Jackson Automobile Battery Charger User Manual
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 proceed 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 individuals with good mechanical sense and with the
proper tools. Use your discretion--if you are not a
competent mechanic, do not attempt this installation.
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 screwdrivers
Multi-purpose pliers
10mm, 12mm, and 17mm open end wrenches
Timing light
A shop manual is useful.
WARNING: Once the installation is complete,
CHECK AND RECHECK ALL fuel system connections 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, 999-157, 999-158 & 999-159 -1- Revised 06/08
1.0 DISASSEMBLY
1.1 Release the airflow meter harness 7-pin connector 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.
1.2 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 a
later step.
1.3 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 rubber 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
MAZDAARE BEST REMOVED BY
APPROACHING FROM THE SIDE WITH NEEDLE NOSE PLIERS. GRASP ALL THREE
T ANGS AT ONCE AND COMPRESS THEM
TOGETHER. THIS IS EASIER TO DO WITH
THE THROTTLE BODY ALREADY LOOSE
FROM THE INTAKE MANIFOLD.
999-156, 999-157, 999-158 & 999-159 -2- Revised 06/08
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
Figure 1.3
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 throttle 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 SURFACES IN ANY WAY.
2.2 Moving to a worktable, remove the idle air
control (ICS) valve from the bottom of the throttle 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 gasket will want to stay with the Mazda throttle
body carefully pick it out with a flat blade screwdriver 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 position. 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 supplied as necessary.
2.5 Reconnect the idle control valve electrical
connector.
2.6 Take the Throttle Position Switch (TPS)
extension wire (4 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 junction you will first have to cut the three pin connector 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 colorcoded wires that match the colors of the Mazda
harness. The 4th (white) wire will not be needed. 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 protective
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, 999-157, 999-158 & 999-159 -3- Revised 06/08
3.0 BELT DRIVES
3.1 NOTE: CARS WITH POWER STEERING:
Use a 12mm socket and combination wrench to
loosen the power steering slide lock bolt. Then
loosen the tensioning bolt. Use a 14mm deep
socket and combination wrench to loosen the
power steering pivot bolt. You may have to rotate
the pulley to access this bolt. Using a 14mm
socket loosen and remove the slide anchor bolt
at the engine. At this point the power steering
pump should be able to pivot. Push the pump
downward towards the air conditioning compressor and remove the belt. Now, use a 12mm socket to remove the bolt securing the power steering
hose to the bracket. Using a 14mm socket,
remove the two bolts securing the power steering
bracket to the power steering pump. Remove the
whole tensioning system including the tensioning
and power steering brackets. Then, remove the
nut from the power steering pivot bolt. Illustration
3.1
3.2 Gather together the new belt tensioner
assembly, the new power steering hose support
bracket and the supercharger strap bracket.
Using a 22mm combination wrench slightly
loosen the power steering hose on the top of the
power steering pump and swing the hose to clear
the new power steering hose support bracket.
Then install the new hose support bracket in the
same place as the factory bracket. Temporarily
install the upper bolt to help with alignment.
Tighten the bottom bolt to 36 ft lbs. Once the bottom bolt is tight, remove the upper bolt. Now,
slide the power steering pivot bolt rearward out of
the pump. It will be reinstalled from the front.
Remove the rubber sleeve holding the shortheaded bolt in the new tensioner assembly. Slip
the new tensioner assembly into place behind the
power steering pulley, aligning its lower hole with
the pivot bolt hole. Reinstall the pivot bolt (from
the front). The bolt may come in contact with the
radiator cooling fan. It this occurs, the fan can be
depressed a slight amount to allow the bolt by or
use a 10 mm socket to remove the two bolts
securing the fan to the radiator and slide it up to
allow the bolt to be installed. Install the shortheaded bolt again just above the pivot bolt. It
should thread into the cast power steering bracket, bolted to the engine. Finally, install the last
bolt through the tensioner assembly and through
the power steering hose support bracket into the
upper hole in the pump. Slide the round hole of
the strap bracket onto the end of the pivot bolt on
the back side of the power steering pump and
start the flanged nut. Tighten the two upper bolts
on the tensioner assembly, securing it to the
power steering pump and the cast power steering
bracket, bolted to the engine. Tighten to 36 ft lbs.
The power steering pump pivot bolt will stay
loose until the supercharger is installed.
Supercharger Installation Instructions
999-156, 999-157, 999-158 & 999-159 -4- Revised 06/08
Illustration 3.1
Slide anchor
bolt
Slide lock
bolt
Tensioning
bolt
Illustration 3.2
3.3 Gather one M8 x 20mm flanged bolt, two M8
flange nuts and the power steering link. Bend the
tabs open on the power steering hose clamp,
using wire cutters. Open the clamp and slide it
down the hose. Make sure that the rubber slides
along with the clamp. Install the power steering
link over the stud on the power steering bracket
and start one of the flange nuts. Align the clamp
on the power steering hose with the remaining
hole in the power steering link. Slip the bolt
through the hole and start the nut. Once the bolts
are started, pull the hose away from the power
steering reservoir to gain clearance and tighten
the bolts to 18 ft lbs. Now tighten the hose on the
power steering pump. Once the two bolts are
tight, the two tabs on the power steering hose
clamp can be bent down again. Illustration 3.3
VERY IMPORTANT: Check the clearance
between the small coolant hose that runs from the
base of the thermostat housing and the passenger
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
Supercharger Installation Instructions
999-156, 999-157, 999-158 & 999-159 -5- Revised 06/08
Illustration 3.2
Illustration 3.3
cause severe engine damage. Not all cars need
this modification.
3.4 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 nonAC, 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 To access the ECU, remove the passenger’s
side 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 carpet. Remove the floor mat and
pull back the carpet 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). Illustration 4.1
4.2 Locate the PowerCard (Fuel Management
System) from your kit. We have included enough
wire to mount it on the center console or in the
glove box (recommended) and still reach the
passenger’s side footwell where the ECU is
located. Decide where you want to mount it,
route the wires from that location to the console
(or thru the glovebox area) back behind the
dashboard and down into the passenger’s side
footwell. Then cut the extra wire to length or
loop and wrap it with tape. Strip 1/4” of insulation
off of each of the PowerCard’s wires. Gather
together one (1) female spade connectors and
five (5) male spade connectors. Crimp the
female spade connector onto the Purple wire
and then crimp the male spade connectors onto
the rest of the wires. Slip the wires into the
included split loom. The split loom can be cut to
length as necessary. The Powercard will connect
to the ECU harness in the passenger (right hand)
foot well. We recommend routing the wires under
the dash or behind the center console on their
way to the footwell to keep them out of the driver’s way.
Supercharger Installation Instructions
999-156, 999-157, 999-158 & 999-159 -6- Revised 06/08
Illustration 4.2
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