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painted body color). Remove the bolt using a 10mm
socket and store the bracket.  On the “flying but-
tress” closest to the firewall, bend the captive nut
tang downward to make room for the plastic elbow
section using a small screwdriver in the hole.

7.3 Bring the air flow meter with the air filter base
installed over to the engine bay. Tilting the assem-
bly at an angle, feed the air flow meter outlet into
the rubber reducer sleeve already in place on the
plastic elbow (install loose hose clamp first). The
air flow meter assembly fits into the space just
inside the shock tower, between the two “flying but-
tresses” of the shock tower. The extra hole and
boss in the air filter base will line up with the hori-
zontal hole you just removed the 6mm body col-
ored bolt from. Using the longer bolt provided (M6
x 30mm, Allen head), attach the air filter base/air
flow meter assembly to the car using this bolt (it
mounts horizontally, through the air filter base, the
flying buttress, and into the Mazda captive nut on
the flying buttress). Use thread-locking compound.

7.4 Make sure that there is no chaffing or rubbing
anywhere along the plastic elbow assembly, even
though it is a very tight fit. Gently reposition any
brake lines that are pressing against the elbow.
Make sure all joints and clamps are secure - a leak
in this area will keep your car from idling correctly.
However, never over tighten your clamps, they
may break somewhere down the road. Use the
small length of rubber hose (1/4” dia) that is slit
along its length to cover the brake line running just
above the elbow. This will prevent any contact at
this point, which may result in noise during opera-
tion.

7.5 Locate the 3/4” diameter idle air hose (5’
length) from your kit. Attach one end to the ‘large’
outside fitting on the plastic elbow downstream of
the airflow meter (just below the brake master
cylinder once the elbow is in place). Use a clamp
to secure the hose to the short 3/4” nipple.  Run 

the hose toward the front of the engine compart-
ment, and across the engine side of the radiator.
Using the tie wraps provided, attach the rubber
hose securely to the radiator fan shroud supports
near the fan motor(s). Attach the end of the hose
to the idle control (ICS) valve nipple that is aimed
toward the front of the vehicle. Make sure that the
hose is attached in a way that will not interfere with
either fan operation or with the engine belts. At a
point along the length of the hose behind the radia-
tor, cut it and install the check valve supplied.
Install the check valve with the flanged end toward
the plastic elbow using the small hose clamps. See
figure 7.6. The hose is supplied a bit longer than it
needs to be. Feel free to trim its length if you pre-
fer. Be careful not to pinch the hose at any point -
doing so will affect your idle stability. You want to
have it tie-off in a low position; the cross over tube
will fit above this hose, hiding it in the final installa-
tion.  On some cars, there might be a slight kink in
the hose where it attaches to the plastic elbow nip-
ple. This is acceptable - orient the hose so it
remains open.

Supercharger Installation Instructions

999-156, 999-157, 999-158 & 999-159

-11-

Revised 06/08

Figure 7.5

Содержание 999-156

Страница 1: ...e not a competent mechanic do not attempt this installa tion TOOLS REQUIRED Most of these tools are available at your local hardware or auto parts stores 17mm 14mm 13mm 12mm 10mm 8mm sockets Deep sock...

Страница 2: ...ll restrictor inside the rubber hose that ran from the cam cover to the chrome tubing It can be felt as a lump in the straight section of the hose near the chrome tube end Persuade it out by gently cl...

Страница 3: ...same position as the standard throttle body on the intake manifold Use the 1104 sealant provided if the original gasket was not salvaged Reconnect the coolant hoses to the idle control valve as you f...

Страница 4: ...en the bottom bolt to 36 ft lbs Once the bot tom bolt is tight remove the upper bolt Now slide the power steering pivot bolt rearward out of the pump It will be reinstalled from the front Remove the r...

Страница 5: ...Now tighten the hose on the power steering pump Once the two bolts are tight the two tabs on the power steering hose clamp can be bent down again Illustration 3 3 VERY IMPORTANT Check the clearance be...

Страница 6: ...ocket remove the four nuts and one bolt that secure the plate to the car Remove the plate to gain access to the Electronic Control Unit ECU Illustration 4 1 4 2 Locate the PowerCard Fuel Management Sy...

Страница 7: ...connector onto the side of the cut wire that leads into the harness Crimp a Female Spade connector onto the side of the cut wire that leads to the ECU connector Connect the Powercard s Red wire to the...

Страница 8: ...t get stretched or pinched in any of the glovebox hinges The split loom plastic sheathing from Step 4 1 will help keep the wires located properly For a dashboard mount you can put Velcro on the back...

Страница 9: ...o the elbow 6 0 SUPERCHARGER INSTALLATION 6 1 Remove the engine lift eyelet at the front of the engine just above the exhaust manifold by removing the bolt using a 14mm socket Using the two new flange...

Страница 10: ...ool Make sure that the cable runs in the center of the groove of the throttle spool If it does not adjust the throttle cable bracket left or right until it is centered in the spool s groove Have an as...

Страница 11: ...it along its length to cover the brake line running just above the elbow This will prevent any contact at this point which may result in noise during opera tion 7 5 Locate the 3 4 diameter idle air ho...

Страница 12: ...allow for engine movement Make sure the line is not pinched in any way and that it has no possibility of interfering with the throttle cable or spool Use tie wraps as necessary to secure the line The...

Страница 13: ...h Complete step 8 5 before starting your engine 8 5 CLEARANCES IMPORTANT MAKE SURE THAT YOU HAVE AT LEAST 3 4 INCH CLEARANCE BETWEEN ANY ENGINE MOUNTED COMPONENT AND ANY BODY MOUNTED COMPONENT CRITICA...

Страница 14: ...see the silver spade connector through the translucent insu lation then you need to disconnect and properly reconnect this connection 9 2 IDLE ADJUSTMENT Restart your engine Using the idle airscrew on...

Страница 15: ...the position that bypasses the boost air back into the supercharger inlet As you blip the throttle the actuator arm will move and close a butterfly valve inside the bypass manifold Using a short piece...

Страница 16: ...or arm contact point and shaft bushing with light grease to insure long life these parts are exposed to under hood dirt and grime TROUBLESHOOTING SYMPTOM Engine cranks but will not start PROBABLE CAUS...

Страница 17: ...and Yellow Black Injectors T Tap these wires White Yellow Green Gray PowerCard wires Ground T Tap this wire ECU Red Blue Exhaust O2 Sensor Cut this wire and splice in PowerCard In Out Purple Purple Ye...

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