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
P/N: 4GM020-010
©2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
14AUG00 V 1.2
(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.
All rights reserved. No parts of this publication may be reproduced, transmitted, transcribed,
or translated into another language in any form, by any means without written permission
P/N: 4GM020-010
©2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
14AUG00 V 1.2
(Vortec 350-2 )4GM
© 2000 VORTECH ENGINEERING, INC.
of Vortech Engineering, Inc.
i
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
©2000 Vortech Engineering, Inc.
ii
All Rights Reserved, Intl. Copr. Secured
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
P/N: 4GM020-010
©2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
14AUG00 V 1.2
(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
iv
4GM218-050S
©2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
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
P/N: 4GM020-010
©2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
14AUG00 V 1.2
(Vortec 350-2 )4GM
v
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