Vortech Engineering 4GD020-010 User Manual

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GM VORTEC 4.3L V-6

S-10/Sonoma/Jimmy/Blazer

Supercharger System

Installation Instructions

50 STATE SMOG LEGAL PER CARB EO #D-213-17

*1999 models Legal in California only for racing vehicles which may never be used upon a highway.

1996-1999 MODEL YEARS*

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

(4.3L V-6/S-10-(4GD))

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

(4.3L V-6/S-10-(4GD))

of Vortech Engineering, LLC.

Table Of Contents

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

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

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

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

PARTS LIST/1996-1999 GM VORTEC 4.3L V-6...............................................................................vi

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

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

3. OIL FEED .............................................................................................................................2

4. MAIN BRACKET ..................................................................................................................3

5. SUPERCHARGER INSTALLATON...................................................................................... 4

6. SUPERCHARGER/ACCESSORY DRIVE BELT..................................................................5

7. COIL RELOCATION/IGNITION INSTALLATION ..................................................................6

8. SUPERCHARGER DISCHARGE ........................................................................................8

9. SUPERCHARGER AIR INLET.............................................................................................9

10. FUEL MANAGEMENT UNIT ................................................................................................11

11. SUPPLEMENTARY FUEL PUMP AND HARNESS..............................................................12

12. FINAL REASSEMBLY AND CHECK ....................................................................................14

iii

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

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.

(4.3L V-6/S-10-(4GD))

1996-1999*

GM VORTEC 4.3L V-6 S-10/Sonoma/Jimmy/Blazer

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...

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

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower between 35-45% can be expected with the boost levels specified by Vortech 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 at least every 3,000 miles. Never attempt to extend the oil change interval beyond 3,000 miles,

regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original

heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every 20,000 miles and spark plug wires at least every 50,000 miles.

*1999 models Legal in California only for racing vehicles which may never be used upon a highway.

the VORTECH

V-2® supercharger!

TOOL & SUPPLY REQUIREMENTS

• Factory repair manual

• 3/8" socket and drive set: SAE & metric

• Drill motor, 3/32" 5/8" and #16 drill bits

• Flat #2 screwdriver

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

13mm, 15mm, 16mm, 17mm, 18mm

• 5mm Hex wrench

• Hammer

• Silicone sealer

• Oil filter wrench

• Oil filter

• SF rated quality engine oil

• Gasket scraper

• Punch (tapered)

• 3/8" NPT tap

• Fuel line disconnect tool

• Rota Broach (9/16) boring tool (Snap-on #GA219-A)

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

• Spark plug socket

• NEW spark plugs

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

1996-1999 GM VORTEC 4.3L V-6

ENGINEERING, INC.

LLC

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

Part Number Description Quantity 2E228-280 Supercharger Assembly 1

2E128-280 V-2 SQ Supercharger 1 2A036-312 Supercharger Pulley 3.125" 6 groove 1 7K375-040 3/8 AN960 Flat Washer 1 2A040-011 Pulley Retainer 1 7B375-125 3/8"-24 x 1-1/4" HX CLS 1 7U100-070 Key, 3/16 x 3/16 x 7/8 1

4GD111-021 Mounting Bracket Assembly 1

7A375-101 3/8 x 1" Socket Head 1 7A375-100 3/8"-16 x 1-1/4” HXHD Cap Screws 2 7K375-040 3/8” AN960 Flat Washers 16 7A375-100 3/8"-16 x 1” HXHD Bolts 5 7A375-275 3/8"-16 x 2-3/4” HX Cap Screws 2 4GM011-021 Mounting Bracket 1 4GM010-033 Mounting Plate 1 7A375-075 3/8-16 x 3/4" HXHD Bolts 6 4GD011-032 Spring Tensioner 1 2A046-102 Belt 1 4FA016-170 Idler Pulley 1 4FD017-011 Spacer, Idler 1 7C012-050 12mm x 1.75 x 50mm Bolt 1 4FA016-171 Dust Cover 1 4GD116-150 Idler Pulley Assembly 1 4GD010-060 Coil Mount Bracket 1 4GM010-050 Heat Shield 1 7A250-050 1/4-20 x 1/2" SH Cap Screw 1 7J250-001 1/4" SAE Washer 1 4GD014-010 Radiator Pipe 1 7R002-024 #24 Gold Seal Hose 2 7C008-100 #8-32 x 1" Socket Head Cap Screw 4 7F008-032 8-32 Hex Lock Nut 4 7J008-001 #8 Flat Washer 4 SW022-120 226A STD. Wire Brown 1' SW001-007 3/16" Heat Shrink Tube 6" SW001-005 3/8" Plastic Wire Loom 1' 7C010-066 M10 x 1.5 x Soc. HD. Bolt 1 7K437-001 7/16" AN Washer 1

4GD112-010 Air Intake Assembly 1

4GD112-012 Air Inlet Tube 1 4GD015-022 Air Inlet Support 1 8H040-085 Air Filter 1 7S350-200 3-1/2 x 2 Sleeve 1 7R002-056 #56 Gold Seal Hose Clamp 2 7U035-001 3-1/2 Flex Hose x 12" 1 7R002-052 #52 Gold Seal Hose Clamp 3 7U038-000 3/4" Heater Hose 1 7U100-056 90° Vent Tube 1 7P500-026 1/2 NPT 3/4 90° Barb 1 7R001-008 #8 Hose Clamp 1 7U034-016 1" GS Hose x 4" 1 4GD112-030 Air Box Duct Assembly 1 7U100-057 Grommet 1 7S300-101 3 x 1 Sleeve 1 7R002-016 #16 Gold Seal Hose Clamp 2

4GD130-036 Oil Drain Assembly 1

7R001-008 #8 Stainless Hose Clamps 2 7P375-017 3/8" NPT x 1/2” Straight Hose Barb 1 7U030-036 1/2” Oil Drain Hose x 24” 1 7U100-055 Tie Wraps 2

4GD130-026 Oil Feed Line Assembly 1

7U030-026 1/4” Oil Feed Hose x 48” 1 7P525-067 .525” Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fittings 2 7P125-103 -4 x 45° 1/8" NPT Male Elbow 1 7P375-033 3/8 NPT x 3/8 NPT SRT EL 1 7P375-018 3/8-1/8 NPT Bushing 2WD/4WD 1 7P125-026 90° 1/8 NPT x #4 Fitting 1 7P250-100 1/4-1/8 NPT Bushing 1 7P250-146 1/4" NPT Street Elbow 1

4GD238-068 FMU With Lines 1

6Z110-134 Fuel Management Unit 1 7U030-046 5/32" Vacuum Line x 4.3" 1 4GD145-010 Female FMU Line (to tank) 1 4GD145-020 Male FMU Line (to rail) 1 7P250-041 Compression ftg. 2 7P250-036 #4 x 1/4" NPT 2 4GM135-056 36" FMU Line 1 4GM135-057 22" FMU Line 1

Part Number Description Quantity

4GD112-020 Air Discharge Assembly 1

7R002-044 #44 Hose Clamps 4 8D001-001 Bypass Valve 1 7R002-016 #16 Hose Clamps 4 7P156-082 5/32” TEE 1 7U030-046 5/32” x 24” Vacuum line 1 4GD012-020 Discharge tube 1 4GD050-011 Discharge Plenum 1 7W100-070 O-Ring, Throttle Body 1 7S275-200 2-3/4 x 2 Sleeve 2 7P500-156 1/2" Vac. TEE x 1/4 NPT 1 7P250-033 1/4 x 5/32 Red Union 1 7P250-039 1/4 NPT Fem. x 1/4 Hose 1 7U030-030 1/4" Vacuum Hose (.0833") 1 7U034-016 1" GS Hose (3/16") 1 7U034-016 1" GS Hose (1/4") 1 2A017-028 Plenum, Spacer A 1 2A017-029 Plenum, Spacer B 1 2A017-030 Plenum Spacer C 2 7C060-600 M6 x 6" TB 4.3 Stud, front 2 7C060-387 M6 x 3.87" 4.3 Stud, RR 1 7F006-093 6mm Nylock Nut 3 7J006-093 6mm Washer 3

4GD101-002 Fuel Pump Assembly 1

5W001-014 Fuse Holder 1 5W001-015 20 amp Blade Type Fuse 1 5W001-017 Large Ring Terminal 1 5W001-019 12-10 Ga. Solderless Connector 1 7J010-001 #10 Flat Washers 4 7U100-055 6" Nylon Tie Wraps 4 8F101-200 T-Rex Wiring Assembly 1 7F008-020 M8 x 1.25 Nut 1 7U031-018 5/16" Fuel Hose x 1.5" 1 8F001-200 200 Inline Fuel Pump 1 7P375-006 3/8 to 5/16 Fuel Fitting 1 7U032-016 3/8" Fuel Hose x 4.75' 1 7R004-003 14.5 Stepless Clamp 2 5W001-022 T-Tap Connector 1 5W001-042 12-10GA 3/16" Ring Terminal 4 7E010-049 #10 x 3/4 Hex Head Sheet 5 7R004-002 17.0 Stepless Clamp 1 7R001-004 #4 Hose Clamp 1 7P375-072 Female Fuel Fitting 1 7R001-008 #4 Clamp 4 7P250-042 Compression ftg. 2 7P250-045 1/4 NPT to 3/8 Barb 1 7P250-043 1/4 NPT to 5/16 Barb 1

5A101-010 HI-6R Assembly 1

5A001-009 HI-6R Ignition System Assy. 1 5W001-001 Wire Tap 1 5W001-009 16-14GA Male Slide 10 5W001-010 16-14GA Female Slide 10 5W001-011 16-14GA Eyelet .25: Hole 2 5W001-014 Fuse Holder 10GA Wire 1 5W001-015 Fuse, Blade Type 20 amp 1 5W001-017 Large Ring Terminal 12GA 2 5W001-020 3/4" Plastic Wire Loom 1 5W012-000 12GA, STRD Wire, Red 1 5W012-010 12GA Wire, Black 1 5W022-120 22GA, STRD Wire, Brown 1 7E010-046 #8 x 3/4 Sheet Metal 1 7P156-082 5/32 TEE 1 7U030-046 5/32" Vacuum Line 1 7U100-055 Tie Wrap, 6" Nylon 10 7U375-001 Velcro-Hook 1" Black 1 7U375-002 Velcro-Latch 1" Black 1 5W018-010 18GA, STRD Wire, Red 1 5W018-020 18GA, STRD Wire, Black 1 5W018-060 18GA, STRD Wire, Orange 1 5W018-240 18GA, STRD Wire, White/Yellow 1 70000 Inspector Number 1 5W001-040 12-10GA Female Slide 2 5W001-041 12-10GA Male Slide 2

Part No. 4GD218-050/058SQ

PARTS LIST

(4.3L V-6/S-10-(4GD))

1. COMPONENT REMOVAL

A. Disconnect the negative battery cable from the battery. B. Remove and set aside the following components:

- The entire air inlet/filter box assembly, including the throttle body resonator and all hardware including the throttle body mounting bolts.

- The crankcase vent tube from the passenger side valve cover.

- The accessory drive belt.

- The tensioner and idler from the alternator mounting bracket.

- The alternator and bracket.

- The 3/8" stud protruding from the right side cylinder head.

(2000 California models only)

the hose connecting to the factory check valve and remove valve from the air injection tube. Remove the air injection tube from the passenger's side exhaust manifold. Remove the two studs using a 5.5mm socket.

C. Drain the contents from the radiator into a clean container. D. Remove lower radiator hose.

Disconnect both ends of

2. OIL DRAIN

A. To provide an oil drain for the supercharger, it is

necessary to make a hole in the oil pan. Locate and mark hole (see

Figs. 2-a, 2-b

NOTE: Removal of the oil pan may ease oil drain fit-

ting installation on some applications.

B. Remove the factory anti-roll bar brackets (2) from the

frame and allow the bar to temporarily drop down. Unplug the factory crank trigger connector from the sensor located in the timing cover.

NOTE: The factory transmission cooler lines may re-

quire bending to clear the supercharger oil drain hose.

C. Carefully drill a pilot hole (the same diameter as the

Rota Broach pilot) into the marked spot on the oil pan (this procedure may also be done by removing the oil pan if you are unsure of your ability to perform the following steps properly). Drill slowly as to catch most of the aluminum chips from the hole being drilled. Using the 9/16" Roto Broach, very slowly machine a hole in the pan (use the previously drilled hole as a guide). Stop machining just before the tool breaks through into the oil pan. Using a scribe or a small screwdriver, remove the remaining disc-shaped oil pan piece (this allows you to remove the pan slug before it falls into the oil pan and keeps most of the aluminum chips out).

PUNCH HOLE THROUGH (DIRECTLY UNDERNEATH CORNER PAN BOLT)

HOLE MUST BE MADE FROM THE SIDE OF THE PAN

OIL PAN BOLTS

3/4”

FRONT VIEW

BOTTOM VIEW

Fig. 2-a

Fig. 2-b

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

2. OIL DRAIN, cont'd.

D. Tap the hole with a 3/8" NPT tap approximately 1/4" deep.

Pack the flutes of the tap with heavy grease to hold chips.

E. Thoroughly clean the threaded area. Apply a small

amount of silicone sealer to the new threads. Apply more sealer to the supplied 3/8" NPT x 1/2" barb fitting. Install the fitting into the pan. Make sure a seal is formed around the entire fitting.

F. Drain the engine oil, install a new filter and refill with

fresh oil.

G. Reattach anti-roll bar and crank trigger connector.

3. OIL FEED

A. The supercharger uses engine oil for lubrication and

must have an oil feed line connected to a filtered oil access on the engine.

B. Remove the 3/8” NPT plug located on the engine block

just above the oil filter boss. Replace the plug with the supplied 3/8" NPT elbow. Connect the remaining fittings as shown (see

Fig. 3-a

NOTE: Use clean engine oil on the pipe threads.

Teflon tape and sealant is not recommended, as it might loosen and cause blockage of the small oil feed orifice resulting in supercharger failure.

TO SUPERCHARGER

Fig. 3-a

OIL

FILTER

C. Connect the supplied feed line to the flare fitting and

make a gentle downward loop around and back toward the front of the engine (see

Fig. 3-b

). Secure the hose with the tie wraps provided, routing it away from exhaust heat, chaffing and/or sharp objects. Temporarily cover the open end from debris until the connection is made to the supercharger in step 5.

4WD MODELS: Connect the feed hose and fittings to the remote oil filter boss at the front of the vehicle. (see Fig. 3-c)

ENGINE BLOCK

3/8 NPT STREET ELBOW

3/8 - 1/8 NPT BUSHING

1/8” NPT 45° FLARE

Fig. 3-b - Rear View, 2WD only

REAR VIEW - 2WD ONLY

ROUTE HOSE AROUND TO FRONT OF VEHICLE (ROUTE ALONG OIL COOLER LINES)

(4.3L V-6/S-10-(4GD))

Fig. 3-c - 4WD only

4. MAIN BRACKET

A. To accommodate the relocation of the alternator onto

the new main bracket, the brown field wire must be extended approximately 12”. Proceed by cutting the wire approximately 4” from the factory plug that attaches to the alternator. Splice the supplied piece of brown wire into the cut wire by soldering. Use the supplied piece of heat shrink tubing to seal the joints. Re-wrap the wire/ harness with the supplied length of plastic flex-loom.

B. The transmission cooler lines may need to be bent

downward as far as possible (toward the frame) to obtain alternator clearance.

C. Attach the supplied stainless steel heat shield onto the

rear of the Vortech main bracket using the supplied 1/4” hardware (see

D. Following Figure 4-d, cut the supplied protective sleeve

Fig. 4-a

as shown. Slide the protective sleeve onto the air injection adapter, following with the 90° compression fitting. Do not tighten compression fitting yet. Mount this assembly to the exhaust manifold using the supplied hardware and stock gasket (replace in necessary). Torque bolts evenly using a 5mm hex wrench. (See

4-e

E. Thread the factory check valve onto the compression

fitting and tighten. Referring to compression fitting slightly upward, then tighten. Use one wrench on the compression fitting and one on the nut to protect the air injection adapter from damage while tightening the compressing nut.

F. Attach the supplied 5/8" x 24" hose to the factory check

valve and to the TEE coming from the air injection pump and secure.

G. Cut factory lower radiator hose as shown (see

Install the supplied 90° steel tube and secure using the supplied #24 clamps (see

H. Place the mounting bracket on the front of the passenger

side cylinder head. Line up the bracket with the holes on the front of the head and block and start the 3/8-16 socket head bolt into the lowest bracket hole. Install the two 3/8-16 x 1.00” bolts and washers into the two remaining upper holes. Torque the three bolts evenly.

I. Place the alternator in position on the bracket and check

for clearance between the air injection adapter and the back cover of the alternator. In some instances, it may be necessary to remove the cover and trim a small portion of the cover before final mounting.

Fig. 4-b

Fig. 4-e

, angle the

Fig.

Fig. 4-c

Fig. 4-a

INSTALL 90° RADIATOR PIPE

Fig. 4-b

7S625-000 HEAT SLEEVE

AFTER TRIMMING

7S625-000 HEAT

SLEEVE

1.00 0

.500

.750

INCISION LINES

Fig. 4-d

TO WATER PUMP

DISCARD

4GD110-070 ADAPTER ASSEMBLY

CA 2000 Models Only

LOWER

RADIATOR

Fig. 4-c

TRIM STOCK HOSE

AND INSTALL 90° TUBE

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

4. MAIN BRACKET, cont'd

J. Reattach the field wire and positive wire to the alternator

(make sure that the large positive wire has the factory rubber boot properly secured to prevent arcing to the heat shield). Using the supplied 3/8-16 x 2.75” bolts and washers, attach the alternator to the main bracket. Secure all alternator wiring from heat and sharp objects.

K. Align the supercharger mounting plate with the bracket

and secure with the supplied 3/8-16 x 3/4” bolts and AN washers.

5. SUPERCHARGER INSTALLATION

A. Attach the 1/2” oil drain hose to the supercharger and

secure with the #8 hose clamp.

B. Route the hose down the rear of the main bracket while

lowering the supercharger into the proper mounting location on the plate. Be sure that the oil drain hose remains unkinked with smooth bends.

C. Using the five supplied 3/8-16 x 1” bolts and AN

washers, secure the supercharger to the mounting plate.

D. Route the oil drain hose around the main casting and

down to the fitting in the oil pan. Make sure that the hose runs below the positive alternator lug, but still remains running “downhill”. (See

Fig. 5-a.

important that the oil drain hose is free from restrictions, tight bends, kinks or any other drain obstructing conflict. Route the hose away from direct exhaust heat. Trim hose length if necessary and secure to the oil pan with the supplied #8 hose clamp.

E. Attach the 1/8 NPT x 45° brass fitting to the

supercharger oil feed. Use a 1/2” wrench to hold the feed fitting while tightening the 45° fitting. Attach the oil feed hose to the supercharger. (See

) It is very

Fig. 5-b.

Fig. 4-e

OIL DRAIN HOSE

Fig. 5-a

)

WARNING: The oil system contains a small orifice

that is easily plugged. Do not use any type of sealant on any of the threads. Instead, use clean engine oil. Disassemble and blow out the entire line if there is any question.

F. Using the tie wraps provided, secure the feed and drain

systems away from heat and/or sharp objects.

(4.3L V-6/S-10-(4GD))

Fig. 5-b

6. SUPERCHARGER/ACCESSORY DRIVE BELT

A. Mount the supplied automatic belt tensioner onto the

main bracket. Rotate the unit so that the small alignment pin falls into the corresponding hole in the bracket. Secure the tensioner to the bracket using the suppplied socket head bolt and 7/16" AN washer.

B. Route the supplied belt as shown (see

installation is easiest when the water pump is the last pulley to be mounted (the radius on the edge of the water pump pulley allows the edge of the belt to be slid over it).

SUPERCHARGER

Fig. 6-a

). Belt

SPRING

TENSIONER

ALT.

IDLER

AIR

CONDITIONER

WATER

PUMP

POWER

STEERING

CRANK

Fig. 6-a

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

7 . COIL RELOCA TION/IGNITION INSTALLATION

A. Remove ignition coil and bracket from the factory

location.

B. Separate the coil and module from factory mounting

bracket.

C. Install the coil and module to the supplied bracket using

the supplied hardware (see

Fig. 7-b

D. Mount the coil and bracket assembly to the intake

manifold. Use the factory studs and nuts to secure the coil. (See

Fig. 7-c.

)

E. Remove the interior center console (between the two

front seats). Mount the supplied ignition control box assembly into the vehicle interior in one of two possible locations (alternate mounting locations of the control box, retard knob and MAP sensor may vary suiting the taste/preference of the installer). (See

Figs. 7-f, 7-g.

1. Pickup truck models (S-10/Sonoma):

a. The suggested mounting location is in the

center console between the two seats (remove the center console and mount the control unit vertically in the rear). (See

7-f.

)

Fig.

b. The retard knob can mount in the forward

portion of the tray in the console. Mount the MAP sensor under the console. (See

Fig. 7-f.

SUPPLIED

COIL

BRACKET

)

Fig. 7-b

)

FACTORY GM

HARNESS

(UNPLUGGED

FROM COIL)

TO BATTERY +

TO GROUND -

RANE

HI-6R

cams

GREEN TACH (TAPE UP)

*GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

MANIFOLD

VACUUM

*NOTE: CABLE CONTAINS RED AND BLACK LEADS. MAKE SURE LEADS DO NOT CONTACT EACH OTHER AND SHORT UNIT WHEN TAPING UP.

HEAVY RED

HEAVY BLACK

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

SUPPLIED MAP SENSOR

3 WIRE HARNESS

Fig. 7-a / 96-97 Coil Relocation

CUT HERE AND ATT ACH CONNECTOR

GREEN

(OR WHITE)

BROWN w/WHITE STRIPE (RETARD INPUT)

RED

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

K IN

WIRE TAP

IGNITION COIL

RED WHITE BLACK

ORANGE

PINK

GREEN

(OR WHITE)

YELLOW (TAPE UP) BLACK (GROUND)

COIL

MOUNTING

LOCATION

Fig. 7-c

Fig. 7-d

(4.3L V-6/S-10-(4GD))

7 . COIL RELOCA TION/IGNITION INST ALLATION, cont'd.

2. SUV models (Blazer/Jimmy) a. The suggested mounting location is in the

storage box located next to the back seat on the passenger side of the vehicle.

b. The retard knob and MAP sensor can mount in

the center console as the pickup trucks do (see

Fig. 7-f

power wire must be run over to the remote mounted ignition box.

F. Connect all components as shown (see

Connect a manifold sourced vacuum line using the supplied 5/32” hose and TEE (use the FMU tap location). Route the extended coil wires and previously attached vacuum hose from the engine compartment back along the frame rail and to the transmission crossmember. Drill a 5/8” hole through the floor of the vehicle from the bottom of the center console location for wire/ vacuum hose pass through. Route the wire/vacuum hose bundle up into the passenger compartment using the previously drilled hole.

G. Use the supplied cable ties to keep the wires secure

and away from moving/sharp/hot objects. Do not attempt to start the vehicle without all components installed as shown.

H. Ignition Boost Control operation

1. The Ignition/Boost Control unit is designed to retard

ignition in relation to boost.

2. The unit is adjustable from 0° of ignition retard to 4° of ignition retard for each pound of boost, up to a maximum of 20°.

3. Using the 1° per pound position as a starting point, adjust the ignition retard knob until just beyond the point of detonation (see testing in a safe area or road. Adjust the retard according to changes in altitude and fuel quality.

). The brown retard wire and thin red

Fig. 7-a

Fig.7-e

). Use third gear for

PICKUP TRUCK MODELS

CENTER

CONSOLE

MAP

SENSOR

VACUUM LINE/

WIRING

IGNITION

CONTROL BOX

Fig. 7-f

RETARD

KNOB

HOLE

THROUGH

FLOOR

SUV MODELS

CENTER

CONSOLE

RETARD

KNOB

MAP

SENSOR

VACUUM LINE/

WIRING

HOLE

THROUGH

FLOOR

Caution: It is extremely important that the boost retard

never be turned to 0°. It is recommended that in stock street applications, the knob be at no less than 1°per lb.

Examples of Ignition Retard vs. Boost:

5 psi at 3° per lb. 7 psi at 2° per lb.

DEGREES OF RETARD

PSI BOOST

Fig. 7-e

MAX. RETARD = 15°

10 psi at

1/2° per lb.

IGNITION

CONTROL BOX

PASSENGER SIDE

STORAGE

COMPARTMENT

Fig. 7-g

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

8 . SUPERCHARGER DISCHARGE

A. Install the supplied discharge plenum using studs,

spacers, nuts and washers (see

Fig. 8-b

B. Thread the three supplied studs into the factory throttle

body mounting holes (into the intake manifold). The shortest of the three studs belongs at the rear of the throttle body. Insert the four spacers into their proper location (see

Fig. 8-c

C. Slide the supplied O-ring around the top flange of the

throttle body. Use a light amount of oil on the O-ring to allow easy installation of the discharge plenum. Carefully align the discharge plenum to the installed throttle body studs. Lower the plenum down onto the throttle body being careful not to upset the O-ring fit. When contact with the O-ring is felt, push down firmly on the plenum until you feel it seat on the top of the throttle body (see

Fig. 8-d

D. Secure the plenum to the throttle body by attaching the

supplied washers and nuts to the previously installed studs.

E. Remove the 1/2” brake booster vacuum line from the

intake manifold and cut approximately 2” off from the end. Splice the supplied adapter TEE into the brake booster line. Run the supplied piece of 1/4” vacuum hose from this TEE to the 1/4”-5/32” reducer (see

8-a

F. Attach the supplied compressor bypass valve and 1” x

2.25” hose to the plenum using #16 clamps. Orient the bypass valve as shown (see

Fig. 8-e

G. Attach the discharge tube from the supercharger to the

plenum using the supplied silicone sleeves and clamps (see

Fig. 8-e

). Connect the 5/32” hose to the nipple located on the bottom of the supercharger bypass valve to the reducer previously installed into the brake booster line.

Fig. 8-b

Fig.

Fig.8-c

SUPERCHARGER AIR INLET ELBOW

SUPERCHARGER DISCHARGE TUBE

(4.3L V-6/S-10-(4GD))

5/32” HOSE 1/4” HOSE

1/4” NPT x 1/4” FITTINGREDUCER

Fig. 8-a

BRAKE

BOOSTER

Fig.8-d

1/2” TEE

INTAKE MANIFOLD FITTING

Fig. 8-e

9. SUPERCHARGER AIR INLET

A. Install the supplied plastic 3/4” x 90° vent adapter into

the factory rubber grommet located on the right side valve cover. Rotate the vent adapter so that it points toward the rear of the vehicle. Attach the supplied 3/4” x 20” hose to the installed adapter.

B. The oil fill riser must be modified to allow for fitment of

the new air inlet duct (see

Fig. 9-a

the plastic oil fill riser and cap located on the right side valve cover. Cut the riser in half (the diameter) using a saw or cut-off wheel. Clean and reinstall the base of the cut riser into the valve cover . Slide the supplied piece of 1” x 4” hose over the base. Insert the remaining top portion of the filler into the hose. The cap should now be approximately 2-3” higher than its factory location. Adjust height if necessary.

C. Install the supplied 1/2” NPT x 90° x 3/4” hose barb

fitting into the 3.5” steel inlet tube. The fitting must be “clocked” so that when the inlet tube is installed, the fitting points down and over to the right side valve cover and attaches to the previously installed 3/4” valve cover vent hose (temporarily place the tube in its installed position to approximate the fitting rotation before final installation).

D. Attach the supplied inlet tube support to the left rear

portion of the intake manifold (see

E. Using the supplied 3.5” silicone sleeve and #56 hose

clamps, attach the 3.5” inlet duct to the supercharger. Lay the duct on top of the previously installed tube support. Connect the 3/4” valve cover vent hose to the 90° fitting on the inlet duct. Trim length if necessary. Situate duct so that it does not contact the firewall or any other object that will cause problems when the engine torques on operation. Secure duct to the tube support using the supplied #52 clamp.

F. Attach the 1” x 3” compressor bypass discharge hose

to the barb located on the inlet duct.

G. Remove the factory MAF sensor and airbox assembly.

Remove the driver's side headlight assembly. Separate the MAF sensor from the airbox (see the filter and venturi-shaped inlet from the box. Modify the lower portion of the airbox as shown and reinstall into the vehicle. Insert the supplied airbox inlet duct through the core support opening behind the headlight and into the modified factory airbox. Rotate the duct (see

Fig. 9-c

). Drill two holes into the core support using the duct flange as a guide. Secure the duct with the two sheet metal screws provided. Reinstall headlight assembly.

H. Install the supplied K&N air filter into the factory airbox.

Drill a 3/4” hole into the airbox top in the location shown (see

Fig. 9-d

). Insert the supplied rubber grommet and the factory air intake temperature sensor into the new hole. Attach the modified airbox lid the airbox base. Reattach the MAF to the airbox lid. Attach the factory MAF and IAT sensor connectors.

). Begin by removing

Fig. 9-b

Fig. 9-e

MODIFIED OIL FILL RISER

Fig. 9-a

INLET TUBE SUPPORT

Fig. 9-b

). Remove

NEW IAT SENSOR LOCATION

Fig. 9-c

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

9. SUPERCHARGER AIR INLET, CONT'D.

I. Slide the supplied 3” orange sleeve onto the outlet of

the MAF meter. Connect the previously installed steel supercharger inlet duct to the MAF meter oultet using the supplied section of flex hose and #52 clamps (see

Fig. 9-f

J. Check to see that there is adequate clearance between

the factory mounted underhood light and the supercharger kit by slowly closing the hood. Remove light if necessary.

Fig. 9-d

Fig. 9-e

(4.3L V-6/S-10-(4GD))

Fig. 9-f

10. FUEL MANAGEMENT UNIT

A. Following the

Fig. 10-a

, position the fuel management unit (FMU) on the inside of the vehicle frame, underneath the driver's seat. Mark and drill two #16 holes. Secure the FMU using the supplied #12 hex head screws.

NOTE: Some earlier model trucks are not equipped with

quick disconnect fittings and will require the use of compression fittings and alternate fuel lines. Proper lines and fittings are supplied to work with both versions of this vehicle. Refer to Figures 10-c, 10-d to verify the vehicle you are modifying.

QUICK DISCONNECT TYPE FITTINGS ONLY

B. Using a fuel line disconnect tool, separate the 5/16”

fuel return (see

Figure 10-b

). Attach the supplied 33” fuel hose with the male fitting into the fuel line coming from the engine compartment. Attach the 17” supplied fuel hose with the female fitting into the line returning back to the tank. Connect the fuel line coming from the engine compartment to the 90° fitting on the side of the FMU. Connect the fuel line returning back to the tank to the straight fitting on the bottom of the FMU. Make sure that both lines have smooth bends and are absolutely free from sharp bends and kinks (see

Fig. 10-c

COMPRESSION STYLE FITTINGS ONLY

B. Separate the factory 5/16" fuel rail return line at the

compression fitting junction underneath the vehicle near the fuel filter . Attach the supplied -4 flare fitting adapters to each end of the open return line (one fitting will point toward the rear , and one toward the front). Connect one end of the supplied 22" FMU hose to the return line running back to the tank, and the other end to the straight fitting on the center of the FMU. Connect one end of the remaining 36" FMU hose to the return line coming from the fuel rail, and the other end to the 90 fitting on the side of the FMU (see

Fig. 10-d

C. Tap into the supercharger bypass valve vacuum hose

using the supplied 52” long length of hose and 5/32” brass TEE. Route the hose in a manner that will keep it away from exhaust heat and will allow gentle bends without pinching. Attach the hose end to the lid of the FMU.

FUEL PUMP HARNESS

Fig. 10-a

FUEL LINE FROM RAIL FUEL LINE TO TANK

Fig. 10-b

FMU

QUICK DISCONNECT TYPE FITTING COMPRESSION TYPE FITTING

5/16” LINE TO TANK

FMU OUTLET (TO TANK)

FMU INLET (FROM FUEL RAIL RETURN)

5/16” LINE FROM RAIL

VACUUM LINE TO MANIFOLD

MOUNT TO FRAME

5/16” LINE TO TANK

FMU OUTLET (TO TANK)

FMU INLET (FROM FUEL RAIL RETURN)

Fig. 10-dFig. 10-c

5/16” LINE FROM RAIL

VACUUM LINE TO MANIFOLD

MOUNT TO FRAME

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

11. SUPPLEMENTARY FUEL PUMP AND HARNESS

NOTE: Some earlier model trucks are not equipped with

quick disconnect fittings and will require the use of compression fittings and alternate fuel lines. Proper lines and fittings are supplied to work with both versions of this vehicle. Refer to the graphic below to verify the vehicle you are modifying.

QUICK DISCONNECT TYPE FITTINGS ONLY

A. Using a fuel line disconnect tool, separate the supply

line from the oulet of the fuel filter.

B. Attach the supplied 3/8" hose to the fuel filter outlet.

Connect the remaining end of the 3/8" hose to the fuel pump inlet. Trim the hose if necessary.

COMPRESSION TYPE FITTINGS ONLY

C. Separate the factory 3/8” fuel rail supply line at the

compression fitting junction underneath the vehicle just to the rear of the fuel filter (see

D. Attach the supplied 3/8” hose to 3/8" compression fitting

to the line coming from the fuel tank. Connect the supplied length of 3/8” fuel hose to the 3/8” fitting previously installed and the remaining end to the supplied inline pump. Secure with a #8 hose clamp.

Fig. 11-b

BOTH APPLICATIONS

E. Attach the discharge end of the fuel pump to the line

running into the fuel filter (use the supplied 5/16" hose to 3/8" compression fitting). Position the pump in such a way that the inlet and discharge hoses are not kinked or restricted and maintain a gentle bend. The pump inlet is the most critical as far as restriction is concerned and may be trimmed if necessary to hold a smooth radius. Make sure that all fuel pump hose connections are secure.

F. Mount the fuel pump to the frame using the 1-1/2” adel

clamp. Position the clamp and drill a #16 hole. Secure using a #12 hex head screw.

G. Using the existing hole in the frame

and supplied #10 hardware, mount the relay to the vehicle frame (see

on this page and

11-a

Figure 10-a

Fig.

on page 11). The relay mounting hole will also work well as a grounding point for the pump and relay. Scrape away the frame coating and paint to provide a proper ground connection. Make sure that the pump and relay grounding terminals are mounted opposed to

under

on top

the relay as

so that a

GROUND

metal-to-metal contact will be made.

RELAY WIRING

SCHEMATIC

87A

(+) FUEL PUMP

SOLID GREY WIRE IN FUEL PUMP HARNESS (RUNNING ALONG THE DRIVER’S SIDE FRAME MEMBER)

(+) BATTERY LUG

(4.3L V-6/S-10-(4GD))

Fig. 11-a

11. SUPPLEMENTARY FUEL PUMP AND HARNESS, cont'd.

H. Following the diagram (see

Figs. 11-c, 11d

), wire the fuel pump and relay. Use the supplied tie wraps to run the wire and keep it away from heat/abrasion. Use the supplied 8mm nut to connect the main power lead on the relay to the factory fuse/power box underhood (the factory has provided two open power lugs under the power box cover). Tap the yellow relay wire (terminal #87) into the solid gray wire in the harness running along the driver's side frame member . Use the supplied wire tap.

3/8” FUEL HOSE

QUICK DISCONNECT STYLE FITTINGS

#8 HOSE

CLAMP

FROM TANK

FUEL PUMP

FACTORY

FUEL FILTER

TO RAIL

5/16” FUEL

HOSE

3/8” FROM TANK

RELY TERMINAL #87

3/8"

1/2” HOSE TO 3/8” COMPRESSION FITTING

GROUND

#8 HOSE CLAMP

Fig. 11-c

COMPRESSION STYLE FITTINGS

5/16” HOSE TO 3/8” COMPRESSION FITTING

3/8” TO RAIL

FACTORY FUEL FILTER

#8 HOSE CLAMPFUEL PUMP

RELAY TERMINAL #87

GROUND

Fig. 11-d

26APR01 V1.2

P/N: 4GD020-010

(4.3L V-6/S-10-(4GD))

12.FINAL REASSEMBLY AND CHECK

WARNING: Do not attempt to operate the vehicle un-

til ALL components are installed and ALL operations are completed including the final check.

A. 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.

B. 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.

C. Check all fluid levels, making sure that your tank(s) is/

are filled with 92 octane or higher fuel before commencing test drive.

D. Start engine and allow to idle a few minutes, then shut

off.

E. Recheck to be sure that no hoses, wires, etc. are near

exhaust headers or moving parts and for signs of any fluid leakage.

F. PLEASE TAKE SPECIAL NOTE: Operating the vehicle

without all sub assemblies completely and properly installed and working may cause FAILURE OF MAJOR

ENGINE COMPONENTS.

G. Test drive the vehicle. H. 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.

Figt 12-a

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

(4.3L V-6/S-10-(4GD))

ENGINEERING, LLC

Vortech Engineering 4GD020-010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual