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

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

© 1997

VORTECH

®

all rights reserved. International Copyrights Secured 1-3-1994

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 • [phone]

FAX [phone] • http://www.vortecheng.com • M-F 8AM - 4:30PM (PST)

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
[phone]
[phone] 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 [phone].

®

ENGINEERING, INC.

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

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

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

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

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

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.

1