| Supercharger, Part 4 -- Intercooler and Computer Reprogramming |
From "Weekend Mechanic"
episode WKM-213 |
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The final steps in the supercharger installation are completion of the cooling system assembly and final re-assembly. Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to the vehicle shown in the episode. With any particular vehicle, there will be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type of performance-enhancement kit you select. Always consult your vehicle's service manual when undertaking significant automotive upgrades, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools. Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components. Cooling System An intercooler is mounted below the supercharger itself. As the air is compressed by the supercharger, the air becomes extremely hot. To dissipate that heat, the air moves through a water-cooled core. - To install the core for the supercharger intercooler, the front grill of the truck needs to be removed.
- The cooler core mounts in front of the condenser for the air-conditioner. A factory-installed brace is removed , and the cooler is mounted on a special bracket that was included with the kit (figure A). The cooler serves to dissipate heat and return coolant to the intercooler, greatly enhancing the efficiency of the supercharger.
- The hoses for the cooler are routed from the engine compartment down to the heat exchanger (figure B).
- Attach the hoses to the fittings and secure them with hose clamps (figure C).
- Secure the attached hoses with zip-ties to keep them in place (figure D).
- Connect the other end of the hoses to the pump (figure E). Make all hose connections according to the manufacturer's instructions. The end of the hose that attaches to the reservoir requires a special fitting. Wrap the threads with thread tape before installing it.
- Finally install a bleeder valve in the inlet hose. Cut the inlet hose about 18 inches from the manifold, and install the T-fitting and cap (figure F). The bleeder valve will be used later when adding coolant to the system. With its cap off, the fitting will also allow air to be released from the system.
- Next, work continues beneath the vehicle with the installation of the secondary fuel-pump. Disconnect the fuel filter from the fuel line, then install a new U-bend adapter onto the fuel filter. The new secondary fuel-pump is installed onto the other end of the adapter (figure G).
- Attach the wiring to the terminals of the new pump (figure H) following the manufacturer's instructions. The terminals above will be connected later.
- Holes drilled into the bottom of the frame rail allow the new fuel-pump to be secured to the truck.
- Feed the wiring harness up into the engine compartment, remove the housing of the truck's electrical-relay center and connect the wiring according to the manufacturer's wiring instructions and diagrams. You'll need to locate the fuel-pump wire that runs from the relay center to the fuel pump.
- Use a test light to ensure that you've made the proper connection. The test-light should illuminate when you turn the ignition key to the "on" position ( figure I).
- Attach the ground-lead from the pump relay to the ground on the chassis.
- It's a good idea to protect all of your wiring with split-loom, and secure the harnesses with zip-ties (figure J).
- Close the relay center by reinstalling the housing (figure K), and reattach the negative battery cable.
- Add new coolant to the reservoir.
- You can now conduct a trial startup and check for leaks (figure L).
- The final step in the project is to reset the truck's computer to take into account the operating changes that result from the new supercharger. An electronic controller (figure M) (provided with the supercharger kit) is connected to the truck's DLC (data link connector) underneath the dash. The DLC is the interface with the truck's computer system. (The location of the DLC varies among vehicles. Check your owner's manual or kit instructions to locate yours if you're uncertain where it is.)
- Follow the manufacturer's instructions carefully to reprogram the computer. For ours, the procedure was as follows:
- Connect the controller;
- Making sure that the battery is fully charged, turn the ignition ON, but don't start the engine;
- Following the prompt on the controller readout, press "Yes" to program the PCM;
- Important: Don't turn the ignition off until the process is over;
- The readout on the controller should indicate that the computer is being programmed; Once the readout indicates that the reprogramming is complete, turn off the ignition and disconnect the cable.
- The reprogramming changes a number of things controlled by the onboard computer including the amount of fuel supplied to the engine via the fuel injectors, the spark-timing, ignition timing and even the shift-points of the automatic transmission. All of these factors are optimized in accordance with the new supercharger. If the supercharger were to ever be removed from the vehicle, the same controller could be used to re-set the computer to stock settings.
With the computer reprogrammed, the supercharger installation is complete.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
Fuel Injection: Installation, Performance Tuning, Modification
Model: 0879387432
Author: Jeff Hartman
Motorbooks International (MBI Publishing)
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