| Supercharger, Part 1 -- Parts Inventory and Getting Started |
From "Weekend Mechanic"
episode WKM-213 |
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In this episode, Weekend Mechanic Bruce Bonebrake takes on an advanced automotive project geared toward avid horsepower enthusiasts -- installation of a supercharger. The problem: Our project car -- Bruce Bonebrake's own personal work-truck -- is fine as a daily driver and for general use, but Bruce plans on using his truck to do some serious trailer-towing. For that, he needs a boost in horsepower to maintain the kind of performance and engine response he desires. Once installed, this performance enhancement will result in a super-boost in towing capacity.
DIY Difficulty Rating for Repair: This job is an advanced automotive project, and has many steps. We gave it a difficulty rating of a full 5 on a 5-point intermediate-level scale. Though it is not recommended for beginners, if you have some experience with do-it-yourself auto-mechanics, you should be able to handle this project as long as you take your time and follow the manufacturer's instructions. Count on it taking at least a full weekend. We finished the project in about 16 hours.
Important: Included below are the steps in this automotive procedure as shown in the episode. The supercharger kit shown in this episode is made especially for the model truck shown. Installation of a supercharger on other vehicles will vary. These steps are general guidelines. With any particular vehicle, there will be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type of performance-enhancement kit you select. Always consult your vehicle's service manual when undertaking significant automotive upgrades, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools. Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.
In addition to standard auto-mechanic's tools, some of the specialty tools that will be needed for this project include heat gun, wires strippers, C-ring pliers, and a die grinder. An air-ratchet will help speed the assembly process considerably.
Supercharger: Parts Inventory
- The supercharger comes as part of a complete installation kit. Kits like this cost around $5,000 to $6,000, and include just about everything you need for the installation.
- The kit includes a new air duct for the engine, a pump and reservoir for the cooling system, and related hoses and fittings.
- Also included is a bracket for the belt assembly, and a new belt (figure A ). There is also a new bracket to mount the condenser core.
- This particular system comes with a secondary fuel pump, and the fittings for that as well. T
- he installation includes a new high-flow air filter.
- An electronic controller (figure B) will be used following the installation to change the settings on the truck's onboard computer to facilitate the newly added power.
- The supercharger itself (figure C) uses forced-air induction. This is functionally similar to the more familiar turbocharger. The disadvantage to turbochargers is that they rely on exhaust gasses to "spin up," resulting in a slight lag time. With a supercharger, the boost occurs instantaneously, as soon as you apply your foot to the throttle.
- This supercharger is fuel injected to increase fuel-flow efficiency. The top section of the supercharger sits atop an intake manifold that incorporates the fuel-rail with high-flow fuel injectors (figure D).
Supercharger Installation: Getting Started
- For easier access (and easier viewing in this demonstration), we removed the hood of the pickup (figure E). You may not need to do this in your installation.
- Tip: It's a good idea to take photos of your engine (preferably digital photos) before and during disassembly. These can be used later, after installation of the new parts, for reference during the re-assembly phase.
- The first preliminary steps to prepare for the installation are to remove the negative battery cable from the vehicle's battery, and drain the coolant from the vehicle.
- Quite a few parts need to be removed before installation of new components can begin. For our truck, we began by unbolting and removing the site cover (figure F).
- Next, remove the duct assembly and air-cleaner box (figure G).
- With the breather removed, disconnect and remove the coolant reservoir (figure H).
- According to our instructions, we widen one of the holes in the inner fender of the truck, then use some foam to fill a portion of the truck body (figure I ). This will help muffle the sound of the supercharger so it won't transfer throughout the truck.
- Disconnect the throttle cable (figure J).
- Several hoses and other parts are removed according to the manufacturer's instructions.
- Disconnect the fuel injectors (figure K) and the fuel line. (In our case, a special tool was required to disconnect the fuel line.)
- Next, disconnect the brake-booster hose.
- Disconnect the canister-purge hose (figure L).
- Disconnect and remove the intake manifold (figure M).
- At this point, it's a good idea to wipe off the block and tape off the ports of the engine so that no debris can fall into them while you're working.
- Disconnect and remove the old coolant-pipe assembly (figure N), and test-fit the new one.
- In our case, the new coolant-pipe was pressing against a bracket, and this could damage the line. A die-grinder was used to cut away a portion of the bracket (figure O) to allow a safe and secure fit for the new coolant-pipe.
- With the necessary portion of the bracket cut away for a correct fit, make sure the ports are covered and blow away any aluminum filings using an air compressor. Now the new coolant pipe can be installed (figure P).
- Next, remove the belt and belt-tensioner (figure Q).
- Finally, unbolt and remove the alternator (figure R).
In the segment that follows, some of the existing accessory parts are transferred onto the new supercharger.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
Fuel Injection: Installation, Performance Tuning, Modification
Model: 0879387432
Author: Jeff Hartman
Motorbooks International (MBI Publishing)
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