Vortech GM 5.3L 6.2L Light Truck SUV

®

GM 5.3L&6.2L

Light Truck/SUV

2007-2008 Model Years

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-27

ENGINEERING, LLC

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)

DP/N: 4GL020-018 - v2.0 11/11/08

FOREWORD

STOP

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

T

mation, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0226 8:00am-4:30pm PST.

Take note of the following before proceeding:

1. Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/ technician. Please contact your dealer or Vortech Engineering for

possible installers in your area.

2. This product was designed for use on stock (un-modified, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard

use (no boost) until the problem is resolved.

5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech warranty coverage considerations

include, but not limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Vortech components with other modifications such as, but

not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

into another language in any form, by any means without written permission of Vortech Engineering, LLC.

ii

TABLE OF CONTENTS

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

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

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

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

PARTS LIST (2007-2008 GM 5.3L Truck) ........................................ vi

PARTS LIST (2007-2008 GM 5.3L Truck, Flex Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

PARTS LIST (2008 6.2L Escalade) ..............................................x

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

2. SUPERCHARGER MOUNTING BRACKET ...................................2

3. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

5. FAN SHROUD MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

6. INLET DUCT INSTALLATION ..............................................6

7A. RADIATOR TUBE INSTALLATION (5.3L) .....................................7

7B. RADIATOR TUBE INSTALLATION (6.2L) .....................................8

8. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

9. SUPERCHARGER BYPASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

10. SURGE TANK AND RESERVOIR TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 13

11A. WATER COOLER INSTALLATION (GM Pickup Truck) . . . . . . . . . . . . . . . . . . . . . . . . . 15

11B. WATER COOLER INSTALLATION (Escalade) ................................16

12A. CHARGE COOLER HOSE ROUTING (GM Pickup Truck) . . . . . . . . . . . . . . . . . . . . . . 19

12B. CHARGE COOLER HOSE ROUTING (Escalade) .............................21

13. WATER PUMP WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

14. HOOD HINGE SPRING REPLACEMENT (Escalade) . . . . . . . . . . . . . . . . . . . . . . . . . . 25

15. REFLASH COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

16. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

iii

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

IMPORTANT NOTE

This kit requires ECM programming. The hand-held ECM programmer is included in the kit box. The hand-held ECM 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.

Vehicles equipped with On-star that have aftermarket stereos will experience problems with the ability to re-program the vehicle’s ECM. It is necessary to disconnect the aftermarket stereo from the 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.

iv

2007-2008 GM Light Trucks

®

ENGINEERING, LLC

50 State Legal Per CARB EO D-213-27

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® 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"

• Springlock 3/8" and 5/8”Fuel Fitting

Disconnect Tool

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• 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 install-

er/puller

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

v

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

2008 6.2L Escalade

®

Part No. 4GL218-350L/358L

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

008341 VORTECH CHARGE COOLER DECAL 1 008447 1 YR S/C STRT INFO PKG ASY VOR 1 009035 S/C LUBE, BOTTLED, VORT 3-PACK 1 2F328-040 V3 SI-TRIM, 01-08 GM LS TR 3.33 1

2A046-113 BELT, 6 RIB X 112.89 EFFECT. L 1 2A046-140 BELT, 6 RIB X 114.00 EFFECT. L 1

4GL011-021 MOUNTING BRACKET-MACH 1 4GL020-018 INSTALL MANUAL, GM TRK 07/08 1 4GL110-120 HINGE, ASY, 07 GM TRK HOOD 1

4GL010-120 HINGE, 07 GM TRK HOOD, LEFT 1 4GL010-130 HINGE, 07 GM TRK HOOD, RIGHT 1 4FB017-041 LOWER SPACER, ALT. BRACKET 2

4GL112-050 AIR INTAKE ASSY, 04 5.3L GM TR 1

4GL010-011 BRKT,D SIDE GM TRK AIR INLET 1 4GL010-012 BRKT,P SIDE 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 7C060-025 M6 X 1.0 X 25MM HX 2 7J006-093 6MM WASHER, PLATED 2 7J250-001 1/4 WASHER, SAE, PLTD 2 7P156-082 5/32 TEE 1 7P250-045 1/4 MALE NPT X 3/8 MALE BARB 1 7P375-050 3/8" HOSE UNION, BRASS 1 7P375-113 PCV VALVE, VIPER, 3/8"-1/2" BA 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE F SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 3 7R002-060 #60 SAE TYPE F SS HOSE CLAMPS 1 7S350-200 SLEEVE, 3-1/2 X 2, BLUE 1 7S350-300 SLEEVE, 3-1/2 X 3, BLUE 1 7S366-350 SLEEVE, REDUCER 3.66 - 3.50 1 7U030-046 5/32" VACUUM LINE 2.5 7U030-056 3/8 PCV/VAC RUBBER HOSE 3.5 7U033-000 5/8" PCV HOSE 0.16 7U034-016 1" GS HEATER HOSE 0.25 7U035-001 3-1/2" FLEX HOSE 0.75 7U133-045 RUBBR ELBO, 1"DIA X 45 DEG 1 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1

4GL114-010 WATER TUBE ASSY, GM TRUCK 1

4GL014-018 WATER TUBE,GM TRUCK,POLISHED 1 7A250-050 1/4-20 X .50 SHCS ZINC PLTD 1 7J006-093 6MM WASHER, PLATED 1 7R002-024 #24 SAE TYPE F SS HOSE CLAMP 2 7R003-022 ADEL CLAMP 1 3/8" 1 7U133-125 HOSE, 1.25DIA 90° LONG LEG 1 5W001-085 SLEEVE, FLEX BRD Ø1.5" NOM. 0.5

4PGL112-070 DISCH ASSY, 07 ESCALADE 1

4GL012-030 ELBOW,3.88"-3.0" X 90º GM TRK 1 4GL012-040 DISCH TUBE A, 6.0 COOLER,CAST 1 4GL012-070 DISCH TUBE B, 07 ESCALADE SAT 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, 3.00-2.75 1

PART NO. DESCRIPTION QTY

5A003-040 DIABLO PRED, 06-07 LS2/LS7 C6 1 8F060-047 FUEL INJ 47LB, DELPHI MULTEC 3 8 8N105-200 WATER TANK ASSY, 07 GM TRUCK 1

2A017-875-08 SPACER, .875 OD X .290 LONG 2 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 2 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 3 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 1 7R007-001 NYLON RATCHET CLAMP 1-1/8" 12 7U030-065 HOSE, 3/4 X 90° RUBBER, SHORT 1 7U038-000 3/4" HEATER HOSE 19 7U038-012 HOSE,3/4"DIA 90°,4X12 LEGS 1 7U038-150 HOSE, 3/4"X150° MOLDED HOSE 1 7U100-055 TIE WRAP, 7.5" NYLON 6 8N010-250 BRKT, SURGE TANK, 07 GM TRK 1 8N010-260 BRKT, COOLANT RES 07 GM TRK 1 8N055-030 TANK, WATER, TRIANGLE SHAPE 1 8N055-050 PLASTIC CAP, SURGE TANK 1 8N056-060 SURGE TANK, PLASTIC 1

8N106-140 WATR COOLR ASY, 07 ESCALADE 1

7A250-050 1/4-20 X .50 SHCS ZINC PLTD 4 7E010-075 #12 X 3/4" SHT METL SCRW HEX 4 7J250-001 1/4 WASHER, SAE, PLTD 8 7R003-016 ADEL CLAMP, 1.0" 1 7U038-012 HOSE,3/4"DIA 90°,4X12 LEGS 1 8N006-020 WATER COOLR, FLDYN DUAL PASS 1 8N010-320 FLDYN BKT, 07 ESCALADE DRVR 1 8N010-330 FLDYN BKT, 07 ESCALADE PASS 1

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

5W001-005 3/8" PLASTIC WIRE LOOM 5 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-013 14-16 GA BUTT CONN BLU INSUL 4 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-019 10-12 GA 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 8F101-320 FUEL PUMP RELAY ASSY, LS1 TRK 1 5W001-002 FUSE TAP 1 7E010-075 #12 X 3/4" SHT METL SCRW HEX 2

8N201-360 CAC ASY, 07 GM TRUCK 1

2A017-875-13 SPACER, .875 OD X .895 LONG 1 4GL010-110 BRKT, CAC SUPPRT 07 GM TRK 1 7C010-040 M10 X 1.5 X 40 HXHD CL8.8 ZN 1 7J010-002 10MM WASHER, ZINC PLATED 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 1 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 1 7U250-200 TAPE, FOAM, 1/4" X 2" X 50' 12 8N101-330 WELDED CORE ASSY, 2007 GM TRK 1

vi

2007-2008 GM 5.3L Truck

®

Part No. 4GL218-360L/368L

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

4GL011-021 MOUNTING BRACKET 1 8F060-047 FUEL INJECTOR, GM 8.1 DELPHI 8 5A003-040 04-07 GM PREDATOR 1 4GL020-018 INSTALLATION MANUAL 1 009035 S/C LUBE, BOTTLED, 3-PACK 1

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

4GL012-030 ELBOW,3.88”-3.0” X 90º 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, 3.00-2.75 1

4GL112-050 AIR INTAKE ASSY, 04 5.3L GM TR 1

4GL010-011 BRKT,D SIDE GM TRK AIR INLET 1 4GL010-012 BRKT,P SIDE GM TRK AIR INLET 1 4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1 7A250-050 1/4-20 X .50 SHCS ZINC PLTD 2 7J006-093 6MM WASHER, PLATED 2 7P156-082 5/32 TEE 1 7P250-045 1/4 MALE NPT X 3/8 MALE BARB 1 7P375-050 3/8” HOSE UNION, BRASS 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE F SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 3 7S350-300 SLEEVE, 3-1/2 X 3, BLUE 1 7U030-046 5/32” VACUUM LINE 2.5 7U030-056 3/8 PCV/VAC RUBBER HOSE 3.5 7J250-001 1/4 WASHER, SAE, PLATED 2 7U034-016 1” GS HEATER HOSE 0.25 7U035-001 3-1/2” FLEX HOSE 0.75 7U375-052 3/8” VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7U133-045 RUBBR ELBO, 1”DIA X 45 DEG 1 7U033-000 5/8” PCV HOSE 0.16 7P375-113 PCV VALVE, VIPER, 3/8”-1/2” BA 1 4PGL012-017 DUCT, S/C INLET, 03 ESCALADE 1 7S350-200 SLEEVE, 3-1/2 X 2, BLUE 1 7R002-060 #60 SAE TYPE F SS HOSE CLAMPS 1 7C060-025 M6 X 1.0 X 25MM HX 2

4GL114-010 WATER TUBE ASSY, GM TRUCK 1

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

2F338-010 V-3 SC TRIM LS1 TRUCK 1

2A036-312 S/C PULLEY 3.125” 6-GRV 1 7U100-070 KEY, 3/16” SQUARE x 7/8” LONG 1 2A040-011 PULLEY RETAINER S/C 1 7B375-110 3/8-24 x 1” GRADE 8 HXHD 1 7K375-040 3/8”AN960 FLAT WASHER PLATED 1 2A046-113 BELT, K061130-GATES 1 7A375-224 3/8-16 x 2.25” GR5 HX 5 7J375-044 3/8” SAE WASHER, PLTD 5 7C012-050 M12 x 1.75” x 50mm HXHD BOLT 1 4FA016-171 DUST COVER (IDLER PULLEY) 1 4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1 2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A046-140 BELT, GATES K061140 1

PART NO. DESCRIPTION QTY

4GL110-010 ASSY, COMPUTER RELOC ‘03 LS1 TR 1

2A017-752-02 SPACER, .750”OD x .894” LONG 2 9AL6061-750 Ø.750” 6061 ALUMINUM ROD 1 7C060-050 M6 x 1.0” 50 HXHD ZINC PLATE 2 7F006-093 6mm NYLOCK NUT 2 7J006-093 6mm WASHER, PLATED 4

8N201-360 CAC ASY, 2007 GMTRUCK 5.3L 1

2A017-875-13 SPACER, .875 OD X .895 LONG 1 9AL6061-0875 7/8” DIA. 6061 ALUMINUM ROD 1.16129 4GL010-110 BRKT, CAC SUPPRT 07 GM TRK 1 7C010-040 M10 X 1.5 X 40 HXHD CL8.8 ZN 1 7J010-002 10MM WASHER, ZINC PLATED 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 1 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 1 7U250-200 TAPE, FOAM-1/4” X 2” X 50’ 12 8N101-330 WELDED CORE ASSY, 2007 GM TRK 1 8N101-001 WELDED CORE ASSY W/ENDS ONLY 1 8N002-011 COOLER TANK A, MACHINED 1 8N002-010 COOLER TANK A, CASTING 1 8N002-021 COOLER TANK B, MACH, STD PAT 1 8N002-020 COOLER TANK B, CAST W/HOLES 1 7P062-188 1/16 NPT PIPE PLUG 4 8N003-070 DUCT.COOLER.OUTLET.LS1.FBODY 2 8N003-070R DUCT.COOLER.OUTLET.LS1.FBODY 1

8N105-200 WATER TANK ASSY, 2007 GMTRUCK 1

8N010-250 BRKT, SURGE TANK, 07 GM TRK 1 8N010-260 BRKT, COOLANT RES 07 GM TRK 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 3 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 3 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8” 12 7U030-065 3/4”X90° RUBBER HOSE, SHORT 1 7U038-000 3/4” HEATER HOSE 19 7U038-012 HOSE,3/4”DIA 90°,4X12 LEGS 1 7U038-150 HOSE, 3/4”X150° MOLDED HOSE 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 LONG 2

8N106-160 WATER COOLER ASY, 2007 GM TRK 1

8N010-270 BRKT “A”, HEAT EXCHGR 07 GMT 1 8N010-280 BRKT “B”, HEAT EXCHGR 07 GMT 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 7R003-016 ADEL CLAMP, 3/4”ID,1/4”EYE 1 7U038-012 HOSE,3/4”DIA 90°,4X12 LEGS 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 2 8N006-010 WATER COOLR, SETRAB SINGLE PAS 1

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

5W001-005 3/8” PLASTIC WIRE LOOM 5 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-013 14-16 GA BUTT CONN BLU INSUL 4 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-019 10-12 GA 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

vii

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

2007-2008 GM 5.3L Truck, cont'd

®

Part No. 4GL218-360L/368L

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

7U100-055 TIE WRAP, 7.5” NYLON 6 8F001-402 PUMP, WATER, PIERBURG 1 8F101-320 FUEL PUMP RELAY ASSY, 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 12 GA,STRD WIRE, RED 9.5 5W012-000 12 GA,STRD WIRE, RED 1.5 5W012-010 12 GA WIRE BLACK 0.5 5W014-030 14GA STRD WIRE BLACK 0.5 5W016-010 16GA STRD WIRE YELLOW 2.5 5W001-002 FUSE TAP 1 7E010-046 #8 X 3/4 SHEET METAL 2

viii

2007-08 GM 5.3L Truck, Flex Fuel

®

Part No. 4GL218-370L/378L

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

4GL011-021 MOUNTING BRACKET 1 8F060-008 FUEL INJECTOR, FLEX 8 5A003-040 04-07 GM PREDATOR 1 4GL020-018 INSTALLATION MANUAL 1 009035 S/C LUBE, BOTTLED, 3-PACK 1

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

4GL012-030 ELBOW,3.88”-3.0” X 90º 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, 3.00-2.75 1

4GL112-050 AIR INTAKE ASSY, 04 5.3L GM TR 1

4GL010-011 BRKT,D SIDE GM TRK AIR INLET 1 4GL010-012 BRKT,P SIDE GM TRK AIR INLET 1 4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1 7A250-050 1/4-20 X .50 SHCS ZINC PLTD 2 7J006-093 6MM WASHER, PLATED 2 7P156-082 5/32 TEE 1 7P250-045 1/4 MALE NPT X 3/8 MALE BARB 1 7P375-050 3/8” HOSE UNION, BRASS 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE F SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 3 7S350-300 SLEEVE, 3-1/2 X 3, BLUE 1 7U030-046 5/32” VACUUM LINE 2.5 7U030-056 3/8 PCV/VAC RUBBER HOSE 3.5 7J250-001 1/4 WASHER, SAE, PLATED 2 7U034-016 1” GS HEATER HOSE 0.25 7U035-001 3-1/2” FLEX HOSE 0.75 7U375-052 3/8” VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7U133-045 RUBBR ELBO, 1”DIA X 45 DEG 1 7U033-000 5/8” PCV HOSE 0.16 7P375-113 PCV VALVE, VIPER, 3/8”-1/2” BA 1 4PGL012-017 DUCT, S/C INLET, 03 ESCALADE 1 7S350-200 SLEEVE, 3-1/2 X 2, BLUE 1 7R002-060 #60 SAE TYPE F SS HOSE CLAMPS 1 7C060-025 M6 X 1.0 X 25MM HX 2

4GL114-010 WATER TUBE ASSY, GM TRUCK 1

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

2F338-010 V-3 SC TRIM LS1 TRUCK 1

2A036-312 S/C PULLEY 3.125” 6-GRV 1 7U100-070 KEY, 3/16” SQUARE x 7/8” LONG 1 2A040-011 PULLEY RETAINER S/C 1 7B375-110 3/8-24 x 1” GRADE 8 HXHD 1 7K375-040 3/8”AN960 FLAT WASHER PLATED 1 2A046-113 BELT, K061130-GATES 1 7A375-224 3/8-16 x 2.25” GR5 HX 5 7J375-044 3/8” SAE WASHER, PLTD 5 7C012-050 M12 x 1.75” x 50mm HXHD BOLT 1 4FA016-171 DUST COVER (IDLER PULLEY) 1 4FH016-150 IDLER PULLEY, 6-RIB 3” FLANGED 1 2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A046-140 BELT, GATES K061140 1

PART NO. DESCRIPTION QTY

4GL110-010 ASSY, COMPUTER RELOC ‘03 LS1 TR 1

2A017-752-02 SPACER, .750”OD x .894” LONG 2 9AL6061-750 Ø.750” 6061 ALUMINUM ROD 1 7C060-050 M6 x 1.0” 50 HXHD ZINC PLATE 2 7F006-093 6mm NYLOCK NUT 2 7J006-093 6mm WASHER, PLATED 4

8N201-360 CAC ASY, 2007 GMTRUCK 5.3L 1

2A017-875-13 SPACER, .875 OD X .895 LONG 1 9AL6061-0875 7/8” DIA. 6061 ALUMINUM ROD 1.16129 4GL010-110 BRKT, CAC SUPPRT 07 GM TRK 1 7C010-040 M10 X 1.5 X 40 HXHD CL8.8 ZN 1 7J010-002 10MM WASHER, ZINC PLATED 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 1 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 1 7U250-200 TAPE, FOAM-1/4” X 2” X 50’ 12 8N101-330 WELDED CORE ASSY, 2007 GM TRK 1 8N101-001 WELDED CORE ASSY W/ENDS ONLY 1 8N002-011 COOLER TANK A, MACHINED 1 8N002-010 COOLER TANK A, CASTING 1 8N002-021 COOLER TANK B, MACH, STD PAT 1 8N002-020 COOLER TANK B, CAST W/HOLES 1 7P062-188 1/16 NPT PIPE PLUG 4 8N003-070 DUCT.COOLER.OUTLET.LS1.FBODY 2 8N003-070R DUCT.COOLER.OUTLET.LS1.FBODY 1

8N105-200 WATER TANK ASSY, 2007 GMTRUCK 1

8N010-250 BRKT, SURGE TANK, 07 GM TRK 1 8N010-260 BRKT, COOLANT RES 07 GM TRK 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 3 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 3 7P500-078 1/2NPT X 3/4 HOSE FIT STRT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8” 12 7U030-065 3/4”X90° RUBBER HOSE, SHORT 1 7U038-000 3/4” HEATER HOSE 19 7U038-012 HOSE,3/4”DIA 90°,4X12 LEGS 1 7U038-150 HOSE, 3/4”X150° MOLDED HOSE 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 LONG 2

8N106-160 WATER COOLER ASY, 2007 GM TRK 1

8N010-270 BRKT “A”, HEAT EXCHGR 07 GMT 1 8N010-280 BRKT “B”, HEAT EXCHGR 07 GMT 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 7R003-016 ADEL CLAMP, 3/4”ID,1/4”EYE 1 7U038-012 HOSE,3/4”DIA 90°,4X12 LEGS 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 2 8N006-010 WATER COOLR, SETRAB SINGLE PAS 1

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

5W001-005 3/8” PLASTIC WIRE LOOM 5 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-013 14-16 GA BUTT CONN BLU INSUL 4 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-019 10-12 GA 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

ix

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

07-08 GM 5.3L Truck, Flex Fuel, cont'd

®

Part No. 4GL218-370L/378L

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

7U100-055 TIE WRAP, 7.5” NYLON 6 8F001-402 PUMP, WATER, PIERBURG 1 8F101-320 FUEL PUMP RELAY ASSY, 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 12 GA,STRD WIRE, RED 9.5 5W012-000 12 GA,STRD WIRE, RED 1.5 5W012-010 12 GA WIRE BLACK 0.5 5W014-030 14GA STRD WIRE BLACK 0.5 5W016-010 16GA STRD WIRE YELLOW 2.5 5W001-002 FUSE TAP 1 7E010-046 #8 X 3/4 SHEET METAL 2

x

1. COMPONENT REMOVAL

A. Drain a sufficient amount of coolant to allow

for removal of the upper radiator hose and

clamps. B. Disconnect the negative battery cable. C. Remove all ducting between the MAF meter

and the throttle body. D. Remove the upper radiator hose and set it

aside for modification in a future step. E. Remove the accessory drive belt. (Keep in

the vehicle as a spare.) F. Remove the idler from the cast bracket and

set aside for later use. G. The plastic engine covers that extend over

the valve covers (if equipped) will need to be

removed. The upper manifold cover section

may either be removed completely or left in

place and trimmed in order to clear super-

charger componentry. H. Remove the power steering pump pulley with

a pulley puller. Remove the three bolts secur-

ing the front of the power steering pump. I. Remove the alternator, bushings and bolts

and set aside for later use. The alternator

bushings can be removed by tapping the

small end through the bracket with an appro-

priately sized socket. J. Remove the alternator and power steering

pump mounting bracket by removing the

three bolts securing it to the head and the

bottom bolt securing it to the engine block. K. Remove the oil filler neck and cap from the

passengers side valve cover. Do this by twist-

ing in a counter-clockwise motion. Re-install

the cap directly into the valve corner. L. Remove retaining clips securing the plastic

cover between the grill and radiator support. M. Remove the grill by depressing the retaining

clip securing it to the radiator core support.

1

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

2. SUPERCHARGER MOUNTING BRACKET

A. Install the original alternator bushings into the

supercharger mounting bracket with the flanged portion pointed back. (See Figs. 2-a,

2-b.) B. Clean front of driver’s side head of debris. C. Bolt the supplied Vortech supercharger

mounting bracket to the head and block using

the original mounting bolts. Make sure the

mounting bracket is seated directly on a

machined surface on the head and that no

wires are pinched. D. Tighten the four mounting bolts to 37 ft-lbs

(50 N-m). E. Install the two original bolts holding the alter-

nator fusible link junction box in the super-

charger mounting bracket so that it is in the

stock location. F. Attach the power steering pump to the

Vortech bracket using the original mounting

hardware. Tighten the four power steering

pump bolts to 37 ft-lbs (50 N-m). (One bolt is

still loosely inserted in the engine block.) G. Reinstall the power steering pump pulley.

Make sure that it is seated flush with the end

of the power steering pump shaft. H. Reinstall the alternator using the original

hardware. (See Fig. 2-c.) I. Install the factory idler pulley at the location

shown in Fig. 4-b. Spin the idler to verify that

the rotating portion does not contact the alter-

nator bolt.

Fig. 2-a

Fig. 2-b

Fig. 2-c

2

3. FUEL INJECTOR REPLACEMENT

NOTE: Complete removal of the fuel rail will aid in injector replace-

ment. Separate the fuel rail supply line from the rail using springlock disconnect tool.

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

and retainers from the injectors.

C. Remove the four 10mm bolts holding down

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

D. Using a small amount of clean motor oil, light-

ly lubricate the O-rings on both ends of the Vortech 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 each injector has been seated properly into the manifold.

G. Tighten down the fuel rail assembly with the

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

3

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

4. SUPERCHARGER INSTALLATION

A. Loosely install the supercharger onto the

Vortech bracket. Start all five 3/8-16 x 2-1/4" supercharger mounting screws with washers.

B. Tighten the supercharger mounting

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

C. Install the Vortech supplied M12 x 50mm

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

D. Install the supplied supercharger/acces-

sory drive belt per Fig. 4-b.

Fig. 4-a

Fig. 4-b

4

5. FAN SHROUD MODIFICATION

A. Locate the large supplied air inlet duct that will

run across the radiator.

B. Thefanshroudwillneedtobemodiedtoallow

access for mounting of the air inlet duct.

C. Remove the two 13 mm headed bolts retaining

the fan shroud (See Fig 5-a).

D. Using the duct as a template, mark the fan shroud

(See Fig 5-b).

E. Lift up on the fan shroud releasing it from the

lower retaining clips.

F. Using an abrasive cut off wheel remove the lip on

the shroud (See Fig 5-b). Reinstall fan shroud. G. Reinstall the 13 mm bolts removed earlier. H. Locate the small angled brackets that will be

attached to the air inlet duct. Using the supplied

hardware, attach the brackets to the duct (See

Fig 5-c). I. Using the supplied M6 bolts and washers, tempo-

rarily attach the duct to the core support using the

factory weld nuts (See Fig 5-b, c). J. Trim the fan shroud for the electric fans to gain ac-

cess to the screw locations (See Fig 5-c). K. Remove the air inlet duct temporarily.

13MM BOLTS TO REMOVE

Fig. 5-a

AREA TO TRIM

WELDNUT LOCATION

FACTORY

SHROUD BOLT

Fig. 5-b

SUPPLIED DUCT

MOUNTING TABS

(LEFT & RIGHT)

SUPPLIED 1/4-20

HARDWARE

AREA TO TRIM

(USE SUPPLIED

6mm HARDWARE)

Fig. 5-c

5

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

6. INLET DUCT INSTALLATION

A. Install the supplied 3.7"x3.5" reducer sleeve

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

B. Remove any plastic clips that are no longer

used to secure the OEM radiator hose.

C. Slide the entry of the large plastic inlet duct

into the sleeve installed on the MAF (See Fig. 6-a). Lower the inlet duct onto the top of the radiator shroud.

NOTE: The end of the plastic inlet duct that fits into the MAF sleeve

may require trimming on some applications.

D. Insert the supplied 1/4-20 x 1/2" screws

through the bracket and into each side of the inlet duct using the supplied washers. Tighten the screws. (See Fig 6-a.)

E. Using Fig. 6-b, drill a 9/16" hole in the shown

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

F. Install the supplied 180° inlet duct onto the

inlet of the supercharger after the supercharger is installed. Orient the duct so that it "swoops" over the side of the supercharger with the end pointing at the crossover duct. (See Fig 6-d.)

G. Install the supplied #52 hose clamps and

3-1/2" x 7" long flex hose between the two ducts previously installed. Trim hose if needed.

H. Use the supplied 3/8" hose from the 3/8" fit-

ting on the inlet duct to the passenger side valve cover breather hose. Secure the hose so that it cannot interfere with the throttle arm or cable. (See Fig 6-c.)

I. Install and tighten the hose clamps on each

connection. (See Fig. 6-a.)

Fig. 6-a

NEW LOCATION

TO DRILL

Fig. 6-b

SUPPLIED 3/8" HOSE

SUPPLIED 3/8"

RUBBER CAP

Fig. 6-c

Fig. 6-d

6

7A. 5.3L RADIATOR TUBE INSTALLATION (5.3L ENGINES ONLY - ALL OTH-

ERS SKIP TO SECTION 7B)

A. Locate the factory upper radiator hose

removed in an earlier step of the installation.

B. Modify the hose by trimmiing the areas noted.

(See Fig.7-a)

C. Using a 2-3" long straight section of the por-

tion of one of the hoses to be discarded, attach it to the outlet of the radiator and secure using the factory clamp.

D. Locate the supplied radiator cross-over tube

and attach it to the short hose with the supplied #24 clamp.

E. Use the supplied adel clamp and 1/4-20 x 1/2"

screw and washer to secure the radiator tube to the insert on the large plastic inlet duct. (See Fig. 7-c, 7-d.)

F. Slide the length of hose protection sleeve over

the radiator hose in the location shown (See Fig. 7-d).

G. Attach the modified factory hose to the cross

over tube with a supplied clamp and secure the other end to the water pump inlet using the factory clamp (See fig 7-b).

H. Refill the coolant reservoir.

DISCARD THESE PORTIONS

Fig. 7-a

Fig. 7-b

Fig. 7-c

Fig. 7-d

7

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

7B. 6.2L RADIATOR TUBE INSTALLATION (6.2L ENGINES ONLY - ALL OTH-

ERS SKIP TO SECTION 8)

A. Locate the factory upper radiator hose

removed in an earlier step of the installation.

B. Modify the hose by trimming the areas noted.

(See Fig.7-a)

C. Using a 3" long straight section of the portion

of one of the hoses to be discarded, attach it to the outlet of the radiator and secure using the factory clamp.

D. Locate the supplied radiator cross-over tube

and attach the bent end to the short hose with the supplied #24 clamp.

E. Use the supplied adel clamp and 1/4-20 x 1/2"

screw and washer to secure the radiator tube to the insert on the large plastic inlet duct. (See Fig. 7-e)

F. Cut another 3 inch long straight section from

the factory radiator hose and attach to long end of the radiator cross over tube.

G. Using the supplied 45 deg hose bend, insert

into the other end of the 3 inch straight piece installed in the previous step. Connect the modified factory hose between the opposite end of 45° elbow and water pump fitting. Secure with 2 clamps. (See Figure 7-f)

H. Be sure that hose transition is smooth and

free from kinks.

I. Trim radiator hose as required to allow for a

kink free transition of the coolant hose as shown in figure 7-f.

J. Refill the coolant reservoir.

DISCARD THESE PORTIONS

Fig. 7-a

Fig. 7-e

Fig. 7-f

8

8. CHARGE COOLER INSTALLATION

A. Remove the screw from the front of the pas-

senger side head. Remove the 10mm nut located between the middle coil packs on the passenger side valve cover, below the white electrical connector. (See Figs. 8-a, 8-b.)

B. Install the charge air cooler support bracket

using the fasteners supplied. (See Figs. 8-a, 8-b.) Apply adhesive foam to the top of the support bracket where the charge air cooler rests. Make sure all hoses and wires are clear from the bracket edges.

NOTE: On later model trucks there will be no EGR assembly. Use the

supplied 10mm x 1.5" screw, washer and .975" spacer in its place. (See Fig. 8-a.)

C. Slightly bend both the transmission and

engine oil dipsticks up and away to give clearance for the charge air cooler.

D. Install the nickel plated 1/2"NPT x 3/4 90°

and straight brass fittings into the charge air cooler using thread sealant on the threads. (See Fig. 8-d.)

E. Install a 20-inch piece of 3/4 hose to the 90°

fitting and secure with a nylon clamp.

F. Attach the long 90° formed hose to the

straight barbed fitting on the charge cooler. (See Fig 8-c).

G. Set the charge air cooler on the support with

the 90° brass fitting in the upper left corner facing toward the passenger’s side. Using the 2-3/4" sleeves and #44 hose clamps, connect discharge tube “A” to the discharge of the supercharger and to the inlet of the charge air cooler (See Fig 8-e).

Fig. 8-a

SECURE HOSES AWAY

FROM BRACKET

Fig. 8-b

9

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

8. CHARGE COOLER INSTALLATION, cont’d.

90 BRASS FITTINGPOINTING TOWARD SURGE TANK

°

VIEW FROM REAR OF COOLER

STRAIGHT BRASS FITTING

H. Slide the 90° silicone elbow sleeve onto the

throttle body. Slide the 2-3/4" end of the reducer sleeve onto the outlet side of the cooler. Using the #48 hose clamps install discharge tube "B" from the 3" end of the 90° sleeve to the 3" end of the reducer sleeve on the cooler. Use the #64 hose clamp to secure the 90° sleeve to the throttle body. Tighten all clamps. (See Fig. 8-c)

Fig. 8-c

Fig. 8-f (6.2L Shown)

Fig. 8-d

Fig. 8-e (5.3L Shown)

10

9. SUPERCHARGER BYPASS INSTALLATION

5/32" TEE HOSE INTO

VACUUM LINE ATTACHED

TO THE FMU

ø

DISCHARGE

TUBESUPERCHARGER

AIR INLET

DUCT

BYPASS VALVE V

A. Connect the 4" length of Ø1" hose from the

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

B. Cut the supplied molded hose as shown in

Fig. 9-a.

C. Using the supplied #16 hose clamps, connect

the barb on the discharge duct to the inlet of the bypass valve using the previously cut Ø1" molded hose. (See Fig. 9-b.)

NOTE: Some vehicles may require trimming of the engine cover to

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

D. Install and tighten hose clamps on each con-

nection.

Fig. 9-b

CUT AND DISCARD

Fig. 9-a

11

Fig. 9-c

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

9. SUPERCHARGER BYPASS INSTALLATION, cont’d.

E. Locate the capped-off manifold vacuum port

on the passenger’s side of the intake manifold. Using a file, hacksaw or standard screwdriver with hammer, remove the tip of the capped-off section. Using the supplied 5/32" vacuum line, connect the bypass valve pressure port to the modified pressure port. (See Fig. 9-d.)

F. Locate the hard plastic line running to the

drivers side rear of the engine. Remove the hard line from the rubber hose.

G. Install the supplied 90° PCV valve into the

rubber hose on the engine.

H. Cut the hard plastic line to reach the PCV

valve and connect them with the supplied length of 3/8" hose. (See Fig. 9-e.)

SUPPLIED 5/32" HOSE

Fig. 9-d

SUPPLIED PCV VALVE

Fig. 9-e

12

10. SURGE TANK AND RESERVOIR TANK INSTALLATION

A. Locate the supplied surge tank, P/N 8N056-060

and the supplied mounting bracket. Attach the bracket to the surge tank with the supplied 1/420 x .50 bolts and washers. Install one nickel

platedstraight1/2NPTx3/4barbedttinginto

the bottom and one 1/2" NPT x 3/4" barb in the side. (See Fig 10-a)

NOTE: Vortech suggests using pipe paste/sealant/tape on all NPT

threads for the cooling system.

B. Locate the hood hinge brace on the passenger

side of the engine compartment. Remove the two 13mm headed bolts securing the bracket. (See Fig 10-b)

C. Place the surge tank bracket between the brace

and the cowl reinstall the two bolts previously removed. (See Fig 10-c)

D. Installtwo1/2X3/4”90ºbarbedttingsinto

the top and bottom of the supplied "triangle shaped" coolant reservoir.

E. Attach the water pump to the reservoir using the

supplied Adel clamp and 1/4-20x.50 screw with washer. (See Fig 10-d)

F. Install the supplied reservoir-mounting bracket

to the reservoir with the hardware provided.

G. Using the bracket and the reservoir as a tem-

plate, mark the mounting location on the frame rail behind the front bumper cover and just in front of the round bar that the skid pan mounts to. (See Fig 10-d)

H. After marking the location for the mounting

bracket, drill two 1/8”size holes. Install the reservoir and the bracket using the self tapping sheet metal screws provided.

I. Install the small 90º hose between the water

pumpandthe90ºbarbedttinginstalledin

an earlier step. Secure with two nylon ratchet clamps. (See Fig 10-d)

J. (GM Pickup Truck Only) Attach the 150º-

formed hose to the outlet of the water pump leave the nylon clamp loose for proper adjustment at a later stage of the installation. (See Fig 10-d)

Fig. 10-a (90 ° fitting not shown)

REMOVE SCREWS

Fig. 10-b

Fig. 10-c

13

Fig. 10-d

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

10. SURGE TANK AND RESERVOIR TANK INSTALLATION, cont’d

K. Install the supplied 3/4 X 90º formed hose to

the1/2x3/4barbedttingonthetopofthe

reservoir. (See Fig 10-e)

L. Install a supplied 3/4 hose union into the

formed 90º hose and secure with a nylon clamp. (See Fig 10-f)

M. Attach a length of 3/4 hose approximately 48”

in length to the opposite end of the hose union and secure with a nylon clamp.

N. Route the length of hose through the radiator

core support. Secure the hose to one of the factory holes in the grille support bracket, using an Adel clamp and the fasteners. (See Fig 10g)

O. Route the hose free of kinks and away from

sharporhotareastothebottomofthellreservoir installed in and earlier step (See Fig 12-a).

90º Hose

Fig. 10-e

Fig. 10-f

Fig. 10-g

14

11A. GM PICKUP TRUCK WATER COOLER INSTALLATION (GM PICKUP

TRUCK ONLY - ALL OTHERS SKIP TO SECTION 11B)

A. Locate the water cooler assembly, P/N 8N106-

160

B. Installtwo1/2x3/4x90ºbarbedttingsinto

heatexchanger.Orientthettingssothatone

faces down and slightly back towards the radia-

torcoresupport.Theremainingttingshould

face back towards the radiator core support. (See Fig 11-d)

C. Assemble the heat exchanger to the lower

mounting bracket using the provided 1/4-20 bolts, washers and nuts.

D. Locate the nylon-retaining clip securing the

plasticaptotheupperradiatorcoresupport. Removetheclipandmovetheplasticapto

the side. (See Fig 11-a)

E. Trim radiator core support as shown in Fig. 11-

c.

F. Attach the lower cooler mounting bracket to the

two 10 mm headed bolts located on the passenger side of the radiator core support. (See Fig 11-b).

G. Attach the upper heat exchanger mount to the

A/C condensor mount. Secure with the factory fastener. Secure the heat exchanger support bracket to the heat exchanger with the supplied bolts, nuts and washers. (See Fig 11-d)

H. Install the 90º formed hose from the outlet (up-

pertting)oftheheatexchangerandroutethe

hose behind the heat exchanger.

I. Install a hose union to the 90º hose and secure

with a nylon clamp.

J. Attach a length of 3/4 hose to the opposite end

of the hose mender and secure with a clamp.

K. Route the hose thru the radiator core support

andundertheairlterenclosuretothecharge

cooler.

L. Itwillbenessacarytotrimtheplasticapfor

clearance. (See Fig 11-e)

Fig. 11.-a

Fig. 11-b

Fig. 11-e

15

Fig. 11-c

Fig. 11-d

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

11B. ESCALADE WATER COOLER INSTALLATION (ESCALADE ONLY - ALL

OTHERS SKIP TO SECTION 12)

A. Locate the water cooler assembly P/N

8N106.140

B. Remove 4 fasteners on each side connecting

the front inner splashguards to the bumper cover. (See Fig 11-e)

C. Remove fasteners that attach the underside

of the bumper cover on each side just in front the tires. (See Fig 11-f)

D. Remove the 6 screws securing the top portion

of the front grill to the body. (See Fig 11-g)

E. Releasethesidesofthebumpercoverbyrst

pulling outward then forward. (See Fig 11-h)

FENDER LINER

FASTENERS

Fig. 11-e

REMOVE SCREWS

FRONT GRILL

FASTENERS

PULL OUT

THEN FORWARD

Fig. 11-f

Fig. 11-g

Fig. 11-h

16

11B. ESCALADE WATER COOLER INSTALLATION, CONT'D (ESCALADE

ONLY - ALL OTHERS SKIP TO SECTION 12)

F. Remove the bumper cover with grill attached

slowly, being sure to unplug the wiring harness on each side located just on top of the front crash bar. (See Fig 11-i & 11-j)

G. Temporarily attach the two supplied brackets to

the water heat exchanger as shown. (See Fig 11-k)

H. Place the heat exchanger with bracket in place

and mark hole locations to drill on trapezoidal radiator support crosslink member. (See Fig 11-m)

DISCONNECT

ELECTRICAL CONNECTORS ON EACH SIDE

Fig. 11-i

Fig. 11-j

Fig. 11-k

17

Fig. 11-m

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

11B. ESCALADE WATER COOLER INSTALLATION, CONT'D (ESCALADE

ONLY - ALL OTHERS SKIP TO SECTION 12)

I. Using an angle drill and extreme caution as to

not damage radiator, drill an 11/64 hole in the locations previously marked. If necessary to prevent radiator damage, remove the Trapezoidal radiator support members to drill holes (See Fig 11-n & 11-o).

J. Using supplied sheet metal screws, attach the

brackets to the Trapezoidal radiator support as shown (See Fig 11-p & 11-q).

K. Using supplied ¼ -20 x .50 SHCS and washers

install cooler on brackets making sure that the cooler is oriented as shown in Fig 11-r.

Fig. 11-n

Fig. 11-o

Fig. 11-p

Fig. 11-r

Fig. 11-q

18

12A. GM PICKUP TRUCK CHARGE COOLER HOSE ROUTING (GM PICKUP

TRUCK ONLY - ESCALADE SKIP TO SECTION 12B)

NOTE: · When routing hoses, refer to Fig. 12-a (next page)

· Make sure to leave the hoses slightly long to allow for engine movement..

· Verify all hose lengths to the vehicle before cutting.

· Ensure that there are no kinks or tight bends in the rubber water hoses.

A. Cut a 13.5" length of 3/4" hose. Run this from the 90°

fitting on the charge air cooler to the 90° brass fitting on the side of the surge tank.

B. Cut a 36.5" length of 3/4" hose. Run it from the bot-

tom fitting on the surge tank along the fender toward the front and down to the 90° brass fitting on the top of the water reservoir.

C. Take the supplied 4" x 12" 90° molded elbow and cut

1-3/4" from the 4" long end end. Connect the trimmed end to the straight brass fitting on the charge air cooler. Route the long end toward the surge tank. Cut a 110" length of hose and connect it to the end of the installed molded elbow with the supplied 3/4" union. Route the hose along the fenderwell, down toward the water reservoir and up under the front bumper. There is a small opening in the rubber apron between the bumper and A/C condenser. Pull the hose up and through, then connect it to the driver’s side 90° fitting.

D. Cut a 64" length of 3/4" hose. Run it from the outlet of

the water pump to the same hole in the rubber apron you pulled the previous hose through. Pull the hose up and through, then connect it to the passenger’s side 90° fitting.

E. Secure all hose ends with the supplied nylon clamps.

19

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

8N010-260 RESERVOIR MOUNTING BRACKET

1/2" SOCKET HEAD CAP SCREW (7A250-050)

1/2 NPT TO 3/4" HOSE BARB (7P500-078)

SURGE TANK (8N156-050) TOP VIEW

90° 1/2 NPT TO 3/4" HOSE BARB (7P500-026)

8N201-360 CHARGE AIR COOLER

1/2 NPT TO 3/4" HOSE BARB (7P500-078)

90° 1/2 NPT TO 3/4" HOSE BARB 7P500-026)

7U038-012 3/4 MOLDED HOSE 4X12

3/4" HOSE UNION (7P375-075)

7U038-065 3/4 FORMED HOSE SHORT

90° 1/2 NPT TO 3/4" HOSE BARB (7P500-026)

8N006-010 CHARGE AIR WATER HEAT EXCHANGER

7U038-150 150º MOLDED HOSE

WATER RESERVOIR (8N055-030)

90° 1/2 NPT TO 3/4" HOSE BARB (7P500-026)

1/2" SOCKET HEAD CAP SCREW (7A250-050) (INSTALL THROUGH ADEL CLAMP AND INTO WATER

TANK TO HOLDWATER PUMP) WATER PUMP (8F001-402)

WATER PUMP CLAMP 8N010-080

90° 1/2 NPT TO 3/4" HOSE BARB, BOTTOM OF TANK (7P500-026)

1" NPT HOLE NOT USED. HOLE SHOULD BE BLIND OR PLUGGED

90° 1/2 NPT TO 3/4" HOSE BARB 7P500-026)

8N010-0270 HEAT EXCHANGER MOUNTING BRACKET

WATER PUMP HOSE ROUTING (PICK-UP TRUCK APPLICATIONS ONLY)

Fig. 12-a

20

12B. ESCALADE CHARGE COOLER HOSE ROUTING (ESCALADE ONLY - ALL

OTHERS SKIP TO SECTION 13)

A. Using a ¾“ hose union and 2 nylon clamps

extend the long leg of the 150º hose bend with additional ¾ hose. (See Fig 12-c)

B. Feed the short end of the 150º hose across

the top of the lateral frame rail that extends just behind the front horizontal crush tube (See Fig 12-d)

C. Connect the short end of the 150º hose to the

outlet of the water pump and secure with clamp. (See Fig 12-e)

D. Sweep the hose attached to the long leg of

the 150 deg hose just under the headlight and turn back to connect to the lower port on the water heat exchanger. (See fig 12-f)

E. Attach a length of ¾“ hose to the top port on

the water heat exchanger and feed through side of radiator as shown and route to hose attached to the lower fitting on the CAC. (See Fig 12-g)

Fig. 12-c

CONNECT

AND CLAMP

Fig. 12-d

Fig. 12-e

Fig. 12-g

21

Fig. 12-f

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

WATER COOLER (8N006-020)

8N010-260 RESERVOIR MOUNTING BRACKET

1/2" SOCKET HEAD CAP SCREW (7A250-050)

1/2 NPT TO 3/4" HOSE BARB (7P500-075)

SURGE TANK (8N156-050) TOP VIEW

90° 1/2 NPT TO 3/4" HOSE BARB (7P500-034)

8N201-360 CHARGE AIR COOLER

1/2 NPT TO 3/4" HOSE

BARB (7P500-075) 90° 1/2 NPT TO 3/4" HOSE BARB 7P500-034)

7U038-012 3/4 MOLDED HOSE 4X12

3/4" HOSE UNION (7P375-075)

7U038-150 150º MOLDED HOSE

WATER RESERVOIR (8N055-030)

90° 1/2 NPT TO 3/4" HOSE BARB (7P500-026)

1/2" SOCKET HEAD CAP SCREW (7A250-050) (INSTALL THROUGH ADEL CLAMP AND INTO WATER TANK TO HOLDWATER PUMP)

WATER PUMP (8F001-402)

WATER PUMP CLAMP 8N010-080

90° 1/2 NPT TO 3/4" HOSE BARB, BOTTOM OF TANK (7P500-026)

1" NPT HOLE NOT USED. HOLE SHOULD BE BLIND OR PLUGGED

WATER PUMP HOSE ROUTING (ESCALADE ONLY)

Fig. 12-h

22

13. WATER PUMP WIRING

A. Mount the supplied water pump relay. (See

Fig. 13-a.)

B. Connect the red 12-gauge wire from terminal

#30 to the supplied ring terminal. Connect to the positive terminal on the power distribution box (See Fig. 13-b.).

C. Feed the yellow wire from relay terminal #85

to the fuse box (electrical center) on the driver’s side of the engine bay.

D. (For 5.3L GM Pickup Truck) Route the yel-

low wire directly to the fuel pump fuse in cavity # 20 (See Fig. 13-c1.) using the supplied fuse tap.

D2. (For 6.2L Cadillac Escalade) Route the relay

trigger wire (yellow wire) to fuse #4 in the power distribution box as shown using the supplied fuse tap. (See Fig 13-c2)

Fig. 13-a

Fig. 13-b

Fig. 13-c1

23

Fig. 13-c2

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

13. WATER PUMP WIRING, CONT'D

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

water pump relay to ground (see Fig. 13-d)

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

the water pump relay terminal #87, route the free end down along the fenderwell and under the base of the radiator over to the positive (blue/green) wire on the water pump. Secure as necessary to avoid heat and sharp edges (see Fig. 13-e).

G. Run the negative (brown) wire from the water

pump to a clean ground.

H. With the key on, make sure the charge cooler

water pump is operating and that water is flowing through the surge tank. Fill the surge tank if necessary. If the water is not flowing, remove the charge cooler supply hose and lower until water flows out of the hose. If necessary, provide light suction to the hose to help prime the pump. Verify water flow. Do not let the pump run for extended periods (30 seconds or more) without water flow. Fill the charge cooler tank until the level stabilizes.

Fig. 13-e

Fig. 13-d

24

14. HOOD HINGE SPRING REPLACEMENT (ESCALADE ONLY - ALL OTHERS SKIP TO SECTION 15)

A. Support hood with prop rod or wooden dowel. B. Remove factory hood hinge springs on both

sides.

C. To allow for proper hole alignment during

installation, temporarily wedge supplied 7/8" spacer into supplied hinge as shown (See Fig. 14-a). Install hinge using original hardware.

NOTE: Use caution with loaded hinge as not to get caught in a

collapsing hinge. Serious injury may result.

D. Be sure that the shoulder on the hardware

locates in hinge’s holes during installation.

E. Remove spacers from hinges once the mount-

ing hardware has been fully seated and tightened.

F. Finally remove Hood Gas Strut Shock by pry-

ing at metal retaining clip on each end to release from swivel ball end.

Fig. 14-a

Fig. 14-b

Fig. 14-c

25

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

15. REFLASH COMPUTER

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

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

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

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

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

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

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

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

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

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

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

in the lower left hand corner of the dash on the driver’s 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 vehicle’s OBD2 port. You don’t want this connector to disconnect during programming or damage may occur to the vehicle’s ECM.

D. TheReashtoolshouldpowerupanddisplay

three parameters.

 •Performancetune  •Diagnostics  •Options

E. Select “performance tune” and press the enter

button in the middle of the arrow keys.

F. Read the disclaimer entirely, then select agree

and press ENTER.

G. At this point please read the screen displayed

onthereashtool.Ifyouhaveanyquestions,

either refer to the manual that is provided with thereashtoolorcontactourservicedepartment for futther assistance.

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

J. Continuetofollowthescreenandwhennished

unplugthereashtoolformthevehiclesOBD2

port.

ESCAPE

ARROWKEYS

ENTER

OR

SELECT

Fig. 15-a

26

16. FINAL ASSEMBLY AND CHECK

A. Reconnect the battery. B. If your vehicle has gone over 10,000 miles

since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

C. Check all fittings, nuts, bolts and clamps for

tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie-wraps.

D. Check all fluid levels, making sure that your

tank(s) is/are filled with 91 octane or higher fuel before commencing test drive.

E. The plastic engine cover that covers the

upper manifold will need to be modified in order to reinstall. Refer to Fig. 16-b to trim

and reinstall. F. Start engine and allow to idle a few minutes. G. Recheck to be sure no hoses, wires, etc. are

near exhaust headers or moving parts and

check for any sign of fluid leakage. Recheck

all fluid levels. H. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without ALL the subassemblies

completely and properly installed may cause

FAILURE OF MAJOR COMPONENTS. I. Test drive the vehicle. J. Read the Street Supercharger System

Owner's Manual and RETURN THE Warranty

REGISTRATION FORM within thirty (30) days

of purchasing your supercharger system to

qualify for the 3 year limited warranty.

Fig. 16-a

Fig. 16-b

27

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

16. FINAL ASSEMBLY AND CHECK, CONT'D

For internally lubricated V3 units only

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

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

should be performed. Prior to operating the supercharger on the vehicle and

after installation onto the vehicle:

Removethefactoryinstalledat-headbrassshipping

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

withoutit.Checkthesuperchargeruidlevel.

Fluid level checking procedure:

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

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

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

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

Checktheuidlevelusingthedipstickatleastevery

2,500 miles.

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

at least every 7,500 miles.

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

the dipstick. DO NOT OVERFILL!!!

WARNING: Useofanyotheruidotherthanthespe-

cial Vortech lubricant will void the warranty and may cause component failure.

28

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29

11NOV08 GM Trk/H2(4GL..018v2.0)

P/N: 4GL020-018

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

30

Vortech GM 5.3L 6.2L Light Truck SUV - 2007-2008 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual