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Jackson 999-205 manual

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Table of contents for the manual

  • Page 1

    READ THESE INSTRUCTIONS THOROUGHL Y! 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 proceed through the installation, you should read a few steps ahead in the instructions so you are certain to catch all notes and warnings. A TTENTION SUPERCHARGER INST A[...]

  • Page 2

    1.0 DISASSEMEMBL Y 1.1 Disconnect your Miata’s battery . 1.2 Release the air flow meter harness 5-pin con- nector by pressing the locking tab on its clip. Remove the stock air flow meter from the air box by removing the two 10mm headed retaining bolts and then remove the Air T emperature sensor with its rub- ber mounting grommet from the Air filt[...]

  • Page 3

    HOSE CLAMPS FROM MAZDA ARE BEST REMOVED BY APPROACHING FROM THE SIDE WITH NEEDLE NOSE PLIERS. GRASP ALL THREE T ANGS A T ONCE AND COMPRESS THEM TOGETHER. THIS IS EASIER TO DO WITH THE THROTTLE BODY ALREADY LOOSE FROM THE INT AKE MANIFOLD. Plug the coolant hoses with a screwdriver , golf tee, or pen- cil to prevent the leakage of coolant (OR - keep [...]

  • Page 4

    2.7 Locate the ICS blanking plate and take it over to your Mazda throttle body . Use the 1 104 sealant between the blanking plate and the Mazda throttle body . Install the blanking plate onto your Mazda throttle body using the two new Phillips head screws supplied in the kit. Insert the shaft of a Phillips or cross head screwdriver into the ends of[...]

  • Page 5

    3.2 When you are done with your trial fit- ting of the flat idler pulley bracket, take this flat bracket to a workbench and install the two nylon idler pulleys using the bolts and Nylock nuts provided. Make sure that the bolt heads point towards the rear of the car . 3.3 Secure the idler pulleys firmly to the flat bracket. Proceed to install the id[...]

  • Page 6

    4.0 FUEL MANAGEMENT 4.1From the kit, locate Jackson Racing “PowerCard” Digital Fuel Management Module (DFMM), it will appear as a small black plastic box with 6 wires coming out of it. Using V elcro pro- vided, you will be attaching the Jackson Racing PowerCard to the side of the factory Engine Computer Unit (ECU). The ECU is located directly a[...]

  • Page 7

    5.2 Locate your throttle cable bracket that is bolted to your standard intake manifold and remove the throttle cable by loosening the pinch nuts surround- ing 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 bracke[...]

  • Page 8

    1/07 999-200 8 sunk bolt removed earlier through the L-bracket, through the main S/C bracket, and through the hole in the exhaust manifold to S/C bracket. The jam nut that goes on this bolt fits tightly between the rear support bracket and the engine’s cam cover . Use an open-end wrench and some masking tape to hold the nut to the wrench while yo[...]

  • Page 9

    assistant operate the gas pedal multiple times to confirm that the action is free and easy with- out 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 position, you will have tr[...]

  • Page 10

    not back towards it. Continue the hose across the engine side of the radiator and under the upper radiator hose. Using the T y-Wrapp straps provid- ed, attach the rubber hose securely to the fan shroud supports near the fan motor(s). Attach the end of the hose to the Brass Elbow fitting attached to the bottom of the new Dummy Throttle Body . Make s[...]

  • Page 11

    power steering bracket to attach your lower bracket to, you will use special bracketry that we have included with your kit. T urn to figure 3.4 in the installation manual and find the note describing the bolt that will be used for the non-power steering car ’s lower strap bracket anchor . The Mazda idler pulley set-up for your 4-rib belt has a ca[...]

  • Page 12

    9.1 Locate the rubber sleeves and the front cross over pipe. Check inside the cross over pipe for debris and clean it out if necessary . Install the cross over tube between the idle air manifold (dummy throttle body now on the intake manifold) and the supercharger manifold. If you find the outlet rubber sleeves hard to slip over their respective la[...]

  • Page 13

    9.7 IDLE ADJUSTMENT : Restart your engine. Using the idle air screw 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 is done by backing the adjustment screw out a half turn at a time until the correct speed is achieved (counter-clockwise rota- tion increases idle speed).[...]

  • Page 14

    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 the connector to air- flow 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 Miat[...]