Honda S2000 Superc Installa harger Sys tem tion In 2 s 0 t 0 ruction 0-2004 2000-2 003 50 M s o del Y STAT E SMO ears G LEGA L *2004 ModelPs ER CARB EO #D-21 3-21 *Legal in Cali for nia only fo r racin g vehic les wh ich ma y neve r be us ed upo n a hig hway. ® 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.
FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.
TABLE OF CONTENTS FOREWORD ..................................................................................................................................... ii TABLE OF CONTENTS .................................................................................................................... iii TOOL & SUPPLY REQUIREMENTS ................................................................................................ iv PARTS LIST - HONDA S2000 .........................................................
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.
2000-2003 HONDA S2000 Part No. 4HS218-010SQ/-018SQ ® PARTS LIST ENGINEERING, LLC IMPORTANT: PART # 2E229-180 Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.
2000-2003 HONDA S2000 Part No. 4HS218-010SQ/-018SQ ® PARTS LIST, ENGINEERING, LLC IMPORTANT: PART # Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. DESCRIPTION QTY 7A250-050 7A250-075 7E010-049 7F250-021 7J250-001 7P375-075 7P500-026 7P500-078 7R003-015 7R007-001 7U038-000 7U038-012 8F001-402 8F101-310 8N006-010 8N055-030 1/4-20 x .
2004 HONDA S2000 Part No. 4HS218-020/028SQ ® PARTS LIST ENGINEERING, LLC IMPORTANT: PART # 2E229-210 2A036-450 Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. DESCRIPTION V2SQ S/C SC-TRM CCW HONDA S2000 S/C PULLEY 4.
2004 HONDA S2000 Part No. 4HS218-020SQ ® PARTS LIST, ENGINEERING, LLC IMPORTANT: PART # Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. DESCRIPTION QTY 8N401-040 008341 7A250-050 7P156-082 7P250-033 7P500-026 7R002-044 7S275-200 7S275-300 7U030-030 7U030-046 8H040-175 8N055-050 8N301-240 PWR COOLR ASSY, 04' HONDA S2000 VORTECH CHARGE COOLER DECAL 1/4-20 x .50 SHCS ZINC PLTD 5/32 TEE 1/4 x 5/32 RED.
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 Figs 1-a,1-b,1-c.) NOTE: Make sure that the rubber hoses that are shown in Fig.
1. PREPARATION/REMOVAL, cont’d. REMOVE SCREWS Fig. 1-d Fig. 1-e Fig. 1-f Fig. 1-g P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
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 passenger side of the engine, toward the front (see Fig. 2-a). Using a 7mm socket, remove the signal 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.
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.
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. Be sure to rotate the aluminum pulley so 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.
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 P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
5. FUEL MANAGEMENT UNIT A. Disconnect and discard the factory rubber fuel return line running from the fuel pressure regulator outlet to the steel return line located under the vehicle. B. Remove the relay from the factory bracket/tab near underhood fuse box. (See Figs 5-a, 5-b.) Remove the bracket/tab from the vehicle and discard. Move the relay toward the underhood fuse box to make space for mounting of the Vortech FMU. C. Position the FMU onto the driver side inner fender as shown in Figs. 5-c, 5-d.
5. FUEL MANAGEMENT UNIT, cont’d. Fig. 5-d FACTORY RETURN LINE INTO TANK Fig. 5-e P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
FUEL PRESSURE REGULATOR ATTACH TO MANIFOLD VACUUM SUPPLIED 34” FMU INLET HOSE — SECURE BOTH ENDS WITH CLAMPS Fig. 5-f SUPPLIED 28” FMU OUTLET HOSE — SECURE BOTH ENDS WITH CLAMPS FMU OUTLET FMU INLET FMU/FUEL LINE DIAGRAM VEHICLE’S STOCK RETURN LINE (TO TANK) 5. FUEL MANAGEMENT UNIT, cont’d. 9 P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
6. FUEL PUMP REPLACEMENT A. Remove the spare tire from inside the vehicle’s trunk. B. Remove the holding tray for the convertible top, located behind the seats. Remove all of the pushpins securing the holding tray. (Refer to page 20-71 of the factory service manual for the location of all the pushpins) Slide the tray out by way of the trunk. (See Fig. 6a.) NOTE: Pressing in on the center of the black plastic removable rivets with a small screwdriver will cause them to release. C.
7. FUEL RAIL/REGULATOR MODIFICATIONS (2004 Models Only) 4.10" .60" DRILL WITH AN ‘R’ DRILL AND TAP 1/8 NPT 2004 FUEL RAIL MODIFICATIONS Fig. 7-a A. Disconnect the fuel feed line running to the middle of the factory fuel rail. B. Remove the hose connected to the return side of the fuel regulator. C. Loosen the factory screws securing the fuel rail and remove the fuel rail from the vehicle. D. Using Figs. 7-a, 7-b, mark the location to be drilled.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION A. Detach the factory wiring harness from the rear of the front crossmember for mounting bracket clearance. Push the harness down toward the steering rack. B. Remove the two factory M6 x 1.0 screws from the passenger side front of the engine near the crank pulley at the location shown in Fig. 8-a. C. Locate the lower supercharger plate spacer. This is a .75" thick aluminum spacer that is 2.9" wide x 4.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. REMOVE FACTORY SCREWS DO NOT INSTALL HARDWARE IN THIS HOLE AT THIS STEP M12 x 1.75 x 50mm SCREW WITH WASHER INSTALLED THROUGH SUPPORT PLATE AND Ø1.0 x .549 SPACER AND INTO SUPERCHARGER BOSS (SPACER SANDWICHED BETWEEN CENTER SUPERCHARGER BOSS AND SUPPORT PLATE) 3/8-16 x 1.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. SMOOTH IDLER PULLEY - Ø3.0 SMOOTH IDLER SPACER - Ø.515 INSIDE DIAMETER M12 x .10” THICK WASHER 1.772 1/2-20 JAM LOCKNUT (DO NOT TIGHTEN UNTIL LAST STEP) BELT TENSIONER ARBOR 1.772 PRE-INSTALLED 3/8-24 “PRESS NUT” INSERT 3/8-24 x 3.5" SCREW BEARING PILOT - Ø.386 INSIDE DIAMETER RIBBED IDLER SPACER Ø.406 INSIDE DIAMETER MAIN SUPERCHARGER MOUNTING PLATE RIBBED IDLER PULLEY - Ø3.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. BELT TENSIONER ARBOR SCREW Fig. 8-g BELT TENSIONER ADJUSTMENT SCREW ADJUSTMENT SCREW LOCATOR BLOCK Fig. 8-h Fig. 8-i 15 P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. fitting. Secure with a #8 hose clamp. Make sure that the hose clamp housing is clocked down toward the supercharger so that it will not cause interference with the supercharger mounting plate that is to be installed. (See Fig. 8-j.) H. Remove the blue plastic dust cap located on the brass oil feed nozzle on the side of the supercharger. Thread the supplied steel 1/8" NPT x 45° x –4JIC fitting into the supercharger oil feed nozzle.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. 3/8-16 x 1.25 SCREWS WITH AN WASHERS (DO NOT TIGHTEN SCREWS UNTIL ENTIRE BRACKET ASSEMBLY IS MOUNTED ONTO ENGINE) SUPERCHARGER PLATE MOUNTING BLOCK (SANDWICHED BETWEEN VTEC SOLENOID AND CYLINDER HEAD) SUPERCHARGER SUPPORT PLATE PRE-INSTALLED 3/8 -24 “PRESS NUT” INSERT (LOCATED ON BACKSIDE OF PLATE) HOLE FOR M12 x 1.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. 3/8-16 x 3/5” SCREW/AN WASHER INSTALLED FROM THE BACKSIDE THROUGH SUPPORT PLATE AND Ø.875 x 1.858 SPACER AND INTO SUPERCHARGER (SPACER SANDWICHED BETWEEN MAIN PLATE AND SUPPORT PLATE) SUPERCHARGER PLATE MOUNTING BLOCK (SANDWICHED BETWEEN VTEC SOLENOID AND CYLINDER HEAD) M12 x 1.75 x 50mm SCREW WITH WASHER INSTALLED FROM THE BACKSIDE - THROUGH SUPPORT PLATE AND Ø1.0 x .
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. 3/8-16 x 3.5” SCREW / AN WASHER INSTALLED FROM THE BACKSIDE THROUGH SUPPORT PLATE AND Ø.875 x 1.858 SPACER AND INTO UPPER SUPERCHARGER MOUNTING BOSS (SPACER SANDWICHED BETWEEN MAIN PLATE AND SUPPORT PLATE) M6 1.0 x 80mm SCREWS THROUGH VTEC SOLENOID (NOT SHOWN), SUPERCHARGER PLATE MOUNTING BLOCK AND INTO CYLINDER HEAD) CENTER M12 SUPERCHARGER BOSS SUPERCHARGER PLATE MOUNTING BLOCK M10 x 1.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. L. M. N. O. P. Q. R. The 3/8-16 x 3.5" screw is to be threaded through the main supercharger plate and into the remaining 3/8" threaded mounting hole on the supercharger unit. (See Fig. 8-p.) Thread the screw down until the head almost touches the plate/ washer. Do not tighten the screw at this time. Mount the remaining three Ø.875 O.D. x 1.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. SLIDE THE Ø1.0” x 2.726” SPACER ONTO THE M10 x 1.25 x 115 SCREW BEFORE ATTACHING THE MOUNTING PLATE TO THE ENGINE Fig. 8-s Fig. 8-t 21 P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. NOTE: When installing the supercharger with bracket assembly onto the engine, the belt must be manipulated so that it is properly routed around the idler, tensioner, supercharger pulley and lower supercharger plate spacer. (Refer back to Fig. 7-n.) S. Align the M10 x 1.25 x 115 screw (previously inserted through the front of the main supercharger plate) into the factory idler pulley mount on the front cover. (See Fig. 8-u.
8. SUPERCHARGER MOUNTING BRACKET/PLATE INSTALLATION, cont’d. located on the supercharger cover. Two 3/8-16 x 1.25" screws with AN washers that attach the supercharger support plate to the supercharger mounting block. 5. M10 x 1.25 x 115 screw through the front of the supercharger mounting plate and into the factory idler pulley mount on the front cover. 6. Two 5/16-18 x 1.0" screws through the supercharger mounting plate and into the lateral support. 7. Two M8 x 1.
9. SUPPLEMENTARY FUEL INJECTOR INSTALLATION (2004 Models Only) A. Locate the supplied charge cooler. Insert the supplied 55lb/hr fuel injector into the injector base welded to the cooler discharge tube so that the injector plug is facing away from the injector base. (See Fig. 9-a.) NOTE: Lightly oil the O-rings on the injector for easier installation. B. Insert the upper block over the injector. Secure the upper injector block with the supplied shoulder bolts. C.
10. SUPERCHARGER BELT TENSIONER ADJUSTMENT A. Make sure that the 1/2-20 jam lock nut previously threaded onto the tensioner arbor is threaded down almost all of the way, but not tight. The belt is tightened/loosened by rotating the belt tensioner adjustment screw. Tighten the belt until light resistance is felt in the belt tensioner adjustment screw. Proper belt tension is achieved when the belt can be twisted approximately 1/4 of a turn by hand. Adjust belt tension as needed. Do not over tension the belt.
12. CHARGE AIR COOLER INSTALLATION A. Attach the supplied breather/filter to the outlet of the Vortech race bypass valve. Attach the Vortech race bypass valve to the charge cooler core using the supplied 1/4-20 x .50" socket head bolts and gasket. (See Fig. 12-a.) B. Install the charge cooler between the supercharger and the throttle body using the supplied 2.75" sleeves and #44 hose clamps. The 3" long sleeve is to be placed on the throttle body. C.
WATER RESERVOIR 27 WATER PUMP WATER TANK MOUNTING BRACKET WATER FLOW FROM SUPERCHARGER (FRONT VIEW) Fig. 12-d MOUNTING BRACKET #2 WATER COOLER CHARGE AIR COOLER WATER COOLER (SIDE VIEW) CORRECT FITTING ORIENTATION 12. CHARGE AIR COOLER INSTALLATION, cont’d. P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
12. CHARGE AIR COOLER INSTALLATION, cont’d. battery. Following Fig. 12-g, route the wire up along the factory wires. L. Remove the factory heater motor relay located in the underhood fusebox and modify to accept the electrical power tap as shown in Fig. 12-h. Reinstall the relay with the power tap. Connect the yellow wire to the power tap. M. Attach the black wire from the supplied relay to a suitable ground. N. Route the red wire from terminal #87 on the supplied relay down to the water pump.
12. CHARGE AIR COOLER INSTALLATION, cont’d. V. A hole approximately Ø1" will have to be made into the lower front plastic valance for the water line to pass through. Locate the point where the hose is to pass through and create a hole using a hole saw or grinder. W. Reinstall the lower front valance and attach the passenger side only, leaving the drivers side loose. Attach the hose previously cut between the water reservoir and the water pump inlet and secure with the provided clamps. (See Fig. 12-m.) X.
13. AIR INLET DUCT INSTALLATION A. When installing this supercharger system on 2002-2004 model year vehicles, the horn mounted inside the engine compartment on the passenger side fender apron must be disconnected and removed. The horn may be relocated or removed completely from the vehicle. The vehicle will still be equipped with the horn located inside of the fender. B. Thread the 3/8" NPT x 1/2" beaded brass hose fitting into the threaded hole on the supplied Ø3.5" x 90° plastic inlet elbow. C.
14. HOSE ATTACHMENTS/EXTENSIONS A. Connect the lower end of the supercharger oil drain hose to the previously installed fitting in the drain pan using the supplied 90° x 1/2" swivel hose end. Hose routing must be downhill with smooth bends and must not have kinks, sharp bends or uphill sections. Trim hose length if necessary. Secure the drain hose to the oil pan fitting with a #8 clamp. B. Connect the supercharger feed line to the previously installed flare fitting near the oil pressure sending unit.
15. ELECTRONIC CONTROL BOX INSTALLATION NOTE: 2004 models do not require the installation of a map controller. A. Unclip the yellow wiring harness near the steering shaft above the accelerator / brake pedals located underneath the dash on the interior of the vehicle. (See Fig. 15-a.) B. Referring to Fig. 15-a, mark the mounting hole locations, spacing should be 3 7/8". Temporarily attach the brackets to the timing controller and check for proper spacing. C.
15. ELECTRONIC CONTROL BOX INSTALLATION, cont’d. O. Connect the blue/red wire from the timing controller to the blue wire leading to the vehicle’s computer. P. Cut the green wire (20 TDC1P) on the 31P connector and install one male and one female slide connector onto each end. Q. Connect the green wire from the timing controller to the green wire leading to the engine compartment. R. Connect the green/red wire from the timing controller to the green wire leading to the vehicle’s computer. S.
ELECTRONIC CONTROL BOX INSTALLATION, cont’d. TIMING CONTROLLER 15. WHITE BLUE BLACK RED MAP CONTROLLER RED YELLOW/BLACK YELLOW GREEN YELLOW/GREEN YEL GRN TO ENGIN E COMP ARTMEN T Fig. 15-f / 2001-2003 MODELS P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
FUEL INJECTOR PLUGS TIMING CONTROLLER ELECTRONIC CONTROL BOX INSTALLATION, cont’d. (2004 Models) RED YELLOW/BLACK YELLOW GREEN YELLOW/GREEN BLUE YELLOW GREEN YEL BLACK BLACK GREEN/ RED GRN BLUE BLUE BLUE/RED GREEN/RED BLACK 32P 25P 31P YELLOW/ BLACK RED 15. TO ENGIN E COMP ARTMEN T Fig. 15-g / 2004 MODELS 35 P/N: 4HS020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 27JUL04 v2.0 S2000 (4HSv2.
16. FINAL CHECK A. Reconnect the battery. B. If your vehicle has gone over 20,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle. C. Check all fittings, nuts, bolts and clamps for tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie wraps. D.
