Vortech 2004 Pontiac GTO User Manual

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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

P/N: 4GJ020-010

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

A. Locate the coils and their bracket on the pas-

senger side of the vehicle.

B. Remove the coils and bracket from the valve

cover as one assembly leaving the plug wires attached. Let the assembly rest against the inner fender. Unplug the wiring har ness from the coil assembly. (See Fig 2-a.)

C. Gently bend the oil dip stick tube forward and

in toward the valve cover. (See Figs 2-a, 2-b.)

D. Using three 6mm x 1.0 x 16mm screws and

washers secure the supplied heat shield to the lower row of holes on the valve cover. Make sure the dipstick is located between the heat shield and the valve cover.

E. Using factory hardware, mount the triangular

coil relocation bracket to the upper rear holes on the passengers side valve cover.Using the supplied 6mm x 1.0 x 16mm hardare, mount the secondary coil relocation bracket on the upper forward most hole location. Make sure the threaded holes hang down for the coil bracket to mount to.(See Fig 2-c.)

F. Using the supplied 6mm x 1.0 x 16mm

screws and washers mount the coil bracket to the installed relocation brackets. (See Fig. 2-c.)

G. Reconnect the har ness plug.

2. IGNITION COIL RELOCATION

Fig. 2-a

Fig. 2-b

Fig. 2-c

DIPSTICK BENT AGAINST VALVE COVER

3 MOUNTING LOCATIONS

TRIANGULAR RELOCATION BRACKET

OIL FILL CAP

SECONDARY

RELOCATION BRACKET

3. COOLANT RESERVOIR MODIFICATIONS

A. Install the supplied coolant reservoir bracket,

containing the factory bumper and grommet stud, in the same location as the factory bracket.

B. Remove the grommet stud from the inside

drivers fender wall.

C. Locate the supplied 1" aluminum spacer.

Thread the supplied 6mm stud into one end half way into the spacer.Thread the grommet stud into the open end.

D. Thread the spacer, stud and grommet stud

assembly into the factory mounting location. (See Fig 3-b.)

E. Remove the Ø1" hose from the bottom of the

coolant reservoir.Use the supplied Ø1.0 x

4.0" piece of hose, #16 hose clamps and Ø1.0 hose mender to lengthen the hose. (See Fig 3-c.)

F. Modify the computer heat shield as shown in

Fig. 3-d and reinstall it back in the factory position. (See Fig 3-e.)

Fig. 3-a

Fig. 3-b

Fig. 3-c

NOTE: The brackets will appear the same, but on the

supplied bracket the tabs are bent 180° from stock. (See Fig 3-a.)

SUPPLIED SPACER WITH GROMMET STUD

SUPPLIED Ø1" x 4" HOSE

P/N: 4GJ020-010

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

Fig. 3-d

Fig. 3-e

AREA TO BE TRIMMED

MODIFIED HEAT SHIELD REINSTALLED

3. COOLANT RESERVOIR MODIFICATIONS, cont’d

Fig. 4-a

4. OIL FEED

A. Remove the oil filter. B. Remove the 6mm nuts holding the small cast-

plate located directly above the oil filter. (Set aside the plate and gasket for later use)

C. Double nut each of the studs and remove

them.

D. Using engine oil on the threads, install the

1/8NPT to –4 90° fitting into the supplied oil feed adapter.

E. Using the adapter, the supplied factory gasket

and the supplied longer 6mm screws, assemble the components as shown in Fig 4-a.

F. Orient the installed fitting so that it is pointing

away from the engine.

G. Install the oil feed hose onto the open -4 end

of the fitting. Route the oil feed hose so that it follows the side of the alternator up to the supercharger mounting location.

ADAPTER BLOCK

1/8NPT TO -4 x 90° FITTING

P/N: 4GJ020-010

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

5. OIL DRAIN

A. Un-secure the hard coolant tube mounted to

the cross member directly in front of the oil pan. Un-secure the power steering line/wiring bracket located on the bottom lip of the oil pan. Push these brackets/tubes down to gain access to the oil drain area. (See Fig 5-a)

B. To provide an oil drain for the supercharger, it

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

C. Use the supplied 9/16" roto broach to drill the

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

D. Pack the flutes of the 3/8NPT tap with

grease.Tap the hole until the fitting can be started.

E. Thoroughly clean the threaded area. Reach

inside the oil pan and retrieve any stray chips. Apply a small amount of sealer to the new threads. Apply more sealer to the supplied 3/8" NPT x 1/2" barb x 90° fitting and secure in the hole. Make sure the seal is formed all around the fitting. Install the supplied 90° elbow pointing to the drivers side and slightly up.(See Fig 5-c.)

F. Re-secure the hard coolant tube to the lower

cross member.

G. Install the supplied spacers between the

power steering/wiring bracket and the oil pan mounting lip with the supplied 8mm x 45mm long hardware.(See Fig 5-a.)

Fig. 5-b

Fig. 5-c

Fig. 5-a

POWER STEERING LINE AND WIRING

BRACKET TO UNSECURE

SUPPLIED SPACERS

HARD COOLANT TUBE

INSTALLED FITTING

FRONT

VIEW

1.70

.80

Ø9/16

6. FUEL INJECTOR REPLACEMENT

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

and retainers from the injectors.

C. Remove the four 10mm bolts holding down

the fuel rails on the intake manifold. Lift up on the rails evenly, removing all eight injectors.

D. Using a small amount of clean motor oil,

lightly lubricate the O-rings on both ends of the Vor tech supplied fuel injectors.

E. Install the new injectors into the fuel rails with

the terminals facing outward.

F. Carefully lower the fuel rail/injector assembly

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

G. Tighten down the fuel rail assembly with the

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

NOTE: Do not reinstall factory injector retaining clips

P/N: 4GJ020-010

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

7. POWER STEERING RESERVOIR MODIFICATIONS

A. Remove the return line from the power steer-

ing reservoir.

B. Trim the factory hose until there is .50"

remaining before the molded bend.

C. Install the supplied Ø3/8" hose mender and

new 90° molded hose. Secure with the supplied #8 hose clamps. (See Fig 8-e.)

D. Lay the reservoir aside in the engine com-

partment until the reser voir bracket is installed.

8. SUPERCHARGER MOUNTING

G. Using the six supplied 1/4-20 x .75" SHCS

secure the anodized drive pulley on the drive hub.Torque the screws to 16 ft/lbs. (Blue loctite is recommended on the 1/4" hardware.) (See Fig. 8-l.)

H. Reinstall the factory belt with the factory belt

routing.

I. Install the oil drain line on the supercharger

and secure it with the supplied #8 hose clamp.

J. Using a 23/32" dr ill make a hole in the alu-

minum inlet duct as shown in Fig. 8-f. Dr ill the hole leaving at least .75" from the lip.

K. Install the T-bolt clamp onto the inlet duct,

then place the inlet duct on the supercharger. Orient the duct as shown in figures 8-g, 8-h. Tighten the t-bolt clamp so that the inlet duct is snug.When the supercharger and inlet duct are installed the clocking of the inlet duct can be fine tuned.

Fig. 8-a

Fig. 8-b

Fig. 8-c

NOTE: When installing the aluminum drive pulley heat

may be necessary for installation due to tight tolerances. Do not force the pulley on the hub. After the pulley is installed spin it to verify that the hub and pulley are mated flush.

A. Turn the power steering pump sideways and

install the supplied power steering/supercharger drive pulley hub. Make sure that the

hub is seated flush with the end of the power steering pump shaft.(See Fig. 8-c.)

B. Locate the power steering reservoir bracket.

The engine lift hook will have to be removed from the bracket.Use a saw or grinder and remove the section as shown in Fig.8-a.

C. Using two 10mm x 1.5 x 110mm screws,

washers and .430 spacers, secure the mounting bracket to the front of the power steering pump.Use the .430 spacers between the pump and back of the plate.(See Fig. 8-c.)

D. For the third mounting location, use a 10mm

x 1.5 x 110mm screw, 10mm washer, 2.2" spacer, power steering bracket and .880" spacer.The 10mm screw will pass through the washer, mounting plate, 2.2" spacer, left hole in power steering reservoir bracket, .880" spacer and thread into the head. (See Fig. 8-d.)

E. Using the other supplied .880 spacer and

10mm x 1.5 x 40mm screw secure the last hole of the power steering reservoir bracket into its factory position.

F. Reinstall the power steering reser voir back

into the holder bracket.(See Fig. 8-e.)

Fig. 8-d

.430 SPACERS BETWEEN THE PLATE

AND P/S PUMP IN TWO LOCATIONS

FIRST TWO MOUNTING

LOCATIONS

THIRD MOUNTING

LOCATION

SUPERCHARGER DRIVE HUB

THIRD MOUNTING

PLATE LOCATION

.880" SPACER

SECTION TO BE

REMOVED

P/N: 4GJ020-010

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

8. SUPERCHARGER MOUNTING, cont’d

L. Install the 1/8NPT x –4 x 90° fitting into the

supercharger.Orient the fitting down. (See Fig. 8-h.)

M. Install the supplied 3/8NPT x 3/8 barb into

the 3/8NPT hole in the inlet duct. Insert the IAT sensor and grommet into the inlet duct.

N. Install the supercharger/inlet duct assembly

onto the mounting bracket and secure with the supplied 3/8-16 x .75" screws and washers. (It may be necessary to unsnap the coolant reservoir to install the supercharger and air inlet duct.)

O. Disconnect the radiator end of the coolant

overflow/return hose and run it below the aluminum A/C line on the driver side and reattach it to the original location. (See Fig 8-j.)

P. Connect the oil drain hose to the fitting at the

pan and secure with a #8 hose clamp.Run the hose around the side of the alternator and secure from any sharp objects.

Q. Connect the oil feed line and route it with the

oil drain hose. Secure it away from heat or sharp objects.

R. Connect the Ø3/8 hose from the passengers

side valve cover to the 3/8" barb on the inlet duct.

Fig. 8-e

Fig. 8-g

Fig. 8-f

Fig. 8-h

INSTALLED Ø3/8" x 90° MOLDED HOSE

1/8NPT x -4 x 90° FITTING

3/8"NPT x 3/8" BARB

.75" MINIMUM

Fig. 8-j

Fig. 8-k

Fig. 8-l

S. Locate the supplied cog belt. Slip it over the

supercharger pulley and the drive pulley.

T. Install the supplied 3/8-16 x 4.25" idler bolt

through the 10mm washer, the flanged aluminum idler, the idler spacer and into the slot in the top of the supercharger mounting bracket.(The bearing retainer snap r ing on the idler must be pointing toward the idler spacer.Install the supplied nut and washer on the bolt and tighten until the idler slides up and down with no play.)

U. Press down on the idler until the belt is snug

with minimal free play. It is not necessar y to have the belt tight.Once the vehicle has been started, as long as the belt does not move around excessively the belt is tight enough. (See Fig. 8-l.)

COOLANT OVERFLOW HOSE

ROUTED BELOW THE A/C LINE

COOLANT LINE RESTING BETWEEN

BARBS ON INLET DUCT

IDLER AND

SPACER ASSEMBLY

S/C DRIVE PULLEY

INSTALLED

NOTE: Verify that the extended hose from the base of

the coolant reservoir rests between the 3/8" barb and the 1" bypass bung on the inlet duct. (See Fig. 8-k.)

Fig. 8-i

8. SUPERCHARGER MOUNTING, cont’d

P/N: 4GJ020-010

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

9. AIR INTAKE INSTALLATION

Fig. 9-a

Fig. 9-b

Fig. 9-c

A. Locate the flat inner fender where the factory

air box was mounted.Using a 3.5" hole saw drill a hole as shown in Fig. 9-a.Remove all burrs with a file or grinder. (See Fig. 9-e for location.)

B. Insert the supplied flange into the hole and

secure with the supplied self tapping screw.

C. Secure the air filter to the bottom of the

flange with the supplied #56 hose clamp located in the fender well.(See Fig 9-c.)

D. Assemble the MAF sensor, flex ducting, 3.5"

x 2" sleeve with #56 hose clamps. The 3.5" sleeve attaches to the inlet of the MAF sensor and the flex ducting attaches to the outlet. Verify correct flow for the MAF sensor.

E. Install the silicone sleeve on the open side of

the flange located in the engine compartment. Connect the open end of flex duct to the cast aluminum inlet duct. Secure both ends with the supplied #56 hose clamps.(See Fig 9-d.)

F. Reconnect the IAT and MAF sensors to the

factory harness.

3.5" HOLE

Fig. 9-d

Fig. 9-e

9. AIR INTAKE INSTALLATION, cont’d

1.00

DRILL Ø3.50" HOLE

FRONT OF VEHICLE

.75

P/N: 4GJ020-010

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

10. POWER STEERING COOLER RELOCATION

Fig. 10-a

Fig. 10-b

A. Locate the power steering cooler that is

mounted directly in front of the radiator. Disconnect the cooler from the mounting straps and let it hang freely. Remove the mounting straps from the vehicle.

B. Disconnect the power steering cooler hard

lines where they pass along the passenger side of the radiator at the section of rubber hose. Remove the power steering cooler and hard line assembly from the vehicle.

C. Trim the hard lines from the power steering

cooler as shown by Fig.10-a.Make sure to leave no less than 5/8" after the bends to allow for the hose connections.

D. Install the supplied L Brackets to the two

bracket mounts on the power steering cooler that were attached to the factory mounting straps. Use the supplied 1/4-20 x 1.25 hardware.

E. As shown in Fig. 10-b mount the power steer-

ing cooler with supplied brackets on the lower cross member and secure with the supplied self tapping screws.

F. Run two lengths of Ø3/8" hose from the

power steering cooler to the hard lines behind the radiator.Route the hoses around the passengers side of the radiator and secure the lines with #8 hose clamps. (See Fig. 10-b.)

G. Bleed system as follows with vehicle off:

1. Raise front wheels off ground

2. Turn steering wheel full left

3. Fill reservoir to "full cold" level. Maintain

level throughout procedure.

4. Turn steering wheel lock to lock at least 20 times or until bubbles stop.

MOUNTING STRAPS

TO BE REMOVED

2 LENGTHS OF Ø3/8 HOSE LEADING

BACK TO THE FACTORY HARD LINES

AREA TO TRIM COOLER

SUPPLIED L-BRACKETS

11. DISCHARGE INSTALLATION

Fig. 11-b

Fig. 11-c

Fig. 11-d

A. Attach the supplied piece of foam tape to the

bottom of the charge cooler.Lay the charge cooler on the passengers’ side of the motor above the relocated coils.Position the cooler close to the oil fill cap.Or ient the charge cooler so that the 1/2NPT ports are pointing toward the front of the car. Install the 90° 1/2 NPT brass fitting in the upper passenger side port and the 1/2 NPT straight brass fitting is in the lower drivers’side por t. (See Figs.11-a, 11-b.)

B. Install the supplied Ø2.75" x 2" sleeve on the

discharge of the supercharger.Install the supplied Ø2.75" x 3" sleeve on the inlet of the charge cooler.

C. Install the longer straight section of the

S-shaped discharge tube into the Ø2.75 x 2" sleeve on the supercharger and the opposite end in the sleeve located on the cooler. Snug the discharge tube in place with #44 hose clamps.

D. Install the Ø2.75 end of the reducer sleeve on

the outlet of the charge cooler.Install the

3.88" end of the 90° elbow on the throttle body pointing toward the passenger side. (See Fig. 11-d.)

E. Install the L-shaped discharge duct with the

shortest leg leading into the Ø3.0 end of the reducer sleeve. The other end of the tube will go into the open end of the silicone elbow on the throttle body. Snug with the supplied #48 and #64 hose clamps. (See Fig. 11-d.)

F. Orient the ducting for best fit then tighten all

hose clamps. #44 hose clamps are for all Ø2.75 ends, #48 clamps are for all Ø3.00 ends and the #64 hose clamp is for the throttle body.

G. Connect the 6" piece of Ø1.0 bypass hose to

the pressure side of the bypass.

“S” SHAPED DISCHARGE TUBE

90° SILICONE ELBOW

Fig. 11-a

1/2"NPT x 90° FITTING

1/2"NPT STRAIGHT FITTING

P/N: 4GJ020-010

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

11. DISCHARGE INSTALLATION, cont’d

Fig. 11-e

Fig. 11-f

Fig. 11-g

H. Trim and orient the supplied molded Ø1.0

long 45° as shown in Fig.11-e.

I. Connect the open end of the straight bypass

hose to the Ø1.0 bung on discharge tube A. Connect the open end of the 45° molded hose to the Ø1.0 bung on the inlet duct. Secure the ends with #16 hose clamps. (See Fig. 11-g.)

J. Cut into the brake booster hose as shown

(see Fig. 11-f) and insert the supplied brass TEE fitting.

K. Connect the 5/32" vacuum line from the

bypass valve nipple to the installed TEE fitting.

6" PIECE OF Ø1.00 HOSE

THAT CONNECTS TO THE

DISCHARGE TUBE

TRIMMED 45° HOSE THAT CONNECTS TO

THE INLET TUBE

SUPPLIED BRASS

TEE FITTING

12. WATER RESERVOIR/SETRAB COOLER INSTALLATION

Fig. 12-a

Fig. 12-b

Fig. 12-c

A. Locate the supplied water reservoir.Using

thread sealant install a Ø3/4" 90° brass fitting into the 1/2NPT hole at the top of the reservoir. Install another 90° fitting into the bottom 1/2NPT hole.

B. Install a 2" piece of Ø3/4" hose on the top

90° fitting. Secure it with a supplied nylon ratchet clamp and orientate it so that it will be pointing to the passenger side. Orientate the bottom fitting so that it will be pointing to the driver side. (See Fig. 12-a.)

C. Secure the upper mounting bracket to the

1/4-20 threaded insert in the top of the reservoir. Mount the lower bracket on the drivers’ side of the tank. Use the supplied 1/4-20 x .75 SHCS to secure the brackets. (See Fig. 12-a.)

D. Place the reservoir and brackets into their

location behind the front bumper on the far passengers side. Mark for drill locations. (See Figs. 12-b, 12-c.)

E. Remove the reservoir and brackets.Use a

self tapping screws to drill the upper hole. Remove the screw after the hole is started. For the lower mounting location use a .280" drill to make a mounting hole in the lower cross member.(See Figs. 12-b,12-c.)

F. Reinstall the reservoir and secure the upper

bracket with the supplied sheet metal screw.

G. Install the Ø3/4" 90° brass fittings into the top

of the supplied Setrab water cooler. Orientate the fittings as shown in Fig. 12-d. Install the cooler to the right of the water reservoir.The passenger side of the water cooler will share a mounting hole with the lower bracket of the water reservoir. (See Fig. 12-e.)

H. Secure the passenger side of the Setrab

cooler and the bottom reservoir bracket to the cross member with the supplied 1/4-20 x 1"SHCS.

I. Mark the driver side location of the Setrab

cooler and drill with a .280 drill. Secure the driver side of the cooler with the supplied 1/420 x 1" hardware. Make sure when mounting the Setrab cooler that you use the rear set of holes so that the cooler sits forward when mounted.

UPPER MOUNTING BRACKET

LOWER MOUNTING BRACKET

UPPER MOUNT LOCATION TO DRILL

LOWER MOUNT LOCATION THAT THE

WATER COOLER AND RESERVOIR

ARE TO SHARE

P/N: 4GJ020-010

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

12. WATER RESERVOIR/SETRAB COOLER INSTALLATION, cont’d

Fig. 12-d

Fig. 12-e

Fig. 12-f

Fig. 12-g

J. Trim the supplied Ø3/4 x 90° molded hoses.

See Fig. 12-g for hose lengths.

K. Installed the 2-3/4 end of the trimmed 90°

molded elbow on the passenger side fitting in the water cooler. Orient the hose as shown in Fig. 12-d.

L. With the cooler and reser voir mounted, install

the aluminum section of water tube so that it snakes around the upper passenger side of the radiator down to the 2" piece of rubber hose installed on the reservoir.Push the aluminum tube into the hose and secure with a supplied nylon ratchet clamp.(See Fig. 12-f.)

SHARED MOUNTING LOCATION

2" PIECE OF Ø1.0" HOSE ON WATER RESERVOIR

6.5

2.75

4.75

6.5

13. WATER PUMP AND HOSE INSTALLATION

Fig. 13-a

Fig. 13-b

Fig. 13-c

A. Mount the supplied water pump relay onto the

inside passenger side fender behind the fuse box. (See Fig. 13-a.)

B. Connect the red 12GA wire from terminal #30

to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt it to the fuse box power supply terminal as shown.

C. Feed the yellow wire from relay terminal #85

to the fuse box on the passengers side of the engine bay. Route the wire to the stock fuel pump relay and connect using the supplied fuse tap.(See Fig. 13-b.)

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

water pump relay terminal to ground.

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

terminal #87, route the free end down to the front of the vehicle where the water pump will be located. Secure as necessary to avoid heat and sharp edges.

F. Mount the water pump to the lower cross

member on the side of the water cooler with the supplied adel clamps and self tapping screws.Connect a 14-16GA r ing ter minal to the brown wire on the water pump and connect it to one of the mounting screws for ground. (See Fig. 13-c.)

G. Using the supplied slide connectors connect

the red wire from the relay to the positive blue/green wire off the water pump.

H. Connect the discharge of the water pump to

the inlet of the water cooler with the trimmed Ø3/4" x 4-3/4 x 6 1/2 molded 90° hose. Secure the ends with nylon ratchet clamps. (See Fig. 12-g.)

I. Cut a 23" piece of Ø3/4" hose and connect

the bottom fitting on the water reservoir to the inlet of the water pump and secure with nylon ratchet clamps.

WATER PUMP

RELAY

YELLOW WIRE FROM

TERMINAL #85

RED WIRE FROM

TERMINAL #30

P/N: 4GJ020-010

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

13. WATER PUMP AND HOSE INSTALLATION, cont’d

Fig. 13-d

Fig. 13-f

Fig. 13-g

J. Install the S-shaped water tube so that the

long end is inserted into the 90° elbow on the charge cooler.With the long end in place, verify that the open end id pointing down and runs behind the battery.(See Figs. 13-g, 13-h.)

K. Cut a 50" piece of Ø3/4" hose. Connect one

end of the cut hose to the 90° molded hose off the outlet of the water cooler using a supplied barbed hose mender.Secure with ratchet clamps. Route the hose below the passenger side head light, into the fender well and bring it into the engine compartment from behind the battery. (See Figs. 13-a, 13-d.) Connect the open end of the 50" hose to the open end of the aluminum water tube.(It may be easier to remove the battery before routing this hose.) Secure all ends with ratchet clamps.

L. Cut a 19" piece of Ø3/4" hose. Connect the

open end of the aluminum water tube near the radiator to the straight fitting in the charge cooler.Secure the ends with nylon ratchet clamps.(See Fig. 13-e.)

HOSE ROUTED BEHIND HEADLIGHT

Fig. 13-h

6.50

4.75

2.75

6.5

3/4" HOSE MENDER

2" PIECE OF

Ø3/4" HOSE

19" PIECE OF HOSE

50" PIECE OF HOSE

FLOW

2 x 90° BRASS FITTING

23" PIECE OF Ø3/4" HOSE

WATER PUMP

WATER

RESERVOIR

ALUMINUM

WATER TUBE

SETRAB COOLER

CHARGE COOLER

S-SHAPED ALUMINUM

WATER TUBE

4.5

Fig. 13-e

13. WATER PUMP AND HOSE INSTALLATION, cont’d

14. REFLASH COMPUTER

Fig. 14-a

A. Reconnect the battery. B. Locate the vehicles OBD2 connector located

below the dash on the drivers side of the vehicle.

C. Attach the OBD2 connector from the Flash

tool that is provided in the kit to the vehicle’s OBD2 port. Make sure this connector is seated all the way in the vehicles OBD2 port. You do not want this connector coming out during programming or damage may occur to the vehicle’s ECM.

D. The Reflash tool should power up and display

three parameters.

1. Perf ormance Tune

2. Diagnostics

3. Options

E. Select “Performance Tune” and press the

enter button in the middle of the arrow keys.

F. Read the disclaimer entirely, then select

agree and press ENTER.

G. At this point follow the instructions on the

screen of the screen displayed on the reflash tool. If you have any questions, either refer to the manual that is provided with the reflash tool or contact our service depar tment for further assistance.

H. Turn the ignition on (do not star t the vehicle).

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

I. SELECT TUNE will be displayed at the top of

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

1. Vortech GTO H.O.

2. Original Backup

J. Continue to follow the screen and when fin-

ished unplug the reflash tool from the vehicles OBD2 port.

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

• Make sure the vehicle's battery is sufficiently charged.

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

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

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

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

NOTE: Do not disturb the cable, or turn the

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

Fig. 14-b

ESCAPE

ENTER

SELECT

ARROW KEYS

0BD2 CONNECTOR

P/N: 4GJ020-010

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

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

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

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

ENGINEERING, LLC

15. FINAL ASSEMBLY AND CHECK

A. If your vehicle has gone over 20,000

miles since its last spark plug change, it is a good idea to change the spark plugs now, before test driving.

B. Make sure that oil drain to oil pan fitting

is tight and that the engine is filled with factory specified oil

C. Make sure radiator and overflow tank are

filled .

D. Make sure that the vehicle is filled with

91 octane fuel or higher before commencing test drive.

E. With key on, make sure charge air cooler

water pump is operating and the water is flowing through the surge tank. Fill as necessary. If water is not flowing, remove the hose from the bottom of the surge tank and lower until water flows out of the hose.This should prime the pump. Reconnect the hose, verify the water flow and top off the surge tank. Do not run the water pump for extended periods (30 seconds or more) without water flow.

F. Check all fittings, nuts, bolts and clamps

for tightness.

G. At this point it is OK to start the vehicle. H. Verify that the belt is tracking properly

with the vehicle running.

I. With engine running, check power steer-

ing hose connections for leakage.Let the engine run for two minutes.Turn steer ing wheel in both directions.

Verify:

• Smooth power assist

• Noiseless operation

• Proper fluid level

• No system leaks

• No bubbles, foam or discoloration in

fluid.

J. Turn the vehicle off and recheck all fluid

levels, verify that no hoses, wires, etc are near exhaust headers or moving parts and that there is no fluid leakage.

K. Test drive the vehicle by gradually work-

ing up to full throttle and paying close attention to any abnormal sounds or engine detonation.

WARNING: Do not attempt to operate the vehicle until

ALL components are installed and ALL operations are completed including final check. Failure to do so may cause PREMATURE FAILURE OF MAJOR COMPONENTS.

Vortech 2004 Pontiac GTO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual