Vortech Engineering S2000 User Manual

Honda S2000

Supercharger System

Installation Instructions

2000-2003 50 STATE SMOG LEGAL PER CARB EO #D-213-21

2000-2004 Model Years

*2004 Models

*Legal in California only for racing vehicles which may never be used upon a highway.

ENGINEERING, LLC

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

4HS020-010 v2.0 07/27/04

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

Due to the horsepower and torque that your vehicle will produce after installation of this supercharger system, it is strongly suggested that the factory clutch be replaced with a high-capacity aftermarket unit.

prior

to beginning the installation to determine if you

NOTE:

or translated into another language in any form, by any means without written permission

2003 VORTECH ENGINEERING, LLC

of Vortech Engineering, LLC.

TABLE OF CONTENTS

FOREWORD.....................................................................................................................................ii

TABLE OF CONTENTS....................................................................................................................iii

TOOL & SUPPLY REQUIREMENTS ................................................................................................iv

PARTS LIST - HONDA S2000 ..........................................................................................................v

1. PREPARATION/REMOVAL ..................................................................................................1

2. OIL FEED.............................................................................................................................3

3. OIL DRAIN ...........................................................................................................................4

4. CRANK DAMPER PULLEY INSTALLATION........................................................................5

5. FUEL MANAGEMENT UNIT................................................................................................7

6. FUEL PUMP REPLACEMENT.............................................................................................10

7. FUEL RAIL/ REGULATOR MODIFICATIONS (2004 Models Only)......................................11

8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION...................................12

9. SUPPLEMENTARY FUEL INJECTOR INSTALLATION (2004 Models Only).......................24

10. SUPERCHARGER BELT TENSIONER ADJUSTMENT ......................................................25

11. AIR PUMP INLET HOSE MODIFICATION...........................................................................25

12. CHARGE AIR COOLER INSTALLATION.............................................................................26

13. AIR INLET DUCT INSTALLATION .......................................................................................30

14. HOSE ATTACHMENTS/EXTENSIONS................................................................................31

15. ELECTRONIC CONTROL BOX INSTALLATION .................................................................32

16. FINAL CHECK .....................................................................................................................35

iii

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

2000-2004

HONDA S2000

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® Supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech

Engineering is not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech prior to using this product.

4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is

resolved.

5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000

miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 2 years or 20,000 miles with

original heat range plugs as specified by the manufacturer and retard timing from factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every at least 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 3/8” Swivel Head Ratchet

• 1/2" Socket and Drive Set: SAE & Metric

• 3/8" NPT Tap and Handle

• Adjustable Wrench

• Open End Wrenches: SAE & Metric

• Center Punch

•5 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16" Drill Bits

• Hex Key Wrench Set

•Wire Strippers and Crimpers

• Utility Knife

• Hand Held Grinder

• Blue Loctite

• 07JAB-001020A (Damper Tool) Available at Honda Dealer

• 07NAB-001040A (Damper Tool) Available at Honda Dealer

• Honda Bond (Sealer) Available at Honda Dealer

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• New Spark Plugs

ENGINEERING, LLC

2000-2003 HONDA S2000

Part No. 4HS218-010SQ/-018SQ

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART # DESCRIPTION QTY PART # DESCRIPTION QTY

2E229-180 SUPERCHARGER ASSY 1 4HS111-021 MOUNTING BRACKET ASSY 1

4HS010-011 MTG. PLATE BLOCK 1 4HS010-021 LOWER S/C PLATE SPACER 1 4HS010-034 UPPER S/C SUPPORT PLATE 1 4HS010-044 S/C MOUNTING PLATE 1 4HS010-051 LATERAL S/C MOUNTING PLATE SUPPORT 1 7A250-075 1/4-20 x .75 SHCS 2 4PFA010-031 TENSIONER ADJ. SCREW LOCATOR 1 7PA375-500 TENSIONER SCREW 1 7B500-325 TENSIONER ARBOR 1 4HS017-051 TENSIONER SPACER 1 4HS017-011 RIBBED IDLER SPACER 1 4HS017-031 UPPER S/C PLATE SPACER 4 4HS017-021 12mm S/C BOSS SPACER 1 4HS017-041 S/C PLATE SPACER (TO STOCK IDLER) 1 7F375-028 3/8-24 PRESS NUTS 4 7B375-350 3/8-24 x 3.50 4 7C010-115 M10 X 1.25 x 115 BOLT 1 7J010-002 M10 WASHER (.080 THK.) 2 7C060-622 M6 x 1.00 x 158 STUD 2 7C010-049 M10 x 1.25 x 50 BOLT 1 7C060-080 M6 x 1.00 x 80 BOLT 3 7C012-050 M12 x 1.75 x 50 BOLT 1 7A375-124 3/8-16 x 1.25 7 7A375-350 3/8-16 x 3.50 1 7K375-040 3/8 AN WASHER 12 7J006-093 M6 WASHER 5 7F006-093 M6 NUTS 2 7J012-092 M12 WASHER 2 7F500-030 1/2-20 JAM LOCK NUT 1 2A017-016 3/8 ID BEARING PILOT (6203 BRG) 1 4GF016-160 RIBBED 3" IDLER 1 4FH016-150 SMOOTH 3" IDLER 1 4HS040-050 V-TECH SOLENOID GASKET 1 7C080-046 M8 x 1.25 x 45 SHCS 2 7A312-100 5/16-18 x 1.0 HXHD 2 7K312-001 5/16 AN WASHER 2

4HS116-011 S/C DRIVE ASSEMBLY 1

4HS016-011 CRANK PULLEY 1 7C010-050 10-24 x .50 SHCS GR8 6 4HS016-021 MODIFIED DAMPER PULLEY 1 2A046-510 S/C DRIVE BELT 1

4HS238-068 FMU assembly 1

6Z110-144 FMU ASSY 1 7U030-016 1/4 FUEL HOSE-FMU “IN” 34" 7U030-016 1/4 FUEL HOSE-FMU “OUT” 28" 7R001-004 #4 HOSE CLAMP 2 7U030-046 5/32" VACUUM HOSE 28" 7P156-082 5/32 TEE 1 7R004-003 14.5 STEPLESS CLAMP 2

4HS130-036 OIL DRAIN ASSEMBLY 1

7U030-036 OIL DRAIN HOSE 18" 7R001-008 #8 CLAMP 2

7P375-004 3/8" NPTF x -8 SAE FLARE FITTING 1 7P500-050 FTG,-8 JIC TUBE x 90° W/BARB 1 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, 9/16" ROTABROACH 1 7P375-041 3/8" NPT x 1.5" HEX NIPPLE 1

4HS130-026 OIL FEED ASSEMBLY 1

7U250-000-360 OIL FEED HOSE 1 7P125-004 #4 JIC x 90 x 1/8 NPT FTG 1 7P125-101 #4 JIC x 45 x 1/8 NPT FTG 1 7P125-125 1/8 NPT FEM x 1/8 BSPT 1 7P125-034 1/8 STREET TEE 1 7U100-055 6" ZIP-TIE 4

4HS112-010 AIR INLET ASSEMBLY 1

8H040-022 3/4" BREATHER FITTING 1 8H040-040 3.5" AIR FILTER 1 7S350-200 3.5 x 2" SLEEVE 1 7R002-056 #56 CLAMPS 2 7R002-052 #52 CLAMP 2 7U030-016 1/4" COOLANT HOSE 16" 4HS013-010 AIR BOX 1 7A250-050 1/4-20 x .5 SHCS 8 7U035-001 3.5" FLEX HOSE 5" 7U030-036 OIL DRAIN HOSE 36" 4HS110-060 AIR FILTER MOUNTING FLANGE ASSY 1 4HS012-011 3.5" PLASTIC INLET ELBOW 1 7P375-017 3/8" NPT x 1/2" BEADED HOSE BARB 1 7E010-049 #10 SHEETMETAL SCREW 2 7C060-020 M6 x 1.0 x 20 HXHD 1 4HS010-110 AIR BOX MOUNTING TAB, UPPER 1 4HS010-120 AIR BOX MOUNTING TAB, LOWER 1

8N401-010 POWERCOOLER/DISCH. ASSY 1

7A250-050 1/4-20 x .5 SHCS 2 8H040-175 RACE BYPASS FILTER 1 8N055-050 SURGE TANK CAP 1 7S275-200 2.75 SLEEVE x 2 SLEEVE 1 7S275-300 2.75 SLEEVE x 3 SLEEVE 1 7R002-044 #44 CLAMP 4 7P500-026 3/4 HOSE BARB x 1/2 NPT x 90 FTGS 2 7U030-046 5/32" VACUUM HOSE 24" 7P156-082 5/32 TEE 1 7U030-030 1/4" VACUUM HOSE 36" 7P250-033 5/32 - 1/4 REDUCER 1 008341 POWERCOOLER DECAL 1 8N301-140 WELDED COOLER CORE ASSY 1

8N106-110 WATER COOLER ASSY 1

4HS010-080 WATER RESERVOIR MNTG BRKT 1 4HS010-090 WATER COOLER MNTG BRKT, UPPER 1 4HS010-100 WATER COOLER MNTG BRKT, LOWER 2 5W001-002 FUSE TAP 1 5W001-009 SLIDE CONNECTOR - 18GA MALE 1 5W001-011 16-14 GA EYELET 2 5W001-014 FUSE HOLDER 10 GA 1 5W001-015 FUSE, BLADE TYPE 20A 1 5W001-017 12GA RING TERMINAL 1 5W001-019 12GA SOLDERLESS CONNECTOR 1

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

ENGINEERING, LLC

2000-2003 HONDA S2000

Part No. 4HS218-010SQ/-018SQ

PARTS LIST,

cont’d

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART # DESCRIPTION QTY

7A250-050 1/4-20 x .50" SHCS 2 7A250-075 1/4-20 x 3/4 SHCS PLTD 3 7E010-049 #10 x 3/4 HXHD SLF TAPNG ST MTL 9 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 3 7J250-001 1/4 SAE WASHER, PLTD 10 7P375-075 3/4" HOSE UNION 1 7P500-026 1/2NPT-3/4 BARB 90° 3 7P500-078 1/2NPT x 3/4 HOSE FIT STRT 1 7R003-015 ADEL CLAMP, 15/16".406 EYELET 1 7R007-001 NYLON CLAMP 1-1/8" 10 7U038-000 3/4" HEATER HOSE 12 7U038-012 HOSE, Ø3/4" 90°, 4 x 12" 2 8F001-402 PUMP, WATER 2 8F101-310 RELAY ASSY, HONDA 1 8N006-010 WATER COOLER 1 8N055-030 TANK, LT1 AFTERCOOLER 1

5A201-001 ELECTRONICS UPGRADE ASSY

4HS010-070 BRKT, FTC MNTG S2K 2 5A001-051 TIMING CONTROL BOX 1 5A101-020 MAP CLAMP 1 5W001-009 16-14GA MALE SLIDE INSULATED 11 5W001-010 16-14GA FEMALE SLIDE INSULATED 8 5W001-022 T-TAP CONN,14-16 AWG 3 7C008-050 8-32 x 1/2 SHCS 2 7E010-049 #10 SHEET METAL SCREW 2 7F008-032 8-32 NYLOCK NUT 2 7P156-082 5/32" TEE, BRASS 1 7P157-219 REDUCER UNION, 5/32" TO 7/32" 1 7U030-046 5/32" VACCUM LINE 4' 7U100-055 TIE WRAP, 6" NYLON 8 7U375-001 VELCRO-HOOK 1" BLACK .166 YD 7U375-002 VELCRO-LATCH 1"BLACK .166 YD

8F001-342 Fuel pump assy. 1 8D204-011 Race blowoff valve 1 4HS020-010 Instruction manual 1 008110 Decals 2 008444 S/C owners packet 1 008130 Lic. plate frame, Vortech 1

ENGINEERING, LLC

2004 HONDA S2000

Part No. 4HS218-020/028SQ

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART # DESCRIPTION QTY PART # DESCRIPTION QTY

2E229-210 V2SQ S/C SC-TRM CCW HONDA S2000 1

2A036-450 S/C PULLEY 4.50" 6-GRV 1

4HS111-021 MOUNTING BRACKET ASSY S2000 1

2A017-016 PILOT, 6203/5 BRG, 3/8 SCREW 1 4FH016-150 IDLR PULLEY, 6-RIB 3" FLANGED 1 4GF016-160 PULLEY, 3" IDLER-RIBBED 1 4HS010-011 MTG BLOCK, SUPPORT PLT S2000 1 4HS010-021 SUPPORT, LWR MTG PLT S2000 1 4HS010-034 S/C SUPPORT PLT, REAR S2000 1 4HS010-044 S/C MOUNTING PLT, S2000 1 4HS010-051 SUPPORT, NTG PLT, LATERAL S2000 1 4HS017-011 RIBBED LIDLER SPACER, S2000 1 4HS017-021 SPACER, S/C BOSS S2000 1 4HS017-031 SPACER, UPPER S/C PLT S2000 4 4HS017-041 SPACER, LOWER S/C PLT S2000 1 4HS017-051 SPACER, TENSNR PULLEY S2000 1 4HS040-050 GASKET, VTEC SOLENOID S2000 1 4PFA010-031 BRACKT, IDLER ADJUST SCREW 1 7A250-075 1/4-20 x 3/4 SHCS PLTD 2 7A312-100 5/16-18 x 1 HXCS GR5P 2 7A375-124 3/8-16 x 1-1/4 HXHD G5 PLATED 7 7A375-350 3/8-16 x 3-1/2 HXHD 1 7B375-350 3/8-24 x 3-1/2" HXHD GR8 4 7B500-325 ARBOR, S/C TENS PLY, S2000 1 7C010-049 M10 x 1.25 x 50 HCHD CL10.9 1 7C010-115 M10 x 1.25 x 115 HXHD CL10.9 P 1 7C012-050 M12 x 1.75 x 50mm HXHD BOLT 1 7C060-080 M6 x 1.00 x 80 SHCS CL 8.8 3 7C060-622 M6 x 1.0 x 6.22" S2000 STUD 2 7C080-046 M8 x 1.25 x 45 SHCS CL8.8 2 7F006-093 6mm NYLOCK NUT 2 7F375-028 PRESS NUT, 3/8-24 x .50 4 7F500-030 1/2-20 HEX JAM LOCK NUT ZINC 1 7J006-093 6mm WASHER, PLATED 5 7J010-002 10mm WASHER, ZINC PLATED 2 7J012-092 12mm WASHER, FLAT 2 7K312-001 5/16 AN WASHER, PLATED 2 7K372-040 3/8 AN960 FLAT WASHER, PLATED 12 7PA375-500 SCREW, IDLER ADJUST, 5.00" 1

4HS116-021 S/C DRIVE ASSY 04’ S2000 1

2A046-500 BELT, K060500-GATES 1 4HS016-011 S/C CRANK PULLEY, 6" S2000 1 4HS016-021 MODIFIED DAMPER PLY S2000 1 7C010-050 10-24 x .50 SHCS GR8 PLT 6

4HS238-048 FMU ASSY, w/LINES 4:1, S2000 1

6Z110-150 FMU, 4:1 1/4 BARB w/SPRING 1 6Z050-151 FMU WASHER, 4:1/38LB. PLATED 1 6Z070-020 FMU 4:1 RING SPACER 1 6Z090-010 SPRING, FMU GM 4.3 1 7C010-050 10-24 x .50 SHCS GR8 PLT 6 7C010-075 10-24 x 3/4 SHCS GR5 ZINC 4 7C024-025 10-24 x 1/4 PHILL HD 3 7E010-046 #8 x 3/4 SHEET METAL 2 7P125-025 1/8 NPT x 5/32 HOSE 90 1 7P125-036 1/8 NPT-STRT 1/4 BARB 1 7P125-037 1/8 NPT-90° TO 1/4 BARB 1

7U100-030 O-RING, FMU 1 7U030-016 1/4" EFI HP FUEL LINE 2 7U030-016 1/4" EFI HP FUEL LINE 2 7R001-004 #4 HOSE CLAMP 2 7U030-046 5/32" VACUUM LINE 2 7P156-082 5/32" TEE 1 7R004-003 STEPLESS CLAMP, 14.5-70 2

4HS130-026 OIL FEED ASSY S2000 1

7U250-000-360 OIL FEED HOSE, 36" -4 STRT 1 7P125-004 1/8 NPT 90° x -4 JIC FTG STL 1 7P125-101 1/8 NPT 45° x -4 JIC FTG STL 1 7P125-125 FTG, 1/8 NPT FEM x 1/8 SPT MALE 1 7P125-034 1/8 NPT x 1/8 NPT STRT T 1 7U100-055 TIE-WRAP, 7.5" NYLON 6

4HS130-036 OIL DRAIN ASSY S2000 1

7P375-004 3/8 NPT x 1/2 SAE MALE FLARE 1 7P375-041 3/8 NPT HEX NIPPLE x 1.5" 1 7P500-050 FTG, -8 JIC TUBE x 90° w/BARB 1 7R001-008 #8 STNLS HOSE CLAMP 2 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1 7U030-036 1/2" OIL DRAIN HOSE 1

8F001-342 FUEL PUMP w/SCREEN, GSS 342 1 5A101-021 ENGINE MNGMNT ASSY 04’ S2000 1

4HS010-070 BRKT, FTC MNTG S2000 2 5A001-121 TIMING BOX, 04’ HONDA S2000, PROG 1 5W001-009 16-14GA MALE SLIDE INSULATED 11 5W001-010 16-14GA FEMALE SLIDE INSULATED 8 5W001-022 T-TAP CONN. 14-16 AWG 3 7C008-050 #8-32 x 1/2" SHCS, ZINC 2 7E010-049 #10 x 3/4 HXHD SLF DRL SHT MTL 2 7F008-032 8-32 HEX LOCK NUT 2 7P156-082 5/32 TEE 1 7P157-219 REDUCER UNION, 5/32" TO 7/32" 1 7U030-046 5/32" VACUUM LINE 4' 7U100-055 TIE-WRAP, 7.5" NYLON 8 7U375-001 VELCRO-HOOK 1" BLACK .16YD 7U375-002 VELCRO-LATCH 1" BLACK .16YD

4HS112-010 AIR INLET ASSY S2000 1

4HS010-110 MNTG BRKT, UPR, S2000 AIRBOX 1 4HS010-120 MNTG BRKT, LWR, S2000 AIRBOX 1 4HS012-011 INLET ELBOW, 3.5" MOD. S2000 1 4HS013-010 AIRBOX, S2000 1 4HS110-060 FLANGE ASSY, AIRBOX S2000 1 7A250-050 1/4-20 x .50 SHCS ZINC PLTD 8 7C060-020 M6 x 1.0 x 20mm HHCS 1 7E010-049 #10 x HXHD SLF DRL SHT MTL 2 7P375-017 3/8 NPT x 1/2 BEADED HSE BRB 1 7R002-052 #52 SAE TYPE F SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 2 7S350-200 3-1/2 x 2 SLEEVE, BLUE 1 7U030-016 1/4" EFI HP FUEL LINE 1 7U030-036 1/2" OIL DRAIN HOSE 3 7U035-001 3-1/2" FLEX HOSE .41' 8H040-022 3/4" BREATHER 1 8H040-040 AIR FILTER, 3.5" FLG x 5.52" 1

vii

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

ENGINEERING, LLC

2004 HONDA S2000

Part No. 4HS218-020SQ

PARTS LIST,

cont’d

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART # DESCRIPTION QTY PART # DESCRIPTION QTY

8N401-040 PWR COOLR ASSY, 04' HONDA S2000 1

008341 VORTECH CHARGE COOLER DECAL 1 7A250-050 1/4-20 x .50 SHCS ZINC PLTD 2 7P156-082 5/32 TEE 1 7P250-033 1/4 x 5/32 RED.UNION 1 7P500-026 1/2 NPT x 3/4 BARB 90° BRASS 2 7R002-044 #44 SAE TYPE F SS HOSE CLAMP 4 7S275-200 SLEEVE, BLUE, 2.75" D x 2.00" L 1 7S275-300 2-3/4" x 3", BLUE 1 7U030-030 1/4" VACUUM HOSE 3 7U030-046 5/32" VACUUM LINE 2 8H040-175 FILTER, 1-3/4" I.D., RACE BYP 1 8N055-050 PLASTIC CAP, SURGE TANK 1 8N301-240 PWR COOLR CORE ASSY, 04' S2000 1

8N106-110 WATER PUMP/COOLR ASY S2000 1

4HS010-080 MNTG BRKT, H20 TANK, S2000 1 4HS010-090 H20 COOLR MNTG BRKT, UPR S2000 1 4HS010-100 H20 COOLR MNTG BRKT, LWR S2000 1 5W001-002 FUSE TAP 1 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-011 16-14GA RING TERM. .26" HOLE 2 5W001-014 FUSE HOLDER 10GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-017 12-10GA x 3/8" RING TERMINAL 1 5W001-019 10-12GA BUTT CONN INSULATED 1 7A250-050 1/4-20 x .50 SHCS ZINC PLTD 2 7A250-075 1/4-20 x 3/4 SHCS PLTD 3 7E010-049 #10 x 3/4 HXHD SLF DRL SHT MTL 10 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 3 7J250-001 1/4 WASHER, SAE, PLTD 10 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7P500-026 1/2 NPT x 1/4 BARB 90° BRASS 3 7P500-078 1/2 NPT x 3/4 HOSE FIT STRT 1 7R003-027 ADEL CLAMP, 1-11/16" 1 7R007-001 NYLON RATCHET CLAMP 1-1/8" 10 7U038-000 3/4" HEATER HOSE 12 7U038-012 HOSE, Ø3/4" 90° 4 x 12 LEGS 2 8F001-402 PUMP, WATER, PIERBURG 1 8F101-310 FUEL PUMP RELAY ASSY, HONDA 1 8N006-010 WATER COOLR, SETRAB SINGLE PAS 1 8N055-030 TANK, WATER, TRIANGLE SHAPE 1

8D204-011 RACE BLOWOFF VALVE-SATIN 1

7A250-074 1/4-20 x .75 HHCS PLTD 2 7A312-126 5/16-18 x 1.25 SET SCRW OVAL P 1 7F312-022 5/16-18 JAM NUT, STAINLESS 1 7J006-093 6mm WASHER, PLATED 2 7P125-109 FTG, 1/8 NPT - 1/4 BARB, AL 1 7U100-086 SNAP RING, COMPACT BYPASS 1 8D003-080 RATAINER, SPRING 1 8D004-023 COVER, RACE BYPASS-BLUE 1 8D004-053 GASKET, MTG FLNG, M.F. RACE BYPASS 1 8D004-083 SPRING, MFRB, 12" HG 1 8D104-042 MFRB BODY ASSY SATIN 1

7C011-200 10-32 SHCS x 2" ZINC PLATE 1 7F010-030 10-32 THIN NYLOCK NUT SST 1 7P125-020 BREATHER, SFMU 1 7U100-049 O-RING, COMP.BYPASS 1 8D004-031 VALVE, COMPACT BYPASS ANODIZED 1 8D004-061 PISTON, COMPACT BYPASS MACHINED 1 8D004-091 DIAPHRAM, COMPACT BYPASS 1

8D004-141 SLEEVE, COMPACT BYPASS MACHINED 1 8D104-042R MINI BYPASS GUIDE ASSY 1

4HS020-010 INSTRUCT MANUAL, HONDA S2000 1

viii

1. PREPARATION/REMOVAL

A. Disconnect the negative battery cable. B. Remove the factory engine air filter enclosure

cover.

C. Disconnect the crankcase ventilation tube and

the air pump inlet hose attached to the rubber inlet duct leading to the throttle body.

D. Remove the vacuum/coolant tubing junction from

the vehicle. Tag and label the vacuum hoses for ease of reassembly in later steps. (See

1-a,1-b,1-c.

)

Figs

NOTE: Make sure that the rubber hoses that are

shown in Fig. 1-c are also removed from the vehicle along with the tubing junction.

E. Detach the pressure solenoid from the plastic air

filter enclosure (single phillips head screw). (See

Fig. 1-b.

)

F. Separate the rubber vacuum hoses and wiring

from the air filter enclosure.

G. Remove the rubber inlet duct from the throttle

body and the air filter.

H. Remove the air filter and enclosure from the

vehicle.

I. Remove the screw securing the plastic vacuum

canister to the backside of the front crossmember (located in front of the engine). Set aside for reinstallation at a later time.

J. Remove the accessory belt and crank damper

pulley from the engine. Removal of the crank damper pulley bolt may require Honda sourced tools (07JAB-001020A handle and 07JAA001020A damper socket). Set aside the damper screw for reinstallation at a later time.

K. Remove the factory idler (smooth) pulley and

hardware and set aside temporarily. (See

)

1-d.

Fig.

L. Remove the two factory M8 x 1.25 screws that

attach the front corner of the cylinder head to the engine front cover (see

Fig. 1-e

M. Disconnect the wiring from the VTEC solenoid

assembly. Remove the three screws attaching the solenoid assembly to the side of the cylinder head. (See

Figs. 1-f,1-g.

) Set the VTEC solenoid assembly aside for mounting in a later step. Make sure that the o-ring sealing gasket does not get lost or damaged, because it will be re-used in a later step.

Fig. 1-a

Fig. 1-b

Fig. 1-c

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

1. PREPARATION/REMOVAL, cont’d.

Fig. 1-d

REMOVE SCREWS

Fig. 1-e

Fig. 1-f

Fig. 1-g

2. OIL FEED

A. The supercharger uses engine oil for lubrication

and must have an oil feed line connected to a filtered oil access on the engine.

B. Locate the oil pressure sending unit on the pas-

senger side of the engine, toward the front (see

Fig. 2-a

wire from the sending unit. Using a 15/16 socket, remove the sending unit from the engine.

C. Install the supplied 1/8" BSP adapter into the

block. Install the supplied 1/8" NPT street TEE into the BSP adapter. Thread the stock sending unit into the tee as shown in the stock signal wire and nut to the sending unit.

). Using a 7mm socket, remove the signal

Fig. 2-b

. Reattach

NOTE: Use only clean engine oil on the pipe

threads. Teflon tape or pipe sealant is not recommended as it might loosen and cause blockage of the small oil feed orifice resulting in possible supercharger failure.

D. Install the supplied 90° x 1/8" NPT x #4 flare fitting

into the previously installed TEE. (See

Fig. 2-c.

Make sure that the fitting is tightened and clocked as shown.

E. Temporarily cover the open fitting hole to keep

out debris until the connection is made to the supercharger hose in step 12.

OIL PRESSURE SENDING UNIT

Fig. 2-a

)

Fig. 2-b

Fig. 2-c

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

3. OIL DRAIN

A. Drain the engine oil and change the filter.

B. To provide an oil drain for the supercharger, it is

necessary to make a hole in the pan.

C. Remove (6 screws) the tubular chassis

crossmember located beneath the rear of the engine.

D. Remove the oil pan bumper that is attached to

the vehicle frame in front of the oil pan.

E. Remove the two screws that attach the oil pan to

the transmission bellhousing.

F. Remove the two lower A/C compressor pump

mounting bolts that attach to the oil pan mounting bracket. Leave the small aluminum mounting bracket attached to the pan.

G. Remove the remaining oil pan screws around the

perimeter of the pan and carefully remove the pan.

H. Locate and mark the drain hole location on the oil

pan as per

Figs. 3-a, 3-b

between the two fins as shown, and down from the sealing surface of the pan 1.25". Grind down the fins on the oil pan as shown.

I. Using the supplied 9/16" rota-broach cutter and

arbor, carefully machine a through hole into the pan in the location specified.

J. From the outside of the pan, tap the hole with a

3/8" NPT tap approximately 1/4" deep. Pack the flutes of the tap with heavy grease to hold the chips. Thoroughly clean the threads and hole with acetone or lacquer thinner.

K. Using a small amount of silicone sealer, install

the 3/8 NPT x 1.5" hex nipple into the oil pan. Thread the supplied 3/8" NPT female x -8 flare fitting onto the hex nipple. Temporarily cap the fitting until the drain hose is connected in step 12.

L. Thoroughly clean the mating surface of the oil

pan flange and the bottom of the engine block. The surfaces must be free from oil so that a proper seal can be achieved when the pan is reinstalled.

M. Apply a small amount of Hondabond sealer (avail-

able at the local Honda dealership) to the oil pan mating flange.

N. Reattach the pan to the engine. Reinstall all of

the factory hardware.

O. Reinstall the two A/C compressor screws, fac-

tory oil pan bumper and chassis crossmember.

P. Re-fill engine with factory specified weight oil.

Vortech recommends the use of synthetic oil.

. The hole location is

1.25”

Fig. 3-a

GRIND FINS AS SHOWN

Fig. 3-b

4. CRANK DAMPER PULLEY INSTALLATION

A. Locate the supplied damper pulley and billet

aluminum supercharger crank pulley.

B. The aluminum supercharger crank pulley is to be

installed over the new damper pulley as shown in

Fig. 4-a

that the holes properly line up with the corresponding threaded holes in the damper. Ensure that the damper is smooth and clean where the aluminum pulley is to be seated.

C. Carefully lower the aluminum pulley down onto

the damper. Make sure that the aluminum pulley is completely seated onto the damper. Do not hammer or pry the pulley into place. If necessary, the aluminum pulley may be lightly heated to allow for an easier fit onto the damper pulley

D. Secure the pulley and damper together using the

six supplied 10-24 x .50 socket head screws. Use a drop of blue Loctite on the threads on each of the screws. Torque the screws to 50 in/lbs (4-5 ft/lbs.)

E. Clean the damper pulley screw and washer that

were removed in step 1. Using a small amount of engine oil, lubricate the screw threads and the bottom side of the screw head (area that mates to the washer). Install the new crank pulley assembly onto the engine. Torque the screw to 181 lb/ft. Do not use an impact wrench. In order to achieve the correct torque on the screw, Honda sourced tools may be required (07JAB001020A handle and 07JAA-001020A damper socket) to keep the assembly from rotating.

. Be sure to rotate the aluminum pulley so

P/N: 4HS020-010

27JUL04 v2.0 S2000 (4HSv2.0)

4. CRANK DAMPER PULLEY INSTALLATION, cont’d.

VORTECH SUPPLIED

CRANK DAMPER

PULLEY

6.0” ALUMINUM SUPERCHARGER CRANK PULLEY

6 x 10-24 x .50 SCREWS (TORQUE EVENLY TO 50 IN/LBS)

Fig. 4-a

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Vortech Engineering S2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual