Charger, Magnum, 300C 5.7L & 6.1L Supercharger Installation Manual Arizona Speed and Marine, Inc. 6313 W. Commonwealth Ave, Chandler, AZ 85226 Phone: 480-753-0208 --- Fax: 480-753-0216
1. Table of Contents 1. Table of Contents 1 2. Fuel and Spark timing Computer Programming Unit (CPU) 2 3. Warranty Information 3 4. Optional 36 Month / 36,000 mile engine Warranty 3 5. Installation 4 5.1 Component Removal 5 5.2 Spark Plug Installation 8 5.3 Fuel Injector Installation 9 5.4 Radiator Overflow Tank & Air Intake Installation 10 5.5 Charge Cooling System & Plumbing 13 5.6 Oil Drain Assembly 18 5.7 Oil Feed Plumbing 19 5.8 Throttle Body Spacer Installation 21 5.9 Intercooler and Discharge Duct Installation 22 5.10 Supercharger Installation 25 5.11 Spark and Fuel Control Box and Wiring 30 5.12 Fan & Traction Control Optional 33 5.13 Final Inspection and Testing 33 5.14 Operational Information 34 6. Appendix 35 6.1 Supercharger/Bracket Assembly 35 6.2 Belt Routing Diagram 36 6.3 Plumbing Diagram 37 6.4 Electrical Diagram Coolant Pump 38 6.5 Unichip Module Wiring Diagram 39 6.6 Revision History 40 Rev B September 21, 2007 1
2. Fuel and Spark timing Computer Programming Unit (CPU) The Unichip CPU is programmed to provide the proper spark timing and fuel enrichment under boost conditions. This additional control unit works with the stock ECU and does not effect the operation of the emission controls or demand on displacement feature of your vehicle, as designed by the manufacture. The CPU is plug-and-play, wired into the factory wiring harness and electronically resides between the cars ECU and engine. The CPU is solid state multiple highspeed processors, about the size of a MP3 player, and makes fine tuning adjustments as needed. The CPU has several advanced features to use input values from the sensors and communicates with the ECU to perform adjustment automatically. The programs are carefully designed based off dyno tested results and are to be used with factory OEM components as delivered by the vehicle manufacture. Any changes to the vehicles exhaust system or power adding components can have an effect on tune up needed by the engine. If you want to install additional performance items manufactured by Arizona Speed & Marine contact your authorized dealer to get the CPU updated with the proper program. Unichip spark and fuel management control box is warranted providing it was installed properly to be free of manufacturing defects and materials for a period of one year after the date of delivery to the original purchaser. Unichip spark and fuel map controller (CPU) has pre-programmed tables that were developed on a stock 5.7L HEMI engine and engine control module (ECU) without any modification to the vehicle. Any modifications to the stock ECU such as power programmers that increase spark timing or raise RPM limits can result in damage to your engine. Any additional modifications such as aftermarket exhaust require a different calibration. Any vehicle required for towing must also be required to have the Unichip CPU calibration modified by Arizona Speed & Marine. Arizona Speed & Marine, Inc. neither implies nor guarantees the calibration is correct for after market exhaust, towing or racing applications. Arizona Speed & Marine, Inc. does offer an optional 36,000 mile 36 month warranty on oil lubricated engine parts. To purchase the engine warranty see your dealer for details. Rev B September 21, 2007 2
3. Warranty Information Vortech Superchargers warrantees their supercharger providing it was installed properly to be free of manufacturing defects in materials and workmanship for a period of one year after the date of delivery, to the original purchaser. Arizona Speed & Marine, Inc warrantees fuel injectors are free from defects for a period of one year after product installation. 4. Optional 36 Month / 36,000 mile engine Warranty Arizona Speed & Marine, Inc. offers an optional 36,000 mile 36 month warranty on oil lubricated engine parts. Contact your dealer or Arizona Speed & Marine, Inc. for additional information. Arizona Speed & Marine Inc. / Vortech Superchargers warranty registration must be completely filled out and registered according to the date and mileage at time of installation. Fill out the form below and return to Arizona Speed & Marine, Inc. Arizona Speed & Marine 6313 W. Commonwealth Chandler, AZ 85226 Arizona Speed & Marine, Inc. will process any claims related to the supercharger with Vortech Superchargers providing the warranty registration was filled out and processed as instructed above. Rev B September 21, 2007 3
5. Installation Important: Read over the entire installation instruction before starting to give you a better understanding of how to install the parts. If you are missing any parts, have questions concerning the installation or need technical assistance, please call us at (480) 753-0208. NOTE: These instructions assume you are a qualified technician and have working knowledge of hand tools, their operation and that of the automotive engine, which you are working on. If these assumptions are not correct, it is recommended that you take the parts to a qualified facility for the installation of these parts. It is recommended you have access to a factory shop manual for installation. Arizona Speed & Marine, Inc. accepts no responsibility for improper or faulty installation of the parts, or for the accuracy or omissions in these instructions. This manual covers installation for multiple model vehicles with various engine types. Consequently, the photos shown may not represent the exact installation details for all variations. Furthermore, this supercharger kit is being continuously updated and some of the components may be different than shown in the photos. It is expected that any qualified technician will be able to understand the procedures necessary to accomplish the tasks described in the installation steps and be able to adapt the steps as needed to suit his vehicle type. Rev B September 21, 2007 4
5.1 Component Removal 5.1.1 Remove the negative battery cable located in the trunk. 5.1.2 Remove pans under vehicle by removing four bolts from the front and rear of the plastic pans. Then remove the row of 7MM bolts located along the front edge of the fascia. 5.1.3 Using a screwdriver or plastic rivet removal tool, remove push rivets along the inner fender well that secures the plastic pans in place. Slide pan out of the way. 5.1.2 5.1.2 5.1.4 Remove all the push rivets along the radiator support and wheel wells, these are one time use rivets, when assembling, use new rivets provided in the kit. 5.1.5 Remove the 10-mm bolts next to the fenders, these can be accessed from under the vehicle. 5.1.5 5.1.4 Rev B September 21, 2007 5
5.1.6 Remove 10-mm bolt and nut located behind the headlamp. 5.1.7 Remove 10-mm nut accessible by reaching through the wheel well opening. 5.1.6 5.1.8 Remove 8 large push rivets from top of fascia, then remove the front fascia. 5.1.7 5.1.8 Rev B September 21, 2007 6
5.1.9 Remove factory air filter box assembly from drivers side frame rail. 5.1.10 Remove factory serpentine drive belt. The belt tensioner idler pulley can be swung out of the way by using a 3/8 drive ratchet. 5.1.9 5.1.11 Disconnect wiring from intake air temperature sensor (IAT) and remove the sensor from the factory air intake duct. The sensor will be reused in the new supercharger intake ductwork. 5.1.12 Open radiator petcock and drain coolant. 5.1.11 Rev B September 21, 2007 7
5.2 Spark Plug Installation 5.2.1 Remove the 10- mm bolts and remove one coil pack. 5.2.2 Remove spark plug wire next to coil pack if necessary. 5.2.3 Remove both spark plugs. 5.2.1 5.2.4 Install new spark plugs and torque to 12 ft-lbs. 5.2.5 Reinstall spark plug wire and coil. 2 Plug Connections per Coil Pack 5.2.6 Repeat process for all 8 coil packs (16 spark plugs). 5.2.1 5.2.3 Rev B September 21, 2007 8
5.3 Fuel Injector Installation New (larger) fuel injectors are supplied. These provide fuel enrichment needed to accommodate the increased air charge density from the supercharger. Spacers are installed under the fuel rail to accommodate the longer injectors on the 6.1L engine only. NO SPACERS are required for the 5.7L engine. 5.3.1 Remove screws retaining fuel rails from both sides of engine. Remove Ball Studs 5.3.2 Unplug electrical connectors from all fuel injectors. 5.3.3 Release pressure from the fuel rail. 5.3.4 Remove clips retaining fuel rails to injectors. Unplug electrical connectors 5.3.1-5.3.2 5.3.5 Remove old injectors and install new injectors. 5.3.6 Reinstall fuel rails. Install spacers as shown on the 6.1L engine. Spacers are not required for the 5.7L engine. 5.3.7 Reconnect all clips and electric plugs. 5.3.8 Reinstall ball studs on passenger side only. New bolts are used on drivers side as described in following sections. Spacers between Fuel Rail Tab and Manifold 5.3.6 Rev B September 21, 2007 9
5.4 Radiator Overflow Tank & Air Intake Installation 5.4.1 Remove the power steering reservoir from the radiator overflow tank by pushing the locking tab towards the passenger fender and sliding the unit straight up. Remove stock overflow tank 5.4.1-5.4.4 5.4.2 Remove the 2-10 mm bolts attaching the overflow tank. 5.4.3 Remove the clamps and both the upper and lower hoses from the overflow tank. Elevate or clamp off the lower hose to minimize coolant loss. 5.4.4 Remove the overflow tank. 5.4.5 Attach the air intake plate/welded tube assembly into the stock air intake hole just behind and below the driver s side headlight using sheet metal screws. 5.4.6 Affix the block-off plate to left inner 0 Air filter Tube Block-Off Plate 0 Rev B September 21, 2007 10
frame with sheet metal screws. 5.4.7 Attach the air filter to the lower tube in the wheel well and affix with provided clamp. 5.4.8 Attach the supplied hose to the oil breather fitting at the oil filler neck. 5.4.9 Route the hose down to and insert on the nipple at the air intake plate. 0 Oil Filler Neck Oil Breather Hose 0 Oil Breather Hose 5.4.9 Rev B September 21, 2007 11
5.4.10 Install the new aluminum radiator overflow tank using factory screws. Power Steering Reservoir 5.4.11 Attach both upper and lower hoses and install clamps. Use a hose mender fitting and short piece of hose to lengthen the lower hose as necessary. 5.4.12 Install a 15 length of 5/16 hose to the radiator cap vent and route it down the fender. This hose vents to atmosphere. 5.4.13 Install the power steering reservoir onto the overflow tank brackets. 5.4.14 Remove the stock thermostat and install the new 180 thermostat. Vent Hose 5.5.10 5.5.13 5.5.11 Hose Mender Splice New 180 Thermostat 5.5.14 Rev B September 21, 2007 12
5.5 Charge Cooling System & Plumbing NOTE: Refer to the Plumbing and Electrical Diagrams in the Appendix for the following sections. From Pump Mounting Brackets To Intercooler 5.5.1 Attach mounting brackets to radiator as shown with nuts and bolts. Center radiator and position it as far back as possible on the frame rail. Otherwise it will interfere with the grill. Mark and drill holes for the mounting brackets. 5.5.1-5.5.3 5.5.2 Using self-tapping screws, secure the radiator brackets to the frame rail. 5.5.3 Apply thread sealant and Install 2 brass 90 elbows in the radiator. 5.5.4 5.5.4 Enlarge opening in radiator support for hose clearance. 5.5.5 Install brass 90 elbows in the top and bottom of the triangular shaped reservoir using thread sealant. P-Clamp 90 Brass Elbows 5.5.5 Rev B September 21, 2007 13
5.5.6 Mount the circulating coolant pump to the reservoir using a rubber lined P-clamp. 5.5.7 Connect the small molded elbow from the end of coolant pump to bottom elbow of reservoir. Secure hoses with clamps. 5.5.8 Connect a 40 length of ¾ hose to the outlet side of the coolant pump and secure with clamp. Other end will be connected later. 5.5.9 Cut the existing electrical connector off the pump. Strip the ground wire and crimp an electrical ring connector to the wire. Strip the red wire and add a 7-foot piece of red wire using a splice terminal. Route the red wire to the fuse box where it will be connected later. Locate outward for air cleaner clearance. 5.5.10 Attach the mounting bracket to the top of the triangular shaped coolant reservoir. 5.5.9-5.5.11 5.5.11 Remove the three screws that secure the driver s side headlamp and swing out of the way to allow room to drill holes in the frame rail. Locate the coolant reservoir assembly to the frame rail, mark, drill and attach with sheet metal screws. Note: Locate reservoir sufficiently outboard to provide 90 Elbow space for the air cleaner. Attach the pump ground wire with one of the screws. Reinstall the headlamp. 5.5.12 Install a 90 elbow fitting to the side and a straight fitting to bottom of Straight Fitting 5.5.12 Rev B September 21, 2007 14
the coolant fill unit. Use thread sealant on the threads. Coolant Fill Unit 5.5.13 Locate the coolant fill unit and bracket next to the brake reservoir as shown. 5.5.14 Locate the bracket on the fender, mark, drill holes and attach with sheet metal screws. Attach coolant fill unit to bracket. 5.5.15 Install 5 molded hose from driver s side of radiator through the firewall and up to intercooler location. Secure at radiator with clamp. Intercooler end will be attached later. Brake Reservoir 5.5.13 Coolant Fill Bracket 5.5.14 5.5.16 Cut to fit hose from bottom of coolant fill to top of coolant reservoir. Secure both ends with clamps. 5.5.17 Route hoses neatly alongside of engine and secure with tie wraps. 5.5.18 Remove screw from top left of 5.5.14 Brake Reservoir Rev B September 21, 2007 15
power distribution block and attach the coolant pump relay with a washer under the mounting tab of the relay. Hose from Bottom of Water Fill to Top of Reservoir 5.5.19 Crimp a spade terminal on the red wire from the coolant pump and attach to the relay. 5.5.20 Crimp a ring terminal to one end of the in-line fuse wire and attach to the +12V lug next to fuse box. 5.5.16 5.5.21 Crimp a splice connector to the other end of the inline fuse wire and attach the splice to the red wire from the relay. 5.5.22 Route the yellow wire from the relay to the fuse box. Crimp a spade terminal on the wire and connect it to a fuse using an adapter terminal. Verify the connection is hot with ignition switch turned ON and OFF when the ignition switch is OFF. Trim the fuse box lip so the yellow wire is not 5.5.17 5.5.18 5.5.22 Coolant Pump Relay Mounting Rev B September 21, 2007 16
pinched when the cover is installed. 5.5.23 Crimp a ring terminal to the ground wire from the relay. Attach the ring terminal to the bolt at the passenger side fender well. 5.5.24 Dress wires neatly and install split sleeving over wires. Tape ends of sleeving to secure. Ring Terminal Inline Fuse Wire 5.5.20 Connect to Switched Hot Fuse Attach to +12V Lug Trim Relay Box Lip 5.5.22 5.5.23 Rev B September 21, 2007 17
5.6 Oil Drain Assembly 5.6.1 Drain engine oil. 5.6.2 Insert oil drain adapter into oil pan and attach the 90 AN fitting to oil drain adapter. 5.6.3 Insert nylon braided hose onto the barbed AN fitting and secure with A CV style clamp. If available, tighten clamp with crimp tool. A set of diagonal cutting pliers may also be used. 5.6.4 Route the nylon braided hose to the location of the supercharger. It is installed in the bottom of the supercharger later. 90 AN Adapter Oil Drain Adapter 5.6.2 Braided Nylon Hose 5.6.3 Rev B September 21, 2007 18
5.7 Oil Feed Plumbing 5.7.1 Remove alternator mounting bolts. Swing alternator to side to allow access to the oil pressure sending unit. Remove Alternator for access to Oil Pressure Sender 5.7.2 Depress the release mechanism and slide the electrical connection off the oil pressure sending unit. 5.7.1 Remove Oil Pressure Sending Unit from Engine Block 5.7.3 Remove the oil pressure sending unit using a 1-1/16 deep well socket. 5.7.3 5.7.4 Apply thread sealant and install the 1/8 NPT 4AN 90 elbow to the block. Be sure the elbow is tight to prevent oil leaks. Install 90 Elbow into Engine Block 5.7.4 Rev B September 21, 2007 19
5.7.5 Attach the 12 SS braided line to the elbow and tighten. 12 Braided Oil Line 5.7.6 Pre-assemble the T-fitting as shown with a 45 adapter in one end and a straight adapter in the opposite end. Apply thread sealant to all pipe threads. 5.7.7 Insert sending unit through the mounting bracket and thread into the center port of the T-fitting. Use thread sealant on the threads and tighten the sending unit. 45 Adapter 5.7.5 Straight Adapter 5.7.8 Bolt the bracket to the engine block oriented as shown. 5.7.9 Attach the SS line coming from the engine block to the 90 elbow. Mounting Bracket 5.7.6 5.8.11 Bolt Bracket to Block 5.7.10 Attach the long SS braided line to the 45 fitting and route to the supercharger location. 5.7.11 Re-connect the electrical connector to the oil pressure sending unit. Rev B September 21, 2007 20
5.8 Throttle Body Spacer Installation 5.8.1 Remove the 4 throttle body bolts and remove the throttle body. 5.8.2 Position the Throttle Body Spacer against the intake manifold with the O-Ring groove facing away from the manifold. 5.8.1 NOTE: The spacer has three ports. One connects to the blowoff valve (¼ tube), one connects to the 2 Bar MAP sensor (1/8 tube). The third (upper) port may be used for an optional boost gauge or must be plugged. Install O-Ring in groove 5.8.3 Install the O-Ring and position the Throttle Body against the Throttle Body Spacer. Install the supplied longer 10 mm bolts and tighten. CAUTION: Do not overtighten. Plugged Port 1/8 Tube Fitting 5.8.2 ¼ Tube Fitting 5.8.3 Rev B September 21, 2007 21
5.9 Intercooler and Discharge Duct Installation 5.9.1 Apply thread sealant and install one 90 elbow fitting and one straight fitting in the end of the Intercooler as shown. 5.9.2 Install the intercooler bracket, fuel rail and spacers with two bolts as shown. Spacers are only required for the 6.1L engine. 90 Elbow Fitting Intercooler Assembly Straight Fitting 5.9.1 5.9.3 Attached the lower intercooler bracket to the engine using two bolts as shown. Note: The bracket is slotted to fit either the 5.7L engine or the 6.1L engines with spacers. 5.9.2 5.10.3 5.10.2 5.10.3 Rev B September 21, 2007 22
5.9.4 Attach Intercooler assembly to engine. Position studs on bottom of intercooler through the support bracket. Install two nuts to the studs and tighten. 5.9.5 Cut-to-fit hose from 90 fitting at coolant filler to the 90 fitting at rear of intercooler. Attach and tighten hose clamps. See Plumbing Diagram in Appendix. Intercooler 5.9.4 5.9.6 Cut-to-fit hose from the 90 elbow on driver s side of radiator to the straight fitting on the rear of the intercooler. Attach and tighten hose clamps at each end. Two Nuts Under Bracket 5.9.4 5.9.7 Install two rubber sleeves and four hose clamps on the long, curved air tube. Position the long air tube between the intercooler and the throttle body. Slide the rubber sleeves onto the intercooler and throttle body. Position all 5.9.7 Install tube, sleeves and clamps Rev B September 21, 2007 23
clamps and tighten securely. 5.9.8 Install the Blow-Off Valve to the flange on the long curved air tube. 5.9.9 Cut-to-fit a piece of ¼ vacuum line from the throttle body spacer plate to the Blow-Off Valve. 5.10.8 5.9.10 Optionally, the engine cover may be trimmed to fit around the new intercooler and ducting as shown, or it may be omitted. Vacuum Hose 5.10.9 Rev B September 21, 2007 24
5.10 Supercharger Installation 5.10.1 Remove the 10 mm power steering bolts and move the unit to the side. 5.10.2 Remove the auto tensioner bolt and the tensioner assembly from the front of the block. 5.10.3 Assemble the supercharger bracket and tensioner parts. Adjust tension to full loose position and leave the idler pulley bolt loose until belt tension is set. See Appendix for assembly drawing. NOTE: Do not attach supercharger to bracket until bracket is installed on engine. Remove Tensioner Power Steering Pump 5.10.1-5.10.2 5.10.3 Rev B September 21, 2007 25
5.10.4 Position the bracket assembly on the face of the engine block and bolt in place using 2 bolts 100-mm long, 1 bolt 90-mm long and 1 bolt 50- mm long. Be sure to include the small spacer between the bracket and engine block on the lower mounting bolt. 5.10.5 Reinstall the automatic tensioner 5.10.6 Reinstall the power steering pump. 5.10.7 The supercharger is pre-aligned before shipment. However, it may be necessary to tweak the alignment to optimize final installation. Loosen the 6 clamping screws that secure the compressor to the gear case. Leave the screws snug but loose enough to allow rotation of the compressor outlet. 5.10.8 Temporarily mount the supercharger to the rear of the Small Spacer Behind Loosen 6 clamping screws to adjust clocking 5.10.4 5.11.7 5.11.8 Rev B September 21, 2007 26
bracket using only 2 bolts as shown. Rotate the compressor outlet so it aligns properly with the intercooler as shown in photo 5.11.19. Remove the supercharger and tighten the 6 clamping screws. 5.10.9 Install oil drain fitting to bottom of supercharger. Attach the hose from the oil pan and install a CV boot style clamp. Crimp the clamp with crimping tool if available or use a diagonal cutting pliers for crimping. 5.10.10 Mount the supercharger to the rear of the bracket using bolts as shown. Oil Drain in bottom of Supercharger 45 Fitting 5.11.9 Oil Input Line 5.11.11 5.11.13 5.10.11 Apply thread sealant to the male threads of a 45 elbow fittings and thread the fitting into the oil input of the supercharger. Use a back-up wrench on the supercharger fitting to prevent over-tightening and breakage. 5.10.12 Apply thread sealant to the male threads of the 1/8 NPT to 4AN Male adapter fitting. Thread the AN fitting into the 45 elbow. Attach the SS braided oil feed line installed previously to the AN fitting. Orient the elbow down and rearward for best oil line routing. 5.10.13 Screw the SS braided oil feed line from the Oil Pressure Sensor T-Fitting onto the AN fitting and tighten. Rev B September 21, 2007 27
5.10.14 Install the new belt. See Appendix for Belt Routing Diagram. 5.10.15 Adjust the manual belt tensioner until the belt is tight and the automatic tensioner is approximately in mid-position. Tighten the idler pulley bolt to lock the belt tensioner. 5.11.16 Securely tie hoses away from belt. 5.10.16 Secure the power steering pump lines away from the belt. 5.10.17 Attach the inlet tube to the rear of the supercharger and secure with clamp. 5.10.18 Attach the flexible rubber air intake hose between the inlet tube and the air filter welded tube assembly. Secure both ends with clamps. 5.11.17 Air Inlet Hose to back of Supercharger Flexible Air Inlet Hose 5.11.18 Rev B September 21, 2007 28
5.10.19 Install two rubber sleeves and four hose clamps on the short aluminum air tube. Position the tube between the supercharger and intercooler. Slide the rubber sleeves onto the intercooler and supercharger tubes and tighten clamps. Install tube, sleeves and clamps Rotate compressor to align with intercooler if necessary. 5.11.19 Rev B September 21, 2007 29
5.11 Spark and Fuel Control Box and Wiring 5.11.1 Remove plastic retainers and remove grill cover over PCM module. Remove plastic rivets and grill. 5.11.1 5.11.2 Remove bolt from bracket and remove PCM module. PCM mounting bolt 5.11.3 Disconnect the Black C1 and Orange C2 connectors from the PCM. 5.11.2 Orange C2 Black C1 5.11.3 Rev B September 21, 2007 30
5.11.4 Layout and prepare the Unichip PnP harness. NOTE: See Appendix for wiring details. 5.11.5 Plug the Black C1 and Orange C2 connectors from the vehicle harness into the Unichip Junction Box. Plug the respective connectors from the Unichip harness into the vehicle PCM. 5.11.6 Install 2 Bar MAP sensor to the engine. Cut to fit a piece of ¼ hose from the sensor to a vacuum port on the throttle spacer. Route wires to PCM area. 5.11.3 5.11.4-5.11.5 Note: Kits are supplied with various versions of MAP sensors so the picture and installation may not apply. Mount the sensor to the engine as required. 5.11.6 Rev B September 21, 2007 31
5.11.7 Install the Unichip computer to the inner fenderwell using one sheet metal screw. Position the junction box and wiring in the fenderwell and then reinstall the stock PCM and cover grill. 5.11.7 Unichip Module attached to fenderwell Note: Installing the Unichip module components and all the wiring into the vehicle fenderwell can be challenging due to the space available. By carefully dressing the wiring, everything will fit neatly. Rev B September 21, 2007 32
5.12 Fan & Traction Control Optional 5.12.1 An optional kit is available to provide improved control of the engine cooling fan to assist cooling of the boosted engine. The kit also provides features to control the factory traction control system. Contract Arizona Speed and Marine regarding pricing and availability for your vehicle. 5.13 Final Inspection and Testing 5.13.1 Re-fill engine with factory specified engine oil. 5.13.2 Re-fill engine cooling system with approved coolant. 5.13.3 Add coolant to the intercooler fill system. Add coolant slowly and toggle the ignition switch periodically to jog the pump to assist filling and purge air from the system. Check for leaks. 5.13.4 With ignition switch ON, check for fuel leaks. 5.13.5 Check all hose clamps for tightness. 5.13.6 Start the engine and let the engine warm up to operating temperature. Ensure oil has been circulated through the superchargers oiling system and there are no oil leaks. 5.13.7 Using an OBD II scan tool ensure the engines ECU displays no trouble codes and there is no timing retard present as a result of the detonation under boost pressure. If detonation is present, ensure fuel pressure is at factory specification under boost conditions and the fuel in the vehicle is fresh and has not been stored for an extended period. 5.13.8 Reassemble the front end of the vehicle by reversing the disassembly steps. Rev B September 21, 2007 33
5.14 Operational Information It is recommended to remove the front crankshaft balancer bolt, apply Loctite or equivalent thread lock material and torque to 245 Ft-Lbs. Use minimum 91 octane fuel to minimize detonation. Do not use E85 fuel, as the fuel system cannot support the volume of fuel required under boost conditions. The OEM computer will remove timing and fuel to decrease power during gear changes, this is feature to minimize transmission wear, and is part of the torque management system. Some noise will be transmitted through the drive belt at idle when the air conditioning compressor is engaged, and will disappear in off idle conditions, this is normal. Some whining noise will be heard as the supercharger spins at higher speeds, this is normal. The lubrication system for the supercharger is supplied by the engines oil pump, and drains out of the supercharger back into the engine oil pan where it will be recirculated and filtered. Use NGK TR5-1 V power spark plugs that are a colder range than the OEM spark plugs. Use coolant in the air/liquid after cooler to prevent corrosion and freezing in cold climate. Check fuel pressure every 6 months of operation to ensure the pressure does not drop from 59-60 PSI under wide open throttle. A drop in fuel pressure can lean the engine out and cause damage. Check the compression and leak down of the cylinders every 12 months of operation as a part of record keeping and maintenance. Perform maintenance on the vehicle as described in the owner s manual. Your kit is supplied with eight new fuel injectors of a larger size. The stock intake manifold is designed to move air, and keep the inlet noise down. It has a tube that extends nearly half way into the manifold from the throttle valve flange. This manifold design does not lend itself to simply install auxiliary injectors placed behind the throttle valve in the air stream. In order to get proper fuel distribution, we install larger injectors in each port as intended by the factory engineers. Rev B September 21, 2007 34
6. Appendix 6.1 Supercharger/Bracket Assembly Rev B September 21, 2007 35
6.2 Belt Routing Diagram Rev B September 21, 2007 36
6.3 Plumbing Diagram Rev B September 21, 2007 37
6.4 Electrical Diagram Coolant Pump Rev B September 21, 2007 38
6.5 Unichip Module Wiring Diagram Rev B September 21, 2007 39
6.6 Revision History 6.6.1 Rev 0, Fall 2007. Initial release for Dodge Charger vehicle with 5.7L engine. 6.6.2 Rev A, April 2007. Expanded info to cover Magnum and 300C models with 5.7L and 6.1L engines. Changed header from Charger 5.7L to HEMI. Section 5: Added comment about various vehicle models and that photos may not representing all variations. Section 5.3.11: Changed photo showing orientation of bracket. Section 5.11: Changed mounting bolt description for intercooler bracket. Section 5.12: Changed photos and description to incorporate the Unichip Plug and Play wiring harness. Section 5.14: Added recommendation to add thread lock and torque crankshaft bolt. Section 6.4: Changed Unichip Wiring Diagram to represent Plug and Play harness. 6.6.3 Rev B, September 21, 2007 Reordered and renumbered to improve assembly efficiency. Removed references to tape thread sealant. Removed references to auxiliary fuel injectors. Section 3 & 4: Revised for clarity. Reference optional Fan & Traction Control kit. Added instructions to drain coolant. Added instructions to refill coolant. Revised instructions about supercharger installation with information for clocking compressor. Moved battery cable removal to first step. Updated photos of overflow tank. Added hose mender splice. Added instructions to install 180 thermostat. Clarified photos of throttle body spacer ports. Revised Setrab radiator mounting. Clarified oil pressure sender mounting. Added information about fuel injector spacers. Updated Plumbing Diagram. Added Supercharger/Bracket Assembly Drawing. Rev B September 21, 2007 40