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

®

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: [phone]

Fax: [phone] • 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.

P/N: 4GL020-018
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
11NOV08 GM Trk/H2(4GL..018v2.0)

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.

©2008 VORTECH ENGINEERING, LLC

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated

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

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

©2008 Vortech Engineering, LLC

iii

All Rights Reserved, Intl. Copr. Secured

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.

P/N: 4GL020-018
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
11NOV08 GM Trk/H2(4GL..018v2.0)

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

©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GL020-018
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
11NOV08 GM Trk/H2(4GL..018v2.0)

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

©2008 Vortech Engineering, LLC

vii

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GL020-018
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
11NOV08 GM Trk/H2(4GL..018v2.0)

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

©2008 Vortech Engineering, LLC

ix

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GL020-018
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
11NOV08 GM Trk/H2(4GL..018v2.0)

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.

©2008 Vortech Engineering, LLC

1

All Rights Reserved, Intl. Copr. Secured

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

P/N: 4GL020-018
©2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
11NOV08 GM Trk/H2(4GL..018v2.0)

Fig. 2-c

2