Vortech 1993-1997 5.7L LT1 F-Body User Manual

GM F-Body LT1

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-17

1993-1997 Model Years

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

FAX (805) 247-0669 • www.v ortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

(4GH V1.2)

ENGINEERING, LLC

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual job to a professional installer/technician. Please call Vortech Engineering for possible installers in your area.

prior

to beginning the installation to determine if you should refer the

or translated into another language in any form, by any means without written permission

of Vortech Engineering, LLC.

(4GH V1.2)

Table Of Contents

FOREW0RD............................................................................................................i

TABLE OF CONTENTS ..........................................................................................ii

IMPORTANT NOTICES ........................................................................................... iii

1993 GM LT1 F-BODY SUPPLEMENT...................................................................iv

1994-95 GM LT1 F-BODY SUPPLEMENT..............................................................v

1996-97 GM F-BODY SUPPLEMENT ....................................................................vi

CARROLL SUPERCHARGING MAF SIGNAL MASSAGER...................................vii

CRANE IGNITION SYSTEM ...................................................................................viii

TOOL AND SUPPLY REQUIREMENTS..................................................................ix

PARTS LIST - 1993 GM LT1 F-BODY.....................................................................x

PARTS LIST - 1994-97 GM LT1 F-BODY ...............................................................xi

1. PREPARATION/REMOVAL ..........................................................................1

2. OIL COOLER LINE MODIFICATIONS .........................................................2

3. CRUISE CONTROL RELOCATION .............................................................4

3. SPLASH GUARD TEMPLATE......................................................................5

4.1 AIR PUMP MODIFICATION AND RELOCATION (1993 ONLY)...................6

4.2 AIR PUMP MODIFICATION AND RELOCATION (1994-97 ONLY)..............7

5. OIL FEED LINE ............................................................................................9

6. OIL DRAIN LINE...........................................................................................10

7. SUPERCHARGER MAIN BRACKETS.........................................................11

8. SUPERCHARGER MOUNTING...................................................................11

9. HARMONIC BALANCER, PULLEYS AND DRIVE BELT .............................12

10. AIR INLET DUCT .........................................................................................13

11. OIL DRAIN HOSE.........................................................................................14

12. OIL FEED HOSE CONNECTION.................................................................14

13. COIL RELOCATION AND IGNITION BOX MOUNTING...............................14

14. IGNITION/BOOST CONTROL OPERATION................................................16

15. SUPERCHARGER DISCHARGE ASSEMBLY.............................................17

16. INTAKE AIR TEMPERATURE (IAT) SENSOR THREADING .......................17

17. BYPASS VALVE CONNECTION ..................................................................17

18. FUEL MANAGEMENT UNIT (FMU) INSTALLATION ...................................18

19. BREATHER HOSE RE-ROUTING ...............................................................19

20. T-REX FUEL PUMP INSTALLATION............................................................19

T-REX FUEL PUMP TEMPLATE..................................................................21

21. FUEL INJECTOR REPLACEMENT (1993 MODELS ONLY)........................22

22. FINAL CHECK..............................................................................................23

iii

P/N: 4GH020-010

05NOV01 v1.2

GM F-BODY LT1

IMPORTANT

NOTICES

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, LLC.

This kit is not designed to fit onto vehicles equipped with the factory traction control option. If you are installing this kit on one of these vehicles, additional non-Vortech parts are required. Call Vortech for further details.

(4GH V1.2)

1993 GM LT1 F-BODY 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.

WHITE OR GREEN

FACTORY GM

HARNESS

(UNPLUGGED

FROM COIL)

TO BATTERY +

TO GROUND

RANE

cams

HI-6R

*GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN TACH (TAPE UP)

SUPPLIED MAP SENSOR

HEAVY RED

HEAVY BLACK

CUT HERE

PINK

WHITE

PINK

IGNITION COIL

WIRE TAP

BLACK CONNECTOR

RED WHITE WHITE

RED

GREY CONNECTOR

RED

WHITE

BLACK

ORANGE

PINK

WHITE

BLACK

ORANGE

GREY TERMINAL

NO CONNECTIONS AT BLACK TERMINAL

3 WIRE HARNESS

MANIFOLD

VACUUM

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

YELLOW (TAPE UP)

BROWN WITH WHITE STRIPE

RED

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

BLACK (GROUND)

P/N: 4GH020-010

05NOV01 v1.2

1994-95 GM LT1 F-BODY 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. Attach the pink and white wires to the red and white wires on the supplied ignition box.

FACTORY GM

HARNESS

(UNPLUGGED

FROM COIL)

TO BATTERY +

TO GROUND

RANE

cams

MANIFOLD

VACUUM

HI-6R

*GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

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

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN TACH (TAPE UP)

HEAVY RED

HEAVY BLACK

SUPPLIED MAP SENSOR

3 WIRE HARNESS

PINK

CUT HERE

WHITE

PINK

WIRE TAP

IGNITION COIL

BROWN WITH WHITE STRIPE

RED

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

BLACK CONNECTOR

RED

WHITE RED

GREY CONNECTOR

RED WHITE BLACK

ORANGE

PINK

WHITE

GREY TERMINAL

NO CONNECTIONS AT BLACK TERMINAL

YELLOW (TAPE UP) BLACK (GROUND)

BLACK

ORANGE

(4GH V1.2)

1996-97 GM LT1 F-BODY SUPPLEMENT

HARDWIRING INSTRUCTIONS FOR KITS NOT EQUIPPED WITH A GM WIRING HARNESS

1. Unplug the two-wire harness 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 the green and pink wires previously cut from the coil connector. Connect the pink wire to the red wire and the green wire to the white wire coming from the supplied ignition box.

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

CUT HERE AND ATTACH CONNECTOR

FACTORY GM

TO BATTERY +

TO GROUND

HARNESS

(UNPLUGGED

FROM COIL)

GREEN

HEAVY RED

HEAVY BLACK

PINK

RANE

cams

MANIFOLD

VACUUM

HI-6R

*GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

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

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN TACH (TAPE UP)

SUPPLIED MAP SENSOR

3 WIRE HARNESS

WIRE TAP

RED

WHITE

BLACK

ORANGE

IGNITION COIL

YELLOW (TAPE UP)

BROWN WITH WHITE STRIPE

RED

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

BLACK (GROUND)

PINK

GREEN

vii

P/N: 4GH020-010

05NOV01 v1.2

SPECIAL NOTICE CONCERNING THE

Carroll Supercharging MAF Signal Massager

1996-97 LT1 F-Bodies may require the Carroll Supercharging MAF Signal Massager to prevent OBD-II trouble codes from being set. This par t 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, Inc. 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 Engineer ing, Inc., 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, Inc., directly at (805) 247-0226, M-F 8AM-4:30PM (PST).

(4GH V1.2)

viii

SPECIAL NOTICE CONCERNING THE

CRANE IGNITION SYSTEM

The ignition system, manufactured by Crane Electronics, included in this kit is serviced exclusively by the manuf acturer. 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 def ectiv e 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, Inc. 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, Inc., be liable for labor charges, special or consequential damages.

When returning this unit for service, proof of purchase must be supplied for warr anty verification. After the w arranty 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 Vor tech Engineering, Inc. directly at (805) 247-0226, M-F 8AM-4:30PM (PST).

P/N: 4GH020-010

05NOV01 v1.2

1993 - 1997

GM LT1 F-Body

Installation Instructions

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

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.

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 at least every 3,000 miles. Never attempt to extend the oil

change interval beyond 3,000 miles, regardless of oil manufacturer's claims, as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with

original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures 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 at least every 50,000 miles.

V-2® 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, 10mm

• 1/8" drill bit

•2 gallons 50/50 coolant and water mix

•Tubing cutter

• Hose cutter or knife

• Loctite threadlocker

•5 quarts 20w/50 synthetic motor oil

• Spring-lock fitting disconnect tool

• Drill motor

• 1/2"-20 die

• Wire cutter/crimp tool

• 1/4" drill bit

• 5/16" allen wrench

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

4GH218-050-15 4GH218-060-15

(4GH V1.2)

1993 GM LT1 F-Body

ENGINEERING, LLC

Part No. 4GH218-050SQ

PARTS LIST

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

Part Number Description Quantity

2E228-120 SUPERCHARGER ASSEMBLY 1

2E128-120 V-2 SQ Supercharger 1

4GH038-333 3.33” supercharger drive pulley 1

8R101-002 Pulley retainer assembly 1

4GH111-021 MOUNTING BRACKET ASSEMBLY 1

4GH010-034 Mounting plate A 1 4GH010-044 Mounting plate B 1 4GH011-021 Upper mounting bracket 1 4GH011-031 Lower mounting bracket 1

7A375-250 3/8-16 x 2-1/2” bolts 2 7J375-044 3/8" SAE washers 4 7A375-124 3/8-16 x 1-1/4” bolts 3 7K375-040 3/8” AN960 flat washers 10 7A375-075 3/8-16 x 3/4” bolts 4 7A375-100 3/8-16 x 1” bolts 4 7A312-100 5/16-18 X 1” bolts 2 7K312-001 5/16” AN washers 2 7L312-000 5/16" split lock washers 2 7F312-018 5/16-18 nuts 2 7A375-125 3/8-16 x 1-1/4” socket head cap screws 3

4GV011-032 Belt tensioner 1

7GL10-150 10M x 1.5 nylock nut 1

4GH112-010 AIR INTAKE ASSEMBLY 1

4GH012-012 Air inlet tube assembly 1

8H040-030 Air filter 1 7U035-000 3-1/2" x 17" flex hose 1

4FA012-012 90° intake elbow 1

7E010-075 #12 x 3/4" sheet metal bolts 4 7S350-200 3-1/2” x 2” sleeves 2 7R002-052 #52 hose clamps 2 7R002-056 #56 hose clamps 4 5W018-050 30" 18GA yellow wire 1 5W018-020 30" 18GA black wire 1 5W018-010 30" 18GA red wire 1 5W001-007 3/16" x 6" shrink tube 1 7P375-045 3/8" NPT 45° street elbow 1 7P375-017 3/8" NPT x 1/2" straight hose barb 1 7P125-025 1/8" NPT x 5/32" hose 1

4GH010-091 Air Inlet bracket 1

7P125-016 1/8" NPT plug 1

4GH013-010 Air filter cover 1

4GH130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 9” oil drain hose 1 7P375-017 3/8” NPT x 1/2” straight hose barb 1 7R001-008 #8 stainless hose clamps 2

4GH101-001 FUEL PUMP ASSEMBLY 1

5W001-001 Wire tap 1 5W001-012 22GA red solderless connector 1 5W001-014 Fuse holder 1 5W001-015 20A blade type fuse 1 5W001-017 Large ring terminals 2 5W001-011 Ring terminals 2 7F008-032 8-32 lock nuts 8

7J008-001 #8 flat washers 8

7J010-001 #10 flat washers 2 7R001-004 #4 hose clamps 2 7R004-002 17.0 stepless clamps 2 7U100-055 6" nylon tie wraps 10 8F101-300 Pump wiring assembly 1 7U032-016 3/8" x 36" fuel hose (pump inlet) 1 7U031-018 5/16" x 12" fuel hose 1 7U032-016 3/8" x 11" fuel hose (pump outlet) 1 7U314-001 #8 Lord mounts 4 8F002-265 Inline 90° T-Rex fuel pump 1 7P312-002 5/16" x 1/4" NPT barbs 2 7P250-045 1/4" NPT x 3/8" fittings 2 7R004-003 14.5 stepless clamps 2 7E010-046 #8 x 3/4" sheet metal screw 1 7U100-044 4" nylon tie wraps 10

4GH150-012 RELOCATION ASSEMBLY 1

4GH010-051 Bent coil mount bracket 1

7A375-075 3/8-16 x 3/4" bolts 2 7F375-016 3/8-16 nuts 2

7J375-044 3/8" SAE washers 2 7E010-150 #10 x 1-1/2" sheet metal bolts 2 7R001-008 #8 stainless hose clamps 4 7GL10-150 10M x 1.5" nylock nut 1 7R003-015 15/16" adel clamp 1 7U033-000 5/8" x 20" PVC hose 1 7U125-000 11-1/2" heat sleeve 1 7U133-024 5/8" x 2' molded elbow hose 1 7P375-020 3/8" NPT x 5/8" straight hose barb fittings 2 7P500-021 1/2" 90° compression fittings 2 7P625-005 5/8" 90° compression fittings 2 7P500-022 1/2" to 3/8" bushings 2

Part Number Description Quantity

4GH112-020 AIR DISCHARGE ASSEMBLY 1

4GH012-020 Discharge tube A 1 4GH012-010 Discharge tube B 1

7S350-300 3-1/2” x 3” sleeve 1 7S400-200 4” x 2” sleeve 1 7R002-044 #44 hose clamps 2 7R002-056 #56 hose clamps 2 7R002-064 #64 hose clamps 2 7S275-300 2-3/4” x 3” sleeve 1 7U034-016 1" x 2-1/2" heater hose 1 7U034-016 1" x 14" heater hose 1 7R002-016 #16 hose clamps 4 7U030-046 5/32" x 26" vacuum hose 1 7P156-082 5/32" tee 1 8D001-001 Bypass valve 1 7P750-100 3/4" NPT x 1" hose fitting 1

4GH116-010 CRANK PULLEY ASSEMBLY 1

4GH016-021 Crank pulley 1 4GH018-021 Factory crank pulley 1

7A437-175 7/16-14 x 1-3/4" bolts 3 7J438-081 7/16” SAE washers 3 7L437-075 7/16” lock washers 3 2A048-408 Belt 1

4GH130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 49” oil feed hose 1 7P525-067 .500 crimp ferrules 2 7P250-066 #4 swivel x 1/4” hose barb fittings 2 7P250-082 1/4 NPT x -4 90° fitting 1 7P250-122 1/4" pipe thread AN917 tee 1 7P125-026 1/8 NPT x #4 90° fitting 1 7P250-121 1/4" NPT x 3" steel nipple 1 7U100-055 6" nylon tie wraps 3 7U100-066 11" nylon tie wraps 2 7P250-080 1/4 NPT 90° street elbow 1 7P250-036 #4 flare to 1/4" NPT 1 7S625-000 32" fire sleeve 1

4GH139-096 PCV ASSEMBLY 1

7U375-052 3/8" vacuum cap 1 7U100-055 6" nylon tie wraps 5 7U030-036 1/2” x 58” oil drain hose 1 7R001-008 #8 stainless hose clamps 2

4GH238-058 FMU (with lines) 1

6Z110-118 10:1 fuel management unit 1 4GH145-156 14" male fuel line assembly 1 4GH146-166 10" female fuel line assembly 1

7P156-082 5/32" tee 1

7U030-046 5/32” x 36” vacuum line 1

7U100-055 6” nylon tie wraps 10

4GH136-060 SMOG PUMP RELOCATION 1

7U100-066 11" nylon tie wraps 8

7P625-004 5/8" tee 1

7R001-008 #8 stainless hose clamp 1 4GH010-061 Bent smog pump bracket 1

7A250-101 1/4-20 x 1" cap screws 3

7F250-021 1/4-20 nylock nuts 3

7J250-001 1/4" SAE washers 6

7E010-075 #12 x 3/4" sheet metal bolts 3

7U033-000 5/8" x 35" PVC hose 1

7U033-000 5/8" x 20" PVC hose 1

8H040-022 3/4" breather 1

5A101-008 HI-6 CRANE IGNITION ASSEMBLY 1

5A001-009 HI-6TR Crane ignition system 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 5W001-019 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 5W022-060 77" 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

5A002-001 GM Wiring harness 1

5W001-014 Fuse holder 1 5W001-015 Blade type 20A fuse 1 5W001-017 Large ring terminals 2

5A002-006 Map sensor 1

P/N: 4GH020-010

05NOV01 v1.2

+ 25 hidden pages

Vortech 1993-1997 5.7L LT1 F-Body User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual