Vortech 2004 Pontiac GTO User Manual

DP/N: 4GJ020-010 v1.0 09/20/04

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

PONTIAC GTO

Supercharger System

Installation Instructions

2004 Model Year*

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

This manual provides information on the installation, maintenance and service of this Vortech supercharger kit expressly designed for the 2004 GTO. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 604-1336 7:00am-3:30pm PST. An understanding of the information contained herein will help novices, as well as experienced technicians, to correctly install and receive the greatest possible benefit from their Vortech supercharger.When reference is made in this manual to a brand name, number, specific tool or technique, an equivalent product may be used in place of the item mentioned. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. All rights reser ved to make changes at any time without notice.

FOREWORD

All rights recerved. No parts of this publication may be reproduced, transmitted, transcrived, or

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

Vortech Engineering, LLC.

iii

P/N: 4GJ020-010

28SEP04 v1.0 GTO(4GJ020-010v1.0)

TABLE OF CONTENTS

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

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

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

RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

1. PREPARATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. COIL RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3. COOLANT RESERVOIR MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

4. OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5. OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

6. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

7. POWER STEERING RESERVOIR MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .9

8. SUPERCHARGER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

9. AIR INTAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

10. POWER STEERING COOLER RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

11. DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

12. WATER RESERVOIR/SETRAB COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . .18

13. WATER PUMP HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

14. REFLASH COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

15. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

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 Vor tech 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 Vor tech Engineer ing, LLC.

NOTICE

P/N: 4GJ020-010

28SEP04 v1.0 GTO(4GJ020-010v1.0)

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.

Vortech 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 Vortech Engineer ing. This product is intended for use on healthy, well maintained engines. Installation on a wor n-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 Vor tech pr ior 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 dr iving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles.Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spar k plugs every 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENT

• Factory repair manual

• 3/8" socket and drive set:SAE & metric

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

• Adjustable wrench

• Open end wrenches

• 5 quarts SF rated quality engine oil, oil filter and wrench

• GM power steering pulley puller/installer

• Hose cutters

• SAE nut drivers

• Lithium grease

• Grinder/hacksaw

• Allen wrenches: SAE & metric

If it has been 10,000 miles or more since your vehicle’s last spark plug change,

then you will also need:

• Spark plug socket

• NEW spark plugs

2004

PONTIAC GTO

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® supercharger!

4GJ130-028 OIL FEED ASSY 1

4GL010-020 OIL FEED ADAPTER PLATE 1 7C060-110 6mm x 1.0 x 110mm HXHD 1 7J006-003 6mm WASHER 1 4GL010-030 GASKET, 5.3 OIL ADAPTER 1 7U250-000-220 OIL FEED HOSE, STL BRD x 23" 1 7P125-004 1/8NPT 90° x -4 JIC, STL 2 7F006-093 6mm x 1.0 NUTS 4 7U100-065 TIE WRAPS 4

4GJ130-036 OIL DRAIN ASSY 1

7U030-036 1/2” OIL DRAIN HOSE 2 7R001-008 #6 HOSE CLAMPS 2 7P375-055 3/8” x 1/2” BARB x 90 1 7T560-002 ARBOR, ROTABROACH 1 7T560-001 CUTTER, 9/16" ROTABROACH 1 2A017-876-09 SPACER, .875 x 1.22 2 7C080-045 8mm x 1.25 x 45mm 2 7J312-000 8mm WASHER 2

4GJ111-021 SUPERCHARGER DRIVE/MOUNT ASSY 1

4GJ016-021 DRIVE PULLEY, GTO 1 4GJ016-011 DRIVE PULLEY HUB, GTO 1 7A250-075 1/4-20 x .75" SHCS 6 2A042-105 COG BELT 1 4GJ010-034 BRACKET, S/C MOUNT 1 2A017-875-10 SPACER, .875 x .430 2 4GR116-300 ALUMINUM IDLER 1 7A375-425 3/8"-16 x 4.25 1 7F375-017 3/8-16 NUT 1 7A375-075 3/8-16 x .75 5 7J010-002 10mm 1 7J375-044 3/8 WASHER 6 7C010-111 10mm x 1.5 x 110mm 3 2A017-880-04 .875 x 2.201 SPACER 1 7J010-002 10mm WASHERS 4 2A017-875-14 SPACER, .875 x .880 2 7C010-040 10mm x 1.5 x 40mm 1 ??? Ø3/8 x 90° MOLDED HOSE 1 7P7P375-050 3/8" HOSE MENDER 1' 7R001-008 #8 HOSE CLAMPS 3 4GJ017-011 SPACER, COG TENSIONER 1

8F060-042 42 LB/HR FUEL INJECTORS 8 8N401-050 DISCHARGE COOLER ASSY 1

7S275-200 2.75 x 2" SLEEVE 1 7R002-044 #44 HOSE CLAMPS 5 4GJ012-010 DISCHARGE DUCT A, GTO 1

8N301-250 CHARGE COOLER ASSY, GTO 1

8N003-010 5.0L TANKS 1 8N003-070 LS1 TANK 1

8N201-001 S2K CORE w/TANKS 1 7S300-275 3.0 x 2.75 REDUCER SLEEVE 1 7R002-048 #48 HOSE CLAMPS 2 4GJ012-020 DISCHARGE DUCT B, GTO 1 7R002-064 #64 HOSE CLAMP 1 4GL012-030 90° ELBOW SLEEVE 1 8N055-050 SURGE TANK CAP 1 7S275-300 Ø2.75 x 3" SLEEVE 1

2E228-400/408 S/C ASSY CW/STRT VOUTE 1

2A021-090 IMPELLER, S-TRIM 1 2A100-010 NAME PLATE 1 7A250-037 1/4-20 x .375 SHCS 6 7U100-023 DRIVE SCREW #4 2 2A100-110 IMPELLER SPACER 0 2A100-020 RETAINER COMPRESSOR 1 2A018-101 VOLUTE, STRT S-TRIM 1 7F375-024 NUT, IMP 3.8LH 1 2E118-000 V-2 G/C ASSY CW 1

2A060-020 OIL SEAL, INPUT SHAFT 1

7X100-026 WAVE WASHER, SMALL 1

7X100-027 WAVE WASHER, LARGE 1

Part No. Description Qty. Part Number Description Qty.

2E190-011 IMP SHFT ASSY G3 GW 1 7U250-022 DOWEL PIN, .25 x .75 2 7A250-102 1/4-20 x 1 SHCS 10 2A013-021 V1 GEARCASE STD 1 2E170-021 IMPUT SHAFT ASSY 1 7W100-018 O-RING SPECIAL 0

2A060-012 IMPELLER SEAD, MECHANICAL 1 7P375-002 3/8 PIPE PLUG 2 7P375-017 3/8NPT x 1/2 BEADED HSE BRB 1 7P375-081 S/C OIL FEED FLTR 1 7J375-024 3/8 COPPER WASHER 2 7P375-104 PLUG, SHORT 1 4GR033-030 COG PULLEY, 30-TOOTH 1 2A100-030 RETAINER, COM 1/2 SIZE 2 8R101-001 S/C PULLEY RET ASSY 1

4GJ112-010 S/C AIR INLET ASSY 1

4GJ012-030 NEW INLET DUCT 1 4HS010-060 S2K INLET FLANGE 1 7R002-056 #56 HOSE CLAMPS 5 8H040-030 AIR FILTER 1 8D001-001 BYPASS VALVE 1 7R002-016 #16 HOSE CLAMPS 4 7U133-045 Ø1" x 45° BYPASS HOSE 1 7U034-016 1" BYPASS HOSE STRT 0.5' 7U030-046 VACUUM LINE 2 7P375-250 VAC TEE 1 7U032-016 3/8 FUEL HOSE 4 7P375-097 3/8NPT x 3/8 BARB 1 7U375-052 3/8 VACUUM CAP 1 7U100-062 RUBBER GROMMET 1 7S350-200 3.5 x 2" SLEEVE 1 7U035-001 FLEX DUCTING 0.83' 7R005-001 T-BOLT CLAMP 1 7E010-049 SELF TAP SHT METL SCRW 4

8N106-120 COOLER/PUMP ASSY 1

8N055-070 RESERVOIR, COOLER 1 4GJ014-010 WATER TUBE, ALUM. COOLER 1 7P500-026 3/4" x 90° BRASS FITTING 5 7P500-078 3/4 STRT FITTING, BRASS 1 7R007-001 NYLON RATCHET CLAMPS 14 7U038-000 3/4" WATER HOSE 10 8N006-010 SINGLE PASS SETRAB 1 7A250-103 1/4-20 x 1 SHCS 2 7F250-021 1/4-20 NUTS 2 7J250-001 1/4 WASHERS 4 7R003-027 ADEL CLAMP 1-11/16" 1 5W001-025 FEMALE SLIDE MINI 1 5W001-013 14-16GA BUTT CONNECTORS 4 5W001-019 12-10GA BUTT CONNECTORS 2 7E010-049 SHT MTL SCREW, SELF-TAP 3 7U038-012 Ø3/4 x 90° MOLDED HOSE 4 7P375-075 Ø3/4 BRASS, BARBED HOSE MENDER 2

8N107-050 WATER PUMP ASSY, LS1 1

5W001-005 3/8 PLASTIC WIRE LOOM 5' 5W001-009 16-14 MALE SLIDE INSUL 1 5W001-013 14-16 SOLDERLESS CONNECTOR 4 5W001-014 FUSE HOLDER 1 5W001-015 FUSE, BLADE 20 AMP 1 5W001-019 10-12GA BUTT CONN 2 5W001-022 T-TAP CONN 14-16 1 5W001-024 MINI ATC FUSE TAP 1 5W001-041 12-10 MALE SLIDE 2 5W001-043 12-10GA x RING TERM 3 7A250-050 1/4-20 x .50 SHCS 2 7F250-021 1/4-20 NYLOCK NUT 1 7R0003-027 ADEL CLAMP 1-11/16" 1 7U100-044 TIE-WRAP 4" 4 8F001-402 PIERBURG WATER PUMP 1 7U100-055 TIE-WRAP 7.5" 6

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

immediately.

2004 Pontiac GTO

Part No. 4GJ218-010/018SQ

ENGINEERING, LLC

PARTS LIST

vii

P/N: 4GJ020-010

28SEP04 v1.0 GTO(4GJ020-010v1.0)

8F101-320 WATER PUMP RELAY ASSY, LS1 TRK 1

SW001-010 16-14GA FEMALE SLIDE INSULATED 2 SW001-016 RELAY, BOSCH 1 SW001-040 12-10GA FEMALE SLIDE INSULATED 2 SW001-042 12-10GA 3/16" RING TERMINAL 2 SW012-000 12GA STRD WIRE, RED 9.5' SW012-000 12GA STRD WIRE, RED 1.5' SW012-010 12GA WIRE BLACK .5' SW014-030 14GA STRD WIRE BLACK .5' SW016-010 WIRE STRND, 16AWG YELLOW 2.5'

4GJ110-010 P/S COOLER RELOCATION ASSY 1

7U032-016 FUEL HOSE Ø3/8 5.5' 7R001-008 #8 HOSE CLAMPS 4 4PGL010-080 BRKT, L-STYLE, P/S MOUNT 2 7A250-126 1/4-20 x 1-1/4 HXHD 2 7J250-001 1/4" WASHERS 4 7A250-125 1/4-20 NYLOCK NUTS 2 7E010-049 SHT MTL SCRWS, SELF-TAP 2

4GJ110-020 COOLANT RESERVOIR RELOC ASSY 1

4GJ010-020 BRKT, COOLANT RESERVOIR 1 7F006-O92 6mm x 1.0 NUTS 2 4GJ017-021 SPACER, 6mm x 1.0 1 7U006-100 6mm x 1.0 STUD x 1.0 1 7U034-016 Ø1.0 HOSE .33' 7R002-016 #16 HOSE CLAMP 2 7P100-010 Ø1.0 PLASTIC HOSE UNION 1 4GJ110-030 COIL RELOCATION ASSY 1 7C060-016 6mm x 1.0 x 16mm HXHD 6 7J006-093 6mm WASHER 6 4GJ010-050 HEAT SHIELD 1 4GJ010-030 TRIANGLE RELOCATION BRKT 1 4GJ010-010 BRKT A, COIL RELOCATION 1

Part No. Description Qty.

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

immediately.

2004 Pontiac GTO

Part No. 4GJ218-010/018SQ

ENGINEERING, LLC

PARTS LIST

viii

This Page Left Intentionally Blank.

P/N: 4GJ020-010

28SEP04 v1.0 GTO(4GJ020-010v1.0)

A. Remove the engine covers, all ducting lead-

ing to the throttle body and the plastic air dam connected to the airbox. (It might be necessary to unsnap the coolant reservoir to remove the airbox assembly.)

B. Remove the air temp sensor from the inlet

and set aside.

C. Remove the power steering reser voir from its

mounting bracket.Remove the reservoir bracket and set aside for modification and reinstallation.

D. Remove the two screws securing the power

steering pump. Pull the pump away from the head and turn so there is enough room to use the pulley puller. Remove the power steering pump pulley. Let the pump rest in the engine compartment.

E. Leaving the coolant reser voir hoses connect-

ed, set the reservoir on the engine so that the area around the computer can be accessed. (See Fig. 1-a.)

F. Remove the plastic lid from the computer.

(See Fig 1-a.) Remove the two nuts securing the coolant reservoir bracket.Remove the screw securing the secondary bracket to the master cylinder and remove both factory brackets.

G. Remove the heat shield protecting the com-

puter from the exhaust.

H. Remove the rubber bumper and grommet

stud from the factory reservoir bracket and install them into the supplied reservoir bracket. (See Fig 1-b.)

I. Modify the plastic computer cover as shown

and reinstall it back over the computer. (See Fig. 1-c.)

J. Remove the plastic pins securing the plastic

cover over the radiator.Remove the plastic cover.

K. Remove the factory skid plate. L. Un-secure the splash panels from under the

front of the vehicle.Remove the splash panels.

M. Remove all hardware securing the front

bumper cover. Below the headlights on each side of the vehicle the bumper cover snaps to the bumper. Unsnap these points and remove the bumper cover from the vehicle.

N. Drain approximately 1 gallon of coolant from

the vehicle.

1. PREPARATION/REMOVAL

Fig. 1-a

Fig. 1-b

Fig. 1-c

FACTORY COOLANT RESERVOIR BRACKET

VORTECH BRACKET WITH THE RUBBER BUMPER AND GROMMET STUD INSTALLED

COOLANT RESERVOIR BRACKETS

COMPUTER

O. Locate the valve cover breather on the pas-

sengers side valve cover.Remove the hose connecting the breather port on the valve cover to the port on the throttle body.

P. Plug the throttle body port with the supplied

3/8 rubber cap.

Q. Install the supplied Ø3/8 hose from the valve

cover port and run the hose across the engine to the future location of the supercharger inlet.

Q. Remove the plastic oil fill. Insert the oil fill cap

directly into the valve cover.(See Fig. 2-c.)

1. PREPARATION/REMOVAL, cont’d

+ 22 hidden pages

Vortech 2004 Pontiac GTO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual