Weistec M113K Supercharger System Installation Guide

Transcription

1 Weistec M113K Supercharger System Installation Guide

2 WARNING! DO NOT HAVE YOUR ECU REPROGRAMMED ANYWHERE BUT AT WEISTEC FOR THIS SUPERCHARGER. THE AMG 55 USES AN ELECTRONIC THROTTLE CONTROL (ETC), WHICH IS CONTROLLED BY THE ENGINE CONTROL UNIT (ECU) AND THE CALIBRATION INSIDE. A REFLASH DOES NOT PROPERLY RECALIBRATE THE ENGINE MANAGEMENT SYSTEM; THIS CREATES A DANGEROUS SITUATION THAT COULD RESULT IN A STUCK THROTTLE AND CAN LEAD TO INJURY OR DEATH. WEISTEC FULLY REPROGRAMS THE ECU TO MERCEDES STANDARDS, AND ENSURES THAT ALL ENGINE SAFETY CONTROLS ARE FULLY FUNCTIONAL. 1

3 WARNING! THE WEISTEC M113K SUPERCHARGER AND ACCOMPANYING PROGRAMMING ARE DESIGNED AROUND THE USE OF 91 OCTANE FUEL OR HIGHER ONLY. BEFORE YOU RUN YOUR MERCEDES WITH THE WEISTEC M113K SUPERCHARGER INSTALLED EVEN ONCE, YOU MUST EITHER DRAIN THE FUEL TANK COMPLETELY AND FILL IT UP WITH 91 OCTANE, OR BEGIN USING 91 OCTANE IN YOUR MERCEDES TWO COMPLETE FILLUPS BEFORE INSTALLATION. 2

4 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. 3

5 WARNING! THE WEISTEC M113K SUPERCHARGER MUST BE FILLED WITH 160 ml OF PROVIDED OIL PRIOR TO ROTATION OF THE COMPRESSOR SCREW SYSTEM OR YOUR WARRANTY WILL BE VOIDED. 4

6 WEISTEC M113K SUPERCHARGER Installation Guide for MERCEDES AMG 55 Thank you for your purchase of the Weistec M113K Supercharger for the Mercedes AMG 55 with the 5.5L Kompressor motor. 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 supercharger. 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 rare and powerful Mercedes 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. We strongly urge that you also have at least one person to help you install the supercharger, as the unit is heavy. You will soon be on your way to installing the World's First Supercharger Upgrade for the 5.5L Kompressor! Again, thank you for choosing Weistec Engineering! 5

7 Table of Contents Tools Required... Error! Bookmark not defined. I. Disassembly... 2 II. M113K Supercharger System Assembly III. M113K FEAD System Install IV. M113K Supercharger Assembly Install

8 Tools Required Hydraulic Jack or service lift Jack Stands or transmission stand 1/4 Drive Ratchet 12" Long 1/4" Drive Extension 6.5mm 1/4 Drive Deep Well Socket 8mm 1/4 Drive Deep Well Socket 10mm 1/4 Drive Deep Well Socket 17mm 3.8" Drive Deep Well Socket 10mm Open End Wrench 13mm Open End Wrench 14mm Open End Wrench 15mm Open End Wrench 17mm Open End Wrench 1" Open End Wrench 8mm Ratcheting Wrench 3/8 Drive Ratchet 13mm 3/8" Drive Socket 16mm 3/8 Drive Deep Well Socket Vice 17mm 3/8" Drive Deep Well Socket 19mm Heavy Duty Deep Well Socket T-25 1/4" Drive Torx Bit T 30 1/4" or 3/8 Drive Torx Bit T-45 3/8" Drive Torx Bit T-50 3/8" Drive Torx Bit E-8 3/8" Drive Reverse Torx Bit E-14 3/8" Drive Reverse Torx Bit Flat Head Screw Driver Wire Cutter Pushpin Removal Tool 6mm Drive Hex Bit 8mm Drive Hex Bit Mechanics Rags Vacuum Painters Tape Fluid evacuator Impact Gun (Optional) 7

9 Crimp Style clamp tool 5mm Drill bit Drill Grinder (Optional) Torque Wrench Ultra Black RTV Silicone 1

10 I. Disassembly Before removing battery terminal, double check vehicle is in Park, and driver side window is completely down. 1. Disconnect the Negative battery terminal by: a. Swinging spare tire panel in truck upward to access battery. b. Pulling top battery panel forward and sliding out. 2. Using 10mm Drive Socket, and 12" extension to remove batter ground strap. Raise and support the hood. 3. Remove ECU by: a. Removing engine bay liner in the upper corner of the engine bay by turning the two plastic screws ¼ counter-clockwise 2

11 b. Sliding the two plastic locks to the unlock position and lifting out the ECU/Fuse Box cover c. Removing ECU by unlocking the grey locks on the connectors, unplugging the harness plugs, and removing the ECU from the car. 3

12 BEFORE MOVING ON, PLEASE FILL OUT THE VEHICLE INFORMATION/TUNE REQUEST FORM AND MAIL THE ECU AND FORM TO 1701 E. EDINGER AVE. SUITE G4, SANTA ANA, CA 92705, USA. ELECTRONIC COMPONENTS SUCH AS THE ECU ARE VERY FRAGILE. PLEASE BE SURE TO SECURELY PACK THE ECU WITH PROTECTIVE COVERING WHEN MAILING. THE VEHICLE INFORMATION/TUNE REQUEST FORM IS INCLUDED WITH THE SUPERCHARGER SYSTEM DOCUMENTATION, AND CAN ALSO BE FOUND AT 4. Remove the air intake system from the vehicle by: a. Gently pulling up on the Mercedes engine cover b. Removing both air box inlet tubes. c. Using Flat Head Screw Driver or 6.5mm Socket to loosen Clamps on the inlet Y and air boxes. d. Lifting the air box assemblies from the vehicle. 4

13 5. Remove AMG manifolds by: a. Using Flat Head Screw Driver or 6.5mm Socket to loosen Clamps on the supercharger outlet 5

14 b. Removing all 7 screws from each AMG Manifold c. Removing AMG Manifolds from the engine bay 6

15 6. Remove Throttle Body and EVAP Lines by: a. Unplugging Throttle body harness. b. Removing all 4 throttle body bolts using a T-30 Torx Bit. c. Disconnecting Throttle Body EVAP line. d. Removing Throttle Body from vehicle and placing it somewhere clean and safe. e. Removing EVAP line from Right Valve Cover. 7

16 f. Removing EVAP line from Left Valve Cover. 7. Remove Fuel Rails and Injectors by: Please be aware that the fuel system may retain fuel pressure that can be extremely dangerous if removed suddenly. Proceed with caution. Please be aware of dripping fuel may get on parts that can be affected. Please cover fuel line with a shop rag in this case. a. Removing 4 bolts for fuel rail removal. 8

17 b. Disconnecting fuel line using 17mm Open End Wrench. c. Unplugging all 8 fuel injectors. d. Lifting up on the fuel rails to remove them along with the injectors 9

18 8. Remove Air Valves by: a. Disconnecting vacuum lines and air lines from both of the air valves b. Unbolting Air Valves from the intake manifold runners and placing them somewhere clean and safe as they will be reused. 10

19 9. Remove Supercharger by: a. Removing Supercharger Belt b. Removing Intercooler water line bracket 11

20 c. Disconnecting rubber intercooler water lines from the hard lines d. Removing Intake manifold bolts e. Removing EVAP Solenoid line by unbolting it from the right Valve cover and disconnecting both ends. f. Unplugging all sensor clips, hoses, and fasteners and make Supercharger free for removal. Supercharger Clutch clip Rear IAT Sensor clip Bypass Valve harness from engine harness 1 map sensor clip (Left side of supercharger outlet) g. Removing Supercharger assembly from engine bay and placing it on a clean work bench h. Vacuuming and cleaning engine valley and intake ports. i. Using painter s tape to seal intake ports until the Weistec M113K Supercharger system is bolted onto the engine. 10. Remove Bypass Valve by: a. Removing MAP Sensor by removing two screws 12

21 b. Removing IAT Sensor by carefully unclipping it c. Removing all screws that attach the Intercooler to the supercharger 13

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23 d. Gently prying the intercooler and supercharger apart e. Removing Bypass Valve rubber gasket and 4 Bypass Valve Bolts 15

24 f. Placing Bypass Valve on a clean workbench as it will be reused. 11. Remove Factory Supercharger Belt Tensioner by: a. Removing Tensioner pulley 16

25 b. Removing Tensioner bolts 17

26 II. M113K Supercharger System Assembly 1. Install IAT Sensor by: a. Installing IAT Sensor into Intake Manifold in the location shown below. Make sure to lubricate the O-Ring to prevent damage during installation 2. Install MAP Sensor by: a. Pressing in MAP Sensor in the location shown below and bolt in using original bolts. Use Blue Loctite on the bolts and make sure to lubricate the O-Ring. 3. Install Bypass Valve by: 18

27 a. Trimming Bypass Valve rubber cover as shown below. Some early models do not have the rubber cover. If your Bypass Valve does not have the cover, skip this step. b. Lubricating included Bypass O-Ring and positioning it in the groove as shown below. c. Bolting on Bypass valve using original hardware. d. Pressing on included Bypass Coupler and loosely fitting on two included 60-80mm European hose clamps 4. Install Inlet Manifold by: 19

28 a. Cleaning then applying Black RTV Silicone to Inlet Manifold as shown below. b. Mounting Inlet Manifold onto Supercharger inlet making sure the Bypass Coupler properly attaches to Inlet Manifold. Be sure to install the Inlet Manifold as shown below to avoid smearing the Black Silicone RTV applied in the previous step. Line up the top of the Inlet Manifold so that is touching the Supercharger inlet. Then press the back of the Inlet Manifold down so that it is properly seating in the Bypass Coupler as well as mated with the Supercharger Inlet It is highly important that care be taken with this step to ensure there are no vacuum leaks. 20

29 c. Bolting on Inlet Manifold using 4 included M8x1.25x25 bolts, Torque to 40 Nm. One of the bolts must be bolted from the opening of the Inlet Manifold as shown below. d. Wiping away excess silicone e. Position and tighten the two 60-80mm European hose clamps on bypass valve coupler 21

30 III. Weistec M113K FEAD System Install 1. Install M113K FEAD System by: a. Tapping the indicated hole using an M8x1.25 Tap. b. Bolting on the M113K FEAD Bracket using the included bolts as shown below. 22

31 c. Bolting on included 8 Rib Belt Tensioner Assembly using included M10x1.5x80 bolt and M10 washer. Make sure tensioner is aligned so that the alignment peg is fully inserted into the alignment hole on the FEAD Bracket. 23

32 IV. Weistec M113K Supercharger Assembly Install 1. Install Supercharger Assembly by: a. Pressing on included ¾ 90 degree molded heater hose onto barbed fittings at back of the Supercharger System using one clamp on each hose. Make sure that the hoses are aligned so that they will be pointing to the left side of the engine bay. b. Removing painters tape from intake ports on the cylinder heads c. Placing on included M113K Intake Manifold Gaskets d. Lowering Supercharger Assembly onto engine with the ¾ hoses routed to the left side of the engine bay, making the assembly is properly seated and no lines or wiring are pinched. 24

33 e. Bolting down the Supercharger Assembly with the included M8x1.25x25 bolts, Torque to 40 Nm 2. Connect All Electrical Connections by: a. Connecting MAP Sensor 25

34 b. Connecting IAT Sensor c. Connecting all 8 Fuel Injectors There are two options, one is to use the plug and play injector clips. The other is to cut off the factory injector clips and wire in the EV6 Female Pigtails (Polarity does not matter) using a soldering iron and heat shrink to cover the solder joints. 26

35 d. Connecting Bypass Harness to Engine Harness 3. Install Air Valves by: a. Pressing in left and right Air Valves and bolting them to the manifold using the original bolts and included gaskets 27

36 b. Connecting 1/8 inch vacuum lines. Be sure to have the filters installed in the proper direction c. Pressing on M113K Air Tube d. Trimming Air Pump hose and pressing it onto the barbed fitting installed in the M113K Air Tube 28

37 4. Connect Fuel Lines by: a. Routing fuel line under the Inlet Manifold between the Bypass Valve and the Supercharger unit. Make sure the side with the 90 degree AN fitting is on the left side of the engine b. Screwing on hose fittings to the fittings on the fuel rails c. Screwing on factory fuel line to the right side fuel rail fitting. 5. Connect Emissions Lines by: a. Fitting the OEM hose shown below to the left side valve cover and connecting it to the middle vacuum port on the Inlet Manifold 29

38 b. Fitting the OEM hose shown below to the right side valve cover and connecting it to the vacuum port on the right side of the Inlet Manifold 30

39 c. Removing the OEM hose shown below from the factory air box. If the plastic barbed coupler comes off in the OEM hose, remove it. Press in the included brass barbed fitting and install an included clamp. 31

40 d. Pressing on the included -10 hose section onto the other end of the brass barbed fitting and installing an included clamp e. Pressing the OEM hose onto the port on the right valve cover and routing the hose as shown below. The other end of the hose will be pressed and clamped onto the M113K Intake Tube 32

41 f. Disassembling the factory EVAP Solenoid hard line as shown below 33

42 g. Installing the Factory EVAP Solenoid hard line as shown below. One end connects the OEM solenoid vacuum line with an included 3/8 clamp. h. Pressing and clamping on the included 3/8 EVAP hose to EVAP hard line 34

43 i. Routing 3/8 EVAP line behind the Inlet Manifold and connecting it to the 3/8 vacuum port on the left side of the Inlet Manifold as shown below. j. Connecting 1/8 Air Valve vacuum line to the 1/8 vacuum port on the left side of the Inlet Manifold, routing it under the left side fuel rail and connecting it to the Air Valve Solenoid line that has the blue filter. 35

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45 6. Install Throttle Body by: a. Holding the Throttle Body in a vice and tapping the hole using the included 1/8 NPT Tap as shown below b. Screwing in the included 1/8 NPT Stainless Plug using pipe sealant. 37

46 c. Screwing in included 1/8 NPT Stainless Plug into Inlet Elbow. Use Teflon Tape to ensure a proper seal d. Pressing Inlet Elbow Gasket into the gasket groove on the Inlet Manifold 38

47 e. Bolting on Inlet Elbow using included 4 M6x1x20 Socket Head Screws torque to 16 Nm f. For 74mm Throttle Body: Positioning Throttle body gasket in the gasket groove on the Inlet Elbow the bolting on the 74mm Throttle Body Throttle Body using included M6x1x30 button head screws as shown below. Torque to 16 Nm. 39

48 g. For 82mm Throttle Body: Applying Black RTV Silicone to the Inlet Elbow and bolting on the 82mm Throttle Body using included M6x1x30 button head screws as shown below. Torque to 16 Nm. 40

49 7. Connect Intercooler Plumbing by: a. Pressing the 5/8 barb side of the included 5/8 to ¾ Barb Couplers into the factory intercooler lines and clamping them with the included 5/8 clamps as shown below. b. Running the ¾ Intercooler lines towards the front of the engine 41

50 c. Pressing the ¾ Intercooler lines onto the ¾ sides of the barb couplers and clamping them on with the included ¾ clamps as shown below 8. Install Intake by: a. For 74mm Throttle Body: Fitting the smaller side of included silicone coupler onto the throttle body and clamping it on using the provided 70-90mm European style hose clamp as shown below 42

51 b. For 82mm Throttle Body: Fitting the included silicone coupler onto the throttle body and clamping it on using the provided SAE No.60 hose clamp c. Pressing in M113K Intake tube and clamping it on using the included SAE No.60 hose clamp d. Pressing the -10 hose onto the vacuum port on the M113K Intake Tube and clamping it on using the included 5/8 hose clamp 43

52 e. Fitting Weistec Air Filter onto the M113K Intake Tube and clamping it on using the included SAE NO.60 clamp 9. Fill Supercharger With Oil by: a. Removing plug on top of supercharger with a 5mm allen bit. 44

53 b. Filling Supercharger unit with supplied oil c. Reinstalling plug on top of supercharger using Black RTV Silicone 10. Install Supercharger Belt by: a. Using a 3/8 drive ratchet to pull back on the tensioner and routing the included 8 Rib Supercharger Belt per the routing diagram shown below. 45

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55 Thank you from Weistec Engineering! Always enjoy the added horsepower and torque of the M113K supercharger responsibly. Use best judgment when driving, and remember to have fun! NOTES: 47