Installation Instructions - Innovate Motorsports

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6012 & 6013
INNOVATE MOTORSPORTS®
SCION FR-S / SUBARU BRZ / TOYOTA FT86
SUPERCHARGER KIT WITH
INTERCOOLER
FOR INNOVATE PART NUMBERS
6012 and 6013
INSTALLATION INSTRUCTIONS
Kit Serial # ___________________________________________________
Supercharger Serial # _____________________________________________
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TABLE OF CONTENTS
Getting to Know your Supercharger System.................................................................................................4
1.1 Intellectual Property used in this Publication ...................................................................................4
1.2 Product Warning ..............................................................................................................................4
1.3 Safety Warning.................................................................................................................................5
1.4 Changes to Factory Specifications ..................................................................................................6
2 Tools ......................................................................................................................................................7
3 System Contents....................................................................................................................................8
4 Disassembly Instructions .......................................................................................................................9
4.1 Preparation.......................................................................................................................................9
4.2 Disconnect Battery .........................................................................................................................11
4.3 Disconnect Inlet Pipe .....................................................................................................................11
4.4 Remove Inlet Manifold Cover.........................................................................................................11
4.5 Disconnect Hoses ..........................................................................................................................12
4.6 Disconnect MAP Sensor ................................................................................................................12
4.7 Disconnect Throttle Body...............................................................................................................12
4.8 Disconnect Harness from Manifold ................................................................................................13
4.9 Remove Sound Generator .............................................................................................................14
4.10 Remove ECU Mount..................................................................................................................14
4.11 Disconnect Fuel Rail Support ....................................................................................................15
4.12 Disconnect Injector Harness......................................................................................................16
4.13 Disconnect Heater Hoses..........................................................................................................17
4.14 Remove Manifold.......................................................................................................................17
4.15 Remove the EVAP. solenoid .....................................................................................................18
5 Installation Instructions ........................................................................................................................19
5.1 Install Engine Breather Hose Extension ........................................................................................19
5.2 Install Throttle Body Heater Hoses ................................................................................................20
5.3 EVAP Solenoid Relocation ............................................................................................................21
5.4 Install Throttle Body Loom Extension ............................................................................................22
5.5 Attach the MAP Sensor loom extension (RHD Vehicles ONLY) ...................................................22
5.6 Remove Brake Booster Hard Line (Automatic Transmission ONLY) ............................................22
5.7 Attach Wiring Harness Relocation Bracket (Automatic Transmission Only) .................................23
5.8 Install Idler Pulley Mount ................................................................................................................24
5.9 Prepare Manifold............................................................................................................................25
5.10 Test Fit The Supercharger Manifold ..........................................................................................26
5.11 Attach throttle body connector...................................................................................................27
5.12 Attach heater hoses...................................................................................................................27
5.13 Install drive belt ..........................................................................................................................27
5.14 Connect Fuel supply line ...........................................................................................................28
5.15 Mount ECU ................................................................................................................................29
5.16 Attach MAP Sensor Connector..................................................................................................29
5.17 Fit Breather Hoses.....................................................................................................................30
5.18 Brake Booster Jumper Hose Connection (Automatic Transmission ONLY) ............................31
6 Heat Exchanger Installation.................................................................................................................32
6.1 Prepare Heat Exchanger................................................................................................................32
6.2 Mounting Heat Exchanger .............................................................................................................33
7 Install Water Pump...............................................................................................................................34
8 Install the Intercooler Hoses ................................................................................................................35
9 Connect Pump Hoses..........................................................................................................................37
9.1 Fit Air Inlet pipe ..............................................................................................................................38
9.2 Reconnect Battery..........................................................................................................................38
9.3 Remove Under Hood Insulation.....................................................................................................39
9.4 Install ECU Calibration...................................................................................................................39
10 Pre Test-Drive Inspection...............................................................................................................40
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10.1 Pre-Start Inspection ...................................................................................................................40
10.2 Engine Warm Up .......................................................................................................................40
10.3 Road Test Vehicle .....................................................................................................................40
11 Supercharger System Maintenance...............................................................................................41
11.1 Drive Belt ...................................................................................................................................41
11.2 Supercharger Gear Oil...............................................................................................................42
11.2.1 Check Oil Level .....................................................................................................................42
11.2.2 Replace Gear Oil ...................................................................................................................43
12 LIMITED WARRANTY ...................................................................................................................44
13 Revision History .............................................................................................................................47
SUPERCHARGER WARRANTY REGISTRATION FORM ........................................................................49
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Getting to Know your Supercharger System
1.1 Intellectual Property used in this Publication
This document is copyright of Innovate Motorsports. This document may not be re-sold, copied or
distributed in any way without prior written authorization of a director of Innovate Motorsports.
Innovate Motorsports has patents for its products or are pending. Any unauthorized copying or
modification of the Innovate Motorsports products may result in legal action.
Copyrights / Trademarks:
Innovate Motorsports® is a registered trademark of Performance Motorsports, Inc. Innovate Motorsports
has patents for its superchargers. Any unauthorized copying or modification of the system may result in
legal action.
Loctite® and Grey Maxx® are registered trademarks of Henkel KGaA, a company incorporated in
Germany. Other than commercial supply arrangements, Henkel KGaA does not have any association
with Innovate Motorsports.
RedLine® is a registered trademark of RedLine Synthetic Oil Corporation, a company incorporated in the
United States of America. Other than commercial supply arrangements, Redline and RedLine Synthetic
Oil Corporation do not have any association with Innovate Motorsports.
Toyota FT86, Subaru BRZ & Scion FR-S are registered trademarks of Toyota, Subaru & Scion
Companies
SAE is a trademark of SAE International (www.sae.org), a global technology information and standards
setting resource organization for the design, manufacturing, operation, and maintenance industry.
Gates is a registered trademark of the Gates Rubber Company, a subsidiary of Tomkins PLC,
incorporated in London, United Kingdom. Other than commercial supply arrangements, Gates and
Tomkins PLC do not have any association with Innovate Motorsports Limited.
1.2 Product Warning
Installation of the Innovate Motorsports Supercharger kit on Scion FR-S, Subaru BRZ & Toyota FT86
vehicles may void all or parts of Toyota, Subaru & Scion Warranties. Customers should consult their
dealer for details.
Innovate Motorsports makes no representation that installation and use of the Innovate Motorsports
supercharger kit is legal for public road use worldwide. Customers should check that installation and use
of the Innovate Motorsports supercharger kit on their vehicle is legal by contacting the relevant statutory
authority in their jurisdiction prior to use on roads.
Innovate Motorsports supports safe driving. So always remember to observe all speed
limits and road rules relevant to the state, city or other local jurisdiction.
Provided in this installation manual are detailed instructions to the installer on how to install the Innovate
Motorsports patent pending supercharger kit to the Toyota FT86 / Subaru BRZ / Scion FR-S vehicle (the
vehicle). The instructions are aimed at being simple yet informative, and are aided with well-presented
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pictures to make installations as simple, fast, and problem free as possible. Please read the entire
instruction manual prior to beginning the installation procedure. Pictures and descriptions
may vary slightly from model to model.
It is recommended that all wiring harness connectors, and vacuum hoses are labeled at the time of
removal for easy and correct refitting. Some components that are removed and are to be refitted are
fragile, and should be stored safely to prevent damage to these components.
Innovate Motorsports recommends performing the following vehicle checks prior to installing the
supercharger.
1) Check that the factory fuel system is operating correctly.
2) Inspect the factory exhaust catalyst for blocks or damage.
3) Check fuel quality in fuel tank ensuring that it is not stale or low octane fuel. Replace
with a higher octane, 91 octane Premium Unleaded Gasoline as required. It is also
recommended to replace the fuel filter if the vehicle has travelled more than 9000 miles or
15,000 Km.
Innovate Motorsports will not be liable for any loss, damage, payment, costs, expenses or other liability,
not expressly stated in this document. In particular, Innovate Motorsports shall not be liable to any
person for any consequential, indirect or economic loss or punitive or exemplary damages of any kind.
Innovate Motorsports reserves the right to change specifications from time to time and will not be liable to
any person for doing so. Innovate Motorsports believes that information in this document is correct at
time of print. Innovate Motorsports limits its liability to the maximum extent permissible at law with regard
to the reliance which any person places on anything in this document.
THIS INNOVATE MOTORSPORTS INSTALLATION REQUIRES THAT THE VEHICLE
BE FITTED WITH AN APPROVED ECU AND ECU CALIBRATION. FAILURE TO ENSURE
THIS WILL CAUSE CATISTROPHIC ENGINE FAILURE AND VOID ALL WARRANTY.
1.3 Safety Warning
No unauthorized service or alteration may be undertaken to the Innovate Motorsports supercharger.
Installation should be carried out in a workshop which is a safe and ventilated working environment with
equipment and procedures compliant with local authority guidelines and legal requirements. Installers
should ensure adequate hearing, eye, and physical protection is used at all times during the installation
process. Installers should take reasonable precautions to avoid fatigue and closely follow the installation
instructions during every installation. Innovate Motorsports recommends installation should not be carried
out unsupervised. Innovate Motorsports, its directors, employees and agents will not accept liability for
damage accident or injury resulting from the installation process. Safety warnings are also provided
throughout this document.
Many of the photos shown in this document are of a typical FT86 Right
hand drive vehicle and are similar to a typical FT86 Left hand drive vehicle.
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Some of the terminology and language used in this instruction may
vary from that of the end user / installer’s expectations, as some tools and
automotive components have different common names in different
geographical locations.
1.4 Changes to Factory Specifications
FUEL: 91 OCTANE (OR HIGHER) PREMIUM UNLEADED PUMP GASOLINE TO BE USED AT
ALL TIMES. NEVER ALLOW THE ENGINE TO KNOCK OR DETONATE AS SERIOUS ENGINE
DAMAGE MAY OCCUR.
REQUIRED SERVICE: (SEE MAINTENANCE SECTION OF MANUAL)
1. INSPECT SUPERCHARGER DRIVE BELT AT EVERY ROUTINE SERVICE AND
REPLACE WHEN REQUIRED.
2. DRAIN AND REPLACE SUPERCHARGER OIL EVERY 30,000 miles or 50,000
km. USE REDLINE 75W90 NS GEAR OIL OR EQUIVALENT. IT IS CRITICAL
NOT TO OVERFILL SUPERCHARGER GEARBOX AS DAMAGE WILL OCCUR.
FILL WITH EXACTLY 5.31oz 157mil.
THE ENGINE SITS AT A REARWARD ANGLE. THIS PREVENTS ACCURATE
MEASUREMENT OF THE GEAR OIL WITH THE DIPSTICK AND PROPER
DRAINING. WHEN MEASRING OR REPLACING THE SUPERCHARGER OIL
LEVEL, ENSURE THE ENGINE IS LEVEL.
CHECK OIL LEVEL WITH THE DIPSTICK PROVIDED IN THE SUPERCHARGER
ASSEMBLY. TIGHTEN DIPSTICK FULLY BEFORE CHECKING THE OIL LEVEL.
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2 Tools
Safety Glasses
Tape For Masking
Spray Lube
3/8” Drive Ratchet
3/8” Drive Breaker Bar
3/8” Drive – Short Length 6-Point Sockets - 10mm, 12mm, 13mm, 14mm
3/8” Drive Elbow
3/8” Drive - 5mm Allen Socket ( Check Supercharger Oil Level )
3/8” Drive Extensions – 5.000” To 7.000”
Torque Wrench
3mm Allen Wrench - Map Sensor Allen Bolt
Flat Heat & Phillips Screw Drivers
Adjustable Pliers, Needle Nose Pliers, Dykes “Cutters”
File
Telescoping Magnet
Panel Push-Pin Clip Removal Tool
Blue Thread Locker (Optional)
Tape Measure (Optional)
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3 System Contents
 Sprintex® Supercharger manifold
assembly
 Inlet pipe and silicone hose
couplers
 Throttle body loom extension
 MAP sensor loom extension
 Idler pulley post, pulley and bolt
 Drive belt
 M14 x 1.5 x 40 hex head bolt
 Idler pulley bracket assembly
 Manifold flange O-rings
 Throttle body O-ring
 EVAP solenoid bracket & screw
 Ancillary parts
 Intercooler radiator, pump & plumbing
 Intercooler mounting brackets
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4 Disassembly Instructions
SAFETY WARNING
No unauthorized service or alteration may be undertaken to the Innovate Motorsports
supercharger. Installation should be carried out in a workshop which is a safe and
ventilated working environment with equipment and procedures compliant with local
authority guidelines and legal requirements. Installers should ensure adequate hearing,
eye, and physical protection is used at all times during the installation process. Installers
should take reasonable precautions to avoid fatigue and closely follow the installation
instructions during every installation. Innovate Motorsports recommends installation
should not be carried out unsupervised. Innovate Motorsports, its directors, employees
and agents will not accept liability for damage accident or injury resulting from the
installation process. Safety warnings are also provided throughout this document.
4.1 Preparation
Ensure that all components required to assemble the supercharger are available. Refer
to the Parts Supplied section provided earlier.
Ensure that all required tools are available.
Please read the entire instruction manual prior to beginning the installation procedure.
Ensure vehicle is located in a secure position with vehicle tires secured and handbrake
applied. To avoid injury, Innovate Motorsports® recommends use of suitable a vehicle
lift or axle stands when the vehicle is required to be lifted for access to. Stands should
be positioned as per the vehicle Manufacturers Owners Handbook.
SAFETY WARNING: Use Personal Protective Equipment such as safety glasses,
gloves, etc. at all times and as necessary. Allow engine to cool prior to proceeding with
disassembly to prevent scalding.
During disassembly and removal of components, take notes and ensure to label
and store them safely; this will help with the reassembly.
Many of the photos shown in this document are of a typical FT86 right hand drive
vehicle and are similar to a typical FT86 left hand drive vehicle.
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Caution:
Connect and disconnect battery cables, jumper cables or battery charger only with the
ignition switched off
Warning:
Disconnecting the battery may erase fault codes stored in control module memory.
Using diagnostic equipment, check for fault codes before disconnecting battery cables.
If the malfunction indicator light (MIL) is illuminated.
MIL (Malfunction Indicator Lamp) light.
The MIL light can be found in one of two locations, dependent on the market the vehicle
has been built for.
1. The MIL light may be an illuminated ENGINE symbol within the speedometer cluster.
2. The MIL light may be displayed as SERVICE ENGINE SOON within the tachometer.
Please refer to the OWNERS HANDBOOK to define which off the above applies to the
vehicle to be fitted with the Innovate Motorsports unit.
Note:
Always disconnect the negative battery terminal before the positive terminal. This
prevents possible shorting and potential battery damage.
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4.2 Disconnect Battery
 First disconnect negative (-) battery
cable (Fig A).
 Lift positive (+) terminal plastic
cover (B), then disconnect positive
(+) cable.
4.3 Disconnect Inlet Pipe
 Disconnect vacuum hoses from
inlet pipe.
 Loosen hose clamps and remove
the inlet pipe and sound pipe from
the vehicle.
4.4 Remove Inlet Manifold Cover
 Depress tabs and lift cover to
remove.
Fig A
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4.5 Disconnect Hoses
 Disconnect engine breather and
brake vacuum hose from the rear of
the manifold.
4.6 Disconnect MAP Sensor
 Disconnect MAP sensor plug.
4.7 Disconnect Throttle Body
 Disconnect throttle body plug.
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4.8 Disconnect Harness from
Manifold
 Disconnect wiring harness from
manifold supports.
 Disconnect alternator harness from
manifold covers.
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4.9 Remove Sound Generator
 Remove Sound Generator (2 bolts)
 Plug the hole in the firewall with the
blanking grommet supplied.
4.10 Remove ECU Mount
 Disconnect ECU from mount (3
bolts) and carefully lower the ECU.
 Remove ECU mount from Engine (2
bolts).
Sound
Generator
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4.11 Disconnect Fuel Rail Support
 Disconnect EVAP solenoid hose from barb (A).
 Remove bolt from fuel rail support (B).
A
B
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4.12 Disconnect Injector Harness
 Disconnect injector plugs from
injectors; disconnect injector
harness from fuel rail on both
banks. (Fig. A & B)
 Disconnect fuel line from fuel rail,
both banks. Note: Be prepared to
catch fuel when lines are
disconnected. (Fig. C & D)
 Disconnect EVAP solenoid
connector and harness from
manifold (right hand side rear).
(Fig. E)
 Be sure to remove injector O-rings
from intake manifold, you will need
to reuse these O-rings on the
Supercharger intake manifold
installation. (Fig. F)
Fig A
Fig B
Fig C
Fig D
Fig E
Fig F
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4.13 Disconnect Heater Hoses
 Disconnect throttle body heater hoses
from throttle body.
Note: Be prepared to catch coolant when
hoses are removed.
4.14 Remove Manifold
 Remove the 6 bolts from the intake
manifold flanges (3 on each bank)
and carefully lift the intake manifold
from engine.
 Cover intake ports with rags or tape
to prevent foreign objects falling into
the engine.
 Remove the belt guards from the
alternator and AC compressor.
 Use a 14 mm wrench to release the
tension on the dynamic tensioner
and remove the drive belt from the
engine.
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4.15 Remove the EVAP. solenoid
 Remove the EVAP solenoid from
the manifold, also remove the
throttle body and fuel rails from the
intake manifold. Ensure that the
injector seals are removed from the
manifold and set aside for
installation to the supercharger
system.
 Remove the 2 throttle body heater
hoses from the engine also remove
the spring band clamps on original
hoses, put aside to re-use later in
the installation.
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5 Installation Instructions
SAFETY WARNING
No unauthorized service or alteration may be undertaken to the Innovate Motorsports
supercharger. Installation should be carried out in a workshop which is a safe and
ventilated working environment with equipment and procedures compliant with local
authority guidelines and legal requirements. Installers should ensure adequate hearing,
eye, and physical protection is used at all times during the installation process. Installers
should take reasonable precautions to avoid fatigue and closely follow the installation
instructions during every installation. Innovate Motorsports recommends installation
should not be carried out unsupervised. Innovate Motorsports, its directors, employees
and agents will not accept liability for damage accident or injury resulting from the
installation process. Safety warnings are also provided throughout this document.
5.1 Install Engine Breather
Hose Extension
 Attach the ½” inch ID. 700mm
long engine breather extension
hose to the OEM engine breather
hose, route the supplied hose as
shown in picture. The extended
hose will connect to the
supercharger inlet later in the
installation
Extension
Hose
OEM Engine
Breather Hose
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5.2 Install Throttle Body Heater
Hoses
 Attach spring band clamp to new
throttle body heater hoses, install
the 900mm long heater hose to
the outlet on the rear of the
engine make sure clamp is
secured correctly.
 Attach 800mm long heater hose
to the outlet, secure hoses in
place with cable ties supplied.
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5.3 EVAP Solenoid Relocation
 Attach the 520mm long fuel tank
purge hose to the solenoid,
attach the other end of the hose
to the fuel tank purge line, route
hose as shown in image. (Fig A &
B)
 Attach the 330mm long fuel vapor
hose to the solenoid; the other
end of this hose will be attached
to the supercharger intake once
installed.
 Attach EVAP solenoid to the
relocation bracket supplied in kit.
(Fig C)
 Secure EVAP solenoid bracket to
the engine with the M8 x 16
SHCS bolt supplied.
Purge hose
Intake Hose
Fuel Tank
Purge Line
Purge hose
Fig A
Fig B
Fig C
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5.4 Install Throttle Body Loom
Extension
 Attach the throttle body loom
extension to the throttle body
connector and route the
extension behind the alternator.
5.5 Attach the MAP Sensor
loom extension (RHD
Vehicles ONLY)
 Attach the MAP sensor loom
extension to the MAP sensor
connector and lay the extension
towards the firewall.
Note: MAP sensor extension
harness is NOT to be used on LHD
vehicles.
5.6 Remove Brake Booster
Hard Line (Automatic
Transmission ONLY)
 Automatic Transmission OEM
Brake Booster Tube must be
removed as it will interfere with
the Supercharger installation.
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5.7 Attach Wiring Harness
Relocation Bracket
(Automatic Transmission
Only)
 Carefully remove the automatic
transmission harness connector
from its mounting bracket.
 Attach the wiring harness
relocation bracket to the existing
bracket with the self-tapping
screw supplied in the kit.
 Re-attach the harness connector
to the new bracket.
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5.8 Install Idler Pulley Mount
 Remove alternator mounting bolt.
 Assemble idler pulley in the order
illustrated in Fig A. using
replacement alternator mounting
bolt supplied.
 Bolt idler pulley assembly to
alternator bracket. (Blue Loctite is
recommended)
Alternator
Mounting Bolt
1
2 3 4
Replacement Alternator Mounting Bolt Fig A
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5.9 Prepare Manifold
 Install the injector O-rings,
injectors and fuel rails onto the
supercharger manifold. Apply
assembly lubrication (petroleum
jelly or engine oil) to the O-rings
prior to installation.
 Turn the supercharger manifold
upside down on a clean rag to
prevent marking supercharger
and install the manifold seals
supplied. Apply assembly
lubrication (petroleum jelly or
engine oil) to the O-rings prior to
installation.
 Turn the supercharger back over.
 Install the throttle body seal and
throttle body to the supercharger
manifold, attach with OEM
fasteners and tighten to 12 Nm.
 Apply assembly lubrication
(petroleum jelly or engine oil) to
the MAP sensor O-ring prior to
installation. Install MAP sensor
with supplied M4 X 0.7 X16 bolt.
Do not use OEM bolt in the
supercharger manifold
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5.10 Test Fit The Supercharger
Manifold
 Carefully lower the supercharger
manifold into place (2 PERSON
LIFT) and check the clearance
around the alternator. Due to
normal fluctuation in the OEM
components, it may be necessary
to file the corner of the alternator
bracket to make sure that the
supercharger manifold is not
prevented from sitting flat on the
intake face of the cylinder heads.
This step, if needed, should be
simple with a large flat file and take
less than 1 minute.
 Make sure that the intake ports are
covered before filing the corner of
the alternator support. (Fig A)
 Use a vacuum cleaner to collect
any metal debris before removing
tape or rags from the intake
runners prior to fitting the manifold.
 Position throttle body plug so it can
be accessed once manifold is in
place.
 Lower the manifold into place and
secure the manifold in place with
the 6 original OEM fasteners.
Torque to 18 ft lb (25 Nm).
It is recommended to re-torque
these 6 intake manifold bolts after
500 miles.
 Secure the manifold with the M14 x
1.5 x 40 Hex Head Bolt (Fig B).
Fig A
Fig B
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5.11 Attach throttle body
connector
 Connect throttle plug connector to
throttle body.
5.12 Attach heater hoses
 Connect the throttle body heater
hoses to the throttle body, making
sure hose clamps are installed
correctly.
5.13 Install drive belt
 Use a 14 mm wrench to release
the tension on the dynamic
tensioner and install new drive belt.
Follow belt routing diagram and
make sure that the belt is properly
aligned on each pulley.
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5.14 Connect Fuel supply line
 Reconnect the fuel supply line to
both left and right fuel rails, making
sure that each locking tab is fully
engaged.
 Reconnect injector harness to all
injectors.
 Install Fuel Rail Support Bracket
Provided - Part# 260P8111  (Fig A)
Fig A
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5.15 Mount ECU
 Install ECU mount and secure with
original fasteners, attach RHS
injector cover and secure with
original bolts.
 Re-attach ECU and secure with
original bolts.
5.16 Attach MAP Sensor
Connector
 Reconnect MAP sensor.
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5.17 Fit Breather Hoses
 Attach loose end of EVAP
solenoid vacuum hose to
supercharger intake.
 Attach crank case breather hose
to supercharger intake.
 Manual Transmission Vehicle:
Attach brake booster hose
supplied to supercharger intake
and attach other end to brake
booster. Use OEM spring band
clamp from original hoses.
Ensure that the vacuum check
valve supplied with this hose is
oriented correctly (‘To Motor’
arrow on the check valve is
installed towards the engine).
Automatic Transmission
Vehicle: Using the supplied
vacuum cap, block off the brake
booster line.
To Crankcase
Breather
To Brake
Booster
To EVAP
Solenoid
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5.18 Brake Booster Jumper
Hose Connection
(Automatic Transmission
ONLY)
 Remove the check valve from the
Brake Booster Hose supplied in
the kit (the two pieces of hose
will not be used.)
 Using the supplied hose from the
Automatic Transmission Kit,
connect check valve to one end
and connect the other end to the
vacuum pump. Make sure the
arrow on the check valve is
pointed towards the passenger
side which is where the vacuum
pump is located.
 Connect the other end of the new
hose to the Brake Booster.
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6 Heat Exchanger Installation
6.1 Prepare Heat Exchanger
 Apply thread sealant to the
thread of the elbow upon
assembly. Install the plastic
elbow to the heat exchanger.
(may be preinstalled)
 Install 2 radiator support pins
Radiator
Support
Pin
Radiator
Support
Elbow
Top
Bracket
Bottom
Bracket
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6.2 Mounting Heat Exchanger
 Remove the screws that retain the
air conditioner condenser.
 Remove the screw that retains the
horn.
 Install the top radiator bracket
onto the condenser mount bracket
and retain with the OEM
fasteners. Repeat process for the
opposite side.
 Fit the heat exchanger by
inserting the support pins into the
bracket grommets.
 Fit the 2 bottom brackets & fix to
the top brackets with the screws
provided.
 Reattach the horn in its original
position.
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7 Install Water Pump
 Attach the water pump to its
bracket with the 300mm heavy
duty cable tie supplied in the kit.
Attach the bracket, pump and
loom to the engine with the 2 x
M6 x 12 SHCS supplied (see
photo).
 Make sure main water pump
power wire connects to the
positive side of the battery using a
2.5amp fuse on the fuse holder
provided on harness.
Attach to the
Injector Plug
Attach Water Pump
Bracket Here
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35
8 Install the Intercooler
Hoses
 Lay the intercooler return hose
into the engine bay towards the
firewall. Attach the other end to
the top of the water pump.
 Attach the hose to the pump
outlet and route the other end of
this hose down beside the
vehicles radiator. Attach the hose
onto the top hose connection of
the radiator.
 Lay the intercooler inlet hose into
the engine bay towards the air
conditioner pump. Route the other
end of the hose down alongside
the washer bottle between the
inner guard and outer panel. Feed
the hose through and connect the
hose to the bottom radiator fitting.
 Connect the 10mm (3/8”) x
1200mm long radiator hose to the
plastic elbow on the radiator.
Feed the hose into the gap beside
the vehicle’s radiator and route
the hose towards the firewall.
 Fasten all the hose connections
with the hose clamps supplied.
Hose
connects to
pump outlet
and top
radiator barb
Intercooler
return
hose
Intercooler
inlet hose
Attach 1.2m
long hose to
the overflow
bottle and the
90° fitting of the
radiator
FRS Manual 1.0 (intercooled).doc
36
 Make a cut out (35mm wide x
40mm high) in the RHS plastic
panel next to the air conditioner
condensor. This will allow the
bottom radiator hose to pass
through when the radiator is
installed.
FRS Manual 1.0 (intercooled).doc
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9 Connect Pump Hoses
 Attach the overflow bottle to the
supercharger mount plate with the
screws supplied (1x M6 x 25
SHCS & M6 washer, 1x M8 x 16
SHCS & M8 washer & 1x overflow
bottle spacer).
 Connect the intercooler hoses as
shown in the hose routing
diagram (right). Note: Connect the
overflow return spigot to the 90°
fitting in the top of the intercooler
radiator using the 3/8” hose &
clamps supplied.
 Fill the intercooler system with
74.4 fluid oz. (2200ml) of ethylene
glycol based automotive engine
coolant approved for use in
aluminium engines. Allow the
system to bleed. Repeatedly
squeeze the hoses to help to
remove any air present in the
system.
 Temporarily connect the battery.
Turn the ignition to the run
position but do not start the
engine. Confirm that the
intercooler water pump is running.
 With the pump running continue
to fill the system until all of the
2200ml of coolant is used. This
step is important as the
intercooler will perform poorly and
restrict the engines performance if
air remains in the system. It may
be necessary to run the vehicle or
‘work’ (squeeze) the hoses some
more to eliminate all air from the
system.
Overflow
Return
90° Fitting
FRS Manual 1.0 (intercooled).doc
38
 Check all the intercooler hose
connections for leaks.
 Disconnect the battery again.
 Refit the vehicles under body
trays.
9.1 Fit Air Inlet pipe
 Using the supplied hose clamps,
attach the inlet pipe to the throttle
body using the coupler with the
hump and the straight coupler to the
air box.
9.2 Reconnect Battery
 Re-install battery if removed and
connect terminals.
NOTE: Battery Positive terminal
(B+) should always be connected
before the negative terminal (B-).
FRS Manual 1.0 (intercooled).doc
39
9.3 Remove Under Hood
Insulation
 Under Hood Insulation will
need to be removed. Use a
commercially available tool
such as the one pictured in
Fig A. to properly remove
plastic retaining rivets which
this insulation is held by.
9.4 Install ECU Calibration
This Innovate Motorsports installation requires that the vehicle be fitted with AN
APPROVED ECU and ECU calibration. Failure to ensure this will cause catistrophic
engine failure and void all warranty.
Fig A
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40
10 Pre Test-Drive Inspection
10.1 Pre-Start Inspection
 Supercharger comes prefilled with gear oil. Verify correct gear oil level.
Refer to instructions on page 42.
 Ensure coolant is at correct level.
 Ensure engine oil is at correct level.
 Ensure vehicle has fresh 91 Octane (or higher) Premium Unleaded Pump
fuel.
 Ensure the belt is aligned.
 Ensure the air filter is clean.
 Check & replace spark plugs, if necessary. Set gap to factory spec.
0.050”.
10.2 Engine Warm Up
 Start engine and allow it to run until engine reaches normal operating
temperature.
 Check for oil leaks.
10.3 Road Test Vehicle
 Road test vehicle.
 Recheck all joints and connections for leaks –rectify as needed.
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41
11 Supercharger System Maintenance
11.1 Drive Belt
 It is recommended that the supercharger drive belt
be checked at every regular service and be
replaced at 50,000 km (30,000 miles) or 2 years,
whichever occurs first. The part number for the
replacement belt is K061015.
 Use a 14mm wrench to release
the dynamic tensioner and
remove the belt.
 Tensioner Arm may be locked
into position by a small Allen
Wrench to provide ease of belt
removal/installation.
Dynamic
tensioner
Allen
Wrench
FRS Manual 1.0 (intercooled).doc
42
11.2 Supercharger Gear Oil
It is recommended that the supercharger gear oil be checked at every regular service,
every 5000 miles, or after a track event, whichever occurs first. The gear oil should be
replaced at 30,000 miles (50,000 km) or 2 years, whichever occurs first.
THE ENGINE SITS AT A REARWARD ANGLE. THIS PREVENTS ACCURATE
MEASUREMENT OF THE GEAR OIL WITH THE DIPSTICK AND PROPER DRAINING.
WHEN MEASRING OR REPLACING THE SUPERCHARGER OIL LEVEL, ENSURE THE
ENGINE IS LEVEL.
11.2.1 Check Oil Level
 Remove the Gear Oil Dipstick
and wipe off with a rag. (Fig A.)
 Reinsert and tighten the
dipstick before removing again
and inspect oil level on the
dipstick
 The scribed mark on the
dipstick indicates proper oil
level.
Gear Oil
Dipstick
Fig A.
FRS Manual 1.0 (intercooled).doc
43
11.2.2 Replace Gear Oil
 Remove the Gear Oil Dipstick.
(Fig A.)
 Using a syringe to draw out the
old gear oil, drain the
supercharger’s gearbox.
 Using Redline 75W90 NS Gear
Oil or equivalent fill with exactly
5.31 oz (157 mil.)
 Check oil level with dipstick.
Gear Oil
Dipstick
Fig A.
FRS Manual 1.0 (intercooled).doc
44
12 LIMITED WARRANTY
Who is the Warrantor
The warrantor for this limited warranty is Innovate Motorsports, 8 Mason, Irvine, CA
92618.
Which Products are Covered
This limited warranty applies to Innovate Motorsports superchargers and supercharger
systems sold and normally operated in the United States, Canada, and Mexico (the
“Product”).
When Warranty Begins
The warranty period begins on date the Product is sold to the first retail purchaser.
Limitations
Repair, replacement, or a refund of not more than the retail price of the Product are the
exclusive remedies under this limited warranty or any implied warranties. Innovate
Motorsports does not authorize any person to create for it any other obligation or liability
in connection with the Product.
Warranty coverage is limited to the first retail purchaser of the Product. This limited
warranty is not transferrable and terminates upon the first retail purchaser’s sale or
other transfer of the Product.
Any implied warranty or merchantability or fitness for a particular purpose is limited to
the duration of this written warranty. Some states and jurisdictions do not allow
limitations on how long an implied warranty lasts, so this limitation may not apply to you.
Your Rights Under State Law
This warranty gives you specific legal rights, and you may also have other rights that
vary from state to state and jurisdiction to jurisdiction.
WHAT IS COVERED AND HOW LONG
Basic Warranty
Innovate Motorsports warrants to the first retail purchaser of the Product that (1) the
Product will be free from defects in materials and workmanship during the period of 12
months or 12,000 miles, whichever comes first, from the date of purchase (the
“Warranty Period”).
This warranty is an express limited warranty. If the Product fails during the Warranty
Period under normal operating conditions as a result of a defect in materials or
workmanship, at Innovate Motorsports’ option, it will either (1) repair the Product, using
new, used or refurbished replacement parts, or (2) replace the Product with a new, used
or refurbished equivalent Product, or (3) refund not more than the retail price of the
Product. You must pay the costs of returning any Product to Innovate Motorsports for a
warranty claim. Innovate Motorsports is not responsible for any freight or handling
charges on Products returned to it. If a Product returned to Innovate Motorsports is
FRS Manual 1.0 (intercooled).doc
45
returned for a reason covered by this limited warranty, Innovate Motorsports will pay for
ground shipping charges only to return the Product to you.
The decision whether the Product should be repaired or replaced or whether a refund of
not more than the retail price of the Product should be given will be made by Innovate
Motorsports.
Innovate Motorsports neither assumes nor authorizes any person to assume for it any
other liability in connection with the sale of the Product.
This limited warranty is subject to the exceptions indicated under “What is Not Covered”
section below.
WHAT IS NOT COVERED
This warranty does not cover damage, defect, or failure resulting directly or indirectly
from any of the following:
 Use of contaminated, poor quality or incorrect fuels;
 Alteration, modification or disassembly;
 Improper or incorrectly performed installation or repairs, or when the
Product is used in an application for which it was not designed or
approved;
 Use of an incorrect pulley size or failure to regularly inspect and replace
the pulley belt;
 Abuse, negligence or neglect;
 Misuse – for example, racing;
 Lack of or improper maintenance;
 Use of non-genuine Innovate Motorsports parts;
 Repair, modification or any other action performed by anyone other
than a Innovate Motorsports approved repairer;
 A matter outside the control of Innovate Motorsports or its employees
and contractors (for example a defect caused by the failure of a
product supplied to you by a person that is unrelated to us such as the
manufacturer or your motor vehicle);
 Corrosion from environmental conditions or chemical treatments;
 Fire, accident or theft; or
 Act of God.
This warranty also does not cover the following:
Normal Wear and Tear
Noise, vibration, cosmetic conditions and other deterioration caused by normal wear
and tear.
Maintenance Expense
Normal maintenance services such as changing oils, belts, injectors and any similar
consumable parts.
FRS Manual 1.0 (intercooled).doc
46
Vehicles With Altered Odometer
Failure of a Product installed on a vehicle on which the odometer has been altered so
that actual vehicle mileage cannot be readily determined.
Vehicles With Unknown Vehicle Identification Number
Any vehicle for which the original factory-assigned vehicle identification number cannot
be determined.
Salvage or Total-Loss Vehicles
Any vehicle that has ever been issued a “salvage” title or similar title under any state’s
law; or has ever been declared a “total loss” or equivalent by a financial institution or
insurer, such as by payment for a claim in lieu of repairs because the cost of repairs
exceeded the cash value of the vehicle.
Incidental and Consequential Damages
Incidental or consequential damages associated with a Product failure. Such damages
include, but are not limited to, inconvenience; the cost of removal, installation,
transportation or towing; labor; telephone calls and lodging; the loss of time; the loss of
personal or commercial property; destruction of other components; and the loss of pay,
profits, business or other opportunities.
Some states and jurisdictions do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
Disclaimer of Extra Expenses and Damages
The performance of necessary repairs, replacement, or refund of not more than the
retail price of the Product are the exclusive remedies under this limited warranty and
under any implied warranty. Innovate Motorsports does not authorize any person to
create for it any other obligation or liability in connection with the Product. Innovate
Motorsports shall not be liable for incidental or consequential damages resulting from
breach of this written warranty or any implied warranty.
Any implied warranty of merchantability or fitness for a particular purpose is limited to
the duration of this written warranty, except in states where this limitation is not allowed.
Some states and jurisdictions do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
WARRANTY CLAIMS
To make a warranty claim contact Innovate Motorsports at 8 Mason, Irvine, CA 92618.
To make a warranty claim, you must provide proof of your purchase of the Product.
While necessary maintenance or repairs on the Product can be performed by any
company, we recommend that you use only authorized Innovate Motorsports repairers.
Improper or incorrectly performed maintenance or repair voids this limited warranty. A
list of approved repairers is available from us by contacting the Innovate Motorsports.
FRS Manual 1.0 (intercooled).doc
47
13 Revision History
1.0 8/31/2013
- Initial Release
FRS Manual 1.0 (intercooled).doc
48
FRS Manual 1.0 (intercooled).doc
49
SUPERCHARGER WARRANTY REGISTRATION FORM
Thank you for purchasing an Innovate Motorsports Supercharger System! In order to
activate this limited warranty, you must return this Warranty Registration Form along
with a copy of your original purchase receipt within 30 days of purchase.
Owner Information
Name (First & Last):
Street Address:
City:
State:
Zip:
Country:
Phone:
Email:
Vehicle Information
Year:
Make:
Model:
VIN:
Purchased Product Information
*Required serial numbers needed to complete this for are located on the front of your
installation manual.
System Serial #:
Supercharger Serial #:
Product Purchase Date:
Name of company where purchased:
Please mail or fax this completed registration form, copy of your original purchase
receipt to:
Innovate Motorsports
Warranty Registration Dept.
8 Mason
Irvine, CA 92618
FAX: (714) 893-2142

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