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ENGINE ADJUSTMENTS
The engine must be
checked and set up as follows before starting the engine.
VALVE CLEARANCES. Valve clearances should be increased to .006".
(.15mm). Adjustments should be made when engine is cold.
IGNITION POINT SETTING. Stock gap of .016 is recommended (50 to 53
degrees if set with cam dwell indicator.
IGNITION TIMING. The correct ignition timing will vary with the grade
of fuel available in your area and the particular ignition distributor.
The correct timing for the supercharged Volkswagen will vary between 2.5
degrees BTC to 10 degrees BTC. Try timing set at stock setting of 7.5
degrees BTC> (When the mark on the pulley lines up with the crankcase
centre line the ignition timing is set at 7.5 degrees BTC). If
detonation is encountered with this setting retard the timing 5 degrees
or ¼" to the right of the crankcase centre line facing engine. If
performance is sluggish at stock setting of 7.5 degrees BTC, advance
timing (to the left) until maximum performance is obtained without
detonation or engine knock.
SPARK PLUGS. The condition and quality of the spark plugs is
extremely important on a supercharged engine. If plugs need replacing or
if ping occurs, the spark plugs should be replaced with Champion L-10 or
L-7. Ignition wiring and coil should also be checked in the event of
ignition failure. Spark plug gap remains stock at .025.
CARBURETTION. The size of the main jet in the carburettor should be
checked to make sure that it is either 120. Or 122.5.
INSTALLATION IS
COMPLETE
Start the engine. It will be difficult to start the engine as the
gasoline has been drained from the carburettor. Use full choke and pump
throttle. As soon as the engine is running adjust the lubricator. After
engine is warm, set idle and mixture on carburettor.
CONVERTIBLE MODEL. It is necessary to
remove a section of the air baffle located on the inside of the lid in
order to mount the carburettor and air cleaner.
KARMANN GHIA COUPE. On this model it
is necessary to make a revision in the rear deck lid because of
insufficient clearance in the engine compartment. A modification or
scoop for the rear deck lid is included in the kit for the Ghia Coupe.
Complete instructions and a template for mounting the modification is
packed with the scoop.
TRANSPORTER, TRUCK AND KOMBI. There is
insufficient clearance in the engine compartment to mount an air cleaner
unless the panel directly over the carburettor is modified. In order to
mount the carburettor it is necessary to remove a 4" section of the
reinforcing rib located on the underside of the panel directly over the
carburettor.
DATA
LUBRICATOR ADJUSTMENT.
To adjust the lubricator proceed as follows; Start the engine. The small
knurled knob on the very top (under protecting cap) should be unscrewed
a half turn to get the oil flowing and then adjusted with your
fingers until the lubricator is putting out approximately one drop of
oil every six seconds at idle. This can be timed through the small
window on the lubricator. Screw clockwise to decrease the amount of oil
consumption. Oil consumption should run one quart of oil every 800 to
1000 miles and the oil level should be checked occasionally so that you
do not run out of lubricant. Engine and lubricant should be warm while
adjustments are being made. The adjustment should be checked after the
first 100 miles. The oil from the automatic lubricator is to oil the
bore of the supercharger housing and also acts as an upper cylinder
lubricant. Use SAE No 10 detergent motor oil. Do not use an upper
cylinder lubricant as most top oils are primarily a cleaner and not a
lubricant. Do not use a multiple viscosity oil. In making a long descent
from high altitudes it is advisable to open the throttle occasionally to
insure adequate lubrication. NOTE; The lubricator should be adjusted and
left alone as any variance that will occur at idle will be slight under
actual operation.
DRIVE BELT ADJUSTMENT.
The tension of the supercharger drive belts should be examined after
approximately 200 miles and an adjustment made if required. Belt tension
can be increased sufficiently by placing one additional thick gasket
between the supercharger and the manifold. Belts should have 1/2"
to 3/4" slack.
AIR CLEANER SERVICE.
The air cleaner should be removed from the carburettor and washed out in
gasoline or kerosene every 3000 to 5000 miles.
FUEL. Premium grade or
high octane gasoline is recommended for maximum performance on the
supercharged engine. Super premium fuels are not necessary.
BREAK-IN PERIOD. No
breaking-in period is required for the Judson Supercharger. We do
however recommend that the engine be run slowly or at idle for at least
15 minutes before placing the engine or supercharger under load.
IDENTIFICATION DECAL.
An identification decalcomania for placing on the inside of the
windshield is included with the installation. See instructions for
mounting on back of decal.
NOISE. The
supercharger may sound noisy when it is first started or within the
first hour of operation. This noise is nothing to be concerned about and
will disappear completely within the first 50 miles of hard driving. A
clicking noise sometimes at idle or after backing off of the throttle
after a hard run is a characteristic of a vane type supercharger.
BELT REPLACEMENT. In
case of drive belt breakage the supercharger will cease functioning but
the engine will continue to operate. The drive belts are a standard size
and can be purchased from any automotive jobber under Gates number 6267*
as a matched set. Belts are of a
premium quality and should last for at least 35000 miles.
WARRANTY.
The Judson Supercharger is warranted to be free from defects in material
and workmanship under normal use and service. In case of any part within
ninety (90) days from date of original purchase by user, due to
defective material or workmanship, we will repair, replace the defective
part or furnish a new supercharger free of charge. F.O.B. factory.
Approval must be obtained before returning supercharger or parts to the
factory for replacement. All transportation charges on supercharger or
parts must be borne by purchaser.
*
The original Gates belt was 8210 but these are no longer
available.
ITEMS TO CHECK FOR LACK OF PERFORMANCE
INSTALLATION. It is very important that the instructions be followed
exactly in installing the supercharger on the engine. Mistakes usually
made; drive belts too tight, the special lock-nuts are placed on the
supercharger mounting studs instead of the carburettor studs, the
support brace is mounted upside-down, the small copper washer gaskets
are not placed on the carburettor studs, the replacement spring is not
installed in the fuel pump and the hole for the choke is drilled
incorrectly which allows the choke extension to catch on the side of the
carburettor. Lock washers are not required and should not be used on the
carburettor studs as the nut furnished is a lock nut.
ENGINE. Maximum performance after supercharging is a function of
engine condition and tuning. Engine deficiencies often unnoticed before
supercharging sometimes prevent increased performance that can be
expected from supercharged engine. Because of this the supercharger will
often be blamed for poor performance when such is not the case. If the
installation has been made in accordance with the instructions and the
performance is poor it is usually due to one of the following; a leak in
the induction system, improper valve clearance or a faulty ignition
system. A leak in the induction system upsets the fuel/air ratio
resulting in a lean mixture, a hot running engine, a poor idle, engine
stalling, detonation, hard starting, a noisy supercharger and restricted
top speed. All connections should be checked for leaks including where
the intake manifold is bolted to the head. The manifold itself should be
checked for a crack. A leak between the heat riser and intake manifold
can be eliminated by blocking off the heat riser at the exhaust. If
installation is equipped with a gauge, both connections should be
checked as well as the hose.
An incorrect setting of the air regulator ring located on the back of
the shroud will cause a hot running engine by not allowing a sufficient
volume of air to enter the shroud. In hot climates we suggest the
removal of the regulator ring which is fastened to the shroud with two
bolts.
The ignition system on the
supercharged engine should be in good condition and properly adjusted.
Incorrect timing and point setting as well as faulty plugs or
ignition wiring affects performance considerably and causes detonation.
A leak in the vacuum advance diaphragm on the distributor will restrict
the top speed of the Volkswagen above 50mph. A faulty or worn fuel pump,
a dirty carburettor or a sticking carburettor float will also account
for a hot running engine and restricted top speed.
If poor performance cannot be
attributed to any of the above after a thorough checking it can be
assumed that the trouble is of an internal mechanical nature and the
engine itself should be checked by a competent mechanic.
Best performance for dependability is
obtained from the stock engine. We do not recommend increasing the
compression ratio or making any other basic engine modifications on the
supercharged engine.
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