S2000 SOS Supercharger Install Manual

Part no: enpp-1061-1063, enpp-1067-1069 Product: ScienceofSpeed Supercharger System Fitment: S2000, all years Last revision: 3/4/17 No warranty is made or implied for products sold through ScienceofSpeed against protection from damage, injury, or death. Under consideration for the purchase of these components, the buyer agrees to release, indemnify and hold ScienceofSpeed harmless for, and assume all risk of any injury or damages that may arise from the installation or use of these components. Installation of these products must be performed by a competent and knowledgeable installer. Some items may only be used off road in some states. User assumes full risk. ScienceofSpeed is not responsible for errors, typographical, or otherwise, in this installation installa tion guide.

Please note: See ways in which we can improve this guide? Please e-mail [email protected]. Professional installation recommended. Factory service manual recommended. Certain aftermarket aftermarket shock tower bars may require removal to fit the supercharger system. system. We recommend that all removed components be retained, and returned to customer upon completion. Supercharger is sealed from the factory. Take care to not not introduce foreign contaminants into supercharger (once seal is removed). Damage from foreign contaminants is not covered under warranty. Estimated completion time: 1. standard aftercooled supercharger, 2000-05: 14 hrs 2. standard aftercooled supercharger, 2006-09: 12 hrs • • • • • •

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Before beginning installation: years . Note that some steps are specific to certain years. Read and note where specific steps are exclusive to certain years. For installations with the oil fed supercharger, the oil oil will be drained to install the oil drain return fittings. This is a good time to complete an oil change on the vehicle. Have a Honda oil filter (part no. 15400-PCX-004) & oil (10W40 recommended) available. 2000-2005 only: only: ScienceofSpeed strongly recommends factory fuel injectors with more than 60k miles to be professionally cleaned and flow tested prior to installation of this supercharger system. We recommend RC Engineering for cleaning and flow testing. RC Engineering: (310) 320-2277. Before installing, inspect, inspect, wash, and blow dry any components such as inlet, intercooler, oil hoses, and water hoses to remove any possible contamination. Please note that once the installation is complete, ScienceofSpeed recommends dyno testing to verify performance and fuel curves. • •

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Length reference (use for checking fastener lengths, etc.):

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Required: screw drivers (phillips no. 2, flat no. 1) socket set & wrench (10, 12, 13, 14, 17, 19mm) wrench set, metric (14, 17mm) wrench, metric allen socket set (4, 8mm) wrench, SAE allen socket set (5/32, 3/16") wrench, adjustable wrench, torque (7-53 lbf-ft) (a more precise torque wrench is suggested for 5x30 bolts (84 lbf-in) is suggested wrench, torque (192 lbf-ft) crankshaft pulley removal tool (Honda part no. 07JAB-001040A & 07JAB-001020A or aftermarket Powerbuilt part no. 648796 – search Amazon.com for “Powerbuilt 648796”) breaker bar (if aftermarket tool used) pliers hole saw, 1 3/8" (35mm) wire cutter wire stripper terminal crimper razor blade (or hose shears) optional: 7mm nut driver (otherwise Phillips screw driver may be used) Installation: INSTALLATION PREPARATION • • • •

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Disconnect battery. Remove fuel fill cap. Remove & inspect spark plugs. Replacement highly recommended if worn. ScienceofSpeed recommended replacement (contact ScienceofSpeed, we stock these spark plugs): o for up to 425 bhp: factory or NGK Iridium IX no. 7 (BKR7EIX-11). o in excess of 425 bhp: NGK Iridium IX no. 8 (BKR8EIX-11). Adjust spark plug plug gap. Reduce the gap from the factory preset .044" by .004" less for every every 50 bhp added. For example, an application producing a 100 bhp gain should use a .036" gap (.044" - .008"). Be .008"). Be careful to not damage the fragile electrode.















INSTALL FUEL PUMP ASSEMBLY (2000-2005 only) •

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Open trunk, and remove spare tire trunk panel (3 pull clips). Next, pull back side trunk panel (2 push-in clips). Lastly, remove spare tire assembly.

In interior, with with top up, remove rear trim panel (3 push-in clips). Next, remove rear lower panel. This will expose the top of the fuel tank.















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From the trunk, the four push-in clips securing the rear lower interior panel will be exposed (see photo). Using pliers, gently remove these clips and pop up into the interior.

Remove fuel tank top panel (3 Phillips screws). Disconnect exposed electrical plug. Lastly, remove fuel hoses. Place rags down in interior to catch fuel that will drip from fuel pump carrier assembly when removed. Remove fuel pump carrier assembly from fuel tank by lifting up 2-3" then rotating top of fuel pump carrier down so that fuel level sensor float remains in tank then lift assembly out of tank. IMPORTANT! Take care to not scratch coating on fuel tank level float. Also, take care to not bend float arm.

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fuel pump

Remove factory fuel pump and inspect filter sock. Clean as needed, then replace pump with supplied pump making sure to place new pump in same orientation as old pump.

Replace fuel pump / carrier assembly, hoses, hoses, electrical plug, panel, and interior panels at this time. SUPERCHARGER MOUNTING BRACKETS INSTALLATION •















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2000-05: remove upper and lower 3.5mm vacuum hoses from front of vacuum hard lines. Remove air valve shown from factory air box in prior step.

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2000-05 only: Remove rear upper and lower vacuum hoses from vacuum hard line shown.

Locate hard line shown. Remove hard line and short hose joining valve cover vent and hard line. Retain hose clamps for future use.















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fitting, 5/16" hose coupler •

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Pull back hose clamps securing water lines on cylinder head and throttle body. Rotate hoses so that they point at each other. Install 5/16” hose coupler fitting and replace both pairs of hose clamps.

2006-2009 only: remove only: remove air temperature sensor from intake and retain sensor for future use. 2000-05 only: locate air control box which is located on front cross member under factory air box assembly in front of pump pulley (pictured below). Remove air control box and pull out of the way to gain access to the crankshaft pulley. Remove crankshaft pulley. Bolt is secured with 192 lbf-ft lbf-ft from the factory. The factory or aftermarket equivalent crankshaft pulley removal tool recommended. pulley, crankshaft

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Install supplied crankshaft pulley pulley with threaded holes. Torque: 192 lbf-ft (260 N-m). pulley, crankshaft adaptor

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Making sure mating surfaces of crankshaft pulley and and crankshaft pulley adaptor are clean and free of debris, slip adaptor over crankshaft pulley and align threaded holes. bolt, 5x30mm socket head thread locker, semi-permanent (Loctite Blue)

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Apply semi-permanent thread locker (Loctite Blue) to threads of 5x30mm socket head bolts and secure adaptor to crankshaft pulley in a star pattern leading to final torque. Torque: 84 lbf-in (9.5 N-m). IMPORTANT! Applying more torque to these bolts than specified may cause bolt failure. Do not apply more than 84 lbf-in (NOT lbf-ft). Many standard torque wrenches are not capable of applying this low of a torque value precisely. A precise torque wrench must be used.

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Replace factory serpentine accessory belt, but leave leave belt off alternator pulley at this time. Remove upper alternator flange hex bolt (labeled “7” in diagram).

















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bolt, 5x25 Phillips Pan spacer, 5/8” long hose, 3.5mm 20" long vacuum •

2000-05 only: Replace air control box assembly to cross member. Relocate air control valve to air control box using 5/8” long spacer between box and valve’s bracket and 5x25mm Phillips pan screw as shown. Install 20” long 3.5mm hose between air control valve and lower vacuum hard line (located under fuel rail). Reuse the factory hose between the upper vacuum hard line and air control box. Install this hose to upper vacuum hard line.

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2006-2009 only: Remove bracket and disconnect harness.

















The following steps including the installation of the mounting brackets are crucial to proper installation. Please pay attention to the order and details of these steps. 1 1

bracket, alternator bolt, 10x60 flange hex •

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Install alternator bracket in the position of the alternator bolt removed in the last step. Using the supplied 10x60mm FH bolt, loosely fasten alternator bracket at the approximate angle shown in the photo.

Remove 10x45mm FH bolt from timing belt cover as shown.

















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bracket, VTEC sub plate bolt, 8x40mm flange hex •

Inspect, wash, and blow dry oil passage ports in VTEC solenoid to remove any possible contamination. Assemble VTEC sub bracket to VTEC bracket as shown using three 8x40mm FH bolts. Torque: 16 lbf-ft (22 N-m)

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Remove VTEC solenoid from cylinder head. Note that oil will drip from cylinder head. Place a rag under the solenoid and cylinder head to prevent oil from dripping on the exhaust manifold. Inspect VTEC gasket. If the gasket shows existing signs of leakage, replace gasket (Honda part no. 15825-PCX-015). gasket, VTEC spool valve bolt, 6x70 flange hex

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Install supplied VTEC solenoid gasket to engine side of VTEC plate. Loosely install VTEC plate and VTEC solenoid (with existing VTEC gasket installed in solenoid) and new gasket in place in VTEC bracket to cylinder head using supplied 6x70 FH bolts. Leave loosely assembled, do not torque.

















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Reuse 10x45mm FH bolt (removed from front timing cover) through rear of VTEC plate into cylinder head. Leave loosely assembled, do not torque. Note: do not use pointed tip 10x45mm FH bolt removed from alternator in prior step. Note: the factory heat shield may need to be bent back slightly if there is a conflict with the VTEC bracket (varies between engines).

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bolt, 10x110 flange hex •

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Next, install 10x110mm flange hex bolt through VTEC sub bracket as shown. Leave loosely assembled, do not torque.

Make sure 10x110, 10x45, and 6x70mm bolts bolts are finger tightened. Important: the bolts must be torqued in this sequence: 1. 10x110mm torque 33 lbf-ft (44 N-m)

















SUPERCHARGER OIL FEED & DRAIN INSTALLATION 1 1

feed fitting & crush washer (included w/ supercharger) fitting, 1/8" NPT - AN-3 adaptor •

Install and tighten oil feed fitting on top most port of supercharger as shown using supplied crush washer. Do not apply thread sealant to this fitting’s threads. Next, install adaptor to threaded hole in this fitting. Thread tape is not required on either the flared

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drain fitting (included w/ supercharger) •

Apply thread sealant tape to drain fitting and install to supercharger in lower port as shown.



















VOLUTE CLOCKING The supercharger volute and fittings need to be configured for the S2000.

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CAUTION! The volute is the outer shell that is the discharge side of the supercharger. It is secured to the body of the supercharger by bolts and retainer tabs. Use extreme caution when manipulating the volute as the fins of the supercharger impeller are fragile. Remove three 2-hole tabs and bolts that secure volute. Rotate volute to approximate location as shown (note the supercharger drain is located in the between the lower and middle tabs). Install bolts into tabs, but leave loose for final clocking once installed.

SUPERCHARGER INSTALLATION 1

supercharger assembly •

If not yet removed, remove these two bolts.



















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bracket, main supercharger mounting bolt, 12x40 flat socket bolt, 12x25 flat socket rubber isolator bushing •

Apply a small amount of anti-seize paste to threads & mating surface of flat socket bolts. Set supercharger onto main supercharger mounting bracket. Thread 12x25 cap head bolt into center mounting hole and three 12x40 cap head bolt into outer mounting holes as shown. Do not yet torque. Lastly, install four rubber isolator bushings into holes on edge of bracket assembly as shown. Place the side of the bushing with the purple and white dots on the supercharger side of the bracket. Make sure rubber isolators are fully compressed and not binding at an angle.

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bolt, 1/4"-20x2.5" flat socket •

Apply a small amount of anti-seize paste to threads & mating surface of flat socket bolts. Insert 1/4”-20x2.5” bolts through main mounting bracket. Next, torque outer 12x40 bolts to 52 lbf-ft (71 N-m) and then inner 12x25 bolt to 52 lbf-ft (71 N-m), and lastly torque 1/4” bolts to 12 lbf-ft (16 N-m).

BELT TENSIONER ASSEMBLY INSTALLATION



















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bolt, 6x25mm flange hex •

Next, install the assembly as shown on to the supercharger mounting bracket. Note that the assembly is placed on the front side of the bracket (see second photo below). Secure the tensioner locating block to the plate with the supplied 6x25mm FH bolts. Torque = 9 lbf-ft (12 N-m).

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pulley, tensioner smooth spacer, thick stepped pulley spacer, thin stepped pulley nut, 10x1.5mm standard hex washer, Nordlock locking (pair) •

Next, turn the assembly over to expose the tensioner pulley bolt’s threads. In this order, assemble these parts on to the tensioner pulley bolt. 1. “thick” spacer 2. pulley 3. “thin” spacer 4. 10mm flat washer



















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pulley, supercharger drive pulley fitting kit (stepped washer, flat washer, keyway, bolt) thread locker, semi-permanent (Loctite Blue) •

Next, install the pulley to the supercharger driveshaft as shown. Insert square key into keyway of pulley and install this pulley/key assembly to the driveshaft. Apply Loctite blue to 3/8”-24 bolt’s threads, and secure bolt to driveshaft using stepped washer and Nord-Lock lock washer pair as shown. Nord-Lock washers are a pre-assembled pair as shown with “ramped” cam teeth facing each other. One pair used between stepped washer and bolt head. Nord-Lock washers are reusable. Tip: wrap belt around pulley to aid in holding it in place when torqued or use a pulley wrench to secure. Torque: 50 lbf-ft (68 N-m).

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The assembly will now look as shown.



















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Remove factory serpentine belt from alternator pulley if installed (do not remove entire belt) by rotating tensioner pulley bolt counterclockwise with 14mm box wrench to gain access to alternator

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Next, secure 10x60 FH bolt securing alternator alternator bracket to alternator. Torque = 33 33 lbf-ft (44 N-m).

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Lastly, torque all four 10x55 flange hex mounting bolts. Torque = 33 lbf-ft (44 N-m).

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Replace factory serpentine belt to alternator pulley.





















INSTALL SUPERCHARGER BELT 1

belt, supercharger •

With supercharger tensioner pulley nut slightly loose, back tensioner away from supercharger pulley. Install supplied supercharger belt as shown.



















INSTALL OIL FEED AND DRAIN (engine oil fed superchargers only) 1

oil feed line •

Install oil feed line as shown.



















REMOVE FRONT BUMPER (aftercooled systems only) Customers with upgraded race heat exchangers should see the supplemental installation guide. Skip the following instructions and continue at “WIRE WATER PUMP TO POWER” once complete. •

The heat exchanger and water pump will now be installed by removing the front bumper. To remove front bumper, first remove five bolts (Phillips) securing top of bumper (under front of hood). Then, remove two 6mm flange hex bolts as shown in photo (one per side). Next, remove two Phillips screws where the bumper meets the fenders. Lastly, remove the three plastic clips under the middle of the bumper and the three 6mm flange hex bolts on each side of these clips.



















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Next, unclip bumper from fender by pulling down bumper and unclipping bumper tab as shown (bumper has a female tab that clips over a male pin on the fender). Lift the female tab over the male pin and pull bumper away from fender. The bumper will now release and should be removed (a helper will aid in the removal of the bumper).



















INSTALL HEAT EXCHANGER (aftercooled systems only) 2 2

spacer, 1/2" long for 6mm bolt bolt, 6x25 flange hex •

Remove dryer bracket mounting bolts and install supplied ½” long spacers behind driver bracket. Secure bracket with supplied 6x25mm flange hex bolts.





















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Inspect A/C dryer bracket screw to make sure that it is not impacting front of heat exchanger. Adjust heat exchanger in brackets to make ensure that heat exchanger is straight and parallel to the ground.



















INSTALL WATER PUMP & WATER HOSES (2000-05 only) 1

bracket, water pump mounting •

Remove two lower 6mm flange nuts from air pump assembly and secure water pump as shown replacing nuts (leave loose at this time).



















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ring terminal, 1/4" stud, 22-18 ga butt connector, 22-18 ga wire, 18 ga black 8 ft long zip tie, 5.6" long (narrow width) •

Install supplied ¼” ring terminal to ground (black) wire of water pump and secure behind flange bolt as shown (trim wire to proper length).



















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Bend the tab slightly as needed to avoid contact with hose (see photo).



















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hose, 3/4" pre-formed 90 degree clamp, 16-27mm hose coupler, ¾” (nylon) •

Next, cut and install the ¾” coupler into a 30” hose segment of hose. Install the other end into the long leg of the 90 degree hose elbow. Secure both ends with 16-27mm hose clamps. Do not over torque.





















































































































































































































S2000 SOS Supercharger Install Manual

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