template. Finish with files and remove all sharp edges. Clean all debris and hot wax from inside frame rail. Mask around holes with tape and paper. Prime and paint all raw areas. Install molding for top and bottom holes. Re-Install (2) plastic retaining clips.
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ADVANCED MOTORSPORT SOLUTIONS
Oil Return Line Passage
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ADVANCED MOTORSPORT SOLUTIONS 3.8
Intake Manifolds
(Upper) • Remove Spark plug wires with factory tool (may be located on hood prop rod or with jack). • Remove (3) Plastic Intake Manifold Covers (6) 8mm Spline fasteners. • Loosen Clamp at Throttle Body and remove Air Intake Boot. • Loosen Clamp for Evap Hose and pull off Hose. • Loosen Clamp and Disconnect brake booster hose. • Disconnect electrical connector at Intake Air Temperature sensor. • Open up Clamp for Vacuum hose at Fuel Pressure Regulator with small straight pic and pull off hose. • Disconnect Vacuum hose at Plastic tee fitting leading to Intake Manifold. • Disconnect Throttle Cable from Throttle Body and undo retaining clip from bracket. • Disconnect Electrical connector at Throttle Body and unclip wiring loom (2) Clips. • Remove (2) rear mounting bracket top bolts for Intake Manifold. • Loosen (2) rear mounting bracket bottom bolts. • Remove (1) Mounting Bolt for Dipstick Tube and remove Tube (Note O-Ring for dipstick tube should be removed from Engine block and put onto Dipstick Tube). • Remove (7) front mounting bolts and lay upper manifold off to the Left side of the Vehicle.
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ADVANCED MOTORSPORT SOLUTIONS 3.8
Intake Manifolds Continued
(Lower) • De-Tension Serpentine Belt by Threading 8mm x 1.25 x 35mm Bolt into the top of the belt Tensioner. • Remove the (3) Mounting Bolts for the Tensioner and Remove Tensioner and set aside. • Remove the Serpentine Belt and set aside. • Remove (1) Mounting Bolt for Secondary Air Tube (Above Alternator) • Loosen Clamp for Secondary Air Tube (Below Alternator) • Remove Upper bolt for Alternator. • Loosen Lower bolt for Alternator. • Open Wiring Tray for Fuel Injectors. • Disconnect Electrical Connectors for all (6) Fuel Injectors. • Release Mounting Clips for Fuel Rail Hoses at side of valve cover. • Slide Vacuum Valve off of bracket for Secondary Air Injection. • Disconnect Electrical Connector for Secondary Air Injection Valve. • Remove (3) Mounting Bolts for Secondary Air Pump. • Disconnect Secondary Air tube (from pump to valve). • Remove (10) Manifold Mounting Bolts • Lift Lower Manifold and Disconnect electrical wiring for Oil Pressure Switches and Oil Temperature Sender (Note Position of wires so they can be reconnected later in the same order) • Lift Lower Manifold and Set on top of the Valve Cover. • Disconnect Electrical Connector for Secondary Air Pump. • Disconnect Air tube from Secondary Air Pump and remove Pump. • Remove Secondary Air Pump Tube.
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ADVANCED MOTORSPORT SOLUTIONS 3.9 • • • •
Removal of Alternator
Disconnect Electrical Connection at A/C Compressor. Remove Bottom Bolt for Alternator Un-clip Wiring Harness for Alternator. Remove Alternator from Bracket and Set off to the left side of Vehicle.
3.10 Removal of A/C Compressor (!DO NOT Disconnect A/C Hoses!) (Eye Protection Required) • Remove (2) Mounting Bolts for Compressor. • Place Fender Cover on top of Radiator Support. • Lift Compressor and set on cloth. 3.11 Modification of A/C Compressor Clutch Pulley (Eye Protection Required) • Remove Clutch Plate Mounting Nut. • Thread (3) Standard ¼ -20“ Bolts or Screws into Clutch Plate and Tighten evenly until Plate is Free. (Be careful not to loose the Key or the shims for the Clutch Plate) • Remove Circlip for Clutch Pulley Bearing. • Remove Clutch Pulley with Puller or Gear Puller. (DO NOT Damage Shaft of Compressor) • Machine off groves from A/C pulley. Leave sides of pulley 1mm thick. • Press Machined Clutch onto Compressor and Re-Install Circlip • Re-Install Clutch Plate and Tighten Mounting Nut.
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ADVANCED MOTORSPORT SOLUTIONS 3.12 Re-Install A/C Compressor (Eye Protection Required) • Check A/C Hoses for Damage near the R/S Cooling Fan Blade. We have also seen the Suction hose leak when lifting up the compressor. The A/C hose is chafed by the R/S fan blade and starts to leak when disturbed. If you need a new hose Contact AMS we keep Genuine VW parts in Stock. • Turn the A/C Clutch Pulley it should be easy to turn and not locked to the Clutch Plate. If everything checks out proceed to the next step. • Lower A/C Compressor back Into the Mounting Bracket and Torque Mounting Bolts to 33 Ft Lbs. 3.13 Re-Install Alternator • Temporarily Install Alternator into position with Standard Mounting Bolts. 3.14 Oil Feed Line Installation • • • • • • • • •
Remove Black Oil Pressure Switch and replace Aluminum Sealing Washer. Remove Oil Temperature Sender and replace Aluminum Sealing Washer. Install the Black Oil Pressure Switch (R/S of Vehicle) into the Oil Temperature Sender Location. Take Tee Adapter and apply Teflon Sealant Paste on the Male Threads. Thread Tee Adapter into Oil filter Housing. (Thread till the side with the Black Mark points towards the Left Side Oil Pressure Switch) be careful not to over tighten the Tee Adapter. Install Oil Temperature Sender into the side of the Tee Adapter with the black mark. Take the Straight –4 Adapter and apply Teflon Sealant Paste. Install –4 Adapter into the Tee Adapter. Install Oil Feed Line with 90º Fitting to the –4 Adapter.
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ADVANCED MOTORSPORT SOLUTIONS • Install Dipstick Tube and check for Interference while Tightening Fitting.
Oil Switch Position and Tee Fitting location
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ADVANCED MOTORSPORT SOLUTIONS 3.15 Install Idler Pulley Bracket • Disconnect Electrical Connector for Cooling Fan Motor • Remove Top Bolt for front Motor Mount. • Prepare Idler Puller Bracket by installing (1) Long 8mm x 110mm bolt with Flat Washer through the Lower Hole in the Bracket and then the Spacer. • Raise Engine with Hydraulic Jack enough to install Long Lower Alternator Bolt. • Place Idler Pulley Bracket onto the Alternator with the 8mm Threaded hole at the top. • Install the Lower Bolt only and leave Loose. • Lower Engine and Re-Install Front Motor Mount Bracket Bolt and Torque to 44 ft Lbs. • Note Leave the Alternator Loose with just the lower Bolt Installed for now, because we will finish mounting after the Lower Manifold is installed. • Connect Electrical Connector for Cooling Fan Motor.
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ADVANCED MOTORSPORT SOLUTIONS
Alternator with Idler Pulley Bracket
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ADVANCED MOTORSPORT SOLUTIONS 3.16 Prepare Secondary Air Pump 1994-1995 • Cut Accordion Tube at Secondary Air Pump. • Oil Small K&N Filter and install onto Accordion Tube and secure Clamp. 1996 + • Loosen Clamp on Accordion Tube for Secondary Air Pump Inlet and Remove Hose • Oil Small K&N Filter and install onto Secondary Air Pump and secure Clamp.
Secondary Air Pump with K&N Filter installed
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ADVANCED MOTORSPORT SOLUTIONS 3.17 Install Manifolds • • • • • • • • • • • • • • • • • •
Place Secondary Air Pump into Position. Place Lower Intake Manifold into Position. Route Wiring Loom for Oil Pressure Switches and Oil Temperature Sender through Lower Manifold. Connect Blue Wire to the Brown Switch. Connect Yellow Wire to the Black Switch. Connect Green Wire to the Oil Temperature Switch. Clean Gasket Mating Surfaces on Cylinder Head and Manifold. Install New Lower Manifold Gasket and Thread in (6) Mounting bolts on the top (Leave Loose). Install Engine Lifting Eye Bracket and remaining (4) Bolts. Torque all (10) Mounting Bolts 18 ft Lbs. Mount Secondary Air Pump (3) Blots and Torque to 18 ft Lbs. Connect Accordion Tube from Secondary Air Pump to Valve. Install Vacuum Valve onto bracket for Secondary Air Injection. Connect Electrical Connector for Secondary Air Injection Valve. Connect Electrical Connector for Secondary Air Pump. Connect Electrical Connectors for all (6) Fuel Injectors. Close up Wiring Tray for Fuel Injector Wiring. Secure Mounting Clips for Fuel Rail Hoses at side of valve cover.
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ADVANCED MOTORSPORT SOLUTIONS 3.18 Alternator Mounting Continued • Position Alternator onto Engine and Install Top Mounting Bolt. • Lift Upwards on Idler Pulley Bracket and Torque (2) 8mm Bolts for Idler Pulley Bracket to 18 ft Lbs. • Prepare Idler Pulley by installing (1) 8mm x 50mm Bolt with Wave Washer through Idler Spacer through Idler Pulley and another Idler Spacer. • Apply Blue Loctite 242 to Bolt and Install Pulley into Top Hole on Bracket and Torque to 18 ft Lbs.
Idler Pulley with Bolt, Washer, Spacer, Pulley, and Spacer
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ADVANCED MOTORSPORT SOLUTIONS 3.19 Upper Manifold Installation • • • • • • • • • •
Place Dipstick Tube into Position. Clean mating surfaces for Intake Manifolds and Install New Gasket. Install (7) Mounting Bolts for Intake Manifold and Torque to 18 ft Lbs. Install (1) Mounting Bolt for Dipstick Tube and Torque to 7 ft Lbs. Install (2) Rear Mounting Bracket Top Bolts and Torque to 18 ft Lbs. Torque (2) Rear Mounting Bracket Bottom Bolts and Torque to 18 ft Lbs. Connect Electrical Connector for Throttle Body and Secure Wiring Loom (2) Clips. Connect Electrical Connector for the Intake Air Temperature sensor. Install Throttle Cable at Throttle Body and Install retaining clip at bracket. Install New Fuel Pressure Regulator and (1) One shot Clamp. (Warning Wear Eye protection when removing regulator) Cover regulator with a shop rag then remove the retaining Clip and twist Regulator out of Fuel Rail. The Fuel system is under Pressure proceed with Caution. • Install the Reaming (3) One shot clamps on all sides of the Plastic Tee Fitting.
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ADVANCED MOTORSPORT SOLUTIONS
Fuel Pressure Regulator with Clamps
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ADVANCED MOTORSPORT SOLUTIONS 3.20 Brake Booster Pipe Update • • • • • • •
Remove old One shot Clamps (2) at Intake Manifold Side and at Middle of Plastic Pipe. Remove Rubber Hoses and clean Plastic tube and Rubber Hoses with brake cleaner. Measure 20mm from end of Pipe and mark with Grease Pencil. Install Metal Inserts into Plastic Pipe Ends. Install Rubber Hose Ends with new clamps and press on to Grease pencil marking. Squeeze both clamps and make sure Rubber ends are secure. Install Brake Booster Hose at Intake Manifold and Secure Clamp.
Brake Booster Pipe Middle
Intake Manifold End
Plastic Pipe with Insert
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ADVANCED MOTORSPORT SOLUTIONS 3.21 Evap Check Valve Installation • Locate Evap Hose at Intake Manifold and Cut 30mm out of hose after the 90Degree bend. • Install Check Valve with (2) One Shot Clamps and the Arrow Pointing Towards the Intake Manifold.
EVAP Check Valve Installed
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ADVANCED MOTORSPORT SOLUTIONS 3.22 Top Cover Installation • • • •
Install Middle Cover with (2) Screws and Torque to 44 In Lbs. Install Side Cover with (2) Screws and Torque to 44 In Lbs. Install Rear Cover with (2) Screws and Torque to 44 In Lbs. Install Cooling Fan Cover (3) Screws.
3.23 Spark Plug Installation • Install (6) New Bosch F6DTC Spark Plugs. • Re-Install (6) Spark Plug Wires 3.24 Supercharger Bracket Installation • • • • •
Prepare Bracket with Spacer Plate, (3) 8mm x 35 Bolts and Wave Washers. Install Onto Cylinder Head Lift up and Secure Bolts. Mark Top Hole W 3/8 Drill Bit By Hand! Remove Bracket. The Next Step Is Very Critical. The Depth of the Hole must be followed Exactly or You Will Drill too far into the cylinder head. • Take the 17/64th Drill Bit and Measure from the Pointed end towards the shank and mark 13mm and set Drill Stop or Tape Drill Bit with Black Tape. • Drill Straight and observe the Depth! • Clean Hole
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ADVANCED MOTORSPORT SOLUTIONS • Start 8mm x 1.25mm Tap with Cutting Oil and Finish with Bottoming Tap. If No Bottoming Tap is Available you can cut a standard tap shorter. • Clean Threads • Install Supercharger Bracket (3) 8mm x 35mm Bolts and Torque to 18 ft Lbs. • Install Top Bolt (1) with wave Washer through Bracket and with Flat Washer on Cylinder Head Side and Torque to 15 ft Lbs.
Cylinder Head with Tapped Hole
Supercharger Bracket Installed
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ADVANCED MOTORSPORT SOLUTIONS 3.25 Supercharger Installation • Install Oil Return Hose onto Supercharger and Secure (Note 90Degree Elbow must point towards the Oil Pan. • Install Supercharger Bracket with (5) 3/8 Bolts and Washers, Torque to 20 ft Lbs. • Re-Position Crankcase Breather Accordion Tube. • Install Clear Vent Hose onto Crankcase Breather Tube. (Heat End with Heat Gun or Boiling Water) • Install the other end of the Crankcase Breather Tube onto the K&N Filter and place Filter into position. • Install new 7-Rib Belt making sure all Ribs are in the proper position. • Place Supercharger into Position and route belt into place. • Mount Supercharger with (2) 10mm x 25mm Bolts and (2) 10mm Wave Washers. • Check Clearance between Supercharger Pulley and Fuel Rail a slight Adjustment to the Bottom of the Fuel Rail is usually necessary. To adjust the clearance between the Fuel Rail and the Supercharger Pulley Bend the Fuel Rail by pressing it by Hand. Also Turn the Clamps out of the way if necessary. • Install (1) 10mm x 30mm Bolt into the rear of the Supercharger Mounting Bracket and Tension Belt. • Torque (2) 10mm Bolts to 20 ft Lbs. • Install K&N Filter and secure Clamp.
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ADVANCED MOTORSPORT SOLUTIONS
Crankcase Breather Re-positioned
Crankcase Breather Tube Installed
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ADVANCED MOTORSPORT SOLUTIONS 3.26 Oil Pan Preparation • • • • • • • • • • • • • • • • • •
Remove Clutch Cover Plate (2) Bolts Remove Oil Pan (26) Bolts. Measure and Mark location for Oil Return Fitting. On Right Side of Pan between the (2) mounting bolts will be the location for the fitting. Locate Middle Hole on Right Side of the Oil Pan and Measure from the center of the hole 27mm towards the front. Measure from the Lower edge of the Oil Pan 20mm Down and Mark Center Punch Location Drill hole With ¾ “ Hole Saw Remove any Burs with a Round File. Weld or Braze fitting onto the Oil Pan Clean Oil Pan Tape Nipple of the Oil Return Fitting. Paint Oil Pan with Gloss Black Paint When Dry Remove Tape Install Oil Pan with new Oil Pan Gasket Torque (26) Oil Pan Mounting Bolts to 11 ft Lbs. Install Clutch Cover Plate (2) Bolts. Check Drain Plug and Secure if necessary. Fill Engine with (6) Quarts.
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ADVANCED MOTORSPORT SOLUTIONS
Engine Oil Pan Marked for Return Fitting
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ADVANCED MOTORSPORT SOLUTIONS 3.27 Charge Pipe Installation • • • •
Assemble Charge Pipe with Mass Air Flow Sensor and Hose Connectors (leave loose) Install Charge Pipe at Supercharger end first then at Throttle Body Side. Adjust Position of Charge Pipe, Mass Air Flow Sensor and Hose Connectors. Secure All (6) Hose Clamps.
Charge Pipe Installed
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ADVANCED MOTORSPORT SOLUTIONS 3.28 PowerProm Installation • Remove the Rubber Gasket across the Plenum Wall. • Remove the Cover for the Computer Box (4) Plastic Retaining Clips (Passenger Side below wiper arm) • Disconnect the Electrical Connector for the Computer Box. • Remove (2) 10mm fasteners securing the Computer Box. • Ship ECU to AMS via Overnight delivery for installation. • Install Computer Box into Vehicle and mount (2) 10mm fasteners. • Connect Electrical Connector. • Install Cover and Secure with (4) Plastic Clips • Install the Rubber Gasket across the Plenum Wall.
Advanced Motorsport Solutions Date 10/28/00 Page 35 Revision 1.1a
850 West 18th Street Suite A Costa Mesa California 92627 Phone 949 515-1672 Fax 949 515-1676 © Advanced Motorsport Solutions
ADVANCED MOTORSPORT SOLUTIONS
PowerProm Installed in ECU Send ECU to AMS for Installation
Advanced Motorsport Solutions Date 10/28/00 Page 36 Revision 1.1a
850 West 18th Street Suite A Costa Mesa California 92627 Phone 949 515-1672 Fax 949 515-1676 © Advanced Motorsport Solutions
ADVANCED MOTORSPORT SOLUTIONS 3.29 Final Steps • Install Battery and connect Terminals • Disarm Alarm System • Check Oil Level 4.0 Final Checks • • • • •
Start Engine and Let Idle Check for any Oil Leakage, Coolant Leakage. Check Cooling Fan Operation Decode Factory Radio Set Clock
5.0 Maintenance Normal Maintenance is as per the factory intervals with the addition of Air Filter servicing and Belt Tension adjustment. • Air Filter service every 15,000 miles or six months which ever occurs first. • Belt Tension adjustment every 15,000 miles or six months which ever occurs first. • Belt Replacement every 30,000 miles or 2 Years which ever occurs first.
Advanced Motorsport Solutions Date 10/28/00 Page 37 Revision 1.1a
850 West 18th Street Suite A Costa Mesa California 92627 Phone 949 515-1672 Fax 949 515-1676 © Advanced Motorsport Solutions
ADVANCED MOTORSPORT SOLUTIONS 5.1 Troubleshooting • Specified Boost Pressure not attained. Boost pressure problems can be caused by various conditions such as the following. • • • • • • •
Loose Intake Manifolds Intake Gasket Leaks Loose Charge Pipe Leaking Charge Pipe Connectors Belt Slippage Belt Alignment Worn Pulleys
Serpentine Belt Alignment and how to check Remove Serpentine Belt and Idler Pulley. Route Serpentine Belt around the Alternator Pulley and then the Supercharger Pulley. Check that the Belt lay flat across the Alternator Pulley and does not show any sign of deflection from the left to right side of the Alternator Pulley. If Belt deflection is present then shimming of the Supercharger Bracket is necessary. Contact AMS for a shim kit or fabricate locally. We have seen the need to shim the Bracket due to production variances from Vehicle to Vehicle.
Advanced Motorsport Solutions Date 10/28/00 Page 38 Revision 1.1a
850 West 18th Street Suite A Costa Mesa California 92627 Phone 949 515-1672 Fax 949 515-1676 © Advanced Motorsport Solutions
