Weistec M157 WMI System

Transcription

1 Weistec M157 WMI System Installation Guide E E63 4matic(S) CLS CLS63 4matic(S) S63 AMG (Without ABC Suspension) This product is legal in California for racing vehicles only and should never be used upon a highway. This product is legal solely for vehicles used in competition which may never be used upon a public road or highway

2 WARNING! THE WEISTEC WMI/ASV SYSTEM IS DESIGNED AROUND THE USE OF A MAXIMUM CONCENTRATION OF 50% METHONAL MIXED WITH DISTILLED WATER ONLY. METHANOL IS A TOXIC AND HIGHLY FLAMMABLE CHEMICAL. 100% METHANOL EASILY IGNITES AND BURNS VIGOROUSLY WITH AN ALMOST UNDETECTABLE FLAME. METHANOL CAN BE ABSORBED THROUGH THE SKIN AND EVEN SMALL AMOUNTS CAN CAUSE BLINDNESS OR EVEN DEATH. USING THIS FLUID AT HIGH PRESSURES WITHOUT DILUTION, IN AN UNDER-HOOD ENVIRONMENT WITH NYLON LINES AND PUSH-TO-CONNECT FITTINGS IS VERY UNSAFE. GREATER THAN 50% CONCENTRATION OF METHANOL WILL PROVIDE LITTLE TO NO ADVANTAGE AND WILL CAUSE SAFETY ISSUES NOTE: WEISTEC ENGINEERING HOLDS NO RESPONSIBILITY FOR ANY ENGINE DAMAGE OR PERSONAL INJURY THAT RESULTS FROM THE MISUSE OF THIS PRODUCT, INCLUDING BUT NOT LIMITED TO INJURY OR DEATH CAUSED BY THE MISHANDLING OF METHANOL 1

3 WARNING! IF YOU ARE NOT EXPERIENCED IN THE AREA OF AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT YOU REFER THIS INSTALLATION TO A CERTIFIED INSTALLER OR TECHNICIAN. Improper installation and/or adjustment of this product can result in major engine/vehicle damage! Only an experienced tuner or technician should make adjustments 2

4 WEISTEC M157 WMI System Thank you for your purchase of the Weistec M157 WMI/ASV System for your Mercedes 63 AMG equipped with the M157 Engine. We appreciate your business, and we know you will enjoy your product. For your benefit, please read the following instructions completely and thoroughly before attempting to install the Upgrade. Many questions we have received from customers about the installation of our products that could have been easily solved by information listed in the accompanying installation guide. We want you to enjoy the product in its fully functional state, and reading this tutorial is the first step to getting you on your way to a more powerful AMG. PLEASE NOTE THAT IF YOU HAVE ANY AFTERMARKET POWERTRAIN PARTS ALREADY INSTALLED ON YOUR VEHICLE, YOU MUST RETURN THE CAR TO STOCK STATUS THIS INCLUDES PULLEYS, PROGRAMMING, ETC. THE CAR WILL NOT FUNCTION AND PARTS MAY NOT FIT PROPERLY IF OTHER AFTERMARKET PARTS ARE INSTALLED. Again, thank you for choosing Weistec Engineering! 3

5 Table of Contents I. Tools Required... 6 II. MAP Adapter Installation... 7 III. Charge Pipes IV. Tank Installation V. Tank Wiring and Plumbing VI. Controller Installation VII. Controller and Nozzle Adjustment

6 INSTALLATION Diagram Controller is NOT waterproof and should be mounted by the cabin air filter or fuse box, away from the engine and water Optional (low fluid) LED for interior *Viewed from Wire Side of Connector 5

7 I. Tools Required Hydraulic Jack Service lift 1/4 Drive Ratchet 12" Long 1/4" Drive Extension Metric Deep Socket Set Metric Open End Wrench Set 8mm Ratcheting Wrench 3/8 Drive Ratchet Torx Socket Set External Torx Socket Set Flat Head Screw Driver Wire Cutter Crimping Pliers Wire Stripper Pushpin Removal Tool 6mm Drive Hex Bit 8mm Drive Hex Bit Mechanics Rags Crimp Style clamp tool Drill Torque Wrench 6

8 II. MAP Adapter Installation Parts Call Out 1. Null 2. Engine covers 3. Engine air intake duct 4. Air filter housing 5. Foam fuel injector covers 6. Refrigerant line 7. Bulkhead 8. Fuel line 9. Fuel distributor 10. Heater shutoff valve 11. Purge line 12. Coolant hose 13. Coolant hose 14. Vacuum line 15. Coolant hose 16. Coolant hose 17. Coolant hose 18. Oil cooling lines 19. Vent line 20. Cooling air lines 20L. Cooling air line 20R. Cooling air line 21. Radiator 22. Cold air intake 23. Radiator cross member 24. Torsion bar linkage 25. Stabilizer bar 26. Brake caliper 27. Suspension strut 28. Transmission 29. Wiring harness 30. Steering coupling 31. Front axle carrier 31a. Screw/bolt 32. Electrical line 33. Bracket 34. Cross strut 7

9 35. Bracket 36. Diagonal struts 37. Supporting struts 38. M13/5. Coolant circulation pump 39. Refrigerant line 40. Low-temperature circuit coolant expansion reservoir 41. Coolant line 42. Coolant hose 43. Coolant line 44. Coolant hose 45. Coolant expansion reservoir high temperature cooling system A80. Intelligent servo module for DIRECT SELECT M42. Electric transmission oil pump Y58/1. Purging switchover valve 8

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14 1. Turn front wheels straight ahead and secure steering wheel 2. Put transmission in neutral and release parking brake 3. Disconnect ground from battery 4. Secure vehicle on a lift IF PROPER MERCEDES PROCEDURE IS NOT FOLLOWED, THE VEHICLE MAY BE PERMANENTLY DAMAGED AND/OR MAY FALL OFF THE LIFT 5. Remove lower engine compartment paneling 6. Remove engine covers 7. Remove front section of the upper engine cover 8. Drain coolant from intercooler system 9. Remove both intake ducts 10. Remove air boxes 11. Remove cold air intake 12. Remove ECU 13. Unbolt harness from intake manifold 14. Lift up harness to gain access to the MAP sensor 15. Unplug MAP sensor 16. Remove the screw holding the MAP sensor to the intake manifold and remove the sensor 17. Install Weistec MAP Adapter in the intake manifold 18. Connect Map Adapter to the MAP Block using a section of the supplied ¼ plastic line 13

15 III. Charge Pipes Parts call out Charge Air Ducts 1. Nuts 1l. Nuts 1r. Nuts 2. Lower charge air ducts 2l. Lower charge air duct on the left 2r. Lower charge air duct on the right 3. Null 4. Air cleaner housing 5. Charge air cooler 14

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17 1. Detach vacuum hose for boost pressure control valve on turbocharger with exhaust manifold (1) 2. Remove charge air ducts by: a. Loosen clamp between upper charge air duct (1l, 1r) and air filter housing (4) b. Loosen clamp between upper charge air duct (1l, 1r) and turbocharger c. Remove screw/bolt for upper charge air duct (1l, 1r) on cylinder head cover d. Remove upper charge air duct (1l, 1r) e. Remove air filter housing (4) f. Detach engine oil cooling oil lines from oil filter hosing and bracket on engine and lay to the side outside the working area g. Loosen clamp between lower charge air duct (2l, 2r) and charge air cooler (6) h. Loosen clamp between lower charger air duct (2l, 2r) and turbocharger i. Remove screw/bolts for right lower charge air duct (2r) from cylinder head j. Remove screw/bolts for lower charge air duct on the left (2l) from cylinder head and oil filter housing k. Remove lower charge air duct (2l, 2r) l. Check boot and rubber seal for cracks or damage and replace if necessary m. Check clamps for damage and replace as necessary 3. Install Weistec Charge Pipes in reverse order of step 2. Be sure to have the pipes installed loosely to allow for adjustment of the T silicone coupler for the Weistec ASV. 4. Once all adjustments are done and the pipes and ASV are positioned and fitting properly, proceed with tightening all the clamps and mounting hardware per reverse order of step 2 5. Connect each Weistec Injector to the supplied Tee Fitting using small sections of the supplied ¼ plastic hose. Be sure to route the hoses so that there are no kinks and they are away from any moving parts 6. Connect the Weistec ASV to the MAP Block using a section of the supplied ¼ plastic hose. Route the hose through the engine valley and under where the ECU sits. 16

18 IV. Tank Installation 1. Open trunk and remove spare tire cover 2. Remove the spare tire and tool kit 3. Position the tank in the spare tire well where you will be mounting it. It is recommended that the pump face the back of the car 4. Mark where the 4 bolt holes need to be drilled for the 2 mounting brackets 5. Remove the tank and drill the 4 holes 6. Bolt the tank in place using the supplied bracket hardware 17

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20 V. Tank Wiring and Plumbing 1. Begin by locating the supplied 20ft section of ¼ plastic hose and 16-4 Service Cord 2. Place both in the trunk 3. Press one end of the ¼ hose into the outlet of the pump 4. Wire the 16-4 Service Cord to the pump and the tank level sensor a. Black to Black wire on pump b. Red to Red wire on pump c. White to one wire on the level sensor (polarity does not matter) d. Green to remaining wire on the level sensor (polarity does not matter) 5. Find a suitable location to drill a hole through the spare tire well large enough to fit the wire harness and ¼ plastic hose 6. Route the harness and hose through the hole. 7. Once out of the spare tire well, route the harness and hose up and over the rear Subframe and differential on the right side of the vehicle (for Left Hand Drive Vehicles). Be sure to avoid tight turns that kink the plastic hose. Use zip ties to keep the harness and hose away from moving parts 8. Route the harness and hose between the body and the right side plastic under tray to the front of the vehicle and then up into the engine bay where the cabin filter is located. 9. Route ¼ Plastic Line to the Tee Fitting 19

21 VI. Controller Installation 1. Find a suitable location and mount the Injection Controller 2. Reference included wiring diagram 3. The Injection Controller is wired to the following a. Ground (black wire) b. 12V (red wire) c. Ignition/arm switch (yellow wire) d. Indicator LED (violet +, gray -) e. Pump (pink +, orange -) f. Tank Level Sensor (white +, brown -) g. The green wire, yellow and brown/white wire on the harness will not be used 4. On the supplied Controller harness, ground the black wire 5. Connect the red wire to a 12V source 6. Connect the yellow wire to an ignition source. 7. The pump and tank level sensor wires will be wired to the 16-4 Service Cord a. Pink Wire to Red Wire on 16-4 Service Cord b. Orange Wire to Black Wire on 16-4 Service Cord c. White Wire to White Wire on 16-4 Service Cord d. Brown Wire to Green Wire on 16-4 Service Cord 8. The Indicator LED can be installed either in the engine bay, or somewhere visible inside the passenger cabin a. Violet Wire to + wire on LED b. Gray Wire to Wire on LED 9. Connect the boost port on the Controller to an open port on the MAP Block Pump/Tank Flush After all wires are hooked up, add water to the tank and, with the hose pointed into a container, press and hold the TEST push button on the controller module. The TEST button can be used to test the system. The pump speed will gradually increase from zero to full speed within 3 seconds and then remain full for another 3 seconds before stopping. Repeat the TEST button procedure until you are sure the system is free of any debris that may have been in the lines or tank. Drain the water out of the tank and refer to the next section on installing the nozzle. 20

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23 VII. Controller and Nozzle Adjustment 1. The Weistec Injectors are shipped with the smallest nozzles installed. As more power is made, it will be necessary to replace the nozzles with the provided larger nozzles a. Stock Turbos Smallest nozzles recommended b. W.3 Turbos Medium nozzles recommended c. W.4 Turbos Medium nozzles recommended. Large Nozzles can be used but may require custom tuning. d. It is possible to use different size nozzles in each injector to fine tune injection amount when having the vehicle custom tuned 2. The Injection Controller has two adjustment knobs. One for start pressure and one for full pressure. a. Recommended Start Pressure is 5psi b. Recommended Full pressure is i. Stock Turbos - 16psi ii. W.3 Turbos - 17psi iii. W.4 Turbos 18psi 3. Fine adjustment of start and full pressures can be performed on a dyno by an experienced tuner. Fluid Compatibility Under NO circumstances should any hydrocarbon based fuel ever be used with this system. Water and methanol are the ONLY fluids to be used 22

24 Thank you from Weistec Engineering! Always enjoy the added horsepower and torque of the Weistec M157 WMI/ASV responsibly. Use best judgment when driving, and remember to have fun! NOTES: 23