Miata Boost Upgrade Kit Installation Instructions

Miata Boost Upgrade Kit
Installation Instructions
For Superchargers with old AFPR Fuel Management
FOR 1994-1997 Supercharged Miatas with Factory 1.8L Motors
PART # 999-165
440 Rutherford St. P.O. Box 847 Goleta, CA 93117
1-800-667-7872 • FAX 805-692-2525 • w w w.miatamania.com
Tools required: 10mm, 12mm, 14mm, 14mm
deep, and 17mm sockets, 13mm combination
wrench, 5/16” nut driver, Phillips and flat blade
screwdrivers, 4mm Allen wrench, Torque
Wrench (6-12 ft-lbs), pliers, strap wrench,
rags.
2.2
Disconnect the vacuum and fuel lines
connected to the AFPR from the vehicle.
Leave the vacuum port open. It will be used
later for the installation of the PowerCard
vacuum line. Illustration 2
Read and understand these instructions
before installing this kit.
1.0 SAFETY PREPARATION
1.1
Do not perform the installation near
open flame and do not smoke.
1.2
Remove the gas cap and then reinstall
it. This is to relieve pressure in the fuel
system.
1.3
Disconnect the negative battery cable.
Caution: If you have a code stereo, make sure
you know the code and make note of your
pre-sets.
Illustration 2
2.3
Remove the charcoal canister in order
to gain access to the bolt holding the AFPR
on. Using a 10mm socket, remove the
mounting bolt and remove the AFPR and
attached lines from the car and replace the
charcoal canister. Illustration 3
2.0 AFPR REMOVAL
2.1
The AFPR will no longer be needed
once this kit is installed, so it will have to be
removed. Illustration 1
Illustration 3
Illustration 1
999-165
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Revised 1/06
Boost Upgrade Installation Instructions
3.2
The next step is to remove the
supercharger belt. Loosen the pillow block bolt
behind the idler pulley bracket using a 13mm
socket, but do not remove. Then, using a
14mm deep socket, just loosen the power
steering pump pivot bolt which holds the pump
to the engine block. Loosen the idler bracket
bolt using a 14mm socket, but do not remove.
Then loosen the power steering bracket
tensioner bolt using a 12mm socket, but do
not remove. Ensure that the power steering
pump and idler pulley bracket assembly are
now free to move. To remove the
supercharger belt, unbolt the driver’s side idler
pulley using a 17mm socket and pull the belt
off with the pulley. This is also how the new
belt will be reinstalled. Illustration 6
Illustration 3 con’t
2.4
Reconnect the fuel lines to the stock
configuration. Illustration 4
Pillowblock Bolt
Illustration 6
Illustration 4
3.0 BOOST UPGRADE PULLEY
3.1
Using a 5/16” nut driver or a flat blade
screwdriver, loosen the hose clamps holding
the crossover tube to the supercharger outlet
manifold and the dummy throttle body. Pull the
crossover tube out and set it aside. If you have
an intercooler type crossover tube, you can
just set it on the top of the radiator without
disconnecting the coolant hoses. Illustration 5
P/S Pump
Pivot Bolt
Idler Bracket Bolt
Illustration 5
999-165
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Revised 1/06
Boost Upgrade Installation Instructions
Once the belt is loose, do not remove it.
Remove the water pump pulley bolts and
replace them with the M6x10mm button head
cap screws included with the kit. Torque each
bolt to 6-8 ft-lbs. Note: Though some of the
photos are taken from under the vehicle, this
install can be accomplished from above or
below the car. Illustration 7
Tensioner Bolt
Illustration 6 con’t
Illustration 7
3.3
Once the supercharger belt is off, you
must install the new water pump hardware.
Loosen the three original water pump pulley
bolts, but do not remove them. Loosen the
upper alternator bolt, which prevents the
alternator from sliding in the slotted tensioner
bracket, using a 12mm socket. Then loosen
the tensioner bolt using a 12mm socket and
see if the alternator rotates freely. If not, the
lower alternator bolt will have to be loosened.
999-165
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Revised 1/06
Boost Upgrade Installation Instructions
3.4
After changing the water pump bolts,
then comes installation of the boost upgrade
pulley. Using a 10mm socket, remove the four
bolts and large washer from the center of the
stock crank pulley. Do not remove the crank
pulley! Use a damp cloth to remove any built
up dirt from the center surface of the pulley.
Next, install the boost upgrade pulley over the
stock crank pulley. Be careful to align the
dowel pin with either of the smaller holes on
the boost pulley. Then place the large washer
over the boost pulley and install the four new
pulley bolts and lock washers supplied.
Tighten the bolts in a cross pattern to 10-12 ftlbs. Illustration 8
3.5
Once the boost pulley is installed,
tighten up the alternator belt at the alternator
tensioner bolt using a 12mm socket. Once
tight, lock the alternator in place by tightening
the upper alternator bolt using a 12mm socket.
Use a 14mm socket to tighten the lower
alternator bolt.
3.6
Now you can install the longer
supercharger belt supplied. Wrap the belt in
the same way around the pulleys as before.
Install the previously removed Idler pulley with
the belt wrapped around it in the proper
manner. It will take a little effort to slip the idler
back over it’s bolt with the belt around it, but it
can be done as long as the belt is in the
grooves of the other pulleys and the slack is
taken out. Tighten up the idler pulley with the
17mm socket and then tighten the tensioner
bolt on the power steering pump bracket using
a 12mm socket. Then tighten the pillow block
bolt with a 13mm socket and the power
steering pump pivot bolt with a 14mm socket.
Finally, tighten the idler pulley bracket bolt
using a 14mm socket.
3.7
Reinstall the crossover tube and
tighten the hose clamps.
Illustration 8
4.0 POWER CARD
4.1
From the kit, locate Jackson Racing
“PowerCard”. It will appear as a small black
plastic box with 6 wires. Locate the factory
Engine Control Unit (ECU) directly behind the
passenger seat.
4.2
Locate the connector on the ECU
closest to the passenger door. It will be a 26
pin connector. The fuel injector wires are
located on the side of the connector closest to
the passenger door. They are color coded,
Yellow, Yellow/Black, Green/White, and
Green. See the ECU Connector Diagrams
attached to assist in locating these wires.
Clamp a “T” Tap onto each of these wires.
Plug the three gray wires and the one blue
wire into these “T” Taps in any order. The
Jackson Racing PowerCard establishes which
injector is which and applies the correct duty
cycle on its own.
4.3
Locate the White/Red wire in the ECU
harness. This is the only White wire with a Red
stripe. Also locate the correct solid Black wire
using the appropriate ECU Connector
999-165
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Revised 1/06
Boost Upgrade Installation Instructions
Diagram for your year of car. Clamp a “T” Tap
onto each of these two wires. 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 wire on the
ECU. This will be your system ground.
4.4
You will need to route a hard plastic
tube from the intake manifold to the Jackson
Racing PowerCard in the interior. Be careful
not to kink this tube during installation as it will
give the PowerCard false pressure readings.
To route the hard plastic vacuum pipe from the
engine compartment to the card, you will need
to route though the firewall and remove some
interior panels to hide the line. The tube will
connect to the intake manifold on the
passenger side of the engine compartment
where the AFPR Vacuum line was
disconnected. Attach the PowerCard vacuum
tube to this port using the 3/16 elbow. If for
some reason this location is already in use,
tap into another intake manifold vacuum
source using the supplied 3/16 tee and elbow.
Then route the tube through the hole in the
firewall that is behind the windshield washer
reservoir. Have someone watch from the
interior with a flashlight as you route it in.
When they see it, they can pull it through to
the interior. Then it must be routed behind the
interior trim. This can be accomplished fairly
easily using a screwdriver. The preferred path
is to run the tube behind the panel near the
passenger’s right foot, under the door sill trim,
and then under the panel behind the
passenger seat by the door jam. Once
through, cut the tube to length and connect the
vacuum tube to the PowerCard. Illustration 9
Illustration 9 con’t
4.5.
Using the Velcro supplied with the kit,
attach the PowerCard to the face of the ECU.
Leave the Velcro attached to itself and peal
the paper off one side. Attach it to the
PowerCard then peal the paper off the
remaining side and position it on the ECU.
5.0 INSTALLATION COMPLETION
5.1
Check to make sure all electrical
connections are properly plugged in and all
fuel hoses are attached and clamped.
5.2
Extensive testing on our dynamometer
has shown the best results are achieved with
the ignition timing set at a MAXIMUM of 8
degrees BTDC using 91-octane fuel. If
detonation is occurring, further retard the
timing to eliminate the problem.
5.3
Reconnect the battery.
Illustration 9
999-165
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Revised 1/06
Boost Upgrade Installation Instructions
ECU Connector Diagrams
1994 – 1995 (OBDI) 2 Connector ECU
Clamp a “T” Tap onto each of these 4 wires (2U, 2V, 2Y, and 2Z).
Plug the three gray wires and the one blue wire into these “T”
Taps in any order.
2Y
2W
2U
2S
2Q
2O
2M
2K
2I
2G
2E
2C
2A
1U
1S
1Q
1O
1M
1K
1I
1G
1E
1C
1A
G/W
L/O
Y
L/W
L/W
R/W
R/B
LG/W
B/W
Y/L
W
B/LG
B
R/B
L/O
LG/B
G/B
G/R
B/LG
L/W
BR/Y
Y/B
V
L/R
G
Y/R
Y/B
LG
Y/G
R/B
R/L
L/R
LG/R
LG/Y
B/R
B/L
B
BR/W
Y/R
Y
L/Y
R
B/G
L/B
BR
?
W/G
W/R
2Z
2X
2V
2T
2R
2P
2N
2L
2J
2H
2F
2D
2B
1V
1T
1R
1P
1N
1L
1J
1H
1F
1D
1B
Clamp a “T” Tap onto the Black wire on the ECU (2B).
Plug the Black wire from the Power Card into this “T”
Tap.
Clamp a “T” Tap onto the White wire with a Red stripe (1B).
Plug the Red wire from the Power Card into this “T” Tap.
1996 – 1997 (OBDII) 3 Connector ECU
Clamp a “T” Tap onto each of these 4 wires (4U, 4V, 4W, and 4X).
Plug the three gray wires and the one blue wire into these “T”
Taps in any order.
4Y
4W
4U
4S
4Q
4O
L/W
G/W
Y
?
L/O
Y
4M
?
G
Y/B
Y/R
BR
Y/W
BR/Y
4Z
4X
4V
4T
4R
4P
4N
4K
4I
4G
4E
4C
4A
3O
3M
3K
3I
3G
3E
3C
3A
1U
1S
1Q
1O
1M
1G
1E
1C
1A
L/R
Y/L
Y/B
B
B/LG
B/L
R/W
R/B
LG/W
L/W
?
R/G
?
LG
?
G/B
B/LG
G/R
LG/B LG/Y
L/B
Y/B
V
B/G
B/W
Y/G
Y/W
W
B
W/R
L/Y
B/Y
R
LG/R
BR/B
R/B
R/L
R/W
?
G/L
G
L/O
?
BR/W R/W
R/B
?
W/B
L/W
4L
4J
4H
4F
4D
4B
3P
3N
3L
3J
3H
3F
3D
3B
1V
1T
1R
1P
1N
1H
1F
1D
1B
? ?
Clamp a “T” Tap onto the Black wire on the ECU (4D).
Plug the Black wire from the Power Card into this “T”
Tap.
1K
1L
1I
1J
Clamp a “T” Tap onto the White wire with a Red stripe. (4B).
Plug the Red wire from the Power Card into this “T” Tap.
? Indicates empty pin
999-165
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Revised 1/06