Vortech 1990-1995 5.7L TBI Truck SUV User Manual

Download

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))

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

4GB160-010 FUEL CONTROL ASSEMBLY SMALL

4GB040-050 Gasket, TBI Standard 1 4GB040-056 Gasket, TBI w/.06 Hole 1 4GB052-011 Spacer Block Inj. -Machined 1

7A312-325 5/16-18 x 3-1/4 HXCS G5 1 7F312-019 5/16-18 Acorn Nut 2 7F312-020 5/16" x 1-1/2" Long Coupling 2 7K156-001 5/16 AN-Washer 5 7P156-082 5/32" TEE 2 7P187-100 3/16 Hose Fitting 2 7P312-082 5/16 TEE Hose Barb 2 7P625-001 Fitting, Fuel Adapter 1 7R004-001 15.7 Stepless Clamp 7 7R004-003 14.5 Stepless Clamp 2 7U100-040 O-ring, Fuel Inj. 6 7U100-055 Tie Wrap, 6" Nylon 4 7U030-046 5/32" Vacuum Line 2.333' 7U030-046 5/32" Vacuum Line 1.333' 7U030-046 5/32" Vacuum Line 5.833' 7U031-018 5/16 Fuel Hose Hi-Pressure 0.229' 7U031-018 5/16 Fuel Hose Hi-Pressure 0.208' 7U031-018 5/16 Fuel Hose Hi-Pressure 0.666' 8F002-001 Fuel Pressure Regulator 1 8F060-011 Fuel Injector 2 7P312-002 5/16 Barb x 1/4 NPT Fem 1 7P250-045 1/4 Male NPT x 3/8 Male Barb 1 7R001-008 #8 Stainless Hose Clamp 2 7U031-018 5/16 Fuel Hose Hi-Pressure 5.333' 7R001-004 #4 Hose Clamp 3 7U312-106 5/16-18 x 8" Threaded Rod 2 7U032-016 3/8" Fuel Hose Hi-Pressure 2.583'

BLOCK CHEVY TRUCK (w/o COMPUTER) 1

Part Number Description Quantity

vii

P/N: 4GB020-010

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

viii

1. COMPONENT REMOVAL

A. Disconnect the battery (negative lead). B. Remove and set aside the following components:

• Top portion of the fan shroud

• Accessory drive belt

• Cooling fan assembly

• Crankshaft pulley

• Air filter canister assembly and hose

• Intake air resonator (detach from inner fender)

• Alternator from bracket (place on manifold)

• Power steering pump pulley (use puller)

• Power steering pump pulley (DO NOT disconnect lines)

• Power steering bracket

2. CRANKSHAFT PULLEY INSTALLATION

A. Remove the crankshaft pulley from the engine if

not already done.

B. Place the Vortech provided crank pulley and

spacer inside the stock pulley.

NOTE: Depending on the model year of the ve-

hicle, the stock pulley location (against the balancer) may need to be switched with the Vortech pulley (check that the pilot of the spacer has a snug fit into the I.D. of the accessory drive pulley).

C. Line up bolt holes and, if necessary, press pieces

together or pull them together by gradually tightening the bolts.

D. Reinstall the pulleys as a unit onto the crankshaft

balancer assembly using three 3/8-16 x 2-3/4" bolts and one 7/16-20 x 4-1/4" center bolt provided.

NEW ADDITIONAL PULLEY

CENTER BOLT: 7/16-20 x 4-1/4"

3 BOLTS: 3/8-24 x 2-3/4"

SPACER

Fig. 2-a

22FEB02 V1.1

P/N: 4GB020-010

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

3. OIL DRAIN LINE

A. Raise the front of the vehicle

and support with appropriate jack stands.

B. To provide an oil drain for

the supercharger, it is necessary to make a hole in the oil pan. It is best to punch the hole rather than drill. Remove paint around the hole area so that it does not flake into the pan.

C. Make a mark on the oil pan

on the driver’s side ahead of the oil filter. The mark must be 2" below the bolt flange and forward of the fourth bolt (from rear) 1". If vehicle is equipped with an external oil cooler, be sure that the drain line fitting clears the oil cooler lines.

D. Use a small center punch to perforate the pan and

expand hole. Switch to a larger diameter punch and expand the hole further to approximately 9/16" diameter. Most punches are made from hexagon material and may be placed in a socket with an extension to make this procedure easier.

E. Tap the hole with a 3/8" NPT tap approximately

1/4" deep. Pack the flutes of the tap with heavy grease to catch and hold the chips. Once the tap is removed, it must be cleaned and repacked before tapping resumes. Use a small magnet to check for any stray chips in the threads after completing the tapping procedure.

OIL PAN

PUNCH HOLE THROUGH

DOWN 2"

OIL FILTER

Fig. 3-a

IN-LINE FOURTH BOLT

NOTE: This method of rolling over the lip of the

hole and tapping works well if CAREFULLY done and should cause no problems.

F. Thoroughly clean the threaded area with acetone

or other solvent. Apply a small amount of silicone sealer to both the new threads and to the threads of the 3/8" NPT hose fitting and secure in hole. Make sure a seal is formed all around the fitting. Allow sealer to cure completely.

G. Route the line forward along the top rail of the oil

pan and secure to the pan bolts with the tie wraps provided. Temporarily cover end of hose and secure out of the way.

H. Drain and replace engine oil and change filter.

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

4. OIL FEED LINE

A. The supercharger uses engine oil for lubrication

and must have an oil feed line connected to a filtered oil access on the engine and an oil return or drain. The return is a gravity drain and should be routed to provide a gradual drop. Connection to the oil pan must be above the oil level.

WARNING: The oil system contains a small ori-

fice that is easily plugged. DO NOT use any type sealant on any feed line threads. Instead, use clean engine oil. Disassemble and blow out entire line if you have any doubts.

B. Remove the 1/4" NPT (pipe) plug from the hole

located on the engine block just above the oil filter and replace with the 1/4" NPT to flare adapter fitting provided.

C. Connect the 1/4" oil feed line to the 1/4" NPT to

adapter fitting. Route the line forward along the top rail of the oil pan next to the drain line upward, towards the supercharger's future location. Secure to the drain line with the tie wraps provided.

D. Temporarily cover the end of the hose and protect

it from dirt until connecting to the supercharger.

ENGINE BLOCK

CLAMPS

TIE WRAPS

OIL PAN

Fig. 4-a

5. SUPPLEMENTARY FUEL INJECTION COMPUTER AND RELATED SYSTEM

A. Remove the TBI unit from the manifold. Remove

old gaskets and clean the gasket surfaces.

B. To prevent pressurized fuel and air leakage around

the throttle shaft, it is necessary to normalize the pressure. To accomplish this, modify the throttle body by drilling two small holes from the base surface to the throttle shafts. You may “layout” the location by following the template on page 6 or transfer it directly from the gasket provided. Use a small center drill to start, then a #56 or 3/64" diameter drill bit and drill through the base of the throttle body until the bit firmly contacts the shafts.

C. Assemble the throttle body, the new injector spacer

block and gaskets. Place the gasket without holes on the bottom. Use the two special threaded rods and nuts provided to secure the throttle body and the Vortech SFIC spacer to the manifold.

Fig. 5-a

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

P/N: 4GB020-010

5. SUPPLEMENTARY FUEL INJECTION COMPUTER AND RELATED SYSTEM, cont'd.

NOTE: Make sure all small holes are lined up

and not plugged with gasket sealer when installed.

D. Remove the stock fuel feed line from between the

fuel filter located on the frame under the driver's side floor and the throttle body.

E. Mount the additional fuel pump to the inner side of

the frame rail beneath the driver's side floor. Use the shorter hose provided to help locate the pump the correct distance from the filter. This hose has an adapter fitting on the filter end. Secure the pump to the frame and to the hose with the clamps provided.

F. Mark and drill a 3/16" hole in the frame near the

fuel pump to mount relay and wiring harness. Mount relay with supplied #10 hardware.

G. From relay terminal #85, tap the yellow wire into

the solid gray wire in the harness running along the driver's side frame member. Use the supplied scotchlock.

H. Connect the short red wire from relay terminal

#87 to the (+) terminal on the fuel pump.

I. Connect the longer black wire from the (-) termi-

nal at the fuel pump to a clean ground.

J. Connect the short black wire from relay terminal

#86 to a clean ground (relay screw mount works well).

K. Connect the long red wire from relay terminal #30

to a (+) battery lug located in the engine compartment.

L. Plumb the pump to the supplementary injectors

as per the schematic on page 5. Much of this assembly has been completed by the Vortech factory.

M. Plumb in the pressure regulator and return outlet

fuel to the throttle body inlet using the adapter fitting and O-ring.

N. Mount the Vortech SFIC unit inside the panel

beneath the steering column with the Vortech SFIC unit inside the panel beneath the steering column with the Velcro strips provided.

O. Connect the wires for the Vortech SFIC. Attach

the black wire to ground. Connect the red to the "4WD" fuse location in the stock fuse block (this location is also found on 2WD trucks) with the special adapter provided. Connect the brown wire to the negative of the ignition coil tach pickup.

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

5. SUPPLEMENTARY FUEL INJECTION COMPUTER AND

RELATED SYSTEM, cont'd.

NOTE: Factory fuel return line must be attached to original fitting on TBI unit.

3/8” HOSE

3/8” BARB

1/4 NPT

FEMALE

5/16” BARB x 1/4 NPT

FEMALE

5/16”

HOSE

PLACE 3/8" ADAPTER FITTING

INTO TBI FUEL INLET

THROTTLE SPACER BLOCK

UPPER FITTING

LOWER FITTING

SUPPLEMENTAL

INJECTORS

CONNECT TO FITTING ON

DISCHARGE PLENUM

INJECTOR CONNECTORS ARE INTERCHANGEABLE AND REVERSIBLE

USE 3/8" ADAPTER FITTING

AT STOCK FUEL FILTER

VORTECH FUEL PUMP

VORTECH FUEL PRESSURE REGULATOR

FUSE BOX

RELAY

TERMINAL #87

(-) GROUND

VORTECH SUPPLEMENTARY FUEL INJECTION COMPUTER

Fig. 5-b

GROUND

BROWN WIRE IGN COIL (-) NEG. BLACK WIRE GROUND

87a

RELAY WIRING

SCHEMATIC

25A

FUSE BOX

4WD

(+) FUEL PUMP

SOLID GRAY WIRE IN FUEL PUMP HARNESS (RUNNING ALONG THE DRIVER'S SIDE FRAME MEMBER

8586

(+) BATTERY LUG

P/N: 4GB020-010

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

5. SUPPLEMENTARY FUEL INJECTION COMPUTER AND RELATED SYSTEM, cont'd.

TEMPLATE

THROTTLE BODY

DRILL TWO HOLES THROUGH BOTTOM OF THROTTLE BODY

UNTIL POSITIVE THROTTLE SHAFT CONTACT

USE 3/64" OR #56 (.046) DIAMETER

.100

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

.100

4.250

Fig. 5-c

6. MAIN BRACKET AND POWER STEERING PUMP

A. Install the main mounting bracket on the engine

using the provided fasteners as shown.

B. Using the original fasteners, fit and secure the

power steering pump to the new bracket. It may be necessary to slightly bend the metal lines at the rear of the pump for a better fit.

C. Reinstall the power steering pump pulley to the

pump using an installation tool.

NOTE: The pulley must be completely on so

that the end of the shaft is flushed with the outer edge pulley boss to assure proper belt alignment.

7. MAIN MOUNTING PLATE AND ALTERNATOR

A. Secure the supercharger mount plate to the new

main mounting bracket as shown.

B. Install the alternator to the plate as shown. Hook-

up the alternator wires if they were removed.

C. Fasten the rear alternator stay to the back of the

alternator with an additional nut and washer (there will be a nut on either side of the support). Fasten the support to the bracket with a 3/8-16 x 1" bolt and washer.

D. Reinstall the cooling fan. E. 1995 models use a new style ABS control unit that

must be adjusted slightly to provide supercharger clearance. Remove the front two of the four 8mm bolts fastening the ABS mounting plate to the vehicle. Pry the front of the ABS mounting plate up approximately 1/2" to 5/8". Install the supplied 1/2" spacers underneath the mounting plate and secure with the supplied 8mm bolt and washers.

3/8-16 x 3.75

3/8-16 x 5.0

Fig. 6-a

3/8-16 X 3.75

STOCK BOLT

3/8-16 x 1.0

Fig. 7-a

ALTERNATOR

STAY

(AT

REAR)

Fig. 7-b

P/N: 4GB020-010

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

8. SUPERCHARGER MOUNTING

3/8-16 x 1"

A. Attach the supercharger drain hose to the fitting

on the bottom of the supercharger and secure with the clamp provided. Make sure to rotate the clamp so it does not interfere with the mounting plate.

B. Mount the supercharger to the mounting plate

with the five 3/8 16 x 1" bolts and washers as shown.

C. Attach the oil feed line and secure. Loosely attach

the tensioner bracket to the supercharger and fit the supercharger drive belt as shown. Adjust belt tension by rotating the adjuster plate and secure.

WARNING: The oil system contains a small ori-

fice that is easily plugged. DO NOT use any type sealant on any of the threads. Instead, use clean engine oil. Disassemble and blow out en-

Fig. 8-a

tire line if you have any doubts.

9. FACTORY ACCESSORY DRIVE BELT AND SUPERCHARGER DRIVE BELT SCHEMATIC

A. Install the new accessory drive belt as per dia-

gram.

B. Install the supercharger drive belt and tensionser

assembly.

C. It will be necessary to reset the belt tension after

approximately 250 miles.

A/C

TENSIONER

ALT

SUPERCHARGER

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

IDLER

WATER PUMP

TENSIONER

POWER STEERING

CRANKSHAFT

Fig. 9-a

10. DISCHARGE PLENUM

A. Thread the supplied 90° plastic fitting into the 3/4

NPT bung located on the discharge plenum. (The fitting should be screwed in until snug, pointing down & to the right at approximately a 45° angle).

B. Attach the discharge tube between the plenum

and supercharger with blue sleeves; secure with clamps as shown.

C. Install the short 1" hose piece onto the 90° fitting

with hose clamps. Attach the supercharger bypass valve (vacuum pointing toward the outside of vehicle) to the short hose.

D. The discharge of the bypass may either be routed

to atmosphere by using the supplied 1" K & N filter (This installation will produce some air noise on deceleration), or back to the supercharger air inlet tube by using the supplied 1" x 10" hose and 3/4" NPT x 1" plastic fitting. If routing the air bypass back to the supercharger inlet:

• Mock-up the steel supercharger inlet tube into its approximate final location.

• Center punch and drill a 59/64" hole into the inlet tube and thread with a 3/4" NPT tap. (See position).

• Thread with the supplied 3/4" NPT x 1" plastic hose barb into the air inlet tube. Connect the long length of 1" hose from the bypass to the air inlet.

E. Connect a vacuum hose to the bypass

valve and a vacuum source.

F. Connect the 5/32" vacuum hose between the

small fitting on the side of the discharge plenum and the TEE that feeds the pressure normalizing holes in the spacer block (see schematic page 5).

Fig. 10-b

for hole

Bypass Valve Not Shown

Fig. 10-a

Backside of Inlet Tube (Installed)

Backside of Plenum

Fig. 10-b

1-7/8"

Approx. Center (Vertically)

Drill:

59/64" 3/4" NPT

Tap: (optional)

Supercharger Bypass Valve

P/N: 4GB020-010

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

11. AIR FILTER, INLET DUCT AND PLENUM

NOTE: On 1993 model years and later, it will be

necessary to replace the resonator unit with the earlier type prior to modifying. The Chevrolet part number is 25097949.

A. Modify the stock resonator chamber by cutting off

the end at the point where the radius stops.

B. Remove the internal baffle tube and deburr the

cut edge.

C. Fit the new end cover, with the air filter element

provided, over the end of the resonator chamber. Secure the covered end by drilling two 3/32" holes (transfer the location from the cover) and fasten with the screws provided.

D.Secure the inlet tube bracket to the second bolt

from the front on the inlet manifold right side.

E. Assemble the inlet tube and inlet elbow and

connect to the supercharger inlet using the blue sleeves and clamps provided.

F. Fasten the inlet tube to the bracket with another

clamp.

G. Connect the new air filter end cover to the inlet

tube with the 3-1/2" diameter flex tube and clamps.

H. Attach the crankcase vent from the left valve

cover to the fitting on the inlet tube.

STOCK RESONATOR

CUT OFF END AT END OF RADIUS

Fig. 11-a

VORTECH FILTER AND

END COVER

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

12. FINAL REASSEMBLY & CHECK

WARNING: Do not attempt to operate the vehicle

until ALL components are installed and ALL operations are completed including final check.

A. Refit the upper fan shroud. B. Reconnect the battery. C. 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.

D. 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.

E. Check all fluid levels, making sure that your

tank(s) is filled with 92 octane or higher fuel before commencing test drive.

F. Start engine and allow to idle a few minutes, then

shut off.

G. Recheck to be sure that no hoses, wires, etc. are

near exhaust headers or moving parts and for signs of any fluid leakage. Check ignition timing to make sure it is set to stock specifications before commencing test drive.

H. PLEASE TAKE SPECIAL NOTE: Operating the

vehicle without the Supplementary Fuel Injec- tion Computer or any other sub assemblies completely and properly installed and working may cause FAILURE OF MAJOR ENGINE COM- PONENTS.

I. Test drive the vehicle. J. The supercharger drive belt stretches initially and

will require adjustment between 250 and 400 miles.

K. Read the STREET SUPERCHARGER SYSTEM

OWNER'S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty (30)

days of purchasing your supercharger system to qualify.

Fig. 12-a

P/N: 4GB020-010

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

ENGINEERING, INC.

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

P/N: 4GB020-010

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

Vortech 1990-1995 5.7L TBI Truck SUV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual