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Toyota Celica Compressor System
User Manual
36 pgs9.57 Mb0

BLITZ Toyota Celica Compressor System User Manual

Installation Manual
TOYOTA CELICA
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
1. SAFETY NOTICE
1) Please read this manual CAREFULLY. This Manual explains in detail the operation
methods and the assembly procedures.
2) Blitz will not be liable for any malfunctions and (or) damages to the vehicle if you alter the
product or by adding any different item(s) to our product.
3) Blitz will not be liable for any injuries and (or) damages caused to you and (or) to a third
party while installing this product.
4) Blitz may update and (or) discontinue this product and (or) it’s components at any time.
WARNING:
1) Install this product in a well-ventilated area.
Ignoring this indication may cause a fire and (or) an explosion.
2) Install this product and its parts firmly at a secured place that would not be of any
interference while driving.
Ignoring this indication would cause an accident.
3) This product is designed to work on 12V DC, and the ground is designed to be the
chassis of the car.
It would cause a fire by installing this product other than a vehicle powered by a 12V DC
4) Disconnect the ground line from the battery while installing this product.
It would cause a fire by an electric short, breakage of electronic part(s) and (or) burn(s).
5) Disconnect the harness’s connectors from the connectors it self. DO NOT pull from
the harness.
It would cause a fire by an electric short, breakage of electronic part(s) and (or) burn(s). Moreover, it would cause some malfunction(s) to this product.
6) Discontinue utilizing this product and contact our retailers or us, if you notice some
irregular noise and (or) odor from this product
It would cause a fire, electrocution, and (or) breakage of electronic part(s), if you disregard this (these) symptom(s).
7) DO NOT operate this product while driving.
It would cause an accident.
Ignoring these indications may cause serious injuries or even DEATH.
.
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
8) DO NOT damage any wiring(s) and (or) piping(s) from the engine room while installing
this product.
It would cause a fire by an electric short, breakage to the engine, vehicle and (or) to the
electronic part(s). Insulate the unnecessary wiring(s) for the installation.
WARNING:
product.
1) Ask for a professional or a technician to perform the installation of this product.
The individual performing this installation must have technical skills and knowledge to perform this installation.
2) Do not drop or insert extreme force to the product while installing it.
It would cause malfunctions.
3) Do not misuse, abuse, alter, take apart and (or) modify this product in any way.
It would cause an accident, fire, electrocution, breakage and (or) burn the electronic parts.. If any of the above indications are executed, the warranty of the product will be voided.
4) Do not install this product at a location where it could get wet and (or) highly heated
It would cause an electrocution, fire, and break and (or) burn the electronic parts.
5) Do not install this product while the engine and its components are hot; wait until
they are fully cooled.
It would cause burn(s) to you or to a third party if the engine itself, radiator, and the exhaust system remain hot.
6) Please perform regular maintenance and be extra cautious.
This product’s durability and components are virtuously tested; however, depending on the vehicle’s driven condition and (or) climate, the durability may decrease.
7) Do not throw away the original detached components from the vehicle. Please keep
the components securely.
We are not liable from any damages caused to the components while installing it. Please be extra careful through the installation.
8) Use the right tools to tighten the nuts and bolts.
It will damage the threads if you over tighten it.
9) This product has been designed and tested on vehicles with manufacturer’s original
components.
It would cause malfunctions to the product or vehicle if you have already installed a third party’s product(s).
Ignoring these indications may cause injuries and malfunctions (breakage) to the
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
Important Notice:
1) This product is based on original vehicles from the manufacturer. We are not liable of able
to warrant it installed to vehicles other than the original from the manufacturer.
2) Take extra caution not to mix foreign materials through the installation procedure. It may
cause a breakage or damage to the engine.
3) Use the manufacturer maintenance manual to install or removal of the original components.
Please purchase the Maintenance manual from the maker if you do not have one.
4) Make sure there are not any oil, coolant and exhaust gas leaks before going for a test drive.
There is a possibility of a fire or breakage if the vehicle is kept with the leaks.
5) This kit is meant to work only on high-octane gasoline. If the vehicle is driven with normal
gas, it may cause knockings or worst, it may break the engine.
6) Take extra caution with a source of fire while working on the gasoline tank.
7) Change the spark plugs to type that can withstand high heat.
8) The original fog lamps will not be able to install if this kit is installed.
Notice to the person installing this product.
Return this installation manual to the customer after finishing the installation.
Before beginning to install this product, check the list below.
Replace any original components such as hoses and bands that have cracks and are deformed
to new original components from the manufacturer.
2. Compatible Vehicle.
□Vehicle Model: TOYOTA CELICA
□Type: ZZT 231 Ｍ/Ｔ
□Year: September, 1999～
◇Product Name: BLITZ COMPRESSOR SYSTEM
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
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3. List of Components.
ressor 1P
2) Intake Manifold 1P
3) Chamber 2P 1) Com
4) Oil Pan 1P
5) Gasket 2P 6) Idle Pulley Bracket 1P 7) Compressor Bracket 1P 8) Alternator Bracket 1P
9) Idle Pulley Collar 2P 10) Cooler compressor
13) Compressor Stay 1P
13) Compressor Stay 1P
Collar 2P
14) Throttle Body Stay 1P
11) Idle Pulley 2P 12) Throttle cable stay 1P
15) A/C pipe stay 1P 16) Air bag sensor stay 1P
17) Level Gauge Guide stay
18) Intercooler stay A 1P 19) Intercooler stay B 1P
20) Air cleaner stay 1P
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
21) Inter Cooler Stay A
22) Inter Cooler Stay B 1P
23) Blow byPipe No.1 1P
24) Blow by Pipe No.2 1P
25) Inter Cooler 1P 26) Intake Pipe No.１ 1P
27) Intake Pipe No.２ 1P 28) Intake Pipe No.３ 1P
31) φ60 elbow pipe 1P
32) Suction Pipe 1P30) Intake Pipe No.6 1P29) Intake Pipe No.４ 1P
33) Silicon Hoseφ60 4P
34) Silicon Hose φ70 2P
35) Variant Type Silicon
Hose φ60-φ70 4P
36) Hose Band L 8P
37) Hose Band S 12P 38) Power steering oil cooler 39) Nipple φ4-1/8PT 1P 40) Nipple φ6-1/8PT 1P
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
41) Nippleφ21-3/4PT 1P
42) Straight nippleφ9 2P 44) φ19 Hose 450mm 1P
43) Straight nippleφ19 1P
45) φ9 Hose 2000mm 2P 46) φ6Tube 2000mm 1P 47) φ4 Hose 2000mm 1P
49) φ15 Colgate Tube 1P
50) Rubber Cap φ19 1P 51) Clamp L 6P
48) φ19 Colgate Tube 1P
52) Clamp S 8P
53) V Belt 1P
57) Pressure sensor 1P 58) Clutch Switch 1P 59) Relay Harness 1P
54) Alternator Harness A 1P
55) Alternator Harness B 1P
56) Cooler Harness 1P
60) Electro tap 2P
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
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61) Female Wire Connector 6P
63) SUS Power LM 1P
68) Access Computer 1P
67) Compressor Plate 1P
65) Lock Tight 15P
69) Instruction Manual 1P
a. Flange Bolt M6×8 1P
e. Flange Bolt M8×16 5P
b. Flange Bolt M6×16 6P c. Flange Bolt M6×20 30P d. Flange Bolt M8×12 3P
f. Flange Bolt M8×35 1P
. Flange Bolt M8×45 1P h. Flange Bolt M8×50 1 P
i. Flange Bolt M10×35 4P
m. Cap Bolt M8×15 3P
. Flange Nut M10 1P
. Hex Bolt M8 X 110 3P
n. Stud Bolt M8 2P
r. Washer M6 2P s. Washer M8 2P t. Washer M10 3P
k. Hex Bolt M10 X 55 1P l. Cap Bolt M6 X 15 2P
o. Flange Nut M6 4P
. Flange Nut M8 7P
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
4. Removal of genuine components.
Junctions Block (Fuse Box)
Circuit opening relay
Engine under cover
(1) Operation to prevent the spillage of fuel.
① Remove the circuit opening relay from the
junction block in the engine room.
②Start the engine, wait until it shuts off it self
then turn OFF the ignition.
③Remove the negative terminal of the battery.
④Reinstall the circuit opening relay.
⑤Release the pressure from the fuel tank by
removing the fuel tank cap.
(2) Remove the engine under cover.
(3) Drain the engine oil by removing the drain
bolt.
(4) Drain the engine coolant.
(5) Remove the apron seal cover.
(6) Remove the cylinder head cover by loosening
the bolts (4P).
Cylinder head cover seal
Apron seal cover
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
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Air Cleaner assembly
Throttle cable
Nut
Bolt
PCV valve
Air cleaner hose
Airflow sensor
Ventilation Hose No. 1
Water bypass hose
(7) Removal of the genuine air cleaner. ※Refer to the
installation.
①Disconnect the air flow sensor and the
VSV connector.
②Pull off (disconnect) the VSVφ4 hose
from the intake manifold.
③Remove the PCV valve and the stay
which are attached behind the air
cleaner box.
④Remove the air cleaner assembly and the
air cleaner hose from the vehicle.
⑤ remove the air flow sensor from the
genuine air cleaner box.
※Be careful not to damage the sensor’s
O ring.
⑥Secure the VSV connector tightly with a
lock tight that is supplied with the LM
kit. ※ Refer to the (C. 62) SUS Power
installation manual) for the location
to secure that VSV connector.
(8) Removal of the throttle body
①Remove the throttle cable. ② Remove the throttle cable bracket by
loosening the bolts (2P).
③Pull off (disconnect ) the No. 1 ventilation
hose 1 from the throttle body.
④Pull off (disconnect) two water bypass
hoses from the throttle body.
⑤Remove two connector. ⑥Remove the throttle body assembly and
the gasket.
C. 62) SUS Power LM kit) for
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
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Ventilation Hose No. 2
Vacuum hose
ＰＣＶ hose.
Bolt
Intake manifold bracket
Nut
Bolt
(9) Removal of the genuine intake manifold.
① Start removing from the ventilation hose
No. 2, vacuum hose, PCV hose and the
intake manifold.
② Remove the sponge cushion from the top
of the intake manifold.
③ Removal of the fuel delivery line.
a.Disconnect the injector connector.
b. Disconnect the cam position sensor. c. Remove the bolts
holding the fuel delivery pipe, then
remove the fuel delivery pipe with the
injectors still on.
※Leave the in
fuel delivery pipe, o r it will cause fuel
leakages.
④ Pull out the oil level gauge, then remove
the bolt holding the intake manifold and
the oil level gauge guide. ※Be careful not to damage the O ring
from the oil level gauge.
⑤ Remove the bolts (2 bolts) that are
holding the intake manifold and the
genuine manifold bracket.
⑥ Remove the alternator bracket. ⑦ Remove the bolt that is holding the
coolant reserve tank and keep the tank
loose.
⑧ Remove three bolts and two nuts to
remove the intake manifold.
⑨ Attach back the c ng-ooli
tank.
(10) Remove the sponge cushion at the
bottom of the intake manifold.
(11) Remove two connectors from the oil level
gauge guide to remove the oil level gauge
guide.
3 bolts) that are
ectors attached in the
ater reserve
WARNING: All images and text in this manual is the property of Blitz Co., Ltd. (Japan). No parts of this manual may be reproduced, stored in retrieval systems, or transmitted in any way without prior written permission of Blitz Co., Ltd. (Japan).
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