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 (805) 247-0226

FAX (805) 247-0669 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 (805) 247-0226 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.

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

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.

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

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

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

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

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

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

x

1. COMPONENT REMOVAL

A. Drain sufcient coolant to remove the upper radia-

tor hose and clamps.

B. Disconnect the negative battery cable at the bat-

tery.

C. Remove all ducting between the MAF meter and

the throttle body.

D. Remove the upper fan shroud and the radiator

hose. (If the vehicle has an electric fan, skip to step E.)

E. Remove the accessory drive belt. (Keep in vehicle

as a spare.)

F. Remove the two bolts holding the alternator fus-

ible link junction box and set aside.

NOTE: If necessary, the supercharger can be by-

passed by installing the factory accessory

drive belt in its original conguration.

G. Remove the idler from the cast bracket and set

aside for later use.

H. If the vehicle is equipped with an engine cover that

extends over the valve covers, it may either be removed completely or left in place and trimmed in order to clear the supercharger componentry.

I. Remove the power steering pulley from the

pump.

J. Remove the three bolts securing the front of the

power steering pump.

K. Remove the alternator, bushings and bolts and set

aside for later use. The alternator bushings can be removed by tapping the small end through the bracket with an appropriately sized socket.

L. Remove the alternator and power steering pump

mounting bracket by removing the three bolts securing it to the head and the bottom bolt securing it to the engine block.

M. Remove the valve cover breather hose from the

passenger’s side of the throttle body and cap off the throttle body nipple with supplied 3/8” vacuum cap and secure with a zip-tie.

N. Remove the oil ller neck and cap from the pas-

senger’s side valve cover. Do this by twisting in a counter-clockwise motion. Reinstall the cap directly into the valve cover.

O. 99-03 Models: Locate the factory PCV on the

driver’s side rear of the motor. Pull the PCV valve out and replace it with the supplied PCV.

P/N: 4GL020-010

1

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

2. COMPUTER RELOCATION (2003 5.3L Only)

A. Remove the plastic cover protecting the vehicle

ECM. Unsnap the ECM from the bracket securing it to the inner fender. Temporarily move the ECM to the side to aid in the bracket relocation.

B. Remove the two screws securing both the bat-

tery tray bracket and the upper tab of the ECM

bracket. Remove the nal screw securing the

bottom of the ECM bracket. Remove the ECM bracket from the vehicle.

C. With a grinder, modify the plastic bracket by

removing the strenthening ribs as shown in (Fig.

2‑a). Slight modication of the mounting tab may be necessary for proper t.

D. Using a .25” drill, enlarge the two threaded holes

where the ECM bracket was secured. (See Fig. 2-b.)

E. Put the ECM bracketry back in the vehicle, plac-

ing the mounting tab underneath the original bracket. Place the battery tray mounting bracket back into its stock position. Using the supplied 6mm x 50mm screws, washers, 6mm nuts and spacers, secure the brackets using the original mounting holes that have been enlarged. Use the spacers between the ECM bracket and the inner fender mount to space the ECM bracket down. (See Fig. 2-b.)

F. Secure the ECM to the relocated bracket and

re-install the cover.

RIBS MUST BE REMOVED

Fig. 2-a

BATTERY BRACKET IN STOCK LOCATION

SUPPLIED SPACER

BRACKET IN RELOCATED POSITION

Fig. 2-a

2

3. SUPERCHARGER MOUNTING BRACKET

A. Install the original alternator bushings into the

supercharger mounting bracket with the anged

portion pointed back. (See Figs. 3-a, 3-b.) B. Clean the driver’s side head of debris. C. Bolt the supplied Vortech supercharger mounting

bracket to the head and block using the original

mounting bolts. Make sure the mounting bracket

is seated directly on a machined surface on the

head and that no wires are pinched. D. Tighten the four mounting bolts to 37 ft-lbs (50

N-m). E. Install the two original bolts holding the alterna-

tor fusible link junction box in the supercharger

mounting bracket so that it is in the stock loca-

tion. F. Attach the power steering pump to the Vortech

bracket using the original mounting hardware.

Tighten the four power steering pump bolts to 37

ft-lbs (50 N-m). (One bolt is still loosely inserted

in the engine block.) G. Reinstall the power steering pump pulley. Make

sure that it is seated ush with the end of the

power steering pump shaft. H. Reinstall the alternator using the original hard-

ware. (See Fig. 3-c.) I. Install the factory idler pulley at the location

shown in Fig. 3-c. Spin the idler to verify that the

rotating portion does not contact the alternator

bolt.

Fig. 3-a

Fig. 3-b

Fig. 3-c

P/N: 4GL020-010

3

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

4. SUPERCHARGER INSTALLATION

SUPERCHARGER

COVER

THROTTLE

BODY

ALTERNATOR

VORTECH

MOUNTING

BRACKET

VORTECH SUPPLIED

IDLER

POWER

STEERING

PUMP

PULLEY

CRANK

PULLEY

WATER PUMP

PULLEY

SPRING

TENSIONER

FACTORY IDLER

SUPERCHARGER

PULLEY

*A. Attach the oil drain hose to the supercharger

and tighten the clamp.

B. Loosely install the supercharger onto the Vortech

bracket. Start all ve 3/8‑16 x 2‑1/4” supercharger

mounting screws with washers.

C. Tighten the supercharger mounting screws in a

rotating pattern to 18 ft-lbs (25 N-m).

D. Install the Vortech supplied M12 x 50mm bolt,

dust cover, idler pulley and spacer onto the supercharger cover as shown in Figs. 4-a, 4-b.

E. Install the supplied supercharger/accessory

drive belt per Fig. 4-b.

NOTE: Vehicles equipped with heavy-duty (130 amp) alterna-

tors require the #2A046-140 (114”) belt. All others must use #2A046-113 (113”) belt. Both belts are supplied in the kit.

* Applies to "engine oil-fed" units only. V-3 applications skip this step

Fig. 4-a

Fig. 4-b

4

5. OIL DRAIN LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGER SKIP AHEAD TO STEP 7)

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

necessary to make a hole in the oil pan. Locate and centerpunch the hole per Fig. 5-a. Drill a 1/8” pilot hole at center location.

B. Use the supplied 9/16” rotobroach to drill the

hole in the oil pan. Take care to break through the pan gently and remove the cut out.

C. Pack the utes of a 3/8 NPT tap with grease.

Tap the hole until the tting can be started.

D. Thoroughly clean the threaded area. Reach

inside the oil pan and retrieve any stray chips. Apply a small amount of sealer to the new threads. Apply more sealer to the supplied 3/8” NPT hex nipple and secure in the hole. Make

sure the seal is formed all around the tting.

Install the supplied 90° elbow and 3/8 NPT x

1/2” barb tting pointing forward and slightly

up.

E. Route the oil drain hose from the supercharger

to the barb tting, attach and tighten the hose

clamp. (See Fig. 5-a.)

IMPORTANT!: Oil in the supercharger is gravity

drained to the oil pan. Trim the supplied oil drain hose as necessary so that it is continuously sloping down towards the oil pan. Avoid dips, kinks etc.

OIL DRAIN

Fig. 5-a

P/N: 4GL020-010

5

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

6. OIL FEED LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGER SKIP AHEAD TO STEP 7)

A. Remove the two screws holding the small casting

or oil cooler block located directly above the oil

lter. (Vehicles with oil coolers will appear the

same as depicted in Fig. 6-a.)

B. Using engine oil on the threads, install 1/8”NPT

to #4 x 90° tting into the supplied oil feed

adapter.

C. Using the adapter, the appropriate supplied

gasket and the supplied longer 6mm screws, assemble the components as shown in Fig. 6-a.

D. Install a 1/8”NPT to #4 90° tting into the su-

percharger oil feed lter. Use a small amount

of engine oil on the pipe threads. Pipe sealant

should not be used as it can clog the lter and

damage the supercharger.

E. Route the oil feed line from the supercharger to

the installed tting. Use an adel clamp on the

side of the oil pan and tie wraps to secure the oil feed and oil drain lines and protect them from kinking, abrasion and high heat areas. (See Fig. 6-a.)

F. Drain the engine oil, install a new lter and rell

the engine with fresh oil.

OIL FEED HOSE

ADAPTOR BLOCK

Fig. 6-a

6

7. FUEL INJECTOR REPLACEMENT (1999, 2003 and 2004-06 Models Only/2000-2002 models Go To Step 8)

A. Relieve the fuel system pressure. B. Disconnect the eight fuel injector wiring clips

and retainers from the injectors.

C. Remove the four 10mm bolts holding down the

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

D. Using a small amount of clean motor oil, lightly

lubricate the O-rings on both ends on the Vortech supplied fuel injectors.

E. Install the new injectors and retainers into the

fuel rails with the terminals facing outward.

F. Carefully lower the fuel rail/injector assembly

down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

G. Tighten down the fuel rail assembly with the

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

P/N: 4GL020-010

7

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

3. ATTACH THE SUPPLIEDVACUUM LINE AND TEEINTOTHE FUEL REGULATOR MANIFOLD VACUUM LINE (LINETO BYPASS VALV EWILL BE INSTALLED LATER)

STOCK RETURN LINE

(TO TANK)

STOCK SUPPLY LINE (FROM TANK)

TO BYPASS VA LVE

STOCK MANIFOLD VACUUM LINE (REMOVED FROM FUEL REGULATOR)

FUEL PRESSURE

REGULATOR

ARROWS INDICATE THE

DIRECTION OF FUEL FLOW

F.M.U.

2. AT TACH EACH OF THE FMU LINES TO THEIR RESPECTIVE SNAP

1. REMOVE THIS FITTING FROM THE FUEL REGULATOR RETURN LINE

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

A. Mount the supplied FMU as shown in Fig. 8-a

using the existing studs on the rewall as follows:

1. Remove the nuts securing the factory ground straps.

2. Install the FMU over the studs.

NOTE: Not all vehicles have the studs in the

same location. Drill an additional 1/4” hole in the FMU bracket as required. See Fig. 8-a.

3. Loosely reinstall the nuts on top of the FMU bracket.

B. Disconnect the fuel return line from the fuel rail

and connect the respective lines to their snap connectors on the end of the FMU lines. (See Fig. 8-c.)

NOTE: The fuel tank return line extends from the

fuel regulator to the tank. It is smaller than the fuel rail supply line.

C. Using the supplied 5/32” vacuum line and TEE,

connect the 90° tting on top of the FMU to the

manifold vacuum line connected to the fuel regulator. (See Fig. 8-c.)

Fig. 8-a

Fig. 8-b

Fig. 8-c

8

8.1

FUEL MANAGEMENT UNIT RECALIBRATION (2000 Models, 2002 4.8L Only)

WARNING: For 2000 model year 5.3 & 6.0L

and 2002 4.8L vehicles, complete Section 7 (previous step). Perform this step then proceed with Section 8 in the instruction manual

A. Remo ve the six allen head screws on

top of the fuel management unit (FMU). (See Fig. 8.1-a.)

WARNING: Do not remove the four screws

holding the valve body. Once taken apart the valve would have to be replaced.

B. Remove the diaphram and 10:1 disk (2.47” O.D.)

and ring from inside of the FMU.

C1.

For 2000 5.3L and 2002 4.8L trucks: Install the

replacement 8:1 ring (with notched part facing down) around the four screws inside the FMU. (The 8:1 components are smaller in diameter than their 7:1 counterparts.) Place the 8:1 disk (2.22” O.D.) inside the ring on top of the piston.

C2.

For 2000 6.0L trucks: Install the replacement

12:1 disk (2.72” O.D.) into the FMU.

D. Install the new diaphram and carefully line up

the holes to the body.

E. Reinstall the FMU cover with the six allen head

screws. Do not over-tighten the screws. The correct torque is 24 in/lb (2 ft/lb).

Fig. 8.1-a

P/N: 4GL020-010

9

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

9.

86

IGNITION

RELAY

SIDE VIEW

85

87

30

FUSE TAP

MODIFICATION

BEND UP 90°

IGNITION

RELAY

MODIFIED FUSE TAP

INSTALLED MODIFIED

FUSE TAP

BOTTOM VIEW

RELAY

87

87A

86

85

30

(+)

BATTERY TERMINAL

(+) TERMINAL

ON T-REX FUEL PUMP

GROUND

FUEL PUMP WIRING AND INSTALLATION (All 2000-2002 Models and 2003

6.0L Models Only)

A. Mount the supplied fuel pump relay onto the

FMU bracket as shown in Fig. 9-a.

B. Connect the red 12-gauge wire from terminal #30

to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt to the fuse box power supply terminal as shown in Fig. 9-b. In order to reach the terminals, the fuse box cover must be unsnapped from the base and raised for access. (See Fig. 9-b.)

C. Feed the yellow wire from relay terminal #85 to

the fuse box (electrical center) on the driver’s side of the engine bay. Route the wire to the stock fuel pump relay and connect using the supplied fuse tap. Bend the fuse tap as shown in Fig. 9-c.

D. Run the black wire from terminal #86 on the fuel

pump relay to ground.

E. With the long red 12-gauge wire connected to

the fuel pump relay terminal #87, route the free

end down to the area near the fuel lter on the

driver’s side inner frame rail under the door. Secure as necessary to avoid heat and sharp edges.

Fig. 9-a

RED WIRE FROM VORTECH SUPPLIED

RELAY TERMINAL #30 ATTACHES HERE

YELLOW WIRE FROM VORTECH SUPPLIED

RELAY TERMINAL #85 ATTACHES HERE

Fig. 9-c

Fig. 9-b

Fig. 9-d

10

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

VORTECH FUEL FILTER FITTING (7P625-031) (MAKE SURE THAT THE SUPPLIED O-RING IS INSTALLED AND TIGHTEN THE FITTING)

STOCK FUEL LINE:

DISCONNECT FROM FUEL FILTER AND CONNECT TO FUEL PUMP

DISCHARGE FITTING. VERIFY THA ACTORY O-RING IST THE F

INSTALLED ON THE END OF THE TUBE (BEND AS NECESSARY SO

THAT THE FUEL PUMP WILL MOUNT EASILY ON THE FRAME RAIL)

MARK AND DRILL TWO HOLES.

INSTALL THE SUPPLIED CLAMPS AND

SUPPLIED FUEL PUMP

SUPPLIED FUEL PUMP FITTING:

(VERIFY THAT THE COPPER WASHER

IS INSTALLED AND FITTING IS TIGHT)

VORTECH FUEL PUMP FITTING:

(7P625-030) (VERIFY THAT THE COPPER

WASHER IS INSTALLED AND FITTING IS TIGHT)

STOCK

FUEL

FILTER

STOCK FUEL LINE

FROM TANK

VORTECH SUPPLIED FUEL HOSE (ROUTE AS SMOOTHLYAS POSSIBLE, SECURE WITH ZIPTIES, ATTACH BOTH ENDS TO THE AVAILABLE BARB FITTINGS AND TIGHTEN THE CLAMPS)

2003 6.0L

F. Remove the fuel line from the outlet (front) of

the fuel lter. Remove the tube from the plastic

retainer holding it so that it can be rotated freely. Some models may vary from the photo slightly. Follow the same procedure, taking care to mount the pump so that the hard line is not stressed.

G. Making sure the O-ring is seated on the threaded

end of the supplied tting, install into the outlet (front) of the fuel lter and tighten.

H. Making sure the O-ring is seated on the tube end

of the fuel line (removed from the lter) thread the bump tube into the tting installed on the

outlet of the fuel pump and tighten.

I. Route the free end of the hose connected to the

fuel pump inlet to the tting previously installed on the fuel lter outlet. Use the supplied hose clamp to secure the hose on the barb tting. Try

to make the bends as large as possible, so as to avoid kinking the hose. Secure the hose using the wraps and tighten all of the hose clamps.

J. Install the supplied adel clamps onto the fuel

pump and mark holes to be drilled for #12 sheet metal screws. Drill an 11/64” hole at each location. Using the supplied black 12-gauge wire with yellow ring terminal connectors, install one end under the sheet metal screw nearest the electrical terminal side of the fuel pump. Attach the other end of the ground wire to the (-) terminal of the fuel pump. Secure to the frame as shown in Fig. 9-e. Tighten both adel clamps.

K. Attach the previously routed red wire to the posi-

tive terminal of the fuel pump using the yellow ring terminal connector.

Models Only), cont’d.

Fig. 9-e

and

Fig. 9-f

11

P/N: 4GL020-010

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

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

A. Install the supplied 3-1/2” x 3” sleeve onto the

MAF sensor outlet.

B. Reinstall the upper fan shroud with the exception

of the top two bolts.

C. Remove any plastic clips that are no longer used

to secure the radiator hose.

D. Slide the entry of the large plastic inlet duct (see

Fig. 10-d) into the sleeve installed on the MAF. Lower the inlet duct onto the top of the radiator shroud. Reinstall the factory radiator shroud bolts through the two supplied inlet duct mounting tabs and into their original bolt holes.

E. Insert the supplied 1/4-20 x 1/2” screws through

the bracket and into each side of the inlet duct using the supplied washers. Tighten the screws.

(See Fig. 10-a.)

NOTE: For 2001-2003 6.0L models, a 180° cast

aluminum duct will be in place of the described plastic duct.

F. Install the supplied 180° inlet duct onto the inlet

of the supercharger after the supercharger is installed. Orient the duct so that the inlet is at the same level as the outlet of the large duct just installed. Tighten the supplied T-Bolt hose clamp on the aluminum ring around the supercharger

inlet. Make sure there is sufcient clearance

between the duct and the master cylinder.

G. Install the supplied #52 hose clamps and 3-1/2”

x 9” long ex hose between the two ducts just

installed. (See Fig. 10-b.)

H. Using the supplied 3/8” hose mender, connect

the supplied 3/8” hose from the back of the inlet duct to the passenger side valve cover breather hose. Secure the hose so that it cannot interfere with the throttle arm or cable. (See Fig. 10-c.)

I. Install and tighten the hose clamps on each

connection. (See Fig. 10-d.)

SUPPLIED 3/8”

RUBBER CAP

Fig. 10-b

SUPPLIED

3/8” HOSE

Fig. 10-c

SHROUD BOLT

SUPPLIED DUCT

MOUNTING TABS

(LEFT & RIGHT)

FACTORY

Fig. 10-d

SUPPLIED 1/4-20

HARDWARE

Fig. 10-a

12

10.B INLET DUCT INSTALLATION (2004 - 2006 4.8L / 5.3L Models)

A. Install the supplied 3-1/2” x 3” sleeve onto the

MAF outlet, and the 3-1/2” x 2” sleeve on the inlet of the supercharger.

B. Reinstall the upper fan shroud with the excep-

tion of the top two bolts.

NOTE: If the vehicle is supplied with electric fans

from the factory, refer to Fig. 10.b-a to modify the plastic shrouding for the Vortech supplied brackets to mount.

C. Remove any plastic clips that are no longer

used to secure the radiator hose.

D. Slide the entry of the large plastic inlet duct

(See Fig. 10.B-d) into the sleeve installed on the MAF. Lower the inlet duct onto the top of the radiator shroud. Reinstall the factory radiator shroud bolts through the two supplied inlet duct mounting tabs and into their original bolt holes.

Fig. 10.B-b

E. Insert the supplied 1/4-20 x 1/2” screws through

the bracket and into each side of the inlet duct using the supplied washers. Tighten the screws. (See Fig 10.B-d.)

F. Using Fig. 10.B-b, drill a 9/16” hole in the shown

location. Use a 1/4”NPT tap and install the supplied 1/4” NPT x 3/8” hose barb.

G. Install the supplied 180° inlet duct onto the inlet

of the supercharger. Orient the duct so that it swoops over the side of the supercharger with the end pointing at the crossover duct.

H. Install the supplied #52 hose clamps and 3-1/2”

x 7” long ex hose between the two ducts just

installed. (See Fig. 10.B-b.)

I. Use the supplied 3/8” hose from the 3/8” tting

on the inlet duct to the passenger side valve

Fig. 10.B-c

cover breather hose. Secure the hose so that it cannot interfere with the throttle arm or cable. (See Fig 10.B-c.)

J. Install and tighten the hose clamps on each

connection. (See Fig 10.B-d.)

AREA TO

TRIM

ELECTRIC

FAN

SHROUD

ON BOTH

SIDES

Fig. 10.B-a

SUPPLIED DUCT

MOUNTING TABS

(LEFT & RIGHT)

SUPPLIED

1/4-20

HARDWARE

13

Fig. 10.B-d

P/N: 4GL020-010

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

11 RADIATOR TUBE INSTALLATION

A. Cut the supplied hose as shown in Fig. 11-

a.

B. Using the two original clamps and the two

supplied #24 hose clamps, attach the previously trimmed hose pieces to each end of the supplied radiator tube, radiator and water pump. (See Figs. 11-a, 11-b.)

C. Orient the radiator tube and hoses for best t

and tighten all clamps.

D. Use the supplied adel clamp and 1/4-20 x 1/2”

screw and washer to secure the radiator tube to the insert on the large plastic inlet duct. (See Fig. 11-b.)

E. Rell the coolant reservoir.

TO SUPPLIED RADIATOR TUBE

(TRIM FOR BEST FIT)

TO WATER

PUMP

Fig. 11-a

2” PIECE TRIMMED FROM

SUPPLIED HOSE

Fig. 11-b

14

12. DISCHARGE DUCT INSTALLATION

NOTE: This section only applies to standard

output kits.

A. Install the supplied 2-3/4” sleeve and rubber

elbow onto the cast discharge duct. Put the discharge duct into position and slide the sleeves onto the supercharger and the throttle body.

B. Install and tighten the #64, #48 and the two

#44 hose clamps.

Fig. 12-a

15

P/N: 4GL020-010

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

13. SUPERCHARGER BYPASS VALVE INSTALLATION

5/32" HOSEø

SUPERCHARGER

DISCHARGE TUBE

BYPASS VALV E

AIR INLET

DUCT

A. Connect a 3” length of 1” hose from the barb on

the supercharger inlet duct to the outlet of the bypass valve.

B. Using the supplied #16 hose clamps, connect the

barb on the aluminum discharge duct to the inlet of the bypass valve using the supplied 1” hose. (See Fig. 13-a.)

NOTE: Some vehicles may require trimming of the

engine cover to clear various components. If necessary, trim the cover to clear the bypass valve hose.

C. Install and tighten hose clamps on each connec-

tion.

D. Using the supplied 5/32” vacuum line and TEE

tting, connect the bypass valve pressure port to

the manifold vacuum hose that is connected to the fuel pressure regulator. (See Fig. 8-c.)

E. 2004-2005 Models: Locate the hard plastic line

running to the driver’s side rear of the engine. Remove the hard line from the rubber hose.

F. 2004-2005 Models: Install the supplied 90° PCV

into the rubber hose on the engine.

G. 2004-2005 Models: Cut the hard plastic line to

reach the PCV valve and connect them with the supplied length of 3/8” hose. (See Fig. 13-c.)

H. 2004-2005 Models: Locate the capped-off

manifold vacuum port on the passenger’s side

of the intake manifold. Using a le or hacksaw,

remove the tip of the capped-off section. Using the supplied 5/32” vacuum line connect the bypass valve pressure port. (See Fig. 13-d.)

Fig. 13-b

Fig. 13-c

Fig. 13-a

Fig. 13-d

16

14.A REFLASH COMPUTER, SUPERCHIPS EQUIPPED KITS

2002 4.8L / 2000-2002 5.3L / 2003 6.0L MODELS ONLY

IMPORTANT! To ensure trouble-free programming of your vehicle’s computer:

• Make sure the vehicle’s battery is sufciently charged.

• Turn off all accessories and close doors to prevent unnecessary drain on the battery.

• Do not attempt to program your vehicle while a battery charger is connected.

• Improper battery voltage will result in failure of the programming process.

• Do not disconnect the cable or turn off the ignition during programming.

• Vehicles equipped with “On‑Star”, please refer to the “On‑Star” notice in Section 15.

A. Reconnect the battery. B. Connect the supplied cable to the 9-pin connec-

tor at the top of the hand-held unit. If present use the thumbscrews to secure the cable to the connector.

C. Connect the other end to your ALDL connector

located under the dash near the steering column. Make sure this connection is seated all the way in and that it is secure. You do not want this cable coming out of the connector during programming.

NOTE:•All vehicles equipped with On-star that have

aftermarket stereos will experience problems with the ability to re-program the vehicle’s ECM. It is necessary to diconnect the aftermarket stereo from the facotry wiring harness before continuing with the programming procedure.

•Do not disturb the cable or turn the ignition off during this time. If the programming is distrupted, the computer will not start or run your vehicle!

D. Turn the ignition key to the “on” or “run” position

but do not start the vehicle.

E. To begin programming your vehicle, you may

either press the YES button or the A button. If you press the YES button on the hand-held unit, this will download the Superchips performance program already stored in the hand-held unit. If

you press “A”, you can alter some pre‑dened

options to suit your needs. These options are not permanently stored in the hand-held unit. When power is removed from the unit, the changes you made will be lost.

F. You only need to press the YES button once

to start the programming cycle. The programming process take 1 minute and 15 seconds to complete.

G. The hand-held unit will inform you that the pro-

gramming process has completed and to turn the ignition off and disconnect the cable. Only at this time should the ignition be turned off and the cable removed.

H. Programming is now completed. Start the vehicle

to ensure proper operation.

17

P/N: 4GL020-010

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

14.B REFLASH COMPUTER, DIABLO PREDATOR EQUIPPED KITS

IMPORTANT! To ensure trouble-free programming of your vehicle’s computer:

• All model years up to 2002:

Locate “interior” fuse panel and remove Qty 2 SEO labeled fuses. Locate “exterior” fuse panel ane remove Qty 2 SEO labeled fues.

• 2003‑2005 model year vehicles”

Locate “exterior” fuse panel and remove Qty 1 INFO, Qty 1 RADIO and Qty 1 RADIO AMP labeled fuses.

• Turn off all accessories and close doors to prevent unnecessary drain on the battery.

• Do not attempt to program your vehicle while a battery charger is connected.

• Improper battery voltage will result in failure of the programming process.

• Do not disconnect the cable or turn off the ignition during programming.

NOTE:•AllvehiclesequippedwithOn-starthathaveaftermar-

ket 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 wiring harness before continuing with the programming procedure.

 •Donotdisturbthecableorturntheignitionoffduring

this time. If the programming is disrupted, the computer will not start or run your vehicle!

ESCAPE

A. Reconnect the battery. B. Locate the vehicle’s OBD2 connector lo-

cated in the lower left hand corner of the dash on the driver’s dise of the vehicle.

C. Attach the OBD2 connector from the Flash

tool that is provided in the kit to the vehicle’s OBD2 port. Make sure this connector is seated all the way in the vehicle’s OBD2 port. You don’t want this connector to disconnect during programming or damage may occur to the vehicle’s ECM.

D. The Reash tool should power up and

display three parameters.

• Performance tune

• Diagnostics

• Options

E. Select “performance tune” and press the

enter button in the middle of the arrow keys.

F. Read the disclaimer entirely, then select

agree and press ENTER.

G. At this point please read the screen dis-

played on the reash tool. If you have any

questions, either refer to the manual that

is provided with the reash tool or contact

our service department for futther assistance.

H. Turn the ignition on (do not start the ve-

ENTER

OR

SELECT

Fig. 16.B-a

hicle). Set the parking brake and press the ENTER button to continue.

I. SELECT TUNE will be displayed at the top

of the screen. Use the arrow keys to select the appropriate tune for your vehicle and press the ENTER button. You will have a choice.

J. Continue to follow the screen and when

nished unplug the reash tool form the

vehicles OBD2 port.

ARROWKEYS

18

15. SUPERCHIPS NOTICE (2002 4.8L / 2000-2002 5.3L / 2003 6.0L Only)

Regarding all GM vehicles with “ON-STAR” and Microtuner 2001. It has come to our attention that GM vehicles equipped with “ON-STAR” communications may have trouble being programmed with a Superchips Microtuner 2001. It appears the “ON-STAR” system interrupts communications between the Microtuner 2001 unit and the vehicle’s PCM. In most cases this results in the following message being displayed on the Microtuner 2001 “No response from PCM...” and after cycling the ignition the vehicle can be started right back up.

Superchips is reviewing this and to temporarily correct for this situation, it is recommended that any vehicle to be programmed that has “ON-STAR” should follow these additional steps FIRST.

1. Ensure the vehicle is off and keys are out of the ignition.

All model years up to 2002: Locate “interior” fuse panel and remove Qty 2 SEO

labeled fuses.

Locate “exterior” fuse panel and remove Qty 1 SEO

labeled fuse.

NOTE: 2004 vehicles equipped 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 wiring harness before continuing with the programming procedure.

2003-2004 Model years:

Locate “exterior” fuse panel and remove Qty 1 INFO labeled fuse.

2. Follow the instructions that came with the Microtuner.

Once programming is completed, ensure the vehicle is off and the keys are out of the ingnition and install the fuses in the correct locations.

On GMC trucks, the interior fuse panel should be located to the left of the instrument panel/dash board. If the panel faces the door, open the door to gain full access.

On GMC trucks, the exterior fuse panel should be located under the hood on the right hand side of the vehicle. It will be labeled Fuse Panel or similar.

19

P/N: 4GL020-010

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

16. FINAL ASSEMBLY AND 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 ttings, nuts, bolts and clamps for tight-

ness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie wraps. (See Fig. 16-a.)

D. Check all uid levels, making sure that your

tank(s) is/are lled with 91 octane or higher fuel

before commencing test drive.

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

then shut off.

F. Recheck to be sure no hoses, wires, etc. are

near exhaust headers or moving parts and check

for any sign of uid leakage. Recheck all uid

levels.

G. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without ALL the subassemblies completely and properly installed may cause

FAILURE OF MAJOR COMPONENTS. H. Test drive the vehicle. I. Read the STREET SUPERCHARGER SYSTEM

OWNER’S MANUAL AND RETURN THE WAR-

RANTY REGISTRATION FORM within thirty (30)

days of purchasing your supercharger system

to qualify for the 3 year limited warranty.

Fig. 16.A-a

20

16. FINAL ASSEMBLY AND CHECK, CONT'D

For internally lubricated V3 units only

This supercharger has been factory pre‑lled with special Vortech synthetic lubricant. Oil does not need to be

added to a brand new unit; however a uid level check

should be performed.

Prior to operating the supercharger on the vehicle and after installation onto the vehicle:

Remove the factory installed at‑head brass shipping

plug (not the dipstick) from the top of the supercharger case. Replace the sealed shipping plug with the supplied “vented” plug. Do not operate the supercharger

without it. Check the supercharger uid level.

Fluid level checking procedure:

1. Ensure that the .06” copper sealing washer is located on the dipstick base.

2. Thread the clean dipstick into the supercharger unit it seats.

3. Once the dipstick has seated, remove the dipstick from the unit. Fluid should register in the crosshatched area on the dipstick.

4. DO NOT OVERFILL!!! Drain excess fluid the unit if it is above the maximum level on the dipstick.

Check the uid level using the dipstick at least every

2,500 miles.

Initial supercharger uid change must be performed at 2,500 miles. The supercharger uid must be changed

at least every 7,500 miles.

Drain the uid, rell the unit with 4 oz. of Vortech V3 lubricating uid and then conrm proper oil level using

the dipstick. DO NOT OVERFILL!!!

WARNING: Useofany otheruidother thanthespecial Vortech

lubricant will void the warranty and may cause component failure.

21

P/N: 4GL020-010

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

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

ENGINEERING, LLC

22