Vortech 1991-1995 5.2L 5.9L Dakota Ram User Manual

Download

Page 1

Dodge 5.2/5.9 Truck

Supercharger System

Installation Instructions for

‘91-‘95 Dakota & ‘94-‘95 Ram/T-300

50 State Smog Legal per CARB EO # D-213-10

ENGINEERING, INC.

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901

VORTECH

Page 2

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 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, Inc.

IMPORTANT

1996 models equipped with 5.9L engines may require an upgrade to 1995 model 5.9L fuel injectors. 1995 and earlier units have slightly higher fuel flow capacity and allow more efficient engine operation on supercharged applications.

ENGINEERING, INC.

1650 Pacific Avenue, Channel Islands, CA 93033 • (805) 247-0226

FAX (805) 247-0669 • http://www.vortecheng.com • M-F 8AM - 4:30PM (PST)

Page 3

SPECIAL NOTICE CONCERNING THE

CRANE IGNITION SYSTEM

The ignition system, manufactured by Crane Electronics, included in this kit is serviced exclusively by the manufacturer. Crane Electronics warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warranty. If found to be defective as mentioned above, it will be repaired or replaced if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Crane Electronics and/or Vortech Engineering, Incorporated. To the extent permitted by law, the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall Crane Electronics and/or Vortech Engineering, Incorporated, be liable for labor charges, special or consequential damages.

When returning this unit for service, proof of purchase must be supplied for warranty verification. After the warranty period has expired, repair service is charged between a minimum and maximum charge. In either case, please send the unit prepaid with proof of purchase to the attention of:

Crane Electronics Customer Service Department 530 Fentress Boulevard Daytona Beach, Florida, 32114 (904) 258-6167 (904) 258-6174 Fax www.cranecams.com

The repaired unit will be returned as soon as possible after receipt, COD for any charges. Be sure you include a detailed account of any problems experienced, the type of vehicle and any modifications.

Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Incorporated, directly at (805) 247-0226.

ENGINEERING, INC.

Page 4

Installation Instructions for

'91-'94 Dodge Dakota & '94-'95 Dodge Ram/T300

50 State Smog Legal, as per CARB EO #D-213-10

'95-'96 Dodge Dakota & '96 Dodge Ram/T300

49 State Smog Legal

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® V-1® Supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Owner's Manual which includes the Vortech V-1 Supercharger Limited Warranty, the Care & Feeding Guide, and the Extended Service Program & Application Form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30 to 35% and horsepower of between 35 and 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 every 3,000 miles or less. 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 every 50,000 miles or earlier.

TOOL & SUPPLY REQUIREMENTS

Factory repair manual Timing light 3/8" drive and socket set: SAE and metric 1/2" drive and socket set: SAE and metric 3/8" NPT tap, 3/8-16 tap and handle Adjustable wrench Open end wrenches: 5/16", 3/8", 7/16", 1/2", 9/16" Center punch and a 5/8" tapered punch 3/8" fuel fitting disconnect tool 5 quarts SF rated quality engine oil, oil filter, and wrench Flat #2 screwdriver Phillips #2 screwdriver Heavy grease Silicone sealer Drill motor 3/32" drill bit Oil sender socket, Snap-on

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

Spark plug socket NEW spark plugs

# A120

4CB020-010-6

Page 5

1991-1993 5.2L Dodge Dakota Truck

ENGINEERING, INC.

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

Part No. 4CB218-060S

PARTS LIST

Part Number Description Quantity

2A228-080 SUPERCHARGER ASSEMBL Y 1

2A128-080 V-1S supercharger 1 2A037-312 3.125” supercharger drive pulley 1

4FA116-150 Idler pulley assembly 1

7J012-092 12 mm flat washer 1

8R101-001 6 rib pulley retainer assembly 1

4CB111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-010 Mounting bracket support 1 4CB010-034 Mounting plate 1 4CB010-040 Coil mount bracket 1 4CB011-021 Mounting bracket 1 4CB017-011 1/2" spacer 1

2A047-113 Belt 1 7A312-351 5/16-18 X 3-1/2” bolt 1 7A375-100 3/8-16 x 1” bolts 10 7A375-300 3/8-16 x 3" bolt 1 7A375-375 3/8-16 x 3-3/4” bolt 1 7F375-016 3/8-16 nut 1

7J375-044 3/8” SAE washers 10 7K375-040 3/8” AN960 flat washers 5 7U100-055 6" nylon tie wraps 2

4CB112-010 AIR INTAKE ASSEMBLY 1

4CB012-030 Air filter mount bracket 1 4CB012-040 Air filter body 1 4FA012-012 90° intake elbow 1 4GB012-010 Air filter covers 2

7E010-046 #8 x 3/4" sheet metal screws 8 7P625-002 5/8" hose barb 1 7R002-052 #52 hose clamps 4 7R002-056 #56 hose clamps 2 7R002-116 #116 hose clamps 2 7S350-200 3-1/2” x 2” sleeve 1 7U100-046 O-ring 1 7U100-055 6" nylon tie wraps 2 7U033-000 5/8" x 40" PCV hose 1 7U035-000 3-1/2" x 16" flex hose 1 7U035-000 3-1/2" x 24" flex hose 1 8H040-040 Air filter 1

4CB155-010 RADIATOR RESERVOIR 1

4CB055-010 Washer reservoir 1

7C011-075 10/32" x 3/4" bolt 1 7F010-032 10-32 nylock nut 1

7J010-001 #10 flat washers 2

4CB130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 22” oil drain hose 1 7P375-017 3/8” NPT x 1/2” straight hose barb 1 7R001-008 #8 stainless hose clamps 2

Part Number Description Quantity

4CB130-026 OIL FEED LINE ASSEMBLY 1

7U030-026 1/4” x 33” oil feed hose 1 7P125-027 1/8" NPT straight fitting 1 7P125-034 1/8" NPT x 1/8" NPT straight tee 1 7P125-103 1/8 NPT -4 x 45° male elbow 1 7P250-066 #4 swivel x 1/4” hose barb fittings 2 7P525-067 .500 crimp ferrules 2

4CB101-002 FUEL PUMP ASSEMBLY 1

4CB010-050 Mounting pump bracket 1

5W001-001 Wire tap 1 5W001-010 16-14GA female slides 3 5W001-011 16-14GA eyelet 1 5W118-021 10" 18GA black wire 1 5W118-034 156" 18GA red wire 1

7C011-075 10/32" x 3/4" bolts 4 7E010-046 #8 x 3/4" sheet metal screw 1 7E010-050 #12 x 1/2" sheet metal screws 2 7F010-032 10-32 nylock nuts 4 7F312-018 5/16-18 nut 1 7P312-002 1/4" NPT x 5/16" hose barb fitting 1 7R001-004 #4 hose clamps 4 7R003-008 1/2" adel clamp 1 7R003-024 1-1/2" adel clamps 2 7U100-055 6" nylon tie wraps 6 7U031-018 5/16" x 12" fuel hose 1 7U030-056 3/8" x 20" fuel hose 1 8F001-002 155 inline fuel pump 1

4CB238-068 FMU (with lines) 1

6Z110-111 12:1 fuel management unit 1 4CB145-156 Male fuel line assembly 1 4CB146-166 Female fuel line assembly 1

7U030-046 5/32” x 25” vacuum tube 1 7E010-046 #8 x 3/4" sheet metal screws 2 7U100-055 6” nylon tie wraps 2

4CD112-020 AIR DISCHARGE ASSEMBLY 1

4CB012-020 Discharge tube 1 4CB050-010 Intake plenum 1 4GB040-060 Air/plenum gasket 1

7A250-400 1/4-20 x 4" HXHD bolt 1

7J250-001 1/4" SAE washer 1

7R002-044 #44 hose clamps 4 7S275-200 2-3/4” x 2” sleeves 2

4CD110-060 Plenum stay assembly 1

8D001-001 Bypass valve 1 8H040-075 1" air filter 1 7U030-046 5/32" x 36" vacuum line 1 7P156-082 5/32" tee 1 7R002-016 #16 hose clamps 2 7U034-016 1" x 4" gas heater hose 1

Page 6

1994-1996

Dodge Dakota/Ram/ T-300 Truck

ENGINEERING, INC.

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

Part No. 4CD218-030S

PARTS LIST

Part Number Description Quantity

2A228-080 SUPERCHARGER ASSEMBL Y 1

2A128-080 V-1S supercharger 1 2A037-312 3.125” supercharger drive pulley 1

4FA116-150 Idler pulley assembly 1

7J012-092 12 mm flat washer 1 8R101-001 6 rib pulley retainer assembly 1

4CC111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-010 Mounting bracket support 1 4CB010-034 Mounting plate 1 4CB011-021 Mounting bracket 1

2A047-113 Belt 1 7A312-351 5/16-18 X 3-1/2” bolt 1 7A375-100 3/8-16 x 1” bolts 10 7A375-300 3/8-16 x 3" bolt 1 7A375-375 3/8-16 x 3-3/4” bolt 1 7F375-016 3/8-16 nut 1 7J375-044 3/8” SAE washers 10 7K375-040 3/8” AN960 flat washers 5 7U100-055 6" nylon tie wraps 2

4CC112-010 AIR INTAKE ASSEMBLY 1

4FA012-012 90° intake elbows 2

7P375-020 3/8" NPT x 5/8" straight hose barb 1 7R001-008 #8 hose clamp 1 7R002-056 #56 hose clamps 2 7S350-200 3-1/2” x 2” sleeves 2 7U100-055 6" nylon tie wraps 2 7U033-000 5/8" x 40" PVC hose 1 8H040-040 Air filter 1

4CC238-068 FMU (with lines) 1

6Z110-111 12:1 fuel management unit 1

4CC147-166 Fuel line assemblies 2

7E010-046 #8 x 3/4" sheet metal screws 2 7U100-055 6” nylon tie wraps 2 7U030-046 5/32” x 40” vacuum line 1

4CB130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 22” oil drain hose 1 7P375-017 3/8” NPT x 1/2” straight hose barb 1 7R001-008 #8 stainless hose clamps 2

4CB155-010 RADIATOR RESERVOIR 1

4CB055-010 Washer reservoir 1

7C011-075 10-32 x 3/4" bolt 1 7F010-032 10-32 nylock nut 1 7S010-001 #10 flat washers 2

4CB130-026 OIL FEED LINE ASSEMBLY 1

Part Number Description Quantity

4CC101-002 FUEL PUMP ASSEMBLY 1

8F001-002 155 inline fuel pump 1 7R003-024 1-1/2" adel clamp 1 7R001-004 #4 hose clamps 4 7C011-075 10/32" x 3/4" bolt 1 7F010-032 10-32 nylock nut 1 7J010-001 #10 flat washers 2 7P250-050 1/4" NPT male branch tee 1 7P250-122 1/4" pipe thread AN917 tee 1 7P250-082 1/4" NPT x -4 90° fittings 2 7P250-045 1/4" NPT x 3/8" hose barb fittings 2 7P250-075 1/4" NPT 45° street elbpw 1 7P250-036 #4 flare to 1/4" NPT 1 7U030-056 3/8" x 3" PVC hose 1

7U030-050 12mm fuel hose 1 4CC145-156 Fuel line assembly A 1 4CC146-166 Fuel line assembly B 1

5W001-010 16-14GA female slides 3 5W118-021 10" 18GA black wire 1 5W118-036 75" 18GA red wire 1 5W001-011 16-14GA eyelet 1 5W001-001 Wire tap 1

7P250-047 1/4" NPT to 1/2" barb 1

5A101-009 H1-6 TR ASSEMBLY 1

5A001-009 HI-6 TR Ignition System 1 5W001-001 Wire Taps 2 5W001-009 16-14GA Male Slides 6 5W001-010 16-14GA Female Slides 6 5W001-011 16-14GA Eyelets 2 5W001-017 Large Ring Terminals 2 7E010-048 #10 x 3/4" HH Bolts 4 7U375-002 3.6" Velcro Latch 1 7U375-001 3.6" Velcro Hook 1 7U030-046 5/32" x 36" Vacuum Line 1 7P156-082 5/32" Tee 1 7U100-050 5/8" Grommet 1 7U100-055 6 Nylon Tie Wrap 1

4CD112-020 AIR DISCHARGE ASSEMBLY 1

4CB012-020 Discharge tube 1 4CB050-010 Intake plenum 1 4GB040-060 Air/plenum gasket 1

7A250-400 1/4-20 x 4" bolt 1

7J250-001 1/4" SAE washer 1

7R002-044 #44 hose clamps 4

7S275-200 2-3/4” x 2” sleeves 2 4CD110-060 Plenum stay assembly 1

8D001-001 Bypass valve 1

8H040-075 1" air filter 1

7U030-046 5/32" x 36" vacuum line 1

7P156-082 5/32" tee 1

7R002-016 #16 hose clamps 2

7U034-016 1" x 12" gas heater hose 1

Page 7

OIL PAN

PUNCH HOLE THROUGH

DOWN

2-1/2"

2-1/4"

1. PREPARATION/REMOVAL A. Disconnect the battery negative cable.

B. Remove the accessory drive belt. C. Remove the belt tensioner assembly and separate it from

the mounting bracket and set aside.

D. Disconnect and remove the crankcase breather hose. E. Remove the entire air filter assembly. F. Remove the radiator overflow reservoir and hose and set aside.

G. Remove the ignition coil and set aside.

2. OIL DRAIN A. To provide an oil drain for the supercharger, it is necessary

to make a hole in the oil pan. The best way to provide this hole is to punch the hole rather than drill. This tried and true method has been used successfully since the early days of turbocharging.

B. Rotate the engine until the mark on the damper is aligned

with the TDC (top dead center) tag on the front of the engine. To aid you in this, remove the distributor cap and watch the ignition rotor. It should end up between #5 and #7 electrodes as shown in the graphic.

C. Temporarily detach the anti-roll bar (sway bar) strap mounts

at the frame and lower the bar out of the way.

D. Locate and mark hole per diagram. Remove paint around

the hole area. Layout the hole center per the diagram.

E. 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.

F. Tap the hole with a 3/8" NPT tap approximately 1/4" deep.

Pack the flutes of the tap with heavy grease to hold chips. Use a small magnet to check for any stray chips.

IGN. ROTOR

TDC

NOTE: This method of rolling over the lip of the hole and tapping it works very well if carefully done and should cause no problems.

G. Thoroughly clean the threaded area. Apply

a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8" NPT hose fitting and secure in hole. Make sure a seal is formed all around the fitting.

H. Drain engine oil and change filter. Reattach

anti-roll bar mounts.

I. The drain hose will be attached to the fitting in later steps.

If your installation is going to be over several days we suggest that you cover the fitting to protect it from dirt.

Page 8

3. RADIATOR OVERFLOW RESERVOIR A. Disconnect and remove the coolant recovery

reservoir and hose.

B. Locate the new reservoir as shown in the

photo so that it is approximately one inch above the frame. Mark and drill a 3/16" hole through the fan shroud and secure with the fastener provided.

C. Cut two inches from the stock hose and use

fitting to adapt the clear hose to the radiator overflow fitting. Connect the clear hose from the radiator overflow fitting to the reservoir.

RESERVOIR

4. MAIN MOUNTING BRACKET AND PLATE A. It is necessary to provide clearance

between the dipstick and accessory drive belt. Remove the bolt holding the dip stick tube. Hold the tube about two inches and gently bend rearward about an inch. With the new fastener resecure.

B. Mount the cast aluminum main

mounting bracket on the front of the engine's right cylinder head using the fasteners provided, as shown.

C. Please note that the 3-3/4" bolt also

ATTACH TO EXHAUST MANIFOLD

holds the supercharger mounting plate. This fastener must be threaded into its hole loosely as a pilot while securing the cast bracket with the other two,

5/16-18 x 3-1/2"

/16-18 X 3.5

then removed for installation of the supercharger mounting plate.

D. Attach the stock belt tensioner to the

front of the supercharger mounting plate as shown. Make sure the indexing tab is engaged in the slot.

E. Now secure the plate and tensioner as

an assembly to the cast bracket.

F. Attach the support strut between the

supercharger mounting plate and the second exhaust manifold stud. If you have installed headers, you will need to make a longer tube spacer to make up the difference between the header and manifold thickness. Secure with the stainless steel bolt.

SUPPORT

SUPERCHARGER

GEARCHARGER

MOUNTING PLATE

3/8-16 x 1"

3/8-16 X 1.0

MAIN MOUNTING BRACKET

STOCK TENSIONER

3/8-16 x 1"

3/8-16 X 1.0

3/8-16 x 3"

3/8-16 X 3.0

3/8-16 x 3-3/4"

3/8-16 X 3.75

3/8-16 X 3.0

3/8-16 x 3"

Page 9

5. SUPERCHARGER MOUNTING A. Attach the oil drain hose to the

drain fitting on the bottom of the supercharger and secure with the clamp provided. Make sure to position the clamp housing to the side so that it does not interfere with the mounting plate.

B. Set the supercharger in place on

the plate and secure with the five 3/8-16 x 1" bolts and washers.

C. Attach the plastic idler pulley to

the inner most threaded boss on the supercharger using the large washer as a spacer in between as shown.

6. SUPERCHARGER/ACCESSORY DRIVE BELT A. The new longer accessory drive

belt is routed the same as the original belt except for accommodation of the supercharger an idler pulley.

B. Route the belt around the outside

of the supercharger drive pulley then around the inside of the idler as shown.

C. The stock tensioner is used as

originally intended in its relocated position.

NOTE: This drive belt is custom made for Vortech and is obtainable as a spare; however, should an emergency arise, a Gates P/N K060113 six rib belt may be used temporarily.

Page 10

7. OIL FEED LINE A. Disconnect and remove the oil pressure sender

from the engine. The sender is found at the rear of the intake manifold to the right side of the distributor.

B. Install the supplied tee fitting into the block and

place the sending unit in the upper end. Install the union fitting in the side port and orient the assembly so that it points rearward and slightly outward towards the passenger seat. Reconnect the pressure sender connector.

NOTE: It is essential that the supercharger oiling orifice not be plugged; therefore, do not use Teflon tape or other sealant that could possibly cause blockage. Use engine oil.

C. Attach the preassembled red oil hose onto the

fitting. Route the hose forward along the inside of the right valve cover. Be careful not to rest the oil hose or ignition wires on the EGR tube at the rear of the head.

D. Before connecting the other end of the hose to the

supercharger, briefly crank over the engine in order to purge the line of oil and remove any contaminants from the line. Use a drain pan or coffee can to catch the oil.

E. Place the 45° union fitting into the supercharger

fitting. Connect the hose to the 45° fitting.

TDC

Page 11

8A. AUXILIARY FUEL PUMP (1991-1993 Models Only) A. An additional fuel pump is supplied to

insure that sufficient fuel is available to theengine. This pump is mounted beside the stock fuel filter beneath the truck.

B. Secure the steel bracket to the frame with

the fasteners provided, as shown.

C. Open, then close the fuel filler cap to vent

any residual pressure. Disconnect the stock fuel hose where it exits the fuel filter and place the hose on to the new fuel pump outlet and secure with the clamp provided.

WARNING: Take great care to minimize fuel spillage and always have a second person stand by with a fire extinguisher as a precaution.

D. Connect the filter outlet to the pump inlet

with the 5/16" to 3/8" adapter and 3/8" fuel hose. Secure the hose and adapter with the clamps provided and attach the hose to

ENGINE

the frame.

E. Place the two clamps around the new fuel

pump and then secure the clamps to the new bracket and the existing one with the fasteners provided.

F. Connect the negative (-) terminal of the fuel

pump to the existing fastener on the frame.

G. The positive terminal connects to the blue

wire at the fuel pump relay. Locate the power distribution center near the brake booster, unfasten it and turn it over.

H. The #5 relay is for the fuel pump. Splice into

the blue wire running to the relay directly beneath it. Tie wrap the wire to the original harness that runs down to the frame keeping it away from moving or heated parts.

VACUUM LINE TO

MANIFOLD PRESSURE

FUEL MANAGMENT UNIT (FMU)

HOSE ADAPTER

FUEL FEED LINE

STD. PUMP

FUEL TANK

NEW ADDITIONAL FUEL PUMP

FUEL RETURN LINE

Page 12

8B. AUXILIARY FUEL PUMP (1994-96 Models Only)

A. An additional fuel pump is supplied to insure

that sufficient fuel is available to the engine. This pump is mounted on the left side inner fenderwell.

B. Open, then close the fuel filler cap to vent any

residual pressure. Disconnect the stock fuel supply hose where it enters the fuel rail.

WARNING: Take great care to minimize fuel spillage and always have a second person stand by with a fire extinguisher as a precaution.

C. Following the graphic on the next page,

inserthose assembly "A" into the factory feed lin until it snaps into place.

D. Drill a .25" hole in the dimple located in the to

center of the left inner fenderwell.

NOTE: On ABS equipped vehicles, the pump mounting position may vary slightly. Remove the windshield washer reservoir to gain access to mounting area.

E. Attach the Vortech fuel pump to the fenderwell

with the outlet pointing forward using the supplied adel clamp and #10 hardware. See photo at right.

F. Attach the supplied length of red wire from the

(+) terminal on the pump through the firewall to the fusebox. Use the power from the heater blower fuse.

G. Connect the ground wire from the (-) terminal

on the pump to the existing ground bolt in the fender apron.

H. Assemble the brass fittings as shown an

connect hose assembly "B" to the fuel rail.

Page 13

8B. AUXILIARY FUEL PUMP (1994-96 Models Only)

FACTORY FUEL LINE

INLET

1/4" ADAPTER

OUTLET

1/4" x 18" HOSE

1/4" x 18" HOSE ASSEMBLY "A"

1/4" NPT x 45°

1/4" x 45° FLARE

FLOW

#4 x 1/4" NPT 90°

1/4" NPT TEE

3/8" x 1/4" NPT

3/8" x 3" SOFT HOSE

#4 HOSE CLAMP (x4)

ADEL CLAMP

155L INLINE PUMP

3/8" x 3" MPI HOSE

5/16" x 30" HOSE ASSEMBLY "B"

3/8" x 1/4" NPT

5/16" FEMALE BARB x 1/4" NPT

1/4" NPT MALE BRANCH TEE

#4 x 1/4" NPT 90°

Page 14

9A. FUEL MANAGEMENT UNIT

(1991-1993 Models Only)

A. Place the fuel management unit (FMU) on

the firewall just below the rubber seal and inward of the two dimples in the sheet metal as shown in the photo. Mark and drill two 3/32" holes and secure the unit with the sheet metal screws provided.

B. Disconnect the fuel rail RETURN line at the

fuel rail. It will be necessary to use a special disconnect tool to accomplish this.

C. Connect the RETURN line to the adapter

fitting that runs from the outlet fitting on the bottom of the FMU.

D. Connect the FMU inlet hose (the hose

running to the 90° fitting on the side of the FMU) to the fitting on the bottom of the stock fuel regulator.

E. Attach the supplied vacuum line from the

fitting on top of the FMU to the small vacuum fitting on the driver's side of the intake manifold. See graphic on page 9.

F. Use tie wraps to secure the lines.

OUTLET

FUEL FROM

HERE

RETURNS

TO TANK

CONNECT TO MANIFOLD VACUUM/PRESSURE

INLET FUEL LINE FROM STOCK REGULATOR

9B. FUEL MANAGEMENT UNIT (1994-96 Models Only) A. Using the photo on page 6 as a reference, place the fuel

management unit (FMU) on the left side fender apron in between the windshield washer reservoir and the power distribution box. Mark and drill two 3/32" holes and secure the unit with the sheet metal screws provided.

NOTE: On ABS equipped vehicles, the fuel management unit must be mounted on the firewall next to the brake booster.

Page 15

9B. FUEL MANAGEMENT UNIT

(1994-96 Models Only) cont'd.

B. Connect the FMU inlet hose (the

hose running to the 90° fitting on the side of the FMU) to the brass 90° fitting on the exit side of the secondary fuel pump.

C. Connect the FMU outlet hose to

the brass #4 flare fitting located before the secondary pump inlet.

D. Attach the supplied vacuum line

from the fitting on top of the FMU to the small vacuum fitting on the driver's side of the intake manifold. See graphic.

E. Use tie wraps to secure the lines.

ATTACH FMU TO SMALL VACUUM CONNECTION

FUEL RAIL

FUEL INJECTORS

INTAKE MANIFOLD

DRIVER'S SIDE

10. DISCHARGE PLENUM AND DUCT A. Remove the air filter hold-down bolt

from the bracket in the center of the throttle body. Fit the 1/4-20 x 4-1/4" bolt into the bracket and secure with the nut provided.

B. Fit the discharge plenum, with the

gasket, onto the throttle body and tighten the nut to position.

C. Secure the discharge duct in place with

the clamps and sleeves provided.

D. Fit the bypass valve to the 1" barb on

the discharge tube using the length of 1" heater hose and #16 hose clamps. (See graphic for proper assembly.) Attach the 1" K & N filter to the discharge portion of the bypass valve. Tighten clamps.

E. Connect the supplied piece of 5/32"

vacuum hose to the nipple located on the bottom of the bypass valve. Tie the opposite end of the hose into the FMU vacuum/boost reference line using the supplied 5/32" brass tee.

5/32" VACUUM HOSE

CONNECT TO

MANIFOLD

VACUUM/BOOST

Page 16

11A. IGNITION COIL RELOCATION (1991-1993 Models) A. Remount the ignition coil on top of the intake

manifold between the alternator and the plenum as shown.

B. Using the 1/8" thick bracket and the 3/8" nut

and washer on the existing front stud and the existing bolt at the rear secure in place.

C. Carefully reroute the coil wire and secure with

tie wraps.

11B. IGNITION COIL RELOCATION (1994-96 Models only) A. Remove the coil from the mounting bracket

and modify the bracket as shown. Remount the coil to the bracket 180° from the original position (with the plug lead towards the front of the vehicle).

B. Attach the coil assembly to the threaded boss

on the intake manifold using the existing alternator brace bolt.

FRONT OF VEHICLE

CUT OFF AND DISCARD

APPROX.

1-3/4"

Page 17

12. IGNITION/BOOST CONTROL

A. Mount the ignition box in the engine

compartment onto the flat area near the fuse box and passenger side headlight. Use the supplied #10 sheet metal screws to secure. (See graphic.)

B. Route the heavy black cable to a

clean ground. Route the heavy red cable to the (+) positive terminal located on the front side of the under hood fuse box.

C. Locate the ignition coil plug-in

connector (grey and green wires) on the vehicle wiring harness near the original spring tensioner location. Cut the connector from the harness leaving 2-3" of wire remaining on the connector.

NOTE: 1996-1997 models have a slightly different coil plug location and do not need wire extensions.

PASSENGER SIDE ENGINE COMPARTMENT

FUSE BOX

(+) TERM

(–) TERM GROUND

VACUUM

RESERVOIR

RANE

HI-6TR

cams

FRONT OF VEHICLE

(VIEW FROM TOP)

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

FRAME RAIL

D. Extend the wires on the coil

connector using the supplied grey and green wires. Connect the grey and green extensions to the black and orange wires from the ignition box. Connect the remaining wires following the diagram on the following page.

E. Mount the timing retard control knob and the map sensor in

the drivers compartment underneath the dash. The knob control must be in an accessible position from the drivers seat.

F. Attach one end of the supplied 5/32" vacuum line to the map

sensor. Route the red and blue (or brown) wires along with the vacuum line through the firewall.

G. Connect vacuum line and wiring harness following graphic

on the next page.

Page 18

12. IGNITION/BOOST CONTROL INSTALLATION, cont'd.

NOTE: 1996-1997 models do not require extensions to properly wire ignition assembly.

MAIN WIRING

HARNESS

GREY

GREEN

TO BATTERY +

HEAVY RED

HEAVY BLACK

TO GROUND

RANE cams

HI-6TR

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN TACH (TAPE UP)

GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

SUPPLIED MAP SENSOR

IGNITION COIL CONNECTOR

GREY

GREEN

WIRE TAP

RED

WHITE

BLACK

ORANGE

GREEN

GREY

WHITE

RED

30" SUPPLIED WIRE EXTENSIONS

SOLDER AND SHRINK SLEEVE CONNECTORS

BLACK

ORANGE

MANIFOLD

VACUUM

3 WIRE HARNESS

BLUE OR BROWN (RETARD INPUT)

RED

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

YELLOW (TAPE UP) BLACK (GROUND)

Page 19

13. IGNITION/BOOST CONTROL UNIT OPERATION A. The Ignition/Boost Control unit

is designed to retard ignition in relation to boost.

B. 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°

C. Using the middle position (knob

pointing straight up) as a starting place, adjust the ignition retard knob until just beyond the point of detonation. Use third gear for testing in a safe area or road. Adjust the retard according to changes in altitude and fuel quality.

Caution: It is extremely important that the boost retard never be turned to 0° using pump fuel. It is recommended that in stock street applications, the knob be at no less than 1°/lb.

Example

[5 psi at 3° per per lb.]

Degrees of Retard

5 7 10

psi Boost

[7 psi at 2° per per lb.]

Maximum Retard = 20°

Maximum Retard = 15°

[10 psi at 1/2° per per lb.]

Page 20

14A. AIR FILTER ASSEMBLY AND DUCT

(1991-1993 Models)

A. The air filter canister assembly is made up of a center

section and two end caps which house a cleanable high flow element. The assembly is attached to a formed aluminum bracket which is secured in place by either screws or rivets to the inner fender. Position the filter assembly so the front of the housing lines up with the front of the ECM as shown in the photo above.

B. After positioning the entire housing and bracket assembly,

mark the bracket location; then with the bracket separated, mark and drill the mount holes. Use a 3/32" drill bit.

C. Secure the bracket to the inner fender with the #8 sheet

metal screws provided.

D. Attach the air filter assembly to the bracket with the two

stainless clamps. Make sure the filtration element is securely attached to the rear end cap and that the crank- case breather fitting is in place.

E. Place the blue sleeve on the rear cap outlet and then the

plastic elbow. Connect the elbow to the supercharger with the longer length of flex tube. Secure with the clamps included.

F. Connect the filter inlet to the stock duct at the right side of

the grill opening.

G. Route the 5/8" breather hose from the fitting on the rear end

cap of the air filter assembly around the rear of the intake manifold to the breather cap on the left valve cover. Secure the hose with tie wraps as necessary.

14B. AIR FILTER ASSEMBLY AND DUCT (1994-96 Models Only) A. Attach the two (2) 3-1/2" elbows, #56 clamps and

air filter to the supercharger inlet using the 3-1/2" blue sleeves.

B. Route the 5/8" breather hose from the fitting on the

inlet duct, around the rear of the intake manifold to the breather cap on the left valve cover. Secure the hose with tie wraps as necessary.

Page 21

WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check.

15. FINAL CHECK A. Reconnect the battery.

B. 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.

C. 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.

D. Check all fluid levels, making sure that your tank(s) is filled

with 92 octane or higher fuel before commencing test drive.

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

G. PLEASE TAKE SPECIAL NOTE: Operating the vehicle

without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS.

H. Test drive the vehicle. I. The supercharger drive belt stretches initially and will require

adjustment between 250 and 400 miles.

J. Read the STREET SUPERCHARGER SYSTEM

OWNER'S MANUAL AND WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger

system to qualify.

ENGINEERING, INC.