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

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Page 1

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

Page 2

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)

Page 3

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

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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.

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Page 5

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

Page 6

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

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Page 7

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

Page 8

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

Page 9

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

Page 10

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)

Page 11

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

Page 12

1994-1997 GM LT1 F-Body

Part No. 4GH218-060SQ

ENGINEERING, LLC

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

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

7P625-002 5/8" Hose Mender 1

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

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

4GH238-068 FMU (with lines) 1

6Z110-117 8:1 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

7U129-036 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

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

(4GH V1.2)

xii

Page 13

1. PREPARATION/REMOVAL

A. Disconnect the negative cable at the battery. B. Jack up the front of the vehicle and secure with jack

stands or use a lift.

C. Crank the engine over just until the arrow on the

crankshaft pulley points in the 6 o'clock position (straight down).

D. Disconnect and set aside the anti-roll bar. E. Drain the radiator completely by removing the radiator

cap and opening the petcock on the lower passenger's side. Catch the coolant in a clean container to reuse or dispose of properly.

F. Unplug the intake air temp sensor connector. Remo ve

the sensor from the intake elbow. Unplug the MAF sensor located between the intake elbow and air filter . (1993 models are not equipped with MAF meters.) Remove the unit and set aside, taking care to protect the wire elements inside. Remove the intake elbow/ resonator assembly. (On 1995-1997 models, the 5/32" hose must be removed from the inlet elbow.) Using an upholstery fastener removal tool, remove the entire air intake assembly including the air box and filter.

NOTE: On models equipped with factory "ram air"

induction, remove the air inlet system entirely and reinstall the fuel rail bolts originally securing the air filter box.

G. Remove the factory air pump from the vehicle. H. Unplug the ignition coil and ignition module

connections along with the attached ground wires and set aside. Remove the coil and related hardware.

I. If the vehicle is equipped with an engine oil cooler,

remove the upper radiator hose assembly (driver's side) from the radiator, water pump and intake manifold. Set the complete assembly and clamps aside for future reassembly.

J. Remove the 5/8" oil cooler hose from the water pump.

Remove the rubber 5/8" hose (on the bottom driver's side of the radiator) that connects to the oil filter/cooler assembly (do not remove the entire cooling line from the vehicle).

K. Remove the accessory drive belt. L. Remove the three (3) bolts that attach the harmonic

balancer to the crankshaft hub (do not remove the hub or center bolt) and remove the balancer.

M. Label and disconnect the four (4) driver's side spark

plug wires from the distributor module.

N. Removing the driver's side radiator fan eases

supercharger mounting somewhat, but is not necessary to complete installation.

P/N: 4GH020-010

05NOV01 v1.2

Page 14

2. OIL COOLER LINE MODIFICATIONS

NOTE: On vehicles not equipped with external

oil cooler lines, skip the steps below and move onto steps 2-H, 2-J and 2-K.

A. Remove the engine oil filter. B. With both coolant lines disconnected from

the radiator and water pump, remove the clamp securing the cooler line assembly to the oil pan. Spreading the clamp slightly may be necessary.

C. Remove the bolt securing the oil cooler line

assembly to the oil filter base. Carefully remove the entire oil cooler line assembly by pulling them through toward the front or the rear of the engine. Use caution not to lose or damage the sealing washers.

D. Using a tubing cutter or hacksaw, carefully

cut the coolant lines as shown in

2-a, 2-b

E. Thread the supplied 5/8" barb and 3/8" NPT

x 5/8" or 1/2" (depending on model year) x 90° compression fittings together. Temporarily install a compression fitting assembly onto the end of each of the cooler lines to aid in installation later. Remove the compression assembly. The nuts and ferrules should remain on the tubes.

F. Reinstall the cooler line assembly onto the

oil filter base using care not to damage the sealing washers.

G. Remount the 90° compression fitting

assemblies back onto the installed cooler line assembly. The 5/8" brass barbs must point up in approximately the two o'clock position.

(See Figure 2-C

H. For clearance purposes, the 5/8" elbow that

exits the water pump must be rotated carefully upward to the two o'clock position. Using a small piece of pipe or cylindrical object, insert the object into the elbow and rotate the elbow counterclockwise. Use caution not to distort or kink the tube. (See

Figure 2-d

Figures

13"

14"

Figure: 2-a

1995-97 Models

13"

14"

Figure: 2-b

1993-94 Models

TO WATER PUMP

TO RADIATOR

Figure: 2-c

ROTATE TO TWO O'CLOCK

(4GH V1.2)

Figure: 2-d

Page 15

2. OIL COOLER LINE MODIFICATIONS, cont'd.

I. Install the 5/8" x 20" long heater hose onto

the upper oil cooler line fitting. Slide the supplied 12" long heat sleeve over the heater hose to protect it from exhaust heat. Route the hose up and around to the 90° fitting on the water pump. (The hose will run near the exhaust manifold.) Secure both ends of the hose with clamps provided. (See

Figure 2-e

J. Install the 5/8" x 24" long heater hose with

the 90° molded end to the lower left side fitting on the radiator. (The 90° end of the hose must be trimmed slightly to fit as close as possible to the radiator.) Route the hose along the frame (front to rear) and around to the lower oil cooler line barb fitting. (For non-oil cooler applications, reattach the factory coolant hose to the previously rotated elbow located on the water pump. Connect this hose to the 5/8" hose coming from the lower radiator using the supplied 5/8" hosemender and #8 clamps. Slide the orange heat sleeve over the hoses to protect them from exhaust heat. Trim hose length if necessary. Clamp and secure both ends of the hose using the supplied #8 clamps and tie wraps to avoid sharp corners and moving parts. An adel clamp and 10mm nut have been supplied to secure the hose to the antiroll bar mount.

K. Refill cooling system.

Figure: 2-e

P/N: 4GH020-010

05NOV01 v1.2

Page 16

3. CRUISE CONTROL RELOCATION

A. Using the template on page 5, mark the

splash guard located in the front lower left side of the vehicle.

B. Remove the splash guard and cut out the

marked area for air inlet tube clearance. (See

Figure 3-a

C. Locate the cruise control box below the

driver's side front frame rail, and remove by disconnecting the electrical connection and fasteners.

D. Disconnect the control box from its mounting

bracket by removing the three bolts and splitting the plastic cable guard.

E. Rotate the unit and mount it on the side of

the frame rail using the front bolt hole of the original bolt pattern on the frame, bolt and front tab. Secure the two front mounting tabs by drilling two 1/8" holes and installing the supplied #10 x 1-1/2" sheet metal screws. (See

Figures 3-b, 3-c

F. Plug the electrical connector back into the

unit (you may find it necessary to reroute the wiring through the air intake opening to reach the control box). Check all cables and connections for routing and possible binding. Use the supplied tie wraps to secure.

Fig. 3-a

➔

Fig. 3-b

(4GH V1.2)

Fig. 3-c

Page 17

TEMPLATE

SPLASH GUARD 1993-1997 LT1 F-BODY

FRONT OF

VEHICLE

CUT OUT

CUT OUT TEMPLATE AND PLACE ON SPLASH GUARD AS A GUIDE

ENGINEERING, INC.

ENGINEERING, LLC

P/N: 4GH020-010

05NOV01 v1.2

Page 18

4.1 AIR PUMP MODIFICATION AND RELOCA TION (1993 MODELS)

TO AIR PUMP

DISCHARGE

ROTATE TEE 180°

HOSE REMOVED FROM ORIGINAL AIR PUMP INLET

5/8" x 23" HOSE

TOP VIEW

FRONT

REMOVE AND DISCARD

A. Unplug the wiring assembly, clamps and

hoses from the air pump.

B. Remove the unit from the mount by removing

the mounting nuts. Remove the pump mount and spark plug wire hold-down from the vehicle.

C. Remove the 90° rubber elbow from the

check valve and TEE on the driver's side exhaust manifold. Rotate the TEE 180°. Remove the hose that was previously connected to the air pump and discard.

D. Cut a 45° bend out of the original 3/4" air

pump inlet hose and attach to the checkvalve and TEE. (See

Figure 4-a

.) Secure

with tie wraps.

E. Take the supplied piece of 5/8" x 35" hose

and remove 12". Attach the 23" piece to the remaining branch on the air pump discharge

Figure: 4-a

TEE.

F. Place the air pump relocation bracket near

the left side inner fender panel (former air filter assembly location). Position the pump bracket so that the pump discharge and inlet tubes face the engine. Mark and drill holes and mount the bracket using the #12 x 1" sheet metal screws provided. (See

4-b

Figure

G. Using the three 1/4-20 x 1" bolts, nylock nuts

and washers, secure the air pump to the relocation bracket.

H. Reroute the pump power cable up to its new

location and attach to the pump.

Figure: 4-b

I. Attach the remaining end of the 5/8" x 23"

hose to the air pump discharge and secure with a tie wrap.

J. Remove a straight 1-1/2" long section from

the original air pump inlet hose. Attach the hose and the supplied 3/4" breather to the air pump inlet.

(4GH V1.2)

Page 19

4.2 AIR PUMP MODIFICATION AND RELOCA TION (1994-97 MODELS)

A. Unplug the wiring assembly, clamps and

hoses from the air pump.

B. Remove the unit from the mount by removing

the mounting nuts. Remove the pump mount and spark plug wire hold-down from the vehicle.

C. Using a tubing cutter or hacksaw, cut the 5/

8" steel air line that runs from the passenger's side exhaust manifold to the driver's side exhaust manifold. Make the cut in the area shown in

Figures 4-c, 4-d

(approximately 2" off of the crank).

D. Attach the supplied 5/8" x 35" hose and #8

clamp onto the previously cut air pump tube.

Figure: 4-c

E. Route the hose along the power steering

lines (on the rack and pinion assembly) and up through and between the engine-to-frame area on the driver's side using tie wraps where necessary.

F. Rotate the left side check valve

elbow on the exhaust manifold

HARMONIC BALANCER

180° from its original position (it should end up pointing to the rear).

G. Cut the 5/8" factory air pump

discharge hose as shown in

Figures 4-e, 4-f

to the supplied 5/8" TEE and exhaust manifold check valve as shown in

Figures 4-h, 4-i

. Attach the hose

on page

CUT HERE AND INSTALL 5/8" X 35" HOSE USING SUPPLIED #8 CLAMP

FRONT

REMOVE THIS PORTION

STEEL TUBE PREVIOUSLY REMOVED

VACUUM LINE

Figure: 4-d

STEEL TUBE REMO VED PREVIOUSLY (SEE GRAPHIC A)

CUT HERE

THIS END TO ROTATED EXHAUST CHECK V AL VE

SOLENOID

VACUUM COUPLING (REINSTALL INTO RELOCA TED AIR PUMP DISCHARGE ALONG WITH VACUUM LINE AND SOLENOID)

ATTACH THIS END TO ROTATED EXHAUST CHECK V AL VE

REINSTALL INTO RELOCATED AIR PUMP DISCHARGE HOSE

CUT HERE

Figure: 4-e - 1996-97 Models Figure: 4-f - 1993-95 Models

P/N: 4GH020-010

05NOV01 v1.2

Page 20

4.2 AIR PUMP MODIFICATION AND RELOCATION (1994-97 MODELS) cont'd.

H. Place the air pump relocation bracket near

the driver's side inner fender panel (former air filter assembly location). Position the pump bracket so that the pump discharge and inlet tubes face the engine. Mark and drill holes and mount the bracket using the #12 x 1" sheet metal screws provided. (See

Figure 4-g

I. Using the three 1/4-20 x 1" bolts, nylock nuts

and washers, secure the air pump to the relocation bracket.

J. Reroute the pump power cable up to its new

location and attach to the pump. (See

4-h

Figure

Figure: 4-g

K. Install the 5/8" x 20" long piece of hose onto

the TEE fitting connected to the exhaust manifold check valve. Connect the remaining end to the air pump discharge. (On 1995 and newer vehicles, install the vacuum breather/check valve into the air pump discharge hose along with the vacuum

FRONT OF

VEHICLE

line and solenoid, if so equipped.) Attach the remaining end of the 5/8" x 35" hose to the last branch on the 5/8" TEE. Secure with the supplied tie wraps. (See

Figure 4-i

L. Remove a straight 1-1/2" long section from

the original air pump inlet hose. Attach the hose and the supplied 3/4" breather to the air pump inlet.

Figure: 4-h

➞

(4GH V1.2)

Page 21

5. 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 or drain. The return is a gravity drain and should be routed so a gradual drop is provided and connected to the pan above oil level and away from suspension components or exhaust headers or 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 the entire line if you have any doubts.

B. Locate the oil pressure sender which is just

above the oil filter assembly. (See

5-a

.) (1995-97 models have the oil sending

unit located in a different position.)

NOTE: For 1995-97 models, skip steps C

and D.

C. Unplug the sender wiring harness. D. Using a 1-1/16" oil pressure sender socket,

remove the unit from the block.

E. Preassemble the 3" x 1/4" NPT nipple, 1/4"

NPT TEE as shown and install into the sender port of the block. (See

Figure: 5-b

For 1995-97 models, remove the 1/4" NPT pipe plug above the oil filter and install the 3" x 1/4" NPT nipple, 1/4" NPT female elbow and #4 x 1/4" NPT straight fitting into the block using engine oil on the threads for lubrication.

F. Reassemble the mounting fitting and oil

sender using engine oil on the pipe threads. Teflon tape, paste or other sealant is not recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure.

Figure:

Figure: 5-a

Oil Pressure Sender

NOTE: Install the supplied piece of metallic

heat sleeve onto the oil feed hose before attaching to the vehicle.

3" x 1/4" NIPPLE

REAR OF CAR

1/4" NPT TEE

#4 x 1/4" NPT 90°

Figure: 5-b

OIL FILTER BASE

View From Underneath Vehicle - 1995

and Later Vehicles Will Not Have an Oil

Pressure Sending Unit Installed in Feed Line.

P/N: 4GH020-010

05NOV01 v1.2

Page 22

5. OIL FEED LINE cont'd.

G. Attach one end of the feed hose assembly

to the 90° flare previously mounted in the block. Route the line around the oil filter mount, along the oil cooler tubing and out to the front of the engine block. Take care to tie wrap and protect the line from kinking, abrasion and high heat areas. (See

5-c

H. Temporarily cover the end of the hose and

protect it from dirt until connecting to the supercharger.

6. OIL DRAIN LIN E

A. To provide an oil drain f or the supercharger ,

it is necessary to make a hole in the oil pan. Locate and mark hole. (See

6-b

.). It is best to punch the hole rather than

Figures 6-a,

drill.

B. Remove paint around the hole area. 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. Use caution so that the hole is not enlarged too much and punch does not contact the crankshaft.

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.

Figure

FRONT VIEW

BOTTOM VIEW

Figure: 6-a

OIL PAN

FRONT

Figure: 5-c

2-1/2"

PUNCH HOLE THROUGH (DIRECTLY UNDERNEATH CORNER PAN BOLT)

HOLE MUST BE MADE FROM THE SIDE OF THE PAN

OIL PAN BOLTS

NOTE: This method of rolling over the lip of

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 hose fitting and secure in hole. Make sure a seal is formed all around the fitting.

F. Drain the engine oil, install a new filter and

refill with fresh oil.

(4GH V1.2)

the hole and tapping it works very well if carefully done and should cause no problems.

Figure: 6-b

Page 23

UPPER MOUNTING BRACKET HOLES

UPPER MOUNTING BRACKET

7. SUPERCHARGER MAIN BRACKETS

A. Install the lower mounting bracket to the front

driver's side of the engine block using two 3/8-16 x 1-1/4" socket head bolts supplied. (See

Figures 7-a, 7-b

B. Install the upper mounting bracket to the

cylinder head and engine block using the two 3/8-16 x 2-1/2" and 3/8-16 x 1-1/4" socket head bolt. (See

Figure 7-c

LOWER MOUNTING BRACKET HOLES

LOWER MOUNTING BRACKET

Figure: 7-a

8. SUPERCHARGER MOUNTING

A. Reinstall the four driver's side spark leads B. On 1995-97 models only, separate the

C. Attach the supplied 1/2" x 9" drain hose to

to the distributor module. distributor ventilation hoses from the black

flex loom. Remove the vacuum hose from the blue one-way valve (next to the throttle body) and cut approximately 7-1/2" off of the end. Run the line back up in between the water pump and the upper main bracket to the blue valve and reconnect. Temporarily leave the remaining 5/32" fresh air hose down below. (See

Figure 8-a

the supercharger oil drain using the supplied #8 clamp. Rotate the clamp so that the screw housing will not interfere with the mounting plate when installed.

Figure: 7-cFigure: 7-b

Distributor V entilation System

(1995-97 Models Only)

FRONT

REMOVE 7-1/2" FROM THIS END

FROM DISTRIBUTOR

ROUTE TO LEFT SIDE INNER FENDER

Figure: 8-a

P/N: 4GH020-010

05NOV01 v1.2

Page 24

8. SUPERCHARGER MOUNTING, cont'd

D. Attach mounting plates A and B together

(see

Figure 8-b

) using two 5/16-18 x 1" bolts

and 5/16" nuts, washers and lock washers.

E. Fasten the supercharger plate assembly to

the supercharger unit using the four supplied 3/8-16 x 1" bolts and washers.

F. From beneath the car, carefully guide the

supercharger and mounting plate assembly up and onto the two mounting brackets.

G. Using the six supplied 3/8-16 bolts and

ANwashers (see

Figure 8-c

), attach the supercharger mounting plate to the mounting brackets. Use caution when mounting the supercharger so that no hoses, wires, etc. are being pinched or cut.

5/16"-18 X 1" BOLTS AND NUTS

Figure: 8-b

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

3/8-16 x 1" BOLTS

3/8-16 x 3/4" BOLTS

9. HARMONIC BALANCER, PULLEYS AND DRIVE BELT

A. Install the supplied spring belt tensioner to the

supercharger mounting plate using the 10mm x 1.5 hardware provided.

B. Be sure that both of the mating surfaces of the crank

and balancer are clean and free from rust and dirt.

C. Slide the supplied harmonic balancer onto the

crankshaft hub. Rotate the balancer on the crankshaft hub to find proper bolt hole alignment. Place the Vortech supercharger crank pulley onto the new balancer also lining up the bolt holes. Use the supplied 7/16-14 x 1-3/4" bolts with Loctite and start all three bolts; then torque to 60 ft./lbs.

D. Install the factory accessory and supercharger belts. E. Check for clearance at supercharger pulley and upper

radiator hose. Rotate hose and/or use tie wraps to keep hose from rubbing the pulley and belt.

Figure: 8-cFigure: 8-d

(4GH V1.2)

Page 25

10. AIR INLET DUCT

A. Attach the appropriate fitting into the 1/8"

NPT bung on the plastic air inlet tube:

a. 1993-94 models - 1/8" NPT plug b. 1995-97 models - 1/8" NPT x 5/32" 90° fitting

B. Slip the 3-1/2" x 2" sleeve onto the

supercharger inlet using the supplied #56 clamps. Slide the short end of the 3-1/2" plastic elbow into the sleeve. Rotate the elbow so that it points downward in approximately the five o'clock position (viewed from the front).

C. Mark and drill four 1/8" holes to mount the

plastic air inlet tube by placing the tube and bracket assembly on the bottom of the driver's side frame rail. Position the tube mounting flange in the center of the rail (left to right) and in between the anti-roll bar mount and the radiator core support. Secure the assembly by installing the supplied #8 sheet metal screws into the frame. (See

Figure 10-a.

)

D. Reinstall anti-roll bar with the factory

hardware.

E. Slide the 3-1/2" x 17-1/2" flex hose onto the

supercharger elbow and the air filter tube. Secure with the supplied #52 clamps.

F. The MAF plug harness (1993 models are

not equipped with MAF meters) must be lengthened to accommodate relocation of the MAF meter using the supplied 30" lengths of wire. Carefully cut the MAF wires, add heat shrink tubing and solder extensions into place.

3-1/2" x 2" SLEEVE

AIR FILTER TUBE

Figure: 10-a

MAF METER

1994-97

ONLY

Figure: 10-b

AIR FIILTER

COVER

AIR FILTER

NOTE: Double check the wire to wire (MAF

and harness) relationship before soldering and sealing.

G. Install the 3-1/2" x 2" sleeve, MAF meter

(directional) and air filter to the open end of the air filter tube. (See

Figure 10-c.

) Secure all pieces with supplied clamps. Reconnect the extended MAF wiring connector to the MAF unit.

H. Install the air filter onto the MAF meter and

secure with the clamp provided. Attach the supplied air filter cover to the top-half of the air filter.(See

Figure 10-b.

) The cover must be installed so that rain water etc. cannot drip onto the air filter. 1995-1997 Models Only: Attach the 5/32" distributor breather line to the fitting located near the MAF meter on the air inlet duct.

Figure: 10-c - Air Filter Cover Not Shown

P/N: 4GH020-010

05NOV01 v1.2

Page 26

10. AIR INLET DUCT, cont'd.

I. Reinstall the plastic splash guard (previously

trimmed) into the lower left fenderwell.

11. OIL DRAIN HOSE

A. Connect the 1/2" x 9" drain hose from the

supercharger to the 1/2" barb in the oil pan. Make sure that there are no dips or kinks in the drain hose. Trim if necessary.

B. Secure both ends with the supplied #8

clamps.

12. OIL FEED HOSE CONNECTION

A. Route the oil feed line up to the supercharger

and connect to the supercharger oil feed.

B. Use care to ensure that there are no kinks,

sharp bends or routing near moving objects.

13. COIL RELOCATION AND IGNITION BOX MOUNTING

A. Use the supplied 3/8-16 x 3/4" bolt to

reconnect the ground wires to the cylinder head. Use the upper left hand hole in the front of the driver's side cylinder head to mount the bolt (include the small bracket securing the 1/4" piece of plastic tubing with the ground wires).

B. Using the two supplied 3/8-16 x 3/4" bolts,

washers and nuts, fasten the coil and ignition module assembly to the V ortech coil bracket. (See

Figure 13-a.

)

Figure: 13-a

(4GH V1.2)

Page 27

13. COIL RELOCATION AND IGNITION BOX MOUNTING, cont'd.

C. Mount the coil and bracket assembly to the

upper supercharger mounting bracket. Use

AIR PUMP

the two 3/8-16 x 1-1/4" bolts previously installed on the supercharger bracket to mount the coil assembly.

D. Reinstall the upper radiator and coolant

TOP VIEW

hoses.

E. Mount the supplied ignition control box onto

the vehicle in the flat area behind the headlight, next to the air pump. (See

)

13-b.

Figure

F. Route the heavy black cable to a clean

ground. Extend the heavy red cable with the supplied wire and connector. Route the red cable to the (+) battery terminal.

G. Install the supplied wiring harness to the coil

and ignition box following

Figure 13-e

. Use the supplied 1/4" male and female quick disconnects.

H. 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 to the red wire from the Vor tech ignition box. Tape up the end of the yellow wire to prevent contact with any metal surface. Route the three wire harness to the supplied map sensor and attach. Connect a manifold sourced vacuum line to the map sensor using a 5/32" TEE and hose.

I. Use supplied cable ties to keep the harness

secure and away from moving objects.

IGNITION

CONTROL BOX

FRONT OF

VEHICLE

➞

Figure: 13-b

NOTE: If your kit is not equipped with MSD

harness #8876, proceed to hardwire the ignition box following the supplemental instruction sheet included.

P/N: 4GH020-010

05NOV01 v1.2

Page 28

13. COIL RELOCATION AND IGNITION BOX MOUNTING cont'd.

5 psi at 3° per lb. 7 psi at 2° per lb.

10 psi at

1/2° per lb.

MAX. RETARD

DEGREES OF RETARD

PSI BOOST

MAXIMUM RETART=20°

FACTORY GM

HARNESS

(UNPLUGGED

FROM COIL)

GM ADAPTER

HARNESS

TO BATTERY +

TO GROUND

RANE

HI-6R

GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

cams

MANIFOLD

VACUUM

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN TACH (TAPE UP)

HEAVY RED

HEAVY BLACK

SUPPLIED MAP SENSOR

3 WIRE HARNESS

BLUE (RETARD INPUT)

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

Figure: 13-e

RED

IGNITION COIL

WIRE TAP

RED

WHITE

BLACK

ORANGE

NO CONNECTIONS

AT GREY TERMINAL

BLACK TERMINAL

YELLOW (TAPE UP) BLACK (GROUND)

1993-1995 VEHICLES ONLY: SEE SUPPLEMENT FOR 1996-97

14. 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

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 saf e area or road. Adjust the retard according to changes in altitude and fuel quality.

(4GH V1.2)

Caution: It is extremely important that the

boost retard never be turned to 0°. It is recom-mended that in stock street applications, the knob be at no less than 1° per lb.

Examples of Ignition Retart vs. Boost

Figure: 14-a

Page 29

REMOVE RIDGES

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

15. SUPERCHARGER DISCHARGE ASSEMBLY

A. Install the 2-3/4" x 2" sleeve and #44 clamps

onto the supercharger discharge. Place the 4" x 2" sleeve and #64 clamps onto the throttle body.

B. Connect the Vortech discharge tube and

aluminum discharge elbow together using the 3-1/2" x 3" sleeve and #56 clamps. Orient the discharge tube so that the 1" barb points toward the front of the vehicle.

C. Install the discharge tube assembly onto the

throttle body and supercharger. Rotate the tubes to get proper alignment and tighten all clamps.

16. INTAKE AIR TEMPERATURE (IAT) SENSOR THREADING

A. Disconnect the IA T 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. (See

Figure 16-a

C. Install the threaded sensor onto the

supercharger discharge duct and secure.

D. Attach wiring connection to sensor.

17. BYPASS VALVE CONNECTION

A. Attach the 1" x 2-1/2" hose to

the discharge tube using a #16 clamp.

B. Slide the 1" x 14" hose onto

SUPERCHARGER DISCHARGE DUCT

the bypass valve outlet (see

Figure 17-a

) and secure with

a #16 clamp.

C. Attach the bypass valve inlet to the supercharger

discharge duct while simultaneously routing the 1" outlet hose down to the barb on the air inlet duct. Secure the hose ends with the supplied #16 clamps.

D. Route the 5/32" vacuum line from the bypass to

the nipple on the driver's side of the intake manifold. Remove the factory vacuum connection from the manifold. Place the supplied 1-1/2" length of line and vacuum TEE on the manif old v acuum spout. Connect the TEE to the factory vacuum line and bypass vacuum line.

Figure: 16-a

BYPASS VALVE

TO MANIFOLD VACUUM

INLET

OUTLET

AIR INLET

TUBE

Figure: 17-a

P/N: 4GH020-010

05NOV01 v1.2

Page 30

18. FUEL MANAGEMENT UNIT (FMU) INSTALLATION

A. Remove the two center bolts that secure the

driver's side valve cover.

B. Install the FMU with the fittings pointing

upward (towards the center of the engine) using the valve cover bolts.

C. Disconnect the fuel return line at the fuel rail

(smaller line) using a spring lock disconnect tool.

D. Connect the 1/4" x 14" fuel line to the center

fitting on the FMU and then snap into the return line running to the tank. (See

18-c

Figure

E. Attach the 1/4" x 10" fuel line to the 90° fitting

on the side of the FMU and snap it into the return fitting coming from the fuel rail.

F. Using the supplied 5/32" vacuum line and

TEE, splice into the bypass valve vacuum line. (See

IMPORTANT!: Pressure check the entire fuel

Figure 18-b

system to confirm that each fitting has a leak-free connection. Make sure fuel lines are routed away from hot exhaust pipes and moving or sharp objects.

Figure: 18-a

ENGINE

ADDITIONAL

FUEL PUMP

FUEL FEED LINE

FILTER

STANDARD

PUMP

FUEL MANAGEMENT UNIT (FMU)

FUEL RETURN LINE

FUEL TANK

ORIGINAL VACUUM LINE

INTAKE

MANIFOLD

FMU

FRONT

BYPASS VAL VE

Figure: 18-b

Vacuum DiagramFigure: 18-c

(4GH V1.2)

Page 31

19. BREATHER HOSE REROUTING

A. Remove the valve cover breather assembly

from the vehicle. Disconnect the plastic valve cover fitting and attach it to the supplied length of 1/2" x 58" long hose.

B. Thread the supplied 1/2" barb into the 3/8"

NPT bung on the inlet duct.

C. Route the hose from the valve cover forward

along the fender apron, down near the air conditioning compressor and then along the front frame K-member to the 1/2" barb on the inlet duct. Secure with a #8 clamp. (See

Figure 19-a

D. Attach the supplied vacuum cap to the nipple

on the throttle body.

20. T-REX FUEL PUMP INSTALLATION

A. Loosen the tank filler cap to vent

any residual pressure.

B. Disconnect the original plastic fuel

feed hose to the fuel filter.

C. Remove the plastic fitting from the

hose and set aside.

D. Using a sharp knife or razor blade,

cut approximately 1" off from the end of the hose.

E. Place the supplied 5/16" barb fitting

into a 400° F oven for approximately 15-20 minutes. Using heat protective gloves or a towel, quickly insert the heated 5/ 16" barb into the plastic fuel hose. (See

Figure 20-a

F. After the fitting has cooled,

thread the 3/8" NPT x 3/8" barb into it using pipe sealant on the threads.

G. Inside the vehicle, remove

the rear carpet and flip the rear seats forward.

GROUND

H. Locate the fuel relay box

underneath the vehicle rear seat floor pan. Disconnect the two plugs entering the box. Trim the "cut-out" from the supplied template on page 21 (see

Figure 20-g

) and place over the fuel relay. Center punch and drill the four holes 3/16" in diameter. Reinstall the f actory relay plugs.

FACTORY SUPPLY LINE FROM T ANK

HEAT FITTING (5/16" END)

RELAY

87A

3/8" HOSE

1/2" BREATHER HOSE

Figure: 19-a

REMOVE FITTING AND ATTACH HERE

STOCK FUEL FILTER

CUT AND REMOVE

FLOW

Figure: 20-a

(+) TERMINAL

ON T -REX FUEL PUMP

(+) BATTERY

TERMINAL

Figure: 20-b

TO FUEL RAIL

3/8" HOSE

GREY PURPLE BLACK

FACTORY FUEL WIRING CONNECTOR

T-REX

P/N: 4GH020-010

05NOV01 v1.2

Page 32

20. T-REX FUEL PUMP INSTALLATION, cont'd.

I. Secure the fuel pump/line assembly to the

vehicle with the supplied rubber isolators, nylock nuts, and hardware. (See

20-c

Figure

J. Reinstall rear carpet and seats. K. Route the T-Rex inlet hose around the front

of the fuel filter to form a smooth, gradual bend to the pump. Attach into the 3/8" barb in the factory feed line. Secure the connection with a #8 hose clamp. (See

Figure 20-a

L. Attach the factory snap connector removed

from the original line into the T-Rex discharge line. Secure with supplied #8 clamp. Attach the line to the fuel filter inlet. Use cable ties to keep all fuel lines tight up against the underbody.

NOTE: It is important that all fuel lines have

no contact with moving parts, exhaust components or sharp corners. Make sure lines are routed with gentle bends and secured with the supplied tie wraps.

View Looking Up From Beneath Vehicle.

Figure: 20-c

M. Using a 1/8" drill, make a mounting hole in

the frame crossmember above the T-Rex pump to mount the relay wiring harness and provide a grounding point. Remove all paint and dirt from around the hole. Mount the relay, fuel pump grounding wire and #86 relay terminal using the supplied sheet metal screw.

N. Using the yellow wire from the #85 relay

terminal and a wire tap, splice into the grey wire in the factory fuel pump harness. (See

Figure 20-b

O. Connect the #87 red wire on the relay to the

positive terminal on the T-Rex pump.

P. Run the remaining long red wire up to the

battery, using tie wraps to keep the wire away from heat and moving parts. Connect the supplied fuse, fuse holder and large ring terminal to the wire and attach to the remote (+) positive battery terminal.

Q. Replace the fuel tank filler cap.

IMPORTANT! Pressurize the fuel system to

check for any leakage before starting the vehicle.

Figure: 20-d

(4GH V1.2)

Page 33

20. T-REX FUEL PUMP INSTALLATION, cont'd.

T-REX

STOCK FUEL FILTER

VORTECH

RELAY

STOCK RELAY BOX ATTACH YELLOW VORTECH RELAY WIRE TO FACTORY GREY WIRE.

FRAME/CROSS MEMBER

FACTORY

PLASTIC

FUEL LINE

REAR VIEW

RIGHT SIDE

VIEW

REX

T-

FACTORY PLASTIC FUEL LINE

STOCK FUEL FILTER

Figure: 20-e Figure: 20-f

TEMPLATE

T-REX FUEL PUMP KIT 1993-1997 LT1 F-BODY

CUT OUT RECTANGLE AND PLACE OVER FUEL SYSTEM RELAY AS A GUIDE

CUT OUT

(RELAY)

CENTER PUNCH AND DRILL FOUR 3/16" HOLES IN FOUR PLACES

RELAY LOCATED UNDERNEATH REAR SEAT FLOORPAN IN DRIVER’S SIDE OF VEHICLE

Figure: 20-g

P/N: 4GH020-010

05NOV01 v1.2

Page 34

21. FUEL INJECTOR REPLACEMENT (1993 MODELS ONLY)

A. Disconnect the eight fuel injector wiring clips

and retainers from the injectors.

B. Remove the four 10mm bolts holding down

the fuel rail on the intake manifold. Lift up on the rails evenly, removing all eight injectors.

C. Using a small amount of clean motor oil,

lightly lubricate the O-rings on both ends on the Vor tech supplied fuel injectors.

D. Install the new injectors into the fuel rails with

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

E. 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.

F. Tighten down the fuel rail assembly with the

original bolts and attach the wiring clips to the injector terminals.

NOTE: Make sure injector retainers are secure

and properly installed. Recheck after cycling fuel system.

(4GH V1.2)

Page 35

22. FINAL ASSEMBLY AND CHECK

A. Reinstall cooling fan if removed in step 1. B. Make sure that the pan fitting is tight and

the engine is filled with factory specified synthetic oil.

C. Fill the coolant surge tank with a 50/50

coolant/water mix.

D. Fill the overflow tank to the proper level. E. Reconnect the battery. F. 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.

G. 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. (See

Figure 22-a

H. Check all fluid levels, making sure that your

tank is filled with 92 octane or higher fuel before commencing test-drive.

I. 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 . Refill the coolant bottle.

J. 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.

K. Test-drive the vehicle. L. Recheck the coolant and oil level. M. Read the STREET SUPERCHARGER

SYSTEM OWNER'S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty (30)

days of purchasing your supercharger system.

Figure: 22-a

WARNING: Do not attempt to operate the

vehicle until ALL components are installed and ALL operations are completed including final check. Failure to do so may cause PREMATURE FAILURE OF MAJOR COMPONENTS.

P/N: 4GH020-010

05NOV01 v1.2

Page 36

1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone (805) 247-0226

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

(4GH V1.2)

ENGINEERING, LLC