Charger, Magnum, 300C 5.7L & 6.1L Supercharger ... · HEMI Supercharger Installation Manual Rev B...

Charger, Magnum, 300C5.7L & 6.1L

Supercharger Installation Manual

Arizona Speed and Marine, Inc. 6313 W. Commonwealth Ave, Chandler, AZ 85226Phone: 480-753-0208 --- Fax: 480-753-0216

HEMI Supercharger Installation Manual

Rev B September 21, 2007 1

1. Table of Contents

1. Table of Contents ___________________________________________________ 12. Fuel and Spark timing Computer Programming Unit (CPU) ________________ 23. Warranty Information _______________________________________________ 34. Optional 36 Month / 36,000 mile engine Warranty ________________________ 35. Installation ________________________________________________________ 4

5.1 Component Removal ______________________________________________ 55.2 Spark Plug Installation ____________________________________________ 85.3 Fuel Injector Installation___________________________________________ 95.4 Radiator Overflow Tank & Air Intake Installation ____________________ 105.5 Charge Cooling System & Plumbing ________________________________ 135.6 Oil Drain Assembly ______________________________________________ 185.7 Oil Feed Plumbing _______________________________________________ 195.8 Throttle Body Spacer Installation __________________________________ 215.9 Intercooler and Discharge Duct Installation __________________________ 225.10 Supercharger Installation _______________________________________ 255.11 Spark and Fuel Control Box and Wiring___________________________ 305.12 Fan & Traction Control – Optional _______________________________ 335.13 Final Inspection and Testing_____________________________________ 335.14 Operational Information ________________________________________ 34

6. Appendix _________________________________________________________ 356.1 Supercharger/Bracket Assembly ___________________________________ 356.2 Belt Routing Diagram ____________________________________________ 366.3 Plumbing Diagram_______________________________________________ 376.4 Electrical Diagram – Coolant Pump ________________________________ 386.5 Unichip Module Wiring Diagram___________________________________ 396.6 Revision History_________________________________________________ 40



2. Fuel and Spark timing Computer Programming Unit (CPU)

The Unichip CPU is programmed to provide the proper spark timing and fuelenrichment under boost conditions. This additional control unit works with thestock ECU and does not effect the operation of the emission controls or demandon displacement feature of your vehicle, as designed by the manufacture.

The CPU is plug-and-play, wired into the factory wiring harness and electronicallyresides between the cars ECU and engine. The CPU is solid state multiple high-speed processors, about the size of a MP3 player, and makes fine tuningadjustments as needed. The CPU has several advanced features to use inputvalues from the sensors and communicates with the ECU to perform adjustmentautomatically.

The programs are carefully designed based off dyno tested results and are to beused with factory OEM components as delivered by the vehicle manufacture.

Any changes to the vehicles exhaust system or power adding components canhave an effect on tune up needed by the engine. If you want to install additionalperformance items manufactured by Arizona Speed & Marine contact yourauthorized dealer to get the CPU updated with the proper program.

Unichip spark and fuel management control box is warranted providing it wasinstalled properly to be free of manufacturing defects and materials for a periodof one year after the date of delivery to the original purchaser.

Unichip spark and fuel map controller (CPU) has pre-programmed tables thatwere 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 suchas power programmers that increase spark timing or raise RPM limits can resultin damage to your engine.

Any additional modifications such as aftermarket exhaust require a differentcalibration. Any vehicle required for towing must also be required to have theUnichip CPU calibration modified by Arizona Speed & Marine.

Arizona Speed & Marine, Inc. neither implies nor guarantees the calibration iscorrect for after market exhaust, towing or racing applications. Arizona Speed &Marine, Inc. does offer an optional 36,000 mile 36 month warranty on oillubricated engine parts. To purchase the engine warranty see your dealer fordetails.



3. Warranty Information

Vortech Superchargers warrantees their supercharger providing it was installedproperly to be free of manufacturing defects in materials and workmanship for aperiod of one year after the date of delivery, to the original purchaser.

Arizona Speed & Marine, Inc warrantees fuel injectors are free from defects fora 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 warrantyon oil lubricated engine parts. Contact your dealer or Arizona Speed & Marine,Inc. for additional information.

Arizona Speed & Marine Inc. / Vortech Superchargers warranty registrationmust be completely filled out and registered according to the date and mileage attime of installation. Fill out the form below and return to Arizona Speed & Marine,Inc.

Arizona Speed & Marine6313 W. Commonwealth

Chandler, AZ 85226Arizona Speed & Marine, Inc. will process any claims related to thesupercharger with Vortech Superchargers providing the warranty registrationwas filled out and processed as instructed above.



5. Installation

Important: Read over the entire installation instruction before starting to give youa better understanding of how to install the parts. If you are missing any parts,have questions concerning the installation or need technical assistance, pleasecall us at (480) 753- 0208.

NOTE: These instructions assume you are a qualified technician and haveworking knowledge of hand tools, their operation and that of the automotiveengine, which you are working on. If these assumptions are not correct, it isrecommended that you take the parts to a qualified facility for the installation ofthese parts. It is recommended you have access to a factory shop manual forinstallation. Arizona Speed & Marine, Inc. accepts no responsibility forimproper or faulty installation of the parts, or for the accuracy or omissions inthese instructions.

This manual covers installation for multiple model vehicles with various enginetypes. Consequently, the photos shown may not represent the exact installationdetails for all variations. Furthermore, this supercharger kit is being continuouslyupdated 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 theprocedures necessary to accomplish the tasks described in the installation stepsand be able to adapt the steps as needed to suit his vehicle type.



5.1 ComponentRemoval

5.1.1 Remove thenegative batterycable located in thetrunk.

5.1.2 Remove pansunder vehicle byremoving four boltsfrom the front andrear of the plasticpans. Then removethe row of 7MMbolts located alongthe front edge ofthe fascia.

5.1.3 Using a screwdriveror plastic rivetremoval tool,remove push rivetsalong the innerfender well thatsecures the plasticpans in place. Slidepan out of the way.

5.1.4 Remove all thepush rivets along the radiator supportand wheel wells, these are one timeuse rivets, when assembling, use newrivets provided in the kit.

5.1.5 Remove the10-mm boltsnext to thefenders,these can beaccessedfrom underthe vehicle.

5.1.2

5.1.2

5.1.45.1.5



5.1.6 Remove 10-mm boltand nut locatedbehind the headlamp.

5.1.7 Remove 10-mm nutaccessible byreaching through thewheel well opening.

5.1.8 Remove 8 large pushrivets from top offascia, then removethe front fascia.

5.1.6

5.1.7

5.1.8



5.1.9 Remove factory airfilter box assemblyfrom drivers sideframe rail.

5.1.10 Remove factoryserpentine drivebelt. The belttensioner idlerpulley can beswung out of theway by using a 3/8”drive ratchet.

5.1.11 Disconnect wiringfrom intake airtemperaturesensor (IAT) andremove the sensorfrom the factory airintake duct. Thesensor will bereused in the newsuperchargerintake ductwork.

5.1.12 Open radiatorpetcock and draincoolant.

5.1.9

5.1.11



5.2 Spark PlugInstallation

5.2.1 Remove the 10-mm bolts andremove one coilpack.

5.2.2 Remove spark plugwire next to coilpack if necessary.

5.2.3 Remove bothspark plugs.

5.2.4 Install new sparkplugs and torque to12 ft-lbs.

5.2.5 Reinstall sparkplug wire and coil.

5.2.6 Repeat process forall 8 coil packs (16spark plugs).

5.2.1

2 Plug Connectionsper Coil Pack

5.2.1

5.2.3



5.3 Fuel Injector InstallationNew (larger) fuel injectors are supplied. These provide fuel enrichment neededto accommodate the increased air charge density from the supercharger.Spacers are installed under the fuel rail to accommodate the longer injectors onthe 6.1L engine only. NO SPACERS are required for the 5.7L engine.

5.3.1 Remove screwsretaining fuel railsfrom both sides ofengine.

5.3.2 Unplug electricalconnectors from allfuel injectors.

5.3.3 Release pressurefrom the fuel rail.

5.3.4 Remove clipsretaining fuel railsto injectors.

5.3.5 Remove oldinjectors and install new injectors.

5.3.6 Reinstall fuel rails.Install spacers asshown on the 6.1Lengine. Spacersare not required forthe 5.7L engine.

5.3.7 Reconnect all clipsand electric plugs.

5.3.8 Reinstall ball studson passenger sideonly. New boltsare used ondrivers’ side asdescribed infollowing sections.

Remove BallStuds

Unplugelectrical

connectors

5.3.1 - 5.3.2

Spacers betweenFuel Rail Taband Manifold

5.3.6



5.4 Radiator OverflowTank & Air IntakeInstallation

5.4.1 Remove the powersteering reservoirfrom the radiatoroverflow tank bypushing the lockingtab towards thepassenger fenderand sliding the unitstraight up.

5.4.2 Remove the 2-10mm bolts attachingthe overflow tank.

5.4.3 Remove theclamps and boththe upper andlower hoses fromthe overflow tank.Elevate or clampoff the lower hoseto minimize coolantloss.

5.4.4 Remove theoverflow tank.

5.4.5 Attach the airintake plate/weldedtube assembly intothe stock air intakehole just behindand below thedriver’s sideheadlight usingsheet metalscrews.

5.4.6 Affix the block-offplate to left inner

Remove stockoverflow tank

5.4.1 - 5.4.4

0

Air filter Tube

Block-Off Plate

0



frame with sheetmetal screws.

5.4.7 Attach the air filterto the lower tube inthe wheel well andaffix with providedclamp.

5.4.8 Attach the suppliedhose to the oilbreather fitting atthe oil filler neck.

5.4.9 Route the hosedown to and inserton the nipple at theair intake plate.

0

Oil Breather Hose

Oil Filler Neck

0

Oil Breather Hose

5.4.9



5.4.10 Install the newaluminum radiatoroverflow tank usingfactory screws.

5.4.11 Attach both upperand lower hosesand install clamps.Use a hosemender fitting andshort piece of hoseto lengthen thelower hose asnecessary.

5.4.12 Install a 15” lengthof 5/16” hose to theradiator cap ventand route it downthe fender. Thishose vents toatmosphere.

5.4.13 Install the powersteering reservoironto the overflowtank brackets.

5.4.14 Remove the stockthermostat andinstall the new180° thermostat.

PowerSteeringReservoir

Vent Hose

5.5.10 – 5.5.13

Hose MenderSplice

5.5.11

New 180°Thermostat

5.5.14



5.5 Charge CoolingSystem &Plumbing

NOTE: Refer to the Plumbing andElectrical Diagrams in theAppendix for the followingsections.

5.5.1 Attach mountingbrackets to radiatoras shown with nutsand bolts. Centerradiator andposition it as farback as possibleon the frame rail.Otherwise it willinterfere with thegrill. Mark and drillholes for themounting brackets.

5.5.2 Using self-tappingscrews, secure theradiator brackets tothe frame rail.

5.5.3 Apply threadsealant and Install2 brass 90° elbowsin the radiator.

5.5.4 Enlarge opening inradiator support forhose clearance.

5.5.5 Install brass 90°elbows in the topand bottom of thetriangular shapedreservoir usingthread sealant.

MountingBrackets

From Pump To Intercooler

5.5.1 - 5.5.3

5.5.4

90° BrassElbowsP-Clamp

5.5.5



5.5.6 Mount the circulating coolant pump to the reservoir using a rubberlined P-clamp.

5.5.7 Connect the small molded elbow from the end of coolant pump tobottom elbow of reservoir. Secure hoses with clamps.

5.5.8 Connect a 40” length of ¾” hose to the outlet side of the coolantpump and secure with clamp. Other end will be connected later.

5.5.9 Cut the existing electrical connector off the pump. Strip theground wire and crimp an electrical ring connector to the wire.Strip the red wireand add a 7-footpiece of red wireusing a spliceterminal. Route thered wire to the fusebox where it will beconnected later.

5.5.10 Attach the mountingbracket to the top ofthe triangularshaped coolantreservoir.

5.5.11 Remove the threescrews that securethe driver’s side headlamp and swing out of the way to allow roomto drill holes in the frame rail. Locate the coolant reservoirassembly to the frame rail, mark, drill and attach with sheet metalscrews. Note:Locate reservoirsufficientlyoutboard to providespace for the aircleaner. Attach thepump ground wirewith one of thescrews. Reinstallthe headlamp.

5.5.12 Install a 90° elbowfitting to the sideand a straightfitting to bottom of

Locate outwardfor air cleaner

clearance.

5.5.9- 5.5.11

90° Elbow

Straight Fitting

5.5.12



the coolant fill unit.Use thread sealanton the threads.

5.5.13 Locate the coolantfill unit and bracketnext to the brakereservoir asshown.

5.5.14 Locate the bracketon the fender,mark, drill holesand attach withsheet metalscrews. Attachcoolant fill unit tobracket.

5.5.15 Install 5’ moldedhose from driver’sside of radiatorthrough the firewalland up tointercoolerlocation. Secure atradiator withclamp. Intercoolerend will beattached later.

5.5.16 Cut to fit hose frombottom of coolantfill to top of coolantreservoir. Secureboth ends withclamps.

5.5.17 Route hoses neatlyalongside ofengine and securewith tie wraps.

5.5.18 Remove screwfrom top left of

Brake Reservoir

Coolant Fill Unit

5.5.13

Brake Reservoir

5.5.14

Coolant Fill Bracket

5.5.14



power distributionblock and attachthe coolant pumprelay with a washerunder the mountingtab of the relay.

5.5.19 Crimp a spadeterminal on the redwire from thecoolant pump andattach to the relay.

5.5.20 Crimp a ringterminal to one endof the in-line fusewire and attach tothe +12V lug nextto fuse box.

5.5.21 Crimp a spliceconnector to theother end of theinline fuse wire andattach the splice tothe red wire fromthe relay.

5.5.22 Route the yellowwire from the relayto the fuse box.Crimp a spadeterminal on thewire and connect itto a fuse using anadapter terminal.Verify theconnection is hotwith ignition switchturned ON andOFF when theignition switch isOFF. Trim thefuse box lip so theyellow wire is not

5.5.17

Hose from Bottom ofWater Fill to Top ofReservoir

5.5.16

Coolant PumpRelay Mounting

5.5.18 – 5.5.22



pinched when thecover is installed.

5.5.23 Crimp a ringterminal to theground wire fromthe relay. Attachthe ring terminal tothe bolt at thepassenger sidefender well.

5.5.24 Dress wires neatlyand install splitsleeving over wires.Tape ends ofsleeving to secure.

Connect to SwitchedHot Fuse

Trim RelayBox Lip

5.5.22

Ring Terminal

Inline Fuse WireAttach to+12V Lug

5.5.20

5.5.23



5.6 Oil Drain Assembly

5.6.1 Drain engine oil.

5.6.2 Insert oil drainadapter into oilpan and attach the90° AN fitting to oildrain adapter.

5.6.3 Insert nylonbraided hose ontothe barbed ANfitting and securewith A CV styleclamp. Ifavailable, tightenclamp with crimptool. A set ofdiagonal cuttingpliers may also beused.

5.6.4 Route the nylonbraided hose tothe location of thesupercharger. It isinstalled in thebottom of thesuperchargerlater.

Oil Drain Adapter

90° AN Adapter

5.6.2

Braided Nylon Hose

5.6.3



5.7 Oil Feed Plumbing

5.7.1 Remove alternatormounting bolts.Swing alternator toside to allowaccess to the oilpressure sendingunit.

5.7.2 Depress thereleasemechanism andslide the electricalconnection off theoil pressuresending unit.

5.7.3 Remove the oilpressure sendingunit using a 1-1/16”deep well socket.

5.7.4 Apply threadsealant and installthe 1/8” NPT –4AN90° elbow to theblock. Be sure theelbow is tight toprevent oil leaks.

Remove Alternatorfor access to OilPressure Sender

5.7.1

Remove Oil PressureSending Unit fromEngine Block

5.7.3

Install 90° Elbowinto Engine Block

5.7.4



5.7.5 Attach the 12” SSbraided line to theelbow and tighten.

5.7.6 Pre-assemble theT-fitting as shownwith a 45° adapterin one end and astraight adapter inthe opposite end.Apply threadsealant to all pipethreads.

5.7.7 Insert sending unitthrough themounting bracketand thread into thecenter port of theT-fitting. Usethread sealant onthe threads andtighten the sendingunit.

5.7.8 Bolt the bracket tothe engine blockoriented as shown.

5.7.9 Attach the SS linecoming from theengine block to the90° elbow.

5.7.10 Attach the long SS braided line to the 45° fitting and route to thesupercharger location.

5.7.11 Re-connect the electrical connector to the oil pressure sendingunit.

12” Braided Oil Line

5.7.5

45°Adapter

StraightAdapter

Bolt Bracketto Block

MountingBracket

5.7.6 – 5.8.11



5.8 Throttle BodySpacer Installation

5.8.1 Remove the 4throttle body boltsand remove thethrottle body.

5.8.2 Position theThrottle BodySpacer against theintake manifoldwith the O-Ringgroove facing awayfrom the manifold.

NOTE: The spacer has threeports. One connects to the blow-off valve (¼” tube), one connectsto the 2 Bar MAP sensor (1/8”tube). The third (upper) port maybe used for an optional boostgauge or must be plugged.

5.8.3 Install the O-Ringand position theThrottle Bodyagainst the ThrottleBody Spacer.Install the suppliedlonger 10 mm boltsand tighten.

CAUTION: Do not overtighten.

5.8.1

Install O-Ringin groove

5.8.2

PluggedPort

1/8” TubeFitting

¼” TubeFitting

5.8.3



5.9 Intercooler andDischarge DuctInstallation

5.9.1 Apply threadsealant and installone 90° elbowfitting and onestraight fitting inthe end of theIntercooler asshown.

5.9.2 Install theintercooler bracket,fuel rail andspacers with twobolts as shown.Spacers are onlyrequired for the6.1L engine.

5.9.3 Attached the lowerintercooler bracketto the engine usingtwo bolts asshown. Note: Thebracket is slotted tofit either the 5.7Lengine or the 6.1Lengines withspacers.

90° ElbowFitting

StraightFitting

IntercoolerAssembly

5.9.1

5.9.2 – 5.10.3

5.10.2 – 5.10.3



5.9.4 Attach Intercoolerassembly toengine. Positionstuds on bottom ofintercooler throughthe supportbracket. Install twonuts to the studsand tighten.

5.9.5 Cut-to-fit hose from90° fitting atcoolant filler to the90° fitting at rearof intercooler.Attach and tightenhose clamps. SeePlumbing Diagramin Appendix.

5.9.6 Cut-to-fit hosefrom the 90°elbow on driver’sside of radiator tothe straight fittingon the rear of theintercooler.Attach and tightenhose clamps ateach end.

5.9.7 Install two rubbersleeves and fourhose clamps onthe long, curvedair tube. Positionthe long air tubebetween theintercooler andthe throttle body.Slide the rubbersleeves onto theintercooler andthrottle body.Position all

5.9.4

Two Nuts Under Bracket

Intercooler

5.9.4

Install tube,sleeves and

clamps

5.9.7



clamps and tightensecurely.

5.9.8 Install the Blow-OffValve to the flangeon the long curvedair tube.

5.9.9 Cut-to-fit a piece of¼” vacuum linefrom the throttlebody spacer plateto the Blow-OffValve.

5.9.10 Optionally, theengine cover maybe trimmed to fitaround the newintercooler andducting as shown,or it may beomitted.

VacuumHose

5.10.9

5.10.8



5.10 SuperchargerInstallation

5.10.1 Remove the 10mm power steeringbolts and move theunit to the side.

5.10.2 Remove the autotensioner bolt andthe tensionerassembly from thefront of the block.

5.10.3 Assemble thesuperchargerbracket andtensioner parts.Adjust tension tofull loose positionand leave the idlerpulley bolt looseuntil belt tension isset. See Appendixfor assemblydrawing. NOTE:Do not attachsupercharger tobracket untilbracket is installedon engine.

Remove Tensioner

Power Steering Pump

5.10.1 - 5.10.2

5.10.3



5.10.4 Position thebracket assemblyon the face of theengine block andbolt in place using2 bolts 100-mmlong, 1 bolt 90-mmlong and 1 bolt 50-mm long. Be sureto include the smallspacer betweenthe bracket andengine block onthe lower mountingbolt.

5.10.5 Reinstall theautomatictensioner

5.10.6 Reinstall the powersteering pump.

5.10.7 The superchargeris pre-alignedbefore shipment.However, it may benecessary to tweakthe alignment tooptimize finalinstallation.Loosen the 6clamping screwsthat secure thecompressor to thegear case. Leavethe screws snugbut loose enoughto allow rotation ofthe compressoroutlet.

5.10.8 Temporarily mountthe superchargerto the rear of the

Small Spacer Behind

5.10.4

Loosen 6clampingscrews to

adjustclocking

5.11.7

5.11.8



bracket using only2 bolts as shown.Rotate thecompressor outletso it aligns properlywith the intercooleras shown in photo5.11.19. Removethe superchargerand tighten the 6clamping screws.

5.10.9 Install oil drainfitting to bottom ofsupercharger.Attach the hosefrom the oil panand install a CVboot style clamp.Crimp the clampwith crimping tool ifavailable or use adiagonal cuttingpliers for crimping.

5.10.10 Mount thesupercharger tothe rear of thebracket using boltsas shown.

5.10.11 Apply threadsealant to the male threads of a 45° elbow fittings and thread thefitting into the oil input of the supercharger. Use a back-upwrench on the supercharger fitting to prevent over-tightening andbreakage.

5.10.12 Apply thread sealant to the male threads of the 1/8 NPT to –4ANMale adapter fitting. Thread the AN fitting into the 45° elbow.Attach the SS braided oil feed line installed previously to the ANfitting. Orient the elbow down and rearward for best oil linerouting.

5.10.13 Screw the SS braided oil feed line from the Oil Pressure SensorT-Fitting onto the AN fitting and tighten.

Oil Drain in bottomof Supercharger

5.11.9

45° Fitting

Oil Input Line

5.11.11 – 5.11.13



5.10.14 Install the new belt.See Appendix forBelt RoutingDiagram.

5.10.15 Adjust the manualbelt tensioner untilthe belt is tight andthe automatictensioner isapproximately inmid-position.Tighten the idlerpulley bolt to lockthe belt tensioner.

5.10.16 Secure the powersteering pumplines away from thebelt.

5.10.17 Attach the inlettube to the rear ofthe superchargerand secure withclamp.

5.10.18 Attach the flexiblerubber air intakehose between theinlet tube and theair filter weldedtube assembly.Secure both endswith clamps.

Securely tie hosesaway from belt.

5.11.16

Flexible AirInlet Hose

5.11.18

Air Inlet Hose toback of

Supercharger

5.11.17



5.10.19 Install two rubbersleeves and fourhose clamps onthe short aluminumair tube. Positionthe tube betweenthe superchargerand intercooler.Slide the rubbersleeves onto theintercooler andsupercharger tubesand tightenclamps.

Install tube,sleeves and

clamps

Rotate compressor toalign with intercooler if

necessary.

5.11.19



5.11 Spark and FuelControl Box andWiring

5.11.1 Remove plasticretainers andremove grill coverover PCM module.

5.11.2 Remove bolt frombracket andremove PCMmodule.

5.11.3 Disconnect theBlack C1 andOrange C2connectors fromthe PCM.

Remove plasticrivets and grill.

5.11.1

PCM mountingbolt

5.11.2

Black C1Orange C2

5.11.3



5.11.4 Layout andprepare theUnichip PnPharness.

NOTE: See Appendix for wiringdetails.

5.11.5 Plug the Black C1and Orange C2connectors fromthe vehicleharness into theUnichip JunctionBox. Plug therespectiveconnectors fromthe Unichipharness into thevehicle PCM.

5.11.6 Install 2 Bar MAPsensor to theengine. Cut to fita piece of ¼”hose from thesensor to avacuum port onthe throttlespacer. Routewires to PCM area.

Note: Kits are supplied withvarious versions of MAPsensors so the picture andinstallation may not apply.Mount the sensor to theengine as required.

5.11.3

5.11.4 - 5.11.5

5.11.6



5.11.7 Install the Unichipcomputer to theinner fenderwellusing one sheetmetal screw.Position thejunction box andwiring in thefenderwell andthen reinstall thestock PCM andcover grill.

Note: Installing the Unichip module components and all the wiring into thevehicle fenderwell can be challenging due to the space available. By carefullydressing the wiring, everything will fit neatly.

Unichip Moduleattached tofenderwell

5.11.7



5.12 Fan & Traction Control – Optional

5.12.1 An optional kit is available to provide improved control of theengine cooling fan to assist cooling of the boosted engine. Thekit also provides features to control the factory traction controlsystem. Contract Arizona Speed and Marine regarding pricingand 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 andtoggle the ignition switch periodically to jog the pump to assistfilling 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 operatingtemperature. Ensure oil has been circulated through thesuperchargers oiling system and there are no oil leaks.

5.13.7 Using an OBD II scan tool ensure the engines ECU displays notrouble codes and there is no timing retard present as a result ofthe detonation under boost pressure. If detonation is present,ensure fuel pressure is at factory specification under boostconditions and the fuel in the vehicle is fresh and has not beenstored for an extended period.

5.13.8 Reassemble the front end of the vehicle by reversing thedisassembly steps.



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 fuelrequired under boost conditions.

• The OEM computer will remove timing and fuel to decrease power duringgear changes, this is feature to minimize transmission wear, and is part ofthe torque management system.

• Some noise will be transmitted through the drive belt at idle when the airconditioning compressor is engaged, and will disappear in off idleconditions, this is normal.

• Some whining noise will be heard as the supercharger spins at higherspeeds, this is normal.

• The lubrication system for the supercharger is supplied by the engines oilpump, and drains out of the supercharger back into the engine oil panwhere it will be recirculated and filtered.

• Use NGK TR5-1 V power spark plugs that are a colder range than theOEM spark plugs.

• Use coolant in the air/liquid after cooler to prevent corrosion and freezingin cold climate.

• Check fuel pressure every 6 months of operation to ensure the pressuredoes not drop from 59-60 PSI under wide open throttle. A drop in fuelpressure can lean the engine out and cause damage.

• Check the compression and leak down of the cylinders every 12 months ofoperation 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 stockintake manifold is designed to move air, and keep the inlet noise down. Ithas a tube that extends nearly half way into the manifold from the throttlevalve flange. This manifold design does not lend itself to simply installauxiliary injectors placed behind the throttle valve in the air stream. Inorder to get proper fuel distribution, we install larger injectors in each portas intended by the factory engineers.



6. Appendix

6.1 Supercharger/Bracket Assembly



6.2 Belt Routing Diagram



6.3 Plumbing Diagram



6.4 Electrical Diagram – Coolant Pump



6.5 Unichip Module Wiring Diagram



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.

Charger, Magnum, 300C 5.7L & 6.1L Supercharger ... · HEMI Supercharger Installation Manual Rev B...

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Transcript of Charger, Magnum, 300C 5.7L & 6.1L Supercharger ... · HEMI Supercharger Installation Manual Rev B...