Damond Motorsports Focus ST OCC Kit Install Guide

Transcription

1 Damond Motorsports Focus ST OCC Kit Install Guide DISCLAIMERS: Failure to follow the instruction included in your purchase from DD2, Inc. DBA Damond Motorsports ( DM) could result in property damage or personal injury. Prior to installation the instructions should be read carefully. Please check our website for updated instructions or other related product information before installing. Professional installation is highly recommended by a certified mechanic. In no circumstances should installation be attempted unless the car has been shut off and the engine is cooled. Neither DM nor any of its employees, officers, directors, or shareholders shall be liable for improper use or installation of our products. DM is not responsible for the misuse, incorrect installation, or failure of any product we sell. Under no circumstances, including but not limited to negligence by third parties not affiliated with DM, will DM be liable for special or consequential damages that result from the use or inability to use our products. DM does not assume responsibility for any damage to the user, driver, passenger or vehicle resulting from the operation of a DM product. Any legal action brought against DM must be brought in the State of Illinois County of Cook. PLEASE DRIVE RESPONSIBLY. LIMITED LIFETIME WARRANTY: All DD2, Inc. DBA Damond Motorsports ( DM ) products carry a lifetime manufacturer warranty to the original purchaser. Warranty is non-transferable. Supporting components, manufactured by companies other than DM, carry the manufacturer s warranty. Warranty does not cover damage to coatings caused by exposure to the elements. Warranty does not cover damage or failure caused by abuse, misuse, faulty installation by any party, non-intended uses, repairs not conducted by DM, act of God, or accidents. DM is not liable for consequential damages arising from the use of our products or any indirect damages resulting in the loss of property, revenue or costs for towing, removal, installation, or re-installation. To receive warranty service you must contact DM to receive an RMA # (Return to Manufacturer Authorization Number) at which time you will be provided with instructions for returning the faulty product THERE ARE NO WARRANTIES, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS AGREEMENT. SELLER DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OF THE GOODS OR THE FITNESS OF THE GOODS FOR ANY PURPOSE, AND THE BUYER AGREES THAT THE GOODS ARE SOLD "AS IS" EXCEPT AS PROVIDED HEREIN. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, THE LAWS OF EACH STATE VARY AND MAY PROVIDE ADDITIONAL PROTECTIONS. Tools required/purpose: Jack and jackstands or lift or ramps/to lift the car Socket wrench: Very long extension/remove throttle body 7mm socket/loosen clamp on intercooler piping 8mm socket/remove throttle body and ECU bracket bolt 10mm socket/attach bracket to OCC, disconnect battery Flathead screw driver/tighten hose clamps #30 Torx driver or socket/remove under tray 1

2 Step 1: Unbox your Damond Motorsports OCC kit. You ll want to prep the OCC kit to be installed. Using the bolts and washers supplied with your kit, attach the included bracket to the back side of the OCC. Now attach the hoses as shown, with the check valve hose going to the top port on the OCC, and the hose with the straight connector going to the bottom OCC port, and secure the hoses with the provided hose clamps. Step 2: Begin by removing the battery cover and disconnecting both the negative and positive battery leads from the terminals, and secure the wires from contacting the battery terminals. Note: Not disconnecting the battery may cause electric shock, as you ll be working around the vehicle s starter motor. Record all radio and other presets, as they may need to be programmed in later. 2

3 Step 3: From above the engine, loosen the hose clamp securing the intercooler tube to the throttle body. Step 4: Safely lift the car in the air, using a lift or jack, and support the car on jackstands. Refer to the owner s manual for proper jack points. 3

4 Step 5: Remove the engine undertray. Begin with the 3 front air dam screws(green), then the remaining 8 undertray screws(red): Step 6: Pull the intercooler tubing from the throttle body. If you have the factory tube installed, you can bend it out of the way (Place a clean towel partially in the tube to prevent debris from entering). If you have an aftermarket intercooler piping, refer to the manufacture s instructions for removing/installing the tube leading to the throttle body 4

5 Step 7: Disconnect and remove the throttle body. Begin by sliding the red clip on the throttle body connector outward, and depressing the clip in the area shown in yellow, and slide the connector from the throttle body. Pull the wire gently downward to unsecure it from the wire clip on the throttle body itself (shown in blue) Remove the 4 8mm bolts attaching the throttle body to the manifold (shown in green). Getting the throttle body out can be quite difficult with the limited space, but if you move the positive lead going to the alternator and surrounding coolant lines, while gently rotating and maneuvering the throttle body, it will come out. If you find it difficult to remove the throttle body, you can do the install with the throttle body moved towards the front or side and rotated, where it s less in the way. 5

6 Step 8: Disconnect the PCV hose from the intake manifold. Squeeze the connector on both sides, and pull back away from the manifold to disconnect it. 6

7 Rotate the PCV valve, hose, and connector within the hose, into the orientation shown here, where the connector port is facing where the OCC will be mounted. 7

8 Step 9: Mount the OCC as shown, by removing the ECU cover bracket bolt, and re-installing the bolt with the OCC in place. 8

9 Step 10: Route the hoses as shown up to near the PCV connections. Start with the straight connector hose (the one without the check valve), and do one hose at a time. The hoses will route above/in front of the ECU wiring harness, behind/below the large coolant hose, above the starter positive wire, and in front of the sound symposer system (if equipped, if not, over the starter motor). 9

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11 Step 11: With the hoses no routed, it is time to connect them into the corresponding PCV connections. Begin with the straight connector; this will go into the PCV hose connector that was re-aimed earlier. When inserting the hose into the connector, you ll hear a satisfying click ensuring that the connectors have mated properly. Now with the 90 degree connector, coming from the check valve hose, insert the connector into the intake manifold port. You ll once again hear a satisfying click ensuring that the connectors have mated properly. Carefully inspect all connections, to double check that the connectors are fully seated. 11

12 Step 12: Install the throttle body back into place. Keep in mind to make sure the throttle body o- ring gasket is held into the intake manifold, and does not fall out or get miss-aligned when putting the throttle body back into place. Secure the throttle body in place and tighten the bolts. DO NOT OVER TIGHTEN. Connect the throttle body wiring connector back into place, by sliding the connector fully on, and pressing the red clip. Re-secure the wiring to the wire clip on the throttle body itself. With the provided zip ties, loosely attach the hose where you see fit. We want there to be a little play for the hose to travel as the engine moves, so don t tighten the zip ties all the way, just to secure the hose in place from coming in-contact with moving parts. Step 13: Reinstall the remaining components as were removed, and reconnect the battery. Now check the system for any leaks, and start the car. Let it run for a little as you double check all the connections for leaks. Step Optional: Each DM OCC kit contains a drain barb and drain tube. You may install these components, if you wish to drain the OCC from above the engine, with the intake box removed. Install the barb into the OCC drain valve. Place the undertray back on, and secure it with a few bolts. Reach down to the OCC, and mark with a paint pen to determine where the hole will need to be drilled. You may also pull down on the cover slightly under with the OCC is located to mark a drain hole. Drill a large enough hole in the undertray to route the drain hose through (bigger than ½ should do) Install the drain tube to the drain barb Re-install the undertray, and cut off the excess hose, so that about only ½-1 is protruding from the undertray. Draining the OCC: The DM OCC features an easy to use drain valve. When the valve arm is vertical the drain is open, and when the arm is horizontal the valve is closed. Be sure to not run the engine with the valve in the open position, as this will cause poor idling conditions and stuttering. Drain the OCC contents into a container as you would engine oil, and dispose of it properly and legally. Be sure to wear protective gloves when handling the OCC fluids, as well as any engine oil, for that matter. We hope you enjoy our Focus ST OCC kit! 12