Vortech 2003-2004 Chevrolet SS User Manual

®

2001-2002, 2004, 2006 Denali,

GM 6.0L

2002-2004 Escalade SUV,

2003-2008 H2 Hummer and

2003-2004 Chevrolet SS

Supercharger System

Installation Instructions

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

ENGINEERING, LLC

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: [phone]

Fax: [phone] • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

DP/N: 4GL020-015 - v5.0 10/08/08

FOREWORD

STOP

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 limit-

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

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

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 LIST (2001-2002 Denali/2002 Escalade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

PARTS LIST (2003 Escalade/SS) ..............................................viii

PARTS LIST (2003 H2 Hummer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

PARTS LIST (2004-2007 H2 Hummer) .......................................... xii

PARTS LIST (2004 Escalade/SS Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

PARTS LIST (2004, 2006 Denali H.O.) ..........................................xv

PARTS LIST (2008 H2 Hummer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

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

2. COMPUTER RELOCATION (All H2 Hummers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3. SUPERCHARGER MOUNTING BRACKET ...................................4

4. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

5. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

6. OIL DRAIN LINE ........................................................7

7. OIL FEED LINE .........................................................8

8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION ('01-'02 Denali/Escalade Only) . . .9

9. BRAKE BOOSTER LINE MODIFICATION (2002 Escalade Only) . . . . . . . . . . . . . . . . 10

10. VACUUM PUMP/BRAKE LINE RELOCATION ('03-04 5.3/SS Truck,

Vehicles Equipped with adjustable pedals only) ...............................11

11.A FUEL PUMP WIRING AND INSTALLATION ('01-'03 Escalade/Denali/SS) . . . . . . . . . 12

11.B FUEL PUMP WIRING AND INSTALLATION, (2003 H2 Hummer) . . . . . . . . . . . . . . . . 14

12.A ESCALADE/DENALI INLET DUCT INSTALLATION ('01-'02 Models) ..............16

12.B ESCALADE/DENALI/SS INLET DUCT INSTALLATION ('03-'06 Models) ...........17

12.C H2 HUMMER INLET DUCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

12.D 2008 H2 HUMMER INLET DUCT INSTALLATION .............................19

13. RADITOR TUBE INSTALLATION (DENALI/ESCALADE/SS ONLY) . . . . . . . . . . . . . . . 21

14. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

15. SUPERCHARGER BYPASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

16.A ESCALADE/DENALI/SS SURGE AND RESERVOIR TANK INSTALLATION . . . . . . . . 26

16.B H2 HUMMER SURGE AND RESERVOIR TANK INSTALLATION .................27

17.A ESCALADE/DENALI/SS HEAT EXCHANGER INSTALLATION ...................28

17.B H2 HUMMER HEAT EXCHANGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

17.C 2008 H2 HUMMER GRILL INSERT REMOVEL ...............................30

18.A ESCALADE/DENALI/SS CHARGE COOLER HOSE ROUTING ..................31

18.B H2 HUMMER CHARGE COOLER HOSE ROUTING ...........................32

19. WATER PUMP WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

20. REFLASH COMPUTER (All 2004, 2006 Denali Models & 2005-2007

Models see page 36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

21. SUPERCHIPS NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

22. REFLASH COMPUTER, (2004, 2006 Denali & all 2005-2007 Model Year) .........37

23. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

©2008 Vortech Engineering, LLC

iii

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2001-2002, 2004, 2006 GMC Denali/

2002-2004 Cadillac Escalade/

2003-2008 H2 Hummer

2003-2004 Chevrolet SS

IMPORTANT NOTES

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

'04-'06 Models: Vehicles equipped with On-star that have aftermarket

stereos will experience problems with the ability to re­program the vehicle’s ECM. It is necessary to discon­nect the aftermarket stereo from the wiring harness
before continuing with the programming procedure.

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. 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.

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

iv

GM 2001-2002, 2004, 2006 Denali/2002-2004

®

ENGINEERING, LLC

Cadillac Escalade/

2003-2008 H2 Hummer/2003-2004 SS Truck

50 State Legal Per CARB EO D-213-25* (2007-2008 Models NOT 50-State Legal.)

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 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 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 modified in any way, check with Vortech prior to using this product.

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

problem is resolved.

5. Perform an oil and filter change upon completion of this installation and prior to test driving
your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality syn­thetic, and change the oil and filter 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 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 at least every 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 En gine
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

• 3/8" Tube Bender

• 3/16" Allen Wrench

• Wire Strippers and Crimpers

• Utility Knife

• Power Steering Pulley/Puller & Installer

• Pliers

• Power steering pulley installer/puller

If your vehicl e has in excess of 10,000
miles since it s last spark plug change,
then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

©2008 Vortech Engineering, LLC

v

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2001-2002 Denali/2002 Escalade

®

Part No. 4GL218-060/068SQ

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 PART NO. DESCRIPTION QTY

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY, 3.33" - 6-GRV 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 M12-1.75 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|
4GL011-021 MTG BRKT 1

4GL130-026 OIL FEED LINE ASY 1

7P125-026 -4 x 1/8"NPT x 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

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HOSE BARB 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'
4GL238-068 FMU ASY 8:1, w/LINES 1
7U030-046 5/32" x 12" VACUUM LINE 1
7P156-082 5/32" TEE 1

4GL101-002 FUEL SYSTEM ASY 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 1M
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 ASY, GM TRUCK 1

7U100-045 O-RING, Ø.301" 1
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-011 16-14GA EYELET Ø.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 ASY 1

7P156-082 5/32" TEE 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 4
7S350-300 3-1/2" x 3" SLEEVE 1
7U030-046 5/32" VACUUM LINE 1.5'
7U030-056 3/8" PCV/VAC RUBBER HOSE 2
7U034-016 1" GS HOSE 0.33'
7U035-001 Ø3-1/2" FLEX HOSE 1.16'
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
4GL010-011 BRKT, D-SIDE GM TRK AIR INLET 1
4GL010-012 BRKT, P-SIDE GM TRK AIR INLET 1

7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLTD 2
7P375-050 3/8" HOSE UNION, BRASS 1
7S350-200 3-1/2" x 2" SLEEVE 1
7U133-045 RUBBER ELBOW, Ø1" x 45° 1
4PGL012-061 INLET DUCT, MACH H.O. LS1 TRK 1
4GL012-010 DUCT, VORTECH, INLET GM TRK I
7P625-375 REDUCER, 5/8" BARB TO 3/8" BARB 1
9BR100-001 Ø1.00" BRASS ROD 2.3225"
7U033-000 Ø5/8" PCV HOSE 0.16'

4GL114-010 WATER TUBE ASY, GM TRK 1

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

4PGL112-020 DISCH. ASY 1

4GL012-030 ELBOW, 3.88" - 3.0" x 90° LS1 TRK 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 5
7R002-048 #48 GOLDSEAL HOSE CLAMP 2
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4" x 2" SLEEVE 2
4GL012-040 DISCH TUBE “A”, 6.0 COOLER POL 1
4GL012-050 DISCH TUBE “B”, 6.0 COOLER POL 1
7S300-275 REDUCER, Ø3.00" - Ø2.75" 1
4GL114-010 ASY, WATER TUBE, 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
8F060-001 FUEL INJECTORS, 8.1 8
4PGL120-020 ECM CHIP PACKAGE GM TRUCK 1
7T560-001 CUTTER, 9/16" ROTOBROACH 1
7T560-002 ARBOR, ROTOBROACH 1

8N106-050 WATR COOLR ASY 1

8N006-010 WATER COOLER 1
7P500-026 1/2"NPT.x 3/4" BARB 90° 2
4GL010-080 BRKT “A”, WATER COOLER 1
4GL010-090 BRKT “B”, WATER COOLER 1
4GL010-100 BRKT “C”, WATER COOLER 1
7A250-075 1/4-20 x 3/4" SHCS PLTD 8
7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 8
7J250-001 1/4"SAE WASHER, PLTD 16

8N105-040 WATER TANK ASY, 1

7U038-000 3/4" HEATER HOSE 19
7R007-001 NYLON CLAMP 1-1/8" 12
8N055-030 TANK, LT1 AFTERCOOLER 1
7P500-026 1/2"NPT x 3/4" BARB.x 90° 2
7U100-055 TIE-WRAP, 6" NYLON 6
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" 1
7U030-065 3/4" x 90° HOSE SHORT 1
7P375-075 3/4" HOSE BARB UNION, BRASS 1
4GL010-060 BRKT, WATER TANK, COOLER 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4
7J250-001 1/4"SAE WASHER, PLTD 4
8N056-060 SURGE TANK, PLASTIC 1
8N055-050 PLASTIC CAP, SURGE TANK 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 2
4GL010-070 BRKT, SURGE TANK, COOLER 1

8N107-050 WATER PUMP ASY, 1

8F001-402 PUMP, WATER 1
7R003-027 ADEL CLAMP, 1-11/16" 1
5W001-025 FEM SLIDE, INSULATED MINI 1
5W001-043 12-10GA x 1/4" RING TERMINAL 3

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

vi

2001-2002 Denali/2002 Escalade, cont’d

®

Part No. 4GL218-060/068SQ

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

7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
5W001-013 14-16AWG, SOLDERLESS 4
5W001-019 SOLDERLESS CONNECTOR 10-12 2
7U100-044 TIE-WRAP, 4" NYLON 4
5W001-022 T-TAP CONN, 14-16AWG 1
7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-005 3/8" PLASTIC WIRE LOOM 2
5W001-014 FUSE HOLDER 10GA WIRE 1
7U100-055 TIE-WRAP, 6" NYLON 6
5W001-041 12-10GA MALE SLIDE 2

8F101-320 FUEL PUMP RELAY ASY 1

8N201-078 PWR COOLER ASY. 1
8N101-118 WELDED CORE ASY. 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7P500-026 1/2"NPT 3/4" BARB x 90° 1
7U250-200 TAPE, FOAM 1/4" x 2" x 50' 1

4GL010-050 BRKT, COOLER CORE SUPPORT 1

4GL114-010 WATER TUBE ASY 1

8N201-070 POWER COOLER ASY 1

8N101-110 WELDED CORE ASY, V-10 S.D. 1
8N101-001 WELDED CORE ASY, w/ENDS ONLY 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7P500-026 1/2"NPT x 3/4" BARB, 90° BRASS 1
7U250-200 TAPE, FOAM-1/4" x 2" x 50' 1
4GL010-050 BRKT, COOLER CORE SUPPORT 1
2A017-875-13 SPACER, .875"OD x .895"LONG 1
9AL6061-0875 Ø7/8" 6061 ALUMINUM ROD 1
7C010-040 M10-1.5 x 40 HXHD CL8.8 ZN 1
7J010-002 10mm WASHER, ZINC PLTD 1
4GL238-068 FMU ASY 8:1 1

4GL238-068 FMU ASY, 8:1 5/16", GM TRK 1

4GPL110-110 '03 5.3L VACUUM PUMP RELOCATION 1

4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1
4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1
7P500-009 1/2" x 90°, HOSE BARB UNION 1
7P500-001 1/2" HOSE UNION 2
7U030-050 12mm (1/2/") FUEL HOSE 0.55m
7U030-050 12mm (1/2/") FUEL HOSE 0.48m
7U133-500 1/2" x 90°, MOLDED RUBBER HOSE 1
7A312-075 5/16-18 x 3/4" HXCS GR5 ZINC 4
7F312-017 5/16-18 NYLOCK NUT 4
7J312-000 5/16" FLAT WASHER-SAE 8

©2008 Vortech Engineering, LLC

vii

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2003 Escalade/SS

®

Part No. 4GL218-080/088SQ

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 PART NO. DESCRIPTION QTY

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY, 3.33" - 6-GRV 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 M12-1.75 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
4GL011-021 MTG BRKT 1

4GL130-026 OIL FEED LINE ASY 1

7P125-026 -4 x 1/8"NPT x 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

4GL130-036 OIL DRAIN ASY 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'
4GL238-068 FMU ASY 8:1, w/LINES 1
7U030-046 5/32" x 12" VACUUM LINE 1
7P156-082 5/32" TEE 1

4GL101-002 FUEL SYSTEM ASY 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 1M
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 ASY, GM TRUCK 1

7U100-045 O-RING, Ø.301" 1
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-011 16-14GA EYELET Ø.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

4GL112-080 AIR INTAKE ASY, LS1 H.O. TRK 1

7P156-082 5/32" TEE 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 4
7S350-300 3-1/2" x 3" SLEEVE 1
7U030-046 5/32" VACUUM LINE 2
7U030-056 3/8" PCV/VAC RUBBER HOSE 2
7U034-016 1" GS HEATER HOSE 0.33'
7U035-001 3-1/2" FLEX HOSE 1
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
4GL010-012 BRKT, P-SIDE GM TRK AIR INLET 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLATED 2
7P375-050 3/8" HOSE UNION, BRASS 1
7S350-200 3-1/2" x 2" SLEEVE 1

7U133-045 RUBBER ELBOW, Ø1" x 45° 1
4PGL012-017 DUCT, S/C INLET, '03 ESCALADE 1
4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1
7P375-097 3/8"NPT x 3/8" BEADED HOSE BARB 1

4GL114-010 WATER TUBE ASY, GM TRK 1

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

4PGL112-020 DISCH. ASY 1

4GL012-030 ELBOW, 3.88" x 3.0" x 90° LS1 TRK 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 5
7R002-048 #48 GOLDSEAL HOSE CLAMP 2
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4" x 2" SLEEVE 2
4GL012-040 DISCH TUBE “A”, 6.0 COOLER POL 1
4GL012-050 DISCH TUBE “B”, 6.0 COOLER POL 1
7S300-275 REDUCER, Ø3.00" x Ø2.75" 1
4GL114-010 ASY, WATER TUBE, 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
8F060-001 FUEL INJECTORS, 8.1 8
4PGL120-020 ECM CHIP PACKAGE GM TRUCK 1
7T560-001 CUTTER, 9/16" ROTOBROACH 1
7T560-002 ARBOR, ROTOBROACH 1

8N106-050 WATR COOLR ASY 1

8N006-010 WATER COOLER 1
7P500-026 1/2"NPT x 3/4" BARB x 90° 2
4GL010-080 BRKT “A”, WATER COOLER 1
4GL010-090 BRKT “B”, WATER COOLER 1
4GL010-100 BRKT “C”, WATER COOLER 1
7A250-075 1/4-20 x 3/4" SHCS PLTD 8
7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 8
7J250-001 1/4"SAE WASHER, PLTD 16

8N105-040 WATER TANK ASY, 1

7U038-000 3/4" HEATER HOSE 19
7R007-001 NYLON CLAMP 1-1/8" 12
8N055-030 TANK, LT1 AFTERCOOLER 1
7P500-026 1/2"NPT x 3/4" BARB x 90° 2
7U100-055 TIE-WRAP, 6" NYLON 6
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" 1
7U030-065 3/4" x 90° HOSE SHORT 1

P/N: 4GL020-015

P/N: 4GL020-015

©2008 Vortech Engineering, LLC

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

All Rights Reserved, Intl. Copr. Secured

10MAR08 GM Trk/H2(4GL..015v4.0)

08OCT08 GM Trk/H2(4GL..015v5.0)

viii

2003 Escalade/SS, cont’d

®

Part No. 4GL218-080/088SQ

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

7P375-075 3/4" HOSE BARB UNION, BRASS 1
4GL010-060 BRKT, WATER TANK, COOLER 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4
7J250-001 1/4"SAE WASHER, PLTD 4
8N056-060 SURGE TANK, PLASTIC 1
8N055-050 PLASTIC CAP, SURGE TANK 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 2
4GL010-070 BRKT, SURGE TANK, COOLER 1

8N107-050 WATER PUMP ASY, 1

8F001-402 PUMP, WATER 1
7R003-027 ADEL CLAMP, 1-11/16" 1
5W001-025 FEM SLIDE, INSULATED MINI 1
5W001-043 12-10GA x 1/4" RING TERMINAL 3
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
5W001-013 14-16AWG, SOLDERLESS 4
5W001-019 SOLDERLESS CONNECTOR 10-12 2
7U100-044 TIE-WRAP, 4" NYLON 4
5W001-022 T-TAP CONN, 14-16 AWG 1
7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-005 3/8" PLASTIC WIRE LOOM 2
5W001-014 FUSE HOLDER 10GA WIRE 1
7U100-055 TIE-WRAP, 6" NYLON 6
5W001-041 12-10GA MALE SLIDE 2
8F101-320 FUEL PUMP RELAY ASY. 1
8N201-078 PWR COOLER ASY. 1
8N101-118 WELDED CORE ASY. 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7P500-026 1/2"NPT x 3/4" BARB, 90° 1
7U250-200 TAPE, FOAM 1/4" x 2" x 50' 1
4GL010-050 BRKT, COOLER CORE SUPPORT 1

4GL114-010 WATER TUBE ASY 1

8N201-070 POWER COOLER ASY 1

8N101-110 WELDED CORE ASY, V-10 S.D. 1
8N101-001 WELDED CORE ASY, w/ENDS ONLY 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 1
7U250-200 TAPE, FOAM-1/4" x 2" x 50' 1
4GL010-050 BRKT, COOLER CORE SUPPORT 1
2A017-875-13 SPACER, .875"OD x .895" LONG 1
9AL6061-0875 Ø7/8" 6061 ALUMINUM ROD 1
7C010-040 M10-1.5 x 40 HXHD CL8.8 ZN 1
7J010-002 10mm WASHER, ZINC PLTD 1

4PGL110-115 '03 5.3L VACUUM PUMP RELOCATION 1

4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1
4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1
7P500-009 1/2" x 90°, HOSE BARB UNION 1
7P500-001 1/2" HOSE UNION 2
7U030-050 12mm (1/2/") FUEL HOSE 0.55m
7U030-050 12mm (1/2/") FUEL HOSE 0.48m
7U133-500 1/2" x 90°, MOLDED RUBBER HOSE 1
7A312-075 5/16-18 x 1.00" HXCS GR5 ZINC 4
7F312-017 5/16-18 NYLOCK NUT 4
7J312-000 5/16" FLAT WASHER-SAE 8

©2008 Vortech Engineering, LLC

ix

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2003 H2 Hummer

®

Part No. 4GL218-070/078SQ

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 PART NO. DESCRIPTION QTY

8F060-005 8.1L INJECTORS 8

4809639 INSTR. MANUAL DENALI/ESCALADE/HUMMER 1

4GL011-021 MTG BRKT GM TRUCK MACH. 1

2E228-390 V2SQ S-TRIM LS1 TRK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1

4GL112-040 AIR INLET ASY, H2 HUMMER 1

4GL012-015 DUCT, INLET, HUMMER H2 TRK 1
7P156-082 5/32" TEE 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 4
7S350-300 3-1/2" x 3" SLEEVE 1
7U030-046 Ø5/32" VACUUM LINE 1
7U030-056 Ø3/8" PVC/VAC RUBBER HOSE 2
7U034-016 Ø1" GS HOSE 0.33'
7U035-001 Ø3-1/2" FLEX HOSE 0.83'
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
4PGL010-011 BRKT, D-SIDE H2 TRK AIR INLET 1
4PGL010-012 BRKT, P-SIDE H2 TRK AIR INLET 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLTD 2
7P375-050 3/8" HOSE UNION, BRASS 1
4PGL012-061 INLET DUCT, MACH H.O. LS1 TRK 1
7S350-200 3-1/2" x 2" SLEEVE 1
7U133-045 RUBBER ELBOW, Ø1" x 45° 1
7C060-050 M6-1.0 x 50mm HXHD ZINC PLTD 2
7J250-150 1/4" FENDER WASHER ZN PLTD 2
7F006-093 6mm NYLOCK NUT 2
2A017-752-02 SPACER, .750"OD x .894"LONG 2
7P625-375 REDUCER, 5/8" BARB x 3/8" BARB 1
7U033-000 5/8" PVC HOSE 0.16'
7S300-275 REDUCER, Ø3.00" x Ø2.75" 1

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HOSE BARB 1
7P375-040 3/8" FEMALE ELBOW 1
7P375-041 3/8"NPT HEX NIPPLE 1
7R001-008 #8 STAINLESS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 1.0" 1
7U030-036 Ø1/2" OIL DRAIN HOSE 2.75'
7T560-001 CUTTER, 9/16" ROTABROACH 1
7T560-002 ARBOR, ROTABROACH 1

4PGL130-026 OIL FEED ASY 1

7U100-055 TIE-WRAP, 6" NYLON 2
7C060-050 M6 x 1.0" x 50 HXHD ZINC PLATE 2
7J006-093 6mm WASHER PLTD 2
4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1
7U250-400 OIL FEED HOSE, 40" -4 x 90° 1
7P125-005 1/8"NPT STR x -4 JIC FTG 1
7P125-004 1/8"NPT x 90° JIC FTG 2

4PGL101-001 FUEL PUMP ASY 1

7P250-047 1/4"NPT to 3/8" BARB x 90° 1
7P312-002 5/16" BARB x 1/4"NPT FEM 1
7R004-002 STEPLESS CLAMP, 17.0-70 4
7R004-001 STEPLESS CLAMP, 15.7-70 2
7U031-018 Ø5/16" EFI FUEL HSE HI-PSR 1.25'
7U032-016 Ø3/8" EFI FUEL HSE HI-PSR .167'
7U032-016 Ø3/8" EFI FUEL HSE HI-PSR .5'
7U100-044 TIE-WRAP, 4" NYLON 10
7U100-055 TIE-WRAP, 6" NYLON 10
8F001-500 PUMP, FUEL, “PRO-FLO 500” 1
7U033-010R HOSE, 5/8"ID p/STEERING RET 2

5W001-042 12-10GA x 3/16" RING TERMINAL 3
7P375-072 3/8" FEMALE FUEL FTG, STEEL 1
7P625-375 REDUCER, 5/8" BARB x 3/8" BARB 1
7P375-010 3/8" GM FUEL x 3/8" BARB FTG 1
7F012-001 M12 CAP HEX NUT, FUEL PUMP 1
7R003-028 ADEL CLAMP, 2-3/8" x .26" HOLE 2
7P312-015 FTNG, BANJO 12mm x .312" BARB 1
7R004-004 STEPLESS CLAMP, 1.0"OD HOSE 2
7E010-075 #12 x 3/4" SHT METAL SCRW, HEX 3
5W012-000 12GA STRD WIRE, RED 15'
5W001-040 12-10GA FEMALE SLIDE INSULATED 1
5W012-010 12GA WIRE, BLACK .5'
7R003-008 ADEL CLAMP, 1/2"ID 2
8F101-320 RELAY ASY, LS1 TRK 1

8N107-050 WATER PUMP ASY. 1

8F001-402 WATER PUMP 1
7R003-027 ADEL CLAMP 1-11/16" 1
5W001-025 FEMALE SLIDE MINI 1
5W001-043 12-10GA x 1/4" RING TERMINAL 3
7A250-050 1/4-20 x .50" SHCS 2
5W001-013 14-16GA BUTT-CONNECTORS 4
5W001-019 12-10GA BUTT-CONNECTORS 2
7U100-044 4" TIE-WRAPS 4
5W001-022 T-SPLICE CONNECTOR 1
7F250-021 1/4-20 NYLOCK NUT 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-005 3/8" PLASTIC WIRE LOOM 2
5W001-014 FUSE HOLDER 10GA WIRE 1
7U100-055 TIE-WRAP, 6" NYLON 6
5W001-041 12-10GA MALE SLIDE INSULATED 2
8F101-320 WATER PUMP RELAY ASY, LS1 TRK 1

8N105-050 WATER TANK ASY 1

8N055-030 LT1 WATER TANK 1
7P500-026 90° BARBED BRASS FITTING 2
4PGL010-060 BRKT “A” 1
4PGL010-070 BRKT “B” 1
4PGL010-080 BRKT “C” 1
7A250-102 1/4-20 x 1" SHCS 1
7J250-022 1/4" WASHER 6
7F250-021 1/4-20 NYLOCK NUT 1
8N056-060 SURGE TANK 1
8N055-050 SURGE TANK CAP 1
4PGL010-090 BRKT, SURGE TANK 1
7P500-078 12"NPT x 3/4" HOSE FIT 2
7U038-020 MOLDED “S” HOSE 1
7A250-050 1/4-20 x .5" SHCS 4
7U038-000 Ø3/4" HEATER HOSE 10
7U033-000 Ø5/8" HOSE 5
7P750-625 3/4-5/8" REDUCER BARB 2
7E010-075 #12 x 3/4" SHT METAL SCRW HEX 4
7U030-065 90° MOLDED ELBOW SHORT 1
7J010-001 #10 FLAT WASHER 2
7R002-020 #20 HOSE CLAMP 2
7R007-002 NYLON CLAMPS 7/8" 4
7R007-001 NYLON CLAMPS 1-1/8" 10

8N201-078 POWER COOLER ASY 1

8N101-118 WELDED CORE ASY V-10 S.D. 1
7P500-078 1/2"NPT x 3.4" HOSE FIT 1
7P500-026 1/2"NPT x 3/4" HOSE BARB 90° 1
2A017-875-13 SPACER, CAC BRKT 1
7C010-040 10mm-1.5 x 1.5mm SCREW 1
7J010-002 10mm WASHER 1
7U250-200 COOLER FOAM 1
4GL010-050 COOLER REST BRACKET 1

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

x

2003 H2 Hummer, con't

®

Part No. 4GL218-070/078SQ

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 PART NO. DESCRIPTION QTY

4PGL112-028 DISCH ASY 1

4GL012-041 6.0 TUBE “A” 1
4GL012-051 6.0 TUBE “B” 1
4GL012-030 ELBOW, 3.88 x 3.0" x 90° LS1 TRK 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 5
7R002-048 #48 GOLDSEAL HOSE CLAMP 2
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4" x 2" SLEEVE 2
7S300-275 Ø3.00" x Ø2.75" REDUCER SLEEVE 1

8N106-075 WATER COOLER ASY 1

8N006-005 WATER COOLR, SETRAB DUAL-PASS 1
7A250-102 1/4-20 x 1" SHCS SS 4
7J250-022 1/4" WASHER SAE STAINLESS 8
7F250-021 1/4-20 NYLOCK NUT, ZINC PLT 2
8N010-140 MTG TAB, SETRAB 2-PASS COOLR 4
7P375-075 3/4" HOSE BARB UNION, BRASS 3
7U125-200 TAPE, FOAM, 1/8" x 2" x 50' 7.5"
7U038-020 HOSE, Ø3/4" “S” MOLDED RUBBER 2
7R007-001 NYLON RATCHET CLAMP, 1-1/8" 4

©2008 Vortech Engineering, LLC

xi

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2004-2007 H2 Hummer

®

Part No. 4GL218-090/098SQ (2004 Models)

Part No. 4GL218-150/158SQ (2005-2007 Models)

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 PART NO. DESCRIPTION QTY

8F060-005 8.1L INJECTORS 8

4809639 INSTR. MANUAL DENALI/ESCALADE/HUMMER 1

4GL011-021 MTG BRKT GM TRUCK MACH. 1

2E228-390 V2SQ S-TRIM LS1 TRK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1

4GL112-040 AIR INLET ASY, H2 HUMMER 1

4GL012-015 DUCT, INLET, HUMMER H2 TRK 1
7P156-082 5/32" TEE 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 4
7S350-300 3-1/2" x 3" SLEEVE 1
7U030-046 5/32" VACUUM LINE 1
7U030-056 3/8" PVC/VAC RUBBER HOSE 2
7U034-016 Ø1"GS HOSE 0.33'
7U035-001 Ø3-1/2" FLEX-HOSE 0.83'
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
4PGL010-011 BRKT, D-SIDE H2 TRK AIR INLET 1
4PGL010-012 BRKT, P-SIDE H2 TRK AIR INLET 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLTD 2
7P375-050 3/8" HOSE UNION, BRASS 1
4PGL012-061 INLET DUCT, MACH H.O. LS1 TRK 1
7S350-200 3-1/2" x 2" SLEEVE 1
7U133-045 RUBBER ELBOW, Ø1" x 45° 1
7C060-050 M6-1.0 x 50mm HXHD ZINC PLTD 2
7J250-150 1/4" FENDER WASHER ZN PLTD 2
7F006-093 6mm NYLOCK NUT 2
2A017-752-02 SPACER, .750"OD x .894"LONG 2
7P625-375 REDUCER, Ø5/8" BARB TO Ø3/8" BARB 1
7U033-000 Ø5/8" PVC HOSE 0.16'
7S300-275 REDUCER, Ø3.00" x Ø2.75" 1
7U033-000 Ø5/8" PCV HOSE .16'
7P375-113 PCV VALVE, VIPER, 3/8" x 1/2" BA 1
7U375-056 Ø3/8" PCV/VAC RUBBER HOSE .25'

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HSE BRB 1
7P375-040 Ø3/8" FEMALE ELBOW 1
7P375-041 3/8"NPT HEX NIPPLE 1
7R001-008 #8 STAINLESS HOSE CLAMP 2
7R003-016 ADEL CLAMP, 1.0" 1
7U030-036 Ø1/2" OIL DRAIN HOSE 2.75'
7T560-001 CUTTER, 9/16" ROTABROACH 1
7T560-002 ARBOR, ROTABROACH 1

4PGL130-026 OIL FEED ASY 1

7U100-055 TIE-WRAP, 6" NYLON 2
7C060-050 M6-1.0 x 50mm HXHD ZINC PLATE 2
7J006-093 6mm WASHER PLTD 2
4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 1
4GL010-040 GASKET, 5.3 OIL ADAPTER 1
7U250-400 OIL FEED HOSE, 40" x -4 x 90° 1
7P125-005 1/8"NPT STR x -4 JIC FTG 1
7P125-004 1/8"NPT x 90° x JIC FTG 2

8N107-050 WATER PUMP ASY 1

8F001-402 WATER PUMP 1
7R003-027 ADEL CLAMP 1-11/16" 1
5W001-025 FEMALE SLIDE MINI 1
5W001-043 12-10GA x 1/4" RING TERMINAL 3
7A250-050 1/4-20 x .50" SHCS 2
5W001-013 14-16GA BUTT CONNECTORS 4

5W001-019 12-10GA BUTT CONNECTORS 2
7U100-044 4" TIE-WRAPS 4
5W001-022 T-SPLICE CONNECTOR 1
7F250-021 1/4-20 NYLOCK NUT 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-005 3/8" PLASTIC WIRE LOOM 2
5W001-014 FUSE HOLDER 10GA WIRE 1
7U100-055 TIE-WRAP, 6" NYLON 6
5W001-041 12-10GA MALE SLIDE INSULATED 2
8F101-320 WATER PUMP RELAY ASY, LS1 TRK 1

8N105-050 WATER TANK ASY 1

8N055-030 LT1 WATER TANK 1
7P500-026 90° BARBED BRASS FITTING 2
4PGL010-060 BRKT “A” 1
4PGL010-070 BRKT “B” 1
4PGL010-080 BRKT “C” 1
7A250-102 1/4-20 x 1" SHCS 1
7J250-022 1/4" WASHER 6
7F250-021 1/4-20 NYLOCK NUT 1
8N056-060 SURGE TANK 1
8N055-050 SURGE TANK CAP 1
4PGL010-090 BRKT, SURGE TANK 1
7P500-078 12"NPT x 3/4" HOSE FIT 2
7U038-020 MOLDED “S” HOSE 1
7A250-050 1/4-20 x .5" SHCS 4
7U038-000 Ø3/4" HEATER HOSE 10"
7U033-000 Ø5/8" HOSE 5"
7P750-625 Ø3/4" x Ø5/8" REDUCER BARB 2
7E010-075 #12 x 3/4" SHT METAL SCRW HEX 4
7U030-065 90° MOLDED ELBOW SHORT 1
7J010-001 #10 FLAT WASHER 2
7R002-020 #20 HOSE CLAMP 2
7R007-002 NYLON CLAMPS 7/8" 4
7R007-001 NYLON CLAMPS 1-1/8" 10

8N201-078 POWER COOLER ASY 1

8N101-118 WELDED CORE ASSEMBLY V-10 S.D. 1
7P500-078 1/2"NPT x 3.4" HOSE FIT 1
7P500-026 1/2"NPT x 3/4" HOSE BARB x 90° 1
2A017-875-13 SPACER, CAC BRKT 1
7C010-040 10mm-1.5" x 1.5mm SCREW 1
7J010-002 10mm WASHER 1
7U250-200 COOLER FOAM 1
4GL010-050 COOLER REST BRACKET 1

4PGL112-028 DISCH ASY 1

4GL012-041 6.0 TUBE “A” 1
4GL012-051 6.0 TUBE “B” 1
4GL012-030 ELBOW, 3.88" - 3.0" x 90° LS1 TRK 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 5
7R002-048 #48 GOLDSEAL HOSE CLAMP 2
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4" x 2" SLEEVE 2
7S300-275 3.00" x 2.75" REDUCER SLEEVE 1

8N106-075 WATER COOLER ASY 1

8N006-005 WATER COOLR, SETRAB DUAL-PASS 1
7A250-102 1/4-20 x 1" SHCS SS 4
7J250-022 1/4" WASHER SAE STAINLESS 8
7F250-021 1/4-20 NYLOCK NUT, ZINC PLT 2
8N010-140 MTG TAB, SETRAB 2-PASS COOLR 4
7P375-075 3/4" HOSE BARB UNION, BRASS 3
7U125-200 TAPE, FOAM, 1/8" x 2" x 50' 7.5"
7U038-020 HOSE, Ø3/4" “S” MOLDED RUBBER 2
7R007-001 NYLON RATCHET CLAMP, 1-1/8" 4

4GL020-020 MTUNER CREDIT TAG (2004 MODEL YEAR) 1

5A003-034 DIABL0 PREDATOR (2003-2007 MODEL YEAR) 1

* It is recommended that you use the K061140 drive belt.

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

xii

2004 Escalade/SS Truck

®

Part No. 4GL218-130/138SQ

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 PART NO. DESCRIPTION QTY

4GL011-021 MOUNTING BRACKET MACH 1

4PGL130-026 OIL FEED ASY, ESCALADE 1

4GL010-020 ADAPTOR, ESCALADE OIL FEED 1
4GL130-030 GASKET, ESCALADE OIL ADAPTER 2
7C060-050 M6-1.0 x 50mm HXHD ZINC PLATE 2
7J006-093 6mm WASHER, PLATED 2
7P125-004 1/8"NPT 90° x -4 JIC FTG STL 2
7P125-005 1/8"NPT STR, x -4 JIC FTG STL 1
7U100-055 TIE-WRAP, 7.5" NYLON 2
7U250-090-400 OIL FEED HOSE, 40" x -4 x 90° 1

4GL130-036 OIL DRAIN ASY, GM TRK 1

7P375-017 3/8"NPT x 1/2" BEADED HSE BRB 1
7P375-040 3/8"NPT BRASS REM/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
7T560-001 CUTTER, 9/16" ROTABROACH 1
7T560-002 ARBOR, ROTABROACH 1

4GL112-080 AIR INT ASY, LS1 H.O. TRK 1

4GL010-011 BRKT, DRIVER’S SIDE SM TRK AIR INLET 1
4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1
4GPL012-017 DUCT, S/C INLET, '03 ESCALADE 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLATED 2
7P156-082 5/32" TEE 1
7P375-050 3/8" HOSE UNION, BRASS 1
7P375-097 3/8"NPT x 3/8" BEADED HOSE BARB 1
7P375-106 PCV VALVE, FORD, 3/8" HOSE 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 4
7S350-200 SLEEVE, 3-1/2" x 2", BLUE 1
7S350-300 SLEEVE, 3-1/2" x 3", BLUE 1
7S030-046 5/32" VACUUM LINE 1
7U030-056 3/8" PCV/VAC RUBBER HOSE 2
7U034-016 1" GS HEATER HOSE 0.33'
7U035-001 3-1/2" FLEX HOSE 1
7U133-045 RUBBER ELBOW, Ø1" x 45° 1
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
7U030-056 Ø3/8" PCV/VAC RUBBER HOSE 0.25'
7P375-113 PCV VALVE, VIPER, 3/8" x 1/2" BA 1

4PGL112-020 DISCH ASY, LS1 H.O. TRUCK 1

4GL012-030 ELBOW, 3.88" x 3.0" x 90° GM TRUCK 1
4GL012-040 DISCH TUBE “A”, 6.0 COOLER, CAST 1
4GL012-051 DISCH TUBE “B”, 6.0 COOLER 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 5
7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 2
7R002-064 #64 SAE TYPE “R” SS HOSE CLAMP 1
7S275-200 SLEEVE, Ø2.75" x 2.00"L, BLUE 2
7S300-275 REDUCER, Ø3.00" x Ø2.75" 1

4GL114-010 WATER TUBE ASY, GM TRUCK 1

4GL014-018 WATER TUBE, GM TRUCK, POLISHED 1
2A250-050 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" x 90° LONG LEG 1

2E228-390 V2SQ S-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
7A040-011 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
7A250-037 1/4-20 x .375" SHCS PLTD 6
7U100-023 DRIVE SCREW, 34 x 1/4" 2
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 M12-1.75 x 50mm HXHD BOLT 1
4F016-171 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

8N201-070 PWR COOLER ASY, GMT LS1 H.O. 1

2A017-875-13 SPACER, .875"OD x .895" LONG 1
4GL010-050 BRKT, COOLER CORE SUPPORT 1
7C010-040 M10-1.5 x 40mm HXHD CL8.8 ZN 1
7J010-002 10mm WASHER, ZINC PLATED 1
7P500-026 1/2"NPT x 3/4" BARB 90° BRASS 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7U250-200 TAPE, FOAM-1/4" x 2" x 50' 12"
8N101-110 WELDED CORE ASY, V-10 S.D. 1

8N107-050 WATER PUMP ASY, GMT LS1 H.O. 1

5W001-005 3/8" PLASTIC WIRE LOOM 5'
5W001-009 16-14GA MALE SLIDE INSULATED 1
5W001-013 14-16AWG, SOLDERLESS CONNECTOR 4
5W001-014 FUSE HOLDER, 10GA 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-019 10-12GA BUTT CONNECTOR, INSULATED 2
5W001-022 T-TAP CONNECTOR, 14-16AWG 1
5W001-024 MINI ATC FUSE TAP 1
5W001-041 12-10GA MALE SLIDE, INSULATED 2
5W001-043 12-10GA x 1/4" RING TERMINAL 3
2A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7F250-021 1/4-20 NYLOCK NUT, ZINC PLATED 1
7R003-027 ADEL CLAMP, 1-11/16" 1
7U100-044 TIE-WRAP, 4" NYLON 4
7U100-055 TIE-WRAP, 7.5" NYLON 6

8F001-402 PUMP, WATER, PIERBURG 1

8F101-320 FUEL PUMP RELAY ASY, LS1 TRK 1
5W001-010 16-14GA FEMALE SLIDE, INSULATED 2
5W001-016 RELAY, BOSCH 1
5W001-040 12-10GA FEMALE SLIDE, INSULATED 2
5W001-042 12-10GA x 3/16" RING TERMINAL 2
5W012-000 12GA, STRD WIRE, RED 9'
5W012-000 12GA, STRD WIRE, RED 1.5'
5W012-010 12GA, WIRE, BLACK 0.5'
5W014-030 14GA STRD WIRE, BLACK 0.5'

©2008 Vortech Engineering, LLC

xiii

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2004 Escalade/SS Truck, cont’d

®

Part No. 4GL218-130/138SQ

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

N105-040 WATER TANK ASY, GMT LS1 H.O. 1

4GL010-060 BRKT, WATER TANK, COOLER 1
4GL010-070 BRKT, SURGE TANK, COOLER 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4
7J250-001 1/4" WASHER, SAE PLTD 4
7P375-075 3/4" HOSE BARB UNION, BRASS 1
7P500-026 1/2"NPT x 3/4" BARB x 90°, BRASS 3
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 3
7r007-001 NYLON RATCHET CLAMP, 1-1/8" 12
7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1
7U038-000 Ø3/4" HEATER HOSE 19'
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1
7U100-055 TIE-WRAP, 7.5" NYLON 6
8N055-030 WATER TANK, TRIANGLE SHAPE 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N056-060 SURGE TANK, PLASTIC 1

8N106-050 WATER COOLER ASY, GMT LS1 H.O. 1

4GL010-080 BRKT “A”, WATER COOLER MOUNT 1
4GL010-090 BRKT “B”, WATER COOLER MOUNT 1
4GL010-100 BRKT “C”, WATER COOLER MOUNT 1
7A250-075 1/4-20 x 3/4" SHCS PLTD 8
7F250-021 1/4-20 NYLOCK NUT, ZINC PLATED 8
7J250-001 1/4" WASHER, SAE, PLTD 16
7P500-026 1/2"NPT x 3/4" BARB, 90° BRASS 2
8N006-010 WATER COOLER, SETRAB SINGLE PAS 1

4PGL110-110 '03 5.3L ESCALADE VACPMP RELOC 1

4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1
4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1
7A312-075 5/16-18 x 3/4" HXCS GR5 ZINC 4
7F312-017 5/16-18 NYLOCK NUT 4
7J312-000 5/16" FLAT WASHER, SAE 8
7P500-001 1/2" HOSE UNION 2
7P500-009 1/2" x 90° HOSE BARB UNION 1
7U030-050 12mm (1/2") FUEL HOSE .55m
7U030-050 12mm (1/2") FUEL HOSE .48m
7U133-500 1/2" x 90° MOLDED RUBBER HOSE 1

8F060-005 FUEL INJECTOR, GM 8.1 MARINE 8

4GL020-015 INSTALL MANUAL, H2/ESCAL/DENALI 01-0 1

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

xiv

2004, 2006 Denali H.O. Kit

®

Part No. 4GL218-140/148SQ

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 PART NO. DESCRIPTION QTY

4GL218-140SQ '04, '06 DENALI H.O. KIT SAT 1

4GL011-021 MOUNTING BRACKET - MACH 1

4PGL130-026 OIL FEED ASY, ESCALADE 1

4GL010-020 ADAPTER, ESCALADE OIL FEED 1
4GL010-030 GASKET, ESCALADE OIL ADAPTER 2
7C060-050 M6 x 1.0 x 50 HXHD ZINC PLATE 2
7J006-050 6mm WASHER, PLATED 2
7P125-004 1/8"NPT x 90° x -4 JIC FTG STL 2
7P125-005 1/8"NPT STR. x -4 JIC FTG STL 1
7U100-055 TIE-WRAP, 7.5" NYLON 2
7U250-400 OIL FEED HOSE, 40" -4 x 90° 1

4GL130-036 OIL DRAIN ASY, 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'

4GL112-080 AIR INT ASY, '03 LS1 H.O. TRK 1

4GL010-011 BRKT, DSIDE GM TRK AIR INLET 1
4GL010-012 BRKT, PSIDE GM TRK AIR INLET 1
4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1
4PGL012-017 DUCT, S/C INLET, '03 ESCALADE 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLATED 2
7P156-082 5/32" TEE 1
7P375-050 3/8" HOSE UNION, BRASS 1
7P375-097 3/8"NPT x 3/8" BEADED HOSE BARB 1
7P375-106 PCV VALVE, FORD, 3/8" HOSE 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 4
7S350-200 SLEEVE, 3-1/2" x 2", BLUE 1
5S350-300 SLEEVE, 3-1/2" x 3", BLUE 1
7U030-046 5/32" VACUUM LINE 2'
7U030-056 3/8" PCV/VAC RUBBER HOSE 2.5'
7U034-016 1" GS HEATER HOSE 0.33'
7U035-001 3-1/2" FLEX HOSE 1.16'
7U375-045 RUBBER ELBOW, Ø1" x 45° 1
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
7U030-056 3/8" PCV/VAC RUBBER HOSE 0.25'
7F375-113 PCV VALVE, VIPER, 3/8-1/2" BA 1

4PGL112-020 DISCH ASY LS1 H.O. TRUCK 1

4GL112-030 ELBOW, 3.88 x 3.0" x 90° GM TRK 1
4GL012-040 DISCH TUBE “A”, 6.0 COOLER, CAST 1
4GL012-051 DISCH TUBE “B”, 6.0 COOLER 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 5
7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 2
7R002-064 #64 SAE TYPE “F” SS HOSE CLAMP 1
7S275-200 SLEEVE, Ø2.75" x 2.00"L, BLUE 2
7S300-275 REDUCER, 3.00" x 2.75" 1

4GL114-010 WATER TUBE ASY, GM TRUCK 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" x 90° LONG LEG 1
2E228-390 V2SQ S-TRIM LS1 TRUCK 1
2A036-333 S/C PULLEY 3.33" 6-GRV 1
4FH016-150 IDLER, PULLEY, 6-RIB 3" FLANGED 1
2A017-462 SPACER, IDLER SMOOTH 6-RIB 1
2A046-140 BELT, 6-RIB x 114.00 EFFECT. L 1

8N201-070 PWR COOLER ASY, GMT LS1 H.O. 1

2A017-875 SPACER, .875"OD x .895"L
4GL010-050 BRKT, COOLER CORE SUPPORT 1
7C010-040 M10-1.5 x 40mm HXHD CL8.8 ZN 1
7J010-002 10mm WASHER, ZINC PLATED 1
7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7U250-200 TAPE, FOAM, 1/4" x 2" x 50' 12"
8N101-110 WELDED CORE ASY. V-10 S.D. 1
5W001-005 3/8" PLASTIC WIRE LOOM 5'
5W001-009 16-14GA MALE SLIDE INSULATED 1
5W001-013 14-16GS BUTT CONN BLU INSUL 4
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-015 FUSE, BLADE TYPE, 20AMP 1
5W001-019 10-12AGA BUTT CONN INSULATED 2
5W001-022 T-TAP CONN, 14-16 AWG 1
5W001-024 MINI ATC FUSE TAP 1
5W001-041 12-10GA MALE SLIDE INSULATED 2
5W001-043 12-10GA x 1/4" RING TERMINAL 3
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7F250-021 1/4-20 NYLOCK NUT, ZINC PLATED 1
7R003-027 ADEL CLAMP, 1-11/16" 1
7U100-044 TIE-WRAP, 4" NYLON 4
7U100-055 TIE-WRAP, 7.5" NYLON 6
8F001-402 PUMP, WATER, PIERBURG 1
5W001-010 16-14GA FEMALE SLIDE INSULATED 2
5W001-016 RELAY, BOSCH 1
5W001-002 FUSE TAP 1

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY 3.33" 6-GROOVE 1
2A046-140 BELT, 6-RIB x 114.00 EFFECT. L 1
2A046-113 BELT, 6-RIB x 112.89 EFFECT. L 1
4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 1
2A017-462 SPACER, IDLER SMOOTH, 6-RIB 1

8N201-070 PWR COOLER ASY, GMT LS1 H.O. 1

2A017-875-13 SPACER, .875"OD x .895"LONG 1
7C010-040 M10-1.5 x 40mm HXHD CL8 .8 ZN 1
7J010-002 10mm WASHER, ZINC PLATED 1
7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1
7U250-200 TAPE, FOAM, 1/4" x 2" x 50' 12"
8N101-110 WELDED CORE ASY, V-10 S.D. 1

©2008 Vortech Engineering, LLC

xv

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

2004, 2006 Denali H.O. Kit, con't

®

Part No. 4GL218-140/148SQ

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 PART NO. DESCRIPTION QTY

8N107-050 WATER PMP ASY, GMT LS1 H.O. 1

5W001-005 3/8" PLASTIC WIRE LOOM 5'
5W001-005 16-14GA, MALE SLIDE INSULATED 1
5W001-013 14-16GA BUTT CONN BLU INSUL 4
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-015 FUSE, BLADE TYPE 20-AMP 1
5W001-019 10-12GA BUTT CONN INSULATED 2
5W001-022 T-TAP CONN. 14-16AWG 1
5W001-024 MINI ATC FUSE TAP 1
5W001-041 12-10GA MALE SLIDE INSULATED 2
5W001-043 12-10GA x 1/4" RING TERMINAL 3
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7F250-021 1/4-20 NYLOCK NUT, ZINC PLTD 1
7R003-027 ADEL CLAMP, 1-11/16" 1
7U100-044 TIE-WRAP, 4" NYLON 4
7U100-055 TIE-WRAP, 7.5" NYLON 6
8F001-402 WATER PUMP, PIERBURG 1
8F101-320 FUEL PUMP RELAY ASY, LS1 TRK 1
5W001-010 16-14GA FEMALE SLIDE, INSULATED 2
5W001-016 RELAY, BOSCH 1
5W001-002 FUSE TAP 1
4GL010-060 BRKT, WATER TANK, COOLER 1
4GL010-070 BRKT, SURGE TANK, COOLER 1
7A2500-050 1/4-20 x .50" SHCS ZINC PLTD 4
7J250-001 1/4" WASHER, SAE, PLTD 4
7P375-075 3/4" HOSE BARB UNION, BRASS 1
7P500-026 1/2"NPT x 3/4" BARB 90° BRASS 3
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 3
7R007-001 NYLON RATCHET CLAMP 1-1/8" 12
7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1
7U038-000 3/4" HEATER HOSE 19'
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1
7U100-055 TIE-WRAP, 7.5" NYLON 6
8N055-030 WATER TANK, TRIANGLE SHAPE 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N056-060 SURGE TANK, PLASTIC 1
2A017-875-08 SPACER, .875"OD x .290"LONG 2
4GL010-080 BRKT, “A”, WATER COOLER MOUNT 1
4GL010-090 BRKT “B”, WATER COOLER MOUNT 1
4GL010-100 BRKT “C”, WATER COOLER MOUNT 1
7A250-075 1/4-20 x .75" SHCS PLTD 8
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 8
7J250-001 1/4" WASHER, SAE PLTD 16
7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 2
8N006-010 WATER COOLER, SETRAB SINGLE PASS 1

008341 VORTECH CHARGE COOLER DECAL 1
4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1
4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1

7A312-075 5/16-18 x 3/4" HHCS, GR5, ZINC 4
7F312-017 5/16-18 NYLOCK NUT 4
7J312-000 5/15" FLAT WASHER, SAE 8
7P500-001 1/2" HOSE UNION 2
7P500-009 1/2" x 90° HOSE BARB UNION 1
7U030-050 12mm (1/2") FUEL HOSE .55M
7U030-050 12mm (1/2") FUEL HOSE .48M
7U133-500 1/2" x 90° MOLDED RUBBER HOSE 1

8N105-040 WATER TANK ASY, GMT LS1 H.O. 1

4GL010-060 BRKT, WATER TANK, COOLER 1
4GL010-070 BRKT, SURGE TANK, COOLER 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4
7J250-001 1/4" WASHER, SAE PLTD 4
7P375-075 3/4" HOSE BARB UNION, BRASS 1
7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 3
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 3
7R007-001 NYLON RATCHET CLAMP 1-1/8" 12
7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1
7U038-000 3/4" HEATER HOSE 19'
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1
7U100-055 TIE-WRAP, 7.5" NYLON 6
8N055-030 TANK, WATER, TRIANGLE SHAPE 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N056-060 SURGE TANK, PLASTIC 1
2A017-875-08 SPACER, .875"OD x .290"L 2

8N106-050 WATER COOLR ASY, GMT LS1 H.O. 1

4GL010-080 BRKT “A”, WATER COOLER MOUNT 1
4GL010-090 BRKT “B”, WATER COOLER MOUNT 1
4GL010-100 BRKT “C”, WATER COOLER MOUNT 1
7A250-075 1/4-20 x .75" SHCS PLTD 8
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 8
7J250-001 1/4" WASHER, SAE, PLATED 16
7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 2
8N006-010 WATER COOLER, SETRAB SINGLE PASS 1
0088341 VORTECH CHARGE COOLER DECAL 1

4PGL110-110 '03 5.3"L ESCALADE VACPMP RELOC 1

4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1
4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1
7A312-075 5/16-18 x 3/4" HHCS, GR5, ZINC 4
7F312-017 5/16-18 NYLOCK NUT 4
7J312-000 5/16" FLAT WASHER-SAE 8
7P500-001 1/2" HOSE UNION 2
7P500-009 1/2" x 90° HOSE BARB UNION 1
7U030-050 12mm (1/2") FUEL HOSE .55M
7U030-050 12mm (1/2") FUEL HOSE .48M
7U133-500 1/2" x 90° MOLDED RUBBER HOSE 1

5A003-034 DIABLO PREDATOR, '04-'06 GM 1

8F060-005 FUEL INJECTOR, GM 8.1 MARINE 8

4GL020-015 INSTALL MANUAL H2/ENC/DEN '01-'05 1

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

xvi

2008 H2 Hummer, V-3

®

Part No. 4GL218-330/338L

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 PART NO. DESCRIPTION QTY

4GL011-021 MTG BRKT GM TRUCK MACH. 1

2F328-040 V-3 SI-TRIM LS1 TRK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1

4GL112-090 AIR INLET ASY, 2008 H2 HUMMER 1

4GL012-090 DUCT, INLET, 2008 HUMMER H2 1

7P156-082 5/32" TEE 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 4
7U030-046 5/32" VACUUM LINE 1
7U030-056 3/8" PVC/VAC RUBBER HOSE 2
7U034-016 Ø1"GS HOSE 0.33'
7U035-001 Ø3-1/2" FLEX-HOSE 0.83'
7U375-052 3/8" VACUUM CAP 1
8D001-001 STD COMPRESS BYPASS VALVE 1
4PGL010-011 BRKT, D-SIDE H2 TRK AIR INLET 1
4PGL010-012 BRKT, P-SIDE H2 TRK AIR INLET 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2
7J006-093 6mm WASHER, PLTD 2
7P375-050 3/8" HOSE UNION, BRASS 1
7S350-200 3-1/2" x 2" SLEEVE 1
7U133-045 RUBBER ELBOW, Ø1" x 45° 1
7C060-050 M6-1.0 x 50mm HXHD ZINC PLTD 2
7J250-150 1/4" FENDER WASHER ZN PLTD 2
7F006-093 6mm NYLOCK NUT 2
2A017-752-02 SPACER, .750"OD x .894"LONG 2
7P275-133 PCV VALVE, VIPER, 3/8"-12" BA 1
2A017-125-0280 SPACER, 1.25 od X .328id X .28 1
4FA012-013 INTAKE ELBOW, 90 DEG W/BOSSES 1
7p375-037 3/8 NPT MALE X 3/8 HSE BARB 90 1
7P750-102 3/4 NPT X 1" X 90° HSE FIT 1
7U030-056 3/8" PCV/VAC RUBBER HOSE .25'

4PGL112-028 DISCH ASY 1

4GL012-041 6.0 TUBE “A” 1
4GL012-051 6.0 TUBE “B” 1
4GL012-030 ELBOW, 3.88" - 3.0" x 90° LS1 TRK 1
7R002-044 #44 GOLDSEAL HOSE CLAMP 5
7R002-048 #48 GOLDSEAL HOSE CLAMP 2
7R002-064 #64 GOLDSEAL HOSE CLAMP 1
7S275-200 2-3/4" x 2" SLEEVE 2
7S300-275 3.00" x 2.75" REDUCER SLEEVE 1

8N107-050 WATER PUMP ASY 1

8F001-402 WATER PUMP 1
7R003-027 ADEL CLAMP 1-11/16" 1
5W001-025 FEMALE SLIDE MINI 1
5W001-043 12-10GA x 1/4" RING TERMINAL 3
7A250-050 1/4-20 x .50" SHCS 2
5W001-013 14-16GA BUTT CONNECTORS 4
5W001-019 12-10GA BUTT CONNECTORS 2
7U100-044 4" TIE-WRAPS 4
5W001-022 T-SPLICE CONNECTOR 1
7F250-021 1/4-20 NYLOCK NUT 1
5W001-015 FUSE, BLADE TYPE 20AMP 1
5W001-005 3/8" PLASTIC WIRE LOOM 2
5W001-014 FUSE HOLDER 10GA WIRE 1
7U100-055 TIE-WRAP, 6" NYLON 6
5W001-041 12-10GA MALE SLIDE INSULATED 2
8F101-320 WATER PUMP RELAY ASY, LS1 TRK 1

8N105-050 WATER TANK ASY 1

8N055-030 LT1 WATER TANK 1
7P500-026 90° BARBED BRASS FITTING 2
4PGL010-060 BRKT “A” 1

4PGL010-070 BRKT “B” 1
4PGL010-080 BRKT “C” 1
7A250-102 1/4-20 x 1" SHCS 1
7J250-022 1/4" WASHER 6
7F250-021 1/4-20 NYLOCK NUT 1
8N056-060 SURGE TANK 1
8N055-050 SURGE TANK CAP 1
4PGL010-090 BRKT, SURGE TANK 1
7P500-078 12"NPT x 3/4" HOSE FIT 2
7U038-020 MOLDED “S” HOSE 1
7A250-050 1/4-20 x .5" SHCS 4
7U038-000 Ø3/4" HEATER HOSE 10"
7U033-000 Ø5/8" HOSE 5"
7P750-625 Ø3/4" x Ø5/8" REDUCER BARB 2
7E010-075 #12 x 3/4" SHT METAL SCRW HEX 4
7U030-065 90° MOLDED ELBOW SHORT 1
7J010-001 #10 FLAT WASHER 2
7R002-020 #20 HOSE CLAMP 2
7R007-002 NYLON CLAMPS 7/8" 4
7R007-001 NYLON CLAMPS 1-1/8" 10

8N201-370 CAC ASY 2008 HUMMER H2 6.2L 1

8N101-110 WELDED CORE ASSY V-10 S.D. 1
7P500-078 1/2"NPT x 3.4" HOSE FIT 1
7P500-026 1/2"NPT x 3/4" HOSE BARB x 90° 1
2A017-875-13 SPACER, CAC BRKT 1
7C010-040 10mm-1.5" x 1.5mm SCREW 1
7J010-002 10mm WASHER 1
7U250-200 COOLER FOAM 1
4GL010-110 BRKT, CAC SUPPORT 1

8N106-075 WATER COOLER ASY 1

8N006-005 WATER COOLR, SETRAB DUAL-PASS 1
7A250-102 1/4-20 x 1" SHCS SS 4
7J250-022 1/4" WASHER SAE STAINLESS 8
7F250-021 1/4-20 NYLOCK NUT, ZINC PLT 2
8N010-140 MTG TAB, SETRAB 2-PASS COOLR 4
7P375-075 3/4" HOSE BARB UNION, BRASS 3
7U125-200 TAPE, FOAM, 1/8" x 2" x 50' 7.5"
7U038-020 HOSE, Ø3/4" “S” MOLDED RUBBER 2

7R007-001 NYLON RATCHET CLAMP, 1-1/8" 4

5A003-040 DIABLO PREDATOR (2003-2007 MODEL YEAR) 1

8F060-047 47 lb. DELPHI INJECTORS 8

4GL020-015 INSTR. MANUAL DENALI/ESCALADE/HUMMER 1

009035 S/C LUBE PACK 1

©2008 Vortech Engineering, LLC

xvii

All Rights Reserved, Intl. Copr. Secured

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

This page intentionally left blank

P/N: 4GL020-015
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
08OCT08 GM Trk/H2(4GL..015v5.0)

xviii