Vortech 1990-1995 5.7L TBI Truck SUV User Manual

GM 5.0 / 5.7

LIGHT TRUCK

Supercharger System

Installation Instructions

50 State Sm

1990-1995 M

og Legal Per CARB EO

DEL

YEARS

# D-213-17

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

(LT. TRUCK (4GB V1.1))

ENGINEERING, LLC

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of

prior

this instruction manual should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

to beginning the installation to determine if you

or translated into another language in any form, by any means without written permission

of Vortech Engineering, LLC.

(LT. TRUCK (4GB V1.1))

Table Of Contents

FOREWORD................................................................................................................................. ii

TABLE OF CONTENTS................................................................................................................ iii

NOTICE......................................................................................................................................... iv

TOOL & SUPPLY REQUIREMENTS............................................................................................ v

PARTS LIST ................................................................................................................................. vi

1. COMPONENT REMOVAL................................................................................................... 1

2. CRANKSHAFT PULLEY INSTALLATION ........................................................................... 1

3. OIL DRAIN LINE..................................................................................................................2

4. OIL FEED LINE ...................................................................................................................3

5. SUPPLEMENTARY FUEL INJECTION COMPUTER AND RELATED SYSTEM................ 3

6. MAIN BRACKET AND POWER STEERING PUMP............................................................ 7

7. MAIN MOUNTING PLATE AND ALTERNATOR .................................................................. 7

8. SUPERCHARGER MOUNTING ......................................................................................... 8

9. FACTORY ACCESSORY DRIVE BELT AND SUPERCHARGER DRIVE

BELT SCHEMATIC .............................................................................................................. 8

10. DISCHARGE PLENUM ....................................................................................................... 9

11. AIR FILTER, INLET DUCT AND PLENUM .......................................................................... 10

12. FINAL REASSEMBLY & CHECK ........................................................................................ 11

iii

P/N: 4GB020-010

(LT. TRUCK (4GB V1.1))

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, LLC. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, 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, LLC.

(LT. TRUCK (4GB V1.1))

1990 - 1995

GM 5.0 & 5.7 LIGHT TRUCK

Installation Instructions

50 State Smog Legal, as per CARB EO #D-213-17

Congratulations on selecting the best performing and best backed automotive super-

charger available today... the VORTECH® V-2® SUPERCHARGER !

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty Registration form and return envelope.

Vortech supercharger 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. Before beginning installation, replace all spark 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 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

• 3/8" socket and drive set: SAE and Metric

• 1/2" breaker bar and 4" extension

• Drill motor, 3/32" and .046" drill bits

• Large screwdriver or pry bar

• Flat #2 screwdriver

• Phillips #2 screwdriver

• Adjustable wrench

• Open end wrenches:

3/8", 7/16", 9/16", 5/8", 3/4", 7/8" a "Slimline" 19 mm - Snap-On part # LTAM1719

• Allen wrenches: 3/8" and 5/16"

• Power steering pulley puller & installer Snap-On Puller #CJ117B2 Snap-On Installer #CJ113B

• Timing Light

• 3/8" NPT tap and handle or socket

• Center punch and 3/4" drift punch

• Silicone sealer

• Heavy grease

• Oil filter wrench

• Oil filter

• SF rated quality (or synthetic) engine oil

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will need:

• Spark plug socket

• NEW spark plugs

(LT. TRUCK (4GB V1.1))

P/N: 4GB020-010

1990-1995 5.0 & 5.7 Light Truck

Part No. 4GB218-050SQ

ENGINEERING, LLC

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.

Part Number Description Quantity

2E228-050 V-2 SUPERCHARGER ASSEMBLY 1

4GB111-021 MOUNTING BRACKET ASSEMBLY 1

4GB010-034 Mounting Plate 1 4GB011-021 Mounting Bracket 1 4GB015-014 Alternator Stay 1

7A375-375 3/8-16 x 3-3/4” Bolts 3 7A375-500 3/8-16 x 5” Bolts 2 7A375-350 3/8-16 x 3-1/2” Bolt 1 7F375-016 3/8-16 Nut 2 7K375-040 3/8” AN960 Flat Washers 10 7J375-044 3/8” SAE Washers 11

7A375-100 3/8-16 x 1” Bolts 10 4GG017-043 1/2" Spacer 2 7K3122-001 8mm Washers 2

7C080-025 8mm x 1.25 x 25 mm 2

4GB116-010 CRANK PULLEY ASSEMBLY 1

4GB016-011 Crank Pulley 1 4GB017-041 Crank Pulley Spacer 1

7B437-400 7/16-20 x 4” Bolt 1

7B375-275 3/8-24 x 2-3/4” Bolts 3

7J375-044 3/8” SAE Washers 3

7L375-075 3/8” Lock Washers 3

2A046-980 Belt 1

2A046-605 Belt 1

4GB112-010 AIR INTAKE ASSEMBLY 1

4GB012-010 Air Filter Cover 1 4GB012-012 Air Inlet Tube 1 4FA012-012 90° Intake Elbow 1

7P375-097 3/8” NPT x 3/8” Barb 1

7S350-200 3-1/2” x 2” Sleeves 2 4GB015-022 Air Inlet Tube 1

7E010-046 #8 x 3/4” Sheet Metal Screws 2

7U035-000 3-1/2” x 14” Flex Hose 1

8H040-040 Air Filter 1

7R002-056 #56 Hose Clamps 4

7R002-052 #52 Hose Clamps 3

7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1

4GB112-020 AIR DISCHARGE ASSEMBLY 1

4GB012-020 Discharge Tube 1 4GB040-060 Air/Plenum Gasket 1 4GB050-011 Intake plenum 1

7P187-100 3/16" Hose Fitting 1

7R002-044 #44 Hose Clamps 4

7S275-200 2-3/4” x 2” Sleeve 1

7S275-300 2-3/4” x 3” Sleeve 1

7P750-102 3/4" NPT x 1" 90° Hose Fitting 1

7P750-100 3/4" NPT x 1" Straight Hose Fitting 1

7R002-016 #16 Hose Clamps 4

8D001-001 Bypass Valve 1

7U030-046 5/32" x 24" Vacuum Line 1

7P156-082 5/32" TEE 1

7U034-016 1" x 3" Heater Hose 1

7U034-016 1" x 8.0" Heater hose 1

8H040-075 1" Filter 1

Part Number Description Quantity

4GB130-026 OIL FEED LINE ASSEMBLY 1

7U030-026 1/4” x 36” Oil Feed Hose 1 7P525-067 .500 Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2 7P250-036 #4 Flare to 1/4” NPT fitting 1 7P125-026 90° 1/8” NPT x #4 Fitting 1 7P250-123 1/4” NPT x 1-1/2” Nipple 1 7P250-080 90° 1/4” NPT Elbow 1 7U100-055 6” Nylon Tie Wraps 4

4GB130-036 OIL DRAIN ASSEMBLY 1

7R001-008 #8 Stainless Hose Clamps 2 7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1 7U030-036 1/2” x 36” Oil Drain Hose 1 7P375-033 3/8” NPT x 3/8” NPT Street Elbow 1

4FA111-032 BEL T TENSIONER ASSEMBLY 1

7J012-092 12mm Flat Washers 3

4FA011-032 Belt Tensioner 1

7C012-050 12mm x 1.75 x 50mm Bolt 1

4FA016-150 Smooth Pulley Tensioner 1

2A017-010 Idler Pulley Spacer 1 7C012-020 12mm x 1.75 x 20mm Bolts 2 7C012-022 12mm x 1.75 x 22mm Thin Head Bolt 1 7G010-175 12mm x 1.75 Nut 1

4GB101-002 FUEL PUMP ASSEMBL Y 1

8F001-002 155 Inline Fuel Pump 1 7R003-024 1-1/2” Adel Clamp 1

5W001-011 16-14 GA Eyelet 1 5W001-001 Wire Tap 1 5W001-010 16-14 GA Insulated Female Slides 6 5W001-014 Fuse Holder 1 5W001-015 Blade Type 20A Fuse 1 5W001-017 Large Ring Terminal 1

8F101-200 T-Rex 5W001-002 Fuse Tap 1

7R001-004 #4 Hose Clamps 2

7P625-001 Fuel adapter fitting 1

7U030-056 3/8” x 8” PCV Hose 1

7J010-001 #10 Flat Washers 4 7F010-032 10-32 Nylock Nut 2 7U100-055 6” Nylon Tie Wraps 4 7C011-075 10/32” x 3/4” Cap Screw 1

5W001-024 Mini Fuse Tap 2

5A001-004 FUEL INJECTION COMPUTER 1

Wiring Assembly 1

(LT. TRUCK (4GB V1.1))

+ 14 hidden pages

Vortech 1990-1995 5.7L TBI Truck SUV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual