Vortech Engineering 4GC020-010 User Manual

GM 7.4 Light Truck

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-17

1988-1995 Model Years

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

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

(88-95 GM Lt Trk(4GC))

ENGINEERING, LLC

FOREWORD

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 call Vortech Engineering for installers in your area.

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

(88-95 GM Lt Trk(4GC))

of Vortech Engineering, LLC

Table Of Contents

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

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

NOTICE.............................................................................................................................. iv

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

PARTS LIST - 1988-1993 7.4 TRUCK ............................................................................... vi

PARTS LIST - 1994-1995 7.4 TRUCK ............................................................................... ix

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

2. CRANKSHAFT PULLEY INSTALLATION .............................................................. 1

3. OIL DRAIN LINE..................................................................................................... 2

4. OIL FEED LINE ...................................................................................................... 3

5. SUPPLEMENTARY FUEL INJECTION COMPUTER AND RELATED SYSTEM ... 3

6A. MAIN BRACKET AND POWER STEERING PUMP - 1988-1993 MODELS .......... 7

6B. MAIN BRACKET AND POWER STEERING PUMP - 1994-1995 MODELS .......... 8

7. COOLING FAN SPACER ....................................................................................... 9

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

9. FACTORY ACCESSORY DRIVE BELT AND SUPERCHARGER DRIVE BELT .... 10

10. DISCHARGE PLENUM .......................................................................................... 11

11. AIR FILTER, INLET DUCT AND PLENUM ............................................................. 12

12. FINAL REASSEMBLY & CHECK ........................................................................... 13

iii

15SEP01 V1.1

P/N: 4GC020-010

(88-95 GM Lt Trk(4GC))

NOTICE

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.

(88-95 GM Lt Trk(4GC))

1988 - 1995

GM 7.4 LIGHT TRUCK

Installation Instructions

50 State Smog Legal, as per CARB EO #D-213-17

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty Registration form and return envelope.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30 to 35% and horsepower of 35 to 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 Engineering is

not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 92 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 every 15,000 miles and spark plug wires at least every 50,000 miles.

V-2® Supercharger!

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

• Timing Light

• 3/8" socket and drive set: SAE and Metric

• Drill motor, 3/32" and .046" drill bits

• 1/2" breaker bar and 4" extension

• Large screwdriver or pry bar

• 3/8" NPT tap and handle or socket

• Flat #2 screwdriver

• Hammer

• Adjustable wrench

• Oil Filter Wrench

• Oil Filter

• SF Rated Quality

(or synthetic) Engine oil

• Heavy grease Silicone

sealer

• Phillips #2 screwdriver

• Center punch and 3/4" drift punch

• Open end wrenches: 3/8", 7/16", 1/2, 9/16", 5/8", 3/4", 7/8", 10, 13 & 15mm

a "Slimline" 19mm - Snap-On part # LTAM1719

• Power Steering Pulley Puller & Installer (1994 models only) Snap-On Puller #CJ117B2 Snap-On Installer #CJ113B

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

• Spark plug socket

• NEW spark plugs

15SEP01 V1.1

P/N: 4GC020-010

(88-95 GM Lt Trk(4GC))

1988-1993 7.4 Truck

Part No. 4GC218-090SQ

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 Number Description Quantity

2E228-090 V-2SQ SUPERCHARGER ASSEMBLY 1

4GC111-021 MOUNTING BRACKET ASSEMBLY 1

4GC010-034 Mounting Plate 1 4GC010-043 Attachment Plate 1 4GC010-054 Stiffener plate 1 4GC011-021 Mounting Bracket 1 4GC017-011 .125 Mounting Plate Spacer 1

7A375-550 3/8-16 x 5-1/2” Bolt 1 7F375-016 3/8-16 Nuts 3 7K375-040 3/8” AN960 Flat Washers 5 7J375-044 3/8” SAE Washers 8 7A375-100 3/8-16 x 1” Bolts 10 7C010-025 M10-1.5 x 25mm Bolts 2 7A312-100 5/16-18 x 1” Bolts 4 7J312-000 5/16” SAE Flat Washers 8

4GC010-010 Mounting Bracket Support 1

7A375-208 3/8-16 x 2” Bolt 1 7A375-276 3/8-16 x 2-3/4” Bolt 1 7F312-018 5/16-18 Nuts 4

4GB017-011 1” Throttle Spacer 1

7A375-124 3/8-16 x 1-1/4” Bolts 2

4GC116-010 CRANK PULLEY ASSEMBLY 1

4GB016-011 Crank Pulley 1 4GC017-041 Crank Pulley Spacer 1

7B375-400 3/8-24 x 4” Bolts 3 7J375-044 3/8” SAE Washers 3 7L375-075 3/8" Lock Washers 3

4GC017-010 Spacer Fan 1

7C080-055 M8 1.25 x 55 Studs 4 2A046-598 Belt 1 7B500-400 1/2-20 x 4” Bolt 1

4GC130-026 OIL FEED LINE ASSEMBLY 1

7U030-026 1/4” x 16" Oil Feed hose 1 7P525-067 .500 Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2 7P250-036 #4 Flare to 1/4” NPT 1 7P125-026 1/8” NPT 90° Fitting 1 7P250-034 1/4” NPT x 1/4” NPT Straight Tee 1 7U100-055 6” Nylon Tie Wraps 3

4GC130-036 OIL DRAIN ASSEMBLY 1

7R001-008 #8 Stainless Hose Clamps 2 7U030-036 1/2” x 36” Oil Drain Hose 1 7P375-033 3/8” NPT x 3/8” NPT Street Elbow 1 7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1 7U100-055 6” Nylon Tie Wraps 4

5A001-004 FUEL INJECTION COMPUTER 1

Part Number Description Quantity

4GC112-010 AIR INTAKE ASSEMBLY 1

4GB012-010 Air Filter Cover 1 4GC012-012 Air Inlet Tube 1

4FA012-012 90° Intake Elbow 1

7P375-017 3/8” NPT x 1/2” Straight Hose Barb 1 7S350-200 3-1/2” x 2” Sleeve 1 7R002-056 #56 Hose Clamps 2 7R002-052 #52 Hose Clamps 4 7E010-046 #8 x 3/4” Sheet Metal Screws 2 7U035-000 3-1/2” x 10” Flex Hose 1 8H040-040 Air Filter 1 7U030-005 1/2” x 5” Oil Drain Hose 1 7U035-000 3-1/2” x 12” Flex Hose 1 7R001-008 #8 Stainless Hose Clamps 2

4GC112-020 AIR DISCHARGE ASSEMBLY 1

4GB040-060 Air/plenum Gasket 1 4GC012-020 Steel Discharge Tube 1 4GC050-011 Intake Plenum 1

7A312-050 5/16-18 x 1/2” Bolts 2 7J312-000 5/16” SAE Flat Washers 2 7P125-025 1/8” NPT to 5/32” Barb 1 7R002-044 #44 Hose Clamps 4 7S275-200 2-3/4” x 2” Sleeves 2 7P750-102 3/4" NPT x 1" 90° Hose Fitting 1 7P750-100 3/4" NPT x 1" Straight Hose Fitting 1 7R002-016 #16 Hose Clamps 4 8D001-001 Bypass Valve 1 7U030-046 5/32" x 24" Vacuum Line 1 7P156-082 5/32" Tee 1 7U034-016 1" x 3" Heater Hose 1 7U034-016 1" x 8.5" Heater hose 1 8H040-075 1" Filter 1

4FA111-032 BELT TENSIONER ASSEMBLY 1

7J012-092 12mm Flat Washers 3

4FA011-032 Belt Tensioner Plate 1

7C012-050 12mm x 1.75 x 50mm Bolt 1

4FA016-150 Smooth Pulley Tensioner 1

2A017-010 Idler Pulley Spacer 1 7C012-020 12mm x 1.75 x 20mm Bolts 2 7C012-022 12mm x 1.75 x 22mm Thin Head Bolt 1 7G010-175 12mm x 1.75 Nut 1

4GC160-010 FUEL CONTROL ASSEMBLY 1

4GC152-011 Spacer Block Assembly 1 4GB112-022 Plenum Rod Assembly 1

4GB101-002 FUEL PUMP ASSEMBLY 1

8F001-002 155 Inline Fuel Pump 1

7R003-024 1-1/2” Adel Clamp 1 5W001-011 16-14 GA Eyelet 1 5W001-001 Wire Tap 1 5W001-010 16-14 GA insulated Female Slides 6 5W001-014 Fuse Holder 1 5W001-015 Blade type 20A Fuse 1 5W001-017 Large Ring Terminal 1

8F101-200 T-Rex 5W001-002 Fuse Tap 1 7R001-008 #8 Hose Clamps 2

7P625-001 Fuel Adapter Fitting 1 7U030-050 12mm x 8” PCV Hose 1

7J010-001 #10 Flat Washers 4

7F010-032 10-32 Nylock Nut 2 7U100-055 6” Nylon Tie Wraps 4

7C011-075 10/32” x 3/4” Cap Screw 1

Wiring Assembly 1

vii

15SEP01 V1.1

P/N: 4GC020-010

(88-95 GM Lt Trk(4GC))

viii

+ 16 hidden pages

Vortech Engineering 4GC020-010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual