| Supercharger, Part 3 -- Reassembly and Cooling System |
From "Weekend Mechanic"
episode WKM-213 |
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With the supercharger installed, work can begin on re-assembly and installation of the cooling system. 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.
Re-Assembly
- There are a number of electrical connectors to re-attach, and some may not quite reach their new terminal points. Wherever necessary, extend the wires by splicing them with butt-connectors (figure A). This is done in the standard way for this type of wiring modification -- using wire strippers, solderless connectors and heat-shrink tubing. This is an expected part of the project, and should be detailed in the manufacturer's instructions.
- Electrical tape will help hold the wiring harness together. Install split-loom to prevent the wires from chafing.
- Tip: If you're installing the turbocharger on an older vehicle, this is a good time to inspect all wiring for any signs of wear. Exposed wires are a fire hazard, so replace them if needed. Additionally, it's a good idea to inspect all hoses and clamps, and replace any of those that appear worn. The life expectancy for most hoses is about 5 years.
- With the fuel lines attached, install the throttle-linkage bracket (figure B) and hook up the throttle assembly (figure C).
- Reinstall the alternator (figure D), reversing the procedure from when it was removed.
- Make all of the necessary electrical connections to the alternator, including the charging lead.
- A support bracket (figure E), provided with the kit, prevents the nose of the supercharger from being damaged when the belt has tension on it. Secure the bracket with the bolts provided.
- The supercharger -- now installed (figure F) -- utilizes forced-air induction to introduce extra air into the combustion chamber. More air in the combustion chamber translates into more power. The only time this will be noticeable is under high demand for acceleration -- such as towing a trailer, passing or accelerating through an on-ramp. At an idle, when there is little or no load demand, a bypass valve prevents the supercharger from pumping. In that way, the extra horsepower provided by the supercharger is only engaged when it is needed.
- With the supercharger and accessory parts in place, the drive-belt can be put installed. Even with all the new parts, the new belt is routed in the same way as the old belt.
- Connect the small ID (inside diameter) water hoses that lead to the throttle body from the repositioned coolant line (figure G).
- The next step is to install the new air-duct assembly (figure H). The supercharger end attaches by a grommet and clamp. (These don't need to be tightened just yet.) Wrap some thread tape around the fitting that installs onto the crank-case ventilation port, and tighten it in place.
- The only pieces needed off of the original air assembly are the box and the mass airflow sensor. Before attaching the box to the new duct assembly, install the new high-flow air filter.
- Place the duct onto the box, and install the air assembly onto the truck. With the coolant reservoir already reinstalled, carefully work the air assembly back into position (figure I).
- Tighten the hose-clamp to secure the end of the duct to the supercharger (figure J).
- Connect the wiring harness onto the pump for the supercharger's intercooler ( figure K).
- The new pump and reservoir assembly are attached to the fan-shroud (figure L). You may need to drill some holes to attach these new parts. Self-tapping screws hold these parts firmly in position.
In the segment that follows, the cooling system and re-assembly are completed to finish the supercharger project.
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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