Vortech 1996-2000 5.7L Vortec Truck SUV User Manual

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GM VORTEC 5.7L Engine

Light Trucks/SUVs

Supercharger System

Installation Instructions

50 STATE SMOG LEGAL PER CARB EO #D-213-16

*Legal in California only for racing vehicles which may never be used upon a highway.

1996-1998 MODEL YEARS

1999-2000 49 STATE LEGAL*

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901

(Vortec 350-2 )4GM

ENGINEERING, INC.

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual

prior

to beginning the installation to determine if you should refer the job to a professional

installer/technician. Please call Vortech Engineering for installers in your area.

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

(Vortec 350-2 )4GM

of Vortech Engineering, Inc.

Table Of Contents

FOREWORD ...................................................................................................................... i

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

NOTICE.............................................................................................................................. iii

TOOL AND SUPPLY REQUIREMENTS............................................................................. iv

PARTS LIST - 1996-2000 GM VORTEC 5.7L ENGINE FOR LIGHT TRUCKS/SUVs ....... v

CARROLL SUPERCHARGING MAF SIGNAL MASSAGER.............................................. vi

1. COMPONENT REMOVAL...................................................................................... 1

2. OIL DRAIN.............................................................................................................. 1

3. OIL FEED ............................................................................................................... 2

4. MAIN BRACKET..................................................................................................... 3

5. SUPERCHARGER INSTALLATION ....................................................................... 4

6. SUPERCHARGER/ACCESSORY DRIVE BELT.................................................... 5

7. SUPERCHARGER AIR INLET ............................................................................... 6

8. SUPERCHARGER DISCHARGE........................................................................... 7

9. FUEL MANAGEMENT UNIT (FMU) ....................................................................... 8

10. SUPLEMENTARY FUEL PUMP AND HARNESS .................................................. 8

11. SUPERCHARGER/ACCESSORY DRIVE BELT.................................................... 9

12. FINAL CHECK ........................................................................................................ 11

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

GM VORTEC 5.7L LIGHT TRUCKS/SUVs

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.

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

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

(Vortec 350-2 )4GM

ENGINEERING, INC.

iii

1996-2000

GM VORTEC 5.7L Engine Light Trucks/SUVs

Installation Instructions

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

Congratulations on selecting the best performing and best backed automotive supercharger available today...

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, 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 35 to 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 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 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 at least every 50,000 miles.

1999-2000 49 State Smog Legal

the VORTECH

V-2® Supercharger!

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• Drill Motor, 3/32" and #16 Drill Bits

• Flat #2 Screwdriver

• Open End Wrenches: 5/16", 3/8", 7/16", 1/2", 9/16", 5/8"

10mm, 13mm, 15mm, 16mm, 17mm, 18mm

• Hammer

• Silicone Sealer

• Oil Filter Wrench

• Oil Filter

• SF rated quality engine oil

• Gasket Scraper

• Punch (Tapered)

• 3/8" NPT Tap

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

4GM218-050S

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

1996-2000 GM VORTEC 5.7L Engine for Light Trucks/SUVs

ENGINEERING, INC.

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

Part No. 4GM218-050SQ/058SQ

PARTS LIST

Part Number Description Quantity

2E228-180 V-2 Supercharger Assembly 1

2E128-240 Supercharger 1 7U100-070 3/16" x 3/16" x 7/8" Key 1 2A040-011 Pulley Retainer 1 7B375-125 3/8"-24 x 1-1/4" HX Bolt 1 7K375-040 3/8" AN960 Flat Washer 1 2A036-361 6 Rib Pulley 1

4GM111-021 Mounting Bracket Assembly 1

4GD011-032 Belt Tensioner 1

7A375-124 3/8"-16 x 1-1/4” HH Cap Screws 2 7K375-040 3/8” AN960 Flat Washers 16 7A375-100 3/8"-16 x 1” HXHD Bolts 5 7A375-275 3/8"-16 x 2-3/4” HX Cap Screws 2 7U133-024 5/8" Molded Elbow Hose 1 7P625-002 5/8" Hose Barb 1 7R001-008 #8 Hose Clamps 3

5W001-007 3/16” x 6" Heat Shrink Tube 1

7U100-055 Tie Wraps 3

2A046-112 Belt 1 4GM011-021 Mounting Bracket 1 4GM010-033 Mounting Plate 1

5W022-120 12" 22GA. Std. Brown Wire 1

7A375-075 3/8-16 x 3/4" HXHD Bolts 6

7A250-050 1/4-20 x 1/2" SH Cap Screw 1

7J250-001 1/4" SAE Washer 1

5W001-005 3/8" x 12" Plastic Wire Loom 1

4GM010-050 Heat Shield 1

7A375-101 3/8 x 1" Socket Head 1

4FA016-170 Wide Idler 1

4FD017-011 Idler Spacer 1

7C012-050 M12 Bolt 1

4FA016-171 Dust Cover 1 4FH016-150 Flanged Idler 1

4GM016-150 4" Idler 1

7C010-066 M10 Bolt 1

7K437-001 7/16 AN Washer 1

4GM112-010 Air Intake Assembly 1

8H040-010 Air Filter 1

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

7R002-056 #56 Hose Clamps 4

7U100-056 90° Vent Tube 1

7U030-060 3/4” x 5/8” -180° Molded Hose 1

7P375-020 3/8” NPT x 5/8” Straight Hose Barb 1

7U100-055 Tie Wraps 4

4FA012-013 90° Intake Elbow w/Boss 1

7P750-102 3/4" NPT x 1" 90° Hose Fitting 1

7U035-000 3-1/2" x 6" Flex Hose 1

7R002-052 #52 Hose Clamps 2

7E010-046 #8 x 3/4" Sheet Metal Screws 2 4GM012-040 Air Box 1 4GM012-050 Fender Adapter 1 4GB012-010 Air Filter Cover 1 4GM012-060 Airbox Clamp 1 4GM012-070 Airbox Clamp Support 1

7C080-016 8mm x 1.25 x 16 HXHD Bolts 2

7J312-000 5/16" SAE Flat Washers 2

4CJ017-051 Spacer Support 1

7E014-015 #14 x 1.5" HXHD Sheet Metal Screw 1

7P375-052 3/8" NPT x 90° x 5/8" Barb 1

7P625-002 5/8 Hose Mender 1

7U033-000 5/8 x 10" Hose 1

4GM130-036 Oil Drain Assembly 1

7R001-008 #8 Stainless Hose Clamps 2

7P375-017 3/8" NPT x 1/2” Straight Hose Barb 1

7U030-036 1/2” x 34” Oil Drain Hose 1

7U100-055 Tie Wraps 2

7P375-045 45° Street Elbow 1

Part Number Description Quantity

4GM020-030 MAF Buffer 1 4GM112-020 Air Discharge Assembly 1

7R002-044 #44 Hose Clamps 3 7R002-052 #52 Hose Clamp 1 8D001-001 Bypass Valve 1 7R002-016 #16 Hose Clamps 4 7P156-082 5/32” Tee 1 7U030-046 5/32” x 24” Vacuum line 1

4GM012-020 Air Discharge Tube 1

7U050-000 1” x 6” Heater Hose 1 7S275-200 2-3/4” x 2” Sleeve 1 7S350-275 2.75-3.5 Reducer 1 7U375-054 3/4" Vinyl Cap 1 7U038-000 1” x 3” Heater Hose 1 7P500-156 1/2" Vacuum Tee x 1/4" NPT 1

4GM010-060 Vortech Discharge Support 1

7R001-008 #8 Hose Clamps 2 7P250-033 1/4" Reducer 1 7P250-039 1/4" NPT x 1/4" Fitting 1 7U030-030 1/4" x 3" Vacuum Hose 1

4GM130-026 Oil Feed Line Assembly 1

7U030-026 1/4” x 65” Oil Feed Hose 1 7P525-067 .525” Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2 7P250-080 1/4 NPT Elbow 90° 1 7P125-103 -4 x 45° 1/8" NPT Male Elbow 1 7U100-055 Tie Wraps 2 7P250-036 -4 Flare to 1/4" NPT 1 7P250-123 1/4" NPT x 1-1/2” Nipple 1 7S625-000 Mylar Fire Sleeve 1

4GM101-002 Fuel Pump Assembly 1

5W001-001 Wire Tap 1 5W001-002 Fuse Tap 1 5W001-010 16-14 GA. Female Slides 3 5W001-011 16-14 GA. Eyelets 2 5W001-014 Fuse Holder 1 5W001-015 20 amp Blade Type Fuse 1 5W001-017 Large Ring Terminal 1 7C011-075 10-32 x 3/4" HXHD Cap Screws 2

7F010-032 10-32 Nylock Hex Nuts 2 7J010-001 #10 Flat Washers 4

7P625-001R Fuel Fitting Adapter 1

7R001-008 #8 Hose Clamps 2 7U030-050 12mm x 16" Fuel Hose 1 7U100-055 6" Nylon Tie Wraps 4

8F001-002 155 Inline Fuel Pump 1

7R003-024 1-1/2" Adel Clamp 1

8F101-200 T-Rex Wiring Assembly 1

7F008-020 M8 x 1.25 Nut 1 5W001-019 12-10 GA. Solderless Connector 1 7U031-018 5/16" x 20" Fuel Hose 1 7R004-003 14.5 Stepless Clamps 2 7P250-124 1/4" NPT to 1/2" Barb 1 7P250-042 1/4" NPT x 3/8" Compressor Fitting 1 7P250-043 1/4" NPT x 5/16" Barb 1

7E010-075 #12 x 3/4" HXHD Sheet Metal Screw 1

4GM238-068 FMU With Lines 1

6Z110-114 8:1 Fuel Management Unit 1 7P525-067 .525 Crimp Ferrules 4 7P250-036 -4 Flare to 1/4" NPT 2 7P156-082 5/32" Tee 1 7U030-046 5/32" x 65" 1 7U030-016 1/4" x 36" Fuel Line 1 7U030-016 1/4" x 22" Fuel Line 1

7E010-075 #12 x 3/4" HXHD Sheet Metal Screws 2 7P250-041 1/4" NPT x 5/16" Compression Fittings 2 7P250-066 -4 Swivel x 1/4" Hose Barb Fittings 4 7U100-044 4" Nylon Tie Wraps 6

(Vortec 350-2 )4GM

SPECIAL NOTICE CONCERNING THE

Carroll Supercharging MAF Signal Massager

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 Engineering, 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 pre-paid 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.

ENGINEERING, INC.

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

vii

1. COMPONENT REMOVAL

A. Disconnect the negative battery cable from the

battery.

B. Remove and set aside the following components:

- The entire air inlet/filter box assembly, including the throttle body resonator.

- The crankcase vent tube from the right side (passenger) valve cover.

- The accessory drive belt.

- The tensioner and idler from the alternator mounting bracket.

- The alternator and bracket.

- The 3/8" stud protruding from the right side cylinder head.

C. Drain approximately one gallon of coolant from

the radiator into a clean container.

D. Remove the formed section of rubber/aluminum

hose running from the water pump to the heater core hose. (See

Fig. 1-a

.) The heater core hose will

be reconnected to a new hose in step 9.

REMOVE TUBE

FROM VEHICLE

Fig. 1-a

2. OIL DRAIN

A. To provide an oil drain for the supercharger,

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

Fig. 2-a

). It is best

to punch the hole rather than drill.

NOTE: Removal of the oil pan may

ease oil drain fitting installation on some applications.

B. Remove the two factory anti-roll bar brack-

ets from the frame and allow the bar to temporarily drop down. Unplug the factory crank trigger connector from the sensor located in the timing cover.

NOTE: The factory transmission

cooler lines may require bending to clear the supercharger oil drain hose.

C. Remove paint around the hole area. D. 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.

PUNCH HOLE THROUGH (DIRECTLY UNDERNEATH CORNER PAN BOLT)

HOLE MUST BE MADE FROM THE SIDE OF THE PAN

OIL PAN BOLTS

2-1/2"

FRONT VIEW

BOTTOM VIEW

Fig. 2-a

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

2. OIL DRAIN, cont'd.

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 works very well if carefully done and should cause no problems.

F. Thoroughly clean the threaded area. Apply a small amount of

silicone sealer to the new threads. Apply more sealer to the supplied 3/8" NPT x 45° elbow and secure in hole. Make sure a seal is formed all around the fitting. Install the supplied 3/8" NPT x 1/2" barb fitting. Rotate the fitting assembly so that the oil drain hose (installed in step 5) can be easily routed to it.

G. Drain the engine oil, install a new filter and refill with fresh oil. H. Reattach anti-roll bar and crank trigger connector.

3. OIL FEED

A. The supercharger uses engine oil for

lubrication and must have an oil feed line connected to a filtered oil access on the engine.

B. Remove the 1/4” NPT plug located on

the engine block just above the oil filter boss. Replace the plug with the supplied 1/4” NPT x 1.5” nipple, 1/4” NPTF x 90° elbow and 1/4” NPT x -4 flare fitting (see

NOTE: Use clean engine oil

on the pipe threads. Teflon tape and sealant is not recommended, as it might loosen and cause blockage of the small oil feed orifice resulting in supercharger failure.

Fig. 3-a

TO SUPERCHARGER

OIL

FILTER

Fig. 3-a

C. Connect the supplied feed line to the

flare fitting (make sure that the silver fire sleeve has been slid onto the feed line to protect from radiant exhaust heat) and make a gentle downward loop around and back up to the rear of the engine (see

Fig. 3-a

). Secure the hose with the tie wraps provided, routing it away from exhaust heat, chaffing and/or sharp objects. Temporarily cover the open end from debris until the connection is made to the supercharger in step 5.

(Vortec 350-2 )4GM

4. MAIN BRACKET

A. To accommodate the relocation of the alternator

onto the new main bracket, the brown field wire must be extended approximately 12”. Proceed by cutting the wire approximately 4” from the factory plug that attaches to the alternator. Splice the supplied piece of brown wire into the cut wire by soldering. Use the supplied piece of heat shrink tubing to seal the joints. Re-wrap the wire/harness with the supplied length of plastic flex-loom.

B. The transmission cooler lines must be bent down-

ward as far as possible (toward the frame) to obtain alternator clearance. Rotate the lower radiator hose clamp (at the water pump) 90° toward the front (the clamp tabs should be facing the front of the vehicle).

C. Attach the supplied stainless steel heat shield onto

the rear of the Vortech main bracket using the supplied 1/4” hardware (see

Fig. 4-a

D. Place the mounting bracket on the front of the

passenger side cylinder head. Line up the bracket with the holes on the front of the head and block and start the 3/8-16 socket head bolt into the lowest bracket hole. Install the two 3/8-16 x 1.25” bolts and washers into the two remaining upper holes. Torque the three bolts evenly.

E. Reattach the field wire and positive wire to the

alternator (make sure that the large positive wire has the factory rubber boot properly secured to prevent arcing to the heat shield). Using the supplied 3/8-16 x 2.75” bolts and washers, attach the alternator to the main bracket. Secure all alternator wiring from heat and sharp objects.

F. Align the supercharger mounting plate with the

bracket and secure with the supplied 3/8-16 x 3/4” bolts and AN washers.

G. Mount the supplied automatic belt tensioner onto

the main bracket. (See

Fig. 4-b

.) Rotate the unit so that the small alignment pins fall into the corresponding holes in the bracket. Secure the tensioner using the supplied M10 bolt.

Fig. 4-a - Stainless Steel Heat Shield.

Fig. 4-b

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

5. SUPERCHARGER INSTALLATION

NOTE: Before the supercharger can be in-

stalled onto the bracket, it will be necessary to carefully bend the aluminum air conditioning line running over to the passenger side of the vehicle. A minor bend pushing the line toward the rear is all that is required.

A. Attach the 1/2” oil drain hose to the supercharger

and secure with the #8 hose clamp.

B. Route the hose down the rear of the main bracket

while lowering the supercharger into the proper mounting location on the plate. Be sure that the oil drain hose remains unkinked with smooth bends. (See

Fig. 5-a

C. Using the five supplied 3/8-16 x 1” bolts and AN

washers, secure the supercharger to the mounting plate.

D. Route the oil drain hose around the main casting

and down to the fitting in the oil pan. Make sure that the hose runs below the positive alternator lug, but still remains running “downhill”. It is very important that the oil drain hose is free from restrictions, tight bends, kinks or any other drain obstructing conflict. Route the hose away from direct exhaust heat. Trim hose length if necessary and secure to the oil pan with the supplied #8 hose clamp.

E. Attach the 1/8 NPT x 45° brass fitting to the super-

charger oil feed. Use a 1/2” wrench to hold the feed fitting while tightening the 45° fitting. Attach the oil feed hose to the supercharger.

OIL DRAIN

HOSE

Fig. 5-a

WARNING: The oil system contains a small

orifice that is easily plugged. Do not use any type of sealant on any of the threads. Instead, use clean engine oil. Disassemble and blow out the entire line if there is any question.

F. Using the tie wraps provided, secure the feed and

drain systems away from heat and/or sharp objects.

G. Using the supplied spacer, bolt and dust shield,

mount the supplied 3" idler pulley (non-flanged) to the boss on the supercharger. (See

(Vortec 350-2 )4GM

Fig. 4-b

6. SUPERCHARGER/ACCESSORY DRIVE BELT

A. Separate the spacer and hardware from the factory idler re-

moved in step 1. Using the supplied flanged idler and spacer with hardware mentioned above, secure the idler to the threaded boss located on the face of the air conditioner compressor pump mounting bracket. (See

Fig. 6-a

B. Route the supplied belt as shown in the graphic. Belt installation

is easiest when the water pump is the last pulley to be mounted (the radius on the edge of the water pump pulley allows the edge of the belt to slide over it).

S/C

SUPPLIED

3” NON-

FLANGED

IDLER

AIR

CONDITIONER

SUPPLIED

SPRING

TENSIONER

ALT.

WATER

PUMP

CRANK

Fig. 6-a

SUPPLIED

3”

FLANGED

IDLER

(NEW LOCATION FOR FACTORY IDLER) MOVED FROM ALTERNATOR BRACKET IN STEP 1

POWER

STEERING

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

7. SUPERCHARGER AIR INLET

A. Install the 1” x 90° plastic fitting into the supplied 90°

x 3.50” plastic inlet elbow. Attach the elbow to the supercharger using the silicone sleeves and #56 hose clamps.

B. Assemble the new air filter housing along with air filter

and end cap. Fit the end housing with the air filter element provided, to the new filter housing. Secure the end by drilling two 3/32” holes (transfer the hole location from the end cover to the housing) and fasten with the screws provided. Attach the filter housing/ assembly to the steel inner fender using the supplied GM adapter, clamp, spacer, support and 6mm bolts with washers. (See

Fig. 7-a

C. Attach the factory MAF sensor to the new filter hous-

ing using the supplied silicone sleeve and #56 hose clamps. The MAF sensor is directional, so make sure that the “flow” arrow is pointed to the supercharger. Connect the MAF to the supercharger inlet elbow with the supplied length of flex hose and #52 hose clamps.

D. Install the factory air temperature sensor and grom-

met into the hole located in the plastic supercharger air inlet elbow. Reattach the factory connector to the sensor. Following

Fig. 7-b

, splice the supplied MAF buffer in between the factory MAF plug and the MAF meter. Mount the buffer unit inside the engine compartment on the inner fender using the supplied Velcro strips. Make sure the unit is away from heat. Removing the plastic nut retaining the main harness to the firewall allows proper slack in the wire.

E. Install the supplied 3/4” vent adapter into the factory

rubber grommet located on the right side valve cover. Rotate the vent adapter so that it points toward the rear of the vehicle. Attach the 3/4" end of the supplied 180° rubber hose to the vent adapter. Attach the supplied length of 5/8" hose and the 5/8" hose splice to the 90° x 5/8” barb located on the top of the supercharger inlet elbow. Connect the 180° rubber hose to the inlet elbow hose. Trim excess hose length.

Fig. 7-a

FACTORY MAF

PLUG/HARNESS

MAF BUFFER

(Spliced in between MAF

and factory MAF plug)

AIRBOX

PASSENGER SIDE VIEW

SUPPORT

(Vortec 350-2 )4GM

SPACER

CLAMP

#14 SCREW

INNER FENDER

SUPPLIED ADAPTER

INNER FENDERWELL

FILTER HOUSING

AIR FILTER

SUPPORT

FRONT VIEW

Figure: 7-b

END CAP

3-1/2” SLEEVE CLAMP

MAF METER

8. SUPERCHARGER DISCHARGE

A. Following

Fig. 8-a

, attach the supplied discharge support between the VORTEC plenum and the throttle body duct. Sandwich the dogleg end of the support in between the #56 hose clamp and the reducer sleeve. Make sure that the circular end of the support is up flush against the bottom of the plenum.

B. Attach the discharge tube between the super-

charger and the throttle body plenum using the supplied 3.5-2.75 reducer, 2.75 sleeve, #56 and #52 hose clamps.

C. Following

Fig. 8-b

, connect the 1” x 6” and 1” x 3” hoses to the supplied supercharger bypass valve and secure with #16 hose clamps. Attach the bypass valve/hose assembly to the bung located on the discharge tube and the plastic 1” fitting located on the inlet elbow (make sure that the bypass valve nipple is pointing down when installed). (See

Fig. 8-c

.) Secure with #16 hose

clamps.

D. Remove the 1/2” brake booster vacuum line from

the intake manifold fitting and cut approximately 2" off the end. Splice the supplied adapter TEE into the brake booster line. Run the supplied piece of 1/4” vacuum hose from this TEE to the reducer, and connect the 5/32" hose to the nipple located on the bottom of the supercharger bypass valve. ( See

Fig. 8d

E. Attach the supplied 3/4" vacuum cap to the

open barb located on the factory throttle body duct (previous crankcase vent tube location). Secure with supplied tie wrap.

Fig. 8-a

Fig. 8-b

BYPASS VALVE

SUPERCHARGER AIR INLET ELBOW

SUPERCHARGER DISCHARGE TUBE

5/32” HOSE 1/4” HOSE

1/4” NPT x 1/4” FITTINGREDUCER

Fig. 8-d

BRAKE

BOOSTER

1/2” TEE

INTAKE MANIFOLD FITTING

Fig. 8-c

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

9. HEATER HOSE EXTENSION

A. Attach the supplied 5/8” x 24” pre-bent 90° hose

to the top water pump fitting (points straight up) and secure using the factory clamp.

B. Route the new hose over to the existing factory

heater hose modified in step 1. (See

Fig. 9-a

the two hoses together using the supplied 5/8” coupling and #8 hose clamps.

C. Refill the cooling system with the previously drained

coolant.

INSTALL NEW HOSE

10. FUEL MANAGEMENT UNIT

A. Position the fuel management unit (FMU) on the

inside of the vehicle frame, underneath the driver seat. (

See Figs. 10-a, 10-b.)

Mark and drill two #16 holes. Secure the FMU using the supplied #12 hex head screws.

B. Separate the factory 5/16” fuel rail return line at the

compression fitting junction underneath the vehicle near the fuel filter. Attach the supplied -4 flare fitting adapters to each end of the open return line (one fitting will point toward the rear, and one toward the front). Connect one end of the supplied 22” FMU hose to the return line running back to the tank, and the other end to the straight fitting on the center of the FMU. Connect one end of the remaining 36” FMU hose to the return line coming from the fuel rail, and the other end to the 90° fitting on the side of the FMU (see

Fig. 10-c

C. Secure the lines away from abrasion using the

supplied tie wraps.

D. Tap into the supercharger bypass valve vacuum

hose using the supplied 65” long length of hose and 5/32” brass TEE. Route the hose in a manner that will keep it away from exhaust heat and will allow gentle bends without pinching. Attach the hose end to the lid of the FMU.

.) Join

Fig. 9-a

Fig. 10-a

5/16” LINE TO TANK

(Vortec 350-2 )4GM

FMU OUTLET (TO TANK)

FMU INLET (FROM FUEL RAIL RETURN)

5/16” LINE FROM RAIL

VACUUM LINE TO MANIFOLD

MOUNT TO FRAME

Fig. 10-c

FUEL PUMP

HARNESS

Fig. 10-b

FMU

11. SUPPLEMENTARY FUEL PUMP AND HARNESS

A. Separate the factory 3/8” fuel rail supply line at the

compression fitting junction underneath the vehicle just to the rear of the fuel filter.

B. Attach the supplied 1/2” hose to 3/8" compression

fitting to the line coming from the fuel tank. Connect the supplied length of 1/2” fuel hose to the 1/2” fitting previously installed and the remaining end to the supplied inline pump. Secure with a #8 hose clamp.

C. Attach the discharge end of the fuel pump to the

line running into the fuel filter (use the supplied 5/16" hose to 3/8" compression fitting). Position the pump in such a way that the inlet and discharge hoses are not kinked or restricted and maintain a gentle bend. The pump inlet is the most critical as far as restriction is concerned and may be trimmed if necessary to hold a smooth radius. Make sure that all fuel pump hose connections are secure.

D. Mount the fuel pump to the frame using the 1.5”

adel clamp. Position the clamp and drill a #16 hole. Secure using a #12 hex head screw.

E. Using the existing hole in the frame and supplied

#10 hardware, mount the relay to the vehicle frame (see

Fig. 11-b

and

Fig. 10-b

in section 10). The relay mounting hole will also work well as a grounding point for the pump and relay. Scrape away the frame coating and paint to provide a proper ground connection. Make sure that the pump and relay grounding terminals are mounted

under

the relay as opposed to

on top

so that a

metal-to-metal contact will be made.

Fig. 11-a

GROUND

RELAY WIRING

SCHEMATIC

87A

Fig. 11-b

(+) FUEL PUMP

SOLID GREY WIRE IN FUEL PUMP HARNESS (RUNNING ALONG THE DRIVER’S SIDE FRAME MEMBER)

(+) BATTERY LUG

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

11. SUPPLEMENTARY FUEL PUMP AND HARNESS, cont'd.

F. Wire the fuel pump and relay (see

Fig. 11-c

). Use the supplied tie wraps to run the wire and keep it away from heat/abrasion. Use the supplied 8mm nut to connect the main power lead on the relay to the factory fuse/power box underhood (the factory has provided two open power lugs under the power box cover). Tap the yellow relay wire (terminal #87) into the solid gray wire in the harness running along the driver side frame member. Use the supplied wire tap.

1/2” HOSE

TO 3/8” 3/8” FROM TANK

COMPRESSION

FITTING

#8 HOSE CLAMP

5/16” HOSE TO 3/8” COMPRESSION FITTING

3/8” TO RAIL

RELAY TERMINAL #87

GROUND

FACTORY FUEL FILTER

#8 HOSE CLAMPFUEL PUMP

Fig. 11-c

(Vortec 350-2 )4GM

12. FINAL CHECK

A. 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.

B. 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

Fig. 12-a

C. Check all fluid levels, making sure that your

tank(s) is/are filled with 92 octane or higher fuel before commencing test drive.

D. Start engine and allow to idle a few minutes,

then shut off.

E. Recheck to be sure that no hoses, wires, etc.

are near exhaust headers or moving parts and for signs of any fluid leakage.

F. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without all sub assemblies completely and properly installed and working may cause FAILURE OF MAJOR ENGINE

COMPONENTS.

G. Test drive the vehicle. H. Read the STREET SUPERCHARGER SYS-

TEM OWNER'S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within

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

Fig. 12-a

WARNING: Do not attempt to operate

the vehicle until ALL components are installed and ALL operations are completed including final check.

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

ENGINEERING, INC.

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

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

14AUG00 V 1.2

P/N: 4GM020-010

(Vortec 350-2 )4GM

Vortech 1996-2000 5.7L Vortec Truck SUV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual