Sony Automobile Battery Charger User Manual To The 72320e91 9dde 483b 9c1a 07b446bd2830

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READ THESE INSTRUCTIONS THOROUGHLY!

Follow the instructions STEP-BY-STEP, and your

installation will be trouble free. If in doubt, CALL

1-888-888-4079. We suggest that as you pro-

ceed through the installation, you should read a

few steps ahead in the instructions so you are

certain to catch all notes and warnings.

ATTENTION SUPERCHARGER INSTALLER!

Before proceeding with the installation, it is

important to know that to validate the 2 year,

100K warranty on your new J/R supercharger,

you must completely fill out the Moss Motors /

Jackson Racing warranty card that comes in

every kit, including serial number which is on a

small white ‘bar code’ label on the body of the

supercharger. Write down all of the numbers

which appear on that label in the appropriate

space on the warranty card. Be certain to do this

now because once your supercharger is

installed, it may be almost impossible to retrieve

that serial number.

SPECIAL NOTE: Jackson Racing Supercharger

Systems are designed to be installed by individu-

als with good mechanical sense and with the

proper tools. Use your discretion--if you are not a

competent mechanic, do not attempt this installa-

tion.

TOOLS REQUIRED: Most of these tools are

available at your local hardware or auto parts

stores.

17mm, 14mm, 13mm, 12mm, 10mm & 8mm

sockets

Deep sockets (14mm or 9/16”, 10mm)

Phillips and Standard screwdriver

Multi-purpose pliers

10mm, 12mm, and 17mm open end wrench

Timing light

A shop manual is useful.

WARNING: Once the installation is complete,

CHECK AND RECHECK ALL fuel system con-

nections for possible leaks before operating the

vehicle. 91-octane gasoline (or higher) is

required when running a supercharger.

During this installation process, you will reuse

some parts or hardware and not reinstall others.

It is recommended that you make space for

those that you will reuse, and a separate space

for those that you will not reinstall. In addition,

you should save the parts that will not get reused

in case you ever have reason to convert the

engine back to stock.

Enclosed is a set of labels that we suggest you

use to label the electrical connectors that you will

be unplugging.

Installation Instructions

SUPERCHARGER

with PowerCard

‘90-’93 Mazda Miata

Part# 999-156, 999-157, 999-158, 999-159

440 Rutherford St. P.O. Box 847 Goleta, CA 93117

1-888-888-4079 • FAX 805-692-2523 • www.supercharger.com

999-156 -1- Revised 1/07

1.0 DISASSEMBLY

1.1 With the engine running, raise the hood and

locate the main under hood fuse box by the fend-

er well near the firewall on the passenger side of

the engine compartment. Lift the main fuse box

cover and locate the relay labeled “FUEL INJ”.

While the engine is running, remove the “FUEL

INJ” relay. The engine will stop running. Turn

your ignition key off. Store the “FUEL INJ” relay

in a safe place until you are finished with the

installation. Release the pressure in your fuel

tank by removing your gas cap momentarily and

then re-installing.

1.2 Release the airflow meter harness 7-pin con-

nector by lifting the small wire clip that runs

around the rectangular base of the connector.

Remove the stock air flow meter, air filter box and

intake snorkel. Remove the air flow meter from

the air box. Store the air box, filter, and snorkel

away. Move the air flow meter to a safe place on

a worktable.

1.3 Remove the molded rubber elbow and hard

plastic tube that lead from the throttle body to the

airflow meter. If you have cruise control, you will

also have to remove the vacuum line from the

intake manifold nipple and from the points where

it attaches to the hard plastic intake tube.

Remove the cruise control vacuum line from the

cruise actuator as well and save it for use in step

#4.4 later.

1.4 Remove the chrome crankcase vent pipe that

is attached to the front of the cam cover and the

rubber hose that leads into the cam cover

(Figure 1.4). These can be stored away.

However, find the small restrictor inside the rub-

ber hose that ran from the cam cover to the

chrome tubing. It can be felt as a lump in the

straight section of the hose near the chrome tube

end. Persuade it out by gently clamping the hose

with a pair of pliers just behind the “lump”. Save

this restrictor for step #7.8. Re-install the chrome

bolts that held the tubing in place. Store the

chrome tube and Mazda hoses away.

2.0 THROTTLE BODY

2.1 Remove the throttle body (Figure 1.4) by

releasing the two electrical connectors (one has

a spring wire, one has a plastic lever clip), the

two small coolant hoses on either side of the

lower Idle Control System (ICS) valve, and the

four bolts.

TIP: THE SPRING HOSE CLAMPS FROM

MAZDA ARE BEST REMOVED BY

APPROACHING FROM THE SIDE WITH NEE-

DLE NOSE PLIERS. GRASP ALL THREE

TANGS AT ONCE AND COMPRESS THEM

TOGETHER. THIS IS EASIER TO DO WITH

THE THROTTLE BODY ALREADY LOOSE

FROM THE INTAKE MANIFOLD.

999-156 -2- Revised 1/07

Supercharger Installation Instructions

2. Stock Air Filter Box

3. Air Flow

4. Stock Plastic / Rubber Cross Over

5. ICS Valve (Idle Air Control)

6. Throttle Body Gasket

7. Throttle Cable

8. Throttle Body

Keep the hose ends above the radiator cap

level to prevent leakage. Release the throttle

cable from the throttle shaft spool. Release the

Throttle Position Switch harness by lifting the

small wire clip that runs around the rectangular

base of the connector. If the throttle body gasket

tears as you remove it, you will need to clean

off the old gasket from both surfaces, the throt-

tle body and the intake manifold. Carefully use a

knife or the backside of a hacksaw blade to

scrape the mounting surfaces clean. DO NOT

SCRATCH OR MAR THE MOUNTING SUR-

FACES IN ANY WAY.

2.2 Moving to a worktable, remove the idle air

control (ICS) valve from the bottom of the throt-

tle body by removing the three Phillips head

screws. Use a good quality screwdriver and be

careful not to strip the Phillips head screws. If

you cannot loosen a screw with the screwdriver,

use a small set of pliers from the side. Carefully

separate the two units making sure not to tear

the rubber gland gasket. The rubber gland gas-

ket will want to stay with the Mazda throttle

body carefully pick it out with a flat blade screw-

driver and save it for the next step.

2.3 Take the Idle Air Manifold (dummy throttle

body) from your supercharger kit and install the

Mazda idle air control valve (ICS) from step 2.2

in the appropriate place. Use the rubber gland

gasket from the Mazda throttle body in this posi-

tion. Reuse the three Mazda Phillips screws.

Use no sealant, just the rubber gasket.

2.4 Install the Dummy Throttle Body and ICS

valve back onto the intake manifold in the same

position as the standard throttle body on the

intake manifold. Use the 1104 sealant provided

if the original gasket was not salvaged.

Reconnect the coolant hoses to the idle control

valve as you found them. Use hardware sup-

plied as necessary.

2.5 Reconnect the idle control valve electrical

connector.

2.6 Take the Throttle Position Switch (TPS)

extension wire (3 conductor with sheathing)

from your kit and use it to extend your factory

TPS harness. We have provided six heat shrink

butt crimp connectors to use for each wire junc-

tion you will first have to cut the three pin con-

nector off of the end of the Mazda TPS harness.

Cut at least 3 inches back from the end of the

plastic connector to give yourself enough room

to work with. Our extender has three color-

coded wires that match the colors of the Mazda

harness. Strip a small section from each wire’s

end on the harness extender and connect it to

the appropriate color wire. Use the heat shrink

butt connectors to secure each splice. Crimp

with an appropriate tool or pliers. Use a heat

gun or similar to shrink the butt connector’s pro-

tective tubing over the crimped connector. We

do not recommend the use of open flame to

shrink the tubing. Wrap the entire grouping of

three connectors with electrical tape at both

ends to protect from moisture and dirt.

2.7 Locate the ICS blanking plate and take it

over to your Mazda throttle body. You will use a

thin layer of sealant between the blanking plate

and the Mazda throttle body. Install this blanking

plate onto your Mazda throttle body using the

three Phillips head screws supplied in the kit.

Supercharger Installation Instructions

999-156 -3- Revised 1/07

3.0 BELT DRIVES

3.1 NOTE: CARS WITH POWER STEERING:

You will be rearranging your power steering

bracket components per figure 3.2. Referring to

figure 3.1, remove the slot bracket and pillow

block by removing bolts “A”, “C”, and “D”. Take

the flat idler pulley bracket from your kit and trial

fit it to the assembly per figure 3.2. You will be

moving the pillow block and bolt “D” to behind the

power steering stamped steel bracket. This

makes room for the flat idler pulley bracket. The

upper support for the repositioned long bolt “D”

comes from a relocated Mazda slot bracket. It

becomes an extension bracket for bolt “D”. The

slot bracket is attached to the stamped steel

power steering bracket using a new

bolt/washer/nut assembly supplied in your kit.

Make sure to point this bolt with its head nearest

the nylon idler pulley and that this bolt goes

through the slot. The forward hole of the reposi-

tioned slot bracket will not be used. The rearward

hole is now used for the relocated “D” bolt, which

will be used to tighten your drive belt. Note: The

power steering pump must be in its lowest posi-

tion for this procedure.

3.2 When you are done with your trial fitting of

the flat idler pulley bracket, take this flat bracket

to a workbench and install the two nylon idler pul-

leys using the spacers, bolts and nyloc nuts pro-

vided. Make sure that the bolts point toward the

front of the car.

Supercharger Installation Instructions

999-156 -4- Revised 1/07

3.3 Secure the idler pulleys firmly to the flat brack-

et. Proceed to install the idler pulley assembly

onto the car per the procedure practiced during

the trial fitting. The final assembly (minus the pul-

leys) should look like figure 3.3.

VERY IMPORTANT: MAKE SURE THAT THE

DRIVER’S SIDE IDLER PULLEY IS FREE TO

SPIN. THE PINCH BOLT THAT YOU INSTALL

THROUGH THE PILLOW BLOCK FROM THE

REAR CAN INTERFERE WITH THE BACKSIDE

OF THE IDLER IF INSTALLED INCORRECTLY

(i.e. leaving out the thick washer under the bolt’s

head). TEST THE ASSEMBLY BY TIGHTENING

THE PINCH BOLT FULLY AND SPINNING THE

IDLER PULLEY. USE ADDITIONAL WASHERS

UNDER THE PINCH BOLT’S HEAD IF NECES-

SARY.

VERY IMPORTANT: Check the clearance

between the small coolant hose that runs from the

base of the thermostat housing and the passen-

ger side plastic idler pulley (see figure 8.1). If the

clearance is less than 1/2 inch between the hose

and the pulley, trim three quarters of an inch of

length off of the thermostat end of the small hose.

Reinstall the hose, reusing the spring clamp. By

removing a small piece of the hose end, the hose

will be pulled away from the idler pulley, avoiding

any damage during operation. This is a critical

area for attention since a hose failure could

cause severe engine damage. Not all cars need

this modification.

3.4 POWER STEERING CARS: Spin the power

steering pump pulley until the nut on the main

pump mounting bolt is visible. Insert a socket

wrench (deep 14mm) here and hold the rear hex

head with a 14mm box wrench. Remove the nut

and the long bolt (item “B” in figure 3.1). The bolt

will retract rearward underneath the exhaust

manifold.

3.5 Pick the flat steel supercharger bracket

from the kit and slip the long power steering

pump mounting bolt through the non-slotted

end. Reinstall the power steering pump bolt

and nut with the flat bracket pinched

between the bolt head and the cast power

steering pump bracket that is on the engine.

When finished, rotate the power steering

pump as far down as possible (the pulley

will touch the AC compressor pulley if so

equipped). This will allow room for the

supercharger to be installed and for the belt

to slip over the pulleys.

Supercharger Installation Instructions

999-156 -5- Revised 1/07

3.6 NON POWER STEERING CARS: Locate

your lower bracket assembly from the kit. The

end with the small 90-degree bracket mounts to

the idler bracket (standard on AC equipped cars)

or to new idler bracket (supplied with kit for non-

AC, non-PS cars). Use the new, longer 10mm

bolt provided to attach this bracket to the engine

(Review figure 3.4 for bolt location).

4.0 POWERCARD

4.1 The Powercard will be installed in the pas-

senger (right hand) foot well. Remove the kick

panel trim by removing the plastic fastener

securing the top, front portion of the panel. Use a

small screwdriver to pull out the center section

and then pull the whole fastener out. There is

also a push in fastener in the center of the panel.

Slip your fingers up behind the panel and gently

pull out on the center until it pops free. Once the

center fastener is free, slide the panel out from

under the door sill trim and set it aside. Remove

the forward two screws from the door sill trim to

allow easy removal and reinstallation of the car-

pet. Remove the floor mat and pull back the car-

pet to expose a large metal plate. Using a 10mm

socket, remove the four nuts and one bolt that

secure the plate to the car. Remove the plate to

gain access to the Electronic Control Unit (ECU).

Supercharger Installation Instructions

999-156 -6- Revised 1/07

Illustration 4.1

Illustration 4.1 con’t

Illustration 4.1

4.2 Locate the fuel injector wires. They are a

large Yellow and a large Yellow/Black wire locat-

ed in the connector nearest the drivers side of

the car. Use the included T-taps and multi-pur-

pose pliers to tap into the wires. Next, locate a

large Black wire in the opposite end of that con-

nector. T-tap the Black wire. This is the system

ground. Now, in the far end of the other connec-

tor, locate the White/Red wire and tap into it.

This is switched battery positive. Connect the

Powercard’s Red wire to the T-tap on the

White/Red wire, the Black wire to the Black wire

at the ECU, and the remaining wires to either of

the injector wires. Illustration 4.2

4.3 Route the vacuum source from the engine

compartment to the Powercard. Start under the

hood and locate a free vacuum port on the

intake manifold (right hand side of the engine).

If there are no free ports, splice into an existing

hose and use the included Tee to connect to the

hard plastic tubing included with the kit. Route

the tube from the intake manifold to the firewall

and across to the left side of the engine com-

partment. The tubing will go through the grom-

met with the wiring harness. Use a long phillips

screwdriver to push through the grommet. Be

cautious not to damage anything inside the car.

Remove the screwdriver and push a piece of

wire through the hole made by the screwdriver.

Wrap the wire around the tubing and secure

with electrical tape. Pull the tubing into the car

using the wire. Once inside the car, find a good

way to route the tubing across the car to the

Powercard location. Cut it to length if necessary

and connect it to the blue hose on the

Powercard. Illustration 4.3

Supercharger Installation Instructions

999-156 -7- Revised 1/07

Illustration 4.2

Illustration 4.3

4.4 The Powercard will mount to the underside of

the large metal plate. Find a location where the

Powercard can be without hitting the ECU. Make

sure both the metal plate and the back of the

Powercard are clean. Peal one half of the includ-

ed Velcro and attach it to the Powercard. Peal

the other half and attach it to the location picked.

4.5 Reinstall the plate, the carpet, the kick panel

trim and the two screws from door sill trim.

5.0 SUPERCHARGER PREPARATION

5.1 Working on a table, set the supercharger unit

in a position easy to work with. Be very careful

not to bump the supercharger pulley in any way

as it can easily damage the front bearing. Check

outlet manifold for debris and clean it out if nec-

essary. Install the outlet manifold as shown in fig-

ure 5.1. Get your Mazda throttle body with the

ICS blanking plate as installed in step #2.7 and

mount it to the supercharger using a thin film of

the sealant provided and the four bolts (8mm x

40) supplied in the kit.

5.2 Locate your throttle cable bracket that is bolt-

ed to your standard intake manifold and remove

the throttle cable by loosening the pinch nuts

surrounding the cable end on either side of the

bracket. Once the nuts are loose, you can pull

the cable out of the bracket - the grommet will

deform and let you do this. Remove the throttle

cable bracket by removing the two 10mm head-

ed

bolts. Unclip the throttle cable from the firewall

anchors. Begin rerouting the throttle cable by

looping the end behind the brake master cylinder

and laying it along the driver’s side fender well.

5.3 Locate the black plastic Roto-mold inlet elbow

from your kit. Check elbow for debris and clean it

out if necessary. You will be placing the assembly

into the position shown prior to installing the

supercharger. Make sure to install the 2.5” to

2.75” reducer hose to the airflow meter end of

this plastic elbow prior to setting it in place. This

will greatly assist in airflow meter installation.

Also, install the 2.5” diameter hump hose to the

throttle body end of this plastic elbow. Use the

Supercharger Installation Instructions

999-156 -8- Revised 1/07

clamps provided to secure the hoses to the

elbow.

6.0 SUPERCHARGER INSTALLATION

6.1 Remove the engine lift eyelet at the front of

the engine, just above the exhaust manifold by

removing the bolt using a 14mm socket. Using

the two new flanged headed bolts supplied with

your kit, install these to the two bosses on the

side of your cylinder head. Leave at least 1/2” of

thread exposed on each bolt.

6.2 Bring the supercharger over to the engine.

Feed the throttle body end into the hump hose

already installed on the black plastic “air flow

meter to throttle body elbow” (make sure to slip a

fully opened hose clamp over the hose first).

Orient the supercharger so that you can slip the

large “keyholes” in the bracket attached to the

supercharger over the two bolt heads installed in

step #6.1. Make sure that the bolts move up their

respective vertical slots and seat against the

upper edge of the horizontal slots in the bracket.

Slide the supercharger towards the firewall as far

as it will go. Tighten down the two pinch bolts

using an open-end wrench. If you find that the

bracket/supercharger assembly collides with your

cam cover vent tube during initial installation, it

means you did not leave enough threads

exposed on the two main mounting bolts

installed in step #6.1. Retry it with the bolts fur-

ther out.

6.3 Swing the flat lower bracket up into place in

front of the supercharger boss. Locate the small

stamped throttle cable bracket from your kit and

thread the new bolt through the throttle cable

bracket hole, through the supercharger boss and

through the flat steel lower bracket. Secure with

the locking nut and bolt supplied. Make sure that

the head of the bolt is on the throttle bracket side

of the assembly. Leave the power steering pump

long bolt and nut finger tight (14mm heads).

6.4 Route your throttle cable so that it is looped

back toward the firewall, routing the cable just

behind the driver’s side headlamp motor. Install

the cable’s threaded end into the small bracket

attached to the underside of the supercharger.

Make certain that the cable/grommet is fully

nested within the slot (this may require some

muscle - we made it tight so your throttle cable

won’t ever fall out). Open the throttle by hand and

insert the cable end into the throttle spool. Make

sure that the cable runs in the center of the

groove of the throttle spool. If it does not, adjust

the throttle cable bracket left or right until it is cen-

tered in the spool’s groove. Have an assistant

operate the gas pedal multiple times to confirm

that the action is free and easy without binding or

interference. Make sure that the cable has a bit of

“sloppy” slack with the gas pedal released and

that full throttle is available when the gas pedal is

fully depressed. If it does not “flop” in the idle posi-

tion, you will have trouble setting your idle speed.

Make sure that the cable is run in such a way as

to allow for engine movement from side to

side.Make very certain that all throttle cable-

mounting points are secure - this installation

area is critical for safe operation of your car.

This bracketry has been carefully designed for

correct operation. It is your responsibility as

the installer to ensure that it is bolted together

successfully without binding or interference.

Supercharger Installation Instructions

999-156 -9- Revised 1/07

7.0 AIRFLOW METER WORK

7.1 Locate the new air filter base from your kit and

install it to the air flow meter intake port, reusing the

Mazda cork gasket and four nuts. The air flow meter

is offset toward the top of the air filter base. The

seven pin electrical connector on the airflow meter

faces upward.

7.2 Locate the driver’s side shock tower support and

notice the Mazda air filter box mounting bracket

(painted body color) on the forward edge. This verti-

cal bracket is held in place by a horizontal bolt (also

painted body color). Remove the bolt using a 10mm

socket and store the bracket. On the “flying but-

tress” closest to the firewall, bend the captive nut

tang downward to make room for the plastic elbow

section using a small screwdriver in the hole.

Supercharger Installation Instructions

999-156 -10- Revised 1/07

7.3 Bring the air flow meter with the air filter base

installed over to the engine bay. Tilting the assem-

bly at an angle, feed the air flow meter outlet into

the rubber reducer sleeve already in place on the

plastic elbow (install loose hose clamp first). The

air flow meter assembly fits into the space just

inside the shock tower, between the two “flying but-

tresses” of the shock tower. The extra hole and

boss in the air filter base will line up with the hori-

zontal hole you just removed the 6mm body col-

ored bolt from. Using the longer bolt provided (M6

x 30mm, Allen head), attach the air filter base/air

flow meter assembly to the car using this bolt (it

mounts horizontally, through the air filter base, the

flying buttress, and into the Mazda captive nut on

the flying buttress). Use thread-locking compound.

7.4 Make sure that there is no chaffing or rubbing

anywhere along the plastic elbow assembly, even

though it is a very tight fit. Gently reposition any

brake lines that are pressing against the elbow.

Make sure all joints and clamps are secure - a leak

in this area will keep your car from idling correctly.

However, never over tighten your clamps, they

may break somewhere down the road. Use the

small length of rubber hose (1/4” dia) that is slit

along its length to cover the brake line running just

above the elbow. This will prevent any contact at

this point, which may result in noise during opera-

tion.

7.5 Locate the 3/4” diameter idle air hose (5’

length) from your kit. Attach one end to the ‘large’

outside fitting on the plastic elbow downstream of

the airflow meter (just below the brake master

cylinder once the elbow is in place). Use a clamp

to secure the hose to the short 3/4” nipple. Run

the hose toward the front of the engine compart-

ment, and across the engine side of the radiator.

Using the tie wraps provided, attach the rubber

hose securely to the radiator fan shroud supports

near the fan motor(s). Attach the end of the hose

to the idle control (ICS) valve nipple that is aimed

toward the front of the vehicle. Make sure that the

hose is attached in a way that will not interfere with

either fan operation or with the engine belts. At a

point along the length of the hose behind the radia-

tor, cut it and install the check valve supplied.

Install the check valve with the flanged end toward

the plastic elbow using the small hose clamps. See

figure 7.6. The hose is supplied a bit longer than it

needs to be. Feel free to trim its length if you pre-

fer. Be careful not to pinch the hose at any point -

doing so will affect your idle stability. You want to

have it tie-off in a low position; the cross over tube

will fit above this hose, hiding it in the final installa-

tion. On some cars, there might be a slight kink in

the hose where it attaches to the plastic elbow nip-

ple. This is acceptable - orient the hose so it

remains open.

7.6 Install the air filter element over the air filter

base. Next, collect the two studs and install them

with the element in place. Install the waffle-pat-

terned air filter cap and secure using the nuts pro-

vided. Use the tie-wraps provided to secure all

components and keep them clear from the belt

runs, exhaust manifolds, and especially the throttle

cable. Reroute the air bag harness over the air fil-

ter, keeping it away from the headlight raising

motor. IMPORTANT! Secure the air bag harness

with tie wraps to keep it from falling into the

engine belt system or being pinched in any

way.

Supercharger Installation Instructions

999-156 -11- Revised 1/07

Figure 7.5

7.7 Take the throttle body wiring harness extension

as left in step #2.6 and route the body of the har-

ness along the firewall using the bright cad plated

firewall clips that originally held the throttle cable on

your stock Miata. Tie-wrap the extension harness

along the firewall in at least two places. Make sure

to leave enough slack on both ends to allow the

engine to rock side to side without pulling on the

harness. Contain any extra length in a neat fashion.

Connect the female end to the throttle body at the

throttle position sensor.

7.8 Find the internal restrictor taken out of your

PCV hose in step #1.4. Locate the 3/8” internal

diameter rubber hose from your kit and press the

restrictor into this hose at least one inch. Attach this

hose from the ‘medium’ size fitting on the plastic

intake elbow (near the throttle body, pointing to the

engine). Cut to length and attach the other end to

the camshaft cover fitting on the exhaust side.

Make sure the hose does not kink at any point and

that the restrictor is not left out. If you leave the

small restrictor out, the engine will not idle correctly.

7.9 Locate the 5/32” internal diameter idle balance

hose and attach it to the ‘small’ fitting on the plastic

elbow. Attach the other end to the unused vertical

vacuum nipple on the bypass block of the super-

charger. Cut the line to the proper length, leaving

some slack to allow for engine movement. Make

sure the line is not pinched in any way and that it

has no possibility of interfering with the throttle

cable or spool. Use tie wraps as necessary to

secure the line. The diagram in figure #7.5 shows

the bypass actuator signal line being attached to

the engine side nipple on the bypass manifold. It

may be connected to the fender side nipple –either

is acceptable. Connect your idle balance line to

whichever vertical nipple is unused. The bypass

actuator may have two nipples on its “can”. The

upper one is used in this kit. The lower nipple

should be left open - it is used in the GM factory

installations.

7.10 Reconnect the 7 pin electrical connector to the

air flow meter. Make sure the harness is not

pinched at any point.

8.0 FINAL ASSEMBLY

8.1 Install the new 4-rib drive belt. This new belt will

run counter-clockwise from the crankshaft, around

the air conditioning compressor, up to the power

steering pump, over to the right nylon idler pulley,

up and over the supercharger pulley, just under the

left nylon idler pulley, and back down to the crank-

shaft. Figure 8.1 shows the belt run for configura-

tions A-D listed below. If you find the belt to fit too

tightly, gently rock the car in fourth gear while

pressing the belt onto the pulley using the following

trick. Put the belt on all pulleys EXCEPT the super-

charger pulley, which you should leave for last.

Feed the belt onto the supercharger pulley in a

COUNTERCLOCKWISE direction; place the car in

fourth gear with the handbrake off (and the ignition

keys OUT!). Gently roll the car backwards with your

body weight while insuring that the belt feeds itself

onto the supercharger pulley the last little bit. Watch

out for your fingers. Make sure the belt does not roll

off of either inside idler pulley while it feeds onto the

supercharger pulley.

UNDER NO CIRCUMSTANCES SHOULD YOU

USE THE ENGINE STARTER TO “BUMP’ THE

BELT ONTO THE SUPERCHARGER. DOING SO

PUTS A HIGH LOAD ON THE SUPERCHARGER

BEARING AND WILL VOID YOUR WARRANTY.

ALSO, IT IS VERY DANGEROUS.

Loosen the pinch bolts on your relocated power

steering adjustment assembly (12mm head on pil-

low block pinch bolt, 14mm head on lower front

bolt). Tighten the long bolt “D” per figure 3.4 to

achieve correct belt tension. The longest run of the

belt should not deflect more than 1/2” when

pressed down with around 22 pounds of thumb

pressure. The tension specification is 90 pounds.

An easy check for proper belt tension is done by

listening to your belts during warm up. If turning the

steering wheel with the air conditioning creates a

squeal, then the tension is too loose. In general,

only a slight amount of black dust should appear

around the supercharger nose when the tension is

correct. Heavy dusting indicates excessive belt

wear from a loose belt. Check your tension again

999-156 -12- Revised 1/07

Supercharger Installation Instructions

after the first 500 miles - it will loosen slightly as the

belt wears in.

NEVER ATTEMPT TO ADJUST THE BELT WITH

THE ENGINE RUNNING! Retighten all bolts and

double-check your work.

8.2 Locate the rubber sleeves and the front cross

over tube. Check the inside of the cross over tube

for debris - clean if necessary. Running a rag

through the pipe pulled by a strong wire is a good

way to do this. Install the cross over tube between

the idle air manifold (dummy throttle body now on

the intake manifold) and the supercharger dis-

charge manifold. If you find the rubber sleeves

hard to slip over their respective landings, use

some spray light oil such as WD40, which dries off

to lubricate the situation. Do not use gasoline prod-

ucts or pure silicone products. The best technique

for installing the cross over tube involves putting

the 2.75” diameter rubber sleeve on the super-

charger manifold and the 2.5” diameter sleeve on

the cross over tube, and attach both with clamps.

Then install the cross over tube, starting at the

supercharger end first.

8.3 If you have cruise control, route the factory

vacuum line from the cruise control back to its orig-

inal position, being careful to tie-wrap it away from

the engine belts or radiator fans. Remove the steel

spacer from one of the mounting grommets on

your stock Mazda air box. Use this 13/16” long

spacer and the 6mm x 25mm hex head bolt sup-

plied to secure your cruise control brace to the air

filter base. The bolt will go vertically through the

cruise control leg brace and into the small ledge

with a threaded hole on the air filter base.

8.4 Once the cross over tube is installed correctly,

double-check all your pipe and tube connections.

There should be no loose ends or connections. Do

not over tighten any hose clamps, but ensure that

they are snug. Double check your supercharger

belt for correct tension. If the cross over tube is

pressing too hard against your upper radiator

hose, you can remove 3/4” to 1” from the radiator

end of the hose to allow for more clearance, if you

wish. You are now ready to start your engine.

8.5 First, crank your engine for a few seconds with

the “FUEL INJ” relay still removed from step 1.1.

Confirm that the supercharger belt stays on and

that no other parts have been left unattended to.

8.6 Reinstall the “FUEL INJ” relay. Complete step

8.7 before starting your engine.

8.7 CLEARANCES

IMPORTANT! MAKE SURE THAT YOU HAVE AT

LEAST 3/4” INCH CLEARANCE BETWEEN ANY

ENGINE MOUNTED COMPONENT AND ANY

BODY MOUNTED COMPONENT. CRITICAL

AREAS: BYPASS ACTUATOR TO BRAKE LINES

(VERY CRITICAL - The engine “rocks” strongly to

the driver’s side upon deceleration. If clearance is

too tight, your brake lines can be gently deformed

away from the super-charger bypass actuator by

hand. ) SUPERCHARGER OUTLET MANIFOLD

TO AIR FILTER (INCLUDING CLAMPS) ALL VAC-

UUM LINES TO THROTTLE SPOOL AND CABLE

8.8 For trouble shooting and testing the PowerCard

prior to driving, follow these procedures. Unscrew

and remove the back of the PowerCard. You will

see 3 LED lights in a row. The Green, Yellow, and

Red lights are fuel enrichment lights and MIL

(Malfunction Indicator Lights) lights. Read the lights

and refer to the following to find the source of the

MIL problem.

If the box has been wired for power and ground cor-

rectly you will see the Green light is illuminated and

flashing with the ignition switch in the “On” position

and the engine off. Start the car and check that the

Green light is illuminated continuously and not flash-

ing. There should be no other lights illuminated. If

you have no lights when you power up the vehicle,

you either have a power (Red wire) or ground

(Black wire) problem. Double check your connec-

tions at these two wires until they test properly.

If the Green light is flashing after the vehicle is

started, the Blue wire is not connected to a fuel

injector wire or the connection is not complete. If

the Yellow light is flashing, one of the Gray wires

has a bad connection or is not connected to an

injector wire. The Yellow MIL light will not function if

the Green light is also flashing. In this case you

must fix the Blue wire problem first.

Inside the box is one more LED located away from

the other three LED’s. This is your “Boost

999-156 -13- Revised 1/07

Supercharger Installation Instructions

Activation” LED. Once the engine is warmed up,

push the throttle hard so that the engine gains RPM

quickly (creates boost) and then let it come back to

an idle. During this process, this LED should

become illuminated temporarily. It only comes on

when the pressure transducer in the box reads

boost from the engine.

9.0 ENGINE ADJUSTMENTS

9.1 SUPERCHARGER BELT DRIVE ADJUSTMENT

Start your engine and observe your belt drive. The

belt should line up with itself as it passes between

the two nylon idlers. To put it a different way, the

portion of the belt running up to the supercharger

should lay almost directly over the portion leaving

the supercharger and heading toward the power

steering pulley. If the upward run is more forward or

rearward than the downward run, you need to

move your supercharger slightly forward or back-

ward with respect to the crankshaft pulley. You can

now access the two bolts attaching the supercharg-

er’s bracket to the cylinder head from step 6.1 with

an open-end wrench. Loosen each bolt slightly to

allow for adjustment. Start the engine. You can now

move the supercharger assembly slightly forward or

rearward to correctly align the drive pulleys. The

slots in the Supercharger mounting bracket will

allow you to find the perfect alignment for the belt

run. NOTE: Do not attempt to move the super-

charger with your hands with the engine run-

ning. Use an appropriate tool. The best tool to

use is a flat blade screwdriver placed between the

forward bracket bolt and the front inside edge of the

bracket. Move the supercharger assembly while

watching the belt run the idler pulley. If you have

the two bracket bolts too loose, the supercharger

will be out of alignment from side to side. Make

sure the two bolts are snug enough to just allow

some leveraged movement. Once you have the

belt running true in the center of the idler pulleys,

tighten the rear bolt to secure the position. Shut off

the engine and tighten the other bracket bolt

securely. Recheck all mounting bolts for tightness.

9.2 IDLE ADJUSTMENT:

Restart your engine. Using the idle airscrew on

your throttle body (now on the back of the super-

charger), adjust your idle speed to 950-rpm after

the engine is warm. This can best be approximat-

ed by closing the screw completely (turning clock-

wise) and backing it out one and a half turns

counter-clockwise. Adjust further to reach the

950-rpm value. Next, turn your headlights on

BRIGHT and put your heater fan on HIGH. Leave

the air conditioning off. Rev the engine briskly in

neutral to at least 2500 rpm and release. Notice if

the idle stops at 900 rpm. If it dips below this

level and feels like it will stall, then recovers to

950 rpm, open the idle airscrew (counterclock-

wise rotation) one tenth of a turn at a time until

most of this “droop” disappears. A slight droop of

100 rpm or so is acceptable and normal. More

than that may create a stalling problem during

driving. Turn off the lights and heater fan and

double check that your idle speed is 950 rpm. If

you open the idle screw too much, you will create

too high of an idle speed when the lights and fan

are turned off. You also may possibly introduce a

stumble on part throttle to full throttle accelera-

tions. In addition, a slow return to idle behavior

will occur.

9.3 If you have difficulty stabilizing the drooping

idle problem, adjust your dashpot to help in slow-

ing the throttle’s closing. The factory specification

is that the dashpot tip just begins to touch the

throttle arm at 2500 rpm. Have an assistant hold

the engine at 2500 rpm from the driver’s seat.

Supercharger Installation Instructions

999-156 -14- Revised 1/07

The dashpot tip should just be touching the throt-

tle arm. Adjust the dashpot so that this contact

point is at 3000 rpm or more to help with the

drooping idle. Your Miata will drive best with the

lowest idle speed possible with only a slight

droop in the idle (checked as described above

with a warm engine, lights and heater fan on

high).

9.4 Using a timing light, adjust your ignition tim-

ing to 6 degrees before top dead center (BTDC).

You have to run a jumper wire (an unfolded

paper clip will do nicely) between terminals

“GND” and “TEN” of your diagnostics center

(located just above the driver’s side shock

absorber). The ignition timing is adjusted using

the position sensor mounted at the firewall end

of the intake camshaft. A 12mm box wrench will

loosen the securing bolt.

9.5 IGNITION TIMING AND FUEL QUALITY: Your

Miata supercharger kit is designed to operate on 91

Octane fuel. Make sure that you run your engine on

91 octane only, which means you should complete-

ly burn up any lower octane gas in your tank and

refill it with 91 octane before installing your super-

charger kit. NOTE: In any case, should you ever

hear “pinging” or knocking from your engine

when under acceleration, you should take

measures to eliminate this detonation, i.e. high-

er-octane fuel or a further retardation in ignition

timing. NEVER CONTINUE TO OPERATE YOUR

ENGINE IF YOU HEAR ANY SIGNS OF DETO-

NATION (PINGING OR KNOCKING).

This kit has been carefully designed to work within

the stock Mazda engine parameters and no deto-

nation will occur if the above settings and fuel are

followed. The only way detonation can creep into

your situation is if your engine has a mechanical

fault, the fuel you are using is of the incorrect

octane, if your timing is set incorrectly or if your

fuel filter is clogged. It is your responsibility as the

installer of this kit to ensure that the supercharger

has been installed according to specification.

DRIVING TIP:

If you should find yourself in a situation where you

cannot find high-octane fuel, you can bypass the

supercharger temporarily. Note the position the

bypass actuator arm is in during idle. This is the

position that bypasses the boost air back into the

supercharger inlet. As you blip the throttle, the

actuator arm will move and close a butterfly valve

inside the bypass manifold. Using a short piece of

wire, fix the bypass actuator arm in the “bypass”

position that it holds at idle. This will prevent boost

from being developed and thus, detonation will not

occur. Of course, your engine will now run like a

stock Miata, but will be quite operable for as long

as you need. When you find higher-octane fuel,

simply remove the wire to release the actuator arm

and the bypass will function normally, closing dur-

ing acceleration, bypassing during idle and cruise.

Try to run the low octane fuel out of your tank

before filling up. Mixing fuels of different octane will

lower the overall rating and detonation could still

be a problem. You can order a Jackson Racing

Boost Timing Controller that retards your tim-

ing during boosted conditions. This is useful

for those who can only find 91 Octane fuel or

wish to increase their low-end power by

advancing the static ignition timing.

9.6 Starting procedure: Start your engine as you

would a standard Miata. Remember to bring the

engine up to operating temperature (as indicated

by your water temperature gauge) before running it

hard. Full boost on a cold engine will greatly

increase your engine wear.

9.7 Oil changes: we suggest you use synthetic oil

such as Mobil 1 and change it regularly (5000

miles maximum). If you use a mineral oil, change it

every 2500 miles. While your supercharger does

not use any engine oil for its lubrication, your

engine will be working a little harder with the addi-

tion of a supercharger. The synthetic oil provides

an extra measure of protection, but is not neces-

sary for safe and reliable operation.

9.8 Breaking-in: Your supercharger will work per-

fectly from the first time you fire it up. However, it

does need about 500 miles to fully seat the rotors.

Up to that time, you may notice a slight noise com-

Supercharger Installation Instructions

999-156 -15- Revised 1/07

Figure 9.4

ing from the supercharger at idle. This is normal.

9.9 Performance: You will notice that your engine

runs stronger on cold days than on very hot ones.

This is due to the nature of the internal combustion

engine. When the air is cold, the engine receives a

denser charge of air, thus more power can be pro-

duced. While this is true with any engine, the

supercharger amplifies this cold air benefit.

10.0 LONG TERM MAINTENANCE

10.1 BELTS

The only item to watch with your supercharger kit

will be the belt tension for the supercharger drive.

If you have a tension gauge for a poly-vee belt, the

tension is to be 90 pounds. If you see a large

accumulation of belt dust on your supercharger, it

is an indication that your belt is slipping. A slight

amount of belt dust is normal. CHECKING YOUR

BELT FOR WEAR: As the belt wears, small

cracks will form in each of the ribs on the inside

run of the belt. Replace your belt when you can

count six cracks within in one inch of length (six

cracks total from all ribs combined).

10.2 DRIVEABILITY

If you notice a driveabilty problem as your car

ages, have your fuel pressure checked. Have a

technician install an accurate 0 to100psi fuel

pressure gauge in the fuel line BEFORE it enters

the fuel rail .

10.3 Every six months or so, check your hose

clamps for correct tension. The rubber hoses will

take a set and the clamps may not be holding as

tight. Also check all mounting bolts and nuts, par-

ticularly the throttle cable anchor bracket.

10.4 Your air filter is a long-life unit needing serv-

ice only every 15,000 miles. To clean, you can

wash the filter element in soap and water. Use a

dish detergent soap such as Dawn, etc. Rinse

thoroughly and allow to dry. Wet the filter element

with a light application of ATF (automatic trans-

mission fluid). Alternatively, a special cleaning kit

is available from Jackson Racing (#901-970).

10.5 At every oil change, lubricate the bypass

actuator arm contact point and shaft bushing with

light grease to insure long life - these parts are

exposed to under hood dirt and grime.

TROUBLESHOOTING

SYMPTOM: Engine cranks but will not start

PROBABLE CAUSES: Airflow meter disconnect-

ed; Idle air line open; Low battery voltage

CURE: Double check that seven pin to airflow

meter is well connected. Re-check the 3/4” ICS

line and the PCV line to see that they are not

leaking. Use a known good battery to “jump” the

Miata’s battery. It is possible to have enough volt-

age to crank a Miata but not enough to correctly

run the engine’s control computer.

SYMPTOM: Unstable Idle

PROBABLE CAUSE: Idle air screw set incorrect-

ly; Restrictor left out in step #7.8; Pinched idle air

balance line; air leak in intake track.

CURE: Re-check restrictor. Check idle adjustment

procedure in step 8.1 above. Check the idle air

balance line for restriction or pinching. Check for

air leaks - vacuum at idle should be at least 17.7

in Hg.

11.0 FURTHER MODIFICATIONS

Now that your Miata has a stronger engine, there

are a few changes you might want to make to the

rest of the car to improve its performance. The fol-

lowing are not required for your supercharged

Miata, but are presented as tuning hints for a bet-

ter all-around car.

We recommend that you install a Jackson Racing

Stage 1 clutch when it comes time to put in a new

clutch. While your new supercharger and the stan-

dard Mazda clutch work well together, it is a good

idea to step up to the Jackson Racing unit when

you are changing your clutch.

We recommend you install a set of Jackson

Racing larger diameter anti-roll bars for the sus-

pension for your Miata. These will tighten up your

steering response. We also recommend a new set

of Tokico shock absorbers if your Miata has over

30,000 miles on it. The Tokico shocks coupled

with a set of the Sport lowing springs will lower the

car about 35mm. This combination yields better

handling with out the harsh ride of competition

springs. Have your car aligned afterward (driver’s

equivalent weight in the driver’s seat) to factory

specifications after any suspension changes.

You might want to add a Jackson Racing Boost

Supercharger Installation Instructions

999-156 -16- Revised 1/07

and A/F ratio gauge to your supercharged Miata.

These are good for keeping an eye on things. A

performance exhaust will make your super-

charged Miata that much faster. Since you are

now flowing 300 cubic feet per minute through a

muffler designed for 177cfm, an improvement

can be made. Jackson Racing offers a Stainless

Steel Cat-back exhaust system designed around

the Supercharger.

WARRANTY: The supercharger system carries a

two-year or 100,000 mile warranty (for the origi-

nal purchaser of the kit) against defects in materi-

als and workmanship. No other warranties apply.

This warranty is void if the subject vehicle is used

in any racing activities of any sort.

HELP: If you experience any problems with your

kit during installation or operation, contact your

retailer or Jackson Racing at 1-888-888-4079.

Supercharger Installation Instructions

999-156 -17- Revised 1/07