Vortech 1997-2001 5.2L 5.9L Durango Dakota User Manual

Download

5.2/5.9L Dodge

Durango/Dakota/Ram

Supercharger System

Installation Instructions

1996-1999 Model Years

49 State Smog Legal*

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901

(Dodge 5.9L Durango/Dak-2)

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

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 possible installers in your area.

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

(Dodge 5.9L Durango/Dak-2)

of Vortech Engineering, Inc.

Table Of Contents

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

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

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

SPECIAL NOTICE-CRANE IGNITION SYSTEM.................................................................... iv

TOOL AND SUPPLY REQUIREMENTS ................................................................................. v

1997-1999 5.9L DODGE DURANGO/DAKOTA...................................................................... vi

1997-1999 5.2L DODGE DURANGO/DAKOTA...................................................................... vii

1996 5.2L DODGE DURANGO/DAKOTA / 1996-1999 5.2L DODGE RAM ............................ viii

1996 5.9L DODGE DURANGO/DAKOTA / 1996-1999 5.9L DODGE RAM ............................ ix

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

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

3. AIR FILTER INSTALLATION (1997-99 DODGE DAKOTA/DURANGO ONLY) ............. 2

4. MAIN MOUNTING BRACKET AND PLATE................................................................... 3

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

6. IGNITION COIL RELOCATION...................................................................................... 5

7. SUPERCHARGER MOUNTING .................................................................................... 6

8. SUPERCHARGER/ACCESSORY DRIVE BELT ........................................................... 6

9A. IGNITION/BOOST CONTROL INSTALLATION (1997-99 Dakota/Durango only) ......... 7

9B. IGNITION/BOOST CONTROL INSTALLATION (1996 Dakota/1996-1999

Ram only) ...................................................................................................................... 9

10. IGNITION/BOOST CONTROL UNIT OPERATION........................................................ 11

11A. SUPERCHARGER AIR INLET DUCT (1997-99 Dakota/Durango only) ........................ 11

11B. SUPERCHARGER AIR INLET DUCT (1996 Dakota/1996-99 Ram only) ..................... 12

12. PLENUM AND DISCHARGE INSTALLATION ............................................................... 12

13A SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED

SYSTEM (1997-99 Dakota/Durango only). ................................................................... 13

13B SUPPLEMENTARY FUEL INJECTION COMPUTER (SFCI) AND RELATED

SYSTEM (1996 Dakota/1996-99 Ram only).................................................................. 15

14. FINAL CHECK ............................................................................................................... 17

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

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 V ortech 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 • vortechsuperchargers.com • M-F 8AM - 4:30PM (PST)

(Dodge 5.9L Durango/Dak-2)

ENGINEERING, INC.

iii

SPECIAL NOTICE CONCERNING THE

CRANE IGNITION SYSTEM

The ignition system, manufactured by Crane Electronics, included in this kit is serviced exclusively by the manufacturer. Crane Electronics warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warranty . If found to be defective as mentioned above, it will be repaired or replaced if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Crane Electronics and/or Vortech Engineering, 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 warranty verification. After the warranty period has expired, repair service is charged between a minimum and maximum charge. In either case, please send the unit prepaid with proof of purchase to the attention of:

Crane Electronics Customer Service Department 530 Fentress Boulevard Daytona Beach, Florida, 32114 (904) 258-6167 (904) 258-6174 Fax www.cranecams.com

The repaired unit will be returned as soon as possible after receipt, COD for any charges. Be sure you include a detailed account of any problems experienced, the type of vehicle and any modifications.

Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Inc., directly at (805) 247-0226.

ENGINEERING, INC.

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

1996-1999

5.2/5.9L Dodge Durango, Dakota and Ram

Installation Instructions for

Part No. 4CE218-010SQ/018SQ/020SQ/028SQ, 4CD218-040SQ/048SQ/050SQ/058SQ

49 State Smog Legal

Congratulations on selecting the best performing and best backed 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 between 35 and 45% can be expected with the boost levels specified by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech Engineering is not

responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 92 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech prior to using this product.

4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until the 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.

V-2® SQ-Trim supercharger!

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

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

• 1/2" Drive and Socket Set: SAE and Metric

• 3/8" NPT Tap and Tap Handle

• Adjustable Wrench

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

• Center Punch and a 5/8" Tapered Punch

• 5 quarts SF Rated Quality Engine Oil, Oil Filter, and

Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 3/32", #25, 5/8", 3/8" Drill Bits

• Oil Sender Socket, Snap-On #A120

If your vehicle has in excess of 15,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

(Dodge 5.9L Durango/Dak-2)

1997-1999 5.9L Dodge Durango/Dakota

Part No. 4CE218-010SQ/018SQ

ENGINEERING, INC.

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

PARTS LIST

Part Number Description Quantity

2E228-140 SUPERCHARGER ASSEMBLY 1

2E128-140 V-2 SQ Supercharger 1 2A037-312 Supercharger pulley, 3.125", 7 groove 1

4FA016-150 Idler pulley, smooth 1

7J012-092 12mm Washer, flat 1 7U100-070 Key, 3/16 X 3/16 X 7/8 1 2A040-011 Supercharger pulley retainer 1 7B375-110 3/8-24 X 1" GR8 HX 1 7K375-040 3/8 AN 960 Flat washer 1

4CE111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-034 Mounting plate 1 4CB011-021 Mounting bracket 1

2A047-113 Belt 1 7A375-100 3/8-16 X 1 G5 HXHD, plated 10 7A375-300 3/8-16 X 3" HXCSG5P 1 7A375-375 3/8-16 X 3-3/4 HXHD 1 7F375-016 3/8-16 HX nut 1

7J375-044 3/8 SAE Washer, plated 10 7K375-040 3/8 AN 960 Flat washer 5 7U100-055 Tie wrap, 6" nylon 2

4CJ010-010 Mounting support 1 4CJ017-041 Support spacer, .250" 1 4CJ017-051 Support spacer, .60" 1

7J312-000 5/16 Flat washer-SAE 1 7A312-375 5/16-18 X 3-3/4" SHCS 1

4CE212-010 AIR INTAKE ASSEMBLY 1

4CE110-050 MAF bracket assembly 1

7R002-056 #56 Goldseal hose clamp 2 7S350-200 3-1/2 X 2 Sleeve 1 8H040-040 Air filter 1 7R002-052 #52 Goldseal hose clamp 2 7U035-001 3-1/2" Flex hose, 1 ft. 1 7E010-049 #10 X 3/4 Hex head 3 7U033-000 5/8" PCV hose, 3.50 ft. 1

4CE112-010 Inlet elbow 1

7P375-020 3/8" NPT X 5/8" Barb 1 7R001-008 #8 Stainless hose clamp 1

4CE112-020 AIR DISCHARGE ASSEMBLY 1

4FG012-030 Discharge Tube 1

7S275-200 2-3/4” X 2” Sleeve 1 7S300-200 3" X 2" Sleeve 1 7R002-044 #44 Goldseal hose clamp 2 7R002-048 #48 Goldseal hose clamp 2 8D001-001 Bypass valve 1 7P750-100 3/4" NPT x 1" Straight hose fitting 1 7U034-016 1" GS hose 1 7R002-016 #16 Goldseal hose clamp 4 7P156-082 5/32" TEE 1 7U030-046 5/32" Vacuum line 1

4CJ050-011 Jeep/Durango plenum 1

4GB040-060 Air/plenum gasket 1

7J250-010 1/4" Gasket washer 1 7U034-016 1" GS hose 1

4CD110-060 Plenum assembly 1

7A250-175 1/4-20 X 1-3/4 HHCS 1

4CJ130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” X 18” Oil drain hose 1 7P375-017 3/8” NPT X 1/2” Straight hose barb 1 7R001-008 #8 Stainless hose clamp 2 7P375-045 3/8" NPT X 45° Street elbow 1

4CJ130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” Oil feed Hose 1 7P125-103 -4 X 45° Male elbow 2 7P250-066 #4 Swivel x 1/4” hose 2 7P525-067 .525 Crimp ferrules 2 7P125-026 1/8" NPT X #4 90° fitting 1 7P125-104 1/8" NPT female TEE 1 7P125-106 1/8" NPT X 3" nipple 1

Part Number Description Quantity

4CJ110-010 COIL RELOCATION ASSEMBLY 1

4CJ010-040 Coil bracket 1

7A250-125 1/4-20 X 1-1/4" SOC. HD. 2 7F250-021 1/4-20 Nylock nut 2 7A312-125 5/16-18 X 1-1/4 HXHD 1 7K312-001 5/16 AN washer 2

4CJ017-021 Spacer, coil, .625" 1

5W001-005 3/8" Plastic wire loom 1

7A312-075 5/16"-18 X 3/4 HXCSG5P 1 5W022-040 22 GA wire, green 1 5W022-090 22 GA wire, grey 1 5W001-007 3/16" Heat - shrink tubing 1

4CE160-010 FUEL CONTROL ASSEMBLY 1

8F060-058 Fuel injector, 58 lbs. rail 2

8F003-024 Fuel rail 1

7P563-016 Plug, fuel rail 1

8F011-027 Mounting tab, fuel rail 2

7C008-050 #8-32 X 1/2" SOC. HD. bolt 2

8F011-028 Spacer, fuel rail 2

7A250-237 1/4-20 X 2-3/8" SOC. HD. bolt 2

4CE145-010 Fuel hose with ends 1

8F011-024 Injector retainer, fuel rail 2

7P250-127 -6 Flair to 1/4" NPT 1

7P250-082 1/4 NPT X -4 90° fitting 1 5W001-024 Mini ATC fuse tap 1

7U030-046 5/32" Vacuum line X 72" 1

7P156-082 5/32" TEE 1

7U100-055 Tie wrap, 6" nylon 6 5W001-001 Wire tap 1 5W001-025 Female slide, insulated, mini 1

7K250-001 1/4" AN washer 2

7U100-059 O-ring, -6 AN flouro 2

5A001-007 FUEL INJECTION COMPUTER 1

5A001-004 Fuel injection, computer 1

7U375-001 Velcro, hook, 1" black 1

7U375-002 Velcro, latch, 1" black 1

5A101-012 HI-6 TR ASSEMBLY 1

5A001-009 HI-6 TR ignition system 1 5W001-001 Wire taps 2 5W001-009 16-14 GA male slides 6 5W001-010 16-14 GA female slides 6 5W001-011 16-14 GA eyelets 2 5W001-014 Fuse Holder 10 GA wire 1 5W001-015 Fuse, blade type 20 AMP 1 5W001-017 Large ring terminals 2 5W001-020 3/4" Plastic wire loom 1 5W012-000 12 GA wire, red 1 5W012-010 12 GA wire, black 1

7E010-046 #8 x 3/4" Sheet metal 4

7P156-082 5/32" TEE 1

7U030-046 5/32" x 36" Vacuum line 1

7U100-055 6" Nylon tie wrap 1

7U375-001 3.6" Velcro hook 1

7U375-002 3.6" Velcro latch 1 5W018-010 18 GA wire, red 1 5W018-020 18 GA wire, black 1 5W018-060 18 GA wire, orange 1 5W018-240 18 GA wire, white and yellow 1 5W001-040 12-10 GA female slide 2 5W001-041 12-10 GA male slide 2 5W001-019 Solderless connector, 10-12 2

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

1997-1999 5.2L Dodge Durango/Dakota

Part No. 4CE218-020SQ/028SQ

ENGINEERING, INC.

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

PARTS LIST

Part Number Description Quantity

2E228-140 SUPERCHARGER ASSEMBLY 1

2E128-140 V-2 SQ Supercharger 1 2A037-312 Supercharger pulley, 3.125", 7 groove 1

4FA016-150 Idler pulley, smooth 1

7J012-092 12mm Washer, flat 1 7U100-070 Key, 3/16 X 3/16 X 7/8 1 2A040-011 Supercharger pulley retainer 1 7B375-110 3/8-24 X 1" GR8 HX 1 7K375-040 3/8 AN 960 Flat washer 1

4CE111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-034 Mounting plate 1 4CB011-021 Mounting bracket 1

2A047-113 Belt 1 7A375-100 3/8-16 X 1 G5 HXHD, plated 10 7A375-300 3/8-16 X 3" HXCSG5P 1 7A375-375 3/8-16 X 3-3/4 HXHD 1 7F375-016 3/8-16 HX nut 1 7J375-044 3/8 SAE Washer, plated 10 7K375-040 3/8 AN 960 Flat washer 5

7U100-055 Tie wrap, 6" nylon 2 4CJ010-010 Mounting support 1 4CJ017-041 Support spacer, .250" 1 4CJ017-051 Support spacer, .60" 1

7J312-000 5/16 Flat washer-SAE 1

7A312-375 5/16-18 X 3-3/4" SHCS 1

4CE212-010 AIR INTAKE ASSEMBLY 1

4CE110-050 MAF bracket assembly 1

7R002-056 #56 Goldseal hose clamp 2

7S350-200 3-1/2 X 2 Sleeve 1

8H040-040 Air filter 1

7R002-052 #52 Goldseal hose clamp 2

7U035-001 3-1/2" Flex hose, 1 ft. 1

7E010-049 #10 X 3/4 Hex head 3

7U033-000 5/8" PCV hose, 3.50 ft. 1 4CE112-010 Inlet elbow 1

7P375-020 3/8" NPT X 5/8" Barb 1

7R001-008 #8 Stainless hose clamp 1

4CE112-020 AIR DISCHARGE ASSEMBLY 1

4FG012-030 Discharge Tube 1

7S275-200 2-3/4” X 2” Sleeve 1

7S300-200 3" X 2" Sleeve 1

7R002-044 #44 Goldseal hose clamp 2

7R002-048 #48 Goldseal hose clamp 2

8D001-001 Bypass valve 1

7P750-100 3/4" NPT x 1" Straight hose fitting 1

7U034-016 1" GS hose 1

7R002-016 #16 Goldseal hose clamp 4

7P156-082 5/32" TEE 1

7U030-046 5/32" Vacuum line 1 4CJ050-011 Jeep/Durango plenum 1

4GB040-060 Air/plenum gasket 1

7J250-010 1/4" Gasket washer 1

7U034-016 1" GS hose 1

4CD110-060 Plenum assembly 1

7A250-175 1/4-20 X 1-3/4 HHCS 1

4CJ130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” X 18” Oil drain hose 1

7P375-017 3/8” NPT X 1/2” Straight hose barb 1

7R001-008 #8 Stainless hose clamp 2

7P375-045 3/8" NPT X 45° Street elbow 1

4CJ130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” Oil feed Hose 1

7P125-103 -4 X 45° Male elbow 2

7P250-066 #4 Swivel x 1/4” hose 2

7P525-067 .525 Crimp ferrules 2

7P125-026 1/8" NPT X #4 90° fitting 1

7P125-104 1/8" NPT female TEE 1

7P125-106 1/8" NPT X 3" nipple 1

Part Number Description Quantity

4CJ110-010 COIL RELOCATION ASSEMBLY 1

4CJ010-040 Coil bracket 1

7A250-125 1/4-20 X 1-1/4" SOC. HD. 2 7F250-021 1/4-20 Nylock nut 2 7A312-125 5/16-18 X 1-1/4 HXHD 1 7K312-001 5/16 AN washer 2

4CJ017-021 Spacer, coil, .625" 1

5W001-005 3/8" Plastic wire loom 1

7A312-075 5/16"-18 X 3/4 HXCSG5P 1 5W022-040 22 GA wire, green 1 5W022-090 22 GA wire, grey 1 5W001-007 3/16" Heat - shrink tubing 1

4CE160-010 FUEL CONTROL ASSEMBLY 1

8F060-058 Fuel injector, 58 lbs. rail 2

8F003-024 Fuel rail 1

7P563-016 Plug, fuel rail 1

8F011-027 Mounting tab, fuel rail 2

7C008-050 #8-32 X 1/2" SOC. HD. bolt 2

8F011-028 Spacer, fuel rail 2

7A250-237 1/4-20 X 2-3/8" SOC. HD. bolt 2

4CE145-010 Fuel hose with ends 1

8F011-024 Injector retainer, fuel rail 2

7P250-127 -6 Flair to 1/4" NPT 1

7P250-082 1/4 NPT X -4 90° fitting 1 5W001-024 Mini ATC fuse tap 1

7U030-046 5/32" Vacuum line X 72" 1

7P156-082 5/32" TEE 1

7U100-055 Tie wrap, 6" nylon 6 5W001-001 Wire tap 1 5W001-025 Female slide, insulated, mini 1

7K250-001 1/4" AN washer 2

7U100-059 O-ring, -6 AN flouro 2

5A001-011 FUEL INJECTION COMPUTER 1

5A001-004 Fuel injection, computer 1

7U375-001 Velcro, hook, 1" black 1

7U375-002 Velcro, latch, 1" black 1

5A101-012 HI-6 TR ASSEMBLY 1

7E010-046 #8 x 3/4" Sheet metal 4

7P156-082 5/32" TEE 1

7U030-046 5/32" x 36" Vacuum line 1

7U100-055 6" Nylon tie wrap 1

7U375-001 3.6" Velcro hook 1

(Dodge 5.9L Durango/Dak-2)

vii

1996 5.2L Dodge Dakota,

1996-1999 5.2 Dodge Ram

ENGINEERING, INC.

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

Part No. 4CD218-040SQ/048SQ

PARTS LIST

Part Number Description Quantity

2E228-140 SUPERCHARGER ASSEMBLY 1

2E128-140 V-2 SQ Supercharger 1 2A037-312 Supercharger pulley, 3.125", 7 groove 1

4FA016-150 Idler pulley, smooth 1

7J012-092 12mm Washer, flat 1

7U100-070 Key, 3/16 X 3/16 X 7/8 1

2A040-011 Supercharger pulley retainer 1 7B375-110 3/8-24 X 1" GR8 HX 1 7K375-040 3/8 AN 960 Flat washer 1

4CE111-021 MOUNTING BRACKET ASSEMBLY 1

4CB010-034 Mounting plate 1 4CB011-021 Mounting bracket 1

7U100-055 Tie wrap, 6" nylon 2 4CJ010-010 Mounting support 1 4CJ017-041 Support spacer, .250" 1 4CJ017-051 Support spacer, .60" 1

7J312-000 5/16 Flat washer-SAE 1 7A312-375 5/16-18 X 3-3/4" SHCS 1

4CD212-010 AIR INTAKE ASSEMBLY 1

7R002-056 #56 Goldseal hose clamp 2

7S350-200 3-1/2 X 2 Sleeve 1 8H040-040 Air filter 1 7U033-000 5/8" PCV hose, 3.50 ft. 1

4CE112-010 Inlet elbow 1

7P375-020 3/8" NPT X 5/8" Barb 1 7R001-008 #8 Stainless hose clamp 1

4CE112-020 AIR DISCHARGE ASSEMBLY 1

4FG012-030 Discharge Tube 1

7S275-200 2-3/4” X 2” Sleeve 1

7S300-200 3" X 2" Sleeve 1 7R002-044 #44 Goldseal hose clamp 2 7R002-048 #48 Goldseal hose clamp 2 8D001-001 Bypass valve 1

7P750-100 3/4" NPT x 1" Straight hose fitting 1 7U034-016 1" GS hose 1 7R002-016 #16 Goldseal hose clamp 4

7P156-082 5/32" TEE 1 7U030-046 5/32" Vacuum line 1

4CJ050-011 Jeep/Durango plenum 1

4GB040-060 Air/plenum gasket 1

7J250-010 1/4" Gasket washer 1 7U034-016 1" GS hose 1

4CD110-060 Plenum assembly 1

7A250-175 1/4-20 X 1-3/4 HHCS 1

4CJ130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” X 18” Oil drain hose 1

7P375-017 3/8” NPT X 1/2” Straight hose barb 1 7R001-008 #8 Stainless hose clamp 2

7P375-045 3/8" NPT X 45° Street elbow 1

4CJ130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” Oil feed Hose 1

7P125-103 -4 X 45° Male elbow 2

7P250-066 #4 Swivel x 1/4” hose 2

7P525-067 .525 Crimp ferrules 2

7P125-026 1/8" NPT X #4 90° fitting 1

7P125-104 1/8" NPT female TEE 1

7P125-106 1/8" NPT X 3" nipple 1

Part Number Description Quantity

4CJ110-010 COIL RELOCATION ASSEMBLY 1

4CJ010-040 Coil bracket 1

7A250-125 1/4-20 X 1-1/4" SOC. HD. 2

7F250-021 1/4-20 Nylock nut 2 7A312-125 5/16-18 X 1-1/4 HXHD 1 7K312-001 5/16 AN washer 2

4CJ017-021 Spacer, coil, .625" 1

5W001-005 3/8" Plastic wire loom 1

7A312-075 5/16"-18 X 3/4 HXCSG5P 1

5W022-040 22 GA wire, green 1 5W022-090 22 GA wire, grey 1 5W001-007 3/16" Heat - shrink tubing 1

4CD160-010 FUEL CONTROL ASSEMBLY 1

8F060-058 Fuel injector, 58 lbs. rail 2

8F003-024 Fuel rail 1

8F011-027 Mounting tab, fuel rail 2 7C008-050 #8-32 X 1/2" SOC. HD. bolt 2

8F011-028 Spacer, fuel rail 2 7A250-237 1/4-20 X 2-3/8" SOC. HD. bolt 2 7K250-001 1/4" AN washer 2

8F011-024 Injector retainer, fuel rail 2

5W001-024 Mini ATC fuse tap 1

7U030-046 5/32" Vacuum line X 72" 1 7P156-082 5/32" TEE 1 7U100-055 Tie wrap, 6" nylon 6

5W001-001 Wire tap 1 5W001-025 Female slide, insulated, mini 1

7P563-015 -6 Male to -6 male 2 7U100-059 O-ring, -6 AN flouro 2

4CD145-010 Fuel line, -6 STR. 1 4CD145-020 Fuel line, -6 90° 1

7P375-073 Fitting, fuel rail 1 7P250-375 1/4 NPT to -6JIC 90° 1

5A001-011 FUEL INJECTION COMPUTER 1

5A001-004 Fuel injection, computer 1 7U375-001 Velcro, hook, 1" black 1 7U375-002 Velcro, latch, 1" black 1

5A101-012 HI-6 TR ASSEMBLY 1

5A001-009 HI-6 TR ignition system 1

5W001-001 Wire taps 2 5W001-009 16-14 GA male slides 6 5W001-010 16-14 GA female slides 6

5W001-011 16-14 GA eyelets 2

5W001-014 Fuse Holder 10 GA wire 1 5W001-015 Fuse, blade type 20 AMP 1 5W001-017 Large ring terminals 2 5W001-020 3/4" Plastic wire loom 1 5W012-000 12 GA wire, red 1 5W012-010 12 GA wire, black 1

7E010-046 #8 x 3/4" Sheet metal 4 7P156-082 5/32" TEE 1 7U030-046 5/32" x 36" Vacuum line 1 7U100-055 6" Nylon tie wrap 1 7U375-001 3.6" Velcro hook 1 7U375-002 3.6" Velcro latch 1

5W018-010 18 GA wire, red 1 5W018-020 18 GA wire, black 1 5W018-060 18 GA wire, orange 1 5W018-240 18 GA wire, white and yellow 1 5W001-040 12-10 GA female slide 2 5W001-041 12-10 GA male slide 2 5W001-019 Solderless connector, 10-12 2

viii

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

1996 5.9L Dodge Dakota,

1996-1999 5.9L Dodge Ram

ENGINEERING, INC.

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

Part No. 4CD218-050SQ/058SQ

PARTS LIST

Part Number Description Quantity

2E228-140 SUPERCHARGER ASSEMBLY 1

2E128-140 V-2 SQ Supercharger 1 2A037-312 3.125” Supercharger Drive Pulley 1

4FA016-150 Smooth Pulley Tensioner 1

7J012-092 12 mm Flat Washer 1

7U100-070 Key, 3/16 x 3/16 x 7/8 1

2A040-011 Pulley Retainer 1 7B375-110 3/8-24 x 1" GR8 HX 1 7K375-040 3/8 AN960 Flat Washer 1

4CE111-021 MOUNTING BRACKET ASSEMBLY 1

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

2A047-113 Belt, K071130 - Gates 1 7A375-100 3/8-16 x 1” Bolts 10 7A375-300 3/8-16 x 3" Cap Screw 1 7A375-375 3/8-16 x 3-3/4” HH Bolt 1 7F375-016 3/8-16 Hex Nut 1 7J375-044 3/8” SAE Washers 10 7K375-040 3/8” AN960 Flat Washers 5

7U100-055 6" Nylon Tie Wraps 2 4CJ010-010 Support, Mounting Plate 1 4CJ017-041 Spacer, Support .250" 1 4CJ017-051 Spacer, Support .60" 1

7J312-000 5/16 Flat Washer 1 7A312-375 5/16-18 x 3-3/4" SHCS 1

4CD212-010 AIR INTAKE ASSEMBLY 1

7R002-056 #56 Goldseal Hose Clamp 1

7S350-200 3-1/2" x 2 Sleeve 1 8H040-040 Air Filter 1 7U033-000 5/8" PCV Hose 1

4CE112-010 Durango Inlet Elbow 1

7P375-020 3/8" NPT x 5/8" Straight Hose Barb 1 7R001-008 #8 Stainless Hose Clamp 1

4CE112-020 AIR DISCHARGE ASSEMBLY 1

4FG012-030 Discharge Tube 1

7S275-200 2-3/4” x 2” Sleeve 1

7S300-200 3" X 2" Sleeve 1 7R002-044 #44 Hose Clamps 2 7R002-048 #48 Hose Clamps 2 8D001-001 Bypass Valve 1

7P750-100 3/4" NPT x 1" Straight Hose Fitting 1 7U034-016 1" x 7" Heater Hose 1 7R002-016 #16 Hose Clamps 4

7P156-082 5/32" TEE 1 7U030-046 5/32" x 24" Vacuum Line 1

4CJ050-011 Jeep/Durango Plenum 1

4GB040-060 Air/Plenum Gasket 1

7J250-010 1/4" Gasket Washer 1 7U034-016 1" GS Hose 1

4CD110-060 Plenum Assembly 1

7A250-175 1/4-20 x 1-3/4 HHCS 1

4CJ130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 18” Oil Drain Hose 1

7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1 7R001-008 #8 Stainless Hose Clamps 2

7P375-045 3/8" NPT x 45° Street Elbow 1

4CJ130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 33” Oil Feed Hose 1

7P125-103 1/8" NPT -4 x 45° Male Elbows 2

7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2

7P525-067 .525 Crimp Ferrules 2

7P125-026 1/8" NPT x #4 90° Fitting 1

7P125-104 1/8" NPT Female TEE 1

7P125-106 1/8" NPT x 3" Nipple 1

Part Number Description Quantity

4CJ110-010 COIL RELOCATION ASSEMBLY 1

4CJ010-040 Coil Bracket 1

7A250-125 1/4-20 x 1-1/4" SOC. HD. 2

7F250-021 1/4-20 Nylock Nut 2 5W022-040 22 GA Wire, Green 1 5W022-090 22 GA Wire, Grey 1 5W001-007 3/16" Heat - Shrink Tubing 1

7A312-125 5/16-18 x 1-1/4 HXHD 1

7K312-001 5/16 AN Washer 2

4CJ017-021 Spacer, Coil .625" 1

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

7A312-075 5/16"-18 x 3/4 HXCSG5P 1

4CE160-010 FUEL CONTROL ASSEMBLY 1

8F060-058 Fuel Injector, 58 lbs. Rail 2

8F003-024 Fuel Rail 1

7P563-016 Plug, Fuel Rail 1

8F011-027 Mounting Tab, Fuel Rail 2 7C008-050 #8-32 x 1/2" SOC. HD. Bolt 2

8F011-028 Spacer, Fuel Rail 2

7A250-237 1/4-20 x 2-3/8" SOC. HD. Bolt 2

4CE145-010 Fuel Hose with ends 1

8F011-024 Injector Retainer, Fuel Rail 2

7P250-127 -6 Flair to 1/4" NPT 1

7P250-082 1/4 NPT x -4 90° Fitting 1 5W001-024 Mini ATC Fuse Tap 1 7U030-046 5/32" Vacuum Line x 72" 1

7P156-082 5/32" TEE 1 7U100-055 Tie Wrap, 6" Nylon 6 5W001-001 Wire Tap 1 5W001-025 Female Slide, Insulated, Mini 1

7K250-001 1/4" AN washer 2 7U100-059 O-ring, -6 AN flouro 2

5A001-007 FUEL INJECTION COMPUTER 1

5A001-004 Fuel Injection, Computer 1 7U375-001 Velcro, Hook, 1" Black 1 7U375-002 Velcro, Latch, 1" Black 1

5A101-012 HI-6 TR ASSEMBLY 1

5A001-009 HI-6 TR Ignition System 1 5W001-001 Wire Taps 2 5W001-009 16-14 GA Male Slides 6 5W001-010 16-14 GA Female Slides 6 5W001-011 16-14 GA Eyelets 2 5W001-014 Fuse Holder 10 GA Wire 1 5W001-015 Fuse, Blade Type 20 AMP 1 5W001-017 Large Ring Terminals 2 5W001-020 3/4" Plastic Wire Loom 1 5W012-000 12 GA Wire, Red 1 5W012-010 12 GA Wire, Black 1

7E010-046 #8 x 3/4" Sheet Metal 4

7P156-082 5/32" TEE 1 7U030-046 5/32" x 36" Vacuum Line 1 7U100-055 6" Nylon Tie Wrap 1 7U375-001 3.6" Velcro Hook 1 7U375-002 3.6" Velcro Latch 1 5W018-010 18 GA Wire, Red 1 5W018-020 18 GA Wire, Black 1 5W018-060 18 GA Wire, Orange 1 5W018-240 18 GA Wire, White and Yellow 1 5W001-040 12-10 GA Female Slide 2 5W001-041 12-10 GA Male Slide 2 5W001-019 Solderless Connector 10-12 2

(Dodge 5.9L Durango/Dak-2)

1. PREPARATION/REMOVAL

OIL PAN

PUNCH HOLE THROUGH

DOWN

TDC

IGN. ROTOR

A. Disconnect the negative side of the battery. B. Remove the accessory drive belt. C. Remove the belt tensioner assembly, separate it from

the mounting bracket and set aside. Remove tensioner mounting bracket.

D. Disconnect and remove the crankcase breather hose. E. Remove the entire air filter/inlet assembly. F. Remove the ignition coil and bracket. Set aside. G. Remove the front plastic splash shield, if equipped.

2. OIL DRAIN

A. To provide an oil drain for the supercharger, it is

necessary to make a hole in the oil pan. The best way to provide this hole is to punch the hole rather than drill.

B. Remove the front passenger's side wheel from the

vehicle.

C. Rotate the engine until the mark on the damper is

aligned with the (TDC) top dead center tag on the front of the engine. To aid you in this, remove the distributor cap and watch the ignition rotor. It should end up between #5 and #7 electrodes (see

Figure 2-a

D. Locate and mark hole per diagram. Remove paint

around the hole area. Layout the hole center (see

Figure 2-b

E. Use a small center punch to perforate the pan and

expand the hole. Switch to a larger diameter punch and expand the hole further to approximately 9/16" diameter. Most punches are made from hexagon material and may be placed in a socket with an extension to make this procedure easier.

ROTATE ENGINE TO DISPLAYED POSITION

Figure: 2-a

NOTE: Use extreme caution not to hit

the crankshaft while punching the pan. If a clearance problem exists, rotate the crankshaft until clearance is obtained.

F. Tap the hole with a 3/8" NPT tap ap-

proximately 1/4" deep. Pack the flutes of the tap with heavy grease to hold chips. Use a small magnet to check for any stray chips.

NOTE: This method of rolling over the

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

Figure: 2-b

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

2. OIL DRAIN, cont'd.

G. Thoroughly clean the threaded area. Apply a

small amount of silicone sealer to the new threads. Apply more sealer to the male threads of the 3/8" NPT x 45° street elbow and secure in the hole. Position the fitting so that it points up toward the top/front of the vehicle at approximately a 45° angle (see

Figure 2-c

). Make sure a seal is formed all around the fitting. Thread the 3/8" NPT x 1/2" barb fitting into the 45° street elbow using a small amount of pipe sealer.

H. Drain engine oil and change filter. I. The drain hose will be attached to the fitting in later

steps. If your installation is going to be over several days we suggest that you cover the fitting to protect it from dirt.

J. Reinstall front wheel and torque lugnuts to proper

specifcations.

3. AIR FILTER INSTALLATION (1997-99 Dakota/Durango only)

A. Attached the new air filter to the supplied

filter as shown and secure with a hose clamp.

B. Place the filter assembly into the right side

fenderwell and mark hole locations to be drilled for mounting. Make sure that the filter mount assembly is sitting on a flat area of the inner fender before marking hole locations. (See

Figure 3-a

C. Punch and drill the three hole locations. D. Mount the filter assembly to the inner

fender using the supplied sheet metal screws (see

Figure 3-b

45° ANGLE UPWARD

Figure: 2-c

Figure: 3-a

(Dodge 5.9L Durango/Dak-2)

Figure: 3-b

4. MAIN MOUNTING BRACKET AND PLATE

A. It is necessary to provide clear-

ance between the dipstick and accessory drive belt. Remove the bolt holding the dipstick tube. Hold the tube approximately two inches from the top and gently bend rearward and inward about one inch. Resecure with the existing fastener after the bracket installation.

B. Mount the cast aluminum main

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

NOTE: Before mounting the

main bracket, the vehicle wiring harness may need to be shifted so that it rests in between the timing chain cover and the supercharger mounting bracket for exhaust clearance.

C. Please note that the 3-3/4" bolt

also holds the supercharger mounting plate. This fastener

must

be threaded into its hole loosely as a pilot while securing the cast bracket with the other two, then removed for installation of the supercharger mounting plate.

D. Slide the 3/8" x 3-3/4" bolt into the

proper hole in the supercharger mounting plate. Attach the stock belt tensioner to the front of the supercharger mounting plate. See graphic on the next page. Make sure the indexing tab is engaged in the slot. The factory stud on the on the tensioner may need to be shortened for proper bracket clearance. Test fit the plate assembly to the bracket before tightening any bolts.

WIRING HARNESS

Figure: 4-a

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

4. MAIN MOUNTING BRACKET AND PLATE, cont'd. 1997-99 Dakota/Durango

NOTE: Slight bending of the factory

3/8" aluminum air conditioning line (running to the firewall) is required before mounting plate can be installed (see photo below).

E. Secure the plate and tensioner as an

assembly to the cast bracket. (See

Figure 4-c

F. Remove the right side exhaust mani-

fold heat shield. Remove the second bolt (from the front) mounting the manifold to the head. Attach the supplied support strut between the supercharger mounting plate and the second exhaust manifold stud. Secure with the supplied stainless steel bolt (see

Figure 4-b

G. Attach the loose ground connection(s)

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

HEAT SHIELD

SUPPILED 5/16" BOLT

(REMOVE FACTORY

BOLT/STUD)

5/16” WASHER

Figure 4-d

.60 SPACER

EXHAUST

MANIFOLD

ATTACH TO EXHAUST

ATTACH TO EXHAUST MANIFOLD

5/16-18 x 3-3/4"

/16-18 X 3.5

SUPERCHARGER MOUNTING PLATE

GEARCHARGER MOUNTING PLATE

MANIFOLD

SUPPORT

GROUND TO ALTERNATOR MOUNTING BOLT

3/8-16 x 1"

3/8-16 X 1.0

Figure: 4-c

MAIN

MAIN HARNESS

STUD MAY NEED TRIMMING

STOCK TENSIONER

MAIN

MAIN MOUNTING

MOUNTING

BRACKET

BACKET

3/8-16 x 1"

3/8-16 X 1.0

3/8-16 x 3"

3/8-16 X 3.0

3/8-16 x 3-3/4" (BOLT MUST BE INSTALLED

3/8-16 x 3-

3/8-16 X 3.75

THROUGH PLATE BEFORE SPRING TENSIONER IS MOUNTED.)

3/8-16 X 3.0

3/8-16 x 3"

(Dodge 5.9L Durango/Dak-2)

.25 SPACER

VORTECH SUPPORT

SUPPORT STRUT DETAIL

Figure: 4-b

Figure: 4-d

5. OIL FEED LINE

A. Disconnect and remove the oil pressure

sender from the engine. The sender is found at the rear of the intake manifold to the right side of the distributor.

B. Install the supplied nipple and tee fitting

into the block and place the sending unit in the upper end. Install the 45° fitting in the side port and orient the assembly so that it points forward and slightly outward towards the passenger's side (see

5-a

). Reconnect the pressure sender con-

nector.

NOTE: It is essential that the super-

charger oiling orifice not be plugged. Therefore, do not use Teflon tape or other sealant that could possibly cause blockage. Use engine oil.

C. Attach the preassembled oil hose onto the

fitting. Route the hose forward along the inside of the right valve cover. Be careful not to rest the oil hose or ignition wires on the EGR tube at the rear of the head.

D. Before connecting the other end of the

hose to the supercharger, briefly crank over the engine in order to purge the line with oil and remove any contaminants from the line. Use a drain pan or coffee can to catch the oil.

NOTE: Supercharger drive belt must

not be attached at this step.

E. Place the 45° union fitting into the super-

charger fitting. Connect the hose to the 45° fitting.

Figure

45° x 1/8" FITTING

ENGINE BLOCK

OIL SENDING UNIT 45° x 1/8" FITTING

Figure: 5-a

STOCK OIL PRESSURE SENDING UNIT

1/8" NPT NIPPLE

Figure: 5-b

6. IGNITION COIL RELOCATION

A. Remove the ignition coil from its original mounting

bracket.

B. Locate the two 5/16" threaded bosses on the intake

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

C. Attach the supplied coil bracket and 1/4-20 hardware to

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

Figure: 6-a

18AUG00 V 2.1

(Dodge 5.9L Durango/Dak-2)

P/N: 4CE020-010

7. SUPERCHARGER MOUNTING

A. Attach the oil drain hose to the drain

fitting on the bottom of the supercharger and secure with the clamp provided. Make sure to position the clamp housing to the side so that it does not interfere with the mounting plate.

B. Set the supercharger in place on the

plate and secure with the five 3/8-16 x 1" bolts and washers.

NOTE: The forward A/C line re-

quires slight bending for supercharger pulley clearance.

C. Attach the plastic idler pulley (follow

the arrow in

Figure 7-a

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

D. Route the supercharger drain hose

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

➔

Figure: 7-a - Idler Pulley

NOTE: Drain hose must be routed

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

8. SUPERCHARGER/ACCESSORY DRIVE BELT

A. The new, longer accessory

drive belt is routed the same

S/C DRIVE

PULLEY

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

B. Route the belt around the

outside of the supercharger drive pulley then around the inside of the idler (see

ure 8-a

Fig-

C. The stock tensioner is used

as originally intended in its relocated position.

A/C

ALT

P/S

PULLEY

WATER

PUMP

CRANK

(Dodge 5.9L Durango/Dak-2)

Figure: 8-a

9A. IGNITION/BOOST CONTROL INSTALLATION (1997-99 Dakota/Durango only)

A. Remove the four phillips head screws attaching

the plastic tray (located beneath the tilt-up console cover) to the armrest/console located between the two front seats. Remove the six console mounting screws with an 8mm socket and lift the center console out of the vehicle (four screws are located underneath the two cup holder mats in the armrest/console). From the bottom side of the console, remove the six phillips head screws attaching the plastic front cover to the console.

Figure: 9A-a

B. Position the main ignition module onto the metal

tray, (offset unit to keep mounting screws from puncturing air duct). (See

Figure 9A-a

.) Mark and drill holes using a #25 drill bit. Secure ignition module with the provided #12 hardware to the metal tray.

C. With the center console removed, mark and drill

a 5/8" hole into the floor. (See

NOTE: Ensure there is room for wires (that

are to be routed into console) underneath vehicle and inside console.

Figure 9A-b

D. Under the hood, cut both wires at the coil con-

nector, leaving a few inches of wire on the connector to work with. Attach the 10' red 18 GA wire extension using the supplied connectors to the green wire coming from the factory harness to the coil. Attach the 10' white 18 GA wire extension to the black wire coming from the factory harness coil. Refer to the ignition wiring diagram.

E. Attach the supplied 10' orange 18 GA wire

extension to the green wire on the factory coil connector plug and the 10' black 18 GA wire extension to the black wire on the same plug.

F. Attach a 12 GA eyelet terminal to one end of the

supplied fuse holder and a solderless connector to the opposite end. Connect the 10' red 12 GA wire to the solderless connector. Install the wired 12 GA eyelet assembly onto the positive accessory terminal, located on the fuse box underhood.

G. Attach the supplied 5/32" vacuum line to the

capped port on the side of the intake manifold. Route the vacuum line from the right side of the engine along the firewall. Route all five wires and vacuum line down the driver's side of the vehicle along the frame (securing along the way with tie wraps) to the previously drilled hole in the floor.

AVOID EXHAUST PIPES AND SHARP OBJECTS! Pull wires and vacuum line into passen-

ger compartment. (See

Figure 9A-b

Figure: 9A-b

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

9A. IGNITION/BOOST CONTROL INSTALLATION, cont'd. (1997-99 Dakota/

Durango only)

H. Refering to

Figure 9A-c

, drill a #25 hole through the floor. Remove all paint from around the hole, ensuring a good electrical connection. Attach a 12 GA eyelet terminal to the supplied 2' black 12 GA wire. Secure this wire to the previously drilled hole on the vehicle's floor using #12 hardware.

I. Using the supplied hook and loop fastener,

attach the manifold air pressure sensor to the underside of the center console's front cover. (See

Figure 9A-d

.) Install the front cover

back onto the center console.

J. Following

center tray where shown with a 3/8" drill and

Figure 9A-d

, drill a hole in the

Drill a Hole Through Floor.

Figure: 9A-c

route the wires from the timing retard control through this hole. Secure to the inside of the tray using the provided #12 hardware.

K. Using the included male and female electri-

cal slide connectors, wire all connections according to the diagram on page 10. Install the center console and center tray back into the vehicle and secure with the previously removed hardware. (See

Figure 9A-e

(Dodge 5.9L Durango/Dak-2)

Figure: 9A-d

Drill Hole in Center Tray.

Figure: 9A-e

Install Center Console and Tray.

9B. IGNITION/BOOST CONTROL INSTALLATION (1996 Dakota/1996-1999 Ram only)

A. Mount the ignition box in the engine compart-

ment onto the flat area between the fuse box and driver's side firewall. Secure the ignition box with the four #8 sheet metal screws supplied (see

Figure 9B-a

). Mount the map

sensor next to the ignition box.

B. Route the heavy black cable to a clean ground.

Route the heavy red cable to the (+) positive terminal located on the front side of the underhood fuse box.

C. Locate the ignition coil plug-in connector

(grey and green wires) on the vehicle wiring harness near the original spring tensioner location. Cut the connector from the harness

Figure: 9B-a

Mounting Ignition Box.

leaving 2"-3" of the wire remaining on the connector.

D. Mount the timing retard control knob in the

driver's compartment underneath the dash. The knob control must be in an accessible position from the driver's seat (see

9B-b

Figure

E. Attach one end of the supplied 5/32" vacuum

line to the map sensor. Route the red and blue (or brown) wires through the firewall.

F. Connect vacuum line and wiring harness

(see

Figure 9B-c

.).

Figure: 9B-b

Timing Retard Control Knob.

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

9B. IGNITION/BOOST CONTROL INSTALLATION, cont'd.

(Dodge 5.9L Durango/Dak-2)

Figure: 9B-c

10. IGNITION/BOOST CONTROL UNIT OPERATION

A. The Ignition/Boost Control unit is

designed to retard ignition in relation to boost.

B. The unit is adjustable from 0° of

ignition retard to 4°of ignition retard for each pound of boost, up to a maximum of 20°

C. Using the middle position (knob

pointing straight up) as a starting place, adjust the ignition retard knob until just beyond the point of detonation. Use third gear for testing in a safe area or road. Adjust the retard according to changes in altitude and fuel quality.

CAUTION: It is extremely important

that the boost retard never be turned to 0 using pump fuel. It is recommended that in stock street applications, the knob be at no less than 1

per lb.

Example

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

DEGREES OF RETARD

PSI BOOST

Figure: 10-a

MAX. RETARD = 20°

10 psi at

1/2° per lb.

11A. SUPERCHARGER AIR INLET DUCT (1997-99 Dakota/Durango only)

A. Slide the supplied 3-1/2" silicone sleeve and

two #56 clamps onto the supercharger inlet. Insert the short leg of the supplied aluminum air inlet duct into the silicone sleeve.

B. Attach the supplied 5/8" hose to the barb on the

air inlet duct and route over to the left side valve cover breather location. Attach the 5/8" hose to the breather fitting and secure with the supplied #8 clamp (trim hose length if necessary). (See

Figure 11A-a

C. Connect the aluminum air inlet duct to the

previously mounted air filter flange on the inner

Figure: 11A-a

fenderwell using the supplied length of the 3-1/2" flex hose and #52 clamps. (See

11A-b

Figure

D. Align inlet assembly and tighten all clamps.

Figure: 11A-b

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

11B. SUPERCHARGER AIR INLET DUCT (1996 Dakota/1997-99 Ram only)

A. Slide the supplied 3-1/2" silicone sleeve

and two #56 clamps onto the supercharger inlet. Insert the short leg of the supplied aluminum air inlet duct into the silicone sleeve.

B. Attach the supplied 5/8" hose to the barb

on the air inlet duct and route over to the left side valve cover breather location. Attach the 5/8" hose to the breather fitting and secure with the supplied #8 clamp (trim hose length if necessary).

C. Attach the supplied air filter to the alumi-

num air inlet using the supplied #52 clamps. (See

D. Align inlet assembly and tighten all

clamps.

Figure 11B-a

Figure: 11B-a

12. PLENUM AND DISCHARGE INSTALLATION

A. Remove the tab holding down the factory

air cleaner mounting stud. Reattach the supplied tab to the throttle body. (See

Figure 12-b

.).

B. (1997-99 Dakota/Durango only)

Remove the cap covering the pressure test port on the intake manifold fuel rail. Carefully release the fuel rail pressure by slowly depressing the schrader valve. Remove the schrader valve from inside of the port. Install the supplied braided fuel line onto the fuel rail. (See

C. Place the gasket and plenum onto the

Figure 12-c

Figure: 12-b

throttle body. Secure with the supplied 1/4" x 1-3/4" bolt and 1/4" gasket washer. (See

Figure 12-d

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

plenum and slide on the two #48 clamps.

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

supercharger discharge. Secure with #44 clamps.

(1997-99 Dakota/

Durango only)

F. Install the discharge tube between the

plenum and supercharger.

G. Slide the two 1" x 2-1/2" hoses onto the

discharge duct and supercharger air inlet duct. Secure with #16 hose clamps. (See

Figure 12-e

Figure: 12-c

SUPPLIED

FUEL LINE

(Dodge 5.9L Durango/Dak-2)

12. PLENUM AND DISCHARGE INSTALLATION, cont'd.

H. Attach the bypass valve to the discharge

and inlet (see

Figure 12-a

I. Secure discharge and bypass assem-

blies.

DISCHARGE

TUBE

2-1/2" x 1" HOSE

INLET DUCT

3-1/2" x 1" HOSE

VACUUM HOSE

Figure: 12-a

Figure: 12-d

Figure: 12-e

13A. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED

SYSTEM (1997-99 Dakota/Durango only)

A. Using the four supplied #8 x 1/2" screws,

attach the fuel rail mounting tabs to the supplementary fuel rail in the orientation shown. Use thread locking compound on the bolt threads for safety.

B. Lightly oil the O-rings on both ends of the

supplied fuel injectors. Install one each of the supplied injector retainers onto each injector into the full circle groove on the end of each injector. Carefully insert the two injectors into the discharge plenum with the injector connectors pointing down and out (see

Figure 12-a

). Make sure that the injectors are inserted straight and are seated firmly into the plenum.

Figure: 13A-a

C. Slide the fuel rail onto the installed fuel injec-

tors. Slowly work the rail over the O-rings being careful not to dislodge or unseat them. Finish mounting the rail to the plenum using the two supplied fuel rail spacers and 1/4" x 23/8" bolts. Use a thread locking compound on the bolt threads for safety. Make sure that the injectors are seated properly.

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

13A. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED

SYSTEM (1997-99 Dakota/Durango only), cont'd.

D. Thread the supplied plug with an O-ring into

the front of the fuel rail. Thread the 1/4" NPTF O-ring adapter fitting into the rear of the fuel rail. Use light oil on the O-rings.

Do not

overtighten fittings. Thread the 1/4" NPT x 90° fitting into the installed adapter fitting at the rear of the fuel rail (use a small amount of Teflon paste on the pipe threads only. Do not get any paste on the inside of the fuel rail). Rotate the 90° fitting so that the flare portion points down toward the valve cover.

E. Attach the previously installed braided hose to

the 90° fitting on the rail. Make sure that the hose is not twisted after the hose has been

Figure: 13A-b

tightened.

F. From the engine compartment, remove (pull

out) the grommet in the firewall that surrounds the transmission gear select cable. Use a razor blade to carefully slit the grommet and temporarily remove it from the cable.

G. Cut the center of the grommet out to make

room for the vacuum line and harness that must attach to the Vortech SFIC which will be located under the dash (see

Figure 13A-d

H. Mount the Vortech SFIC unit inside the panel

beneath the steering column with the Velcro strips and adhesive pads provided (see

ures 13A-b, 13A-c

Fig-

I. Using the supplied 5/32" TEE, tap into the

previously installed ignition vacuum line. Con-

BYPASS VALVE

Figure: 13A-c

BROWN TO

WHITE WIRE

ON CRANE BOX

RED TO

FUSE BOX

nect the wires and vacuum line for the SFIC. Attach the black wire to ground. Connect the red wire to the interior fuse

MANIFOLD

VACUUM

panel cavity #3 (ABS) with the special mini fuse tap and female connector provided. Route the brown wire, two injector harnesses and vacuum line

(4) #8 X 1/2 SCREW

(2) SUPPLEMENTARY

FUEL INJECTORS

(2) FUEL RAIL

MOUNTING TABS

out into the engine compartment. Connect the brown wire to the negative wire going to the coil (white wire to the Crane ignition

VORTECH

(2) 1/4 X 2-3/8

BOLTS

(2) INJECTOR

RETAINERS

box). Attach the two injector harnesses to the supplementary injectors

TOP VIEW (EXPLODED)

(2) FUEL RAIL

SPACERS

(1) SUPPLEMENTARY

FUEL RAIL

(plugs are interchangeable and reversible). Connect

FRONT VIEW (ASSEMBLED)

the vacuum line to the manifold (TEE into the bypass valve hose).

Figure: 13A-d

SFIC

(Dodge 5.9L Durango/Dak-2)

13B. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED

SYSTEM (1996 Dakota/1996-99 Ram only)

A. Using the four supplied #8 x 1/2" screws,

attach the fuel rail mounting tabs to the supplementary fuel rail in the orientation shown (see

Figure 13B-a)

. Use thread locking compound

on the bolt threads for safety.

B. Lightly oil the O-rings on both ends of the

Fig ure 13B-d

). Make sure that the injectors are inserted straight and are seated firmly into the plenum.

Figure: 13B-a

C. Slide the fuel rail onto the installed fuel injec-

tors. Slowly work the rail over the O-rings being careful not to dislodge or unseat them. Finish mounting the rail to the plenum using the two supplied fuel rail spacers and 1/4" x 2-3/8" bolts. Use a thread locking compound on the bolt threads for safety. Make sure that the injectors are seated properly.

D. Thread the supplied -6 fittings with O-rings into

both ends of the fuel rail. Use light oil on the O- rings. Do not overtighten fittings.

E. Attach the supplied Vortech fuel rail inlet to the

TO FACTORY

FUEL RAIL

FITTING

-6AN TO 1/4

NPT 90° FITTING

front of the rail, such that the line is pointing straight down.

F. Thread the 1/4” NPT x 90° fitting into fuel rail

adapter fitting using a small amount of Teflon paste on the pipe threads. Do not get any paste on the inside of the fuel fitting. Attach one of the braided hose ends to the 90° fitting on the rail and loosely connect the other end to the back of the Vortech fuel rail (see

Figure 13B-b

G. Raise the spring clip, located on the driver’s

side factory fuel rail, and gently remove the

VORTECH FUEL RAIL

INLET LINE

VORTECH

ENGINEERING, INC.

O-RINGS

-6AN TO -6AN FITTINGS

VORTECH ADDITIONAL

INJECTOR RAIL

VORTECH FUEL RAIL

OUTLET LINE

fuel line. Rotate the fuel line 90°, so it is pointing up, and connect it to the spring-lock fitting on the Vortech fuel rail inlet line. Insert the Vortech fuel rail outlet line into the factory

INSERT FACTORY FUEL LINE

Figure: 13B-b

fuel rail and secure it with the spring clip. Tighten the fuel line on the back of the Vortech fuel rail.

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

13B. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED

SYSTEM, cont'd. (1996 Dakota/1996-99 Ram only)

H. From the engine compartment, remove

(pull out) the grommet in the firewall that surrounds the transmission gear select cable. Use a razor blade to carefully slit the grommet and temporarily remove it from the cable.

I. Cut the center of the grommet out to make

room for the vacuum line and harness that must attach to the Vortech SFIC which will be located under the dash (see

13B-d

Figure

J. Remove the panel covering the steering

column. Drill two 1/4” holes as shown in photo. Mount the Vortech SFIC and secure with the supplied 1/4” bolts and nyloc nuts. (See

Figure 13B-c

Figure: 13B-c

K. Using the supplied 5/32" TEE, tap into the

previously installed ignition vacuum line. Connect the wires and vacuum line for the SFIC. Attach the black wire to ground. Connect the red wire to the interior fuse panel cavity #3 (ABS) with the special mini fuse tap and female connector provided. Route the brown wire, two injector harnesses and vacuum line out into the engine compartment. Connect the brown wire to the negative wire going to the coil (white wire to the Crane ignition box). Attach the two injector harnesses to the supplementary injectors (plugs are interchangeable and reversible). Connect the vacuum line to the manifold (TEE into the

BYPASS VALVE

BROWN TO

WHITE WIRE

ON CRANE BOX

RED TO

FUSE BOX

SFIC

bypass valve hose).

MANIFOLD

VACUUM

(Dodge 5.9L Durango/Dak-2)

(4) #8 X 1/2 SCREW

(2) SUPPLEMENTARY

FUEL INJECTORS

VORTECH

TOP VIEW (EXPLODED)

FRONT VIEW (ASSEMBLED)

Figure: 13B-d

(2) FUEL RAIL

SPACERS

(2) FUEL RAIL

MOUNTING TABS

(2) 1/4 X 2-3/8

BOLTS

(2) INJECTOR

RETAINERS

(1) SUPPLEMENTARY

FUEL RAIL

WARNING: Do not attempt to operate the ve-

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

14. FINAL CHECK

A. Reconnect the battery. B. If your vehicle has gone over 10,000 miles

since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

C. Check all fittings, nuts, bolts and clamps

for tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie wraps. (See

ure 14-a

D. Check all fluid levels, making sure that

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

E. Start engine and allow to idle a few min-

utes, then shut off.

F. Recheck to be sure that no hoses, wires,

etc. are near exhaust headers or moving parts and check for signs of any fluid leakage. Check ignition timing to make sure it is set to stock specifications before commencing test drive.

G. PLEASE TAKE SPECIAL NOTE: Oper-

ating the vehicle without

ALL

the subassemblies completely and properly installed may cause FAILURE OF MAJOR COM-

PONENTS.

H. Test drive the vehicle. I. Read the STREET SUPERCHARGER

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

purchasing your supercharger system.

Fig-

Figure: 14-a

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

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

18AUG00 V 2.1

P/N: 4CE020-010

(Dodge 5.9L Durango/Dak-2)

Vortech 1997-2001 5.2L 5.9L Durango Dakota User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual