Vortech 2003-2005 Lexus 3.0L IS300 User Manual

DP/N: 4LA020-010 - v1.1 07/10/07

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

Lexus

3.0L IS300

Supercharger System

Installation Instructions

2001-2005 Model Year

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

FOREWORD

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into another language in any form, by any means without written permission of Vortech Engineering, LLC.

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 installatlion 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. Vo r tech 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.

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

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) 247-0228 8:00am-4:30pm PST.

NOTICE

Due to variances in each vehicle, Vortech recommends that the vehicle get a “custom tune” from a local, reputable tuner.

This kit is supplied with a “universal” fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your specific vehicle can be obtained from a competent tuner. A “wideband” exhaust oxygen sensor must be used to confirm proper air/fuel ratio. Vortech suggests a proper WOT air/fuel ratio range of 10.8-11.0:1 for 91 octane fuel.

STOP

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

iii

TABLE OF CONTENTS

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

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

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

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

PARTS LIST (2002-2005 3.0L Lexus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

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

2. OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4. ABS RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION . . . . . . .7

6. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

7. AIR INLET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

8.1 FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003

Automatic Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

8.2 FUEL PUMP AND FMU INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .23

9. POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

10. ELECTRONIC CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . .27

11. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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.

IMPORTANT NOTE

2001-2005 3.0L Lexus IS300

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

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

Vor tech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower between 35-45% can be expected with the boost levels specified by Vor tech 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 modified in any way, check with Vortech prior to using this product.

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

5. Perform an oil and filter change upon completion of this installation and prior to test driving

your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles. Never attempt to extend the

oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1-year or 15,000

miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as

indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every 20,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factory repair manual

• 3" hole saw

• 1/2" socket and drive set: SAE & metric

• 3/8-18 tap & handle

• Adjustable wrench

• Open end wrenches: 3/8", 7/16", 1/2", 9/16",

10mm, 12mm

• Metric Allen wrench set

• Center punch and a 5/8" tapered punch

• Fractional drill bit set

• Grinder (electric right-angle)

• 6 quarts (or what is specified in your owner’s manual)

SF rated quality engine oil, oil filter and wrench

If it has been 20,000 miles or more since your vehicle’s last spark plug change, then you will also need:

• Spark plug socket

• NEW spark plugs

2001-2005 3.0L Lexus IS300

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® supercharger!

ENGINEERING, LLC

008110 SMALL SILVER DIE-CUT DECAL 2 008130 LICENSE PLATE FRAME, VORTECH 1 008444 S/C STRT INFO PKG ASY VORT 1 2E248-080 SUPERCHARGER V-5F SQ CW, LEXUS IS300 1 4LA020-010 INSTRUCTION MANUAL, IS300 1 4LA110-010 POWER STEERING COOLR ASY 1

8N006-025 COOLER, P/S 4-PASS PERMA/CL 1 8N100-001 NYLON MOUNTING KIT 1 7P375-312 3/8" BARB x 5/16" BARB REDUCER 2 7R004-003 STEPLESS CLAMP, 14.5-70 4 7U031-018 5/16" EFI FUEL HOSE HI-PSR 4'

4LA111-044 S/C MOUNT BRKT ASY, LEXUS IS300 1

2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A017-501-153 SPACER, .50"OD x 1.538"L ALUM 1 2A017-750-08 SPACER, .75"OD x .1.437"L 1 2A017-875-13 SPACER, .875"OD x .895"L 5 2A046-100 BELT, GATES K061010 1 4FA016-171 DUST COVER (IDLER PULLEY) 2 4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 2 4LA010-010 BRKT, SUPPORT IS300 1 4LA010-021 BRKT, LOWER SUPPORT IS300 1 4LA010-044 BRKT, 5/16" S/C MOUNT IS300 1 4LA017-011 SPACER, IDLER, 1.060"L IS300 1 7A375-100 3/8-16 x 1" G5 HHCS PLT 2 7A375-100 3/8-16 x 1" G5 HHCS PLT 1 7A375-178 3/8-16 x 1-3/4" HXHD G8 5 7A375-276 3/8-16 x 2-3/4" HXHD ZINC 1 7C010-016 M10-1.25 x 16mm, FLG HD, 10.9 1 7C012-040 M12-1.75 x 40mm HXHD BOLT, CL10.9 1 7C060-070 M6-1.00 x 70mm HXHD CL8.8 PLT 2 7C080-040 M8-1.25 x 40mm, SHCS, CL12.9 1 7C080-081 M8-1.25 x 80mm, HXHD, CL10.9 1 7E010-075 #12 x 3/4" SHT METAL SCRW, HEX 3 7F375-017 3/8-16 NYLOCK NUT 2 7J006-094 6mm WASHER SS 2 7K312-001 5/16"AN WASHER, PLATED 1 7K375-040 3/8"AN960 FLAT WASHER PLATED 12

4LA112-010 INLET ASY, LEXUS IS300

8H040-035 AIR FILTER, 3.5" FLANGE, G35 OFFSET 1 7U030-036 1/2" OIL DRAIN HOSE 0.75' 7P500-001 1/2" HOSE UNION 2 7R001-006 #6 STNLS HOSE CLAMP, NARROW 3 7U031-016 5/16" PCV/VAC RUBBER HOSE 2.5' 7R004-003 STEPLESS CLAMP, 14.5-70 4 7P312-050 5/16" HOSE MENDER 1 7P312-060 ELBOW, PLASTIC 5/16" x 90° UNION 1

4LA130-026 OIL FEED LINE ASY, IS300 1

7P125-004 1/8"NPT x 90° x -4 JIC FTG STL 1 7P125-005 1/8"NPT STR x -4 JIC FTG STL 1 7P125-034 1/8"NPT x 1/8"NPT STRT T 1 7P125-125 FTG, 1/8"NPT FEM x 1/8"BSPT MALE 1 7U100-055 TIE-WRAP, 7.5" NYLON 5 7U250-090-320 OIL FEED HOSE, 32" x -4 x 90° 1

4NZ101-068 FUEL PUMP ASY, INLINE 350Z 1

5W001-045 16-14GA RING TERM., .17" HOLE 1 5W001-032 1/4" WIRE LOOM 10' 5W001-011 16-14GA RING TERM. .26" HOLE 1 5W014-030 14GA STRD WIRE BLACK .5' 7E010-075 #12 x 3/4" SHT METAL SCREW, HEX 2 7P312-017 5/16" HOSE BARB TO M10 x 1.0mm 1 7P312-082 5/16" TEE HOSE BARB 2 7R003-027 ADEL CLAMP, 1-11/16" 2 7R004-001 STEPLESS CLAMP, 15.7-70 8

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

7U031-0018 5/16" EFI HOSE, HI-PSR 5.5' 7U100-044 TIE-WRAP, 4" NYLON 10 7U100-055 TIE-WRAP, 7.5" NYLON 5 8F001-068 WALBRO INLINE FUEL PUMP, 68 GP 1

4NZ130-036 OIL DRAIN LINE ASY, 350Z 1

7P375-017 3/8"NPT x 1/2" BEADED HSE BARB 1 7R001-008 #8 STNLS HOSE CLAMP 2 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1 7U030-036 1/2" OIL DRAIN HOSE 1.5' 7U100-066 TIE-WRAP, 11" NYLON 5

4NZ238-088 FMU, 8:1 w/LINES, w/SPRING, 3 1

6Z010-101 FMU HOUSING (BLUE ANODIZED) 1 6Z010-111 FMU VALVE BODY (BLUE ANODIZED) 1 6Z010-131 COVER, FMU - GM 4.3 1 6Z020-130 SML DIAPHRAGM, FLUORO 1 6Z020-140 LRG DIAPHRAGM, FLOURO 1 6Z030-150 BRACKET, FMU 1 6Z040-160 PISTON, FMU 1 6Z050-191 FMU WASHER, 8:1 PLATED 1 6Z060-181 SHIM, FMU 1 6Z070-030 FMU 8:1 RING SPACER 1 6Z080-011 RETAINER, FMU SPRING GM 4.3 1 6Z090-010 SPRING, FMU GM 4.3 1 7C010-050 10-24 x .50" SHCS GR8 PLT 6 7C010-075 10-24 x 3/4" SHCS GR5 ZINC 4 7C024-025 10-24 x 1/4" PHILL HD 3 7E010-075 #12 x 3/4" SHT MTL SCRW, HEX 2 7P125-025 1/8"NPT x 5/32" HOSE, 90° 1 7P125-031 1/8"NPT x 90° x 5/16" BARB 1 7P125-032 1/8"NPT-STR, 5/16" BARB 1 7P156-082 5/32" TEE 1 7P312-005 5/16" FEM FUEL CNCT, STEEL 1 7P312-007 FUEL FTG, 5/16" GM x 5/16" HSE 1 7R004-001 STEPLESS CLAMP, 15.7-70 4 7U030-046 5/32" VACUUM LINE 7' 7U031-018 5/16" EFI FUEL HSE, HI-PSR 2.5' 7U031-018 5/16" EFI FUEL HSE, HI-PSR 1.25' 7U100-030 O-RING, FMU 1 7U100-096 ROLL PIN, 3/16" x 1/2" SS 1

5A003-130 ECU, UNICHIP QT, '02-'05 IS300 SAFE TUNE 1 8N201-330 CHARGE COOLR ASY, LEXUS IS300 1

4LA010-061 BRKT, HOOD LATCH SPRT IS300 1 4LA012-010 TUBE “A” S/C DISCHARGE IS300 1 4LA012-020 TUBE “B” S/C DISCHARGE IS300 1 4LA012-040 TUBE “D” S/C DISCHARGE IS300 1 4LA012-050 TUBE “E” S/C DISCHARGE IS300 1 4NZ012-020 TUBE, COOLER INLET, 350Z 1 7A250-074 1/4-20 x .75" HHCS PLTD 1 7A312-050 1/4-20 x 1/2" HXHD GR5 ZINC 2 7C008-050 #8-32 x 1/2" SHCS, ZINC 2 7E010-049 #10 x 3/4" HXHD SLF DRL SHT MTL 2 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1 7J006-094 6mm WASHER SS 4 7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 2 7R002-040 #40 SAE TYPE “F” SS HOSE CLAMP 12 7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 2 7S250-025 ELBOW, 2.5"ID x 25° BLUE 5 7U030-046 5/32" VACUUM LINE 3' 7U133-090 RUBBER ELBOW, Ø1.0" x 90° 1 8D001-001 STD COMPRESS BYPASS VALVE 1 8H040-075 1" AIR FILTER BYPASS 1 8N010-210 BRKT, CLR MNT, IS300 1 8N101-350 CHARGE AIR COOLER, 350Z 1 7S300-275 REDUCER, 3.00" x 2.75" 2

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

immediately.

2002-2005 3.0L Lexus

Part No. 4LA218-010SQ/018SQ

ENGINEERING, LLC

PARTS LIST

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

vii

8F101-350 RELAY ASY, 350Z FUEL PUMP 1

5W001-005 3/8" PLASTIC WIRE LOOM 8' 5W001-010 16-14GA FEMALE SLIDE INSULATED 2 5W001-016 RELAY, BOSCH 1 5W001-040 12-10GA FEMALE SLIDE INSULATED 2 5W001-046 16-14GA RING TERM. .33" HOLE 2 5W001-054 16GA FUSE HOLDER WITH WIRE 1 5W014-010 14GA STRD WIRE, RED, UL1015 7' 5W014-030 14GA STRD WIRE BLACK 1' 5W014-030 14GA STRD WIRE BLACK 7'

6Z170-040 10:1 RING SPACER ASY 1

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

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

immediately.

2002-2005 3.0L Lexus, cont’d

Part No. 4LA218-010SQ/018SQ

ENGINEERING, LLC

PARTS LIST

viii

This Page Left Intentionally Blank

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

A. Disconnect the negative battery cable. B. Remove the four 10mm headed fasteners

securing the plastic engine cover and set aside.

C. Disconnect the valve cover vent hose from

the air inlet assembly but leave it attached to the valve cover.

D. Using a 10mm socket and ratchet, remove

the factory air filter enclosure, air scoop, and ducting leading to the throttle-body and set aside. (See Fig. 1-a.)

E. Remove the MAF electronics from the previ-

ously removed intake ducting and set aside to be reused in a later step. (See Fig. 1-b.)

F. Detach the pressure solenoid from the plastic

air filter enclosure (a single 10mm head screw). Set solenoid and screw aside to be reinstalled in a later section. (See Fig. 1-c.)

1. PREPARATION/REMOVAL

Fig. 1-a

Fig. 1-b

Fig. 1-c

NOTE: It is a good idea to label the line connec-

tions to prevent confusion later.

G. Disconnect the ABS module harness plug

from the module. Using a 10mm wrench, loosen the ABS module retaining nuts. Remove the module from its mounting bracket. Using a 12mm wrench, remove the hardware securing the ABS module bracket. Remove the module mounting bracket from the frame rail and set aside. Be careful not to

lose the rubber stud mounts or the rubber bushing on the bottom of the module.

MAF ELECTRONICS

LEAVE CONNECTED

TO HARD LINE

H. Drain the engine coolant into a clean contain-

er and set aside. Remove the lower radiator hose located on the passenger’s side of the engine. Trim approximately 1" from the end of the hose that was attached to the radiator, and set aside. Remove the upper radiator hose and set aside to be reinstalled in a later step. Remove the thermostat housing. Rotate the thermostat housing 180° and reinstall. Disconnect the fan’s power connectors, radiator overflow bottle and remove the fan mounting hardware. Remove the engine fan assembly and set aside. Remove the upper radiator mounts/hardware and set aside. Remove the radiator and set aside. (See Fig. 1-d.)

I. Remove the four 5mm socket-head screws

retaining the cam sprocket cover and set the cover and hardware aside. Locate the plastic wire loom channel on the passenger’s side of the engine. Remove the wire loom from the channel. Remove the 5mm socket-head fastener securing the channel to the cylinder head. Cut the channel as shown. (See Fig. 1-e.) Install the supplied piece of flex loom onto the exposed section of wire and wrap with electrical tape. Reinstall the cam sprocket cover using the factory hardware.

NOTE: Automatic transmission vehicles will

need to disconnect the cooler lines running to the radiator. Cover any open line connections to avoid possible fluid contamination.

Fig. 1-e

Fig. 1-d

1. PREPARATION/REMOVAL, cont’d

THERMOSTAT HOUSING

ROTATED 180°

TUBE PREVIOUSLY

CONNECTED TO

PRESSURE SOLENOID

CUT LOOM HERE

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Fig. 1-f

J. Remove the wire loom bracket secured to the

top of the water pump and discard. (See Fig. 1-f.) Remove the 10mm headed screw located just above and to the driver’s side of the previously removed bracket as shown. (See Fig. 1-g.)

K. Remove the 12mm headed bolt and wire har-

ness on the side of the water pump and discard. (See Fig. 1-g.)

L. Cut the small black cross-over tube located

just above the water pump where indicated. (See Fig. 1-f.)

M. Loosen the four water pump pulley retainers.

Un-tension the accessory drive belt and remove. Remove the water pump pulley retainers and pulley, setting them aside to be reinstalled in later step.

N. Remove the bolt securing the alternator to

the water pump. Remove the 12mm headed bolt just to the right (driver’s side) and down from the previously removed alternator bolt. Remove the 10mm headed bolt just above the alternator. (See Fig. 1-g.)

Fig. 1-g

1. PREPARATION/REMOVAL, cont’d

BOLT SECURING LOOM BRACKET

LOWER

W/P BOLT

ALT. BOLT

REMOVE

CUT TUBE HERE

PREVIOUSLY

SECURED

LOOM

BRACKET

REMOVE

10mm HEADED

SCREW

A. The supercharger uses engine oil for lubrica-

tion and must have an oil feed line connected to a filtered oil access on the engine.

B. Locate the oil pressure sending unit on the

driver’s side of the engine, just in front of and above the engine mount. (See Fig. 2-a.)

C. Disconnect and remove the pressure sender

and set aside to be re-installed later.

D. Locate the supplied oil feed assembly

(4LA130-026).

E. Install the supplied 1/8"BSP adapter into the

hole previously occupied by the oil pressure sender. Install the supplied 1/8"NPT street TEE into the BSP adapter. Orient the branch of the TEE so that it faces up. Thread the factory sending unit into the TEE as shown. (See Fig. 2-b.)

2. OIL FEED

Fig. 2-a (View From Below)

Fig. 2-b

OIL PRESSURE

SENDER

OIL PAN

1/8"NPT x #4 FLARE

FACTORY OIL

PRESSURE SENDER

1/8"NPT STRT TEE

BSP

ADAPTER

NOTE: The factory wiring harness may need to

be unclipped from the engine block to gain the necessary length to reach the repositioned sending unit.

NOTE: Pipe tape, paste or other sealant is not

recommended as it may loosen and cause blockage of the oil feed orifice resulting in supercharger failure. Use engine oil on the threads.

F. Install the supplied 1/8"NPT x #4 flare fitting

into the previously installed TEE. (See Fig. 2-b.)

G. Attach the straight end of the supplied oil feed

line to the #4 flare fitting previously installed and route up and over the engine valve cover.

H. Temporarily cover the open oil feed line end

to keep out debris until the connection is made to the supercharger in a later step.

I. Reconnect the factory oil pressure sender

wire.

+ 26 hidden pages

Vortech 2003-2005 Lexus 3.0L IS300 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual