I installed a switch to control the pump, in the event the car is shut off and I am listening to the radio, I don't have the pump running and eating my battery. I recommend getting a switch that draws some attention, so you know when the intercooler is on. You do not want to make any Wide Open Throttle(WOT) runs with the intercooler not working.

Step 1. Remove dash bezel and then the Drivers Information Center(DIC).

Step 2. Remove the face plate on the DIC, and cut a hole in the face plate for the switch.

Step 3. Cut a hole in the back plate. (Depending on what type of switch you get, some have enough room to connect the wires, and a hole big enough for the wires will be fine, others have the terminals that will stick out the back, so the hole needs to be big enough to connect the spade connectors).

Step 4. Install the switch into the face plate, and reassemble the DIC.

Step 5. Connect a ground wire (needed if there is a light on the switch).

Step 6. Connect a Accessory wire (so the pump will only run when the car is running).

Step 7. Connect the power wire for the pump.

Step 1. Remove the air duct going into the throttle body.

Step 2. Remove the vacuum line and 4 electrical connections (3 on the throttle body and 1 on the air duct)

Step 3. Remove the supercharger belt

Step 4. Disconnect the fuel supply and return lines from the fuel rail using a fuel rail disconnect tool.

Step 5. Remove the alternator brace (15mm on the alternator side, and 13mm on the supercharger side)

Step 6. Remove the 4 10mm bolts on the fuel rail assembly.(One on each corner of the fuel rail assembly) Remove the 13mm bolt on the top of the supercharger that bolts the fuel rail to the supercharger assembly.

Step 7. Use a vacuum and clean around the area of the injectors. This will keep debris from falling into the intake when you remove the fuel rail and injectors.

Step 8. Remove the electrical connections on the injectors. (Push in on the metal bar, and pull the connector off)

Step 9. Gently pull up on one corner of the fuel rail assembly preferable right above the injector. Once it is pulled free, move to the next one until they are all free.

Step 10. If you have new fuel rails, follow the instructions for the fuel rail install and then skip to step 12.

Step 11. I did not modify my fuel rails, I bought the ZZP Fuel Logs, but I checked with Zoomer and he gave me permission to use his install pics, so here it is:

Fuel rail

After installation the supercharger will sit 1 inch higher than stock. You will need to modify the fuel rail to accommodate this. Once all of the attachments are unhooked from the rail it will lift off the car. Some cars will require some bit of force in doing this the first time. After the rail is off the car, remove the injectors by first taking the steel retainers off of the injectors and then just pulling the injectors out. If they are stuck you will need to pry. Blow the fuel out of the rail with an air gun. Mark your fuel rail in the spot shown in red

and the spots shown in blue in

Their is only one spot of the tube that has to be cut and extended using the supplied fuel injection hose and continuous torque clamps. You will need to cut the passenger side rear bracket off of the rail as shown by the red line (First Pic). You can see what the rail looks like after this bracket has been cut off in the back (Second Pic). Cut the rail with a grinding disk, pipe cutter or worst-case hack saw. You will need to cut the fuel pressure regulator tab and two spots of the top of the rail as shown by the blue marks(Second Pic). The 3/8" feed line of the rail can be bent to fit over the blower once it's been cut free from the return line as shown.

When you are finished modifying the rail put the injectors back in. To help the injectors pop in it is a good idea to smear a light amount of grease on the rubber seals of the injectors. You will need to modify the rear bracket piece that you cut off.

Shown is the change that has to be made.

Step 12. Remove the bracket on the rear side of the supercharger.

Step 13. Remove the 10 10mm bolts that mate the supercharger to the intake (1 bolt on the side of the snout, 1 bolt next to the throttle body, 4 on each side of the supercharger).

Step 14. Remove the supercharger. Clean the old gasket off. DO NOT GOUGE UP THE MATING SURFACE. This must me smooth so get a good seal. Replace the 2 yellow O-ring in the intake with the ones provided in the kit.

Step 15. Prep the gasket. You will need to cut the center out of the 2 provided gaskets. (Cut just to the inside of the red seal line. On one side of the gasket there is a red seal circle, cut through the circle to make it nice and straight (about 1/2 the circle will be cut out)).

Step 16. Place the gasket (red seal up) on the intake manifold, followed by the bottom plate for the intercooler. Take note that the back right side is showing the red seal where the core will be. You will need to put a LIGHT coat of RTV on this corner when you are ready to bolt it all together. DO NOT APPLY RTV YET.

Step 17. Place the core in the bottom plate, with the black side to the Throttle body and the silver side to the Snout. Connect the Intercooler lines, and then move the core out of the way. We are now ready to RTV.

Step 18. Put a LIGHT coat of RTV in the corner of both gasket as described in Step 16 (make sure you put the RTV on the red seal side of the gasket). Now put a SMALL bead of RTV around the bottom plate of the IC Core as shown.

Step 19. Place the first supercharger gasket back on the intake, then put the bottom plate of the IC Core on top, and line up the bolt holes. Put the Intercooler Core in the plate, Now put the top plate on (make sure there is RTV around the hose area on the top plate).

Step 20. Now place the 2nd supercharger gasket on top of the IC Core.

Step 21. Install the supercharger and line up the bolt holes. You will need to use the supplied lock washers with these to keep them tight. Torque these bolts to ~18 ft lbs. Snug them all first, then torque them in a sequence doing one bolt on each side of the SC at a time. (Kind of like you are doing lug nuts on a tire) This will keep the blower rotors from getting bound and scoring the insides of your M90.

Step 22. Install the fuel rail per Step 10 or the How to section for FUEL LOGS.

Step 23. Reconnect all injector connections and throttle body connections.

Step 24. Replace the alternator brace and brackets on the back side of the supercharger.

Step 25. Reconnect the air inlet hose for the throttle body.

If you would like to make a comment or rate this write-up, please do so here.