Vortech 1992-1996 5.7L LT1 Corvette User Manual

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Page 1

Corvette LT1

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-16

1992-1996 MODEL YEARS

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.

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

ATTENTION

CORVETTE OWNERS!

The 3-Year Unlimited Mileage Warranty is automatically included with the purchase of your Corvette kit. However, you must still fill out the Warranty Registration Form along with a copy of the original purchase receipt and mail it back to V ortech Engineering within 30 days from time of purchase so that we can activate your warranty. Thank you for choosing Vortech Engineering!

VORTECH

ENGINEERING, Inc.

Page 4

SPECIAL NOTICE CONCERNING THE

Carroll Supercharging MAF Signal Massager

Some 1996 LT1 Corvettes may require the Carroll Supercharging MAF Signal Massager to prevent OBD-II trouble codes from being set. This part is available separately at an additional cost under P/N: 4GM020-030 direct from Vortech Engineering, Inc. The MAF Signal Massager, manufactured by Carroll Supercharging Co., INC., is serviced exclusively by the manufacturer. Carroll Supercharging Co., INC. warrants this product to be free from defects in material and workmanship under normal use and if properly installed for 90 days. 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 Carroll Supercharging Co., INC. 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 Carroll Supercharging Co., INC. 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. Please send the unit prepaid with proof of purchase to the attention of:

Carroll Supercharging Co., INC. Customer Service Department 14 Doty Rd. Haskell, NJ 07420 (973) 835-1705 (973) 835-1660 Fax www. carrollsupercharging.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, M-F 8AM-4:30PM (PST).

ENGINEERING, INC.

Page 5

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 V ortech 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) 258-6174 (904) 258-6167 Fax www.cranecams.com

Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Incorporated, directly at (805) 247-0226, M-F 8AM-4:30PM (PST).

ENGINEERING, INC.

Page 6

Installation Instructions for

1992 - 1996

Congratulations on selecting the best performing and best supported automotive

supercharger available today... the VORTECH

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% to 35% and horsepower of between 35% and 45% can be expected with the boost levels specified by Vortech Engineering, Inc. 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, Inc. 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 either a high grade SF rated engine oil or a high quality synthetic lubricant, 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 outlined in 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 sooner.

Corvette LT1 -

50 State Smog Legal, as per CARB EO #D-213-16

V-1® Supercharger!

TOOL & SUPPLY REQUIREMENTS

Factory repair manual 3/8" socket and drive set: SAE & metric 1/2" breaker bar and 4" extension Flat #2 screwdriver Phillips #2 screwdriver Adjustable wrench Open end wrenches:

3/8", 7/16", 9/16", 5/8", 3/4", 7/8", 15mm 5/32" allen wrench 1992-1993 Models:

1-3/16" crow's foot tool 1994-1995 Models:

1-1/16" crow's foot tool

Center punch and 5/8" taper punch

3/8" x 2" swivel extension 2 gallons 50/50 coolant and water mix Tubing cutter Hose cutter or knife Loctite

threadlocker Drill motor #7 drill bit 1/2"-20 die 5 quarts 20w/50 synthetic motor oil T-15 torx screwdriver Spring-lock fitting disconnect tool 3/8" NPT tap

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

Spark plug socket 8 - new OE heat range spark plugs

4GV020-010-10

Page 7

1992-93 CORVETTE LTI SUPPLEMENT

HARDWIRING INSTRUCTIONS FOR KITS NOT EQUIPPED WITH A GM WIRING HARNESS

1. Unplug the grey and black connectors from the coil. Cut the

connectors off from the main harness approximately 2" from the end.

2. Attach the supplied male and female connectors to lengthen the white and pink wires previously cut from the coil connectors. Connect the two pink wires together to one red wire and the two white wires to the supplied single white wire. Attach the pink and white wires to the red and white wires on the supplied ignition box.

3. Reattach the grey connector to the coil (leave the black connector disconnected). Using the supplied male and female connectors, attach the pink wire on the grey connector to the orange wire on the supplied ignition box and attach the white wire to the black wire on the ignition box.

VORTECH

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

*NOTE: CABLE CONTAINS RED AND BLACK LEADS. MAKE SURE LEADS DO NOT CONTACT EACH OTHER AND SHORT UNIT WHEN TAPING UP.

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

ENGINEERING, INC.

Page 8

1994-1996 CORVETTE LTI SUPPLEMENT

HARDWIRING INSTRUCTIONS FOR KITS NOT EQUIPPED WITH A GM WIRING HARNESS

1. Unplug the grey and black connectors from the coil. Cut the con-

nectors off from the main harness approximately 2" from the end.

2. Attach the supplied male and female connectors to lengthen the white and pink wires previously cut from the coil connectors. Connect the two pink wires together to one red wire. Attach the pink and white wires to the red and white wires on the supplied ignition box.

VORTECH

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

*NOTE: CABLE CONTAINS RED AND BLACK LEADS. MAKE SURE LEADS DO NOT CONTACT EACH OTHER AND SHORT UNIT WHEN TAPING UP.

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

ENGINEERING, INC.

Page 9

1992-1993 Corvette LT1

ENGINEERING, INC.

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

Part Number Description Quantity

2A229-018 SUPERCHARGER ASSEMBLY 1

2A129-028 V-1S supercharger 1 2A036-312 Supercharger 3.125" drive pulley 1 8R101-001 6 rib pulley retainer assembly 1

4GV111-021 MOUNTING BRACKET ASSEMBLY 1

4GV011-021 Mounting bracket 1 4GV010-034 Mounting plate 1 4GV010-010 Attachment plate 1 4GV010-040 Coil mount bracket 1 4GV017-011 Idler spacer 1 4GV017-021 Coil mount spacer 1 4FA016-170 Wide idler pulley 1

7A375-075 3/8-16 x 3/4" bolts 8 7A375-100 3/8-16 x 1" bolts 2 7A375-425 3/8-16 x 4-1/4" bolt 1 7A375-525 3/8-16 x 5-1/4" bolt 1

7J375-044 3/8" SAE washers 7 7F375-016 3/8-16 nuts 2 7K375-040 3/8" AN960 washers 7 7A375-375 3/8-16 x 3-3/4" bolt 1 7U125-000 6" heat sleeves 3 7P375-050 3/8" hosemender 1 7U030-056 3/8" x 7-1/4" hose 1 7U030-000 5/8" x 10" hose 1 7R001-004 #4 hose clamps 2 7R001-008 #8 hose clamps 2 7U100-055 6" nylon tie wraps 6 7A250-100 1/4-20 x 1" flat head screw 1 7F250-021 1/4-20 nut 1 7A375-224 3/8-16 x 2-1/4" bolts 3

4GV101-004 A/C LINE ASSEMBLY 1

4GV010-060 A/C drier bracket 1

7R005-003 200-87 T-bolt clamp 1

4GV014-040 A/C lines with ends 1

7E010-050 #12 x 1/2" sheet metal screw 1

4GV101-002 FUEL PUMP ASSEMBLY 1

4GV010-050 Pump mounting bracket 1

8F101-300 Pump wiring assembly 1 7R001-004 #4 hose clamps 2 7U100-055 6" nylon tie wraps 10 8F060-024 Fuel injectors 8 7R004-002 17.0 stepless clamps 2 7P375-050 3/8" hosemender 1 7C060-025 M6 x 1.00 x 25mm bolts 2 7C011-075 10/32" x 3/4" bolt 1 7F010-032 10-32 nylock nut 1

7J010-001 #10 flat washers 2 7C008-032 8-32 x 3/4" bolts 4 7F008-032 8-32 nylock nuts 4

7J008-001 #8 flat washers 8 5W001-014 Fuse holder 1 5W001-015 Blade type 20A fuse 1 5W001-012 Solderless connector 1 5W001-001 Wire tap 1

7J006-093 6mm washer 1 5W001-017 Large ring terminal 1 7U032-016 3/8" x 28" fuel hoses 2 8F001-200 200 inline fuel pump 1 7R004-001 15.7 stepless clamp 1

4GV114-020 WATER LINE ASSEMBLY 1

4GV055-010 Water tank 1 4GV014-010 Water pipe, L bend 1 4GV014-020 Water pipe, S bend 1 4GV014-030 Water pipe, Z bend 1 4GV014-051 Radiator pipe, polished 1

7R002-024 #24 hose clamps 2 7C010-050 10-24 x 1/2" socket heads 2 7R003-022 1-3/8" adel clamps 2 7R001-008 #8 stainless hose clamps 8

7J010-001 #10 flat washers 2 7P250-074 1/4-20 x 3/4" HXHD cap screw 1 7F250-021 1/4-20 nylock nut 1

7J250-001 1/4 SAE washer 2

4GV130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2" x 35" oil drain hose 1 7P375-033 3/8" NPT x 3/8" NPT street elbow 1 7P375-017 3/8" NPT x 1/2" straight hose barb 1 7R001-008 #8 hose clamps 2 7U100-055 6" nylon tie wraps 4 7U100-066 11" tie wraps 4

Part Number Description Quantity

4GV112-010 AIR INTAKE ASSEMBLY 1

8H040-030 Air filter 1

4GV012-031 Air filter mount tube 1

7S300-000 3" 90° rubber elbow 1 7R005-002 200-84 T-bone clamps 2

4GV012-011 Air inlet tube 1

7R005-001 208-91 T-bone clamp 1 7U100-055 6" nylon tie wraps 3 7U375-052 3/8" vacuum cap 1

7U033-000 5/8" x 50" PVC hose 1 4GV012-041 Mass air tube 1 4GV011-034 Air filter tube bracket 1

7R001-008 #8 hose clamp 1

7R002-040 #40 hose clamp 1

7S350-200 3-1/2" x 2" sleeve 1

7R002-056 #56 hose clamps 2

7P750-100 3/4 NPT x 1" hose fitting 1

4GV112-020 AIR DISCHARGE ASSEMBLY 1

4GV012-028 Discharge tube, polished 1

7S400-200 4" x 2" sleeve 1

7R002-044 #44 hose clamps 2

8D001-002 Bypass valve 1

7S275-200 2-3/4" x 2" sleeve 1

7U136-020 7/8" x 20" heater hose 1

7R002-016 #16 hose clamps 2

7U030-046 5/32" x 46" vacuum line 1

7U030-046 5/32" x 1.5" vacuum line 1

7P156-082 5/32" tee 1

7R002-064 #64 hose clamps 2

4GV238-068 FUEL MANAGEMENT UNIT (w/lines) 1

6Z110-119 Fuel management unit, 10:1 1 4GV145-156 29" male fuel line assembly 1 4GV146-166 45" female fuel line assembly 1

7U030-046 5/32" x 36" vacuum line 1 7P156-082 5/32" tee 1 7J010-001 #10 flat washer 1 7U100-055 6" nylon tie wraps 6

5A101-007 HI-6TR ASSEMBLY 1

5A001-009 Crane HI-6TR ignition system 1 5A002-001 GM wiring harness 1 5W001-001 Wire tap 1 5W001-009 16-14GA male slides 11 5W001-010 16-14GA female slides 15 5W001-011 16-14GA eyelets 2 5W001-012 22-GA red solderless connectors 6 5W001-014 Fuse holder 1 5W001-015 20A blade type fuse 1 5W001-017 Large ring terminals 2 5W001-019 12-10GA solderless connectors 4 5W001-020 3/4" x 35" plastic wire loom 1 5W012-000 72" 12GA red wire 1 5W012-010 24" 12GA black wire 1 5W018-010 18" 18GA red wire 1 5W018-020 18" 18GA black wire 1 5W018-060 18" 18GA orange wire 1 5W018-070 50" 18GA green wire 1 5W018-240 18" 18GA white/yellow wire 1 5W022-060 78" 22GA blue wire 1 7E010-046 #8 x 3/4" sheet metal screws 2 7P156-082 5/32" tee 1 7U030-046 5/32" x 60" vacuum line 1 7U100-055 6" nylon tie wraps 6 7U375-001 9" Velcro® hook 1 7U375-002 9" Velcro® latch 1 5A002-006 Map sensor 1

4GV130-026 OIL FEED ASSEMBLY 1

7P125-034 1/8" NPT x 1/8" NPT street tee 1 7P125-027 1/8" NPT straight fitting 1 7P125-026 90° 1/8" NPT x #4 flare fitting 1 7P525-067 .500 crimp ferrules 2 7U030-016 1/4" x 54" fuel hose 1 7U100-055 6" nylon tie wraps 4 7P250-066 #4 swivel x 1/4" hose barb 2

4GV11 1-042 BELT TENSIONER ASSEMBLY 1

4GV011-032 Belt tensioner 1 4GV016-150 Idler-ribbed pulley 1

7GL10-150 10mm x 1.5" nylock nut 1

4GV116-021 DAMPENER PULLEY ASSEMBLY 1

4GV016-021 Harmonic balancer 1

2A046-510 Goodyear belt 1 7A437-176 7/16-14 x 1.75 belts 3

Part No. 4GV218-078S

PARTS LIST

Page 10

1994-1996 Corvette LT1

ENGINEERING, INC.

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

Part Number Description Quantity

2A229-018 SUPERCHARGER ASSEMBLY 1

2A129-028 V-1S supercharger 1 2A036-312 Supercharger 3.125" drive pulley 1 8R101-001 6 rib pulley retainer assembly 1

4GV111-021 MOUNTING BRACKET ASSEMBLY 1

4FA016-170 Wide idler pulley 1 4GV010-010 Attachment plate 1 4GV010-034 Mounting plate 1 4GV010-040 Coil mount bracket 1 4GV011-021 Mounting bracket 1 4GV017-011 Idler spacer 1 4GV017-021 Coil mount spacer 1

7A375-075 3/8-16 x 3/4" bolts 8 7A375-100 3/8-16 x 1" bolts 2 7A375-425 3/8-16 x 4-1/4" bolt 1 7A375-525 3/8-16 x 5-1/4" bolt 1

4GV11 1-042 BELT TENSIONER ASSEMBLY 1

4GV011-032 Belt tensioner 1 4GV016-150 Idler-ribbed pulley 1

7GL10-150 10mm x 1.5" nylock nut 1

4GV114-020 WATER LINE ASSEMBLY 1

4GV055-010 Water tank 1 4GV014-010 Water pipe, L bend 1 4GV014-020 Water pipe, S bend 1 4GV014-030 Water pipe, Z bend 1 4GV014-051 Radiator pipe, polished 1

7R002-024 #24 hose clamps 2 7C010-050 10-24 x 1/2" socket heads 2 7R003-022 1-3/8" adel clamps 2 7R001-008 #8 stainless hose clamps 8

7J010-001 #10 flat washers 2 7P250-074 1/4-20 x 3/4" HXHD cap screw 1 7F250-021 1/4-20 nylock nut 1

7J250-001 1/4 SAE washer 1

4GV112-030 AIR INTAKE ASSEMBLY 1

4GV011-034 Air filter tube bracket 1 4GV012-011 Air inlet tube 1 4GV012-031 Air filter mount tube 1

5W001-012 22 GA solderless connectors 6 5W001-067 3/16" x 6" shrink tube 1 5W011-010 3/8" x 36" flex loom 1 5W118-035 36" 18GA standard red wire 1 5W118-037 36" 18GA standard black wire 1 5W118-038 36" 18GA standard yellow wire 1 7P750-100 3/4 NPT x 1" straight hose fitting 1 7R001-008 #8 hose clamp 1 7R002-040 #40 hose clamp 1 7R002-056 #56 hose clamps 2 7R005-001 208-91 3.75" T-bone clamp 1 7R005-002 200-84 T-bone clamps 2 7S300-000 3" 90° rubber elbow 1 7S350-200 3-1/2" x 2" sleeve 1 7U100-055 6" nylon tie wraps 3 7U033-000 5/8" x 50" PVC hose 1 7U375-052 3/8" vacuum cap 1 8H040-022 3/4" breather 1 8H040-030 Air filter 1

4GV238-068 FUEL MANAGEMENT UNIT (w/lines) 1

6Z110-119 Fuel management unit, 10:1 1

4GV145-156 29" male fuel line assembly 1 4GV146-166 45" female fuel line assembly 1

7U030-046 5/32" x 36" vacuum line 1 7P156-082 5/32" tee 1

7J010-001 #10 flat washer 1 7U100-055 6" nylon tie wraps 6

4GV101-006 A/C LINE ASSEMBLY 1

4GV010-060 A/C drier bracket 1 4GV114-045 A/C line, with ends 1

7E010-050 #12 x 1/2" sheet metal screw 1 7R005-003 200-87 T-bolt clamp 1

Part Number Description Quantity

4GV112-020 AIR DISCHARGE ASSEMBLY 1

4GV012-020 Discharge tube, polished 1

7S400-200 4" x 2" sleeve 1 7R002-044 #44 hose clamps 2 8D001-002 Bypass valve 1 7S275-200 2-3/4" x 2" sleeve 1 7U136-020 7/8" x 20" heater hose 1 7R002-016 #16 hose clamps 2 7U030-046 5/32" x 46" vacuum line 1 7U030-046 5/32" x 1.5" vacuum line 1 7P156-082 5/32" tee 1 7R002-064 #64 hose clamps 2

4GV116-021 DAMPENER PULLEY ASSEMBLY 1

4GV016-021 Harmonic balancer 1

2A047-510 Goodyear belt 1 7A437-176 7/16-14 x 1.75 belts 3

4GV130-026 OIL FEED ASSEMBLY 1

4GV101-005 FUEL PUMP ASSEMBLY 1

4GV010-070 Fuel pump bracket 1

5W001-001 Wire tap 1 5W001-012 Solderless connector 1 5W001-014 Fuse holder 1 5W001-015 Blade type 20A fuse 1 5W001-017 Large ring terminal 1

7C008-032 8-32 x 3/4" bolts 4 7C011-075 10/32" x 3/4" bolts 2 7F008-032 8-32 nylock nuts 4 7F010-032 10-32 nylock nuts 2 7J006-093 6mm washer 1 7J008-001 #8 flat washers 8 7J010-001 #10 flat washers 4 7P375-050 3/8" hosemender 1 7R001-004 #4 hose clamps 2 7R004-002 17.0 stepless clamps 3 7U100-055 6" nylon tie wraps 10 7U032-016 3/8" x 28" fuel hoses 2 8F001-200 200 inline fuel pump 1 8F101-300 Pump wiring assembly 1

5A101-007 HI-6TR ASSEMBL Y 1

5A001-009 Crane HI-6TR ignition system 1

5A002-001 GM wiring harness 1 5W001-001 Wire tap 1 5W001-009 16-14GA male slides 11 5W001-010 16-14GA female slides 15 5W001-011 16-14GA eyelets 2 5W001-012 22-GA red solderless connectors 6 5W001-014 Fuse holder 1 5W001-015 20A blade type fuse 1 5W001-017 Large ring terminals 2 5W001-019 12-10GA solderless connectors 4 5W001-020 3/4" x 35" plastic wire loom 1 5W012-000 72" 12GA red wire 1 5W012-010 24" 12GA black wire 1 5W018-010 18" 18GA red wire 1 5W018-020 18" 18GA black wire 1 5W018-060 18" 18GA orange wire 1 5W018-070 50" 18GA green wire 1 5W018-240 18" 18GA white/yellow wire 1 5W022-060 78" 22GA blue wire 1

7E010-046 #8 x 3/4" sheet metal screws 2

7P156-082 5/32" tee 1

7U030-046 5/32" x 60" vacuum line 1

7U100-055 6" nylon tie wraps 6

7U375-001 9" Velcro® hook 1

7U375-002 9" Velcro® latch 1

5A002-006 Map sensor 1

4GV130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2" x 35" oil drain hose 1

7P375-033 3/8" NPT x 3/8" NPT street elbow 1

7P375-017 3/8" NPT x 1/2" straight hose barb 1

7R001-008 #8 hose clamps 2

7U100-055 6" nylon tie wraps 4

7U100-066 11" tie wraps 4

Part No. 4GV218-088S

PARTS LIST

Page 11

1. COMPONENT REMOVAL A. It is necessary to remove the refrigerant from the air condi-

tioning system. This should be performed by a qualified technician using a Refrigerant Recycling System. Releasing refrigerant into the atmosphere is environmentally irresponsible and should be avoided.

B. Disconnect the battery (negative lead). C. Remove the air inlet. Pull out the intake air temperature

(IAT) sensor but leave it connected to the harness. Remove the bellows, air filter cover and the entire assembly forward of the throttle body. (If the vehicle is a 1994 model or later, the mass air meter must be removed and set aside by unplugging the wiring connection and cutting the clamps fastening it to intake bellows).

D. Remove the radiator overflow tank underneath the right

(passenger) side headlight.

E. Remove the accessory drive belt and harmonic balancer.

(Do not remove the hub from the crankshaft.)

F. Drain coolant from the radiator. The drain fitting is located on

the bottom of the right tank.

G. Remove the radiator hose from the right side. H. Remove the power steering reservoir and its related brack-

ets and hardware. Use a small container to catch the fluid when the hoses are removed.

I. Remove the ignition coil and all of its mounting hardware on

the right side.

J. Number and remove the spark plug wires from the right

bank of the distributor. Place the wires out of the way.

K. Remove the right side injector cover.

Page 12

2. POWER STEERING LINE MODIFICATION A. Remove the rubber hose and the two

fasteners from the 5/8" steel power steering reservoir return line located on the front of the engine. It is not necessary to remove the line from the pump.

B. Use the tubing cutter to cut the steel reservoir

line 1-1/2" from the lower tab as shown in the graphic and photo.

C. Use the 3/8" hose splice fitting, #4 clamps

and the section of 3/8" x 7-1/4" rubber hose to extend the small rubber reservoir line. Extend the 5/8" steel line with the 5/8" x 10" rubber hose and the #8 clamps provided.

D. Reattach the 5/8" steel line to the engine

block using the tab and original fastener.

E. Slide a 6" section of heat protectant sleeve

over the end of each of the rubber power steering lines. The lines should be positioned as low and tight to the block as possible to make room for the mounting bracket. The 3/8" rubber line, which runs back over the crossmember, should be held tightly to the frame horizontally and brought up next to the 5/8" line. Refer to the photo. (Use tie wraps to hold it to the frame and parallel to the 5/8" reservoir line.)

F. Slide the third heat sleeve over all four (4) of

the spark plug wires located to the right and reconnect them to the distributor.

TO RESERVOIR

DISCARD THIS END

5/8" POWER STEERING STEEL RESERVOIR RETURN LINE

TO PUMP

1-1/2"

HEAT PROTECTANT SLEEVE

5/8" x 10" RUBBER HOSE

3/8" x 7-1/4" RUBBER HOSE

HEAT SLEEVES

•

3/8" ORIGINAL HOSE CONNECTED TO POWER STEERING RESERVOIR

Page 13

3. HARMONIC BALANCER A. Be sure that both of the mating surfaces of the crank and

balancer are clean and free from rust and dirt.

B. Slide the new harmonic balancer onto the crankshaft hub. C. Rotate the balancer on the crankshaft to find the proper bolt

hole alignment. Use the supplied 7/16" x 1-3/4" bolts with Loctite® and start all three bolts; then torque to 60 ft./lbs.

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. The return is a gravity drain and must have a gradual drop connecting to the oil pan and away from suspension components or exhaust pipes.

WARNING: The oil system contains a small orifice that is easily plugged. DO NOT use any type sealant on any of the threads. Instead, use clean engine oil. Disassemble and blow out entire line if you have any doubts.

B. Remove the factory oil pressure sending unit located at the

rear of the intake manifold with a 1-3/16" crow's foot tool (1994-1995 models need a 1-1/16" crow's foot tool).

C. Install the supplied 1/8" NPT street tee pointing to the right

side of the vehicle. (Refer to the graphic at right.)

D. Install the oil sending unit into the top of the tee. E. Install the straight #4 flare into the remaining branch in the

tee, pointing toward the right side.

F. Install the black oil feed line onto the #4 flare. Cover the end

of the oil feed line to protect it from dirt and place it on top of the manifold for later connection.

5. OIL DRAIN FITTING

5TH BOLT FROM

A. To provide an oil drain for the super-

THE FRONT

charger, it is necessary to make a hole in the oil pan. It is best to punch the pan rather than drill. Remove paint around

2-3/4"

the hole area so that it does not flake into the pan.

B. Make a mark on the driver's side of the oil

pan ahead of the oil filter. The mark must be 2-3/4" below the oil pan mounting flange and rearward of the fifth bolt (from the front) 3/4".

1/8" NPT

STREET

TEE

ENGINE BLOCK

OIL SENDING UNIT

#4 FLARE

PASSENGER SIDE

3/4"

Page 14

5. OIL DRAIN FITTING, cont'd. C. 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.

CAUTION: Use care so as not to strike internal engine components when punching oil pan.

D. 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.

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.

E. Thoroughly clean the threaded area. Apply a

small amount of silicone sealer to the new threads. Apply more sealer to the 3/8" NPT street elbow and secure in hole (elbow must point toward the front of the vehicle). Make sure a seal is formed all around the fitting. Thread the 3/8" NPT x 1/2" barb fitting into the fitting installed in the pan using pipe sealer.

F. Change the engine oil and filter.

6. FUEL MANAGEMENT UNIT INSTALLATION A. Attach the Fuel Management Unit (FMU) to the

FMU bracket with the flare fittings pointing down and toward the front of the vehicle as shown in the graphic.

B. Install the FMU and bracket assembly in the space

between the heater blower and coolant surge tank. Sandwich one end of the bracket between the blower motor and the relay bracket. Use the #8 washer as a spacer in the rear relay hole. Secure the inboard end at the surge tank bracket. Use the original bolts. (Refer to the photos on next page.)

CONNECT TO MANIFOLD VACUUM/PRESSURE

OUTLET (FUEL FROM HERE RETURNS TO TANK)

FMU BRACKET

INLET (FUEL LINE FROM STOCK REGULATOR)

Page 15

6. FUEL MANAGEMENT UNIT INSTALLATION, cont'd. C. Using a spring-lock fitting disconnect tool,

disconnect the return line (the line closest to the front of the car) from the fuel rail (at the top rear of the intake manifold).

D. Install the supplied 45" fuel line by

connecting the female spring-lock end onto the fuel rail. Run the line parallel to the feed line and then downward behind the wheel well to the FMU. The flare end will be connected to the 90° inlet fitting on the FMU.

E. Fit the 28" male fuel line into the braided

tank return line. Route the braided tank return line assembly forward to form a smooth radius pointing downward. Use tie wraps to hold the line in position. Route the flared end of the line downward behind the wheel well with the other FMU line to the FMU. Connect the line to the

•

center fitting.

TO FMU OUTLET

NOTE: Make sure you have routed all fuel lines away from all moving parts, sharp edges, exhaust pipes and manifold. Secure the fuel lines with the tie wraps.

MANAGEMENT

FUEL

UNIT (FMU)

FUEL RETURN LINE

STANDARD

PUMP

TO MANIFOLD PRESSURE

FUEL FEED LINE

ADDITIONAL FUEL PUMP

FUEL TANK

•

TO FMU INLET

ENGINE

Page 16

7. COOLANT LINE MODIFICATIONS A. Radiator hose

1) Modify the previously removed radiator

hose as shown in the graphic at right. Cut a 2" piece from the upper end for the thermostat housing.

2) Remove a 1-1/2" section where the hose attaches to the radiator and discard. Reconnect the modified hose.

3) Cut and discard the portion of the bottom section as shown in the graphic.

B. Surge tank hose

NOTE: On 1992 LT1 models the coolant hoses are slightly different. Remove the upper coolant lines and modify according to the diagram on page

7. The throttle body coolant hose must be routed near the valve cover using the "Z" bend 3/4" diameter tube. Disregard points 1 and 2 in section B.

DISCARD

SAVE THIS PORTION

SAVE FOR

THERMOSTAT HOUSING

CUT AT END OF STRAIGHT PORTION

1-1/2"

RADIATOR

DISCARD

•

1) Cut the hoses at the left and right sides of the plastic tee in the surge hose (refer to the graphic on page 7, 1993-1994 models; 1995-1996 models do not have a tee located in the surge tank hose line).

2) Discard the short portions and reconnect the modified hoses to the plastic tee with the original clamps.

3) Cut a 2" section off the end that connects to the water pump and reconnect one of the ends with the OEM clamp.

4) Cut off the remaining portion as shown in the graphic on page 8 and install the "S" shaped aluminum tube with the short end into the 2" hose on the water pump.

'S' BEND ALUMINUM TUBE

•

'L' BEND ALUMINUM TUBE (HEATER CORE HOSE)

Page 17

C. HEATER CORE HOSE

NOTE: For 1992 LT1 models, disregard the following five points. There are no lower water pump hoses to modify.

1) Remove the heater core hose from the water pump

(refer to the graphic on page 7). Cut off the last 4" of hose at the water pump end. Set aside for now.

2) Cut off 2-1/2" of hose at the restrictor end.

3) Assemble the short end of the "Z" shaped aluminum

tube into the 2-1/2" hose on the restrictor with a #8 clamp.

4) Slide the 4" connector piece that was previously set aside and the #8 clamps onto the long end of the remaining single "L" curve aluminum tube. Slide the "L" bend assembly onto the "Z" bend. Connect the hoses as shown in the graphic on the next page.

5) Using the rubber "S" shaped coolant hose cut from the original heater core hose and #8 clamps, connect the single "L" curved aluminum tube to the water pump.

1992 MODELS ONLY

"Z" BEND

ALUMINUM TUBE

THROTTLE

BODY HOSE

SURGE TANK

OUTLET HOSE

VALVE COVER

DISCARD

"S" BEND ALUMINUM TUBE HERE

Page 18

1993-1996 MODELS ONLY

WATER

PUMP

USE "S" BEND ALUMINUM TUBE HERE

RADIATOR SURGE TANK HOSE

NOTE: 1995 MODELS DO NOT HAVE A THROTTLE BODY HOSE AND PLASTIC TEE. DO NOT CUT MAIN COOLANT HOSE.

USE THIS PORTION

1-3/4"

HEATER CORE HOSE

RESTRICTOR

2-1/2"

TO THRO TTLE BODY

CUT AND DISCARD

TOP VIEW

DISCARD THIS PORTION

1-1/4"

DISCARD THIS PORTION

CUT A T END OF STRAIGHT PORTION

USE THIS PORTION

LOWER WATER PUMP

(USE FOR CONNECTOR)

"Z" BEND

ALUMINUM

TUBE

NOTE: THE "Z/L"BEND WATER TUBE ASSEMBLY NEEDS TO BE ROUTED DOWN ON TOP OF THE VEHICLE FRAME AND UNDER THE PIVOT OF THE RIGHT SIDE CONTROL ARM.

CONNECTOR

USE THIS PORTION

CUT A T END OF STRAIGHT PORTION

"L" BEND ALUMINUM TUBE

Page 19

8A. AIR INLET (1992-1993 Models) A. Trim the fiberglass splash guard as shown in the

graphic.

B. Install the air filter mounting tube and bracket into

the right side front headlight well (ahead of the wheel) where the coolant reservoir was originally located. Use the original holes and bolts to secure the bracket.

C. Install the rubber 90° elbow with a #200-84 band

clamp onto the air inlet on the engine compartment side.

D. Use a #40 clamp to attach the filter tube to the

mounting bracket. Install the 3-1/2" sleeve and #56 clamps, attaching one of the clamps to the bracket as shown.

E. Install the air filter extension and clamp onto the air

inlet tube inside of the right side headlight pocket (1992-1993 models only). Attach air filter.

8B. AIR INLET (1994-1996 Models) A. Follow steps 8A-D above.

B. Locate the MAF sensor connector in the vehicle

wiring harness and cut all three wires approximately 2" away from the connector.

C. Extend the MAF connector by using the supplied

36" wires and shrink sleeve. Soldering is recommended. Crimp connectors have been supplied for applications where soldering is not possible.

VIEW FROM

BOTTOM

RIGHT

FRONT

TIRE

FRONT

NOTE: Double check the wire to wire (MAF and harness) relationship before soldering and sealing.

D. Attach the MAF meter to the air filter tube as

shown. Route the MAF connector down into the headlight well and attach to the air meter. 3/8" flex loom has been provided to protect the extended harness. Attach the supplied air filter to the air meter inlet.

1992-1993 AIR FILTER TUBE BRACKET

#40 CLAMP

#56 CLAMPS

AIR FILTER

EXTENSION

3-1/2" X 2" SLEEVE

1994-1995

MAF METER

TOP VIEW

AIR FILTER TUBE

RUBBER ELBOW

AIR INLET DUCT

HEADLIGHT

WELL

BRACKET

RIGHT

FRONT

TIRE

Page 20

9. COOLANT RECOVERY TANK A. Install the supplied coolant reservoir into the right side

front headlight well (next to the air inlet). Use the existing hole and supplied fasteners to attach the reservoir to the fender well (see photo).

B. Carefully bend the original overflow line around the

fender well and connect to the new reservoir.

C. Attach the 5/32" vent line to the top fitting on the

reservoir and route out of the engine compartment.

AIR FILTER

RECOVERY TANK

COOLANT

10. AIR CONDITIONING ACCUMULATOR RELOCATION A. Remove the air conditioning line from

the accumulator to the evaporator (right

TOP VIEW

side).

B. Remove the air conditioning line clamp

and screw located on the frame crossmember in front of the water pump

FRAME

near the accumulator.

C. Use the mounting hole and bolt to line

up the supplied "T" bracket (refer to the graphic). Mount the adel clamp and air conditioning line on top of the "T" bracket. Drill a hole with a #12 drill in the frame using the remaining hole in the bracket for a template. Install the

EXISTING HOLE,

SCREW IN CLAMP

supplied #12 sheet metal screw.

D. Carefully bend the outermost line at the

air conditioning compressor outward slightly to pull the accumulator into position onto the bracket. Use a second hand to support the line at the compressor, being careful not to kink the line (refer to the photo).

E. Position the accumulator onto the

bracket and secure with the band clamp provided.

F. Install the supplied aluminum air

conditioning line making sure the O-rings are in place at the ends of each fitting.

CANISTER

•

CLAMP

AIR CONDITIONING LINE

DRILL HOLE #12 USE #12 SHEET METAL SCREW

FRONT

"T" BRACKET

ACCUMULATOR

Page 21

11. INTAKE AIR TEMPERATURE (IAT)

CUT

DRILL OUT DIMPLE TOP .25"

COUNTERSINK TO .40"

SENSOR THREADING

A. Disconnect the IAT sensor from the harness. B. With a file, remove the ridges from the sensor and

thread the sensor to 1/2"-20 with a die.

C. Install the threaded sensor into the supercharger

discharge duct and secure.

12. MOUNTING BRACKET A. Mount the spring tensioner to the mounting bracket with

the supplied hardware. Place the bolt through the center hole in the bracket and position it so that the alignment stud fits into the hole.

B. Fasten the mounting bracket to the engine block and

heads using three (3) 3/8-16 x 2-1/4" bolts, one (1) 3/8-16 x 4-1/4" bolt, and four (4) 3/8" flat washers. Make sure that the power steering lines and plug wires are safely secured behind the bracket and the three sections of heat sleeve are positioned properly, staying clear of the exhaust.

C. Modify the power steering bracket by cutting the existing

tab to mirror the opposite side of the bracket (refer to graphic).

D. Attach the power steering reservoir to the appropriate

hoses with the supplied clamps.

E. Using the dimple as a location point, drill a .25" through

hole. Countersink to .40".

F. Attach the modified power steering reservoir bracket to

the backside of the mounting bracket with the 1/4-20 x 1" flat head screw, locking nut and flat washer. Refer to graphic on following page for further reference.

REMOVE RIDGES

USE A 1/2"-20 DIE TO THREAD THIS PORTION

Page 22

12. MOUNTING BRACKET

3/8-16 x 5-1/4"

1/4-20 x 1" FLATHEAD

POWER STEERING RESERVOIR MOUNT

SPRING TENSIONER MOUNTING BOLT

SPRING TENSIONER ALIGNMENT STUD

SPRING TENSIONER

ATTACHMENT PLATE

3/8-16 x 2-1/4"

SMOOTH IDLER

PULLEY

3/8-16 x 3/4"

PULLEY SPACER

TUBE SPACER

MOUNTS TO SUPERCHARGER

3/8-16 x 2-1/4"

3/8-16 x 4-1/4"

3/8-16 x 2-1/4"

3/8-16 x 1"

3/8" AN WASHER

RIBBED TENSIONER PULLEY

3/8-16 x 1"

3/8" AN WASHER

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

3/8" AN WASHER

Page 23

13. SUPERCHARGER MOUNTING PLATE

A. Place the supercharger belt around the

crank pulley and under the spring tensioner.

B. Make sure the belt routes around the large

riser on the mounting bracket (passenger side, above the spring tensioner), as shown in the graphic, BEFORE the mounting plate is put into position.

C. Place the smooth idler pulley and spacer

onto the bracket (make sure that the belt is routed underneath the idler pulley). Place the plate into position with a 3/8-16 x 3-1/2" bolt and 3/8" AN washer through the plate to hold the pulley and spacer in position. Fasten down the plate with the remaining two (2) 3/8-16 x 1" bolts and 3/8" AN washers to the bracket.

SUPERCHARGER PULLEY

RISER

14. SUPERCHARGER INSTALLATION A. Attach the air inlet duct to the supercharger inlet with the

#208-91 clamp. Position the inlet so that it points downward, parallel to the drain fitting. Leave the clamp loose so that the air inlet duct can be rotated for adjustment.

B. Attach the 36" drain hose and clamp to the fitting on then

bottom of the supercharger. Make sure that the clamp is rotated so that it will not interfere with the mounting plate when installed.

C. Slide a #200-84 clamp onto the 90° rubber inlet elbow. D. Lower the supercharger/air inlet duct assembly down onto

the supercharger plate. Rotating the air inlet duct and supercharger slightly to clear the radiator and mounting plate bolts will ease installation. Feed the oil drain downward and toward the left side.

E. Install the four (4) 3/8-16 x 3/4" bolts and 3/8" AN washers

into the supercharger through the bracket underneath, using a 9/16" socket and 1/4" drive ratchet with swivel.

F. Use the 3/8-16 x 5-1/4" bolt, 3/8" washer, 4 hole attachment

plate (use the single hole in the middle with the upper single hole offset toward the throttle body) and the tube spacer (in the same order) to connect the upper portion of the supercharger to the supercharger bracket.

Page 24

14. SUPERCHARGER INSTALLATION (cont'd.)

G. Mount the spacer/bolt assembly onto

the main mounting bracket with the two (2) 3/8-16 x 3/4" bolts and washers. Thread the 5-1/4" bolt into the supercharger (refer to the photo).

H. Tighten the air filter mount to the 90°

elbow. Tighten the air inlet duct onto the supercharger.

I. Mount the short end of the coil-mount

bracket to the throttle body (remove the upper right bolt from the throttle body) and the other end to the coil (refer to the graphic). Mount the opposite end of the coil to the attachment plate. Fasten with the two (2) 3/8-16 x 3/4" bolts, nuts and washers.

J. Route the supercharger belt around

the crank pulley on the rear set of grooves and underneath both the spring tensioner and smooth idler pulley. From the left side, place a 15mm box wrench on the spring tensioner hex. Pull up to provide room for the belt to slip onto the supercharger pulley. Release tension and install the accessory belt following the factory procedure.

K. Install the 90° 1/8" NPT fitting into the

supercharger oil feed with the flare pointing to the right side.

L. Fasten the oil feed line to the flare

fitting on the supercharger.

5-1/4-16 x 3/8" BOLT

WARNING: The oil system contains a small orifice that is easily plugged. DO NOT use any type sealant on any of the threads. Instead, use clean

TOP VIEW PASSENGER SIDE

engine oil. Disassemble and blow out entire line if you have

any doubts.

THROTTLE

BODY

3/8-16 x 3/4"

BOLT

4 HOLE ATTACHMENT PLATE

DISCHARGE

DUCT

COIL-MOUNT BRACKET (SHORT STRAIGHT END)

3/8-16 x 3/4" BOLT

COIL

TUBE SPACER

3/8-16 x 3/4" BOLT

SUPERCHARGER

FRONT

Page 25

15. DRAIN LINE NOTE: It is important that the super-

charger oil drain line be routed gradually downward without dips, away from heat, sharp objects and moving parts.

A. Route the supercharger drain hose downward

behind the front frame crossmember. Using tie wraps, secure the drain hose to the steel power steering pressure line located on the steering rack. See fig. A.

B. Route the drain hose around the front of the

crank pulley to the driver's side of the engine. Make sure that the hose maintains smooth downhill routing.

C. Use tie wraps to secure the hose to the rear

power steering line, away from the crank pulley and accessory belt. See fig. A and B.

D. Attach the end of the drain hose to the 1/2"

drain fitting barb in the oil pan and secure with the supplied #8 hose clamp. Trim the hose length if necessary.

FROM SUPERCHARGER

FRAME

POWER STEERING RACK

ROUTE THE DRAIN HOSE AROUND THE CRANK PULLEY AND BACK TO THE 1/2" BARB IN THE PAN

TIE WRAP TO POWER STEERING LINE

VIEW FROM FRONT

FIG. A

DAMPENER PULLEY

OIL DRAIN HOSE

FIG. B

CRANK PULLEY

OIL PAN

16. RADIATOR PIPE

A. Install the previously cut radiator hoses on the radiator and

water neck with OEM clamps.

B. Install the supplied stainless coolant pipe and #24 clamps. C. Install the two adel clamps, #10-24 x 1/2" screws and #10

washers to hold the coolant pipe in place on top of the air inlet duct.

17. DISCHARGE TUBE A. Using the #44 clamps, place the 2-3/4" blue sleeve onto the

supercharger discharge. Place the large sleeve onto the throttle body using #72 clamps.

B. Install the discharge tube and secure with the clamps to the

supercharger and throttle body.

C. Hook up the IAT sensor connector. D. Connect the length of 7/8" hose from the bypass valve to the

barb on the air inlet duct with the #16 hose clamps. Trim the hose, if necessary.

Page 26

18. VACUUM AND BREATHER LINES A. Remove the fuel regulator vacuum connection from the

manifold. Place the 1-1/2" length of 5/32" tubing and a 5/32" vacuum tee on the manifold vacuum spout. Connect the tee to the original fuel regulator line and the 32" vacuum line to the bypass valve.

B. Connect the 36" FMU vacuum line from the FMU to the

bypass vacuum line by using a 5/32" tee to splice the lines together.

C. Remove the breather line that connects the throttle body to

the valve cover. Place a 1/2" vacuum cap on the nipple at the throttle body. Take the plastic 90° breather line and cut as shown in the graphic at right.

D. Install the supplied 5/8" breather line from the fitting on the air

filter tube to the 90° valve cover breather.

E. On 1994-1995 models, remove the 3/4" air pump inlet hose

and section out a straight 4" piece. Install the supplied breather in one hose end and install the other end onto the pump inlet.

NOTE: On some 1994/1995 models there is a 5/32" vacuum line running from the spark distributor module to the throttle body air inlet hose. Reroute the end originally connected to the air inlet hose to the new inlet duct located in between the MAF and the supercharger.

INTAKE

TO REGULATOR

5/32" VACUUM LINE

VALVE COVER

FMU

THROTTLE BODY

POWER STEERING RESERVOIR

BYPASS VALVE

TO MSD

SUPERCHARGER

5/8" VALVE COVER BREATHER LINE

AIR FILTER

Page 27

19. IGNITION/BOOST CONTROL INSTALLATION A. Mount the Ignition/Boost Control unit above the

radiator shroud using Velcro

strips (see photo).

B. Route the heavy black cable to a clean ground.

Route the heavy red cable to the battery. Using a solderless connector, connect the supplied fuse holder and fuse to the end of the wire. Set the wire aside for now (do not connect to the battery).

D. Install the Ignition/Boost Control wiring harness

following the graphic on the next page. Use the supplied wire and connectors to extend some of the wires, if needed.

E. Locate the tachometer filter in the factory coil

harness. (Note: 1994 and 1995 models are not equipped with tach filters. In this case, ignore step "E".) Cut the thin white wire located near the filter. Splice the supplied length of wire and connectors into the thin white wire and run to the green tach output wire on the Ignition/Boost Control unit.

F. Mount the timing control knob in an easily

accessible position from the drivers seat. Attach the black wire to a clean ground and the red wire to a keyed on 12V power source or the red wire from the Vortech ignition box. Tape up the end of the yellow wire to prevent contact with a metal surface. Route the three-wire harness out into the engine compartment near the battery. Connect the supplied GM-style map sensor to the three-wire harness and secure.

G. Route a vacuum line from the supplied map

sensor to the bypass/vacuum line assembly using a 5/32" tee.

Page 28

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

FACTORY GM

HARNESS

(UNPLUGGED

FROM COIL)

GM ADAPTER

HARNESS

VORTECH

CRIMP

CONNECTOR

TO BATTERY +

TO GROUND

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN T ACH OUTPUT

GREY MAGNETIC TRIGGER

HARNESS (TAPE UP)

MANIFOLD

VACUUM

CUT THIN WHITE WIRE AND SPLICE INTO SUPPLIED WIRE TO T ACH OUTPUT

HEAVY WHITE HEAVY BLACK

HEAVY RED

HEAVY BLACK

SUPPLIED MAP SENSOR

3 WIRE HARNESS

TACH

FILTER

BLUE (RETARD INPUT)

RED

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

IGNITION COIL

WIRE TAP

RED

WHITE

BLACK

ORANGE

NO CONNECTIONS

AT GREY TERMINAL

BLACK TERMINAL

YELLOW (TAPE UP) BLACK (GROUND)

Page 29

20. IGNITION/BOOST CONTROL 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

Example of Ignition Retard vs. Boost:

[5 psi at 3° per per lb.]

retard to 4° of ignition retard for each pound of boost, up to a maximum of 20°.

C. Using the 1° per pound position as a

starting point, 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.

Degrees of Retard

[7 psi at 2° per per lb.]

Maximum Retard = 20°

Maximum Retard = 15°

[10 psi at 1/2° per per lb.]

Caution: It is extremely important that the boost retard

5 7 10

psi Boost

never be turned to 0°. It is recommended that in stock street applications, the knob be at no less than 1°/lb.

21. AUXILIARY FUEL PUMP INSTALLATION A. Remove the license plate and frame, gas door, gas cap and

rubber fuel overflow catch.

B. Using a 3/4" socket, lower the spare tire and cover assembly. C. Install the wiring harness/relay assembly into the spare tire

well area on the inside of the bumper (underneath the car). Use one of the square holes in the seam of the fuel tank, a #10 screw and nylon locking nut to secure the relay assembly. On some models, a hole for the relay mount may have to be drilled. Make sure the relay is positioned well inside the spare tire well to eliminate possible spare tire and fuel overflow contact.

D. Secure the fuel pump/lines assembly onto the steel mounting

bracket with the provided clamps and #8 fasteners in the direction shown in the graphic on page 21.

Page 30

21. AUXILIARY FUEL PUMP INSTALLATION, cont'd.

NOTE: On 1994-1996 Models disregard step E. Install the fuel pump assembly onto the vehicle through the license plate opening. Use the supplied 1032 hardware to mount the pump assembly to the existing hole in the aluminum rear section. See photo.

E. Remove the 6mm bolt that holds the spare tire bracket in

position (threads from the front). Install the fuel pump assembly onto the vehicle through the license plate opening. Use the spare tire bracket hole and supplied 6mm x 25mm bolt to line up the left side fuel pump bracket hole. Use the corresponding hole in the fuel tank seam to mount the right side pump bracket. Use the supplied 6mm screw, nylon locking nuts and washers to secure (see photo).

F. Disconnect the factory fuel supply hose and connect the

new hoses as shown in the graphic on the next page. Use the supplied tie wraps to keep the fuel lines away from sharp objects. Make sure the lines are routed in such a way that they make gradual turns with no sharp kinks or bends.

G. Wire the negative terminal on the pump and the #86 relay

terminal to a clean ground, free from rust and paint.

H. Using the yellow wire from the #85 relay and a wire tap,

splice into the grey wire in the factory fuel pump harness.

I. Connect the #87 red wire on the relay to the positive terminal

on the T-Rex® fuel pump.

J. Run the remaining long red wire up to the battery, using tie

wraps to keep the wire away from heat and moving parts. Using a solderless connector, connect the supplied fuse holder and fuse to the end of the wire. Using the large ring terminal, crimp both the ignition/boost control fuse wire and the fuel pump fuse wire together (in the same terminal). Connect the ring terminal to the (+) positive battery post.

K. Replace the license plate and frame, gas door, fuel overflow

catch and gas cap.

L. Refer to the graphic on the next page to confirm that all wires

are routed correctly. Replace the spare tire and cover, making sure that the wires and relay are not contact with the spare tire and mounting fasteners.

Page 31

21. AUXILIARY FUEL PUMP INSTALLATION (cont'd.)

RELAY

(+) TERMINAL ON

87A

T-REX FUEL PUMP

GROUND

3/8" x 28"

1994-95 MODELS

(+) BATTERY TERMINAL

GREY PURPLE BLACK

3/8" HOSE MENDER

3/8" x 28"

WIRE TAP

FUEL WIRING CONNECTOR

RETURN

ORIGINAL TANK OUTLET

M6 x 1.00 x 25 mm HEX HEAD NOTE: 1994-95 MODELS DO NOT HAVE A LEFT SIDE MOUNTING PLATE HOLE

T-REX

FLOW

#8-32 x 3/4" #8 LOCKNUT (4x) #8 WASHERS (4x)

FUEL PUMP MOUNTING PLATE

1992-93 MODELS M6 x 1.00 x 25mm HEX HEAD M6 LOCK NUT M6 WASHERS (2) OR 1994-95 MODELS 10-32 X 3/4" HEX HEAD 10-32 LOCK NUT #10 WASHERS (2)

Page 32

22. FUEL INJECTOR REPLACEMENT (1992-1993 Models only)

A. Remove the right side injector cover. B. Disconnect the eight (8) fuel injector wiring connectors and

retainers from the injectors.

C. Remove the four (4) 10mm bolts holding down the fuel rail

on the intake manifold. Lift up on the rails evenly, removing all eight (8) injectors.

D. Using a small amount of clean motor oil, lightly lubricate the

O-rings on both ends on the Vortech supplied fuel injectors.

E. Install the new injectors into the fuel rails with the terminals

facing outward. Attach the injector retainers into the top injector groove.

F. Carefully lower the fuel/rail injector assembly down onto the

intake manifold. Check to see that each injector has been seated properly into the manifold.

G. Tighten down the fuel rail assembly with the original bolts

and attach the wiring connectors to the injector terminals.

H. Replace the left and right side injector covers.

NOTE: Make sure injector retainers are secure and properly installed. Recheck after cycling fuel system.

23. FINAL ASSEMBLY AND CHECK A. Make sure that the pan fitting is tight and the engine is filled

with factory specified synthetic oil.

B. Fill the coolant surge tank with a 50/50 coolant/water mix. C. Fill the overflow tank approximately one quarter full. D. Reconnect the battery. E. 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.

F. 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.

G. Check all fluid levels, making sure that your tank is filled with

92 octane or higher fuel before commencing test drive.

NOTE: Do not attempt to operate the air conditioning until a qualified air conditioning technician has performed the necessary steps to purge and recharge the air conditioning system.

Page 33

23. FINAL ASSEMBLY AND CHECK (cont'd.)

H. Start the engine and bleed the cooling

system at the water neck until a steady stream of coolant comes out of the fitting. Retighten the bleed screw.

I. 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.

J. Test drive the vehicle. K. Recheck the coolant and oil level. L. Read the STREET

SUPERCHARGER SYSTEM OWNER'S MANUAL AND WARRANTY REGISTRATION FORM

within thirty (30) days of purchasing your supercharger system to qualify.

NOTE: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS.

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

ENGINEERING, INC.