Vortech HP500 EFI Installation Instructions Manual

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MERCRUISER

MARINEHP500EFI

Supercharger System

Installation Instructions

1998 - 2002

FOREWORD

Proper installation of this system 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 call Vortech Engineering for installers in your area.

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

of Vortech Engineering, LLC.

TABLE OF CONTENTS

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

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

TOOL AND SUPPLY REQUIREMENTS ...........................................................................................iv

NOTICE.............................................................................................................................................v

PARTS LIST - HP500........................................................................................................................vi

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

2. SUPERCHARGER OIL DRAIN ............................................................................................2

3. SUPERCHARGER OIL FEED..............................................................................................3

4. MOUNTING BRACKETS .....................................................................................................4

5. FUEL INJECTOR REPLACEMENT .....................................................................................8

6. FUEL SYSTEM UPGRADE..................................................................................................10

7. COMPUTER AND MAP SENSOR SENSOR .......................................................................12

8. THERMOSTAT REPLACEMENT/EXHAUST MANIFOLD MODIFICATIONS ......................13

9. FUEL/WATER SEPARATOR INSTALLATION ...................................................................... 14

10. FUEL COOLER INSTALLATION..........................................................................................15

11. CRANK PULLEY INSTALLATION........................................................................................16

12. SUPERCHARGER MOUNTING ..........................................................................................17

13. CHARGE COOLER/DISCHARGE DUCTING......................................................................22

14. FINAL CHECK......................................................................................................................24

iii

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

Mercruiser Marine HP500 EFI

Installation Instructions

PLEASE READ CAREFULLY

This kit should only be installed by qualified marine mechanics . It is imperative that the correct air/fuel mixture be maintained at all times. Before beginning this installation, please read through this entire instruction manual and the Owner's Manual which includes the Vortech Supercharger Limited Warranty.

This kit should only be installed by qualified marine engine and drive mechanics that can properly set correct air-to-fuel ratios, proper drive specifications and fuel systems.

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.

Vortech Engineering is not responsible for engine damage. Installation on new engines will not harm or adversely affect the break-in period so long as factory breakin 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 or lower than 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 operating the vessel. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 25 hours.

TOOL AND SUPPLY REQUIREMENTS:

• Factory Repair Manual

• Masking Tape

• Marking Pen

• GM Pin Tool P/N:12014012-1

• 3/8" Drive and Socket Set: SAE and Metric

• 1/2" Drive and Socket Set: SAE and Metric

• Adjustable wrenches

• Open End Wrenches: SAE and Metric

• 8 Quarts SF Rated Quality Engine Oil

• Loctite Sealer #RC-609

• Oil Filter and Wrench

• Screwdrivers: Flat and Phillips

• Heavy Grease

• Silicone Sealer

• Drill Motor and Drill Bit Set

• Teflon Paste Sealant

• Zinc Chromate Spray

• Anti-seize

NOTICE

Proper operation of this supercharger kit requires the installation of a reprogrammed ECM. An ECM core charge has been included into the purchase price of this supercharger kit and will be refunded upon the return of the stock ECM to Vortech. Fill out the supplied "ECM Credit Tag" and contact Vortech.

WARNING: Due to the increased horsepower output of the Vortech supercharger kit,

it is imperative that the fuel lines and tank switch valve allow adequate flow to support the engine fuel requirements. Vortech recommends the installation of larger fuel lines and an Imco type tank switch valve if required.

After the boat is supercharged, use caution when making propeller selection. Selecting a propeller which will allow the engine to constantly "bump" against the engine speed limiter (the Vortech supplied ECM is programmed for 5400 RPM rev-limit) will cause engine damage. Vortech recommends the installation of an MSD-6M with revlimiter capacity if the engine speed will reach 5200+ RPM at maximum sustained vessel speed. The MSD unit limits engine speed by cylinder spark elimination rather than fuel elimination as the ECM does. This is the safest way of limiting engine speed in supercharged applications that approach maximum engine speed on a consistent basis.

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, Inc. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, LLC.

NOTE: Additional fuel system components are required to complete the installation of this system.

• 8F060-050 50 lb/hr fuel injectors (8 ea.)

• 8F0130-040 Fuel Pressure Optimizer

• 8F030-040 -6 Fuel Adapter Fitting

• 8F001-300 Fuel Pump

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

Mercruiser Marine HP500 EFI

Part No. 4MB218-010/018

PARTS LIST

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

Part Number Description Quantity Part Number Description Quantity

8N201-100/108 PWR COOLER ASSY. MARINE EFI 1

8N101-100 Weld Core Assy. Marine Clr 1

4MA012-061 Cooler Duct, Mach 1

8N002-041 Cap, Top, Marine Cooler 1 7U100-087 O-ring, Marine Cooler Cap 1 7A250-076 1/4-20 x 3/4 SCHS Stainless 8 7A312-451 5/16-18 x 4/5" S.S. SCHS 4 7P500-625 1/2 NPT x -10 45° Flare Ftg 2

7P625-020 Hose End, -10 Brass Push on 2 4MA040-010 Foam Seal, Merc Charge cooler 1 4MA018-040 TEE, Marine Charge cooler 1

7R002-020 #20 SAE Type F SS Hose Clamp 2

7U033-000 5/8" Fuel/PCV Hose 8

7P625-018 5/8" Thru-Hull Dump, Plstc 1

7R001-008 #8 Stnls Hose Clamp 2

2B228-080/088 S/C, V-4-J, HP500 W/PLY SATIN 1

4MA130-026 OIL FEED ASSY. BBC MARINE 1

7P125-034 1/8 NPT x 1/8 NPT Strt T 2

7P125-103 -4 Flare x 45° 1/8 NPT 2

7P125-026 Fitting, 90° 1/8 NPOT x #4 1 4MA145-020 Oil Feed Hose Assy. BBC Kit 1

7P250-036 -4 SAE Flare to 1/4 NPT 1

7P250-120 1/4 NPT Pipe Plug 1

4MA130-036 OIL DRAIN ASSEMBL Y 1

7U030-036 1/2" Oil Drain Hose 2.5'

7P375-017 3/8 NPT x 1/2 Beaded Hose Barb 1

7P375-045 45° Street Elbow 1

7R001-008 #8 Stnls Hose Clamp 2

7P500-090 Fitting, 1/2" Oil Drain Flange 1

7U100-088 O-ring, S/C Oil Drain Ftg 1

7P375-033 3/8 NPT x 3/8 NPT Srt El 1

7C011-051 10-32 x .50 SHCS Plated 2

7J010-001 #10 Flat Washer 2

4MB116-011 S/C DRIVE ASSY. HP500 1

2A041-618 Belt, 10 Rib 1

2A046-930 Belt, 6 Rib 1 4MA018-051 7" Crank Pulley, Universal 1 4MA016-001 Crank Pulley, HP500 Merc 1

7A375-475 3/8-16 x 4.75 HXHD GR8 Pltd 3

7J375-044 3/8 SAE Washer, Pltd 3

7L375-075 3/8 Lock Washer 3

4MB112-041/048 AIR INLET ASSY. HP500 1

4MB012-041/048 Air Inlet Duct, HP500 1

4MA010-088 Cover, A/F Marine S.C. Pol 1 4MA017-031 Standoff , A/F Marine 2

7A250-076 1/4-20 x 3/4 SHCS S.S. 2

7A250-105 1/4-20 x 1 Set Screw 2

7P250-124 1/4 NPT To 1/2 Barb 1

7P250-146 1/4 NPT Street Elbow 1

7R005-006 T-Bolt Clamp, Ø5.2" 1

8H040-160 Air Filter, Marine S.C. 1

4MB101-001 FUEL SYSTEM ASSY. HP500 1

4MA010-044 Fuel Pump Block Off 1

5W001-013 14-16 AWG, Solderless Connector 2 5W001-014 Fuse Holder 10 GA Wire 1 5W001-015 Fuse, Blade Type 20 Amp 1 5W001-017 12-10 GA x 3/8" Ring Terminal 2 5W001-019 10-12 GA Butt Conn Insulated 2 5W001-043 12-10 GA x 1/4" Ring Terminal 2 5W012-010 12 GA Wire, Black 8

7A250-102 1/4-20 x 1" SHCS SS 4 7F250-022 1/4-20 Nylock Nut, Stainless 4

7J250-022 1/4" Washer SAE, Stainless 8 7P250-138 #6 Hose End, 37° 4 7P375-002 3/8 Pipe Plug, Steel, Znc Pltd 1 7P375-111 3/8 NPT x #8 x 45°, 37°JIC 1 7P500-001 1/2" Hose Union 1 7P500-024 1/2 NPT x #6 2 7P500-025 Nipple, Threaded 1 7P500-027 1/2 NPT x #6 x 90°, 37°JIC 1 7P500-028 1/2 NPT x #8, 37°JIC 1 7P500-029 1/2 NPT x #8 x 90°, 37°JIC 1 7P500-030 1/2" Pipe Plug 1 7P500-064 #8 x 45° Hose End, 37°JIC 2 7P500-083 #8 Hose End, 37°JIC 2 7P500-500 -8 x 90° Al. Hose End, Pshloc 1 7P625-015 #10 x #8 Male Hose Union, 37°JIC 2 7P625-022 -10 Union 1 7R002-024 #24 SAE Type F, SS Hose Clamp 4 7U030-051 -6 USCG Fuel Hose, Push-on 8 7U034-020 Hose, 1.25 Dia. Rubber Rad. 1 7U037-030 1/2" Fuel Line, Pushlock 10 7U100-043 #10 O-Ring 4 7U133-125 Ø1.25 Black Hose 1 7U375-050 1/4" Vac. Cap 1 8F101-200 T-Rex Wiring Assy. Mustang 1 8H040-080 Fuel Separator Filter 1

8J050-020 Fuel Separator 1

4MA014-030 Fuel Cooler, 5" 1

5A002-006 Map Sensor, 2 Bar 1 5A002-011 Map Sensor Harness 1

4MB112-020/028 DISCHARGE ASSY ., HP500 1

4MB012-031/038 Discharge Tube "B" 1

7S400-200 4 x 2 Sleeve 1 7R002-064 #64 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 2 7R002-056 #56 SAE Type F, SS Hose Clamp 4

4MB012-020/028 Duct, Disch. HP500 1

7A312-078 5/16-18 x 3/4, SS SHCS 4

4MB111-011 MOUNTING BRACKET ASSY. 1

2A017-042 Brkt Spacer A, 502 EFI 10 Rib 1 2A017-043 Brkt Spacer B, 502 EFI 10 Rib 1

4GD011-032 Spring Tensioner 1 4MA010-084 Mtng. Plate, Alumn. Merc. EFI 1 4MA010-094 Support Plate, Merc. EFI 1 4MA116-160 Idler Assy. Marine GEN2 1

Mercruiser Marine HP500 EFI

Part No. 4MB218-010/018

PARTS LIST

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

Part Number Description Quantity

4MB010-001 Plt. Fuel/H 4MB010-010 Brkt., Engine Oil Filter 1 4MB010-011 Brkt., Cooler Support 1 4MB011-001 Mtng. Brkt, HP500 1 4MB014-010 Thermostat, 120° F HP500 1 4MB016-002 Pulley, Eng. H20 Pmp, HP500 1 4MB017-002 Spcr, Plt Pwr Steering, HP500 1 4MB017-003 Spcr, Alt, HP500 2 4MB017-004 Spcr, Idler, HP500 1 4MB017-011 Spcr, Idler , #2 1 4MB017-021 Spcr, Raw H 4MB017-031 Spcr, Cool Fuel 1 4MB040-050 Gasket, Thermostat, HP500 1

7A312-152 5/16-18 x 1.5 SHCS, Znc Plt 2 7A312-250 5/16-18 x 2-1/2 HHCS 1 7A375-100 3/8-16 x 1 G5 HXHD Plt 1 7A375-101 3/8-16 x 1" SHCS Stnls 11 7A375-102 3/8-16 x 1" Flt Allen Znc Plt 1 7A375-103 3/8-16 x 1" HXHD Stnls 2 7A375-126 3/8-16 x 1.25 HXHD GR8 Plt 2 7A375-201 3/8-16 x 2" SHCS 2 7A375-226 3/8-16 x 2-1/4 SS HCS 1 7A375-277 3/8-16 x 2.75 SHCS Stnls 1 7A375-350 3/8-16 x 3-1/2 HXHD 1 7A375-450 3/8-16 x 4-1/2 SHCS S.S. 2 7A375-451 3/8-16 x 4.50 HXHD GR5, Znc 1 7A437-125 7/16-14 x 1.25 G8 SHCS 2 7A437-150 7/16-14 x 1-1/2 HXHD GR8 1 7A437-200 7/16-14 x 2" SHCS 2 7A437-201 7/16-14 x 2.00 HXHD Znc Plt 2 7A437-275 7/16-14 x 2-3/4 SHCS Znc 1 7A437-451 7/16-14x 4-1/2 HHCS 1 7B375-250 3/8-24 x 2.5 SHCS Stnls 1

7B375-275 3/8-24 x 2-3/4 HXHD 1 7C012-020 12mm x 1.75 x 20mm Plt 3 7C012-025 M12 x 1.75 x 25mm HXHD Plt 1 7C012-051 M12 x 1.75 x 50 L.H. Bolt 1 7F312-017 5/16-18 Nylock Nut 2 7F375-017 3/8-16 Nylock Nut 5 7F375-028 Press Nut, 3/8-24 x .50 1 7F437-000 7/16-14 Hex Nylock Nut 1 7F438-001 7/16-20 Jam Nut, Plt 4

7J012-092 12mm Washer, Flat 6

7J375-044 3/8 SAE Washer, Plt 3

7J438-081 7/16 SAE Washer, Plt 5 7K312-001 5/16" AN Washer, Plt 4 7K375-030 3/8 AN Flat Washer, Stnls 30 7K437-001 7/16 AN Washer 3 7U032-020 Hose, 3/8" ID S/Steering Ret (24") 24 7U033-010 Hose, 5/8" ID S/Steering Ret (17") 1

4FD017-011 Bearing Pilot, 12mm Bore 1

7P750-010 3/4" Pipe Plug 1 7P375-106 PCV Valve 1

4MB017-041 Idler Spacer #1, No P/S 1 4MB017-051 Idler Spacer #2, No P/S 1

2O Filter, HP500 1

2O Pmp, HP500 2

Part Number Description Quantity

vii

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

viii

1. PREPARATION/REMOVAL

NOTE: It may be desirable to drain the engine oil, cool-

ant and power steering systems to ease installation and minimize possible contamination.

A. Disconnect the batteries and/or switch. B. Remove the stock flame arrestor and hardware

from the throttle body.

C. Remove the stock accessory belt. D. Remove the crank pulley.

E. Remove the 3/8" screw securing the idler bracket

to the engine water pump. Remove the idler bracket assy. (See Fig. 1-a.)

F. Remove the nuts securing the raw water pump

bracket.

G. Remove the cooling hose. (See Fig. 1-b.) H. Disconnect the water lines connecting to the

back of the raw water pump. Slide the raw water pump (with the bracket still attached to it) off of the engine.

I. Remove the three 7/16" studs from the front

starboard side of the engine.

J. Remove the power steering reservoir bracket

and the oil filter bracket assembly. Disconnect the power steering lines.

K. Remove the alternator and the power steering

pump.

L. Remove the alternator/power steering pump

bracket.

M. Remove the 7/16" stud in the port side head

using the two provided 7/16-20 nuts locked against each other. (See Fig. 1-c.)

Fig. 1-a

Fig. 1-b

Fig. 1-c

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

2. SUPERCHARGER OIL DRAIN

A. Place the provided oil drain tap on the port side

valve cover and mock up the drain line to ensure it does not come in contact with the exhaust manifold.

B. Place the supplied adapter fitting as low as

possible onto the outside of the valve cover in the place where it is to be mounted (see Fig. 2-a). Mark three points onto the valve cover with a marker or scribe using the adapter as a template. One point will be for the oil passage and the other two will be for the 10-32 screws to pass through the valve cover and thread into the fitting.

C. Remove the engine's port side valve cover and

cover the exposed valve train with a clean rag to keep debris out and prevent contamination. Drill two Ø.203" holes through at the locations marked. Drill one Ø.391 hole through at the location marked.

D. Make sure the outside O-ring sealing surface of

the valve cover is smooth and free from paint chips. Clean the inside of the valve cover area with acetone or mineral spirits. Attach the adapter and O-ring onto the outside of the valve cover. Thread the two 10-32 x 1/2" screws with washers through the valve cover and into the adapter from the inside out. Use silicone sealer under each screw head and washer.

E. Reinstall the valve cover.

Fig. 2-a

NOTE: The drain hose must be routed downhill

without any dips or kinks.

3. SUPERCHARGER OIL FEED

7P125-026 FITTING,

1/8 NPT x #4 X 90°

4MA145-020

OIL FEED HOSE

STOCK OIL PRESSURE

TRANSDUCER

STOCK OIL FITTING & TRANSDUCER

7P125-034 1/8

NPT x 1/8 NPT

STREET TEE

A. Remove the stock oil pressure transducer lo-

cated behind the power steering cooler on the port side of the engine block. Remove the larger of the two pressure transducers.

CAUTION: Improper application of pipe sealants

such as Teflon tape and paste to oil system fittings may cause oil system blockage and/or failure which could lead to severe supercharger and engine damage. Use any sealants on the oil feed system sparingly!

B. Install in its place the provided 1/8" street TEE

(see Fig. 3-a). Reinstall the previously removed pressure transducer into the bottom of the TEE fitting. Orient the TEE fitting so that the horizontal female port is pointed toward the transom.

C. Thread a 1/8" NPT x #4 x 90° fitting into the open

port on the TEE fitting.

D. Attach the oil feed line to the previously installed

#4 fitting and tighten.

E. Temporarily plug the open end of the oil feed line

to keep debris out.

Fig. 3-a / Supercharger Oil Feed

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

4. MOUNTING BRACKETS

A. Referring to Fig. 4-a and using the provided

template (see template on Pg. 6), mark and cut the stock power steering and alternator bracket as shown. Using a Ø13/32" drill bit and motor, enlarge the proper hole per the diagram. These modifications will leave the bracket exposed to the outside elements and therefore this bracket should be treated with paint or rust preventative.

B. Reattach the modified alternator bracket to the

engine using the stock hardware. Install a 3/816 x 3/4" HHCS with washer into the hole previously enlarged and tighten.

C. Following the diagram (see Fig. 4-b), install two

3/8-16 x 4-1/4" HHCS with washers into the backside of the cast bracket. Attach the Vortech cast bracket to the upper holes located on the cylinder head using two 7/16-14 x 2" and one 7/16-14 x 4-1/2" SHCS.

N0.

1 2 3 4 5

PART #

4MB011-011

7A437-200 7A437-450 7A375-450 7K375-030

DESCRIPTION

Supercharger Mounting Bracket

7/16-14 x 2" SHCS

7/16-14 x 4-1/2" SHCS

3/8-16 x 4-1/2" HHCS

3/8 AN Flat Washers

Fig. 4-a

QTY.

1 2 1 2 2

Fig. 4-b

4. MOUNTING BRACKETS, Cont'd.

NOTE: Due to manufacturing differences in the ex-

haust manifold, the water tube may come into contact with the cast bracket. (See Fig. 4-c.) If this occurs, the water tube will have to be shortened or serious misalignment and failure of the accessories and supercharger will occur. Removal and cutting of the exhaust manifold will be required. See the "Thermostat change/exhaust manifold" section for modification details (Pg. 13).

D. To align the bracket properly, thread the 7/16-14

x 4-1/2" socket head cap screw into the third threaded hole on the cylinder head. Tighten the two 7/16-14 x 2" socket head screws. Remove the 7/16-14 x 4-1/2" socket head cap screw and put aside. (See Fig. 4-b.)

E. Slide the supplied power steering pump spacer

plate onto the two 3/8-16 x 4.5" HHCS screws that were previously installed into the backside of the cast bracket. (Note that the plate is NOT symmetrical and may need to be turned over to provide proper fit). (See Fig. 4-d.)

F. Install the alternator onto the modified stock

bracket using two spacers (Ø7/8" O.D. x 13/32" I.D. x 39/64" length) behind it. Use the stock 5/16-18 screw. (See Fig. 4-d.)

Fig. 4-c

SPACERS

Fig. 4-d

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

4. MOUNTING BRACKETS, Cont'd.

CUT HERE

DRILL HOLE OUT Ø13/32"

SCALE - 1:1

4. MOUNTING BRACKETS, Cont'd.

G. Slide the power steering pump onto the power

steering pump spacer plate and bolts. Orient the pump so that the inlet is pointing to the port side. Secure the pump with the stock nylock nuts and washers. (See Fig. 4-d.)

H. Remove the engine's stock water pump pulley

(located above the crank pulley) and replace with the one provided. (See Fig. 4-e.)

POWER STEERING

PUMP SPACER PLATE

Fig. 4-d

Fig. 4-e

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

5. FUEL INJECTOR REPLACEMENT

A. Disconnect the wiring connecting to the throttle

position sensor (TPS), manifold air pressure (MAP) and the idle air controller (IAC)

B. Remove all the screws securing the upper mani-

fold to the lower manifold.

C. Carefully lift the upper manifold off of the lower.

Note that the throttle cable may stay attached if the upper manifold is tilted over onto its side. Cover each of the ports of the lower manifold to prevent debris from falling in. (See Fig. 5-a.)

D. Remove the stock fuel filter and hard line located

at the back of the manifold. (See Fig. 5-b.)

E. Remove the four screws securing the fuel rails to

the lower intake manifold.

F. Mark each of the injector connectors (with mask-

ing tape and a pen) corresponding to each cylinder/port. This will aid in reinstallation.

G. Disconnect each one of the electrical connectors

from each injector by pressing down on the spring clip and pulling up. Do not pull on the wires as this could cause an open circuit.

H. Remove the fuel rails with the injectors still at-

tached to it. (See Fig. 5-c.) Look into each injector port for any loose O-rings that may have come off of the injectors. Remove the clips securing the injectors to the fuel rail. Remove each injector from the fuel rails and look for any loose O-rings in the fuel rail. (See Fig. 5-e.)

I. Remove the #6 fitting on the fuel rail and replace

with the provided #8 x 3/8 NPT x 45° fitting. Orient the fitting so that when the fuel rail is installed the fitting will be pointing toward the starboard side.

Fig. 5-a

Fig. 5-b

Fig. 5-c

5. FUEL INJECTOR REPLACEMENT, cont'd.

J. Remove the stock fuel regulator and cut the

upper portion off of the regulator using a fine tooth hacksaw or an abrasive cutoff wheel as shown in Fig. 5-d. Clean the regulator out and make sure that there are no loose chips or debris. Install the adjustable top.

K. Remove the sealing nut at the bottom of the

regulator and remove the brass plug from the inside (this may require air to be blown into the open end to force out the brass plug). Install the fitting onto the bottom of the regulator and make sure the O-ring is still there and tighten. Reattach the regulator to the fuel rail. (See Fig. 5-f.)

L. Install the new injectors into the fuel rail first using

a small amount of oil to lubricate the O-rings. Reinstall the injector retaining clips.

M. Install the rail assembly into the lower manifold

and secure with the stock hardware. Reconnect each one of the electrical connectors to each injector.

N. Install the fuel lines to the fuel rail before reinstall-

ing the upper manifold.

O. Remove the stock PCV valve and replace with

the one provided.

Fig. 5-e

1/4”

Fig. 5-d

TOP OF FUEL

REGULATOR

TO BE DISCARDED

FACTORY

REGULATOR

ADAPTER FITTING w/MODIFIED

REGULATOR INSTALLED

Fig. 5-f

NOTE: Two types of regulators are supplied by

Mercruiser from the factory. The exit orifice will measure either .090" or .120" If the regulator on your engine is the .090" unit, it must be replaced with a .120" unit for proper fuel bypass.

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

6. FUEL SYSTEM UPGRADE

A. Disconnect the fuel lines connecting to the

mechanical fuel pump.

NOTE: Some engine systems do not have a me-

chanical fuel pump.

B. Remove the mechanical fuel pump and plug the

vacuum port on the manifold that has a vacuum line running to it. Use the provided fuel pump block-off plate and gasket along with the stock hardware to cover the exposed area. (See Fig.6-a .)

C. Disconnect the fuel lines from the fuel water

separator and remove the fuel/water separator mount and filter.

D. Disconnect and remove all fuel lines. E. Remove the cool fuel pump assembly located

below the crank pulley and both water lines connecting to it.

F. Remove the cool fuel bracket assembly from the

bracket.

G. Mock up the new fuel pump and filter on the

bracket to check for clearance.

H. Using the new fuel pump as a guide, center the

fuel pump (see Fig. 6-b) on the bracket and mark the four holes onto the bracket. Using a letter "K" (Ø.281") drill bit and drill motor, drill out the previously marked holes. Secure the fuel pump to the bracket using the four 1/4-20 x 1" SHCS, 1/4" washers and nylock nuts.

Fig. 6-a

NOTE: The inlet of the fuel pump should point to-

ward the starboard side when mounted.

I. Supplied in this kit is ten feet of #8 and eight feet

of #6 fuel line, 5 #8 and 4 #6 female swivel fittings. Measure the distances between each of the fuel system components and write the lengths next to each fuel line on the diagram. It is important to maintain a fuel line routing that is not near moving parts, having excessive length or unusually tight bends that will inhibit the proper operation of the fuel system.

NOTE: Cut all hoses square with a fine tooth hacksaw or abrasive cut-off wheel.

Lubricate the nipple of the female swivels with oil to aid installation and all O-rings to avoid pinching of chafing. Clean all fuel lines prior to installation as any debris in the fuel line may cause complete or partial fuel system failure. Hose assemblies should be tested hydrostatically at twice the recommended working pressure of the hose (150 psig). All

fuel system components must be completely and properly installed into hoses or death may occur. Route each fuel line per Fig.5-c. As-

semble the ends with their associated fuel system hardware fittings. When routing fuel lines be sure not to kink or have any tight bends in the lines. Keep lines away from any moving parts or hot surfaces. Use a small amount of clean engine oil to lubricate all of the O-rings in the fuel system prior to installation.

Fig. 6-b

6. FUEL SYSTEM UPGRADE, cont'd.

13 17

FUEL COOLER

(SEE ALSO FIG. 10-a)

MODIFIED

FACTORY

REGULATOR

ATTACHED TO

FUEL RAIL

SOME APPLICATIONS MAY REQUIRE A 90° FITTING FOR CLEARANCE PURPOSES

TO FUEL

RAIL

CONNECT STOCK FUEL LINE HERE

NOTE: SHOWN IS A COMPLETE FUEL SYSTEM,

BUT DUE TO MANUFACTURERS DIFFERENCES

THIS SYSTEM MAY REQUIRE SOME MODIFICATION.

ADAPTER

FITTING

LOCATION DESCRIPTION PART NO. QTY

#6 HOSE END 37°

3/8 PIPE PLUG

3/8 NPT x #8 x 45° 37°JIC

1/2” HOSE UNION

1/2 NPT x #6

1/2 NPT x #6 x 90° 37°JIC

1/2 NPT x #8 37°JIC

1/2 NPT x #8 x 90 37JIC

1/2" PIPE PLUG

#8 x 45° HOSE END 37°

#8 HOSE END 37°

#8 x 90° AL. HOSE END

#10 x #8 HOSE UNION 37°

#10 UNION

#6 USCG FUEL HOSE

1/2" FUEL LINE

#10 O-RING

FILTER MOUNT FUEL SEPARATOR

FUEL COOLER 5"

7P250-138

7P375-002

7P375-111

7P500-001

7P500-024

7P500-027

7P500-028

7P500-029

7P500-030

7P500-064

7P500-083

7P500-500

7P625-015

7P625-022

7U030-051

7U037-030

7U100-043

8J050-020

4MA014-030

10'

Fig. 6-c

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

7. COMPUTER AND MAP SENSOR REPLACEMENT

A. Disconnect the two connectors that connect to

the engines computer located next to the distributor on the starboard side.

B. Remove the computer and install the new one.

(See Fig. 7-a.) Reconnect the two connectors.

C. Using a Phillips screwdriver, remove the two

screws securing the MAP sensor to the upper intake manifold (the MAP sensor is located on the top port side of the manifold). Carefully remove the MAP sensor from the manifold.

D. Remove the rubber grommet from the stock MAP

sensor and install it on the one provided.

E. Install the new MAP sensor back onto the mani-

fold using the stock hardware.

F. Using a GM pin removal tool (purchased sepa-

rately) Remove the three pins from the stock connector and install the new connector. (See Fig. 7-b.)

NOTE: Write down the color combination with re-

gards to pin location or remove only one pin at a time to avoid improper installation.

G.Reconnect the new plug to the MAP sensor.

Fig. 7-a

Fig. 7-b

8. THERMOSTAT REPLACEMENT/EXHAUST MANIFOLD MODIFICATIONS

A. Disconnect all the water lines connecting to the

thermostat housing.

B. Remove the thermostat housing from the intake

manifold. Remove the brass TEE from the housing and plug with the provided 3/4" pipe plug. (See Fig. 8-a.)

C. Remove the stock thermostat and gasket and

replace with the ones provided.

D. Remove the two water lines that connected to the

brass TEE and running back to each exhaust manifold. Reconnect the remaining water lines to the thermostat housing.

NOTE: The upper most nipple on the exhaust mani-

fold, port side will need to be removed to allow clearance of the air inlet assembly (see Fig. 8-b). This will require removal of the exhaust manifold and the cutting and welding of stainless steel. The starboard side exhaust manifold will have to be plugged, either welded closed or with a rubber cap and hose clamp. If the water tube makes contact with the cast bracket it will have to be shortened. (See Fig. 8-c.)

Fig. 8-a

Fig. 8-b

Fig. 8-c

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

9. FUEL/WATER SEPARATOR INSTALLATION

A. Following Fig. 9-a install the supplied 3/8" fuel /

water separator plate using the .236" spacers, stock raw water pump, two 7/16-14 x 2" HHCS and 7/16" washers. Note the modified cool fuel bracket must be installed onto the .423" spacer before the raw water pump to provide proper spacing. Use 1-7/16-14 x 1-1/2 hex head cap screw and 7/16" washer.

B. Install the threaded nipple into the fuel/water

separator housing. Install the housing and the cooler support bracket onto the previously installed 3/8" plate using 2 5/16-18 x 1 1/2" SHCS, 5/16" washers and 5/16" nylock nuts. (See Fig. 9-b.)

C. Apply a small amount of lubricant to the O-ring of

the fuel/water separator filter, and tighten onto the housing.

Fig. 9-b

.236"

SPACERS

COOLER SUPPORT BRACKET

SUPPLIED

ENGINE’S HEAD

STARBOARD SIDE

SUPPLIED

FUEL/WATER

SEPARATOR HOUSING

FRONT OF ENGINE

.423" SPACERS

MODIFIED COOL FUEL BRACKET

SIDE VIEWFRONT VIEW

Fig. 9-a

10. FUEL COOLER INSTALLATION

A. Referring to Fig. 10-a thread the 3/8 pipe plug

into the 3/8" port onto the fuel cooler. Thread the 1/2" NPT x #6 fittings into each of the 1/2" ports. Use thread sealant only on the pipe threads.

B. Cut 8" off of the long leg of the supplied Ø1-1/4"

x 90° hose and 1" from the opposite end. Install the longer leg of the previously mentioned hose onto the fuel cooler.

C. Install the Ø1-1/4" stainless steel TEE into the

open end of the line. Cut 5-1/4" off of the 8" piece of hose and install onto the TEE. (See Fig. 10-b.) Install the fuel cooler into the open hose.

D. Connect the fuel cooler to the raw water pump

using the supplied 36" hose (trim to fit). Secure the hose connections using 4 of the provided hose clamps and 2 that were previously removed.

TO OIL COOLER

Fig. 10-b

REUSE STOCK HOSE CLAMP

7U133-125 HOSE Ø1.25" x 90

° LONG LEG

4MA018-040

TEE

7P500-024 1/2 NPT x #6 FITTING

5 1/4"

7P375-002

3/8 PIPE PLUG

7R002-024 #24 HOSE CLAMP

Fig. 10-a / Fuel Cooler

4MA014-030 FUEL COOLER 5"

7U034-020 HOSE Ø 1-1/4"

(TRIM TO FIT)

TO RAW WATER PUMP

REUSE STOCK HOSE CLAMP

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

11. CRANK PULLEY INSTALLATION

A. Assemble the provided crank pulley and 10 rib

pulley. Line up the three corresponding mounting holes in the crank pulley and 10 rib pulley. Ensure that the "dished" side of the 10-rib pulley faces away from the engine.

B. Using the three 3/8-16 x 4 3/4" HHCS and wash-

ers, mount the crank pulley assembly to the balancer. Use a small amount of thread locking compound on each of the screws. Torque each of the screws to 35 ft/lbs.

C. Using the supplied 6 groove belt, route onto the

accessories in the stock configuration and tighten to the stock specifications.

3/8-16 x 4-3/4” HHCS

3/8 LOCK WASHER

3/8 SAE WASHER

SUPPLIED 10-RIB PULLEY

STOCK HARMINIC

DAMPER (BALANCER)

SUPPLIED CRANK

PULLEY

Fig. 11-a

12. SUPERCHARGER MOUNTING

A. Remove the blue plastic oil drain cap and install

the 1/2" x 30" oil drain hose to the supercharger drain fitting and secure with a hose clamp.

CAUTION: Rotate the clamp screw housing to the

side so that it does not interfere with the mounting plate during installation.

B. Thread the supplied 1/4-20 set screws tightly into

the inlet duct. Attach the two supplied threaded aluminum spacers onto the set screws. Place the air filter element into the groove of the inlet duct and install the billet filter cap and secure with the 1/4-20 SHCS. (See Figs. 12-a, 12-b.)

Note that the air filter element is not symmetrical and will properly fit into the inlet duct only one way.

C. Use a small amount of anti-seize lubricant on the

threads of the supplied 1/4 NPT street elbow brass fitting and install into the threaded boss on the inlet duct. Thread the 1/4 NPT x 1/2" barb into the previously installed fitting.

D. Put a small thin layer of anti-seize lubricant on the

inside of the air inlet duct where it will mate with the supercharger. Install the supplied T-bolt clamp onto the supercharger inlet duct and carefully slide the duct onto the supercharger inlet flange. Use caution when sliding the duct onto the supercharger. It is very important that the duct is lined up and not “cocked” in relation to the supercharger or binding will occur. If the fit is somewhat tight, carefully heat up the duct with a propane torch before sliding it onto the supercharger unit. The brass fitting assembly may need to be rotated to provide proper clearance and allow the inlet duct assembly to be completely installed. (See Fig. 12-c.)

E. Install the supercharger to the mounting plate.

Check to make sure there is no interference between the mounting plate and the drain hose clamp at the supercharger. (See Fig. 12-d.)

F. Secure the supercharger in place with the ten 3/8

x 1" SHCS and washers.

G. Route the drain hose over to the previously

installed fitting on the valve cover. Oil drain hose must always maintain a “downhill” slope. Tight bends or drain flow restrictions may cause supercharger failure.

Fig. 12-a

Fig. 12-b

Fig. 12-c

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

12. SUPERCHARGER MOUNTING, cont'd.

H1. Engines With Power Steering Pump:

Attach the support plate to the mounting plate and supercharger. Three of the supplied 12mm washers must be placed in between the support plate and the supercharger cover as spacers. Install the remaining three 12mm washers under the head of each of the M12-1.75 x 30 screws. The two

1.536" lower spacers must be installed with the Ø.750 piece in the lower hole position as shown. (See Fig. 12-e.)

H2. Engines without power steering pump:

Remove the Ø4" idler from the factory bracket. Attach the support plate to the mounting plate and supercharger. Three of the supplied 12mm washers must be placed in between the support plate and the supercharger cover as spacers. Install the remain-

ing three 12mm washers under the head of each of the M12 - 1.75 x 30 screws. The Ø1.00 x 1.536 spacer along with the idler spacer #1, #2 and the factory idler in between the supercharger mounting plate and the support plate. (See Fig. 12-f.)

I. Install the automatic tensioner to the

mounting plate using the 7/16-14 x

2.75 socket head bolt with washers and 7/16 nut.

N0.

1 2

PART #

7A375-101 7K375-030

DESCRIPTION

3/8-16 x 1" SHCS

3/8" Washers

QTY.

10 10

Fig. 12-d

12. SUPERCHARGER MOUNTING, cont'd.

N0.

1 2 3 4 5 6

7 7a 7b

9 10 11 12 13 14 15

PART #

4GD011-032

7K375-030 7F437-000 4K437-001 7A437-275

4MA116-150

2A017-042 4MB017-041 4MB017-051

2A017-043 4MA010-094

7C012-051

4FD017-011

7A375-277

7J012-092

7C012-020

7B375-250

DESCRIPTION

Automatic Belt Tensioner

3/8" Flat Washer

7/16-14 Nut

7/16 AN Washer

7/16-14 x 2.75 SHCS

Idler

Ø.750 x 1.536 Spacer Idler Spacer, No Pwr Strng #1 Idler Spacer, No Pwr Strng #2

Ø1.00 x 1.536 Spacer

Support Plate

M12 x 1.75 LH Bolt

Spacer, Pilot

3/8-16 x 2.75 SHCS

M12 Washer

M12 x 20 Bolt

3/8-24 x 2.50 SHCS

QTY.

1 2 1 2 1 1 1 1 1 1 1 1 1 1 6 3 1

BEHIND

PLATE

7a 7b

Fig. 12-e

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

12. SUPERCHARGER MOUNTING, cont'd.

J. Route the supplied supercharger belt onto the

crank and supercharger pulleys. Using a boxend wrench on the tensioning wheel bolt, pull the tensioner as far back as possible and carefully slip the belt over the crank pulley. See Fig 12-g for belt routing.

WARNING: 1. Do not wrench excessively on the belt

tensioner wheel bolt or it may break loose.

2. If idler pulley removal is required for any reason, note that the idler pulley retaining screw has left hand threads.

NO.

PART #

2A041-618

DESCRIPTION

10 Rib Belt

QTY.

CAUTION: Ensure that the oil supply system is

free of contamination that might plug the supercharger oil inlet orifice.

K. Carefully route the oil feed line up to the super-

charger oil feed fitting taking care not to kink or cut the hose near any sharp edges. Carefully thread the hose end onto the fitting while supporting the fitting. LIGHTLY LUBRICATE FIT-

TING WITH ENGINE OIL.

L. Attach the supplied length of 1/2" x 24" breather

hose to the 90° barb on the supercharger air inlet and the factory breather fitting.

CAUTION: Hold the supercharger oil feed fitting

with wrench while tightening the oil feed line fitting.

Fig. 12-g

SUPPORT

PLATE

IDLER SPACER #1

Spacer

Ø1.00 x 1.536

SUPERCHARGER MOUNTING PLATE

FACTORY

IDLER

IDLER SPACER #2

Fig. 12-h

Fig. 12-f

12. SUPERCHARGER MOUNTING, cont'd.

FROM SUPERCHARGER

VOLUTE DISCHARGE

3/8" COPPER WASHER

TO SUPERCHARGER GEARCASE OIL FEED

(7J375-024)

2 PLACES

V-2 AIR ASSIST

ADAPTER

(7P375-105)

1/8 NPT HEX NIPPLE

FLOW

(7P125-111)

AIR CHECK VALVE (7P125-110)

OIL FILTER FEED (7P375-095)

FILTERED ENGINE OIL

V-4 AIR ASSIST ASSEMBLY 2E100-020

Fig. 12-i

NOTE: If the supplied oil filter/power steering reservoir plate is to be used, remove

the 3/8-24 x 2-1/2" and the M12 x 20mm HHCS and replace with the provided 3/8-24 x 2-3/4" HHCS and M12 x 25mm HHCS. (See Fig. 12-j.) The stock steering bracket will have to be cut and welded to the oil filter bracket. (See Fig. 12-k.)

Fig. 12-j Fig. 12-k

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

13. CHARGECOOLER/DISCHARGE DUCTING

NOTE: This charge cooler system requires lake/sea

water for proper operation. A TEE has been supplied to tap into the raw water pump discharge line for charge cooler water supply. A throughhull dump fitting has been supplied to route the charge cooler exiting water to the outside of the boat. Alternate methods such as a hull mounted water tube pickup may also be used as long as the charge cooler can be supplied with at least 5 gallons per minute of water flow through the cooler.

A. Attach the supplied charge cooler housing to the

discharge duct using the four supplied 5/16-18 x 3/4" socket head screws. Use a thin coating of RTV sealer between the mating surfaces of the charge cooler housing and the discharge duct (see Figs. 13-a,13-b).

B. Attach the supplied adhesive foam strip to the

welded charge cooler core as shown in Fig. 13-c. Insert the charge cooler core into the housing. Make sure that the female port on the bottom of the core is on the same side as the hole in the chargecooler housing before completely inserting the core. Ensure that the core flange seats securely and flush into the housing flange.

C. Attach the billet aluminum cap and O-ring to the

top of the charge cooler assembly so that the ports of the cap face the rear of the engine. A few small dabs of white grease will keep the O-ring in the groove cap during assembly if needed. Make sure that the O-ring is properly seated into the Oring groove.

Fig. 13-a

Fig. 13-b

Fig. 13-c

13. CHARGECOOLER/DISCHARGE DUCTING, cont'd.

D. Secure the after cooler cap to the housing with

the supplied 1/4-20 x .75 socket head screws (see Fig. 13-d).

E. Thread the two supplied 1/2” NPT x #10 fittings

into the charge cooler cap ports.

F. Using the supplied Ø 5/8” hose, hose ends and

thru-hull dump, plumb the charge cooler per Fig. 12-f.

G. Thread the supplied 3/8” NPT plug into the bot-

tom of the chargecooler core.

H. Slide the Ø4" x 2" sleeve and two #64 hose

clamps onto the throttle body. Insert discharge duct "B" into the sleeve and secure with the hose clamps.

I. Slide one of the Ø3.5" x 2" sleeves and two #56

hose clamps onto the discharge of the supercharger and the outlet of the charge cooler.

J. Install the charge cooler assembly into the previ-

ously installed sleeves and secure with the hose clamps. (See Fig. 13-e.)

Fig. 13-d

AFTERCOOLER (TOP VIEW)

TO THRU HULL DUMP FITTING

SEA

STRAINER

OPTION #1: HULL MOUNTED WATER PICKUP (NOT SUPPLIED)

OPTION #2: VORTECH SUPPLIED TEE (CUT AND SPLICE INTO PUMP DISCHARGE LINE)

RAW WATER PUMP DISCHARGE LINE

Fig. 13-f

Fig. 13-e

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

13. FINAL CHECK/FUEL PRESSURE ADJUSTMENT

A. PLEASE TAKE SPECIAL NOTE: Operating the

vessel without ALL the subassemblies completely and properly installed may cause FAIL-

URE OF MAJOR COMPONENTS.

B. With a proper water supply connected to the

engine, start the engine. Observe the fuel pressure with the engine running (vacuum hose to the fuel regulator is still disconnected). Readjust pressure to 49-50 psi if required.

C. Re-attach the vacuum hose to the fuel regulator.

Fuel rail pressure should drop slightly. If fuel pressure does not drop, ensure that the vacuum hose is not kinked.

D. Water test the vessel with the fuel pressure

gauge still attached. Important! When water testing the vessel, be sure the fuel pressure increases to 49-50 psi at wide open throttle and full engine load at 5000-5200 RPM. If fuel pressure does not reach this level, abort the run immediately. Check to see that the vacuum line to the fuel regulator has not been kinked or come loose. If the vacuum hose connection is intact, the factory Mercruiser fuel pump may need replacement. Contact Vortech for further assistance if required.

E. Read the Vortech Supercharger Limited War-

ranty and Owner's Manual.

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

06DEC02 V1.0(4MB HP500 v1.0)

P/N: 4MB020-010

Vortech HP500 EFI Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual