PONTIAC GTO Supercharger System Installation Instructions

Transcription

1 PONTIAC GTO Supercharger System Installation Instructions Model Years* *Legal in California only for racing vehicles which may never be used upon a highway. ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands CA Phone: Fax: M-F 8:00AM - 4:30PM (PST) DP/N: 4GJ v1.0 03/12/08

2 FOREWORD This manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for this vehicle. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) :00am- 4:30pm PST. Take note of the following before proceeding: 1. Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the STOP installation to determine if you should refer the job to a professional installer/technician. Please contact your dealer or Vortech Engineering for possible installers in your area. 2. This product was designed for use on stock (un-modified, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product. 3. Use only premium grade fuel with a minimum of 91 octane (R+M/2). 4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost) until the problem is resolved. 5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage. Exclusions from Vortech warranty coverage considerations include, but not limited to: 1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation. 2. Continued operation with an impaired vehicle or sub-system. 3. The combined use of Vortech components with other modifications such as, but not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes. Notes: The driver side supercharger kits are compatible with the 1965 GTO power steering pump and alternator (others similar) and air conditioning. The passenger side supercharger kits are not compatible with air conditioning. The crank pulley supplied in this kit is designed to accommodate stock 1965 GTO water pump pulley, alternator, and power steering. Vehicles with different accessories may need custom spacing or elimination of some accessories. Distributor clearance to the carburetor enclosure is minimal. Distributors may need a small diameter cap in order to fit. If a charge cooled kit is being installed, battery relocation will be necessary. The charge cooler reservoir will be installed in the original battery location. (Vortech 8N may be used) 2008 VORTECH ENGINEERING, LLC All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into another language in any form, by any means without written permission of Vortech Engineering, LLC. P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) ii

3 TABLE OF CONTENTS FOREWORD.... ii TABLE OF CONTENTS...iii TOOLS & SUPPLY REQUIREMENTS...iv PARTS LIST PONTIAC GTO... v 1. PREPARATION/REMOVAL OIL FEED OIL DRAIN FUEL SYSTEM INSTALLATION DRIVER-SIDE SUPERCHARGER BRACKET INSTALLATION PASSENGER-SIDE SUPERCHARGER BRACKET INSTALLATION SUPERCHARGER INSTALLATION CRANK PULLEY, SUPERCHARGER PULLEY AND BELT INSTALLATION BELT AND BELT TENSIONER INSTALLATION CARBURETOR ENCLOSURE INSTALLATION AIR FILTER INSTALLATION STANDARD DISCHARGE DUCT INSTALLATION CHARGE AIR COOLER (CAC) CORE INSTALLATION CAC WATER COOLER INSTALLATION CAC WATER RESERVOIR ASSEMBLY INSTALLATION CAC WATER PUMP WIRING CAC PLUMBING AND BLEEDING SYSTEM FINAL ASSEMBLY AND CHECK...18 iii P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

4 PONTIAC GTO Installation Instructions Congratulations on selecting the best performing and best backed automotive supercharger available today... the VORTECH Supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form. Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a wornout 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 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 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 2 years or 20,000 miles with original heat range plugs as specified by the manufacturer and retard timing from 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 at least 15,000 miles and spark plug wires at least every 50,000 miles. TOOL & SUPPLY REQUIREMENTS: Factory Repair Manual 3/8" Socket and Drive Set: SAE & Metric 3/8 Swivel Head Ratchet 1/2" Socket and Drive Set: SAE & Metric 3/8" NPT Tap and Handle Adjustable Wrench Open End Wrenches: SAE & Metric Center Punch 5 Quarts SH/CF Rated Quality Engine Oil Oil Filter and Wrench Flat #2 Screwdriver Phillips #2 Screwdriver Heavy Grease Silicone Sealer Drill Motor 1/8", 3/16" Drill Bits Hex Key Wrench Set Wire Strippers and Crimpers Utility Knife Hand Held Grinder Blue Loctite If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need: Spark Plug Socket New Spark Plugs P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) iv

5 ENGINEERING, LLC PONTIAC GTO Part No. 4GJ SQ/-218SQ DRIVER'S SIDE STANDARD DISCHARGE KIT PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART # DESCRIPTION QTY PART # DESCRIPTION QTY 2E (8) V2 S/C, SI-TRM,CW SATIN CAP, TAMPER PROOF, VORT S/C 1 2A (8) VOLUTE, CURVED SI-TRIM 1 2A IMPELLER, MACHINED SI-TRIM 1 2A PLY RETAINER, TAMPER PRF CAP 1 2A RETAINER CUP, VORT S/C PLY 1 2A RETAINER, COMPRESSOR 3 2E (8) V-2 G/C ASSY CW-SATIN 1 4MA S/C DRIVE PULY 3.87" GEN2 MERC 1 7B /8-24 X 1-1/2 GR8 HX 1 7P /8 PIPE PLUG STEEL,Zn PLT'D 2 7P /8NPT X 1/2 BEADED HSE BRB 1 7P S/C OIL FEED FILTER FTG, BRASS 1 7U KEY,3/16 SQUARE X 1-1/8 LONG 1 4GJ OIL FEED ASSY, 65 GTO DRVR 1 7P /8 NPT 90^ X -4 JIC FTG 1 7P /8 NPT STR. X -4 JIC FTG STL 1 7P /8 NPT FEMALE TEE 1 7P /8 NPT X 1" NIPPLE 1 7U TIE WRAP, 7.5" NYLON 5 7U OIL FEED HOSE,51.0",-4 STR 1 4GJ OIL DRAIN ASSY, 65 GTO 1 7U /2" OIL DRAIN HOSE 2 7R #8 STNLS HOSE CLAMP 2 7P /8 NPT 90 X 1/2 HOSE BRB 1 4GJ MTG BRKT ASSY, 65 GTO DRVR 1 2A SPACER W/PLT,.935 L 1 2A SPACER, FORD ALT, SBF CARB 1 2A SPACER, SC PLT TO SPT PLATE, A SPACER, HEAD TO SPT PLATE, FA BELT TENS PLATE, HEAVY DUTY 1 4FP IDLER W/BRNG ASSY, 36MM COG 1 4GJ PLATE, SC MTG, 65 GTO 1 4GJ PLATE, SC MTG, 65 GTO HEAD 1 4GS BUSHING, Ø.725 X.67, SLOTTED 1 4HS SPACER, LOWER S/C PLT S A /8-16 X 1.25 HXHD GR8 PLT 6 7A /8-16 X 1-3/4 FLTALN 4 7A /8-16 X 4 1/4" HXHD GR5 5 7A /8-16 X 4.5" FLT HD ALN 2 7C M12 X 1.75 X 20MM HXHD CL C M12 X 1.75 X 80MM HHCS 1 7J /8 SAE WASHER, PLTD 12 7G MM X 1.75 NUT 1 7J MM WASHER, FLAT 5 7F /8-16 HX NUT 1 4FP ALTER.STAY,UPPER 1 4GJ (8) DISCHARGE ASSY, GTO STD 1 4PFX (8) DISCHARGE TUBE, SBF, A /16-18 X 3/4 SS SHCS 4 7R #44 SAE TYPE F SS HOSE CLAMP 1 7R #56 SAE TYPE F SS HOSE CLAMP 3 7S SLEEVE, 3-1/2 X 2, BLUE 1 7S REDUCER, U /32" VACUUM LINE 2 8PM (8) MACH DUCT,ENCL. INLET MOD 1 8M (8) CARB ENCL ASSY, 65 GTO 1 2A SPACER,CARB.ENCLOSURE 2 7C Ø1/4" SHOULDER SHCS 1 7A /16-18 X 3/4 SS SHCS 12 7A /16-18 X 1.25" SHCS ZINC PLT 1 7A /16 STUD 4 7C X 3/4 SS BHCS 1 7C PLUG SCREW 1 7F NUT, THROTTLE 1 7F /16-18 NYLOCK NUT 1 7F /16-24 JAM NUT 4 7J #10 FLAT WASHER 4 7J WASHER, THROTTLE 1 7J /16 FLAT WASHER-SAE 4 7P /32 TEE 2 7P FITTING, -3 TO 1/4 HOSE 2 7P PLUG,-3 O-RING PORT 2 7P /4NPT TO 3/8"BARB P PLUG, OIL HOLE 2 7P PLUG,AN-8 ORING PORT 2 7P FITTING, -8 BULKHEAD NUT, BLK 1 7U /32" VACUUM LINE 4.5 7U O-RING, U O-RING, U GASKET 1 8M HOLLEY 4BARREL BASE GASKET 3 8M GASKET, 90mm THROTTLE BODY 1 8M (8) CARB CVR, VORTECH POLISHED 1 8M RETAINER, SPRING THROTTLE 1 8M SPRING, H/D, THROTTLE ENCL. 1 8M BRKT, THROTTLE EXT. 65 GTO 2 8M FTG, 65 GTO THROTTLE CABLE 1 8M NUT, 65 GTO THROTTLE CABLE 1 8M WASHER, 65 GTO THROTTLE CABLE 1 8M (8) ENCL. STD. MACH. ASSY. 1 4GJ FUEL ASSEMBLY, 65 GTO CARB 1 7P /8 NPT PLUG 1 7P HOSE END, 90 DEG. 1 7P AN -8 HOSE END, STRAIGHT 1 7P MALE TEE -8,-6,-6 1 7P FITTING, -8 BULKHEAD W ORING 1 7P TO 1/2" BARB 1 7P FITTING, -8 BULKHEAD NUT, BLK 1 7P AN -8 MALE SHORT -6 MALE STD 1 7U /2" FUEL LINE U O-RING, GJ ASSY, CRANK PLY, 65 GTO 6IN 10RIB 1 4GJ PULLEY, ACSY DRIVE, 65 GTO 1 4GJ SPCR, CRANK PLLY, 65 GTO 1 4MA CRANK PLY, 6", UNIVERSAL 1 7A /16-18 X 2.25" SS SHCS 4 7A /16-18 X 3" SHCS 6 7A /8-16 X 1.25 HHCS, GR8, PLT 4 7K /8 AN960 FLAT WASHR PLATED 4 8M HOLLEY 4150 FLOAT BOWL LINE ASSY 1 8M FUEL LINE FRONT SS, M FUEL LINE REAR SS, M DEMON FLOAT BOWL LINE ASSY W/FTGS 1 8M FUEL LINE, SS, FRONT DEMON 1 8M FUEL LINE, SS, REAR DEMON 1 7P FTG, -6 TO 9/16-24 BG ADPTR 2 8D (8) RACE BLOWOFF VALVE-SATIN 1 8H AIR FILTER 3.5"FLG X 7"L 1 2A BELT, K GATES 10-RIB 1 4GJ PONTIAC GTO INST MANUAL SMALL SILVER DIE CUT DECAL LICENSE PLATE FRAME, VORTECH S/C STRT INFO PKG ASSY VORT 1 8M HOLLEY 4150 FLOAT BOWL ASSY 1 8M FUEL LINE FRONT SS, M FUEL LINE REAR SS, M DEMON FLAOT BOWL LINE ASSY W/FTG 1 8M FUEL LINE FRONT SS, M FUEL LINE REAR DEMON 1 7P FTG, -6 TO 9/16-24 BG ADPTR 1 vv P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

6 IMPORTANT: ENGINEERING, LLC PART # DESCRIPTION QTY 2A BELT, K GATES 10-RIB 1 2E (8) V2SQ S/C, SI-TRM,CW SATIN* 1 4GJ BRKT, CAC RESERVOIR MTG 1 4GJ PONTIAC GTO INST MANUAL 1 4GJ FUEL ASSEMBLY, 65 GTO CARB* 1 4GJ MTG BRKT ASSY, 65 GTO DRVR* 1 4GJ (8) DISCH ASSY, 65 GTO DRVR CAC POWERCOOLER DECAL 1 4GJ (8) TUBE, DISCH A, 65 GTO DRVR CAC 1 4GJ (8) TUBE, DISCH B, 65 GTO DRVR CAC 1 8D FLANGE,COMACT BYPASS-ALUMN. 1 7A /16-18 X 1 SHCS PLATED 4 7R #44 HOSE CLAMP 6 7R CLAMP, V-BAND, 4.25" FLANGE 1 7S ELBOW, 2.75 X 90 SILICONE 1 7S X 2" SLEEVE 1 7S X 3" SLEEVE 1 7U O-RING CAC TO ENCL 1 8M (8) INLET, CARB ENCL, V-BAND 1 8M PLATE, T-BODY, V-BAND AL. 1 8M V-BAND FLG, FEMALE, 2.8 ID AL. 1 8N (8) WELDED CORE, 65 GTO DRVR SIDE 1 8N END TANK, N WELDED CORE ASSY W/ENDS ONLY 1 8N COOLER DUCT,LS1,GROUND 1 8M V-BAND FLG, MALE, 2.8 ID AL. 1 4GJ ASSY, CRANK PLY, 65 GTO 7IN 10RIB 1 4MA CRANK PLY, 7", UNIVERSAL 1 4GJ OIL FEED ASSY, 65 GTO DRVR* 1 4GJ OIL DRAIN ASSY, 65 GTO* 1 8D (8) RACE BLOWOFF VALVE-SATIN 1 8H AIR FILTER 3.5"FLG X 7"L 1 8M (8) CARB ENCL ASSY, 65 GTO* 1 8N WATER COOLER 1 8N CAC SPT COMPTS, GTO CARB 1 7P /4" HOSE UNION 3 7P /2NPT X 3/4 BARB 90 BRASS 3 7P /2NPT X 3/4 HOSE FIT STRT 1 7R NYLON RATCHET CLAMP 1-1/8" 14 7U /4"X90 RUBBER HOSE, SHORT 1 7U /4" HEATER HOSE 10 7U HOSE,3/4"DIA 90DEG,4x12" 2 7U HOSE, 3/4"X150 MOLDED HOSE 2 7U TIE WRAP, 4" NYLON 5 7U TIE WRAP, 7.5" NYLON 5 8N NYLON MOUNTING KIT 2 8N WATER TANK W/ FTG,5.0 MUST 1 7P /2NPT X 3/4 BARB 90 BRASS 2 8N ASSY, WTR PUMP GTO CARB PONTIAC GTO Part No. 4GJ (8) DRIVER'S SIDE CHARGE AIR COOLED KIT PARTS LIST Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. 5W GA FEMALE SLIDE INSULATED 1 5W GA RING TERM.26" HOLE 1 5W GA BUTT CONN BLU INSUL 2 5W GA FUSE HOLDER 1 5W GA STRD WIRE BLACK 7 7A /4-20 X.75 HHCS PLTD 1 7E #10X3/4 HEX HD SLF DRL SHT MTL 1 7F /4-20 NYLOCK NUT 1 7J /4 WASHER, SAE, PLTD 2 7R ADEL CLAMP,1-11/16" 1 8F PUMP, WATER, PIERBURG 1 8M HOLLEY 4150 FLOAT BOWL LINE ASSY* 1 8M DEMON FLOAT BOWL LINE ASSY W/FTGS* SMALL SILVER DIE CUT DECAL LICENSE PLATE FRAME, VORTECH S/C STRT INFO PKG ASSY VORT 1 Optional: 8N UNIVERSAL BATT RELOCAT.ASSY 1 *See page V for individual parts in each assembly P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) vi

7 ENGINEERING, LLC PONTIAC GTO Part No. 4GJ /238SQ PASSENGER SIDE STANDARD DISCHARGE KIT PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART # DESCRIPTION QTY SMALL SILVER DIE CUT DECAL LICENSE PLATE FRAME, VORTECH S/C STRT INFO PKG ASSY VORT 1 2A BELT, K GATES 10-RIB 1 2E (8) v2 S/C, Si-TRM, 65 GTO PSGR* 1 4GJ PONTIAC GTO INST MANUAL 1 4GJ FUEL ASSEMBLY, GTO CARB* 1 4GJ MTG BRKT ASSY, GTO PSGR 1 2A SPACER, SC PLATE, PSGR 65 GTO 1 2A SPACER W/PLT,.935 L 1 4FA BELT TENS PLATE, HEAVY DUTY 1 4FP IDLER W/BRNG ASSY, 36MM COG 1 4GJ PLATE, SC MTG,PSGR 65 GTO 1 4GJ PLATE, PSGR SIDE SPT, 65 GTO HEAD 2 7A /8-16 X 1.25 HXHD GR8 PLT 7 7A /8-16 X 4.75" HXHD GR8 PLTD 4 7C M12 X 1.75 X 20MM HXHD CL C M12 X 1.75 X 80MM HHCS 1 7A /2-13 X 1.00" HHCS 1 7G MM X 1.75 NUT 1 7J MM WASHER, FLAT 6 7J /8 SAE WASHER, PLTD 12 4GJ (8) DISCHARGE ASSY, GTO STD* 1 4GJ ASSY, CRANK PULLEY, 65 GTO 10RIB*1 4GJ OIL FEED ASSY, 65 GTO PSGR 1 7P /8 NPT 90^ X -4 JIC FTG 1 7P /8 NPT STR. X -4 JIC FTG STL 1 7P /8 NPT FEMALE TEE 1 7P /8 NPT X 1" NIPPLE 1 7U TIE WRAP, 7.5" NYLON 5 7U OIL FEED HOSE, 36" -4 STRT 1 4GJ OIL DRAIN ASSY, 65 GTO* 1 8D (8) RACE BLOWOFF VALVE-SATIN 1 8H AIR FILTER 3.5"FLG X 7"L 1 8M (8) CARB ENCL ASSY, 65 GTO* 1 8M HOLLEY 4150 FLOAT BOWL LINE ASSY* 1 8M DEMON FLOAT BOWL LINE ASSY W/FTGS* 1 *See page V for individual parts in each assembly vii P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

8 ENGINEERING, LLC PONTIAC GTO Part No. 4GJ /248SQ PASSENGER SIDE CHARGE COOLED KIT PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART # DESCRIPTION QTY 2E v2 S/C, Si-TRM, 65 GTO PSGR 1 4GJ BRKT, CAC RESERVOIR MTG 1 4GJ PONTIAC GTO INST MANUAL 1 4GJ FUEL ASSEMBLY, 65 GTO CARB* 1 4GJ MTG BRKT ASSY, GTO PSGR*** 1 4GJ DISCH ASSY, GTO PSGR CAC POWERCOOLER DECAL 1 4gj (8) discharge tube, 65 gto psgr cac 1 7A /16-18 X 1 SHCS PLATED 4 7R #44 HOSE CLAMP 3 7R #48 SAE TYPE F SS HOSE CLAMP 1 7R CLAMP, V-BAND, 4.25" FLANGE 1 7S X 2" SLEEVE 1 7S REDUCER, u o-ring cac to encl 1 8M (8) INLET, CARB ENCL, V-BAND 1 8N (8) WELDED CORE, 65 GTO PSGR SIDE 1 8N END TANK, N WELDED CORE ASSY W/ENDS ONLY 1 8M V-BAND FLG, MALE, 2.8 ID AL. 1 8N COOLER DUCT, 65 GTO PSGR SIDE 1 8N COOLER DUCT,C5, 3" INLET 1 8D FLANGE,COMACT BYPASS-ALUMN. 1 4GJ ASSY, CRANK PLY, 7IN 10RIB** 1 4GJ OIL FEED ASSY, 65 GTO PSGR* 1 4GJ OIL DRAIN ASSY, 65 GTO* 1 8D (8) RACE BLOWOFF VALVE-SATIN 1 8H AIR FILTER 3.5"FLG X 7"L 1 8M (8) CARB ENCL ASSY, 65 GTO* 1 8N WATER COOLER 1 8N CAC SPT COMPONENTS, GTO CARB** 1 8N WATER TANK W/ FTG,5.0 MUST** 1 8N ASSY, WTR PUMP GTO CARB** SMALL SILVER DIE CUT DECAL LICENSE PLATE FRAME, VORTECH S/C STRT INFO PKG ASSY VORT 1 2A BELT, K GATES 10-RIB 1 8M HOLLEY 4150 FLOAT BOWL LINE ASSY** 1 8M DEMON FLOAT BOWL LINE ASSY W/FTGS** 1 Optional: 8N UNIVERSAL BATT RELOCAT.ASSY 1 *SEE PAGE V FOR INDIVIDUAL PARTS IN EACH ASSEMBLY ** SEE PAGE VI FOR INDIVIDUAL PARTS IN EACH. ASSEMBLY *** SEE PAGE VII FOR INDIVIDUAL PARTS IN EACH ASSEMBLY P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) viii

9 1. PREPARATION/REMOVAL A. Disconnect the negative lead from the battery. B. Loosen and remove the alternator, power steering pump and air conditioning pump v-belts. C. Remove the stock crank pulley. D. If a charge cooled kit is being installed, remove the battery from the vehicle. It will need to be relocated to the trunk using a battery relocation kit. Follow the instructions supplied with the battery relocation kit of your choice. (Vortech 8N may be used) NOTE: If you have not changed the spark plugs in the last 15,000 miles, do so prior to the installation of this kit. 1ix P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

10 2. OIL FEED Installation A. The supercharger uses engine oil for lubrication and must have an oil feed line connected to a filtered oil high pressure source on the engine. B. Remove and set aside the 1/8 NPT oil pressure sending unit from the engine block (located on the rear passenger side of the engine). C. Install the supplied 1/8 NPT nipple into one end of the supplied female TEE and the oil pressure sender into the opposite end. Install the assembly into the engine block. NOTE:Use clean engine oil on the pipe threads. Teflon tape or pipe sealant is NOT recommended as it might loosen and cause blockage of the small oil feed orifice resulting in supercharger failure. D. Attach the supplied 4 fitting into the side of the installed TEE. Attach the braided oil feed line to the installed fitting (See Fig. 2-a). Secure the hose with the tie wraps provided, routing it away from exhaust heat, chaffing and sharp objects. Temporarily cover the open end from debris until the connection is made to the supercharger. Fig. 2-b 2

11 3. OIL DRAIN INSTALLTION A. To provide an oil drain for the supercharger, it is necessary to make a hole in the oil pan. Locate and mark the hole location. (See Fig. 3-a, 3-b or 3-c, depending on which side of the engine the supercharger will be mounted on. NOTE: Removal of the oil pan may ease oil drain fitting installation on some applications. B. Remove any paint from around the hole area. C. Use a small center punch to perforate the pan and expand the hole. Switch to a larger diameter punch and expand the hole to about 9/16. Most punches are made from hexagonal material and may be placed in a socket with an extension to make this procedure easier.. Use caution so that the hole is no enlarged too much and that the punch does not contact the engine internals. D. Tap the hole with a 3/8 NPT tap approximately ¼ deep. Pack the flutes of the tap with heavy grease to hold the chips. Use a small magnet to check for any stray chips. NOTE: This method of rolling over the lip of the hole and tapping works very well if carefully done and should cause no problems. E. Thoroughly clean the threaded area. Apply a small amount of silicone sealant to the new threads. Apply more sealant to the supplied 3/8 NPT x ½ barb and secure in the previously threaded hole. Make sure a seal is formed all around the fitting. F. Drain the engine oil, install a new filter and refill with fresh oil. Fig. 3-a Pontiac GTO (Driver side oil drain) 1.0 OIL PAN RAIL Fig. 3-b Pontiac GTO (Passenger side oil drain) TAP HOLE, 3/8 NPT 2.0 TAP HOLE, 3/8 NPT 2.0 OIL PAN RAIL 1.0 Fig. 3-c 3

12 4. FUEL SYSTEM INSTALLATION NOTE:A stock fuel pump may be satisfactory for mild engines. The following steps will allow the mechanical pump to increase fuel pressure in proportion to boost pressure. (I.E.: stock fuel pressure = 0psi boost/ supercharged fuel pressure = 7psi boost.) If fuel pressure is not maintained at least 4 psi above boost pressure, replace the stock fuel pump with a higher flow unit. Alternatively, a system utilizing an electric fuel pump may be used as long as the regulator is boost referenced. A. Remove the fuel lines from the fuel pump and remove pump from vehicle. B. Drill and tap the vent hole located in the side of the fuel pump. If the hole is tapped to 1/16 NPT, a 3/16 hose barb fitting (P/N: 7P ) may be installed. C. Plug any additional fuel pump vent holes. D. Re-install the fuel pump. E. Run a boost pressure line from the carburetor enclosure to the top of the fuel pump diaphragm. The end of the bulkhead fitting that is inside the enclosure should be left open. 4

13 5.1 driver-side Supercharger bracket installation (FOR Passenger Side supercharger mount, skip to section 5.2) A. Remove the alternator bracket and power steering pump brackets from the engine. Clean the front of the cylinder head so that the mounting plate will sit flat when installed. B. Install the Primary mounting plate using the four.972 long spacers and 1.75 flat socket head cap screws. C. If vehicle is equipped with power steering, install the power steering pump mounting bracket along with the factory front mounting plates to the supercharger primary plate using the supplied 3/8 x 4.25" bolts and spacers. D. Attach the supercharger mounting plate to the primary plate using the 3.2 spacers and 3/8 x 4.25 bolts. E. Install the alternator onto the mounting bracket assembly and use the supplied alternator tensioner bracket to secure the free end of the alternator to the water pump housing. F. Skip to section 6 Fig. 5.1-a Fig. 5.1-b SUPPLIED 4.25" BOLT AND 3.2" SPACER 3/8x1.25" BOLT, NUT AND WASHERS Fig. 5.1-d SUPPLIED 3/8X4.25" BOLT AND 2.76" SPACER Fig. 5.1-c 5

14 5.2 Passenger-side Supercharger bracket installation A. Remove any accessories from the front of the passenger side head. Clean the cylinder head so that the mounting plate will sit flat when installed. B. Attach the support plates and spacer to the supercharger mounting plate as shown. Make sure to install the two 1 ¼ bolts through the side of one of the support plates and into the end of the other. C. Install the assembly onto the passenger side cylinder head. Progressively tighten both the bolts that secure the assembly to the engine and those that tie the support plates together. D. Verify that all mating surfaces are flush and all fasteners are tight. Fig. 5.2-a Fig. 5.2-b 6

15 6. Supercharger installation A. Attach the oil drain line to the supercharger and secure using one of the #8 hose clamps provided. NOTE: Some applications (depending on intake manifold height) may require the reclocking of the supercharger volute. If reclocking is required for your application, loosen and remove the six ¼-20 cap screws and retaining plates that hold the compressor housing (volute) to the gearcase. If the compressor housing does not rotate freely relative to the gearcase, DO NOT FORCE IT. SERIOUS SUPERCHARGER DAMAGE MAY OCCUR. The machined mating surfaces are designed to prevent pressurized air from escaping and have minimal tolerances. If the housing will not move or is very tight, contact Vortech Engineering immediately at (805) and ask for our service department for further assistance. Fig. 6-d Driver side shown (Passenger side similar) B. Lower the supercharger onto the mounting plate installed on the engine. C. Loosely start the 3/8 X 1 1/4 bolts with washers through the mounting plate and into the supercharger gear case. Tighten in steps. D. Attach the oil drain line to the fitting previously installed in the oil pan and secure using the supplied #8 hose clamp. NOTE: The oil drain hose must maintain a "Downhill" routing always. "Uphill routing", dips, kinks or restrictions in the drain hose may cause supercharger seal failure E. Install the 1/8 NPT X 4 90º fitting into the oil feed fitting using oil to lubricate the threads. Attach the oil feed hose to this fitting and tighten. 7

16 7. Crank pulley, supercharger pulley and belt installation Note: The crank pulley assembly supplied with this kit is designed to work on 389 and 400 cubic inch engines. For this reason, pay close attention to fitment during installation. A. For vehicles with a 6 bolt damper, place the crank pulley spacer onto the damper oriented so that the pilot on the damper centers the spacer. (For later vehicles with a 4 bolt damper, the spacer is not used). B. Place the v-belt crank pulley onto the spacer (or damper) and secure using the original number of the supplied bolts. C. Place the supplied 10 rib supercharger crank pulley onto the v-belt pulley. Install using the four 3/8 x 1.25 bolts and washers supplied. Fig. 7-a Note: Check vehicle for radiator fan to crank pulley clearance. If there is interference, either space the fan forward or replace it with a low profile electric fan. D. If the supercharger did not come with a pulley already installed, lightly grease the supercharger input shaft and/or the supercharger drive pulley bore. Install the pulley onto the supercharger input shaft and rotate the pulley to align the keyway. Slide the square key into the keyway. Install the pulley retainer assembly into the input shaft and hand tighten. Note: If the supercharger drive pulley will not slide onto the shaft, DO NOT FORCE IT. Light heating of the supercharger pulley with a propane torch will aid installation. 8

17 8. Belt and Belt Tensioner installation A. Due to the various pulley diameters and accessory locations, belts for the factory accessories will need to be sourced independently. Installing the belts that were removed, and marking or cutting them to the desired length, before purchasing new belts, may most easily accomplish this. B. Install all of the accessory drive belts. C. Loosely install the supercharger belt tensioner plate onto the face of the supercharger using 12mm x 20mm bolts and washers. D. Install the supercharger belt around the supercharger and crank pulleys. E. Install the supplied smooth idler and spacer onto the belt tensioner plate using 12mm hardware. F. Rotate the belt tensioner assembly until the belt is tight and tighten the bolts. G. Tighten the supercharger pulley retainer assembly to 35 ft/lbs if pulley was not installed at Vortech. Fig. 8-a Fig. 8-b 9

18 9. Carburetor enclosure installation Note: Due to the many possible configurations of intake manifolds (with regard to carburetor flange height), if hood interference is a problem, a lower profile intake manifold may be required. Factory 4-barrel intake manifolds as well as the Edelbrock Performer have been verified to fit. The Edelbrock Performer RPM intake is too tall to work on a 1965 GTO with carburetor enclosure. A. Remove the carburetor from the intake manifold and thoroughly clean the intake manifold carburetor flange. Remove all throttle linkage brackets from the intake manifold. B. Replace the carburetor studs in the intake manifold with those supplied and install a carburetor gasket. C. Install the supplied 1/4npt x 3/8 90º barb fitting into the rear of the carburetor enclosure and orient so that it will point towards the driver side. D. Install the lower part of the carburetor enclosure over the studs until it sits flat on the intake manifold. (An extra carburetor base gasket is included that may be stacked between the enclosure and the intake if there is a minor clearance problem or used with a spacer if more clearance is needed). E. Install a carburetor gasket on the carburetor mounting surface. F. Test fit the carburetor in the enclosure and bend the throttle arm if it contacts any part of the enclosure from idle to wide open throttle positions. Remove carburetor. G. Install a vacuum cap over the PCV barb fitting (if equipped) on the base plate of the carburetor and secure with a small tie-wrap or clamp. Attach short lengths of hose to any necessary remaining vacuum sources on the base plate of the carburetor. These hoses will later be connected to a bulkhead fitting and run from there to the necessary accessory. H. Install the carburetor and secure with four 5/16 nuts and washers. 10

19 9. Carburetor enclosure installation con't I. Install the fuel lines on the carburetor as follows: 1. Install the 8 bulkhead nut and O-ring on the bulkhead fitting. 2. Thread the bulkhead fitting into the front hole in the carburetor enclosure. 3. Loosely install fuel lines onto the carburetor float bowls (some fuel lines come with additional fittings). 4. Connect the free end of each fuel line to the 8/-6/-6 TEE. 5. Install the 8 straight hose barb fitting on the inside of the bulkhead fitting. Install the 8 120º fitting on top of the TEE. 6. Measure and cut the supplied pushlock hose so that it will fit well between the two installed barb fittings. 7. Remove the barbed fittings, coat the barbs with grease, and fully insert the barbed fitting in the hose. 8. Adjust the TEE so that it does not interfere with installation of the enclosure cover. Install the fuel hose assembly and tighten all of the fuel line connections. J. Connect the fuel supply from the fuel pump to the bulkhead fitting. Plug the unused holes in the bulkhead fitting with a 8 and 1/8 NPT plug Note: All -8 fittings must have an O-ring installed before using. K. Insert the OEM throttle cable through the bulkhead fitting mounted through the rear of the carburetor enclosure. Install the split washer behind the rib on the end of the throttle cable. Install the threaded cap over the washer and cable assembly and hand tighten. L. Install a x ¾ cap screw through the two supplied brackets and sandwich the end of the throttle cable between the plates and two washers as shown. Secure with the nylock nut so that the brackets are free to rotate. M. Install the throttle nut through the large hole on the outside of the throttle arm. Use the supplied shoulder bolt installed through the brackets on the end of the throttle cable and then through a washer and the #10 fender washer and into the throttle nut. R. Install the throttle return spring bolt through the two small spacers and into the inside front of the enclosure as shown. Install the throttle return spring. Fig. 9-a Fig. 9-b Fig. 9-c 11

20 9. Carburetor enclosure installation con't R. Install the throttle return spring bolt through the two small spacers and into the inside front of the enclosure as shown. Install the throttle return spring. S. Check for full throttle by having an assistant press the accelerator to the floor while verifying that the carburetor butterflies open fully. If they do not, loosen the jam nut on the bulkhead fitting and adjust the depth until the throttle opens and closes fully. Tighten jam nut. T. If it is possible to pressurize the fuel system without starting the engine, do so and check for leaks. U. Using the supplied 5/16 cap screws, install the top cover on the enclosure and tighten the screws. V. Hose connections to the carburetor enclosure may vary. All holes that are not used should be plugged with the supplied 3, -8, and ¼ NPT plugs. Fig. 9-d Fig. 9-e 10. Air Filter Installation A. Install the supplied air filter onto the supercharger inlet. P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) 12 xx

21 11. Standard Discharge Duct Installation (Charge Cooled Kits, skip to step 12) A. Install the carburetor enclosure cover so that the opening is on the same side of the engine as the supercharger. B. Install the 2.75 to 3.5 reducer onto the supercharger discharge. C. Connect the 3.5 tube (has bypass valve flange) to the 90º elbow using a sleeve. D. Insert the tube into the reducer on the supercharger and connect the 90º elbow to the cover using a gasket and 5/16" hardware. E. Install the bypass valve onto the tube using 1/4" hardware and orient for best fit. F. Tighten hose clamps on each connection. G. Skip to Step 17. Fig. 11-a Passenger side Fig. 11-b Driver side 13 xxi P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

22 12. Charge Air Cooler (CAC) Core Installation (STANDARD Kits, skip to step 17) A. Install the carburetor enclosure cover so that the opening is on the passenger side of the engine. B. Install the inlet flange onto the enclosure cover using a gasket and 5/16 x 1" socket head cap screws. C1. Driver Side S/C Mount. (Passenger Side S/C Mount skip to step C2.) 1. Attach the CAC core to the inlet flange using the supplied V-band clamp and O-ring so that the open duct is left pointing rearward. 2. Install the bypass valve onto the flange on the discharge tube. Connect the discharge tube to the open CAC duct using the 90º silicone elbow. 3. Connect the discharge tube to the supercharger using the large 90º tube. C2. Passenger Side S/C Mount. (Driver Side S/C Mount go back to step C1.) 1. Install the bypass valve onto the flange on CAC core so that it will point forward. 2. Attach the CAC core to the inlet flange using the supplied V-band clamp and O-ring so that the open duct is left pointing forward. 3. Connect the open duct to the supercharger using the small discharge tube and two sleeves. D. Install and tighten a hose clamp on each connection. Fig. 12-a Fig. 12-b Fig. 12-c Fig. 12-e Fig. 12-d P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) xxii 14

23 13. CAC Water Cooler Installation (Standard kits, skip to step 17) A. Using sealant install a 1/2" NPT X 3/4" barb 90º fitting into each end of the supplied water cooler so that they point away from each other. B. Connect the supplied electric water pump to the bottom of the CAC radiator using an adel clamp and 1/4-20 x.75 hex head cap screw, washers and nut. Connect the CAC radiator inlet to the water pump outlet using the supplied 90º hose and nylon ratchet clamps. C. From the passenger side, feed a section of straight hose in front of the engine radiator and secure it to the CAC radiator outlet using a clamp. D. Use the supplied 8N Nylon Mounting Kit to attach the water cooler to the front of the vehicle s radiator. Make sure to place the supplied foam spacers between the radiator and the water cooler Fig. 13-a Note: Hose routing must have smooth bends and no kinks. Fig. 13-b xxiii 15 P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

24 14. CAC Water Reservoir Assembly Installation (Standard kits, Skip to step 17) A. Remove the battery tray from the vehicle. Install the supplied CAC reservoir mounting bracket in its place using the original hardware. B. Install a 1/2 NPT 90 hose barb fitting in the side of the supplied water reservoir so that it points down. C. Install a 1/2 NPT 90 hose barb into the bottom hole of the reservoir pointing down. D. Test fit the reservoir in the installed bracket (the supercharger pulley may need to temporarily be removed if there is interference). E. Attach a 90º hose to the bottom reservoir fitting so that it runs under the reservoir mounting bracket and toward the passenger side of the vehicle. F. Install the original battery hold down to secure the reservoir. Fig. 14-a 15. CAC Water Pump Wiring (Standard kits, Skip to step 17) A. Install the supplied eyelet onto the ground (brown) wire of the water pump. Ground the water pump using the sheet metal screw in the next step. B. Route the water pump power wire to a keyed power source and attach using the supplied fuse holder and butt connectors. P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) xxiv 16

25 16. CAC Plumbing and Bleeding System (standard kits skip to step 17) A. Connect the bottom fitting in the reservoir to the inlet (center) barb on the water pump. B. Connect the top fitting on the CAC to the upper fitting on the reservoir. C. Install and tighten the supplied plastic ratchet clamps on all hose connections. D. Remove the reservoir cap and fill system with 25%/75% coolant/water mix. E. Make sure that all wires and hoses are routed away from hot, moving or sharp objects. F. Key on and verify coolant circulation through the system. Check for leaks. If water is not flowing, remove the hose from the water pump discharge to prime the pump, by flowing some water through the system. Reconnect the hose and verify circulation. Do not run the water pump for extended periods (30 seconds or more) without water flow. xxv 17 P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)

26 17. Final assembly and check Warning: Do not attempt to operate the vehicle until all components are installed and all operations are completed including final check. A. Run the supplied 5/32 hose from the manifold pressure (vacuum and boost under the throttle blades), through a bulkhead fitting in the enclosure and connect to the fitting on the bypass valve fitting. B. Reconnect the battery. C. If your vehicle has gone over 15,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle. D. Check all fitting, nuts, bolts and clamps for tightness. Pay particular attentions to oil and fuel lines around moving parts. Make sue all wires and lines are properly secured with clamps or tie wraps. E. Check all fluid levels, making sure that your tank is filled with 91 octane or higher fuel before commencing test drive. F. Start engine, allow to idle a few minutes, then shut off. G. Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts. H. Check all connections for signs of fuel leakage. Re-jet the carburetor as required. Install a boost referenced high performance fuel pump or high performance electric fuel pump with boost referenced fuel regulator. I. Check ignition timing to make sure it is properly set before test drive. NOTE: Operating the vehicle without all sub assemblies completely and properly installed and working may cause FAILURE OF MAJOR ENGINE COMPONENTS. J. Keep in mind that this manual does not address air/fuel or ignition timing considerations but that both are very important and must be set appropriately for performance and reliability. K. Test drive the vehicle. L. 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. P/N: 4GJ MAR08 v1.0 GTO(4GJ v1.0) xxvi 18

27 ENGINEERING, LLC 1650 PACIFIC AVENUE CHANNEL ISLANDS, CA (805) FAX (805) M-F 8:00 AM - 4:30 PM PST xxvii 19 P/N: 4GJ v1.0 12MAR08 v3.0 GTO(4GJ v1.0)