Vortech Engineering 4GD020-010 User's Manual
Contents
1. Ql MAX RETARD 15 10 psi at 1 2 per Ib DEGREES OF RETARD e O1 5 7 10 PSI BOOST Fig 7 e PICKUP TRUCK M ODELS CONSOLE RETARD 24 KNOB MAP SENSOR VACUUM LINE HOLE WIRING 7 THROUGH x FLOOR A V IGNITION CONTROL BOX Fig 7 f SUV MODELS RETARD KNOB MAP SENSOR VACUUM LINE WIRING HOLE THROUGH FLOOR IGNITION CONTROL BOX PASSENGER SIDE STORAGE COM PARTM ENT Fig 7 g 8 SUPERCHARGER DISCHARGE A Install the supplied discharge plenum using studs spacers nuts and washers see Fig 8 b B Thread thethree supplied studs into the factory throttle body mounting holes into the intake manifold The shortest of the three studs belongs at the rear of the throttle body Insert the four spacers into their proper location see Fig 8 c C Slide the supplied O ring around the top flange of the throttle body Use a light amount of oil on the O ring to allow easy installation of the discharge plenum Carefully align the discharge plenum to the installed throttle body studs Lower the plenum down onto the throttle body being careful not to upset the O ring fit When contact with the O ring is felt push down firmly on the plenum until you feel it seat on the top of the throttle body see Fig 8 d D Securethe plenum to the throttle body by attaching the supplied washers and nuts to the previously installed2. NPT plug located on the engine block E q E Eas P P uuu just above the oil filter boss Replace the plug with the tosupercnarcer supplied 3 8 NPT elbow Connect the remaining fittings as shown see Fig 3 a Fig 3 a NOTE Use clean engine oil on the pipe threads Teflon tape and sealant is not recommended as it might loosen and cause blockage of the small oil feed orifice resulting in supercharger failure C Connect the supplied feed line to the flare fitting and make a gentle downward loop around and back toward the front of the engine see Fig 3 b Secure the hose with the tie wraps provided routing it away from exhaust heat chaffing and or sharp objects Temporarily cover the open end from debris until the connection is made to the supercharger in step 5 4WD MODELS Connect the feed hose and fittings to 1 8 NPT s 45 FLARE the remote oil filter boss at the front of the vehicle see ROUTE HOSE AROUND Fig 3 c TO FRONT OF VEHICLE d ROUTE ALONG OIL COOLER LINES Fig 3 b Rear View 2WD only Fig 3 c AWD only 4 MAIN BRACKET A To accommodate the relocation of the alternator onto the new main bracket the brown field wire must be extended approximately 12 Proceed by cutting the wire approximately 4 from the factory plug that attaches to the alternator Splice the supplied piece of brown wire into the cut wir
3. 6 8 SUPERCHARGER DISCGHAROE rey 8 9 SUPEBOGHABGER AIR INCE Possiet EE E EAE O 9 10 FJELMANAGEMEN TUNET e mantel eat a e EN Un aS 11 11 SUPPLEMENTARY FUEL PUMP AND HARNESS i osetiarnbean RU xiUs x DUI ub SIRE eui REDUCES 12 12 FINAL REASSEMBLY AND CHECK pect cache tts crto ace ntnr asa ctnn pec KSOPEA nU EEUUU ERO cR REIN FUM SUE VU 14 lii NOTICE This product is protected by state common law copyright and or patent All legal rights therein are reserved The design layout dimensions geometry and engineering features shown in this product are the exclusive property of Vortech Engineering Inc This product may notbe copied or duplicated in whole or part abstractly orfundamentally intentionally or fortuitously nor shall any design dimension or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering LL C 1996 1999 GM VORTEC 4 3L V 6 S 10 Sonoma Jimmy Blazer Installation Instructions 50 State Smog Legal as per CARB EO D 213 17 1999 models Legal in California only for racing vehicles which may never be used upon a highway Congratulations on selecting the best performing and best backed automotive supercharger available today the VORTECH V 2 supercharger Before beginning this installation please read through this entire instruction booklet and the Street Super charger System Owner s Manual and Warranty Registration form Vortech supercha
4. ENGINEERING LLC 1650 PACIFIC AVENUE CHANNEL ISLANDS CA 93033 9901 805 247 0226 FAX 805 247 0669 www vortechsuperchargers com M F 8 00 AM 4 30 PM PST FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience Please browse through each step of this instruction manual priorto beginning the installation to determine if you should refer the job to a professional installer technician Please call Vortech Engineering for installers in your area 2003 VORTECH ENGINEERING LLC All rights reserved No part of this publication may be reproduced transmitted transcribed or translated into another language in any form by any means without written permission of Vortech Engineering LLC Table Of Contents 29 10 D T 1 t lii NOTICO e E IV TOOL amp SUPPLY REQUIREMEN S ea UN SCUSA SS GU eiiie V PARTS LIS1 1996 1999 GM VORTEC 4 3L V D ississci pati tust ntato snc RR ATRUpEEDRbawE GE Inr UdoK PEDI GO RE Eo I qe PONE vi 1 PREFARATON 0 1 2 emp 2 3 0 E 2 4 VAIN 3 oe SUPERCHARGER INS TAELEATODBL sa seswovanisimnavaceccunseiatassasaraniiceasaa ia eaaa ai iesaki 4 6 SUPERCHARGER ACCESSORY DRIVE 0 5 f COIL RELOGATION IGNITION INSTALLATION
5. B Route the hose down the rear of the main bracket while lowering the supercharger into the proper mounting location on the plate Be sure that the oil drain hose remains unkinked with smooth bends C Using the five supplied 3 8 16 x 1 bolts and AN washers secure the supercharger to the mounting plate D Route the oil drain hose around the main casting and down to the fitting in the oil pan Make sure that the hose runs below the positive alternator lug but still remains running downhill See Fig 5 a It is very important that the oil drain hose is free from restrictions tight bends kinks or any other drain obstructing conflict Route the hose away from direct exhaust heat OIL DRAIN HOSE Trim hose length if necessary and secure to the oil pan with the supplied 8 hose clamp Fig 5 a E Attach the 1 8 NPT x 45 brass fitting to the supercharger oil feed Use a 1 2 wrench to hold the feed fitting while tightening the 45 fitting Attach the oil feed hose to the supercharger See Fig 5 b WARNING The oil system contains a small orifice that is easily plugged Do not use any type of sealant on any of the threads Instead use clean engine oil Disas semble and blow out the entire line if there is any question F Using the tie wraps provided secure the feed and drain systems away from heat and or sharp objects SUPERCHARGER ACCESSORY DRIVE BELT A Mount the supplied
6. 7 a Connect a manifold sourced vacuum line using the supplied 5 32 hoseand TEE usethe FMU tap location Route the extended coil wires and previously attached vacuum hose from the engine compartment back along the frame rail and to the transmission crossmember Drill a 5 8 hole through the floor of the vehicle from the bottom of the center console location for wire vacuum hose pass through Route the wire vacuum hose bundle up into the passenger compartment using the previously drilled hole Use the supplied cable ties to keep the wires secure and away from moving sharp hot objects Do not attempt to start the vehicle without all components installed as shown Ignition Boost Control operation 1 Thelgnition Boost Control unit is designed to retard ignition in relation to boost 2 The unit is adjustable from 0 of ignition retard to 4 of ignition retard for each pound of boost up to a maximum of 20 3 Usingthe 1 per pound position as a starting point adjust the ignition retard knob until just beyond the point of detonation see Fig 7 e Use third gear for testing in a safe area or road Adjust the retard according to changes in altitude and fuel quality Caution Itis extremely important that the boost retard never be turned to 0 It is recommended that in stock street applications the knob be at no less than 1 per Ib Examples of Ignition Retard vs Boost 5 psi at 3 per Ib 7 psi at 2 per Ib
7. automatic belt tensioner onto the main bracket Rotate the unit so that the small alignment pin falls into the corresponding hole in the bracket Secure the tensioner to the bracket using the suppplied socket head bolt and 7 16 AN washer Route the supplied belt as shown see Fig 6 a Belt installation is easiest when the water pump is the last pulley to be mounted the radius on the edge of the water Dump pulley allows the edge of the belt to be slid over it SUPERCHARGER SPRING TENSIONER WATER PUMP Fig 6 a AIR CONDITIONER POWER STEERING 7 COIL RELOCATION IGNITION INSTALLATION A Remove ignition coil and bracket from the factory location SUPPLIED COIL B Separate the coil and module from factory mounting BRACKET bracket C Install the coil and moduleto the supplied bracket using the supplied hardware see Fig 7 b D Mount the coil and bracket assembly to the intake manifold Use the factory studs and nuts to secure the coil See Fig 7 c E Remove the interior center console between the two front seats Mount the supplied ignition control box assembly into the vehicle interior in one of two possible locations alternate mounting locations of the control box retard knob and MAP sensor may vary suiting the taste preference of the installer See Figs 7 f 7 g 1 Pickup truck models S 10 Sonoma a The suggested mounting location is in the center console betwee
8. drill a 16 hole Secure using a 12 hex head screw G Using the existing hole in the frame and supplied 10 hardware mount the relay to the vehicle frame see Fig 11 aon this page and Figure 10 aon page 11 The relay mounting hole Will also work well as a grounding point for the pump and relay Scrape away the frame coating and paint to provide a proper ground connection Make sure that the pump and relay grounding terminals are mounted under the relay as opposed to on top so that a GROUND metal to metal contact will be made FUEL PUMP SOLID GREY WIRE IN FUEL PUMP HARNESS RUNNING ALONG THE DRIVER S SIDE FRAME MEM BER BATTERY LUG RELAY WIRING SCHEM ATIC Fig 11 a 11 SUPPLEMENTARY FUEL PUMP AND HARNESS cont d H Following the diagram see Figs 11 c 11d wire the fuel pump and relay Use the supplied tie wraps to run the wire and keep it away from heat abrasion Use the supplied 8mm nut to connect the main power lead on the relay to the factory fuse power box underhood the factory has provided two open power lugs under the power box cover Tap the yellow relay wire terminal 87 into the solid gray wire in the harness running along the driver s side frame member Use the supplied wire tap dic ud QUICK DISCONNECT STYLE FITTINGS TO RAIL MEM 5 16 FUEL HOSE RELY TERMINAL 87 GROUND Fig 11 c 3 8 HOSE 3 8 FROM OPRESSION 8 HOSE COMPRESSION STYLE FITTI
9. studs E Remove the 1 2 brake booster vacuum line from the intake manifold and cut approximately 2 off from the end Splice the supplied adapter TEE into the brake booster line Run the supplied piece of 1 4 vacuum hose from this TEE to the 1 4 5 32 reducer see Fig 8 a F Attach the supplied compressor bypass valve and 1 x 2 25 hose to the plenum using 16 clamps Orient the bypass valve as shown see Fig 8 e G Attach the discharge tube from the supercharger to the plenum using the supplied silicone sleeves and clamps see Fig 8 e Connect the 5 32 hose to the nipple located on the bottom of the supercharger bypass valve to the reducer previously installed into the brake booster line BRAKE UA 5 32 HOSE 1 4 HOSE 1 2 TEE 1 4 NPT x 1 4 REDUCER FITTING H MANIFOLD FITTING SUPERCHARGER AIR INLET ELBOW SUPERCHARGER DISCHARGE TUBE m Fig 8 a 9 SUPERCHARGER AIR INLET A Install the supplied plastic 3 4 x 90 vent adapter into the factory rubber grommet located on the right side valve cover Rotate the vent adapter so that it points toward the rear of the vehicle Attach the supplied 3 4 x 20 hose to the installed adapter The oil fill riser must be modified to allow for fitment of E ie the new air inlet duct see Fig 9 a Begin by removing the plastic oil fill riser and cap located on the right side valve cover Cu
10. Discharge Assembly 1 2A036 312 Supercharger Pulley 3 125 6 groove 1 7R002 044 44 Hose Clamps 4 7K375 040 3 8 AN960 Flat Washer 1 8D001 001 Bypass Valve 1 2A040 01 1 Pulley Retainer 1 2 am ps 7B375 12 1 4 i oo 9 a Veta 7U030 046 9 32 x 24 Vacuum line 1 4GD111 021 Mounting Bracket Assembly 1 7 2 7A375 101 3 8 x 1 Socket Head CO ST Ring Throttle Body 1 7A375 100 3 8 16 x 1 1 4 HXHD Cap Screws 2 79275 200 2 3 4 x 2 Sleeve 2 7K375 040 3 8 AN960 Flat Washers 16 7P500 156 1 9 Vac TEE x 1 4 NPT 1 1579 100 3 8 16 x 1 HXHD Bolts 5 7P250 033 1 4 x 5 32 Red Union 1 7A375 275 3 8 16 x 2 3 4 HX Cap Screws 2 7P250 039 1 4 NPT Fem x 1 4 Hose 1 4GM01 1 021 Mounting Bracket 1 7U030 030 1 4 Vacuum Hose 0833 4GM010 033 Mounting Plate 1 70034 016 1 GS Hose 3 16 1 4GD01 1 032 Spring Tensioner 1 2A017 028 Plenum Spacer A 1 ns Belt 2A017 029 Plenum Spacer B 1 ule LE 0 2 0 Plenum Spacer C 2 Spacer Idler 1 oe 7C060 600 M6 6 TB 4 3 Stud front 2 7C012 050 12mm x 1 75 x 50mm Bolt 1 7C060 387 M6 3 87 4 3 Stud RR 1 AIDT Dust Cover 1 7F006 093 6mm Nylock Nut 3 4GD116 150 Idler Pulley Assembly 1 7006 093 6mm Washer 3 4GD010 060 Coil Mount Bracket 1 4GM010 050 Heat Shield 1 2 Fuel Pump Assembly 1 25 ie ie l a oe DELE Type Fuse r 4GD014 010 Radiator Pipe 1 5W001 017 Large Ring Terminal 1 7R002 024 324 Gold Seal Hose 2 5W001 019 12 10 Ga Solderless Connector 1 7008 100 48 32 x 1 Socket Head Ca
11. NGS TANK FITTING CLAMP 5 16 HOSE TO 3 8 COM PRESSION FITTING 3 8 TO RAIL FACTORY FUEL FILTER FUEL PUMP 8 HOSE CLAMP RELAY TERMINAL 87 GROUND M 12 FINAL REASSEMBLY AND CHECK WARNING Do not attempt to operate the vehicle un til ALL components are installed and ALL operations are completed including the final check A If your vehicle has gone over 10 000 miles since its last spark plug change you will need to change the spark plugs now before test driving the vehicle B Check all fittings nuts bolts and clamps for tightness Pay particular attention to oil and fuel lines around moving parts sharp edges and exhaust system parts Make sure all wires and lines are properly secured with clamps or tie wraps C Check all fluid levels making sure that your tank s is are filled with 92 octane or higher fuel before commencing test drive D Start engine and allow to idle a few minutes then shut off E Recheck to be sure that no hoses wires etc are near exhaust headers or moving parts and for signs of any fluid leakage F PLEASE TAKE SPECIAL NOTE Operating the vehicle without all sub assemblies completely and properly installed and working may cause FAILURE OF MAJOR ENGINE COM PONENTS Test drive the vehicle H Readthe STREET SUPERCHARGER SYSTEM OWNER S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty 30 days of purchasin
12. Wire oom 1 7U030 036 1 2 Oil Drain Hose x 24 1 70100 055 Tie Wraps 2 5W012 000 12GA STRD Wire Red 1 4 5W012 010 12GA Wire Black 1 4GD130 026 Oil Feed Line Assembly 1 5W022 120 22GA STRD Wire Brown 1 7U030 026 1 4 Oil Feed Hose x 48 1 7E010 046 8 x 3 4 Sheet Metal 1 7P525 067 525 Crimp Ferrules 2 7P156 082 5 32 TEE 1 7P250 066 4 Swivel x 1 4 Hose Barb Fittings 2 7U030 046 5 32 Vacuum Line 1 7P125 103 4 x 45 1 8 NPT Male Elbow 1 7U100 055 Tie Wrap 6 Nylon 10 7P375 033 3 8 NPT x 3 8 NPT SRT EL 1 7U375 001 Velcro Hook 1 Black 1 7P375 018 3 8 1 8 NPT Bushing 2WD 4WD 1 7U375 002 Velcro Latch 1 Black 1 7P125 026 90 1 8 NPT x 4 Fitting 1 5W018 010 18GA STRD Wire Red 1 7P250 100 1 4 1 8 NPT Bushing 1 5W018 020 18GA STRD Wire Black 1 7P250 146 1 4 NPT Street Elbow 1 5W018 060 18GA STRD Wire Orange 1 4GD238 068 FMU With Lines 1 5W018 240 18GA STRD Wire White Yellow 1 6Z110 134 Fuel Management Unit 1 70000 Inspector Number 1 7U030 046 5 32 Vacuum Line x 4 3 1 5W001 040 12 10GA Female Slide 2 4GD145 010 Female FMU Line to tank 1 5W001 041 12 10GA Male Slide 2 4GD145 020 Male FMU Line to rail 1 7P250 041 Compression ftg 2 7P250 036 4 x 1 4 NPT 2 4GM 135 056 36 FMU Line 1 4GM 135 057 22 FMU Line 1 P N 4GD020 010 2001 Vortech Engineering LLC All Rights Reserved Intl Copr Secured Vi 26APRO1 V1 2 4 3L V 6 S 10 4GD 1 COMPONENT REMOVAL A Disconnect the negative battery cable from the batt
13. ct Remove the factory MAF sensor and airbox assembly Remove the driver s side headlight assembly Separate the MAF sensor from the airbox see Fig 9 e Remove the filter and venturi shaped inlet from the box Modify the lower portion of the airbox as shown and reinstall into the vehicle Insert the supplied airbox inlet duct through the core support opening behind the headlight and into the modified factory airbox Rotate the duct see Fig 9 c Drill two holes into the core support using the duct flange as a guide Secure the duct with the two sheet metal screws provided Reinstall headlight assembly Install the supplied K amp N air filter into the factory airbox Drill a 3 4 hole into the airbox top in the location shown see Fig 9 d Insert the supplied rubber grommet and the factory air intake temperature sensor into the new hole Attach the modified airbox lid the airbox base Reattach the MAF to the airbox lid Attach the factory MAF and IAT sensor connectors Fig 9 a INLET TUBE SUPPORT Fig 9 b NEW IAT SENSOR LOCATION Fig 9 c 9 SUPERCHARGER AIR INLET CONT D l Slide the supplied 3 orange sleeve onto the outlet of the MAF meter Connect the previously installed steel supercharger inlet duct to the MAF meter oultet using the supplied section of flex hose and 52 clamps see Fig 9 f Check to see that there is adequate clearance between the factory mounted unde
14. e by soldering Usethe supplied piece of heat shrink tubing to seal the joints Re wrap the wire harness with the supplied length of plastic flex loom B The transmission cooler lines may need to be bent downward as far as possible toward the frame to obtain alternator clearance C Attach the supplied stainless steel heat shield onto the rear of the Vortech main bracket using the supplied 1 4 hardware see Fig 4 a D Following Figure 4 d cut the supplied protective sleeve as shown Slide the protective sleeve onto the air injection adapter following with the 90 compression fitting Do not tighten compression fitting yet Mount this assembly to the exhaust manifold using the supplied hardware and stock gasket replace in necessary Torque bolts evenly using a5mm hex wrench See Fig 4 8 E Thread the factory check valve onto the compression fitting and tighten Referring to Fig 4 e angle the compression fitting slightly upward then tighten Use one wrench on the compression fitting and one on the INSTALL 90 RADIATOR PIPE nut to protect the air injection adapter from damage Fig 4 b while tightening the compressing nut 78625 000 HEAT SLEEVE 4GD110 070 AFTER TRIMMING ADAPTER F Attach the supplied 5 8 x 24 hose to the factory check ASSEMBLY valve and to the TEEcoming from the air injection pump Jn and secure G Cut factory lower radiator hose as shown see Fig 4 c 2 Install the supp
15. ery B Remove and set aside the following components The entire air inlet filter box assembly including the throttle body resonator and all hardware including the throttle body mounting bolts The crankcase vent tube from the passenger side valve cover The accessory drive belt The tensioner and idler from the alternator mounting bracket The alternator and bracket The 3 8 stud protruding from the right side cylinder head 2000 California models only Disconnect both ends of the hose connecting to the factory check valve and remove valve from the air injection tube Remove the air injection tube from the passenger s side exhaust manifold Remove the two studs using a 5 5mm socket C Drain the contents from the radiator into a clean container D Remove lower radiator hose 2 OIL DRAIN A To provide an oil drain for the supercharger it is necessary to make a hole in the oil pan Locate and mark hole see Figs 2 a 2 b PUNCH HOLE THROUGH DIRECTLY UNDERNEATH CORNER PAN BOLT NOTE Removal of the oil pan may ease oil drain fit ting installation on some applications Remove the factory anti roll bar brackets 2 from the frame and allow the bar to temporarily drop down Unplug the factory crank trigger connector from the sensor located in the timing cover NOTE The factory transmission cooler lines may re quire bending to clear the supercharger oil drain hose Carefully dril
16. g your supercharger system to quality for the 3 year limited warranty Figt 12 a O ENGINEERING LLC 1650 PACIFIC AVENUE CHANNEL ISLANDS CA 93033 9901 805 247 0226 FAX 805 247 0669 www vortechsuperchargers com M F 8 00 AM 4 30 PM PST
17. ith both versions of this vehicle Refer to the graphic below to verify the vehicle you are modifying QUICK DISCONNECT TYPE FITTINGS ONLY A Using a fuel line disconnect tool separate the supply line from the oulet of the fuel filter B Attach the supplied 3 8 hose to the fuel filter outlet Connect the remaining end of the 3 8 hose to the fuel pump inlet Trim the hose if necessary COMPRESSION TYPEFITTINGS ONLY Fig 11 b C Separate the factory 3 8 fuel rail supply line at the compression fitting junction underneath the vehicle just to the rear of the fuel filter see Fig 11 b D Attach the supplied 3 8 hose to 3 8 compression fitting to the line coming from the fuel tank Connect the supplied length of 3 8 fuel hose to the 3 8 fitting previously installed and the remaining end to the supplied inline pump Secure with a 8 hose clamp BOTH APPLICATIONS E Attach the discharge end of the fuel pump to the line running into the fuel filter use the supplied 5 16 hose to 3 8 compression fitting Position the pump in such a way that the inlet and discharge hoses are not kinked or restricted and maintain a gentle bend The pump inlet is the most critical as far as restriction is concerned and may be trimmed if necessary to hold a smooth radius Make sure that all fuel pump hose connections are secure F Mount the fuel pump to the frame using the 1 1 2 adel clamp Position the clamp and
18. l a pilot hole the same diameter as the Rota Broach pilot into the marked spot on the oil pan this procedure may also be done by removing the oil pan if you are unsure of your ability to perform the following steps properly Drill slowly as to catch most of the aluminum chips from the hole being drilled Using the 9 16 Roto Broach very slowly machine a hole in the pan use the previously drilled hole as a guide Stop machining just before the tool breaks through into the oil pan Using a scribe or a small screwdriver remove the remaining disc shaped oil pan piece this allows you to remove the pan slug before it falls into the oil pan and keeps most of the aluminum chips out HOLE MUST BE MADE FROM THE SIDE OF THE PAN OIL PAN BOLTS 2 OIL DRAIN cont d D Tapthehole with a 3 8 NPT tap approximately 1 4 deep Pack the flutes of the tap with heavy grease to hold chips Thoroughly clean the threaded area Apply a small amount of silicone sealer to the new threads Apply more sealer to the supplied 3 8 NPT x 1 2 barb fitting Install the fitting into the pan Make sure a seal is formed around the entire fitting F Drain the engine oil install a new filter and refill with fresh oil G Reattach anti roll bar and crank trigger connector 3 OIL FEED A The supercharger uses engine oil for lubrication and must have an oil feed line connected to a filtered oil access on the engine B Remove the 3 8
19. lied 90 steel tube and secure using the supplied 24 clamps see Fig 4 b H Placethe mounting bracket on the front of the passenger S078 EE side cylinder head Line up the bracket with the holes on the front of the head and block and start the 3 8 16 socket head bolt into the lowest bracket hole Install the two 3 8 16 x 1 00 bolts and washers into the two remaining upper holes Torque the three bolts evenly Place the alternator in position on the bracket and check for clearance between the air injection adapter and the back cover of the alternator In some instances it may be necessary to remove the cover and trim a small portion of the cover before final mounting 4 RADIATOR TRIM STOCK HOSE CA 2000 Models Only Fig 0 AND INSTALL 90 TUBE 4 MAIN BRACKET cont d J Reattach the field wire and positive wire to the alternator make sure that the large positive wire has the factory rubber boot properly secured to prevent arcing to the heat shield Using the supplied 3 8 16 x 2 75 bolts and washers attach the alternator to the main bracket Secure all alternator wiring from heat and sharp objects Align the supercharger mounting plate with the bracket and secure with the supplied 3 8 16 x 3 4 bolts and AN washers 5 SUPERCHARGER INSTALLATION A Attach the 1 2 oil drain hose to the supercharger and secure with the 8 hose clamp
20. n the two seats remove the center console and mount the control unit vertically in the rear See Fig 7 f b The retard knob can mount in the forward portion of the tray in the console Mount the MAP sensor under the console See Fig 7 f COIL MOUNTING LOCATION CUT HERE AND ATTACH CONNECTOR FACTORY GM HARNESS UNPLUGGED 2 FROM COIL AINN GS GREEN HEAVY RED OR WHITE TO BATTERY e HEAVY BLACK TO GROUND 8 WIRE TAP WHITE BLACK ORANGE GREEN TACH TAPE UP GREY MAGNETIC TRIGGER HARNESS TAPE UP BROWN w WHITE STRIPE RETARD INPUT LH SUPPLIED MAP SENSOR 0 IGNITION COIL 1 YELLOW TAPE UP BLACK GROUND a 3 WIRE HARNESS RANE cus MANIFOLD Sy a EA VACUUM Tita RETARD CONTROL NOTE CABLE CONTAINS RED AND BLACK LEADS MAKE SURE LEADS DO NOT CONTACT EACH OTHER AND SHORT UNIT WHEN TAPING UP Fig 7 a 96 97 Coil Relocation 7 COIL RELOCATION IGNITION INSTALLATION cont d F H 2 SUV models Blazer Jimmy a he suggested mounting location is in the storage box located next to the back seat on the passenger side of the vehicle b Theretard knob and MAP sensor can mount in the center console as the pickup trucks do see Fig 7 f The brown retard wire and thin red power wire must be run over to the remote mounted ignition box Connect all components as shown see Fig
21. p Screw 4 UE 4 m uS H 7F008 032 32 Hex Lock Nut 4 i 7J008 001 h i 4 8F101 200 T Rex Wiring Assembly 1 SW022 120 226A STD Wire Brown 1 7F008 020 M8 x 1 25 Nut 1 SW001 007 3 16 Heat Shrink Tube 6 ae A OR ipee SW001 Plastic Wire Loom 1 70010 066 M10x 15x Soc HD Bol 7P375 006 3 8 1o 5 16 Fuel Fiting 7K437 001 7 16 AN Washer 1 i i 4GD112 010 Air Intake Assembly 1 ps 7 i A M a 5W001 042 12 10GA 3 16 Ring Terminal 4 Sold ces Rear PP j 7E010 049 10 x 3 4 Hex Head Sheet 5 7R004 002 17 0 Stepless Clamp 1 78350 200 3 1 2 x 2 Sleeve 1 7R001 004 4 Hose Clamp 1 7R002 056 56 Gold Seal Hose Clamp 2 7P375 072 Fernale Fuel Fitting 1 7U035 001 3 1 2 Flex Hose x 12 1 7R001 008 4 Clamp 4 7R002 052 52 Gold Seal Hose Clamp 3 7250 042 Compression ftg 2 NEC A 7P250 045 1 4 NPT to 3 8 Barb 1 7P250 043 1 4 NPT to 5 16 Barb 1 7P500 026 1 2 NPT 3 4 90 Barb 1 7R001 008 8 Hose Clamp 1 5A101 010 HI 6R Assembly 1 7U034 016 1 GS Hose 4 1 5A001 009 HI 6R Ignition System Assy 1 4GD112 030 Air Box Duct Assembly 1 5W001 001 Wire Tap 1 7U100 057 Grommet 1 5W001 009 16 14GA Male Slide 10 79300 101 3 x 1 Sleeve 1 5W001 010 16 14GA Female Slide 10 7R002 016 16 Gold Seal Hose Clamp 2 9W001 011 16 14GA Eyelet 25 Hole 2 4GD130 036 Oil Drain Assembly 1 DE ix ype 20 amp 1 7R001 008 8 Stainless Hose Clamps 2 5W001 017 Large Hina Terminal 194 i i ge Ring Termina 2 7P375 017 3 8 NPT x 1 2 Straight Hose Barb 1 5W001 020 3 4 Plastic
22. plugs that are older than 1 year or 10 000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications follow the procedures indicated within the factory repair manual and or as indicated on the factory underhood emissions tag Do not use platinum spark plugs unless they are original equipment Change spark plugs every 20 000 miles and spark plug wires at least every 50 000 miles TOOL amp SUPPLY REQUIREMENTS Factory repair manual 3 8 socket and drive set SAE amp metric Drill motor 3 32 5 8 and 16 drill bits Hat 42 screwdriver Open end wrenches 5 16 3 8 7 16 1 2 9 16 5 8 10mm 13mm 15mm 16mm 17mm 18mm 5mm Hex wrench Hammer Silicone sealer Oil filter wrench Oil filter SF rated quality engine oil Gasket scraper Punch tapered 3 8 NPT tap Fuel line disconnect tool Rota Broach 9 16 boring tool Snap on GA219 A If your vehicle is in excess of 10 000 miles since its last spark plug change then you will also need e Spark plug socket e NEW spark plugs 1996 1999 GM VORTEC 4 3L V 6 Part No 4GD218 050 058SQ PARTS LIST Y ENGINEERING LLC IMPORTANT Before beginning installation verify that all parts are included in the kit Report any shortages or damaged parts immediately Part Number Description Quantity Part Number Description Quantity 2E228 280 Supercharger Assembly 1 m 2E128 280 V 2 SQ Supercharger 1 00 Air
23. rger systems are performance improving devices In most cases increases in torque of 30 35 and horsepower between 35 45 can be expected with the boost levels specified by Vortech Engineering This product is intended for use on healthy well maintained engines Installation on a worn out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger Vortech Engineering is not responsible for engine damage Installation on new vehicles will not harm or adversely affect the break in period so long as factory break in procedures are followed For best performance and continued durability please take note of the following key points 1 Use only premium grade fuel 92 octane or higher R M 2 2 The engine must have stock compression ratio 3 If the engine has been modified in any way check with Vortech prior to using this product 4 Always listen for any sign of detonation pinging and discontinue hard use no boost until problem is resolved 5 Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle Thereafter always use a high grade SF rated engine oil or a high quality synthetic and change the oil and filter at least every 3 000 miles Never attempt to extend the oil change interval beyond 3 000 miles regardless of oil manufacturer s claims as potential damage to the supercharger may result 6 Beforebeginning installation replace all spark
24. rhood light and the supercharger kit by slowly closing the hood Remove light if necessary 10 FUEL MANAGEMENT UNIT A Following the Fig 10 a position the fuel management unit FMU on the inside of the vehicle frame underneath the driver s seat Mark and drill two 16 holes Secure the FMU using the supplied 12 hex head screws NOTE Someearlier model trucks are not equipped with quick disconnect fittings and will require the use of compression fittings and alternate fuel lines Proper lines and fittings are supplied to work with both versions of this vehicle Refer to Fig ures 10 c 10 d to verify the vehicle you are modifying QUICK DISCONNECT TYPE FITTINGS ONLY B Using a fuel line disconnect tool separate the 5 16 FUEL PUMP HARNESS FMU fuel return see Figure 10 b Attach the supplied 33 Fia 10 a oL g fuel hose with the male fitting into the fuel line coming from the engine compartment Attach the 17 supplied fuel hose with the female fitting into the line returning back to the tank Connect the fuel line coming from the engine compartment to the 90 fitting on the side of the FMU Connect the fuel line returning back to the tank to the straight fitting on the bottom of the FMU Make sure that both lines have smooth bends and are absolutely free from sharp bends and kinks see Fig 10 c COM PRESSION STYLE FITTINGS ONLY B Separate the factory 5 16 fuel rail return line a
25. t the compression fitting junction underneath the vehicle near the fuel filter Attach the supplied 4 flare fitting adapters to each end of the open return line one fitting will point toward the rear and one toward the front Connect one end of the supplied 22 FMU hose to the return line running back to the tank and the other end to the straight fitting on the center of the FMU Connect one PARE EINE Era Ween RS end of the remaining 36 FMU hose to the return line Fig 10 b coming from the fuel rail and the other end to the 90 fitting on the side of the FMU see Fig 10 a C Tap into the supercharger bypass valve vacuum hose using the supplied 52 long length of hose and 5 32 brass TEE Route the hose in a manner that will keep it away from exhaust heat and will allow gentle bends without pinching Attach the hose end to the lid of the FMU QUICK DISCONNECT TYPE FITTING COMPRESSION TYPE FITTING Du FROM RAIL Wt Sou RAT VACUUM LINE TO MANIFOLD VACUUM LINE FMU OUTLET TO MANIFOLD TO TANK FMU OUTLET TO TANK MOUNT TO FRAME MOUNT TO FRAME FMU INLET FMU INLET FROM FUEL FROM FUEL RAIL RETURN RAIL RETURN Fig 10 c Fig 10 d 11 11 SUPPLEMENTARY FUEL PUMP AND HARNESS NOTE Some earlier model trucks are not equipped with quick disconnect fittings and will require the use of compression fittings and alternate fuel lines Proper lines and fittings are supplied to work w
26. t the riser in half the diameter using 8 saw or cut off wheel Clean and reinstall the base of the cut riser into the valve cover Slide the supplied piece of 1 x 4 hose over the base Insert the remaining top portion of the filler into the hose The cap should now be approximately 2 3 higher than its factory location Adjust height if necessary Install the supplied 1 2 NPT x 90 x 3 4 hose barb fitting into the 3 5 steel inlet tube The fitting must be clocked so that when the inlet tube is installed the fitting points down and over to the right side valve cover and attaches to the previously installed 3 4 valve cover vent hose temporarily place the tube in its installed position to approximate the fitting rotation before final installation Attach the supplied inlet tube support to the left rear portion of the intake manifold see Fig 9 b Using the supplied 3 5 silicone sleeve and 56 hose clamps attach the 3 5 inlet duct to the supercharger Lay the duct on top of the previously installed tube support Connect the 3 4 valve cover vent hose to the 90 fitting on the inlet duct Trim length if necessary Situate duct so that it does not contact the firewall or any other object that will cause problems when the engine torques on operation Secure duct to the tube support using the supplied 52 clamp Attach the 1 x 3 compressor bypass discharge hose to the barb located on the inlet du
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