JHM stage 1 supercharger kit

[sar]

next job was to remove the inlet manifold to fit some intake spacers and fit a new check valve (part of the supercharger kit) between the manifold and oil separator.

intake manifold removed, stock air box stripped out.

i wasnt desperate to do carbon clean it was only done 13,000 miles ago, but i thought it was rude not while everything was stripped.
the build up wasnt crazy so i decided i would do it the old fashioned way, the soak and scrub.

carbon clean action!, i filled a couple of ports with carb cleaner let it soak for 30 min then wicked it out with cloth and set about it with the wooden picks. i did this twice for each port.

i ground down a couple of the wooden picks to make them a more useful shape. i also experimented with some cable ties/red scotch combo in a drill.

i imagine this would work good for removing the bulk of heavy build up but as i only had a light ish coating these were not that effective for me, i ended up cutting some small strips of scotch and dragged and scrubbed them round the ports manually with the wooden picks while they were still full of carb cleaner.

[sar]

with the carbon clean done its time to fit the inlet spacers and get the manifold back on.

inlet spacers

when you fit inlet spacers you have to lift the fuel lines that run over the top of the manifold up about 10mm to allow for the extra height.
i had forgot to do this before i removed my manifold so we quickly re installed it and used a pry bar to lift the fuel lines the required amount.

fuel lines tweaked and manifold back off, spacers can go in.

manifold back on, new plugs fitted and coil packs back on.

[neilparf]

This is better than following the Soprano's! Nice work, Sar!

[kernowrs4]

More i want to see more looks good so far! Keen to see how this performs as i may be looking at charging next year!

[rob-s]

This is better than following the Soprano's! Nice work, Sar!

Agree! This really makes you want a supercharger too:)

[hlbeckley]

with the carbon clean done its time to fit the inlet spacers and get the manifold back on.

inlet spacers

IMG_20140802_145158.jpg

when you fit inlet spacers you have to lift the fuel lines that run over the top of the manifold up about 10mm to allow for the extra height.
i had forgot to do this before i removed my manifold so we quickly re installed it and used a pry bar to lift the fuel lines the required amount.

fuel lines tweaked and manifold back off, spacers can go in.

IMG_20140802_151540.jpg

IMG_20140802_151606.jpg

manifold back on, new plugs fitted and coil packs back on.

IMG_20140802_165307.jpg

The OEM gaskets and spacer dont appear to be lining up?
My car is in today getting these fitted and guy called to say same thing and he thinks there will be leaks?
I have long bolts etc as well. DO you think this will seal ok?

[sakimano]

More i want to see more looks good so far! Keen to see how this performs as i may be looking at charging next year!

What do you want to see? We have seen tons of data from the first couple dozen cars with it over here


0-60
0-100
1/4 mile
60-90
60-130
Dyno

Etc

[sakimano]

with the carbon clean done its time to fit the inlet spacers and get the manifold back on.

inlet spacers

IMG_20140802_145158.jpg

when you fit inlet spacers you have to lift the fuel lines that run over the top of the manifold up about 10mm to allow for the extra height.
i had forgot to do this before i removed my manifold so we quickly re installed it and used a pry bar to lift the fuel lines the required amount.

fuel lines tweaked and manifold back off, spacers can go in.

IMG_20140802_151540.jpg

IMG_20140802_151606.jpg

manifold back on, new plugs fitted and coil packs back on.

IMG_20140802_165307.jpg

The OEM gaskets and spacer dont appear to be lining up?
My car is in today getting these fitted and guy called to say same thing and he thinks there will be leaks?
I have long bolts etc as well. DO you think this will seal ok?

Usually this is because they either have them upside down, or in the wrong side, or both .

It's hard to not sound rude when you tell them though lol

If they're misshapen or something that's a real surprise since JHM have sold those for literally thousands of cases over 7-8 years (b5/6/7/8). I doubt they'd get it wrong.

[hlbeckley]

Haha my exact problem today
Needless to say I couldn't get out of the damn office to go see for myself so they left them off and put everything back together

Must carbon clean really makes a huge difference! The kick is back!

[sakimano]

Just noticed your are not JHM correct? So maybe the new company just got it wrong?

[hlbeckley]

They drilled perfect round bolt holes, JHM set have more of a slot so you can wiggle! Think an angled drilled set up would be best
Either way the fit is not flush on mine and apparently the ECS has same issue so for now they stay off until redesigned

Removed the separators though, there is now a 2.5k kick as well.....awesome

Hijack over

[sar]

The OEM gaskets and spacer dont appear to be lining up?
My car is in today getting these fitted and guy called to say same thing and he thinks there will be leaks?
I have long bolts etc as well. DO you think this will seal ok?

my spacers fit fine, in the original pic they were just rested on.
heres what they look like bolted down.

back to the install.

[hlbeckley]

Ah excellent Sar, thanks a mil for that photo, I am sending my ones back with your pic to show how they should sit!

How is the install coming? Are you doing any clutch/brake/suspension work? Do you "have" to with all the extra power or with the standard OEM set up handle the power on stage 1 kit

[sar]

Ah excellent Sar, thanks a mil for that photo, I am sending my ones back with your pic to show how they should sit!

How is the install coming? Are you doing any clutch/brake/suspension work? Do you "have" to with all the extra power or with the standard OEM set up handle the power on stage 1 kit

install is getting there hopefully find the time to get it finished this next week.
i already have a loba 550nm clutch and flywheel, loba front discs with ds2500 pads and ohlins shocks.
ill see how the clutch holds up, and im looking into front and rear bbk options. but the shocks are sublime so no upgrade needed there!

[sar]

right where were we...
here is the oil separator with the new check valve that needs installing.

in hindsight i should have installed this on the manifold while it was out, the aluminium piece that houses the valve needs bolting onto the manifold first then the oil separator bolts to that. there is very little room to work behind the manifold when its on and when trying to slide the separator into the the aluminium piece we managed to damage the o ring, audi dont sell the o ring separate so i have measured it up and ordered some online.

so whilst waiting for the o rings i decided to crack on and remove the secondary air injection system and ac dryer.
SAI no longer needed.

ac dryer bagged up waiting to be re homed.

with them removed there might just be enough room for a supercharger!

i couldn't resist a little mock up