2006 Honda Civic SI Supercharger Kit Installation Instruction Kit #

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1 2006 Honda Civic SI Supercharger Kit Installation Instruction Kit # MONIER CIRCLE, STE.5 RANCHO CORDOVA, CA FAX INS-157 VERSION: Thank you for purchasing the CT Engineering Supercharger kit for the 2006 Honda Civic SI. All components have been designed and manufactured utilizing the latest in technology and materials. Please take a moment to read this instruction manual and warranty information page thoroughly before starting any work. Always work in a clean environment and use the appropriate safety equipment and tools to avoid any potential damage or injuries. CT Engineering recommends the use of a Genuine Honda Service Manual to supplement these instructions. All CT Engineering products are intended to be installed by a professional installer. Many stock parts are reused during installation. Do not damage or discard any pieces during disassembly or installation. We recommend marking any hose or wire before disconnecting to avoid confusion during reassembly. Torque Specifications: M5 = 3 ft-lbs M6 = 6 ft-lbs M8 = 16 ft-lbs M10 = 31 ft-lbs M12 = 54 ft-lbs M14 = 87 ft-lbs 1

2 STEP #1 Evacuate A/C system: Have your local Air conditioning shop remove the HFC-134a refrigerant from your A/C system. They can reuse your coolant. After the supercharger installation you will need to return the car to them and have them refill and charge the system. This service should cost approximately $ STEP #2 Remove ECM and ship to Hondata: Remove the battery. Remove ECM cover (A). Remove bolts (D), then lift up the ECM. Disconnect the ECM connectors A, B, and C. Remove ECM and ship to Hondata (see Address to right.) Ship ECM to: HONDATA 2840 COLUMBIA ST. TORRANCE, CA

3 STEP #3 Drain Coolant: Jack up and support the front of the car on jack stands. Make sure the engine is cool and remove the radiator cap. Drain the cooling system by loosening the drain plug (A) at the bottom of the radiator. Once all of the coolant is drained close the drain plug. STEP #4 Remove Manifold Cover & Splash shield: Remove the intake manifold cover. The cover and hardware will not be reused. Remove the splash shield. Make sure to retain all of the hardware; it will be reused. STEP #5 Remove Intake Tube: Disconnect the vacuum hose (A) and the breather pipe (B) from the intake tube. Loosen the clamps and remove the intake tube (C). Everything will be reused. 3

4 STEP #6 Remove Air Box: Disconnect the Mass Air flow sensor connector. Remove the mounting hardware and remove the air box assembly. Keep all of the parts because they will be reinstalled. STEP #7 Remove the Manifold Harness: Disconnect the negative side of the battery, then disconnect the positive side. Remove the battery. Disconnect the harness connectors for the fuel injectors, Manifold Absolute Pressure (MAP) sensor, and Throttle Actuator. Remove the bolt from the ground (A) and clamp (B) bracket. Then remove the harness holder (C) from the fuel rail. STEP #8 Disconnect Hoses: Remove the positive crankcase ventilation (PCV) hose (A). Remove the evaporative emission (EVAP) canister hose (B). Remove brake booster vacuum hose (C). Disconnect the two water hoses connected to the bottom of the throttle body, as well as the harness clip. STEP #9 Remove Fuel Rail: Remove the cover (A) off the fuel rail connection. Disconnect the fuel line from the rail by squeezing the lock tabs, push and pull the line until it is loose. Remove the two M8 nuts holding the rail to the manifold and remove the rail with injectors. Keep the two rail spacers and the rail; they will be reused. 4

5 Step #10 Remove Throttle Body: Remove the hardware holding the throttle body to the manifold. Remove the throttle body from the intake manifold, all parts will be reused. STEP #11 Remove Manifold supports: From the bottom of the car disconnect the connector from the brace (A). Remove the hardware holding the support to the manifold/block and remove the brace (B). They will not be reused. STEP #12 Remove Stock Manifold: Remove the (2) M8 nuts and (6) M8 flange bolts. Using the two M8 Nuts as Jam Nuts, remove the two studs from the cylinder head. Remove the intake manifold and disconnect the water line as you remove the manifold. Neither manifold, gasket or hardware will be reused. Remove the MAP sensor (A), screw and o-ring from the stock manifold; they will be reused. Remove the Intake Air Bypass Thermal Valve (B) from the stock manifold; it will be reused in the new Supercharger manifold. Make sure to also remove the throttle body studs, they will be installed in the supercharger inlet manifold. A B 5

6 STEP #13 Remove Belt: Release the auto-tensioner (A) with a Snap-on tool (YA9317) or similar tool. Once the pressure is released remove the belt; it will not be reused. STEP #14 Remove the Idler Pulley: Remove the A/C support bracket bolt. It will not be reused. Remove the (2) M8x45 bolts holding the idler pulley assemble. The hardware will be reused but the bracket and pulley will not. Step #15 Remove Tensioner pulley: Remove the M10 bolt holding the tensioner pulley to the tensioner making sure to not lose the nut. All parts will be reused. Step #16 Remove Tensioner: Remove the three M8 bolts holding the tensioner to the block and remove the tensioner. The outer two M8 bolts will not be reused but the M8 bolt going through the center of the tensioner will be reused along with the tensioner. 6

7 Step #17 Preinstall the Adjuster base Plate: Mount the adjuster base plate to the stock tensioner using the two M8x45 bolts removed in step #14. Torque the bolts to 20 ft-lbs. STEP #18 Reinstall Tensioner: Reinstall the tensioner/base plate to the block using the original M8x70 center bolt, the new M8x70 front bolt and the new M8x60 rear bolt. It may be easier to put the bolts in place and then position the tensioner in place. Once everything is in place torque the bolts to 20 ftlbs. Step #19 Assemble Idler Plate Assembly: First install the Adjuster lug into the mating oval slot in the Idler Plate. Next slide the Adjuster Plate onto the Adjuster Lug And install the M8x1.25x45 bolt from step#16 through the rear most slot in the Idler Plate, but do not tighten. Using the new M10x1.25x75 bolt provided in the kit and the smooth idler pulley, install bolt through pulley, through the Adjuster Plate and Idler Plate and install M10 nut, but do not tighten. Using the new M10x1.25x80 bolt, Stepped Bushing and Grooved Idler Pulley provided in the kit; install bolt through bushing, pulley, Adjuster Plate, and Idler Plate. Then install M10 nut, but do not tighten. Install A/C Line Bracket Adjuster Plate Grooved idler pulley Stepped Bush M10x1.25x80 M8x1.25x60 Idler Plate Adjuster Lug Idler Pulley A/C Line Bracket M10x1.25x75 M8x1.25x70 7

8 STEP #20 Assemble Idler Plate Assembly (continued) : These photos show what the assembly should look like when assembled. STEP #21 Move Harness: Remove the two harness support brackets from their mounting points and then remove them from the harness, they will not be reused. Move the harness to the engine side of the thermostat housing tab and secure it with the supplied tyrap. Move the harness to the bottom side of the steel waterline ear and secure with the supplied tyrap. STEP #22 Preinstall Manifold support bracket: Loosely mount the lower block to the engine using the supplied M12x60 flange bolt. Using the supplied M8x25 flange bolt loosely mount the drop link to the lower support. Loosely attach the top mounting block using the supplied M8x25 flange bolt to the passenger side of the drop link. Leave all the hardware loose; they will be tightened after the manifold is installed. STEP #23 Manifold Prep: Install the MAP sensor to the side of the new supercharger manifold reusing the original o-ring and screw. Reinstall the Intake Air Bypass Thermal Valve from the stock manifold into the new supercharger manifold. 8

9 STEP #24 Main Manifold Installation: The blower is shipped already attached to the main manifold. Remove the (6) M8x20 bolts holding the blower plate to the manifold and separate the two. Install the main manifold to the cylinder head using the supplied (6) M8x25 bolts, (2) M8x60 flange bolts, and heat insulation gasket. Use the supplied Loctite on the threads of all the bolts. Torque the manifold bolts to 20 ft-lbs. Install the manifold brace to the manifold using the supplied M8x30 flange bolt. Use Loctite on the threads going into the manifold. Now tighten all of the bolts left loose in Step #22. Reconnect the water line to the new manifold fitting reusing the original hose and clamp. STEP #25 Blower Area Preparation: Install the new PCV hose (5/16 x 30 ) using the stock clamps removed in step #7. Run the hose out through the gap between the radiator and chassis for now, it will be connected in a later step. STEP #26 A/C Line Spacer: Remove upper A/C Line from the A/C compressor and add supplied spacer using o-rings and M6x60 bolt. Install A/C line bracket supplied in the kit onto the Idler Plate as seen in step #19. 9

10 STEP #27 Blower Installation: Make sure the (6) M8x20 flange bolts are in place before lowering the blower to the main manifold. Install the blower on to the main manifold making sure to line up the roll pins already installed in the main manifold. Start the M8x20 flange bolt under the by-pass valve first. Tighten all 6 of the blower mounting plate flange bolts. Install the blower by-pass valve vacuum hose onto the barbed brass fitting in manifold. STEP #28 Install Inlet Manifold: Using the supplied M8x20 bolts, install the inlet manifold starting with the rear lower bolt first. STEP #29 Install the Blower belt: Route the new belt supplied in the kit around all of the pulleys except the blower. Once the belt is in place, release the pressure on the tensioner and slip the belt over the blower pulley. STEP #30 Setting Belt Tension: With the belt in place, release the belt tension again. Turn the adjusting screw in the top of the idle plate until the Auto tensioner indicator is lined up with the notch in the idle plate. 10

11 STEP #31 Remove cowlings: Remove plastic cowling at the base of the windshield. Remove steel panel below plastic cowling. STEP #32 Install Spark Plugs: Remove the Ignition Coil cover (A). Remove the Coils (C). Remove the stock spark plugs. Install the supplied Denso IK24 plugs. Reinstall the coils and ignition coil cover. Reinstall the cowlings in the reverse order of removal. STEP #33 Fuel Rail Installation Prep: Make sure the injector adaptor bushings are pushed all the way into the manifold. These adaptors make the Comptech manifold work with the Honda factory fuel injectors. Install the supplied bushings onto each stud along with the original fuel rail spacers. STEP #34 Install Fuel Rail: Use a small amount of oil on the fuel injector seal and reinstall the fuel rail with all of the injectors still in the rail. Use the supplied spacer nuts to secure the rail to the manifold. Reconnect the fuel supply hose and connector cover. A small amount of oil on the end will help. 11

12 STEP #35 Reinstall Manifold Wiring Harness: Reinstall the factory wiring harness cover onto the rail and reconnect each fuel injector. Open the right side plastic harness guide by releasing the five clips. Free the ground and MAP sensor wires from the harness by removing the black tape wrapping and short length of corrugated plastic sheathing. Route the ground wire to the boss just below the cam cover on the right end of the cylinder head. Route the MAP sensor wire under the inlet casting to the new MAP sensor location. STEP #36 Install Throttle Body: Install the studs removed in step #10 in to the new inlet manifold. Using the supplied new throttle body gasket and original hardware, mount the throttle body to the blower inlet manifold. STEP #37 Throttle Body Connections: Reconnect the throttle body wiring connector. Reinstall the two water lines to the bottom of the throttle body that were removed in step #8. STEP #38 Install Vacuum Lines: Using the supplied 5/16 x 12 hose connect the brake booster hard line to the top fitting on the new inlet manifold. Reinstall the factory EVAP hose. Route the PCV hose installed in step #25 along the radiator support. Connect it to the lower fitting on the new lower inlet manifold. 12

13 STEP #39 Reinstall Air Intake Box : Be sure to reconnect the Mass Air flow sensor and the air tube for the Intake Air Bypass Control Thermal Valve as seen in step #23. STEP #40 Refill Cooling System: Refill the cooling system using a mixture of 50% antifreeze and 50% water. Fill the radiator to the base of the filler neck. Loosely install the radiator cap and proceed to step#41. STEP #41 Raise Fuel line pressure: Remove the rear lower seat cushion (Note: M6 bolt attaching lower cushion is located slightly to left of center between upper and lower cushions.). Remove trunk floor panel by unsnapping front edge of panel from cross member. Remove the access panel (A) from the floor (attached with four M8 bolts) and then remove the fuel sender access panel (B) (attached with four Phillips Head screws). Disconnect the electrical connector (C), and using a rag to catch the excess fuel, remove the fuel and vent lines (D) by releasing quick disconnect fittings from the top of the pump/ sender unit. Use the factory Honda tool to unscrew the plastic fuel pump retaining ring (E) (We have also found you can also use a larger flat bladed screw driver as a punch to remove it.). Using rags to catch the fuel, slowly pull the pump assembly out of the tank, tipping it forward as it comes up to prevent damaging the sending unit float. With the fuel pump/sender unit on a counter, remove the plastic lower cover to gain access to the fuel pressure regulator. The fuel pump and sender wire plugs must be disconnected from the underside of the pump/sender unit and released from a clip to do this. Working from the bottom of the pump, remove the fuel pressure regulator retaining clip (F), ground ring (G) and remove regulator. Remove the o-rings (I) from the regulator, and using the supplied setting tool, insert the regulator into the tool and compress in a vice until the regulator flange is bottomed out on the tool. (See photos) Re-install the o-rings on the regulator and push back into the pump/sender assembly (a little oil on the o-rings will help). Reverse the disassembly process to finish assembly of pump. Install the pump/sender unit into tank and attach electrical and fuel connections. Make sure to get the top of the unit clocked correctly in the tank (see drawing). Reconnect the electrical connector and fuel line. Install covers, trunk flooring, and seat cushion. Before After E A B C I D G H F 13

14 STEP #42 Reinstall ECM and Battery: Install the re-flashed ECM and battery in reverse order of step #2. STEP #44 Install Fuel Rail Cover: Using the supplied M6x10 Button head allen bolts install the CT Carbon Fiber fuel rail cover. STEP #43 Starting the Car: Turn the ignition key on and off a few times to run the fuel pump and build fuel pressure. Check for any fuel or coolant leaks. If everything checks out OK, start the car. Once the car is running let it idle until the cooling fans come on at least twice. Make sure all of the air is bled out of the cooling system. Shut the engine off. Check the coolant level in the radiator. Top it off if necessary and install the radiator cap tightly. STEP #45 Install Prop Rod Cover: Install hose on Prop Rod and Zip-Tie in place as shown in the picture below. This will keep the Prop Rod from rubbing against the A/C Line. STEP #46 Drive the car : Always use the Highest Octane fuel available. Check your engine oil level on a regular basis. Check your belt tension. If you have any questions please call (916) between the hours of 8:00 AM and 5:00 PM Pacific Standard time. Please put a copy of these installation instructions in the car for your customer. To further improve the performance of your Comptech Supercharger kit we recommend the use of a CT Engineering Header and Cat-Back exhaust system. Enjoy. 14

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