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HOTROCKER |
Box 835067 Richardson TX 75083
Phone (972) 335-2464 Fax (972)713-0901
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Table Of Contents
Hotrocker Installation Instructions
Chevrolet 4.3L V-6
If your heads have press in studs, they will have to have the studs
pulled and the stud bosses milled .375, and tapped for 7/16" coarse
threads. The bosses must all be the same heights as if milled on a
Bridgeport Mill.
Before mounting parts on head, test them by lining 3 pedestals on
table, tall uprights towards you, and position shaft, flat side toward
you, into correct position in the pedestals. Roll the shaft the full
range front to back and feel the 4 positions. This lines up the
pedestals, as you will do to correctly align them on the head.
Installing Pedestals
Remove valve cover from engine. Unbolt rocker arms and remove, being
careful not to let the pushrods move up and out of the lifters.
Using 7/16" bolts, bolt on 3 pedestals, one at a time with tall
uprights toward the valve springs. Leave the bolts slightly loose.
Press the bare shaft into the pedestal teeth and roll shaft back and
forth to align all pedestals. Finger tighten all bolts. Slide the
shaft slightly one-way to allow access to an end bolt for tightening
with a box-end or socket wrench. Slide the shaft a slight bit more to
allow access to the next bolt. Slide the shaft the opposite way to
tighten the pedestal bolts on the other end of the head. Continue
this process until you have all bolts wrench tight. During this
bolting process, it is a good idea to roll the shaft back and forth to
continue assuring correct alignment of the pedestals. Be sure to
press the shaft firmly into the pedestals during this entire
procedure.
Shift Lever Location
Between two of the pedestals there is enough space (more than .250")
to install the shaft shift lever. There is not enough room at the
other space between the two pedestals. When installed, four rocker
arms will be on one side of the lever, and 2 rocker arms on the other
side of the lever. Select the correct location on the shaft before
proceeding to the next section.
Installing Rocker Arms, Shafts & Caps
Install adjusters into rocker arms, run in completely, but finger
tight. To familiarize yourself with the process described below,
install one rocker arm on the shaft and place it between pedestal
uprights on the engines using the instructions below. When you have
familiarized yourself with the process, continue the procedure
described below using the shaft with 6 rocker arms and the shaft
lever. Assemble rocker arms on shaft with flat side of shaft facing
the roller-tip end of the rocker arm. Install the shaft lever in
correct order between the rocker arms. When installed, it will fall
between the two pedestals where there is space for the lever and
protrude between two valve springs. Slide the rocker arms along the
shaft spaced approximately where they will be when installed on the
engine. Lower the shaft and rocker arm assembly into pedestals,
fitting each rocker arm between pedestal uprights with roller tips on
valve stems and adjuster bolts on pushrods.
The simplest way to do this is to let the rocker arms lay on the
roller tip and drag the roller across the valve spring retainer as you
the lower the shaft into the pedestals. This should correctly engage
the shaft in the proper tooth on the rocker arms. This is usually the
most challenging maneuver in installing the hotrocker, and may need to
be repeated if any of the rocker arms slide to a different tooth.
Check to see that all roller tips line up with each other. One
protruding out of line indicates it has been installed on an incorrect
tooth.
Roll the shaft to the minimum lift position (towards the valve
springs) and press it into the correct pedestal tooth. Pushrods
resting in lifters already lifted by the cam lobes will stand higher
than the other pushrods (two out of six will usually be elevated at
all times). Holding the shaft assembly firmly, install caps (oil hole
up away from you) and bolts, beginning farthest from the most elevated
pushrod and moving closer with each cap. Use 1/4" 28 x 3/4" button
head screws. This will require concentration and some finesse to get
all the caps bolted down while keeping the shaft teeth in the correct
teeth of the pedestal. Do not completely bolt down the caps as you
are installing them. Tighten cap bolts only tightly enough to force
the shaft into the pedestal teeth and to prevent it from jumping into
another tooth. Raising and lowering the rocker arm lever using the
link, helps confirm that teeth of the rockers and shaft are correctly
positioned in the pedestals. Note that the 8 standoffs serve as cap
bolts, 4 on each head. Install them on each side of the shift lever.
If your engine has center bolt valve covers, you will need to use the
screw-in studs in place of button head screws in the lower center bolt
hole of each pedestal. Into each of these locations screw in a 1/4" x
32 stud by hand and install a lock washer and nut to hold down the
cap. The top of this stud will protrude through the hole in your
valve cover for a washer and nut to be installed to hold it down. The
hole in the valve cover will need to be enlarged towards the center
line of the valve cover which is here the stud will protrude. Do not
concern yourself with the valve covers until all other installations
are complete. See "Installing Valve Covers"
below.
Squirt oil along shaft assembly, especially in oil holes along caps.
Rotate the shaft back and forth through all 4 positions by lifting and
pushing down the shaft lever using the shift link. With the shaft
held in position #1 (against the valve spring side) firmly tighten all
cap bolts. Identify the pushrods that are in the full down position
(on base circle of cam) and turn the adjusters clockwise until all
slack is removed from the rocker arms. Turn the adjuster an
additional 3/4 turn and tighten locknut firmly while preventing the
adjuster from turning any additional amount. Turn the engine as
needed to similarly adjust the remaining rocker arms. When finished,
manually rotate the shaft through all 4 positions, and end at position
one (closest to valve springs).
Installing Shift Motors and Rotation Sensors
Before attempting to install valve covers and before cutting or
drilling, completely install and operate the electronic control
system. The standoffs should now be bolting down the caps on either
side of the shift lever. Using 1/4" 28 x 1/2" button head screws,
bolt the shift motor bracket to the uprights. Install the shift link
into the shaft lever. Install a cotter pin where the eye is inside
and you are looking at the two ends as you spread them around the link
end.
Using #10 x 1/2" screws and lock washers, install the shift motor into
the bracket. The motor can be mounted in one of three positions, 2
horizontal, and one vertical. Choose the one that fits best. Install
the motor lever on the square drive motor shaft using a #10 screw and
flat washer. Be aware that screwing in the screw presses the lever to
the motor shaft, making removal difficult. Screw partially on at this
time so that removal is easier if that is needed. Push the lever to
where it lines up with the shift link and install the link in the
hole. Do not install the cotter pin at this time. The Hotrocker
assembly must be in position one, minimum lift, to correctly
initialize the control module. If your bracket, motor, Position
Sensor Bracket are already assembled, you may skip the rest of this
paragraph. Using long #10 screws, nuts, and lock washers, install the
rotation sensor on its bracket, lever up. Using pliers, install the
spring clamp/clutch onto the shift motor short shaft. Using #10 x 32
x 1/2" screws with lock washers, install the sensor unit onto the
shift motors. The sensor lever will be moved back and forth by the
clamp ears as the motor rotates back and forth through the 4
positions. Adjust the sensor stroke where the spring-loaded lever is
always in tension off its base stop. Adjust the sensor arm by
rotating the clutch clamp around the shaft until the spring tension of
the sensor lever is pressing against the clutch clamp. See "Rotation Sensor Adjustment" if additional help
is needed.
Installing Wiring Harness and Control Module
Lay out the wiring harness with the rectangle connector in or near the
cockpit. There are 2 branches, the longer one going to the passenger
side of the engine and the shorter one to the driver's side. The
single long wire is to be connected to a tachometer source. See "Tachometer Connection" for more information.
The red and black wires are hot and ground, usually connected under
the instrument panel. For test purposes, temporary hot and ground
connections can be made elsewhere. On each branch, connect the 3-pin
connector to the rotation sensor. Leave the 2-pin connector to the
shift motor disconnected at this time. Now you need to initialize and
test the electrical control system.
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NOTE: Valve cover is not
installed at this point.
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Using The Control Module
In daily use your control module (CM) will be used in three different
read-out modes, which you select by pressing and releasing the button
on the left side of the panel. These are the "A" mode, the rpm mode,
and the "P" mode. The A mode reads A1, A2, A3, and A4 as the engine
revs up and down. This tells you it is automatically shifting the
Hotrocker into positions 1, 2, 3, and 4. The A mode appears when you
first energize the CM after is has been shut down. It will stay in A
mode until the push button is pressed.
When you press the button, the LED panel will read rpm in hundreds.
While in the rpm mode, the module is still automatically shifting the
Hotrocker just as it does in A mode. In both A and rpm modes the
Hotrocker automatically shifts following its rpm shift program. The
only difference is the information given by the LED panel.
When the button is pressed again the P mode appears; this allows you
to manually select the positions you wish, P1, P2, P3, P4, by turning
the knob on the right side of the panel. This will hold the Hotrocker
in that position until you turn the knob to a different position or
until you push the button, which will return to A mode.
When power is disconnected, the Hotrocker stays in the position it is
in when it's disconnected. Upon re-powering, it starts again in A1
position.
The CM has four brightness levels which are selected by turning the
knob while in A mode or rpm mode.
Initializing For Use
Your Control Module will read rpm correctly once the wiring is
connected. All shift functions will not work until after you
initialize you CM.
To Initialize:
- Disconnect the two pin connectors from the shift motors.
- Manually push down the shift levers all the way into position 1
(towards the heads).
- Make sure that the LED reads A1.
- Press and hold the button for two (2) seconds.
- Release. You will read F1.
- Turn the control knob, clockwise to F2, F3, F4, then FF.
- Press and release the button. You will read 00.
- Turn the knob clockwise to 03.
- Reconnect the two pin connectors to the shift motors.
- While in 03, press and hold the button for two (2) seconds and
release.
- The motors will cycle through a four (4) movement routine to
measure correct positions one (1) and four (4) and to determine
correct positions for positions two (2) and three (3). It will stop
with motors in position one (1). The panel will read A1 and your
Hotrocker is ready for use.
- Using the P mode, shift through each position one at a time and
confirm that each shift motor is operating correctly, stopping at each
of the four (4) positions in turn. If it doesn't shift correctly,
disconnect the 2-pin connectors from the shift motors and start back
at "To Initialize". If the initialization process ends with one side
in position 4 and the other side in position 1, leave the 2-pin
connectors connected and levers where they are. Then repeat steps
3-12, skipping steps 1, 2, and 9. If the Hotrocker system still
does not function properly, check the adjustment on the clamp/clutch
on the motor shaft. The sensor arm must always have spring tension
against the clamp during the full sweep of all four positions. The
best results come by having the sensor stroke in the upper range
rather than the lower range just off the lever stop. See "Rotation Sensor Adjustment" for more
information.
- If further help is needed please phone 972-335-2464.
Selecting Shift Points
Your control module comes with pre-selected shift points, which are
set lower than optimal for daily driving. This allows under-hood
observation of Hotrocker operations w/out using very high rpm.
To read the existing shift rpm and to change the shift points (in any
readout mode, engine off, or while running):
- Press the button and hold for two (2) seconds and release. You
will read F1.
- Press and release the button and the shift rpm will read in
hundreds. 17 means the 1-2 shift occurs at 1700 rpm.
- Turn the knob clockwise to raise the shift rpm, counter-clockwise
to lower it.
- Press and releases the button and the readout will return to
F1.
- Turn the knob clockwise to F2.
- Press the button again and the readout gives rpm for the 2-3
shift.
- Turn the knob to change rpm.
- Press the button and the readout reads F2.
- Turn the knob to F3.
- Press the button to read the 3-4 shift rpm.
- Turn the knob to change the shift point.
- Press the button to return to F3.
- When you are through checking and changing shift points, press the
button and hold for two (2) seconds to return to A mode. This two
second (2) press can be done at any point whether the LEDs read F1,
F2, F3, or rpm.
Installing Valve Covers
Unbolt the shift motor bracket from the standoffs and lay it aside.
Drill holes in the valve cover using the template. If holes are
drilled 1/2" for standoffs and 3/4" for the boot, they can be moved
for best centering for final enlargement. Before installing grommets
and boot, lower the valve cover over the standoffs and link to confirm
correct location for holes. Enlarge holes to final size. Install
grommets in final holes, and install valve cover. Bolt the shift
motor assembly to standoffs. Slide the boot over the shift link and
press it into the valve cover. Connect shift link and install pin.
Points To Remember
- Any time the system is connected to power, the shift motors are
energized in "hold" mode. This makes them very difficult to shift by
hand. Disconnect the two pin connectors at the motor or turn off the
system to shift by hand.
- "Press the button," means press and release unless using the two
(2) second press. The two second press is using for initializing and
checking and changing the shift rpm.
- Pressing the button cycles through A mode, rpm mode, and P mode in
turn.
- In A mode and in rpm mode, shifting is done automatically; only
the readout differs.
- LED brightness is altered in A mode and rpm mode by turning the
knob in either direction. (Turning the knob in P mode shifts the
motors; it doesn't change the brightness).
- Power can be disconnected at any point without damage.
- The Hotrocker will remain in that position until it is powered
again, then it will return to A1.
- Your engine will run fine in any of the four positions. But,
performance will downgrade to the performance of a non-variable valve
train engine (like an engine without Hotrocker). The engine will run
fine even with the two sides in different positions, and if left
between positions. There is no need for a "Limp home mode".
Tachometer Connection
The tachometer wire (yellow) must be connected to a tachometer lead,
or the negative side of the ignition coil or distributor. On many
distributors, there is a parallel tab on the negative side of the
distributor for connecting a tachometer. Male an female connectors
are mounted on the end of the yellow tachometer wire.
Where there is no tab, or where it is already occupied by a tachometer
wire, use the blue splice connector. Clip the connector off the end
of the yellow tachometer wire. Lay the yellow wire alongside the wire
you need to splice into. Open the connector and lay the car's
tachometer wire into the through channel and the yellow wire into the
blocked channel. Close the blue connector and snap it shut. Then,
using pliers, press the piercing tab into the wire, connecting the two
wires.
Rotation Sensor Adjustment
The rotation sensor has a spring loaded lever which will be held
against its stop when not pushed off the stock by some other action.
In order to correctly communicate with the control module, when
installed, the sensor lever must always be off the stop, preferably at
the high end of its stroke away from the stop. However, in operation
it must not be pushed completely to the high end either.
With the shift motor bracket, shift motor, spring-clamp/clutch,
rotation sensor and bracket all assembled, push the clamp around the
shaft until one of the clamped tabs shoves the sensor lever well off
its stop. The lever must not be between the two clamp tabs, but
outside the two clamp tabs. The clamp is easily pushed around the
motor shaft by pressing on the tab that is opposite of the way you
want the clamp to move. Pressing this tab loosens the clamp; making
it easier to turn the clamp around the shaft. Pressing the tab
closest to the way you want to go tightens the clamp, making it
difficult to move the clamp around the shaft.
Test your adjustment by manually rotating the gear motor (using the
lever on the front of the shaft) through a full 90° sweep that the
motor makes running from position 1 (lever down towards head) to
position 4 (90° up from position 1). In position 1 the sensor lever
should be well off its stop. In position 4 you should still be able
to push with your finger the sensor several degrees off the clamp tab
that has pushed the lever to that point.
Phone (972)335-2464 Fax (972)713-0901
info@hotrocker.com http://www.hotrocker.com/
