Installation Manual
Contents
1. 34 Limited Warranty 36 Procharger Extended 37 NOTOS 38 Wh 206 Corvette H O System Installation Guide PF Introduction IMPORTANT TUNING NOTE For complete system installations please review the tuning section of this manual to ensure you have the proper components to complete the installation Tuning for certain model years of the Corvette Z06 is a multi step process that should be initialized before the installation has begun If there are any questions about this process or any other step during your installation please call ProCharger Technical Service at 913 338 2886 d XY CI pm p a AGF 2 6 A SUPERCHARGER SYSTEMS 206 Corvette H O System Installation Guide 1 4 Getting Started GETTING STARTED Disconnect the negative battery cable Russer RETAINING MAF MAF Connector from the battery The battery is located in CES Fa the rear hatch A Va ui 1 aig i amp ey ET ES Am P oon Remove the driver s and passenger s side plastic engine covers by pulling firmly up ward Set the covers aside Remove the wiring connector from the Mass Airflow Meter MAF Disconnect the PCV hose from the bellows connector2. Dm ACIS 8 20667 8 gs LAAOV aa O T ACIS SSVd 44100 ACIS 55 4 48 44100 UH Vds TIO ACIS SL8 qOWVHOSIG OL YOLOANNOOD z 1 OL OL Z I T IAL 9 1 p ge D C O 42 O J Y 4 Y gt Y M p 4 42 gt UO SO O N SO CN v 2 3 Q Note To ease installation leave all hose clamps loose until all of the tubes have been installed This will allow you to adjust the tubes as needed for best possible fit Trim and re install hoses as needed Intercooler and Tubing Installation and Tubing Installation m Install the intercooler in front of the con denser using the supplied 3 8 hardware Install the 3 rubber elbow to the inter cooler inlet on the passenger s side Se cure the connection with the supplied 52 hose clamp Insert the 3 metal 90 tube into the 3 rubber 90 elbow Secure the connection with a 52 hose clamp Install the 3 x 4 rubber connector to the supercharger discharge Insert the 3 surge tube Secure connections using the supplied 52 hose clamps Install the ProFlow anti surge val
3. Loosen the hose clamp that attaches the bellows to the throttle body Remove the factory air bridge and bellows from the vehicle using a firm upward motion to pull it off of the throttle body and free of the rubber retention grommets Remove the plastic radiator hold down by removing the two bolts on each side using a 10mm socket RADIATOR HOLD DOWN 2006 2011 C6 206 Corvette System Installation Guide Getting Started Place a 15mm wrench on the center bolt of the factory rotary spring tensioner and rotate the tensioner clockwise until it bottoms out Hold the tensioner in place and slide the factory serpentine drive belt off of the water pump pulley making sure not to pinch your fingers Once the belt is free slowly return the factory tensioner to its rest position Remove the belt from the vehicle Remove the factory tensioner from the vehicle using a 15mm socket to remove the two bolts that hold it to the water pump Raise the front of the vehicle using jack stands or a vehicle lift This will allow you access to the factory harmonic balancer from underneath the vehicle 9 Remove both front wheels Remove the two bolts that attach the trac tion control module bracket to the alumi num front cross member using a 13mm socket or wrench 2006 2011 206 Corvette System Installation Guide FACTORY RIB SERPENTINE Drive BELT PASSENGER S SIDE FACTORY ROTARY CYLINDER HEAD
4. 1 to prepare your vehicle in order to load the new tune From the opening screen on the handheld select a Program Vehicle b Custom Tune c Select the new tune file you loaded to the handheld d Follow onscreen instructions 9 Your ProCharger tune is now installed v in the vehicle Tech Tip Tuning your vehicle correctly is extremely important and is necessary for proper vehicle operation and safety If you have any questions regarding tuning your vehicle or with any of the steps outlined here call a technical service representative at 913 338 2886 SupplementalNotes Notes SUPPLEMENTAL 5 Tuning OFF ROAD 5 Proper air fuel ratio is the main tuning issue If using a stock ignition system the plug gap of your system The ProCharger is nothing may be reduced to approximately 0 035 to more than an efficient air pump used to avoid blowing out the flame or spark The substantially increase the volumetric efficiency use of non platinum plugs one heat range of your engine Intercooling is utilized to cooler than stock is also helpful remove the heat caused by compressing the air Maintaining the proper air fuel ratio is extremely important In order to extract as much power as possible from this increased air flow the proper amount of fuel must be added A lean condition will cause the car to detonate which under higher boost conditions can cause engine damage run hot or br
5. 5 Remove the two bolts that attach the pow er steering cooler to the cross member using a 10mm socket Remove the oil lines from the cooler These can be plugged or joined together temporarily A new cooler will be added later 6 Using a pry bar and carefully prying up wards free the steering rack and bushings from the front cross member Be careful not to damage the rack or any of the lines Once the rack has been lifted free of the cross member lift the rack up and towards the driver s side of the vehicle A X J SuPPORT RACK 7 Using a jack stand to support the alumi num K member loosen BUT DO NOT REMOVE the four K member attachment nuts This will lower the engine slightly List ano E NU allowing access to the harmonic balancer d EDI ESSO bolt D M M Pl cad LAS N RACK RELOCATED FOR BALANCER BOLT REMOVAL ws gt 5 SIDE FRONT K MEMBER 2006 2011 206 Corvette System Installation Guide Harmonic Balancer Remove the harmonic dampener center bolt using a 24mm socket and an impact wrench DO NOT REMOVE THE HAR MONIC BALANCER It may be necessary to heat the head of the bolt with a small propane torch to allow the bolt to break loose 9 Install the supplied harmonic balancer pin ning tool drill jig using the supplied M16 hex bolt as shown Tighten the bolt to hold the tool in place and prevent spin ni
6. 0 j ENGINE COOLER DRIVER S SIDE ENGINE COOLER TUBING CLIPS 2006 2011 206 Corvette System Installation Guide Radiator Oil Cooler Temporarily remove the engine oil cooler from the car 5 Remove the baffle shroud from the car and set aside There are 4 clips that hold this shroud in place 6 Remove the factory front air dam retain the hardware as it will be reused 7 Re attach the lines to the engine oil cooler using the clips previously removed 8 Drain your engine coolant into a clean con tainer Turn the drain cock at the bottom passenger s side of the radiator approxi mately 1 2 turn The coolant will drain out of the nipple Removing the reservoir cap may speed this process but leaving the cap on will help to siphon all the fluid from the reservoir per the GM Service Manual Once the coolant stops draining return the drain cock to its closed position You will now need to modify the lower radia tor hose to allow the radiator cradle and radiator to be lowered Cut your factory hose and insert the provided 1 5 tube us ing the supplied 20 clamps 2 lt 5 wN LOWER RADIATOR Hose 2006 2011 C6 206 Corvette System Installation Guide ALTE Disconnect and separate the wiring harnesses that are routed through each side of the radiator cradle Using a 10mm socke
7. ATI s limited warranty does not apply to your product THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHERS ORAL OR WRITTEN EXPRESS OR IMPLIED THE DURATION OF ANY AND ALL WARRANTIES ON THE PRODUCTS DISCUSSED ARE LIMITED TO THE PERIOD IDENTIFIED ABOVE ATI IS NOT RESPONSIBLE IN ANY EVENT FOR DIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES No ATI dealer agent or employee is authorized to make any modification extension or addition to this warranty To obtain service under this warranty you must do the following during the warranty period Phone ATI 913 338 2886 and provide us with the following information ProCharger supercharger serial number Vehicle year make model engine modifications and other modifications Description of perceived issue If a solution to your issue can not be found after the above phone consultation you will be assigned a return authorization number RMA You must then properly package and ship your product at your expense to the ATI factory The product should be carefully packaged in a rugged box Include the following information inside the box with your product Copy of your original invoice or receipt Name address and daytime telephone number Return authorization number RMA Vehicle year make model engine modifications and other modifications Description of perceived issue Clearly mark the warranty claim number on
8. Diameter Blower Pulley Diameter step up Ratio Max engine RPM Blower RPM ___ ____ Supercharger 15 15 1 15 2 Disc Max Impeller Speed 62 000 65 000 60 000 62 000 4 10 b 34 2006 2011 206 Corvette System Installation Guide Operation amp Maintenance amp Maintenance ProCharger Oil Level The ProCharger superchargers oil level must be checked periodically to ensure the proper lubrication The dipstick can be loosened using a flat blade screwdriver or a coin When installed the oil level should remain between the minimum MIN and maximum MAX indicators at all times than the maximum level on the dipstick can lead to bearing and seal damage The supercharger is a sealed unit and should not normally require the addition of oil between service intervals If excessive usage is noted the unit should be sent to ATI for inspection and repair The dipstick fitting should be firmly tightened after changing or checking the oil level q Warning Filling the ProCharger higher Oil Change Intervals The first oil change should be performed at 500 miles and at 6 000 mile intervals thereafter Drain oil by removing the drain plug Clean drain plug after every oil change The drain plug should be firmly tightened after changing the oil SEALED PLUG HEAD MAGNETIC DRAIN PLUG HEX HEAD SEALED PLUG SOCKET HEAD DIPSTICK FLAT HEAD 2006 2011
9. frequently 2006 2011 206 Corvette System Installation Guide b 38 2006 2011 206 Corvette System Installation Guide cut along the dotted line cut along the dotted line ProCharger Extended Coverage Program Registration Form Return this completed form and a 49 check within 30 days of original purchase Name Address City State Zip Daytime phone Evening phone E mail L118 24 L145 54 Income 915 000 29 000 1 45 000 69 000 125 34 55 and up 1 30 000 44 000 1 70 000 and up Age 35 44 What magazines do you read Car amp Driver Car Craft Chevy High Performance Four Wheel and Off Road Hot Rod Motor Trend Muscle Mustangs and Fast Fords GM High Tech Performance 5 0 Mustang Super Street Mustang Monthly Truck Trends Popular Hot Rodding Road amp Track Super Chevy Truckin Street Truck L E1 L1 P1 E1 L1 P1 EI DI EI EI DI DI E C Who installed your ProCharger system Have you own a forced induction system previously If yes Supercharger Brand s Turbocharger Brand s O Self Date of Purchase Purchased From ProCharger Serial Vehicle Year Vehicle Make Vehicle Model Please rank in order of importance starting with 1 being most important Which information sources most influenced your decision to purchase a ProCharger system ___ Magazine advertising ___ Dealer recommendation ___ ProCharg
10. pump by tightening the 6 bolts with a 10mm socket If you removed the throttle body replace it at this time as well If you have not already done so refill the cooling system with acceptable Dexcool coolant at this time as well e M WarER Pump Botts 5 SIDE 2006 2011 206 Corvette System Installation Guide Installation Installation All Model Years 8 Insert one 3 8 16 X 6 1 2 longest HHCS with flat washer into the bottom outer hole of the sub bracket Then insert one 3 8 16 X 6 medium length HHCS with flat washer into the top outer hole of the sub bracket Slide the supplied 3 435 billet spacer block ABO29A 008 over the bolts 9 Attach the billet main bracket ABO29A 005 to the ProCharger using the supplied 5 16 18 X 3 4 low head socket cap screws LHSCS and the 2 3 8 16 X 1 LHSCS as shown Be sure to insert the 3 8 16 X 5 1 2 HHCS through the slot in the bracket The slot will allow the bolt to act as a stud enabling the brass lock nut to be tightened when the brackets are as sembled 10 Slide the supplied 3 435 aluminum tube spacer part SP87 406 3 435 over the 3 8 bolt in the main bracket A 8 16 X 52 7753 8 18 X 6 AND SPACER PLACEMENT 3 8 16 X 6 1 2 HHCS LONGEST W usi 6X6 HHCS MEDIUM 6 X 5 1 2 5 SHORTEST Bott LENGTHS Main Bracket m i BOLTING S
11. the top and one side of the box in characters at least 2 tall Properly package the product and ship it prepaid and insured for the retail value of the component s being returned to the following address Accessible Technologies 14801 West 114th Terrace Lenexa Kansas 66215 b 36 2006 2011 206 Corvette System Installation Guide ProCharger Extended Coverage Extended Coverage PROCHARGER EXTENDED COVERAGE The ProCharger Extended Coverage Program extends the ProCharger warranty coverage for an additional twenty four 24 months for a total of thirty six 36 months or three years of coverage This extended coverage applies to parts for the ProCharger supercharger head unit only and does not include other system components With your extended coverage registration you will receive two 2 additional boxes of ProCharger Supercharger oil Under the extended coverage program Accessible Technologies Inc ATI will repair or replace any component within the supercharger head unit which is found to be defective Only the supercharger head unit itself is included in the extended coverage Service under the extended coverage program is obtained through the same process as described in the Limited Warranty Race kits are not eligible for the ProCharger Extended Coverage Plan To qualify for the ProCharger Extended Coverage Only the original owner of the ProCharger supercharger is eligible Completion
12. wide open throttle road test Cockpit or hood mounted gauges are preferable In order to obtain usable readings the gauges should measure pressure at the intake manifold and fuel rail IF VEHICLE DOES NOT MAINTAIN PROPER FUEL PRESSURE DECREASE THROTTLE APPLICATION IMMEDIATELY In some cases extra vehicle modifications can strain the stock fuel pump If your vehicle has difficulty retaining adequate fuel pressure contact ATI ProCharger about the availability of an upgraded fuel system The engine on which the ProCharger is to be installed should retain the factory compression ratio If it has been modified in any way please consult ProCharger staff before proceeding with the installation This supercharger system is intended for use on STOCK strong well maintained engines transmissions Installation on a worn or troublesome powertrain should be reconsidered ATI PROCHARGER WILL NOT BE HELD RESPONSIBLE FOR DAMAGE TO A VEHICLE S POWERTRAIN ATI ProCharger is not responsible for ECM tuning programming on non stock vehicles ATI PROCHARGER recommends verifying that your vehicle has current ECM updates from the vehicle manufacturer before installation For best performance and reliability always use premium grade fuel 91 octane or higher and listen closely for signs of detonation which might sound like ball bearings rolling around in a tin can IF DETONATION SHOULD OCCUR OR IF YOU ARE UNSURE WHETHER WHAT YOU RE HEARING IS DETONATION DECRE
13. 2006 2011 206 Corvette High Output Intercooled System Installation Guide 6 iC ADU Du je esiti dels The Intercooled Supercharging Experts 2007 Accessible Technologies Inc Accessible Technologies Inc 14801 W 114th Terrace enexa KS 66215 Phone 913 338 2886 913 338 2879 techserv procharger com All rights reserved Accessible Technologies Inc hereby grants permission to use and reproduce this document for personal use provided that all copyright information be retained Reproduction of this document for unauthorized commercial use is strictly prohibited Information in this document is subject to change without notice ProCharger is a registered trademark and The Intercooled Supercharging Experts and Designed to Blow Away the Competition are trademarks of Accessible Technologies Inc and may not be used without express permission 18 8 Stainless Steel Grade 5 Thread Size Torque Torque Torque 9 9 0 a 9 9 Your supercharged Corvette must always be run on 91 octane or higher gas The best way to insure this is to run the tank near empty below 1 4 and fill with 91 octane for several tanks prior to installing the supercharger If this is not possible a single fill up with higher octane fuel will help Example 1 4 tank 87 octane 3 4 tank 93 octane 91 5 octane o lt Revised 5 10 Part Num
14. 206 Corvette System Installation Guide General When removing the dipstick be sure to retain the nylon washer A spare nylon washer and o ring is included Use only the ATI supplied nylon washer and o ring when servicing the oil dipstick and drain plug A discoloration of the oil and residue on the drain plug may occur during the initial oil changes This is normal and will gradually decrease For the proper positioning of the ProCharger supercharger the serial tag should be pointing upwards Installing the ProCharger supercharger in another position will cause inadequate oiling and supercharger failure If you have any questions about the maintenance of your supercharger contact ATI Warning The 15 1 or D1SC e supercharger contains no oil from the factory The unit must be filled prior to use Use only ATI supplied oil in your ProCharger The ATI oil has been specially formulated for the bearings in the ProCharger and use of oil other than that supplied by ATI will void your warranty DU OVERFILL C PROCHARGER USE OIL ONLY N N N N AH N Pd M x _ Limited Warranty LIMITED WARRANTY Accessible Technologies Inc provides a limited twelve 12 month warranty on the ProCharger supercharger against defects in materials and workmanship unless otherwise specified This limited warranty starts on the date of original purchase
15. 25 X 120mm long HHCS and two 3 875 long spacers T NTC vt B 0 f wmm 1 E ox mes iiU E og iip M 5 MUI S SIDE ENGINE OL COOLER BRACKET Zip tie the ambient air temperature sensor to the new cradle AA MMC t t MORAL LAU dU MULA UV Y AH EN mmm DU ULL ADD a m TW m iii DRIVER S SEES ENGINE OIL COOLER BRACKET STITT TN NNN a E YT TEMPERATURE SENSOR RELOCATION 2006 2011 206 Corvette System Installation Guide Coolant Hose Modification Hose Modification CooLANT Hose MobpiricATION 1 Locate the coolant hose that connects the coolant overflow reservoir to the engine block as shown This is the hose that will be relocated Cut the factory Tee after each connection as shown Remove the factory hose section between the heater core and the cut made at the Tee Install the supplied 3 4 hose mender and 3 4 hose section One end of the 3 4 hose will connect to the hose mender and the other end will connect to the heater core Splice the supplied 3 4 Tee into the now installed 3 4 hose Con nect the factory hose from the block to the open end of the Tee Secure all connec tions with the supplied 20 hose clamps A i To COO I
16. ASCIA Remove the driver s side inner splash panel push pins as shown Remove the splash panel and retain for later use Remove the passenger s side inner splash panel push pins Remove and discard the splash panel your kit provides a modified passenger s side splash panel Using a 10mm socket remove the two nuts which retain the fascia to the front fenders on both sides of the vehicle 4 Unplug both turn signals and fog lights Remove all the air dam screws from the underside of the front fascia Remove the four 6mm screws located at the front of the engine bay which retain the fascia to the body Carefully unclip the fascia from the body and set aside Use a rag in between the fascia and the center of the hood to pre vent scratching REMOVE DRIVER S INNER SPLASH PANEL REMOVAL STANDARD C6 SHOWN TURN SIGNAL E PASSENGER S SIDE FRONT FASCIA PASSENGER S FASCIA REMOVAL FRONT Fascia VIEWED FROM UNDERNEATH 2006 2011 206 Corvette System Installation Guide ALT Cooler RADIATOR OIL COOLER Unclip the ambient air temperature sensor from it s stock location Remove the plastic bracket holding the sensor Remove the two bolts that hold the engine oil cooler to the shroud on each side Remove the two clips that hold the tubing MAA 4 to the engine oil cooler m AMBIENT AIR TEMP SENSOR REMOVAL vL cag P 4 REY ove Botts a ef
17. ASE THROTTLE APPLICATION IMMEDIATELY and please consult ATI ProCharger staff Detonation should not be an issue with a properly installed intercooled supercharger system though OEM factory shipped engine and parts inconsistencies are possible on any vehicle 2006 2011 206 Corvette System Installation Guide ay Introduction TABLE OF CONTENTS CU T T T TD TS i Table of CON ODIS _______________ ii Gening SU ai see ogc sp ews 2 _ _ _______________ 4 8 Radiator Oll COG i _ _ _______ ____ 9 Coolant HOSES MoOSBITICSEIDEL 13 PROC OM EET 14 Intercooler and Tubing Installation ccccsccsscssccescsccescnsccsscesccsscsccsscscosscessosscessosceesseees 20 Fuel Injector Replacement ccsscssccssccsscssccsscnsccsscescosccescesccescesccsssscoescscosscessosscessosseesseess 25 Vacuum Manifold INSEAN ATOM 27 ll RN T 28 imet 30 Supplemental NOTOS E E tes ad abe nV x NIMM PME 32 Installation Review and Safety Check 33 Operation
18. E NGOGLANTNEOS TO BLoC OIR TM 3 REMOVE HOSB AND 2 A NU hi 7 BELOW RE Hose MODIFICATION Fadrory Hose 4 TO BLOCK ND 3 Whip e v 4 4 gt P ZA 3 3 7 2 5 i r A M 4 5 Dg 4 a 4 ww Eas New 3 4 Hose SECTION New VIEWED FROM PASSENGER SIDE 2006 2011 206 Corvette System Installation Guide Cy ProCharger Installation Installation PROCHARGER INSTALLATION Warning Never strike the ProCharger pulley with a hammer or other tool under any circumstance Evidence of such force will void the warranty as serious damage to the precision bearings within the ProCharger could occur If not already completed remove the air solenoid from the passenger s side cylinder head and unclip the bracket from the air solenoid Tech Tip A portion of the exhaust manifold gasket may bent over the edge of the passenger s side cylinder head If this is present it will need to be broken off to insure proper bracket to cylinder head mounting 2006 2008 Model Years 2 Insert the 10mm x 1 5 x 50mm SHCS socket head cap screw through the bottom hole of the sub bracket ABO29A 010 and then thread it into the cylinder head M10 1 5 x 60MM HHC
19. Guide Final Assembly Assembly FINAL ASSEMBLY 1 Remove the short factory vent hose that runs from the crankcase valley port near the underside of the throttle body back to the intake manifold Install a 6 piece of 3 8 hose to this port and insert the supplied 3 8 check valve Be certain the arrow on the check valve points towards the intake manifold connection preventing boost from entering the valve cover On the other end of the check valve install another 6 piece of 3 8 hose then route and secure that back to the intake manifold port Refer to the illustration for routing of the PCV lines 2 Remove the factory vent hose from the dry sump tank The line you are removing is the one that is towards the front of the vehicle and is the line that previously ran to the air inlet bellows Next attach the remaining 3 8 rubber hose to the front port of the dry sump tank HOSE ATTACHED TO DRY SUMP TANK T 2006 2011 C6 206 Corvette H O System Installation Guide Final Assembly Assembly v 2006 2011 206 Corvette System Installation Guide Connect the supplied 3 3 4 rubber hose to the ProCharger inlet and secure with a 60 hose clamp Drill a 3 8 hole in the bottom of the air filter and install the supplied 3 8 plastic 90 barb fitting Connect the crankcase vent hose to the end of the air filter Install the plastic air bridge and air filter as shown Secure the connectio
20. KS 66215 Phone 913 338 2886 Fax 913 338 2879 techserv procharger com Accessible Technologies Inc 2007 ATI All Rights Reserved Part Number PMGP1A 002 Rev G
21. NSIONER BACK n0 045 _TENSIONER 2 rotating the tensioner nut counter clock Eu 5 wise The belt will be properly tensioned Norcues VEN when the notch in the tensioner back is aligned with the second notch the ten sioner front Y zm S 7 14 Finally secure the tensioner arm tight ening the 1 2 bolt in the back of the sub bracket Be sure to tighten the 3 8 hex head which threads into the back of the tensioner arm Tech Tip Tighten the belt after the first 100 miles have been run on the belt New belts stretch and need to be adjusted periodically i x m n ve n M SSS At this time fill your ProCharger with the supplied oil 6 ounces for a P1SC 1 or D1SC 16 Install the supplied power steering cooler to the lower portion of the fan cage using zip ties then route and attach the hoses to this cooler POWER STEERING COOLER MOUNTING amp PLUMBING 2006 2011 206 Corvette System Installation Guide 4 Em ES 4 N E H Ke im O O U Tw INTERCOOLER AND TUBING INSTALLATION JILVIN3HOG 3310O02331N SCeIHDNHSS Vd TYLA 006 MOTH 506 t 481 30805 Bore HSOH HOUNDS C TI T MO TOUd E LHMOVAE
22. RGER INSTALLATION 2006 2011 206 Corvette System Installation Guide Operation amp Maintenance OPERATION amp MAINTENANCE Cold Starting Never race your engine and ProCharger when your engine is cold Allow the water temperature to climb into operating range for several minutes before driving above 2 500 rom to ensure adequate oil lubrication Fuel Quality For best performance and reliability always use premium grade fuel 91 octane or higher Always listen for signs of detonation after refueling and after replacement or modification of any fuel system components Back off throttle should detonation occur With a properly installed ProCharger intercooled supercharger system detonation should not be an issue Ignition System Maintenance If your spark plugs are more than a year old or have more than 10 000 miles logged you should consider changing them before driving your vehicle under load Additionally spark plug wires should be changed if visibly damaged or whenever resistance exceeds factory specifications Air Filter Maintenance Your air filters should be cleaned periodically potentially as often as every 10 000 miles or 6 months even though a service interval of 50 000 100 000 miles is quoted by the manufacturer under normal driving conditions A clogged air filter will result in decreased boost levels and vehicle performance K amp N air filter cleaner is recommended and be sure to r
23. S M10 1 5 x 50 M10 1 5 x 60mm HHCS SHCS First SUB BRACKET Borr INSTALL IRE 4 5 IF L Toe NO B REMOVAL E EXHAUST GASKET TA 2006 2011 C6 206 Corvette System Installation Guide Installation Installation 3 Insert the two supplied 10mm x 1 5 x 60mm hex head bolts with flat washers into the sub bracket then thread them into the passenger s side cylinder head M10 1 5 x 60MM Hex HEAD AND FLat WASHER SuB BRACKET MOUNTING 2006 2011 206 Corvette System Installation Guide 4 ProCharger Installation 8 Installation 2009 Model Years Note If installing this kit onto a 2009 Corvette Z06 the water pump must be removed in order to mount the sub bracket If installing on any other model year proceed to step 8 For ease of installation remove the throt tle body by removing the 4 bolts with a 10mm socket Unplug the harness on the passenger s side of the throttle body pressing together and sliding it off Remove the 3 passenger s side water pump bolts with a 10mm socket Remove the 3 driver s side water pump bolts with a 10mm socket Pull the water pump away from the front cover for clearance for the Procharger mounting bolts on the passenger s side cylinder head Tech Tip For 2009 206 installations place the new water pump gaskets onto the water pump and re install the
24. SPRING TENSIONER LR Y ws Ansa att A NW NW petis XE 7h 7 M 1 STOCK ROTARY SPRING TENSIONER VIEWED FROM FRONT PASSENGER S SIDE TRACTION CONTROL Borts TRACTIONSCONTROL MopuLe BRACKET TRACTION CONTROL MODULE STANDARD C6 SHOWN Harmonic Balancer HARMONIC BALANCER Remove the bolts which attach the sway Xx d au gt Sway BAR bar to the aluminum K member Hold the stud with a Torx bit T40 and remove the sway bar end links from the lower control arms and set sway bar aside Mouninc Botts 2 Remove the two bolts that attach the steering rack to the front cross member using an 18mm socket on the front and an 18mm wrench on the rear nut Note clips and their orientation for re installation Lift the traction control module up and to the driver s side and secure with a wire tie to keep it out of the way N DRIVER s SipE SWAY BAR MOUNT 3 Rotate the steering wheel hard left ex tending the tie rod ends fully toward the driver s side 4 Disconnect the tie rod ends from the REMOVE steering arms gt oe 2 RACTION CONTROL BRACK Rack Mount Driver s SIDE MOUNT PASSENGER S SIDE RAC v 2006 2011 C6 206 Corvette System Installation Guide Harmonic Balancer Balancer
25. UPERCHARGER TO THE MAIN BRACKET 2006 2011 206 Corvette System Installation Guide ProCharger Installation 8 Installation 11 Install the supercharger main bracket with gt gt o 14 supercharger attached to the sub bracket n as shown using the supplied 3 8 brass 4j 2 lock nuts and flat washers It may be nec essary to slightly rotate the volute of the supercharger for proper fit If you choose to rotate the volute make sure all fasten ers are retightened so you do not damage the supercharger You may also need to slightly bend the cooling lines out of the way to make room for the supercharger Ld and tubing PROCHARGER INSTALLED STANDARD C SHOWN Route the supplied 6 rib belt using the schematic below Tech Tip When installing the main bracket assembly note the orientation of the 2 hole block spacer The spacer has different distances from the thru holes to the ends of the spacer The end with the BEND LINES 45 longer distance must face upwards in the NECESSARY vehicle See image below LINES CORVETTE BELT ROUTING PROCHARGER THIS END UP ALTERNATOR ATI TENSIONER POWER STEERING PUMP FACTORY IDLER 2 Hole Block Spacer Installation Orientation CRANK Yn 2006 2011 206 Corvette System Installation Guide ProCharger Installation Installation 13 Using 1 2 wrench tension the belt by TE
26. ber PMGP1A 002 Rev G Printed in the USA PF Introduction INTRODUCTION Congratulations on purchasing your ProCharger 206 Corvette High Output Intercooled System For best results we recommend reviewing the installation instructions beforehand and following the installation instructions closely and in sequence A detailed packing list has been provided to assist you in identifying the components of your ProCharger system If you have any questions regarding any aspect of this installation call us at 913 338 3086 Warning Failure to comply with e instructions in this manual could result in personal injury property damage and or voiding your warranty Required Tools and Supplies e 3 8 amp 1 2 Socket Sets standard amp metric e 1 2 Impact Gun amp Sockets e C Clip Pliers 1 2 Breaker Bar amp 4 Extention e 20 Torx Wrench Open End Wrench Set standard amp metric e Dex Cool Coolant 3 8 Hex Bit Set allen head e Flat amp Phillips Screwdrivers e Plier Set Propane Torch e 1 2 Torque Wrench e Adjustible Wrench e Utility Knife e Drill You should also have the following gauges available to properly check the finished installation and monitor your vehicle s performance especially for testing e Manifold Boost Pressure Gauge Fuel Pressure Gauge e Wide Band Oxygen Sensor and Gauge Gauges should be of a type that can be read from the cockpit while performing a
27. e elasticity over time and could cause a fuel leak and or potential fire 2006 2011 206 Corvette System Installation Guide Fuel Injector Replacement Injector Replacement 10 Install the retainer clips that were removed in step 8 onto the new injectors Push each injector into the fuel rail injector socket with the electrical connector facing outward The retainer clip should lock onto a flange on the fuel rail tQ ED lt 11 Install the fuel rail assembly onto the intake manifold making sure that the injectors are rotated to line up with their corresponding electrical connectors Using Loctite 272 high temperature Fue RAIL FUEL INJECTOR thread locker or equivalent install the fuel rail bolts and the supplied 7 spacers and torque to 90 in lbs FUEL RAIL SUPPLY LINE INJECTOR WIRING CONNECTOR Connect each injector to the factory E harness p Replace the gas cap and negative battery cable Re install the fuel supply hose by pressing the fitting onto the fuel rail fitting until a snap is heard 14 Check the new injectors for leaks by turning the ignition to the on position for 2 seconds but do not start the engine Turn the ignition off for 10 seconds Turn the ignition to the on position Check for fuel leaks at both ends of each injector and at the fuel supply hose fittings f i 5 Uy FUEL RAIL AND INJECTORS Proceed to the next section i
28. e oil the cleaned filter before re installing Always operate your vehicle with an air filter failure to do so may result in damage to your ProCharger and or personal injury Belt Replacement The belt which turns your ProCharger will stretch after initial run in and should be re tightened after approximately the first hundred miles After possibly one more tightening of the belt with the tensioner further stretching should not occur Tighten the belt sufficiently to avoid slippage but do not overtighten as this could cause damage to the ProCharger precision bearings When removing belts ensure that they are re installed to turn in the same direction as before Should you reuse a thrown belt and find that it needs frequent re tightening the belt is damaged and should be replaced Belts can be purchased from ATI or from your local parts store Gates Micro V belts are recommended these belts are available at CarQuest amp NAPA and other auto parts stores Your nearest CarOuest store can be found by dialing 800 492 7278 the nearest store at 800 538 6272 Impeller Speed Maximum impeller speed should not exceed the redline of the blower see table below or contact ATI Maximum impeller speed crankshaft pulley diameter N1 divided by supercharger pulley diameter N2 multiplied by the step up gear ratio of the blower multiplied by maximum engine rpm Impeller RPM N1 N2 X Step up Ratio X Engine RPM Crank Pulley
29. eak up To get the most out of your system it will prove beneficial to utilize an air fuel ratio meter Wide band units are most ideal when tuning an engine for maximum performance Usage of a wide band sensor will provide data that will allow you to achieve optimum performance throughout your engine s operating range It is highly recommended that you monitor the air fuel ratio during operation and you should see proper fuel ratios throughout the RPM range Engine operating temperature for 157 vette has been designed by the factory to be between 204 and 235 F The factory has designed the cooling fan to come on at 204 F 1096 duty cycle and reaches 9096 duty cycle high speed when the coolant temperature reaches 235 F to maintain this temperature range The factory thermostat is 187 F unit and will remain closed below that temperature In other words below 187 F no coolant will circulate between the radiator and the water pump The vehicle PCM will illuminate the COOLANT OVER TEMP indicator if the engine temperature exceeds 256 F 2006 2011 206 Corvette System Installation Guide installation Review amp Safety Check Review amp Safety Check INSTALLATION REVIEW amp SAFETY CHECK Y Carefully review the entire installation Examine all lines routed near moving parts and exhaust components to ensure that they are protected from chafing or abrasion secure and free of t
30. er Brochures ___ Witnessed performance a car Test drive ___ Magazine editorials ___ Friends ___ Conversations with ATI technicians ___ Web Site please specify ___ Other please specify What most influenced your decision to purchase a ProCharger system ___ Reliability ___ Standard warranty ___ Extended coverage warranty ___ Performance ___ Quiet operation ___ ability to return car to stock ___ Cost Ease of Installation Dealer O Other O Yes Vehicle s Vehicle s have read and understand the policy for the ProCharger Extended Coverage Program have not and will not modify my ProCharger supercharger in any way during my participation in the extended coverage program have read and answered all questions on this form have enclosed my check for 49 payable to ATI for enrolling my ProCharger supercharger serial number indicated above in the extended coverage program for an additional twenty four 24 months beyond the standard limited warranty period of twelve 12 months Signature Date Mail this completed registration form with a 49 check to ATI at 14801 West 114th Terrace Lenexa KS 66215 If you have any questions contact us at techserv procharger com or 913 338 2886 8 30 AM 5 30 PM CST Monday Friday THIS PAGE IS INTENTIONALLY LEFT BLANK THIS PAGE IS INTENTIONALLY LEFT BLANK Accessible Technologies Inc 14801 W 114th Terrace Lenexa
31. f no leaks are detected otherwise review the installation and remedy any problems T 2006 2011 C6 206 Corvette H O System Installation Guide ABT Manifold Installation VACUUM MANIFOLD Brake Boost 1 Locate the 7 ID brake booster hose T inm Sr To Surge Valve that runs along the driver s side of the brake booster to the rear of the intake manifold To Boost Gage gt 2 Using a utility knife or razor blade remove a 37 long section of the hose c t 3 Install the supplied vacuum manifold and securely clamp in place using the Vacuum supplied 6 hose clamps making sure 8 i Manifold E that there are no vacuum leaks at the Vacuum System splice points Warning Improper clamping of the splice into the brake booster hose could cause a vacuum leak and could cause the power brakes to become inoperable Use extreme caution in installing the vacuum manifold to prevent any possible leaks o lt 4 Attach the 3 5 vacuum hose to of the barb fittings on the installed vacuum manifold then route and attach to the ProFlow anti surge valve vacuum port if not already done Attach a boost gauge to the other 3 6 barb fitting If you are not using a boost gauge remove the unused 97 barb fitting and replace it with the supplied pipe plug Secure all vacuum hoses to their fittings with zip ties 2006 2011 206 Corvette System Installation
32. from your local dealer or date of shipment from the factory This limited warranty coverage is extended only to the original owner and excludes hoses sleeves and electronic components manufactured by other companies IF THE SUPERCHARGER S DRIVE RATIO IS ALTERED IN ANY WAY FROM THE FACTORY SETTING WARRANTY COVERAGE IS VOID USE OF ANY PULLEY NOT MANUFACTURED OR SUPPLIED BY ATI VOIDS ALL WARRANTY COVERAGE ATI s warranty obligations are limited to the terms below ATI agrees to honor a warranty claim at its sole discretion and only after inspection at the ATI factory No warranty will be honored if any part of the product is found to have been improperly installed tampered with mishandled or misused in any way Disassembly of the ProCharger supercharger or removal of the ProCharger superchargers serial plate voids all warranties Claims for freight damages should be directed to the freight company If ATI s limited warranty applies your product will be repaired or replaced at ATI s discretion and shipped back If the limited warranty does not apply ATI will advise you of the specific reason cost of the repair and delivery time After advising you of this information we will at your option either proceed with repairs or return your product to you in the state in which it was received In either case the product will be shipped to you insured at replacement value Therefore you will pay the return shipping and insurance charges if
33. ng during the drilling process 10 Tape the supplied 1 4 HSS drill bit 1 5 8 from the tip Using this taped drill bit drill a hole in the crankshaft and harmonic balancer stopping once the tape reaches the edge of the drill jig The hole will be centered on the OD of the crankshaft Do not drill deeper than 0 800 into the face of the crankshaft Remove the pinning tool and set aside koc T DRILLING CRANKSHAFT AND HARMONIC BALANCER STANDARD C SHOWN DRILL JIG CRANK PINNING FIXTURE 11 001 ES 9 CRANKSHAFT AND HARMONIC BALANCER DRILL JIG 2006 2011 206 Corvette System Installation Guide Balancer Balancer 11 Install the supplied 1 4 OD x 0 75 long stainless steel dowel pin in the hole and then install the supplied new factory center bolt ATI Part BO16MI 125 GM Part 11589178 and torque to the factory specification of 37 ft lbs plus an additional 140 rotation 12 Re install the steering rack bolts the trac tion control module and the tie rod ends and tighten the carrier bolts Re install the sway bar end links but don t attach the sway bar to the K member at this time This will ease installation of the intercooler tub ing later in the install HARMONIC BALANCER PINNED TO CRANKSHAFT TORQUE PROCEDURE 2006 2011 206 Corvette System Installation Guide rom __________________ FRONT F
34. not start to bleed fuel pressure from the fuel lines and fuel rail assembly Remove the keys from the ignition Replace the fuel pump fuse Disconnect the negative battery cable Warning The fuel system should de e pressurized but some fuel may leak out when the lines are disconnected Take the necessary precautions to avoid injury or fire o lt Using the supplied fuel fitting quick disconnect tool remove the supply line from the fuel rail place a shop towel underneath the fitting on the driver s side to minimize fuel leakage Disconnect the fuel injector electrical connectors one at a time labeling them by their corresponding injector location Disconnect the fuel rail wiring harness from the fuel rail Remove the fuel rail attaching bolts Remove the fuel rail assembly as one piece with the injectors still attached and place on a clean work surface making sure to support the assembly to avoid damaging any of the components Have a shop rag accessible for leaking fuel Spread the injector retainer clips to release each injector from the fuel rail Remove the old injectors and set aside You are now ready to install the new injectors Remove the protective plastic caps from each end of the new injectors being careful not to damage the o ring seals Lubricate each new injector o ring seal with several drops of clean engine oil Warning Never re use fuel injector o ring seals as they los
35. ns with 60 hose clamps The tabs or fins on top of the radiator can be bent down if desired to make more room for the air inlet Re install the plastic engine covers trimming the passenger s side cover as necessary to clear the bracket Check all fluids and correct levels as necessary Reconnect the negative battery cable Re install the wheels PASSENGER S SIDE ENGINE COVER FACTORY LINE Note Check the belt tension after 50 100 miles have been driven on the vehicle after the ProCharger system has been installed Making sure the belt is properly tensioned will ensure longer belt life and maximum performance from the system C Y DRY SUMP OIL TANK am VALLEY INTAKE MANIFOLD CHECK VALVE FLOW ONLY ALLOWED IN THIS DIRECTION THROTTLE BODY PCV SCHEMATIC INLET AIR FILTER __________________ 2006 2008 Corvette 206 TUNING INSTRUCTIONS Warning Apply the parking brake e before you begin 1 Turn the ignition on and plug the 5 handheld device into the OBD port located beneath the steering colum 2 From the opening screen select a Program vehicle b Custom tune c Select Procharger tune d Follow onscreen intructions e Your Procharger tune is now installed in the vehicle Tech Tip Tuning your vehicle correctly is extremely important and is necessary for proper vehicle operation and safety If you have any question
36. of the Extended Coverage Registration Form is required along with a 49 registration fee This form must be completed in its entirety and must be submitted along with payment within 30 days from the date of original purchase from your local dealer or date of shipment from the factory Participants must have a ProCharger P 1SC P 1SC 1 C1 or C2 supercharger head unit using the maximum warranted boost level All terms and conditions within The Limited Warranty apply Acts resulting in disqualification include but are not limited to the following Disassembly or modification the ProCharger supercharger Removal or attempted removal of the ProCharger drive pulley s Removal or attempted removal of the ProCharger supercharger serial number plate Removal or attempted removal of the compressor housing or transmission case Participants agree to properly maintain the ProCharger supercharger and provide proof of compliance with the following recommended maintenance Change the ProCharger supercharger oil after the initial break in period of 500 miles automotive or 15 hours marine Change the ProCharger supercharger oil every 6 000 miles after the initial break in period Use only the specified amount of ProCharger Supercharger oil in the ProCharger supercharger Inspect and clean the magnetic drain plug at every ProCharger supercharger oil change Check the ProCharger supercharger oil level
37. r and secure the connection with a 52 hose clamp 15 Remove the MAF sensor from the factory air inlet assembly using a T20 Torx bit Re install the MAF sensor into the steel throttle body tube using the M4 X 12mm HHCS Make sure the arrow on the MAF sensor is pointing towards the throttle body Install the steel throttle body tube to the rubber reducer using a 56 hose clamp Finally connect the throttle body tube to the 3 1 2 end of the 4 to 3 1 2 rub ber reducer using a 56 hose clamp then connect the 4 end of this reducer to the throttle body using a 64 hose clamp MAF Sensor amp THROTTLE TUBE INSTALLATION 2006 2011 C6 206 Corvette System Installation Guide Fuel Injector Replacement Injector Replacement FUEL INJECTOR REPLACEMENT Note This section only applies to full systems which include upgraded fuel injectors If you do not have a full system upgraded fuel injectors will be required before starting the vehicle 1 Remove the gas cap to relieve vapor pressure in the fuel tank and connect the negative battery cable Tech Tip If the vehicle cannot be started to depressurize the fuel system relieving the pressure by pressing the pin on the schrader valve is acceptable Place a shop rag under the valve to collect leaking fuel v Remove the fuel pump fuse from the fuse block in front of the battery Crank the engine over for 5 seconds the engine will
38. s regarding tuning your vehicle or with any of the steps outlined here call a technical service representative at 913 338 2886 2006 2011 206 Corvette System Installation Guide 2009 Corvette 206 TUNING INSTRUCTIONS 0 Warning Apply the parking brake before you begin 1 Turn the ignition on and plug the 5 handheld device into the OBD port located beneath the steering colum 2 From the opening screen select a Program vehicle b Scroll over to Upload Stock c Follow onscreen intructions This will copy the stock file to the handheld 3 Go to www sctflash com and download the SCT Device Updater software It is located in Tech Support Device Updates and Downloads a Select your device from the drop down menu X3 3415 3416 b Select Device Update Software c Download the updater software 4 Use the SCT Device Updater to get the stock file from the device Follow the onscreen instructions This will generate 2 files 1 bef 2 vin sul Email these 2 files along with your serial number from the blower and the X3 handheld to tuning procharger com 2006 2011 206 Corvette System Installation Guide The tune for your vehicle will be emailed back to you from tuning procharger com Upload the tune from your computer to the X3 handheld using the Device Updater Software Follow the same instructions from Step
39. sh pins Slight trimming to the left and right air dams may be necesary to clear the lower cradle legs 11 Connect the driver s and passenger s side radiator core support brackets to the up per shroud using the supplied 1 4 hard ware You will have one 1 4 20 X 3 4 button head socket cap screw BHSCS two 1 4 flat washers and one 1 4 20 hex lock nut for each hole 12 Connect the supplied rubber flaps to each side of the upper shroud using the sup Ar DAM plied plastic push pins 13 Install the upper shroud assembly to the front fascia mounting holes as shown us ing the factory original screws Place the Y Tech Tip Removing the retaining clip on radiator support brackets over the rubber the A C line near the service port may mounts located on both sides of the radia allow the A C condenser and radiator to tor The upper shroud seals the area in sit lower in the cradle front of the radiator and acts as a support for the radiator and fan assembly 2006 2011 C6 206 Corvette H O System Installation Guide Intercooler and Tubing Installation S and Tubing Installation PASSENGER S SIDE RADIATOR CORE SUPPORT BRACKET CAN ALSO BE PLACED ON THE BOTTOM OF THE SHROUD SHROUD DRIVER S SIDE RADIATOR CORE SUPPORT BRACKET CAN ALSO BE PLACED ON THE BOTTOM OF THE SHROUD UPPER SHROUD RUBBER FLAP 14 Connect the supplied 3 1 2 to 3 rubber reducer to the 3 port on the top of the intercoole
40. t disconnect and remove the horn assembly Remove the horns from the factory mounting bracket discard the factory bracket Unbolt the 4 cradle bolts with a 13mm socket and extension and 4 remove the cradle Remove the driver s 7A Radiator Cradle N side fascia mounting hardware and install onto the new cradle bracket Install the new rubber air dam onto the cradle using the factory hardware FACTORY CRADLE REMOVAL 10 Install the supplied intercooler brackets passenger s side AIGO21 001 amp driver s side AIGO21 002 The intercooler bracket fits against the frame followed by the cradle Install the cradle utilizing the factory hardware Reconnect all of the wiring harnesses previously disconnected in order to drop the cradle and route the lines back through the new cradle Refer to the intercooler schematic for correct orientations of the brackets Utilizing the factory nuts re install the horns directly onto the new cradle Plug in the wiring harness HoRN RELOCATION 2006 2011 206 Corvette System Installation Guide sy Radiator Oil Cooler Install the passenger s side engine oil cool er bracket AIGO21 013 to the passenger s side of the engine oil cooler using two M8 1 25 X 40mm long HHCS Hex Head Cap Screws and two 1 long spacers md A Install the driver s side engine oil cooler bracket AIGO21 012 to the driver s side of the engine oil cooler using two M8 1
41. ve us ing the intercooler system schematic for placement The ProFlow valve will be located between the cooling fan and the front of the engine Insert the supplied 3 rubber 90 elbow onto the surge tube Secure the connec tion with a 52 hose clamp Using a M6 X 25mm HHCS two flat wash ers and a jam nut create a stud on the new cradle tab on the passenger s side for later mounting the fascia re using the fac tory nut Attach the sway bar to the K member using the original factory hardware at this time NANA 1 i m 4 bea E E 1 T S si Y N WX Tubing Between Fan and Engine Cradle A 7 y y d Fascia Bracket 2006 2011 C6 206 Corvette H O System Installation Guide Intercooler and Tubing Installation and Tubing Installation Trim the front fascia as shown below FASCIA RIMMING 2006 2011 206 Corvette System Installation Guide Intercooler and Tubing Installation and Tubing Installation 9 Re install the front fascia and secure with the factory hardware Do not fully tighten the 4 6mm screws located at the front of the engine bay at this time Install the supplied trimmed passenger s side splash panel and re install the factory driver s side splash panel 10 Fasten the rubber air dam to the left and 5 right side air dams using the supplied TRIMMED SPLASH PANEL plastic pu
42. wists and kinks All wires and hoses should be firmly secured with clamps or wire ties Also ensure that the air filter is installed Check and correct all fluid levels oil power steering and coolant Your vehicle should be filled with 91 or higher octane fuel before any hard driving Start engine and idle for a few minutes Inspect connections for air or fluid leaks 3 Shut off engine and check for fluid leakage signs of rubbing parts and other potential problems Your vehicle should display a significant detonation free increase in performance when you step into the throttle yet maintain its previous driveability during daily driving If this is not so review your installation then contact your dealer or ATI for assistance v Be sure you have purchased and properly installed a fuel pressure gauge to monitor fuel delivery while driving An air fuel ratio meter is also helpful for monitoring fuel delivery Installation of a boost pressure gauge is also recommended Please review the maintenance and warranty sections within this owner s manual Note Larger cities especially in winter months often use oxygenated or reformulated fuels to reduce pollution Although these fuels have the same octane ratings as unaltered fuels some people have experienced problems detonation with their use If you experience similar problems it is advised to use octane booster to avoid detonation COMPLETED PROCHA
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