257d1001 installation instructions

SPRINTEX® Jeep- TJ (Non-Intercooled)
SUPERCHARGER KIT
(TO SUIT 2005- 2006 MODEL VEHICLES)
257D1001
INSTALLATION INSTRUCTIONS
Kit Serial #
_______________________________________________________________
Supercharger Serial # ________________________________________________________
Tuner (ECU reflash unit) Serial # ________________________________________________
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Table of Contents
INTELLECTUAL PROPERTY USED IN THIS PUBLICATION_______________- 4 IMPORTANT INFORMATION________________________________________- 4 SAFETY WARNING_______________________________________________- 5 CHANGES TO FACTORY SPECIFICATIONS___________________________- 6 RECORD OF AMENDMENTS_______________________________________- 8 PARTS SUPPLIED________________________________________________- 9 SUMMARISED INSTRUCTIONS FOR EXPERIENCED TECHNICIANS______- 11 DISASSEMBLY INSTRUCTIONS____________________________________- 12 PREPARATION ________________________________________________ - 13 1.
DISCONNECT BATTERY ______________________________________ - 14 -
2.
LOOSEN FUEL FILLER CAP ____________________________________ - 15 -
3.
DISCONNECT AIR TEMP SENSOR FROM THE AIR INLET PIPE _________ - 15 -
4.
REMOVE AIR INLET PIPE _____________________________________ - 15 -
5.
REMOVE THROTTLE CABLE BRACKET ____________________________ - 16 -
6.
REMOVE THROTTLE BODY AND GASKET __________________________ - 16 -
7.
DISCONNECT ENGINE BREATHER AND BRAKE BOOSTER HOSES _______ - 17 -
8.
DETACH CABLE CONDUIT FROM THE MANIFOLD ___________________ - 17 -
9.
REMOVE ENGINE ACCESSORY DRIVE BELT _______________________ - 17 -
10.
REMOVE 3 SCREWS OF THE POWER STEERING PUMP _____________ - 18 -
11.
REPLACE CRUISE CONTROL BRACKET (IF EQUIPPED) _____________ - 18 -
INSTALLATION INSTRUCTIONS
- 19 -
1.
BLANK OFF MANIFOLD VACUUM PORTS __________________________ - 20 -
2.
REPLACE FUEL INJECTORS ____________________________________ - 20 -
3.
EXTEND THE WIRES OF TPS AND IAC SENSORS (IF NECESSARY) ______ - 22 -
4.
CONNECT THE NEW T-MAP SENSOR PLUG ________________________ - 23 -
5.
FIT CABLE CONDUIT WITH SUPPLIED 2 STEEL BRACKETS____________ - 23 -
6.
REMOVE ADAPTOR WITH PLUG ON THE CABLE CONDUIT AND RELOCATE - 24 -
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
7.
FIT DISCHARGE ASSEMBLY TO THE MANIFOLD ____________________ - 25 -
8.
BEND THE REAR AIR-CONDITIONER PIPE (L/H DRIVE VEHICLES ONLY) - 26 -
9.
FIT SUPERCHARGER ASSEMBLY TO THE DISCHARGE ASSEMBLY ______ - 27 -
10.
FIT IDLER PULLEY BRACKET & POWER STEERING PUMP ___________ - 28 -
11.
FIT NEW THROTTLE CABLE BRACKET __________________________ - 28 -
12.
FIT THROTTLE BODY ______________________________________ - 29 -
13.
GLUE BAYONET ADAPTOR TO THE NEW AIR INLET PIPE ___________ - 30 -
14.
FIT NEW AIR INLET PIPE ___________________________________ - 31 -
15.
FIT THE FACTORY AIR TEMP SENSOR _________________________ - 31 -
16.
HOLD THE THROTTLE CABLE IN POSITION ____________________ - 31 -
17.
FIT BREATHER AND VACUUM LINES ___________________________ - 32 -
18.
PLUG IN ELECTRICAL COMPONENTS __________________________ - 32 -
19.
FIT NEW ACCESSORY DRIVE BELT ____________________________ - 33 -
20.
RECONNECT BATTERY _____________________________________ - 34 -
21.
REFLASHING THE ECU _____________________________________ - 35 -
22.
CHANGING TYRE SIZE, AXLE RATIO TO THE REFLASHED TUNE
PRE TEST-DRIVE INSPECTION
- 36 -
- 37 -
PRE-START INSPECTION ________________________________________ - 38 ENGINE WARM UP _____________________________________________ - 38 ROAD TEST VEHICLE ____________________________________________ - 38 -
MAINTENANCE INSTRUCTIONS
- 39 -
1.
SUPERCHARGER DRIVE BELT REPLACEMENT ______________________ - 40 -
2.
SUPERCHARGER REMOVAL ___________________________________ - 41 -
3.
SUPERCHARGER LUBRICATION SERVICE_________________________ - 41 -
4.
SUPERCHARGER SERVICE ____________________________________ - 41 -
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Intellectual Property used in this Publication
This document is copyright of Sprintex Ltd, a company incorporated in Australia. This document may not be re-sold,
copied or distributed in any way without prior written authorisation of a director of Sprintex Ltd.
Sprintex has patents for its products or are pending. Any unauthorised copying or modification of the Sprintex products
may result in legal action.
Copyrights / Trademarks:
Sprintex® is a registered trademark of Sprintex Limited, an Australian company ACN: 106 337 599 (“Sprintex”). Sprintex
has patents for its superchargers. Any unauthorised copying or modification of the system may result in legal action.
Loctite® and Grey Maxx® are registered trademarks of Henkel KGaA, a company incorporated in Germany. Other than
commercial supply arrangements, Henkel KGaA do not have any association with Sprintex.
RedLine® is a registered trademark of RedLine Synthetic Oil Corporation, a company incorporated in the United States of
America. Other than commercial supply arrangements, Redline and RedLine Synthetic Oil Corporation do not have any
association with Sprintex.
Jeep, Jeep- TJ, Jeep Wrangler are registered trademarks of Jeep Co, a company Headquartered in Detroit, MI, USA
(http://www.chryslergroupllc.com)
SAE is a trademark of SAE International (www.sae.org), a global technology information and standards setting resource
organisation for the design, manufacturing, operation, and maintenance industry.
Gates is a registered trademark of the Gates Rubber Company, a subsidiary of Tomkins Plc, incorporated in London,
United Kingdom. Other than commercial supply arrangements, Gates and Tomkins Plc do not have any association with
Sprintex Limited.
IMPORTANT INFORMATION
PRODUCT WARNING
Installation of the Sprintex Supercharger kit on your Jeep- TJ vehicle may void all or parts of Jeep Warranty. Customers
should consult their Jeep dealer for details.
Sprintex® makes no representation that installation and use of the Sprintex supercharger kit is legal for public road use
worldwide. Customers should check that installation and use of the Sprintex supercharger kit on their vehicle is legal by
contacting the relevant statutory authority in their jurisdiction prior to use on roads.
Sprintex supports safe driving. So always remember to observe all speed limits and road rules
relevant to your state, city or jurisdiction.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Provided in this installation manual are detailed instructions to the installer on how to install the Sprintex patent pending
supercharger kit to the Jeep- TJ vehicle. The instructions are aimed at being simple yet informative, and are aided with
well-presented pictures to make installations as simple, fast, and problem free as possible. Please read the entire
instruction manual prior to beginning the installation procedure. Pictures and descriptions may vary slightly
from model to model.
It is recommended that all wiring harness connectors, and vacuum hoses are labelled at the time of removal for easy and
correct refitting. Some components that are removed and are to be refitted are fragile, and should be stored safely to
prevent damage to these components.
Sprintex recommends performing the following vehicle checks prior to installing the supercharger.
1) Check that the factory fuel system is operating correctly.
2) Inspect the factory exhaust catalyst for blocks or damage
3) Check fuel quality in fuel tank ensuring that it is not stale or low octane fuel. Replace with a higher
octane, Premium Unleaded Gasoline / Fuel (Refer details on the next page) as required. It is also
recommended to replace the fuel filter if the vehicle has travelled more than 15,000km or 9000 miles.
Sprintex will not be liable for any loss, damage, payment, costs, expenses or other liability, not expressly stated in this
document. In particular, Sprintex shall not be liable to any person for any consequential, indirect or economic loss or
punitive or exemplary damages of any kind.
Sprintex reserves the right to change specifications from time to time and will not be liable to any person for doing so.
Sprintex believes that information in this document is correct at time of print. Sprintex limits its liability to the maximum
extent permissible at law with regard to the reliance which any person places on anything in this document.
THIS SPRINTEX INSTALLATION REQUIRES THAT YOUR VEHICLE BE FITTED WITH A
STANDARD JEEP-TJ FACTORY ECU AND CALIBRATION. FAILURE TO ENSURE THIS WILL
AFFECT THE PERFORMANCE AND MAY VOID YOUR WARRANTY.
SAFETY WARNING
No unauthorised service or alteration may be undertaken to the Sprintex supercharger. Installation should be carried out
in a workshop which is a safe and ventilated working environment with equipment and procedures compliant with local
authority guidelines and legal requirements. Installers should ensure adequate hearing, eye, and physical protection is
used at all times during the installation process. Installers should take reasonable precautions to avoid fatigue and closely
follow the installation instructions during every installation. Sprintex recommends installation should not be carried out
unsupervised. Sprintex, its directors, employees and agents will not accept liability for damage accident or injury resulting
from the installation process. Safety warnings are also provided throughout this document.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
CHANGES TO FACTORY SPECIFICATIONS
FUEL: MINIMUM 95 RON (91 Octane USA) PREMIUM UNLEADED GASOLINE/FUEL TO BE USED AT
ALL TIMES. NEVER ALLOW THE ENGINE TO KNOCK OR DETONATE AS SERIOUS ENGINE DAMAGE
MAY OCCUR.
REQUIRED SERVICE: (SEE MAINTENANCE SECTION OF MANUAL)
1.
INSPECT SUPERCHARGER DRIVE BELT AT EVERY ROUTINE SERVICE AND REPLACE
WHEN REQUIRED.
2.
DRAIN AND REPLACE SUPERCHARGER OIL EVERY 50,000 km or 30,000 miles. USE
REDLINE 75W90 NS GEAR OIL. FILL WITH 157 millilitres or 5.3 US fluid ounces.
CHECK OIL LEVEL WITH THE DIPSTICK PROVIDED IN THE SUPERCHARGER ASSEMBLY.
TIGHTEN DIPSTICK FULLY AND THEN CHECK THE OIL LEVEL.
3.
OIL LEVEL SHOULD BE CHECKED WITH THE DIPSTICK PERIODICALLY (Recommended
every 3000km depending on driving style).
Dipstick
Oil level mark
Note:
1. Many of the photos shown in this document are of a typical Jeep- TJ Right hand drive
vehicle and are similar to a typical Jeep- TJ Left hand drive vehicle.
2. Some of the terminology and language used in this instruction may vary from that of
the end user / installer’s expectations, as some tools and automotive components have
different common names in different geographical locations.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Tools and Consumables Required to Complete Installation

Set Metric Wrenches and Sockets

Cable Ties

Cobra clamp pliers

Metric Allen keys

Electrical Tape

Solder and Soldering Gun

Flat and Philips Screwdrivers

Pipe Sealer, sealant,
thread locker

Rubber grease or Silicone
spray

Pliers and Side Cutters

Top-up Engine Oil

Loctite 406

½” Breaker bar

Top-up coolant
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Record of Amendments
Abbreviations (Symbols)
SHCS
MAP
T-MAP
TPS
IAC
Reference
Socket Head Cap Screw
Manifold Absolute Pressure
Temperature & Manifold Absolute Pressure
Throttle Position Sensor
Idle Air Control
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
PARTS SUPPLIED
Supercharger assembly with air intake housing
Discharge assembly
Inlet pipe assembly
Throttle cable bracket assembly
Idler pulley bracket assembly & drive belt
Ancillary parts assembly
Fuel injectors
ECU Reflash unit
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
1. Sprintex® Supercharger assembly
with intake housing
5. Idler pulley bracket assembly
and drive belt
2. Discharge Assembly with nonintercooled duct
6. Fuel injectors (6x)
7. Extension wires and plugs
3. Inlet pipe assembly
8. ECU Reflash unit
4. Throttle cable bracket, Cruise
9. Ancillary parts
controller bracket (optional part)
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10. Installation Manual
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
SUMMARISED INSTRUCTIONS FOR EXPERIENCED TECHNICIANS
DISASSEMBLY
1. Disconnect battery (See details, Section-1 on Page-14)
2. Loosen fuel filler cap (See details, Section-2 on Page-15)
3. Disconnect air temp sensor from the air inlet pipe (See details, Section-3 on Page-15)
4. Remove air inlet pipe (See details, Section-4 on Page-15)
5. Remove throttle cable bracket (See details, Section-5 on Page-16)
6. Remove throttle body and gasket (See details, Section-6 on Page-16)
7. Disconnect engine breather and brake booster hoses (See details, Section-7 on Page-17)
8. Detach cable conduit bracket from the manifold (See details, Section-8 on Page-17)
9. Remove engine accessory drive belt (See details, Section-9 on Page-17)
10. Remove 3 top screws of the power steering pump (See details, Section-10 on Page-18)
11. Replace cruise control bracket, if equipped. (See details, Section-11 on Page-18)
PREPARATION AND ASSEMBLY
1. Blank off manifold vacuum ports for engine breather and brake booster. (See details, Section-1 on
Page-20)
2. Replace Fuel injectors (See details, Section-2 on Page-20)
3. Extend the wires of TPS, if necessary and connect the IAC sensor with the supplied wire with plugs.
(See details, Section-3 on Page-22)
4. Connect the new T-MAP sensor plug (See details, Section-4 on Page-23)
5. Fit cable conduit with the provided 2 steel brackets (See details, Section-5 on Page-23)
6. Remove plug on top of the cable conduit and relocate (See details, Section-6 on Page-24)
7. Fit discharge assembly to the manifold (See details, Section-7 on Page-25)
8. Bend the rear air conditioner pipe (LH drive vehicles only) to clear supercharger drive extension (See
details, Section-8 on Page-26)
9. Fit Supercharger assembly to the discharge assembly (See details, Section-9 on Page-27)
10. Fit Idler pulley bracket and power steering pump (See details, Section-10 on Page-28)
11. Fit new throttle cable bracket (See details, Section-11 on Page-28)
12. Fit throttle body (See details, Section-12 on Page-29)
13. Glue the bayonet adaptor to the new air inlet pipe (See details, Section-13 on Page-30)
14. Fit new air inlet pipe (See details, Section-14 on Page-31)
15. Fit the factory air temp sensor to the air inlet pipe (See details, Section-15 on Page-31)
16. Hold the throttle cable in position (See details, Section-16 on Page-31)
17. Fit breather and vacuum lines (See details, Section-17 on Page-32)
18. Plug in electrical components (See details, Section-18 on Page-32)
19. Fit new accessory drive belt (See details, Section-19 on Page-33)
20. Reconnect battery (See details, Section-20 on Page-34)
21. Reflash ECU (See details, Section-21 on Page-35)
22. Change tyre size, axle ratio to the reflashed tune (See details, Section-22 on Page-36)
PRE TEST-DRIVE INSPECTION
1. Pre-Start inspection.
2. Engine warm up.
3. Road test vehicle.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Jeep- TJ SUPERCHARGER KIT
(NON- INTERCOOLED)
SECTION 1
DISASSEMBLY INSTRUCTIONS
SAFETY WARNING
No unauthorised service or alteration may be undertaken to the Sprintex supercharger. Installation should be carried out
in a workshop which is a safe and ventilated working environment with equipment and procedures compliant with local
authority guidelines and legal requirements. Installers should ensure adequate hearing, eye, and physical protection is
used at all times during the installation process. Installers should take reasonable precautions to avoid fatigue and closely
follow the installation instructions during every installation. Sprintex recommends installation should not be carried out
unsupervised. Sprintex, its directors, employees and agents will not accept liability for damage accident or injury resulting
from the installation process. Safety warnings are also provided throughout this document.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
Preparation
Ensure that all components required to assemble the supercharger are available. Refer to the
Parts Supplied section provided earlier.
Ensure that all required tools are available.
Please read the entire instruction manual prior to beginning the installation procedure.
Ensure vehicle is located in a secure position with vehicle tyres secured and handbrake applied.
Sprintex® recommends to avoid injury you should use a vehicle lift or axle stands when the vehicle
is required to be lifted for access. Stands should be positioned as per the Manufacturers Owners
Handbook.
SAFETY WARNING: Use Personal Protective Equipment such as safety glasses, gloves, etc. at
all times and as necessary.
SAFETY WARNING: Allow engine to cool prior to proceeding with disassembly to prevent
scalding.
SAFETY WARNING: High pressure fuel.
Note: During disassembly and removal of components, take notes and ensure to label and
store them safely; this will help with the reassembly.
Note: Many of the photos shown in this document are of a typical Jeep- TJ right hand drive
vehicle and are similar to a typical Jeep- TJ left hand drive vehicle.
Left hand drive vehicle
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Right hand drive vehicle
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
Caution:
Connect and disconnect battery cables, jumper cables or battery charger only with the
ignition switched off
Warning:
Disconnecting the battery may erase fault codes stored in control module memory.
Using diagnostic equipment, check for fault codes before disconnecting battery cables.
If the malfunction indicator light (MIL) is illuminated.
MIL (Malfunction Indicator Lamp) light.
The MIL light can be found in one of two locations, dependant on the market the vehicle
has been built for.
1. The MIL light may be an illuminated ENGINE symbol within the speedometer cluster.
2. The MIL light may be displayed as SERVICE ENGINE SOON within the Revolution
counter.
Please refer to your OWNERS HANDBOOK to define which of the above applies to your
vehicle.
Note:
Always disconnect the negative battery terminal first. This prevents possible
shorting and potential battery damage.
1. Disconnect Battery
The Jeep- TJ battery is located in the
passenger side corner of vehicle (LH & RH
drive).
1. First disconnect negative (-) battery
cable.
2. Lift positive (+) terminal plastic cover,
then disconnect positive (+) cable.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
2. Loosen fuel filler cap
Loosen fuel filler cap to relieve pressure
in the system.
3. Disconnect air temp sensor
from the air inlet pipe
1. Disconnect wiring to factory air temp
sensor.
2. Remove factory air temp sensor and
store in a safe location.
4. Remove air inlet pipe
1. Loosen hose clamps on each end of
the pipe and remove the air inlet pipe.
2. Remove the hose clamps and store
in a safe location.
3. Mask the air box outlet with sealing
tape to avoid dirt and foreign particles
entering the assembly.
Remove hose clamps
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
5. Remove throttle cable
bracket
1. Disconnect throttle cable, optional
cables like cruise control cable, line
pressure cable (kick down cable)
from the throttle cable bracket.
2. Remove 2x M6 SHCS screws,
throttle cable bracket and store in a
safe location.
Remove throttle cable bracket
6. Remove throttle body and
gasket
1. Disconnect wiring plugs from the
throttle body.
2. Remove 4x M6 Hex head screws,
throttle body with gasket and store in
a safe location.
3. Seal the throttle hole with sealing
tape to avoid dirt and foreign particles
entering manifold.
NOTE: The gasket is re-used in the
assembly at a later stage. So check the
condition of the gasket and replace, if
necessary.
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Disconnect plugs
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
7. Disconnect engine breather
and brake booster hoses
1. Disconnect Engine breather and
brake booster hoses from the
manifold.
2. Seal the manifold holes with sealing
tape to avoid dirt and foreign particles
entering manifold.
Disconnect hoses
Remove screws
8. Detach cable conduit from
the manifold
1. Remove two M6 x 20 Hex head
screws and detach the cable conduit
from the manifold and store the
screws in a safe location.
9. Remove engine accessory
drive belt
Remove existing
drive belt
Remove the drive belt using long
series ½” breaker bar, to release the
dynamic tensioner. Store the used
belt in a safe location.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
10. Remove 3 screws of the
Power steering pump
Remove 3x M8 screws and store in a
safe location.
Remove screws
11. Replace Cruise control
bracket (if equipped)
1. Disconnect wiring plug and hose from
the cruise control unit
2. Remove 2 nuts and remove cruise
control unit, cruise control cable from
the standard factory steel bracket.
3. Remove carbon canister unit from the
standard factory steel bracket.
4. Remove 3x M6 hex head screws and
remove the factory steel bracket.
5. Fit the supplied new cruise control
bracket with the previously removed
factory screws.
6. Fit the cruise control unit, cruise
control cable and carbon canister unit
back into the new steel bracket.
7. Reconnect wiring plug and hose to
the cruise control unit
Remove standard
bracket
Fit new
bracket
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
Jeep- TJ SUPERCHARGER KIT
(NON- INTERCOOLED)
SECTION 2
INSTALLATION INSTRUCTIONS
SAFETY WARNING
No unauthorised service or alteration may be undertaken to the Sprintex supercharger. Installation should be carried out
in a workshop which is a safe and ventilated working environment with equipment and procedures compliant with local
authority guidelines and legal requirements. Installers should ensure adequate hearing, eye, and physical protection is
used at all times during the installation process. Installers should take reasonable precautions to avoid fatigue and closely
follow the installation instructions during every installation. Sprintex recommends installation should not be carried out
unsupervised. Sprintex, its directors, employees and agents will not accept liability for damage accident or injury resulting
from the installation process. Safety warnings are also provided throughout this document.
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
ASSEMBLY
1. Blank off manifold Vacuum
ports
1. Blank off vacuum ports for the engine
breather, brake booster with the
supplied 3/8” & 5/8” hoses, plugs and
clamps.
2. Use cobra clamp pliers to tighten the
smaller hose clamp.
NOTE: If not using proper pliers damage
can occur to the clamps.
WARNING: High pressure fuel
Blank off vacuum
ports
2. Replace fuel injectors
1. Disconnect fuel line fitting using fuel
line removal tool
2. Disconnect plugs from the fuel
injectors (6x)
3. Remove fuel rail mounting screws
(2x) and nuts (2x) and gently lift fuel
rail assembly out.
Disconnect fitting
Remove screws and nuts
Disconnect plugs
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
4. Remove the injector retaining clips
from fuel rail assembly.
5. Remove existing standard fuel
injectors (6x) and store in a safe
location
6. Fit new supplied fuel injectors
0280158193 (6x) and ensure
orientation. Apply a thin layer of
rubber grease to the O-Rings of
injectors for ease of fitting.
7. Fit the retaining clips back to hold the
injectors securely
8. Fit the fuel rail back with previously
removed standard screws and nuts
Remove clips
Fit fuel rail
9. Connect the plugs back into the fuel
injectors
Connect plugs
back into position
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
10. Reconnect the fuel line fitting to the
fuel rail
Reconnect fuel
line fitting
3. Extend the wires of TPS and
IAC sensors (if necessary)
1. Carefully strip back wiring harness
50mm to separate TPS and IAC
plugs.
2. Extend the wires of TPS plug with
new wires (3x) supplied.
3. Connect standard IAC plug to the
supplied plug extension.
4. Wrap the wires with the supplied split
sleeve conduit and insulation tape.
TPS before Modification
Plug & play interfaces for IAC wires
extension
TPS after Modification
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
4. Connect the new T-MAP
sensor plug
1. Cut the wires (3x) approx.50mm
away from the standard MAP sensor
plug. Remove the MAP sensor plug
and store it in a safe location.
2. Splice the wires (3x) of the standard
MAP sensor from the conduit with the
supplied wires (3x) of the new T-MAP
sensor plug. See the following
information for details.
TMAP Connection info
TMAP
1
=>
2
=>
3
=>
4
=>
New T-MAP sensor plug
TJ MAP wiring
DB/DG
No connect
YL/PK
VT/BR
On the plug tail, the colours and
connections are as below,
Pin 1 (ground) Black, connect to Jeep Blue/
Green
Pin 2 (Temp) Blue , do not connect
Pin 3 (Power) Red, connect to Jeep Yellow/
Pink
Pin 4 (MAP Signal) Yellow, connect to Jeep
Violet/Brown
5. Fit cable conduit with
supplied 2 steel brackets
1. Fit the supplied 2 steel brackets with
the cable conduit using previously
removed factory M6 Hex head
screws and nyloc nuts (supplied).
2. Do not tighten the screw fully until the
clamps are fitted to the discharge
manifold at a later stage.
Fit new brackets
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257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
6. Remove adaptor with plug
on the cable conduit and
relocate
1. Remove the adaptor with plug from
cable conduit and relocate as per the
pictures given to clear the bottom
side of the Supercharger discharge
duct. Use cable tie to hold the
adaptor with the conduit.
Remove adaptor and plug
Relocate adaptor and plug
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
7. Fit discharge assembly to
the manifold
1. Remove sealing tape from the
bottom surface of the discharge
manifold.
2. Apply rubber grease to O-Ring and fit
it into the groove.
3. Clean the mounting surfaces on the
vehicle manifold and carefully place
the discharge assembly on top of the
manifold as shown in the pictures.
4. Ensure that the assembly clears all
hoses, cables, fuel rail and wirings.
5. Tighten the assembly with the
provided SHCS M6 x 80 (torque to
11Nm)
Tighten screws
6. Mount the cable conduit with steel
brackets (2x) to the discharge
manifold and tighten using two M6 x
50 SHCS supplied (torque to 11Nm).
NOTE: Ensure that the cable
conduit clears manifold, discharge
manifold and discharge ducts.
Tighten screws
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
7. Use other two M6 x 50 SHCS
supplied and tighten the discharge
manifold (torque to 11Nm).
Tighten screws
8. Bend the rear airconditioner pipe (L/H drive
vehicles only)
1. Using rubber mallet, carefully tap the
rear air-conditioner pipe on top
allowing it to lower by minimum
12mm from the original position.
Bend the pipe down
NOTE: Ensure that air-conditioner pipe is not damaged while trying to bend and also
take special care to avoid the gas leak through the pipes and mountings.
NOTE: Ensure that the rear airconditioner pipe clears the
supercharger assembly.
Ensure clearance
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
9. Fit Supercharger assembly
to the discharge assembly
1. Remove sealing tape from the
discharge outlet of Supercharger
2. Fit the supercharger assembly (as
supplied in the kit) into the discharge
assembly and clamp them using six
M8 x 25mm SHCS screws (torque to
23Nm).
3. Locate the spigots in the
supercharger clamp plate and the
intake housing carefully to avoid
damage to the O-Ring and bypass
hose.
NOTE: If required, apply a thin layer
of rubber grease to the O-Ring and
bypass hose for smooth fitting.
Tighten screws (6x)
4. Tighten the top hose clamp for the
bypass hose.
NOTE: Ensure orientation of the hose
clamp to avoid interference with bypass
actuator lever during operation.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
5. Connect the bypass actuator hose to
the hose fitting in the intake housing.
10. Fit Idler pulley bracket &
power steering pump
1. Fit the idler bracket assembly using
two M8 x 30 SHCS and flat washers
provided.
2. Use the previously removed standard
three M8 Hex head screws to mount
the power steering pump and the
idler pulley bracket as shown in the
picture.
NOTE: Tighten all screws uniformly
(torque to 23Nm).
Tighten screws uniformly
11. Fit new throttle cable
bracket
1. Fit new throttle cable bracket
supplied, using previously removed
standard M6 Hex head screws (2x)
into the intake housing (torque to
11Nm).
2. Tighten other side of the bracket
using M6 x 25 SHCS (supplied) with
the manifold (torque to 11Nm).
Tighten using factory
M6 Hex head screws
Tighten using M6 x 25 SHCS
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
12. Fit throttle body
1. Connect TPS & IAC wiring plugs to
the throttle body.
2. Fit the standard throttle body with the
factory gasket using the previously
removed factory M6 screws (4x).
Torque to 11Nm.
3. Connect the throttle cable.
4. Connect the cruise control cable (if
equipped) and kick down cable (if
equipped).
5. Fit the factory MAP sensor back to
the throttle body. Do not connect
the wiring plug to the MAP sensor
as it is replaced by supplied new
T-MAP sensor.
Tighten using factory
M6 Hex head screws (4x)
NOTE: Check for free play of throttle
cables.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
13. Glue bayonet adaptor to
the new air inlet pipe
1. Apply Loctite 406 on the flat surface
of the bayonet adaptor and attach it
to the new air inlet pipe as shown in
the pictures. Ensure orientation.
2. For earlier model vehicles use the
supplied blanking plug (grommet)
instead of the bayonet adaptor, if
necessary.
Apply Loctite 406 on
this flat surface only
Ensure orientation
for top side
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
14. Fit new air inlet pipe
1. Connect new air inlet pipe between
throttle body and air box. Secure with
the hose clamps (3x) supplied. Use a
hose clamp from the standard factory
air inlet pipe.
NOTE: Ensure the orientation of the
air temp sensor hole as shown in the
picture.
15. Fit the factory air temp
sensor
1. Fit the factory air temp sensor to new
air inlet pipe.
2. Connect the wiring plug back to the
air temp sensor.
16. Hold the throttle cable in
position
1. Hold the throttle cable in position with
inlet pipe using a cable tie as shown
in the picture.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
17. Fit breather and vacuum
lines
1. Connect the engine breather, brake
booster hoses to the intake housing
as shown in the picture.
a. Use new supplied hose for
engine breather
b. Use the existing standard
hose for brake booster
NOTE: If necessary, use the supplied
brass T- fitting (optional part) for
additional vacuum ports. Apply Loctite
577 to threads of hose fittings and
blanking plugs upon assembly.
New breather hose
18. Plug in electrical
components
1. Connect the miscellaneous wiring
plugs.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
19. Fit new accessory drive
belt
1. Fit new accessory drive belt
6PK2530 (Gates No.K060997) as
per the belt routing diagram leaving
the idler pulley as the last component
for belt to be fitted over.
2. Use long series ½” breaker bar to
release the dynamic tensioner.
BELT ROUTING DIAGRAM (WITH A/C)
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
20. Reconnect battery
NOTE: Battery Positive terminal
should always be connected first.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
21. Reflashing the ECU
Follow the instructions given below to
reflash the factory ECU,
1. Connect the reflash unit to OBD II
connector in the R/H footwell (LH
footwell, if L/H drive)
2. Turn ignition key ‘ON’ (run only
position) as per the instruction on the
screen and press ‘Y’
3. Use ↑↓ keys for options and ‘Y’, ‘N’
keys on the reflash unit for selections
4. Wait for the instructions, then select
‘DTCS’ and scroll ↑↓ for ‘CLEAR’
option and press ‘Y’
5. Scroll ↑↓ for previous menu, then
select ‘TUNING’ and press ‘Y’
6. Scroll ↑↓ for ‘ENGINE TUNING’ and
press ‘Y’. Select ‘SUPERCHARGER’
and press ‘Y’
7. Scroll ↑↓, then select ‘INSTALL
TUNING’ and press ‘Y’.
8. Under ‘NAME THIS TUNE’ option,
leave the default name ‘STOCK’
(recommended) and press ‘Y’
9. Follow prompts. Turn ‘OFF’ & Turn
the ignition key ‘ON’ (run only
position) as per the instructions and
press ‘Y’
10. Turn ignition key ‘OFF’ and press ‘Y’
wait for the instructions
11. Turn ignition key ‘ON’ (run only
position) as per the instruction on the
screen and press ‘Y’
12. Now the reflash unit should have
successfully loaded the tune.
13. Press ‘Y’ and then disconnect the
reflash unit.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
22. Changing tyre size, axle
ratio to the reflashed tune (if
necessary). The tyre (tire)
and gear ratio is to allow
speedometer correction
only.
a. Refer ‘Hypertech” website for details
and other functions.
www.hypertech.com
NOTES:
It is critical during the programming process that the tuner doesn’t get interrupted. This
could cause the vehicle computer to “crash”, and the vehicle to be inoperable.
Interruptions can be caused by a drop in battery voltage, causing the vehicle’s computer to
cycle on and off, by accessories that communicate with the vehicle’s computer or by the
programming cable being unplugged or not securely connected.
We recommend removing fuses for any aftermarket accessories that draw voltage from the
battery.
NOTES:
1. The link for the software update to the tuner via PC web browser
http://www.webservice99.com/downloads/tunerupdateapplication/V2/Current/Update
InstallV2.exe
It should only offer the latest update to the tuner that is plugged into the USB.
2. The link for the software is subject to change. Contact Hypertech for further details.
Hypertech, Inc.
3215, Appling road
Bartlett, TN 38133-3999
Phone: 901-382-8888
Tech Support Hours: 8:00am-5:00pm CST. Mon-Fri
For tech support please have your product’s serial number available at the time of
your call.
Phone: 901-382-8888
techsupport@hypertech.com
Sprintex limited, Australia
info@sprintex.com.au
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
Jeep- TJ SUPERCHARGER KIT
(NON- INTERCOOLED)
SECTION 3
PRE TEST-DRIVE INSPECTION
Page - 37 - of 41
Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
TESTING PROCEDURES
Pre-Start Inspection
Ensure coolant is at correct level.
Ensure engine oil is at correct level.
Ensure vehicle has fresh 95 RON (91 Octane USA) Premium Unleaded fuel.
Ensure the belt is aligned.
Ensure the air filter is clean.
Check & replace spark plugs, if necessary. Set gap to factory spec. 0.035”.
SAFETY WARNING: Ensure adequate steps are taken to prevent injury, spillage or fire
should any of the required installation steps not have been carried out to specification.
Engine Warm Up
Start engine and allow to run, until engine reaches normal operating temperature.
Check for oil leaks.
Road Test Vehicle
Road test vehicle.
Recheck all joints and connections for leaks –rectify as needed.
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Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
Jeep- TJ SUPERCHARGER KIT
(NON- INTERCOOLED)
SECTION 4
MAINTENANCE INSTRUCTIONS
Page - 39 - of 41
Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
MAINTENANCE PROCEDURES
1. Supercharger Drive Belt Replacement
It is recommended that the supercharger drive belt be checked at every regular service
and be replaced at 50,000 km (30,000 miles) or 2 years, whichever occurs first.
Use long series ½” breaker bar to release the
dynamic tensioner and remove the belt.
Page - 40 - of 41
Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit
JEEP- TJ (NON- INTERCOOLED)
SUPERCHARGER KIT
MAINTENANCE PROCEDURES
2. Supercharger Removal
Refer to section 1
DISASSEMBLY INTRUCTIONS, Pages 12 to 18.
Dipstick
& Fill
3. Supercharger Lubrication
Service
1. Drain and replace oil every 50,000 km or
30,000 miles
2. Place a suitable funnel under drain plug at
front side bottom of Supercharger extension
housing. Remove dip stick on top centre of
cover to allow complete draining. Remove
bottom plug and drain.
Drain
3. Fit the bottom drain plug back. Use Loctite
577 to threads upon assembly.
4. Use Redline 75W90 NS gear oil. Fill with
157 millilitres or 5.31 US fluid ounces.
5. Fit the dip stick back on top of the
supercharger extension housing (torque to
10Nm).
NOTES:
Check oil level with the dipstick provided
in the Supercharger assembly. Tighten
dipstick fully and then check the oil level.
Oil level should be checked with the
dipstick periodically (Recommended every
3000km depending on driving style).
Oil level mark
4. Spark plugs
Replace spark plugs every 50,000 km.
Page - 41 - of 41
Copyright ©
257D1001 Installation Instructions, Rev 1.03
Jeep- TJ (Non-intercooled) Supercharger Kit