Vortech 1993-1996 5.2L Grand Cherokee User Manual

5.2L Jeep Cherokee

Supercharger System

Installation Instructions for
’93-’95 5.2L Jeep Cherokee

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

1996 5.2L Jeep Cherokee

49 State Smog Legal

®

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.

®

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

Part No. 4CJ218-010S

Part No. 4CJ218-020S

Congratulations on selecting the best performing and best backed automotive

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

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

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30 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.

‘93-’95 5.2L Jeep Cherokee

1996 5.2L Jeep Cherokee

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

- 49 State Smog Legal

TOOL & SUPPLY REQUIREMENTS

Factory Repair Manual
3/8" Drive and Socket Set: SAE and Metric
1/2" Drive and Socket Set: SAE and Metric
3/8" NPT Tap and Tap 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® # A120

Rivet Gun
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

4CJ218-010S-3

1993-95 5.2 Jeep Cherokee

Part No. 4CJ218-010S

®

ENGINEERING, INC.

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

PARTS LIST

Part Number Description Quantity

2A228-140 SUPERCHARGER ASSEMBLY 1

2A128-140 V-1S Supercharger 1
2A037-312 3.125” Supercharger Drive Pulley 1

4FA016-150 Smooth Pulley Tensioner 1

7J012-092 12 mm Flat Washer 1

8R101-001 6 Rib Pulley Retainer Assembly 1

4CJ111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-010 Mounting Bracket Support 1
4CB010-034 Mounting Plate 1
4CB011-021 Mounting Bracket 1

2A047-104 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" Cap Screw 1
7A375-375 3/8-16 x 3-3/4” HH Bolt 1
7F375-016 3/8-16 Hex Nut 1

7J375-044 3/8” SAE Washers 10
7K375-040 3/8” AN960 Flat Washers 5
7U100-055 6" Nylon Tie Wraps 2

4CB017-011 1/2" Spacer 1

7A312-450 5/16-18 x 4.5" Stainless HXHD 1

4CJ112-010 AIR INTAKE ASSEMBLY 1

4FG112-022 Inlet Duct 1

7R001-056 #56 Hose Clamp 1
8H040-040 Air Filter 1
7P375-020 3/8" NPT x 5/8" Straight Hose Barb 1
7U033-000 5/8" x 42" PVC Hose 1

4CJ112-020 AIR DISCHARGE ASSEMBLY 1

4FG012-030 Discharge Tube 1

7S275-200 2-3/4” x 2” Sleeve 1
7S300-200 3" X 2" Sleeve 1
7R002-044 #44 Hose Clamps 2
7R002-048 #48 Hose Clamps 2
8D001-001 Bypass Valve 1
7P750-100 3/4" NPT x 1" Straight Hose Fitting 1
7U034-016 1" x 7" Heater Hose 1
7R002-016 #16 Hose Clamps 4
7P156-082 5/32" Tee 1
7U030-046 5/32" x 24" Vacuum Line 1

4CJ050-010 Air/Plenum 1

4GB040-060 Air/Plenum Gasket 1

7J250-001 1/4" SAE Washers 3
7F250-030 1/4-20 Acorn Nut 1

4CJ110-010 COIL RELOCATE ASSEMBLY 1

4CJ010-040 Coil Bracket 1

7A250-103 1/4-20 x 1" SH Cap Screws 2
7F250-021 1/4-20 Nylock Nuts 2

5W022-040 30" 22GA Green Wire 1
5W022-090 30" Grey Wire 1
5W001-007 3/16" x 8" Heat-Shrink Tubing 1

7A312-125 5/16-18 x 1-1/4" HH Bolts 2
7K312-001 5/16" AN Washers 2

4CJ017-021 5/8" Coil Spacer 1

5W001-005 3/8" x 40" Plastic Wire Loom 1

4CJ120-010 FUSE BOX RELOCATION ASSEMBLY 1

4CJ010-060 Fuse Box 1

7U100-025 1/8" Dia. x 1/4" Rivets 5
7E010-075 #12 x 3/4" HH Sheet Metal Screws 3

4CJ130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 18” Oil Drain Hose 1
7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1
7R001-008 #8 Stainless Hose Clamps 2
7P375-045 3/8" NPT x 45° Street Elbow 1

Part Number Description Quantity

4CJ130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 33” Oil Feed Hose 1
7P125-103 1/8" NPT -4 x 45° Male Elbows 2
7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2
7P525-067 .525 Crimp Ferrules 2
7P125-026 1/8" NPT x #4 90° Fitting 1
7P125-104 1/8" NPT Female Tee 1
7P125-106 1/8" NPT x 3" Nipple 1

4CJ101-003 FUEL PUMP ASSEMBLY 1

8F001-002 200 Inline Fuel Pump 1
7C011-075 10/32" x 3/4" HH Cap Screw 1
7F010-032 10-32 Nylock Nut 1

7J010-001 #10 Flat Washers 3

7P250-082 1/4" NPT x -4 90° Fitting 1

7P250-036 1/4" NPT #4 Flares 3
4CJ145-010 Male Fuel Line 1
4CJ145-020 Female Fuel Line 1

5W001-010 16-14GA Female Slides 3
5W018-020 12" 18GA Black Wire 1
5W001-011 16-14GA Eyelets 2
5W001-001 Wire Tap 1
5W001-017 Large Ring Terminals 2

8F101-400 Pump Wiring Assembly 1

7E010-050 #12 x 1/2" Sheet Metal Screw 1

7U031-018 5/16" x 4" Fuel Hose 2

7P250-034 1/4" NPT x 1/4" NPT Straight Tee 1

7P312-002 5/16" x 1/4" NPT Barbs 2

7P250-037 #4 Male Run Tee 1

7R003-023 Adel Clamp 1

7R001-004 #4 Hose Clamps 4

4CJ238-068 FMU (with lines) 1

6Z110-111 12:1 Fuel Management Unit 1
4CJ145-030 Fuel Line (FMU In) 1
4CJ145-040 Fuel Line (FMU Out) 1

7U030-046 5/32” x 25” Vacuum Line 1
7U100-055 6” Nylon Tie Wraps 2

5A101-009 HI-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

4CJ150-012 BATTERY RELOCATE ASSEMBLY 1

4CJ010-070 Battery Tray 1

7A375-351 3/8-16 x 3-1/2" SH Flat Screws 3

7F375-017 3/8-16 Nylock Nuts 3

4CJ017-031 2-5/8" Battery Tray Spacers 3

5W013-000 82" 1 Gauge Red Cable 1
5W013-001 30" 1 Gauge Black Cable 1
5W001-027 3-Way Splice 1
5W001-028 Battery Post Terminals 2
5W001-029 Lug End Terminals 2

7U100-055 6" Nylon Tie Wraps 10

7R003-008 1/2" Adel Clamps 3

7E010-050 #12 x 1/2" Sheet Metal Scews 3

7J375-044 3/8" SAE Washers 3

7P437-375 7/16-20 x 3/8" Set Screws 2
5W001-030 1-1/2" x 8" Heat-Shrink Tubing 1

1996 5.2 Jeep Cherokee

Part No. 4CJ218-020S

®

ENGINEERING, INC.

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

PARTS LIST

Part Number Description Quantity

2A228-140 SUPERCHARGER ASSEMBLY 1

2A128-140 V-1S Supercharger 1
2A037-312 3.125” Supercharger Drive Pulley 1

4FA016-150 Smooth Pulley Tensioner 1

7J012-092 12 mm Flat Washer 1

8R101-001 6 Rib Pulley Retainer Assembly 1

4CJ111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-010 Mounting Bracket Support 1
4CB010-034 Mounting Plate 1
4CB011-021 Mounting Bracket 1

2A047-104 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" Cap Screw 1
7A375-375 3/8-16 x 3-3/4” HH Bolt 1
7F375-016 3/8-16 Hex Nut 1

7J375-044 3/8” SAE Washers 10
7K375-040 3/8” AN960 Flat Washers 5
7U100-055 6" Nylon Tie Wraps 2

4CB017-011 1/2" Spacer 1

7A312-450 5/16-18 x 4.5" Stainless HXHD 1

4CJ112-010 AIR INTAKE ASSEMBLY 1

4FG112-022 Inlet Duct 1

7R001-056 #56 Hose Clamp 1
8H040-040 Air Filter 1
7P375-020 3/8" NPT x 5/8" Straight Hose Barb 1
7U033-000 5/8" x 42" PVC Hose 1

4CJ112-020 AIR DISCHARGE ASSEMBLY 1

4FG012-030 Discharge Tube 1

7S275-200 2-3/4” x 2” Sleeve 1
7S300-200 3" X 2" Sleeve 1
7R002-044 #44 Hose Clamps 2
7R002-048 #48 Hose Clamps 2
8D001-001 Bypass Valve 1
7P750-100 3/4" NPT x 1" Straight Hose Fitting 1
7U034-016 1" x 7" Heater Hose 1
7R002-016 #16 Hose Clamps 4
7P156-082 5/32" Tee 1
7U030-046 5/32" x 24" Vacuum Line 1

4CJ050-010 Air/Plenum 1

4GB040-060 Air/Plenum Gasket 1

7J250-001 1/4" SAE Washers 3
7F250-030 1/4-20 Acorn Nut 1

4CJ110-010 Coil Relocate Assembly 1
4CJ010-040 Coil Bracket 1

7A250-103 1/4-20 x 1" SH Cap Screws 2
7F250-021 1/4-20 Nylock Nuts 2

5W022-040 30" 22GA Green Wire 1
5W022-090 30" Grey Wire 1
5W001-007 3/16" x 8" Heat-Shrink Tubing 1

7A312-125 5/16-18 x 1-1/4" HH Bolts 2
7K312-001 5/16" AN Washers 2

4CJ017-021 5/8" Coil Spacer 1

5W001-005 3/8" x 40" Plastic Wire Loom 1

4CJ120-010 FUSE BOX RELOCATION ASSEMBLY 1

4CJ010-060 Fuse Box 1

7U100-025 1/8" Dia. x 1/4" Rivets 5
7E010-075 #12 x 3/4" HH Sheet Metal Screws 3

4CJ130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 18” Oil Drain Hose 1
7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1
7R001-008 #8 Stainless Hose Clamps 2
7P375-045 3/8" NPT x 45° Street Elbow 1

4CJ160-010 1996 SUPPLEMENT ASSEMBLY 1

7P125-107 1/8" NPT x 2" Nipple 1

5W018-010 60" 18 Ga. Red Wire 1
5W018-020 60" 18 Ga. Black Wire 1
5W001-007 3/16" x 8" Heat Shrink Tube 1
5W001-032 18 Ga. Solderless Connectors 4

4CJ010-080 1996 Fuse Box Bracket 1

Part Number Description Quantity

4CJ130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 33” Oil Feed Hose 1
7P125-103 1/8" NPT -4 x 45° Male Elbows 2
7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2
7P525-067 .525 Crimp Ferrules 2
7P125-026 1/8" NPT x #4 90° Fitting 1
7P125-104 1/8" NPT Female Tee 1
7P125-106 1/8" NPT x 3" Nipple 1

4CJ101-004 FUEL PUMP ASSEMBLY 1

8F001-200 200 Inline Fuel Pump 1
4CJ145-050 Fuel Line FMU Out 1
4CJ145-030 Fuel Line FMU In 1
4CJ145-020 Female Fuel Line 1

7U032-016 3/8" x 36" Fuel Hose 1

7P250-122 1/4" Pipe Thread Tee 1

7P250-036 1/4" NPT #4 Flares 2

7P250-045 1/4" NPT x 3/8" Fitting 1

7P250-050 1/4" NPT Male Branch Tee 1

7P250-082 1/4" NPT x -4 90° Fittings 2

7P312-002 5/16" x 1/4" NPT Barb 1

7R001-008 #8 Hose Clamps 4

7U031-018 5/16" x 2-1/2" Fuel Hose 2

7R003-023 1.8" Adel Clamps 2

7C010-075 10-24 x 3/4" SHCS 2

7F010-024 10-24 Nylock Nuts 2

7J010-001 #10 Flat Washers 4
7U100-055 6" Nylon Tie Wraps 10
7R003-008 1/2" Adel Clamps 2
7R001-004 #4 Hose Clamps 4

4CJ238-068 FMU (with lines) 1

6Z110-111 12:1 Fuel Management Unit 1

4CJ145-030 Fuel Line (FMU In) 1
4CJ145-040 Fuel Line (FMU Out) 1

7U030-046 5/32” x 25” Vacuum Line 1
7U100-055 6” Nylon Tie Wraps 2

5A101-009 HI-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

4CJ150-012 BATTERY RELOCATE ASSEMBLY 1

4CJ010-070 Battery Tray 1

7A375-351 3/8-16 x 3-1/2" SH Flat Screws 3
7F375-017 3/8-16 Nylock Nuts 3

4CJ017-031 2-5/8" Battery Tray Spacers 3

5W013-000 82" 1 Gauge Red Cable 1
5W013-001 30" 1 Gauge Black Cable 1
5W001-027 3-Way Splice 1
5W001-028 Battery Post Terminals 2
5W001-029 Lug End Terminals 2

7U100-055 6" Nylon Tie Wraps 10
7R003-008 1/2" Adel Clamps 3
7E010-050 #12 x 1/2" Sheet Metal Scews 3

7J375-044 3/8" SAE Washers 3
7P437-375 7/16-20 x 3/8" Set Screws 2

5W001-030 1-1/2" x 8" Heat-Shrink Tubing 1

1. PREPARATION/REMOVAL

A. Disconnect the battery, remove the battery box and battery

tray. Set aside. Separate the vacuum canister from the
bottom of the tray.

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

mounting bracket and set aside.

D. Disconnect and remove the crankcase breather hose.
E. Remove the entire air filter/inlet assembly.
F. Remove the windshield washer reservoir and set aside.
G. Remove the ignition coil and bracket. Set aside.
H. Remove the front skid plate, if equipped.

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.

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. Locate and mark hole per diagram. Remove paint around

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

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

the 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.

NOTE: Use extreme caution not to hit
the crankshaft while punching the
pan. If a clearance problem exists,
rotate the crankshaft until clearance
is obtained.

ROTATE ENGINE TO
DISPLAYED POSITION

IGN. ROTOR

2"

TDC

DOWN

1-3/4"

E. 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.

OIL PAN

PUNCH HOLE THROUGH

1

2. OIL DRAIN, cont'd.
F. Thoroughly clean the threaded area. Apply a small

amount of silicone sealer to the new threads. Apply
more sealer to the male threads of the 3/8" NPT x 45°
street elbow and secure in the hole. Position the fitting
so that it points up toward the top/front of the vehicle
at approximately a 45° angle. Make sure a seal is
formed all around the fitting. Thread the 3/8" NPT x 1/2"
barb fitting into the 45° street elbow using a small
amount of pipe sealer.

G. Drain engine oil and change filter.
H. 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.

3. POWER DISTRIBUTION CENTER

45° ANGLE
UPWARD

A. Remove the plastic power distribution center

(PDC) (main fuse box located underhood on
the passenger side) from its mounting bracket.
Remove bracket from vehicle.

B. Drill the rivets out of the PDC mounting bracket.

Retain the upper portion and discard lower.

C. Re-rivet the upper bracket to the lower bracket

provided in the kit. See graphic.

NOTE: Due to different vehicle
applications, two mounting brackets are
supplied in each kit. 1995 and earlier
models will use the bracket with four
mating holes (see graphic) and 1996­1997 models will use the bracket with
three mating holes.

D. Disconnect the positive battery cable from the

PDC. Carefully remove about one inch of the
tape and wire cover over the wire loom going
into the power distribution center.

E. Place the new PDC bracket against the

passenger side inner fenderwell, allowing
enough space for the power distribution center
to slide into its forwardmost position with the
positive terminal cover on. (See photo above.)

F. Mark mounting hole location. Drill and secure

with supplied sheetmetal screws.

RIVET
BRACKETS
TOGETHER

VORTECH
SUPPLIED BRACKET

(1996-1997 bracket appears

slightly different)

2

4. VACUUM RESERVOIR
A. Remove the vacuum reservoir from

the bottom of the battery tray.

B. Place the vacuum reservoir in the

forward most corner of the passenger
side fenderwell. See graphic.

C. Using the existing mounting flanges,

drill and secure with the provided
sheetmetal screws.

D. Reattach the vacuum hose.

NEW
BRACKET

VACUUM
RESERVOIR

PDC

5. 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 approximately
two inches from the top and gently bend
rearward and inward about one inch.
Resecure with the existing fastenera
after the bracket installation.

B. Mount the cast aluminum main

mounting bracket on the front of the
engine right cylinder head using the
fasteners provided, as shown in the
graphic on the next page.

NOTE: Before mounting the main
bracket, the vehicle wiring harness
must be shifted so that it rests in
between the timing chain cover and
the supercharger mounting bracket
for exhaust clearance.

WIRING HARNESS

3

5. MAIN MOUNTING BRACKET AND PLATE, cont'd.
C. Please note that the 3-3/4" bolt also 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, then removed
for installation of the supercharger
mounting plate. Reinstall the bolt after
mounting the plate and before attaching
the spring tensioner.

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. Secure the plate and tensioner as an

assembly to the cast bracket.

GROUND TO ALTERNATOR
MOUNTING BOLT

F. Attach the support strut between the

supercharger mounting plate and the
second exhaust manifold stud. Secure with
the supplied stainless steel bolt.

G. Attach the 3 loose ground connections

from the main harness (near the
supercharger mounting bracket) to the
existing alternator mounting bolt and
secure.

MAIN
HARNESS

HEAT
SHIELD

5/16" BOLT

.25 SPACER

VORTECH
SUPPORT

.60 SPACER

EXHAUST

MANIFOLD

ATTACH TO
EXHAUST MANIFOLD

5/16-18 x 4-1/2"

/16-18 X 3.5

SUPERCHARGER

GEARCHARGER

MOUNTING PLATE

MOUNTING PLATE

SUPPORT

3/8-16 X 1.0

3/8-16 x 1"

MAIN MOUNTING
BRACKET

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 3-3/4" -

3/8-16 X 3.75

(BOLT MUST BE
INSTALLED BEFORE
SPRING TENSIONER
IS MOUNTED.)

3/8-16 x 3"

3/8-16 X 3.0

STOCK TENSIONER

4

6. 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 (arrow) to

the inner most threaded boss on the
supercharger. Use the supplied large
washer as a spacer in between the pulley
and the supercharger.

NOTE: Drain hose must be routed downhill
with no kinks or sharp turns. Supercharger
life will be affected by an improperly routed
drain hose.

D. Route the supercharger drain hose downhill towards the drain

fitting in the pan. Trim hose if necessary and secure to fitting
with the supplied #8 hose clamp.

7. SUPERCHARGER/ACCESSORY DRIVE BELT
A. The new, longer accessory

drive belt is routed the same

S/C DRIVE

PULLEY

as the original belt except
for accommodation of the
supercharger and a 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.

A/C

ALT

P/S

PULLEY

WATER

PUMP

CRANK

5

8. OIL FEED LINE

OIL SENDING UNIT
45° x 1/8" FITTING

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 nipple and tee fitting into

the block and place the sending unit in the
upper end. (1995 and earlier models will use
the 3" long nipple, while 1996-1997 models
will use the 2" nipple.) Install the 45° fitting in
the side port and orient the assembly so that
it points forward and slightly outward towards
the passenger side. 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 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. (On 1996-1997 models,
no EGR is present).

D. Before connecting the other end of the hose to

the supercharger, briefly crank over the engine
in order to purge the line with 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.

45° x 1/8"
FITTING

ENGINE BLOCK

STOCK OIL
PRESSURE
SENDING
UNIT

1/8" NPT
NIPPLE

1/8" NPT
NIPPLE

6

9a. BATTERY RELOCATION
A. Loosen the power steering lines on

the power steering pump and pivot
them toward the radiator
approximately 2". This will provide
enough clearance for the battery in
its new location. Retighten fittings.

B. Remove the two nut clips from the

original battery tray and attach them
to the provided tray.

C. Using the three existing holes in the

lower plane of the drivers side inner
fenderwell (the previous position of
the air filter assembly), mount the
new battery tray parallel to the head
light assembly. See photo.

D. 1996-1997 models are equipped

with a battery temperature sensor.
This unit must be relocated to the
new battery tray using the supplied
red and black wire extensions.

E. Place the battery on the tray

and secure with the original
retaining parts.

NEW TRAY

NUT CLIPS

7

9b. NEGATIVE BATTERY CABLE
A. Disconnect the negative battery cable

from the inner fenderwell ground location.

B. Cut the engine ground cable as close as

possible to the battery terminal end. Strip
the end of the cut cable and attach the
eyelet connector provided. Reconnect
the new engine ground and all previously
removed ground wires to the original
fenderwell location.

C. Remove the lower power steering pump

bracket bolt (on the drivers side) and
attach the eyelet end of the new negative
battery cable provided.

D. Secure the cable with the tie straps

provided. Trim as necessary. Connect
the negative cable end to the battery.

1"

9c. POSITIVE BATTERY CABLE
A. Cut both positive cables as close as

possible to the battery terminal end and
discard terminal.

B. Strip cable cover back about one inch.

Connect both ends to the provided splice
connector.

C. Attach the provided length of cable to the

opposite end of the splice. Slide the heat
shrinkable tube over the splice. Apply
heat with heat gun or hair dryer until tube
shrinks snugly around connector and
cable end assembly.

D. Route the cable under the radiator to the

new battery location. Secure the cable
with the tie straps and adel clamps. Trim
as necessary.

E. Connect the cable end to the battery.

Reinstall the skid plate. (If equipped.)

WARNING: It is imperative that the
cable is carefully routed and
secured so that no sharp edges or
moving parts can damage the
insulation.

1"

SPLICE
CONNECTOR

8

10A. AUXILIARY FUEL PUMP

(1993-1995 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 beneath the windshield washer
reservoir and the brake master cylinder.

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,

insert hose assembly "A" into the factory
feed line until it snaps into place. Route the
hose assembly along the rear firewall near
the base of the brake booster.

D. Attach the Vortech fuel pump to the vehicle

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

NOTE: On ABS equipped vehicles,
the pump mounting position may vary
slightly.

AUXILIARY
FUEL PUMP

FUEL
MANAGEMENT
UNIT

E. Use the supplied length of short black wire

to ground the fuel pump.

F. Mark and drill a 1/8" hole and mount the

supplied relay on the passenger side inner
fenderwell near the fuse box. Connect the
short black wire from the relay terminal #86
to ground.

G. From relay terminal #85, route the yellow

wire to the bottom of the underhood fuse
box. Tap the yellow relay wire into the factory
fuel pump relay wire connected to pin #87
on the factory fuel pump relay (the wire can
be various colors but usually is green with a
white stripe) using the supplied wire tap.
Double check the wire choice by using a test
light to confirm that when the key is initially
turned on, the wire has power for 4-8
seconds and then turns off.

H. Connect the long red wire from relay terminal

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

GROUND

86

87

87A

30

RELAY

85

(+) FUEL PUMP

GREEN/WHITE @
PIN #87 OF
FACTORY FUEL
PUMP RELAY

LUG FROM BATTERY
TO FUSE PANEL
UNDERHOOD

9

10A. AUXILIARY FUEL PUMP, cont'd.

(1993-1995 Models Only)

I. Connect the short red wire from relay terminal #30 to the

external fuse box (+) lug.

J. Assemble the brass fittings and hoses as shown in the

graphic. Make sure hose "B" makes a positive snap
connection onto the fuel rail.

K. Using the supplied tie wraps, secure all hoses from sharp

edges, moving parts or chaffing.

L. Activate the fuel pump and check all fittings, connections

and hoses for leaks.

1/4" NPT x 45°
FLARE

3/8" x 1/4" NPT

1/4" x 28" HOSE

3/8" x4"
FUEL HOSE

1/4" x 5" HOSE

FUEL PUMP

5/16" x 4"
FUEL HOSE

#4 MALE
RUN TEE

HOSE ASSEMBL Y "B"

1995 AND EARLIER MODELS ONLY

10

FLOW

FRONT OF VEHICLE

10B. AUXILIARY FUEL PUMP

(1996-1997 Models Only)

A. An additional fuel pump is supplied to ensure that

sufficient fuel is available to the engine. The pump
is mounted underneath the new battery tray.

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, insert

hose assembly A into the factory feed line until it
snaps into place. Loop the hose assembly around
and into the 1/4" tee assembly.

D. Attach the Vortech fuel pump to the bottom of the

battery tray using the supplied #10 hardware and
adel clamps. See graphic.

E. Use the supplied length of short black wire to

ground the fuel pump.

F. Mark and drill a 1/8" hole and mount the supplied

relay on the passenger side inner fenderwell near
the fuse box. Connect the short black wire from the
relay terminal #86 to ground.

G. From relay terminal #85, route the yellow

wire to the bottom of the underhood fuse
box. Tap the yellow relay wire into the
factory fuel pump relay wire connected to
pin #87 on the factory fuel pump relay (the
wire can be various colors but usually is
green with a white stripe) using the supplied
wire tap. Double check the wire choice by
using a test light to confirm that when the

GROUND

key is initially turned on, the wire has power for
4-8 seconds and then turns off.

H. Connect the long red wire from relay terminal #87

to the (+) terminal on the fuel pump.

I. Connect the short red wire from relay terminal #30

to the external fuse box (+) lug.

J. Assemble the brass fittings and hoses as shown in

the graphic. Make sure hose "B" makes a positive
snap connection onto the fuel rail.

K. Using the supplied tie wraps, secure all hoses

from sharp edges, moving parts or chaffing.

L. Activate the fuel pump and check all fittings,

connections and hoses for leaks.

86

FUEL PUMP MOUNTED

UNDERNEATH

BATTERY TRAY

(+) FUEL PUMP

87

87A

30

RELAY

85

GREEN/WHITE @
PIN #87 OF
FACTORY FUEL
PUMP RELAY

LUG FROM BATTERY
TO FUSE PANEL
UNDERHOOD

11

10B. AUXILIARY FUEL PUMP, cont'd.

(1996-1997 Models Only)

1996-1997 FUEL SYSTEM

1/2" ADEL
CLAMP

1/4" x 20"
MALE LINE
ASSEMBLY "A"

FACTORY
FEED LINE

1/4" NPT x #4
FLARE

1/4" NPT x 3/8"
BARB

3/8" x 35"
FUEL HOSE

FUEL PUMP
(ATTACH TO BOTTOM
OF BATTERY TRAY)

1/4" NPT
FEMALE TEE

®

1/4" NPT x #4
FLARE

CONNECT TO
MANIFOLD
VACUUM/PRESSURE

FMU

INLET

1/2" ADEL
CLAMP

1/4" x 20" HOSE

OUTLET

1/4" x 30"
FEMALE LINE
ASSEMBLY "B"

1/4" NPT x 90°
FLARE

FLOW

T-REX

1/4" x 28" HOSE

5/16" x 2-1/2"
FUEL HOSE

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

1/4" NPT x 90°
FLARE

1/4" NPT
BRANCH TEE

12

11. FUEL MANAGEMENT UNIT
A. Using the photo on page 9 as a reference, place the fuel

management unit (FMU) on the firewall. Mark and drill two
3/32" holes and secure the unit with the sheet metal screws
provided. (Temporarily placing the washer reservoir back
into its original location will help reference proper FMU
placement.)

B. Connect the FMU inlet hose (the hose running to the 90°

fitting on the side of the FMU) to the brass tee 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.
F. Reinstall wiper washer reservoir, lines and wire connections.

FUEL RAIL

FUEL
INJECTORS

INTAKE
MANIFOLD

ATTACH FMU TO
SMALL VACUUM
CONNECTION

12. IGNITION COIL RELOCATION
A. Remove the ignition coil from its original

mounting bracket.

B. Locate the two 5/16" threaded bosses

on the intake manifold between the
throttle body and rear of the air
conditioning unit.

C. Attach the supplied coil bracket and

1/4-20 hardware to the ignition coil.
Secure the coil assembly to the intake
manifold using the supplied spacer,
5/16" bolts and washers. The
distributor lead must point toward the
rear of the vehicle.

DRIVER'S SIDE

IGNITION
COIL

13

13. IGNITION/BOOST CONTROL INSTALLATION

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

®

C

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.

14

13. 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

C

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

T

E

ELECTRONICS

R

C

HI-6TR

TIMING RETARD CONTROL

15

YELLOW (TAPE UP)
BLACK (GROUND)

A

R

D

14. 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.]

15

10

5

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.]

16

15. PLENUM AND DISCHARGE INSTALLATION

THROTTLE

BODY

SIDE VIEW

(2) 1/4" WASHERS

FACTORY
AIR CLEANER
MOUNTING STUD

A. Remove the tab holding down the

factory air cleaner mounting stud. Use
the two (2) supplied 1/4" washers as
spacers underneath the mounting stud
tab. Reattach the assembly to the
throttle body. (See graphic.)

B. Place the gasket and plenum onto the

throttle body. Secure with plenum nut.

C. Fit the 3" x 2" silicone sleeve onto the

plenum and slide on the two #48 clamps.

D. Slide the 2-3/4" x 2" sleeve onto the

supercharger discharge. Secure with
#44 clamps.

E. Install the discharge tube between the

plenum and supercharger and secure
with clamps.

16. BYPASS VALVE INSTALLATION
A. Slide the 1" x 3-1/2" hose onto the

bypass valve. Secure with #16 hose
clamps. (See the graphic on the next
page.)

B. Slide the 1" x 2-1/2" hose onto the

discharge duct and bypass valve inlet.
Secure with hose clamps.

C. Route the 5/32" vacuum line to the

bypass valve and FMU tee as shown in
the graphic on the next page.

D. Using the supplied tee and length of

hose, cut the hose 4" from the FMU.

E. Install the tee fitting and connect the

hose to the bypass valve.

17

16. BYPASS VALVE INSTALLATION, cont'd.

DISCHARGE

TUBE

FMU

TO INTAKE
MANIFOLD

TO BYPASS
VALVE

2-1/2" x 1"
HOSE

INLET
DUCT

3-1/2" x 1" HOSE

VACUUM
HOSE

17. SUPERCHARGER INLET
A. Slide the inlet duct and T-bolt clamp

onto the supercharger inlet.

B. Route the new 5/8" hose from the

drivers side valve cover breather,
around the rear portion of the intake
manifold and attach to the
corresponding hose barb on the air
inlet duct.

C. Connect the bypass assembly to

the 1" barb on the air inlet.

D. Mount the air filter and secure with

supplied hose clamp.

18

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

18. 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. Read the STREET SUPERCHARGER

SYSTEM OWNER'S MANUAL AND

WARRANTY REGISTRATION FORM within

thirty (30) days of purchasing your supercharger

system to qualify.

19

®

ENGINEERING, INC.

© 1994 VORTECH® ENGINEERING, INC. all rights reserved