Jackson Racing 999-200 Installation Instructions Manual Download Page 6

4.0 FUEL MANAGEMENT

4.1From the kit,
locate Jackson
Racing “PowerCard”
Digital Fuel
Management Module
(DFMM), it will
appear as a small
black plastic box with
6 wires coming out of
it. Using Velcro pro-
vided, you will be
attaching the
Jackson Racing
PowerCard to the
side of the factory
Engine Computer
Unit (ECU). The ECU is located directly above
the brake/clutch pedals.

4.2 Locate the plug closest to the clutch/brake
pedal. There is a White/Red wire on this plug that
will serve as your 12volt power source. Clamp a T-
Tap on this wire.

4.3 Locate the plug furthest from the clutch/brake
pedals. It is home to the 5 remaining wires used for
the Powercard installation.  Find the Black/Blue wire
which is your ground wire and clamp on a T-Tap.
Next you will be locating the 4 injector wires. They
are colored as follows: Yellow/Black, Violet/Green,
Yellow/Red and a Yellow/Green. Clamp a “T” Tap
onto each of these 4 wires. Now plug the red wire
from the Jackson Racing PowerCard into the

White/Red wire. This will be your system 12v power.
Plug the black wire from your Jackson Racing
PowerCard into the Black/Blue wire.  This will be
your system ground. Plug the 3 grey wires and 1
blue wire into the 4 remaining injector wires. It does-
n’t matter in what order.

4.4 You will need to route a hard plastic pipe from
the intake manifold to the Jackson Racing

PowerCard in the interior. To route the hard plastic
vacuum pipe to the engine compartment, you will
need a long narrow rod or screwdriver shaft approxi-
mately 24+” long. On the driver side of the engine
compartment you will find a rubber grommet where
the main wiring harness goes through the firewall.
From inside the engine compartment, carefully push
your long tool through the grommet. Have someone
watch from the interior so that you don’t drive the
tool through any vital parts other than insulation.
Once through, you can tape the hard plastic vacu-
um pipe to the tool and carefully pull it back through
the firewall. You should end up with a good weather
tight seal and your vacuum pipe tucked cleanly
away under the dash.

4.5. Route the hard plastic pipe across the back of
the engine and across the valve cover. Connect this
hard plastic pipe to the vacuum fitting on the intake
manifold with the small, 90-degree adapter hose.
Connect the other end to the Jackson Racing
PowerCard by sliding the hard plastic pipe into the
silicone hose of the PowerCard.

4.6. Using the “Hook and Loop” material supplied
with the kit, attach the PowerCard to the side of the
ECU once the vacuum hose is connected. 

5.0 SUPERCHARGER PREPARATION

5.1 Working on a table or bench, set the super-
charger in a position easy to work with. Be careful
not to bump the supercharger pulley in any way as it
can easily damage the front bearing. Install your
Mazda throttle body with the ICS blanking plate as
installed in step #2.7 and mount it to the super-
charger using the new gasket or 1104 adhesive and
the two new 8mm x 35mm long bolts supplied in the
kit.

1/07

999-200

6

Summary of Contents for 999-200

Page 1: ...petent mechanic do not attempt this installation TOOLS REQUIRED 17mm 14mm 13mm 12mm 10mm 8mm sockets 10mm 12mm and 17mm open end wrenches Deep sockets 14mm or 9 16 10mm Phillips and Standard screwdriv...

Page 2: ...the hose near the end Persuade it out by gently clamping the hose with a pair of pliers just behind the lump If your hose does not have this restrictor there is one provided in the hose bag of the sup...

Page 3: ...the ICS electrical connection until after the next step 2 6 Wiring Harness Modifications Locate the main engine wiring harness on the left side of the engine as viewed from the front of the engine whe...

Page 4: ...olt that secures the small bracket for the Crank Angle Sensor cable Remove the bracket and reinstall the 10mm head ed bolt Referring to figure 3 1 remove the slot bracket and pillow block by removing...

Page 5: ...ocket wrench deep 14mm here and hold the rear hex head with a 14mm box wrench Remove the nut item B in figure 3 1 VERY IMPORTANT MAKE SURE THAT THE DRIVER S SIDE IDLER PULLEY IS FREE TO SPIN THE PINCH...

Page 6: ...vacuum pipe to the engine compartment you will need a long narrow rod or screwdriver shaft approxi mately 24 long On the driver side of the engine compartment you will find a rubber grommet where the...

Page 7: ...at least 1 2 of thread exposed on the bolt Remove the heat shield from the exhaust mani fold Make sure to spray the small bolts with WD 40 or such and let them soak for a bit to make sure that they d...

Page 8: ...amped throttle cable bracket from your kit and thread the new bolt through the throttle cable bracket hole through the spacer through the supercharger boss and through the flat steel lower bracket Sec...

Page 9: ...k tower Install the rubber grommet that you earlier removed from the stock Mazda air filter box into the 3 4 hole in the base of the new Air Filter Insert the grommet from the backside so that the gro...

Page 10: ...grommet in the back of the air cleaner base 7 8 Find the internal restrictor taken out of your PCV hose in step 1 4 or in the hose bag Locate the 3 8 internal diameter hose from your kit and press th...

Page 11: ...belt If you are careful a screwdriver can be placed in the cast iron Bracket s vertical slot to lever the pulley downward This will help you get the proper tension on the belt You should have less th...

Page 12: ...e the supercharger assembly slightly forward or rear ward to correctly align the drive pulleys The slots in the supercharger mounting bracket will allow you to find the perfect alignment for the belt...

Page 13: ...d engine will greatly increase your engine wear 9 9 Oil changes we suggest you use synthetic oil such as Mobil 1 and change it regularly 5000 miles maximum If you use a mineral oil change it every 250...

Page 14: ...re presented as tuning hints for a better all around car When it comes time to put in a new clutch we recommend the Jackson Racing Stage 1 clutch kit While your new super charger and the standard Mazd...

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