Vortech 1999-2006 4.8L 5.3L 6.0L Light Truck SUV User Manual

®

GM 4.8/5.3/6.0L

Light Truck

Supercharger System

Installation Instructions

50 State Smog Legal Per CARB EO #D-213-26

1999-2006 Model Years

ENGINEERING, LLC

1650 PACIFIC AVENUE CHANNEL ISLANDS, CA 93033-9901 [phone]

FAX [phone] www.vortechsuperchargers.com M-F 8:00 AM - 4:30 PM PST

P/N: 4GL020-010 v5.0 10/08/08

FOREWORD

his manual provides information on the installation, maintenance and service of the
Vortech supercharger kit expressly designed for this vehicle. All information, illustra-

T

tions and specifications contained herein are based on the latest product information
available at the time of this publication. Changes to the manual may be made at any time
without notice. Contact Vortech Engineering for any additional information regarding this kit
and any of these modifications at [phone] 8:00am-4:30pm PST.

Take note of the following before proceeding:

1. 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 contact
your dealer or Vortech Engineering for possible installers in your area.

2. This product was designed for use on stock (un-modified, OEM) vehicles. The
PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If
the vehicle or engine has been modified in any way, check with Vortech prior to installa­tion and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no

boost) until the problem is resolved.

5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech warranty coverage considerations include, but not

limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Vortech components with other modifications such as, but not lim-

ited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM program­ming or other such changes.

P/N: 4GL020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated

©2008 VORTECH ENGINEERING, LLC

into another language in any form, by any means without written permission of Vortech Engineering, LLC.

ii

TABLE OF CONTENTS

FOREWORD .............................................................................................................. ii

TABLE OF CONTENTS ............................................................................................. iii

IMPORTANT NOTES ................................................................................................ iv

TOOL & SUPPLY REQUIREMENTS .......................................................................... v

PARTS LISTS

1999 GM 4.8/5.3/6.0L Truck ................................................................................................. vi

2000-2002 GM 4.8/5.3 ..........................................................................................................vii

2001-2003 GM 6.0L Truck ....................................................................................................viii

2003 GM 4.8/5.3 Truck ......................................................................................................... ix

2004-2005 GM 4.8L/5.3L Truck ............................................................................................x

2007 GM 5.3L Truck ............................................................................................................. xi

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

2. COMPUTER RELOCATION (2003 5.3L Only) ..................................................................... 2

3. SUPERCHARGER MOUNTING BRACKET .........................................................................3

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

5. OIL DRAIN LINE ...................................................................................................................5

6. OIL FEED LINE ....................................................................................................................6

7. FUEL INJECTOR REPLACEMENT (1999 and 2003-2007 Models Only)

2000-0002 Models go to step 8 ............................................................................................ 7

8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION (2000-2002 Models Only) .................8

8.1 FMU RECALIBRATION (2000 Models , 2002 4.8L Models Only) ........................................ 9

9. FUEL PUMP WIRING AND INSTALLATION (All 2000-2002 Models and

2003 6.0L Models Only) .......................................................................................................10

10.A INLET DUCT INSTALLATION (‘99-’03 Models) ...................................................................12

10.B INLET DUCT INSTALLATION (2004 4.8L/5.3L Models) ...................................................... 13

11. RADIATOR TUBE INSTALLATION ....................................................................................... 14

12. DISCHARGE DUCT INSTALLATION ................................................................................... 15

13. SUPERCHARGER BYPASS VALVE INSTALLATION ..........................................................16

14.A REFLASH COMPUTER (Superchips) ................................................................................. 17

14.B REFLASH COMPUTER (Diablo Predator) .......................................................................... 18

15. SUPERCHIPS NOTICE ........................................................................................................19

16. FINAL ASSEMBLY AND CHECK ..........................................................................................20

iii

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

P/N: 4GL020-010

1999-2007 GM 4.8/5.3/6.0 Light Truck

IMPORTANT NOTES

2002 4.8L / 2000-2002 5.3L / 2000, 2003-2004 6.0L Models

This kit requires ECM programming. The hand-held ECM programmer is not included
in the kit box and must be ordered directly from Vortech by the installing customer (the
charge for this unit has been included in the purchase price).

Included in this kit is a credit tag for one hand-held programmer. The programmers are

made specically for each individual vehicle with respect to the factory ECM calibration

and VIN. Simply follow the instructions on the hand-held programmer credit tag.

Your ECM hand-held programmer comes with a twelve month limited warranty from
the original date of purchase of your supercharger system (see the Owner’s Manual for
details).

2003-2005 Models: Vehicles with On-star that have aftermarket stereos will experience

problems with the ability to re-program the vehicle’s ECM. It is
necessary to disconnect the aftermarket stereo from the factory
harness before continuing with the programming procedure.

Vortech Engineering is not responsible for engine or ECM damage due to an improperly
installed/mishandled ECM module or ECM.

2003-2007 4.8L / 2003-2004 5.3L / 2001-2002 6.0L Models

This kit requires ECM programming. The hand-held ECM programmer is included in
the kit box.

The ECM hand-held programmer comes with a twelve month limited warranty from
the original date of purchase of our supercharger system. (See the owner’s manual for
details.)

2003-2007: Vehicles with On-star that have aftermarket stereos will experience problems

with the ability to re-program the vehicles’s ECM. It is necessary to disconnect
the aftermarket stereo from the factory harness before continuing with the
programming procedure.

Vortech Engineering is not resposible for engine or ECM damage due to an improperly
installed/mishandled ECM module or ECM.

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, LLC. This product
may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally
or fortuitously, nor shall any design, dimension, or other information be incorporated into
any product or apparatus without prior written consent of Vortech Engineering, LLC.

P/N: 4GL020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

iv

GM 1999-2006 4.8/5.3/6.0 Light Truck

®

ENGINEERING, LLC

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® V-2® Supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Street
Supercharger System Owner’s Manual which includes the Automotive Limited Warranties Program
and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of

30‑35% and horsepower of 35‑45% can be expected with the boost levels specied 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 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modied 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 lter change upon completion of this installation and prior to test driving your ve-
hicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change

the oil and lter every 3,000 miles or less. 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 specied by the manufacturer and reset timing to factory specications

(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 at least 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

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

• 1/2” Socket and Drive Set: SAE & Metric

• 3/8” NPT Tap and Handle

• Adjustable Wrench

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

• Center Punch and a 5/8” Tapered Punch

• Springlock 3/8” and 5/8”Fuel Fitting Disconnect Tool

• 5 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8”, 3/16”, 27/64” Drill Bits

• 1/2” Tube Bender

• 3/16” Allen Wrench

• Wire Strippers and Crimpers

• Utility Knife

• Power Steering Pulley/Puller & Installer

I

f 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

P/N: 4GL020-010

v

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

1999 GM 4.8/5.3/6.0L Truck

®

Part No. 4GL218-030/038SQ

ENGINEERING, LLC

PARTS LIST

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

immediately.

PART NO. DESCRIPTION QTY
2E228-300 V2SQ SC TRIM, GM TRUCK 1

2A036-333 S/C PULLEY 1
2A046-113 BELT, K061130-GATES 1
2A046-140 BELT K061140 GATES 1
7C012-050 12mm x 1.75” x 50mm HXHD BOLT 1
4FA016-171 DUST COVER (IDLER PULLEY) 1
4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1
2A017-462 SPACER, IDLER SMOOTH 6-RIB 1
7A375-224 3/8-16 x 2.25” GR5 HX 5
7J375-044 3/8” SAE WASHER, PLTD 5

4GL011-021 MTG BRKT GM TRUCK 1
4GL130-026 OIL FEED LINE ASSY 1

7P125-026 -4 TO 1/8”NPT 90° MALE 2
7P525-067 .500” CRIMP FERRULES 2
7P250-066 #4 SWIVEL x 1/4” HOSE BARB 2
7U030-026 1/4” OIL FEED HOSE 3.17’
7U100-055 TIE-WRAP, 6” NYLON 2
7C060-050 6mm x 1.0 x 50mm HXHD ZINC PLT 2
7J006-093 6mm WASHER, PLATED 2
4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1

4GL130-036 OIL DRAIN ASSY 1

7P375-017 3/8”NPT x 1/2” BEADED HOSE BAR 1
7P375-040 3/8” FEMALE ELBOW 1
7P375-041 3/8”NPT HEX NIPPLE 1
7R001-008 #8 STNLS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 7/8” 1
7U030-036 1/2” OIL DRAIN HOSE 2.75’

4GL112-010 AIR INTAKE ASSY 1

4FG112-022 PLASTIC INLET DUCT 180° 1
4GL012-010 DUCT, GM TRUCK AIR INLET 1
4GL010-011 INLET DUCT BRKT, DS 1
4GL010-012 INLET DUCT BRKT, PS 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLT 2
7J006-093 6mm WASHER, PLT 2
7P156-082 5/32” TEE 1
7P250-045 1/4” MALE NPT x 3/8” MALE BARB 1
7R002-016 #16 HOSE CLAMP 4
7R002-052 #52 GOLDSEAL HOSE CLAMP 2
7R002-056 #56 GOLDSEAL HOSE CLAMP 3
7S350-200 3-1/2” x 2” SLEEVE 1
7U030-046 5/32” VACUUM LINE 1.5’
7U030-056 3/8” PCV HOSE 2.5’
7U034-016 1” GS HOSE 0.25’
7U034-016 1” GS HOSE 1.5’
7U035-001 3-1/2” FLEX HOSE 0.75’
7U375-052 3/8” VACUUM CAP 1
8D001-001 BYPASS VALVE 1
7P375-050 3/8” HOSEMENDER 1

4GL112-020 DISCH. ASSY GM TRUCK 1

4GL012-020 DUCT, GM TRUCK DISCHARGE 1
4GL012-030 ELBOW, GM TRUCK 3.88” - 3” 90° 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 2
7R002-048 #48 GOLDSEAL HOSE CLAMP 1

PART NO. DESCRIPTION QTY

7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4” x 2” SLEEVE 1

4GL114-010 ASSY, WATER TUBE, GM TRUCK 1

4GL014-010 WATER TUBE, GM TRUCK 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLATED 1
7R002-024 #24 GOLDSEAL HOSE CLAMP 2
7R003-022 ADEL CLAMP, 1-3/8” 2
7U133-125 HOSE, 90° LONG LEG 1

4GL020-020 ECM CHIP PACKAGE GM TRUCK 1
7T560-001 CUTTER, 9/16” ROTOBROACH 1
7T560-002 ARBOR, ROTOBROACH 1
8F060-001 FUEL INJECTOR 8

P/N: 4GL020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

vi

2000-2002 GM 4.8/5.3

®

Part No. 4GL218-010/018SQ

ENGINEERING, LLC

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

mediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

2E228-300 V2SQ SC TRIM, GM TRUCK 1

2A036-333 S/C PULLEY 1
2A046-113 BELT, K061130-GATES 1
2A046-140 BELT K061140 GATES 1
7C012-050 12mm x 1.75” x 50mm HXHD BOLT 1
4FA016-171 DUST COVER (IDLER PULLEY) 1
4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1
2A017-462 SPACER, IDLER SMOOTH 6-RIB 1
7A375-224 3/8-16 x 2.25” GR5 HX 5
7J375-044 3/8” SAE WASHER, PLTD 5

4GL011-021 MTG BRKT GM TRUCK 1
4GL130-026 OIL FEED LINE ASSY 1

7P125-026 -4 TO 1/8”NPT 90° MALE 2
7P525-067 .500” CRIMP FERRULES 2
7P250-066 #4 SWIVEL x 1/4” HOSE BARB 2
7U030-026 1/4” OIL FEED HOSE 3.17’
7U100-055 TIE-WRAP, 6” NYLON 2
7C060-050 6mm x 1.0” x 50mm HXHD ZINC PLT 2
7J006-093 6mm WASHER, PLATED 2
4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1

4GL130-036 OIL DRAIN ASSY 1

7P375-017 3/8”NPT x 1/2” BEADED HOSE BAR 1
7P375-040 3/8” FEMALE ELBOW 1
7P375-041 3/8”NPT HEX NIPPLE 1
7R001-008 #8 STNLS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 7/8” 1
7U030-036 1/2” OIL DRAIN HOSE 2.75’

4GL238-078 FMU ASSY 10:1, W/LINES 1

7U030-046 5/32” x 12” VACUUM LINE 1
7P156-082 5/32” TEE 1
6Z050-191 FMU WASHER, 8:1 1
6Z070-030 FMU 8:1 RING SPACER 1
6Z050-171 FMU WASHER, 12:1 1

4GL101-002 FUEL SYSTEM ASSY 1

7E010-075 #12 x 3/4” SHEET METAL SCREW 2
7P625-030 FTG, GM TRUCK FUEL PUMP 1
7P625-031 FTG, GM TRUCK FILTER 1
7R003-027 ADEL CLAMP, 1-11/16” 2
7U030-050 12mm FUEL HOSE 1MTR
7R001-008 #8 STNLS HOSE CLAMP 2
8F001-002 155 INLINE FUEL PUMP 1
7C010-050 10-24 x 1/2” SOC HD CAP, ZINC PL 1
7F010-024 10-24 NYLOCK NUT 1
7J010-001 #10 FLAT WASHER 2
8F101-320 FUEL PMP RELAY ASSY, GM TRUCK 1
7U100-045 O-RING, .301” 1
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-011 16-14GA EYELET .25” HOLE 1
5W001-025 FEMALE SLIDE, INSULATED, MINI 1
5W001-024 MINI ATC FUSE TAP 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-017 3/8” RING TERMINAL 12GA. 1
5W001-042 12-10GA 3/16” RING TERMINAL 1
5W001-005 3/8” PLASTIC WIRE LOOM 2
5W001-019 SOLDERLESS CONNECTOR 10-12GA 1
5W001-044 TIE-WRAP, 4” NYLON 8
7P375-050 3/8” HOSEMENDER 1

4GL112-010 AIR INTAKE ASSY 1

4FG112-022 PLASTIC INLET DUCT 180° 1
4GL012-010 DUCT, GM TRUCK AIR INLET 1
4GL010-011 INLET DUCT BRKT, DS 1
4GL010-012 INLET DUCT BRKT, PS 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLT 2
7J006-093 6mm WASHER, PLT 2
7P156-082 5/32” TEE 1
7P250-045 1/4” MALE NPT x 3/8” MALE BARB 1
7R002-016 #16 HOSE CLAMP 4
7R002-052 #52 GOLDSEAL HOSE CLAMP 2
7R002-056 #56 GOLDSEAL HOSE CLAMP 2
7S350-200 3-1/2” x 2” SLEEVE 1
7U030-046 5/32” VACUUM LINE 1.5’
7U030-056 3/8” PCV HOSE 2.5’
7U034-016 1” GS HOSE 0.25’
7U034-016 1” GS HOSE 1.5’
7U035-001 3-1/2” FLEX HOSE 0.75’
7U375-052 3/8” VACUUM CAP 1
8D001-001 BYPASS VALVE 1
7P375-050 3/8” HOSEMENDER 1
7R005-001 T-BOLT CLAMP 1

4GL112-020 DISCH. ASSY GM TRUCK 1

4GL012-020 DUCT, GM TRUCK DISCHARGE 1
4GL012-030 ELBOW, GM TRUCK 3.88” - 3” 90° 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 2
7R002-048 #48 GOLDSEAL HOSE CLAMP 1
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4” x 2” SLEEVE 1

4GL114-010 ASSY, WATER TUBE, GM TRUCK 1

4GL014-010 WATER TUBE, GM TRUCK 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLATED 1
7R002-024 #24 GOLDSEAL HOSE CLAMP 2
7R003-022 ADEL CLAMP, 1-3/8” 2
7U133-070 FILLER HOSE 1
7U133-125 HOSE, 90° LONG LEG 1

4GL020-020 ECM CHIP PACKAGE GM TRUCK 1
7T560-001 CUTTER, 9/16” ROTOBROACH 1
7T560-002 ARBOR, ROTOBROACH 1

PARTS LIST

P/N: 4GL020-010

vii

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

2001-2003 GM 6.0L Truck

®

Part No. 4GL218-020/028, 4GL218-040/048SQ

ENGINEERING, LLC

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

mediately.

PART NO. DESCRIPTION QTY

2E228-300 V2SQ SC TRIM, GM TRUCK 1

2A036-333 S/C PULLEY 1
2A046-113 BELT, K061130-GATES 1
2A046-140 BELT K061140 GATES 1
7C012-050 12mm x 1.75” x 50mm HXHD BOLT 1
4FA016-171 DUST COVER (IDLER PULLEY) 1
4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1
2A017-462 SPACER, IDLER SMOOTH 6-RIB 1
7A375-224 3/8-16 x 2.25” GR5 HX 5
7J375-044 3/8” SAE WASHER, PLTD 5

4GL011-021 MTG BRKT GM TRUCK 1
4GL130-026 OIL FEED LINE ASSY 1

7P125-026 -4 TO 1/8”NPT 90° MALE 2
7P525-067 .500” CRIMP FERRULES 2
7P250-066 #4 SWIVEL x 1/4” HOSE BARB 2
7U030-026 1/4” OIL FEED HOSE 3.17’
7U100-055 TIE-WRAP, 6” NYLON 2
7C060-050 6mm x 1.0” x 50mm HXHD ZINC PLT 2
7J006-093 6mm WASHER, PLATED 2
4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1

4GL130-036 OIL DRAIN ASSY 1

7P375-017 3/8”NPT x 1/2” BEADED HOSE BAR 1
7P375-040 3/8” FEMALE ELBOW 1
7P375-041 3/8”NPT HEX NIPPLE 1
7R001-008 #8 STNLS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 7/8” 1
7U030-036 1/2” OIL DRAIN HOSE 2.75’

4GL101-002 FUEL SYSTEM ASSY 1

7E010-075 #12 x 3/4” SHEET METAL SCREW 2
7P625-030 FTG, GM TRUCK FUEL PUMP 1
7P625-031 FTG, GM TRUCK FILTER 1
7R003-027 ADEL CLAMP, 1-11/16” 2
7U030-050 12mm FUEL HOSE 1MTR
7R001-008 #8 STNLS HOSE CLAMP 2
8F001-002 155 INLINE FUEL PUMP 1
7C010-050 10-24 x 1/2” SOC HD CAP, ZINC PL 1
7F010-024 10-24 NYLOCK NUT 1
7J010-001 #10 FLAT WASHER 2

8F101-320 FUEL PMP RELAY ASSY, GM TRUCK 1

7U100-045 O-RING, .301” 1
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-011 16-14GA EYELET .25” HOLE 1
5W001-025 FEMALE SLIDE, INSULATED, MINI 1
5W001-024 MINI ATC FUSE TAP 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-017 3/8” RING TERMINAL 12GA. 1
5W001-042 12-10GA 3/16” RING TERMINAL 1
5W001-005 3/8” PLASTIC WIRE LOOM 2
5W001-019 SOLDERLESS CONNECTOR 10-12GA 1
5W001-044 TIE-WRAP, 4” NYLON 8
7P375-050 3/8” HOSEMENDER 1

4GL112-070 AIR INTAKE ASSY 1

PART NO. DESCRIPTION QTY

4GL112-060 DUCT INLET, ALUM 1
4GL012-010 DUCT, GM TRUCK AIR INLET 1
4GL010-011 INLET DUCT BRKT, DS 1
4GL010-012 INLET DUCT BRKT, PS 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLT 2
7J006-093 6mm WASHER, PLT 2
7P156-082 5/32” TEE 1
7P375-097 3/8”NPT x 3/8” MALE BARB 1
7R002-016 #16 HOSE CLAMP 4
7R002-052 #52 GOLDSEAL HOSE CLAMP 2
7R002-056 #56 GOLDSEAL HOSE CLAMP 4
7S350-200 3-1/2” x 2” SLEEVE 1
7U030-046 5/32” VACUUM LINE 1.5’
7U030-056 3/8” PCV HOSE 2.5’
7U133-045 RUBBER ELBOW 1
7U034-016 1” GS HOSE 1.5’
7U035-001 3-1/2” FLEX HOSE 0.75’
7U375-052 3/8” VACUUM CAP 1
8D001-001 BYPASS VALVE 1
7P375-050 3/8” HOSEMENDER 1
7S350-200 3-1/2” x 2” SLEEVE 1
7R005-001 T-BOLT CLAMP 1

4GL112-020 DISCH. ASSY GM TRUCK 1

4GL012-020 DUCT, GM TRUCK DISCHARGE 1
4GL012-030 ELBOW, GM TRUCK 3.88” - 3” 90° 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 2
7R002-048 #48 GOLDSEAL HOSE CLAMP 1
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4” x 2” SLEEVE 1

4GL114-010 ASSY, WATER TUBE, GM TRUCK 1

4GL014-010 WATER TUBE, GM TRUCK 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLATED 1
7R002-024 #24 GOLDSEAL HOSE CLAMP 2
7R003-022 ADEL CLAMP, 1-3/8” 2
7U133-070 FILLER HOSE 1
7U133-125 HOSE, 90° LONG LEG 1

7T560-001 CUTTER, 9/16” ROTOBROACH 1
7T560-002 ARBOR, ROTOBROACH 1
8F060-005 HIGH-FLOW INJECTORS 8
4GL020-020 2003 6.0L ECM CHIP PACKAGE 1
5A003-037 01-02 6.0L DIABLO PREDATOR 1

PARTS LIST

P/N: 4GL020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

viii

2003 GM 4.8/5.3 Truck

®

Part No. 4GL218-050/058SQ

ENGINEERING, LLC

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

mediately.

2E228-300 V2SQ SC TRIM, GM TRUCK 1
2A036-333 S/C PULLEY 1
2A046-113 BELT, K061130-GATES 1
2A046-140 BELT K061140 GATES 1
7C012-050 12mm x 1.75” x 50mm HXHD BOLT 1
4FA016-171 DUST COVER (IDLER PULLEY) 1
4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1
2A017-462 SPACER, IDLER SMOOTH 6-RIB 1
7A375-224 3/8-16 x 2.25” GR5 HX 5
7J375-044 3/8” SAE WASHER, PLTD 5

4GL011-021 MTG BRKT GM TRUCK 1

4GL130-026 OIL FEED LINE ASSY 1

7P125-026 -4 TO 1/8”NPT 90° MALE 2
7P525-067 .500” CRIMP FERRULES 2
7P250-066 #4 SWIVEL x 1/4” HOSE BARB 2
7U030-026 1/4” OIL FEED HOSE 3.17’
7U100-055 TIE-WRAP, 6” NYLON 2
7C060-050 6mm x 1.0” x 50mm HXHD ZINC PLT 2
7J006-093 6mm WASHER, PLATED 2
4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1

4GL130-036 OIL DRAIN ASSY 1

7P375-017 3/8”NPT x 1/2” BEADED HOSE BAR 1
7P375-040 3/8” FEMALE ELBOW 1
7P375-041 3/8”NPT HEX NIPPLE 1
7R001-008 #8 STNLS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 7/8” 1
7U030-036 1/2” OIL DRAIN HOSE 2.75’
4GL110-010 ASSY, COMPUTER RELOCATION 1
2A017-752-02 SPACER, .750” x .894”LNG 2
7F006-093 6mm NYLOCK NUT 2
7C060-050 M6 x 1.0” x 50 HXHD 2
7J006-093 6mm WASHER 4

4GL112-010 AIR INTAKE ASSY 1

4FG112-022 PLASTIC INLET DUCT 180° 1
4GL012-010 DUCT, GM TRUCK AIR INLET 1
4GL010-011 INLET DUCT BRKT, DS 1
4GL010-012 INLET DUCT BRKT, PS 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLT 2
7J006-093 6mm WASHER, PLT 2
7P156-082 5/32” TEE 1
7P250-045 1/4” MALE NPT x 3/8” MALE BARB 1
7R002-016 #16 HOSE CLAMP 4
7R002-052 #52 GOLDSEAL HOSE CLAMP 2
7R002-056 #56 GOLDSEAL HOSE CLAMP 2
7S350-200 3-1/2” x 2 SLEEVE 1
7U030-046 5/32” VACUUM LINE 1.5’
7U030-056 3/8” PCV HOSE 2.5’
7U034-016 1” GS HOSE 0.25’
7U034-016 1” GS HOSE 1.5’
7U035-001 3-1/2” FLEX HOSE 0.75’
7U375-052 3/8” VACUUM CAP 1
8D001-001 BYPASS VALVE 1
7P375-050 3/8” HOSEMENDER 1
7R005-001 T-BOLT CLAMP 1

4GL112-020 DISCH. ASSY GM TRUCK 1

4GL012-020 DUCT, GM TRUCK DISCHARGE 1
4GL012-030 ELBOW, GM TRUCK 3.88” - 3” 90° 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 2
7R002-048 #48 GOLDSEAL HOSE CLAMP 1
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4” x 2 SLEEVE 1

PART NO. DESCRIPTION QTYPART NO. DESCRIPTION QTY

4GL114-010 ASSY, WATER TUBE, GM TRUCK 1

4GL014-010 WATER TUBE, GM TRUCK 1
7A250-050 1/4-20 x 1/2” SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLATED 1
7R002-024 #24 GOLDSEAL HOSE CLAMP 2
7R003-022 ADEL CLAMP, 1-3/8” 2
7U133-070 FILLER HOSE 1
7U133-125 HOSE, 90° LONG LEG 1
7T560-001 CUTTER, 9/16” ROTOBROACH 1
7T560-002 ARBOR, ROTOBROACH 1

8F060-005 HIGH-FLOW FUEL INJECTORS 8
5A003-036 GM PREDATOR, 03 1

PARTS LIST

P/N: 4GL020-010

ix

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

2004-2005 GM 4.8L/5.3L Truck

®

Part No. 4GL218-120/128SQ

ENGINEERING, LLC

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

parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY
4GL011-021 MOUNTING BRACKET 1
4GL130-026 OIL FEED ASSY, GM TRK 1

4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1
5C060-050 M6 x 1.0 x 50 HXHD ZINC PLATE 2
7J006-093 6mm WASHER, PLATED 2
7P125-026 1/8”NPT x #4 SAE FLARE, 90° 2
7P250-066 -4 45° FEM SWIVEL x 1/4” HOSE 2
7U100-055 TIE-WRAP, 7.5” NYLON 2

4GL130-036 OIL DRAIN ASSY, GM TRK 1

7P375-017 3/8”NPT x 1/2” BEADED HOSE BARB 1
7P375-040 3/8”NPT BRASS FEM/FEM ELBOW 1
7P375-041 3/8”NPT HEX NIPPLE x 1.5” 1
7R001-008 #8 STNLS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 1.0” 1
7U030-036 1/2” OIL DRAIN HOSE 2.75’
7T560-001 CUTTER, 9/16” ROTABROACH 1
7T560-002 ARBOR, ROTABROACH 1

4GL112-050 AIR INTAKE ASSY, ‘04 5.3L GM TRK 1

7S350-200 Ø3.5” x 2” SLEEVE 1
7R002-060 #60 HOSE CLAMP 1
7C060-025 6mm x 25mm HXHD 2
4GL010-011 BRKT, D-SIDE GM TRK AIR INLET 1
4GL010-010R BRKT, GM TRK AIR INLET 1
4GL010-012 BRKT, P-SIDE GM TRK AIR INLET 1
4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1
7A250-050 1/4-20 x .50” SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLATED 2
7P156-082 5/32 TEE 1
7P250-045 1/4” MALE NPT x 3/8” MALE BARB 1
7P375-050 3/8” HOSE UNION, BRASS 1
7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4
7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2
7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 3
7S350-300 SLEEVE, 3-1/2” x 3”, BLUE 1
7U030-046 5/32” VACUUM LINE 2.5’
7U030-056 3/8 PCV/VAC RUBBER HOSE 3.5’
7U034-016 1” GS HEATER HOSE .25’
7U035-001 3-1/2” FLEX HOSE .75’
7U375-052 3/8” VACUUM CAP 1
8D001-001 BYPASS VALVE 1
7U133-045 RUBBER ELBOW, Ø1” x 45° 1
7U033-000 5/8” PCV HOSE .16’
7P375-113 PCV VALVE, VIPER, 3/8” - 1/2” BA 1
4PGL012-017 DUCT, S/C INLET, ‘03 ESCALADE 1

4GL112-020 DISCH ASSY, GM TRUCK STD 1

4GL012-020 DUCT, DISCH 5.3 GM TRUCK 1
4GL012-030 ELBOW, 3.88” - 3.0” x 90° GM TRK 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 2
7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 1
7R002-064 #64 SAE TYPE “F” SS HOSE CLAMP 1
7S275-200 SLEEVE, Ø2.75” x 2.00”, BLUE 1

4GL114-010 WATER TUBE ASSY, GM TRUCK 1

4GL014-018 WATER TUBE, GM TRUCK POLISHED 1
7A250-050 1/4-20 x .50” SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLATED 1
7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2
7R003-022 ADEL CLAMP 1-3/8” 1
7U133-125 HOSE, Ø1.25” 90° LONG LEG 1

4GL020-010 INSTALL MANUAL GM TRUCK ‘99-’05 1

2E228-300 V2SQ SC TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY 3.33” 6-GRV 1
7U100-070 KEY, 3/16” SQUARE x 7/8” LONG 1
2A040-011 PULLEY RETAINER S/C 1
7B375-110 3/8-24 x 1” GRADE 8 HXHD 1
7K375-040 3/8”AN960 FLAT WASHER PLATED 1
2A046-113 BELT, K061130-GATES 1
7A375-224 3/8-16 x 2.25” GR5 HX 5
7J375-044 3/8” SAE WASHER, PLTD 5
7C012-050 M12 x 1.75” x 50mm HXHD BOLT 1
4FA016-171 DUST COVER (IDLER PULLEY) 1
4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1
2A017-462 SPACER, IDLER SMOOTH 6-RIB 1
2A046-140 BELT, GATES K061140 1

4GL110-010 ASSY, COMPUTER RELOC ‘03 LS1 TR 1

2A017-752-02 SPACER, .750”OD x .894” LONG 2
9AL6061-750 Ø.750” 6061 ALUMINUM ROD 1
7C060-050 M6 x 1.0” 50 HXHD ZINC PLATE 2
7F006-093 6mm NYLOCK NUT 2
7J006-093 6mm WASHER, PLATED 4

8P060-005 FUEL INJECTOR, GM 8.1 MARINE 8
5A003-034 04-05 GM PREDATOR 1

PARTS LIST

P/N: 4GL020-010
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

x