Lexus 3.0L IS300. Supercharger System Installation Instructions Model Year ENGINEERING, LLC

Transcription

1 Lexus 3.0L IS300 Supercharger System Installation Instructions Model Year *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) D - v1.1 07/10/07

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 installatlion 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. STOP 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. NOTICE Due to variances in each vehicle, Vortech recommends that the vehicle get a custom tune from a local, reputable tuner. This kit is supplied with a universal fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your specific vehicle can be obtained from a competent tuner. A wideband exhaust oxygen sensor must be used to confirm proper air/fuel ratio. Vortech suggests a proper WOT air/fuel ratio range of :1 for 91 octane fuel VORTECH ENGINEERING, LLC All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into another language in any form, by any means without written permission of Vortech Engineering, LLC. ii

3 TABLE OF CONTENTS FOREWORD ii TABLE OF CONTENTS iii IMPORTANT NOTES iv TOOL & SUPPLY REQUIREMENTS v PARTS LIST ( L Lexus) vi 1. PREPARATION/REMOVAL OIL FEED OIL DRAIN ABS RELOCATION MOUNTING BRACKET AND SUPERCHARGER INSTALLATION CHARGE COOLER INSTALLATION AIR INLET INSTALLATION FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003 Automatic Models Only) FUEL PUMP AND FMU INSTALLATION POWER STEERING ELECTRONIC CONTROL BOX INSTALLATION FINAL CHECK iii

4 L Lexus IS300 IMPORTANT NOTE 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, LLC. 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. iv

5 L Lexus IS300 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 Limited Warranty Program, the Warranty Registration form and return envelope. 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 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 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 15,000 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. TOOL & SUPPLY REQUIREMENTS Factory repair manual 3" hole saw 1/2" socket and drive set: SAE & metric 3/8-18 tap & handle Adjustable wrench Open end wrenches: 3/8", 7/16", 1/2", 9/16", 10mm, 12mm Metric Allen wrench set Center punch and a 5/8" tapered punch Fractional drill bit set Grinder (electric right-angle) 6 quarts (or what is specified in your owner s manual) SF rated quality engine oil, oil filter and wrench ENGINEERING, LLC If it has been 20,000 miles or more since your vehicle s last spark plug change, then you will also need: Spark plug socket NEW spark plugs v

6 IMPORTANT: ENGINEERING, LLC L Lexus Part No. 4LA SQ/018SQ PARTS LIST Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY SMALL SILVER DIE-CUT DECAL LICENSE PLATE FRAME, VORTECH S/C STRT INFO PKG ASY VORT 1 2E SUPERCHARGER V-5F SQ CW, LEXUS IS LA INSTRUCTION MANUAL, IS LA POWER STEERING COOLR ASY 1 8N COOLER, P/S 4-PASS PERMA/CL 1 8N NYLON MOUNTING KIT 1 7P /8" BARB x 5/16" BARB REDUCER 2 7R STEPLESS CLAMP, U /16" EFI FUEL HOSE HI-PSR 4' 4LA S/C MOUNT BRKT ASY, LEXUS IS A SPACER, IDLER SMOOTH 6-RIB 1 2A SPACER,.50"OD x 1.538"L ALUM 1 2A SPACER,.75"OD x.1.437"l 1 2A SPACER,.875"OD x.895"l 5 2A BELT, GATES K FA DUST COVER (IDLER PULLEY) 2 4FH IDLER PULLEY, 6-RIB 3" FLANGED 2 4LA BRKT, SUPPORT IS LA BRKT, LOWER SUPPORT IS LA BRKT, 5/16" S/C MOUNT IS LA SPACER, IDLER, 1.060"L IS A /8-16 x 1" G5 HHCS PLT 2 7A /8-16 x 1" G5 HHCS PLT 1 7A /8-16 x 1-3/4" HXHD G8 5 7A /8-16 x 2-3/4" HXHD ZINC 1 7C M x 16mm, FLG HD, C M x 40mm HXHD BOLT, CL C M x 70mm HXHD CL8.8 PLT 2 7C M x 40mm, SHCS, CL C M x 80mm, HXHD, CL E #12 x 3/4" SHT METAL SCRW, HEX 3 7F /8-16 NYLOCK NUT 2 7J mm WASHER SS 2 7K /16"AN WASHER, PLATED 1 7K /8"AN960 FLAT WASHER PLATED 12 4LA INLET ASY, LEXUS IS300 8H AIR FILTER, 3.5" FLANGE, G35 OFFSET 1 7U /2" OIL DRAIN HOSE 0.75' 7P /2" HOSE UNION 2 7R #6 STNLS HOSE CLAMP, NARROW 3 7U /16" PCV/VAC RUBBER HOSE 2.5' 7R STEPLESS CLAMP, P /16" HOSE MENDER 1 7P ELBOW, PLASTIC 5/16" x 90 UNION 1 4LA OIL FEED LINE ASY, IS P /8"NPT x 90 x -4 JIC FTG STL 1 7P /8"NPT STR x -4 JIC FTG STL 1 7P /8"NPT x 1/8"NPT STRT T 1 7P FTG, 1/8"NPT FEM x 1/8"BSPT MALE 1 7U TIE-WRAP, 7.5" NYLON 5 7U OIL FEED HOSE, 32" x -4 x NZ FUEL PUMP ASY, INLINE 350Z 1 5W GA RING TERM.,.17" HOLE 1 5W /4" WIRE LOOM 10' 5W GA RING TERM..26" HOLE 1 5W GA STRD WIRE BLACK.5' 7E #12 x 3/4" SHT METAL SCREW, HEX 2 7P /16" HOSE BARB TO M10 x 1.0mm 1 7P /16" TEE HOSE BARB 2 7R ADEL CLAMP, 1-11/16" 2 7R STEPLESS CLAMP, U /16" EFI HOSE, HI-PSR 5.5' 7U TIE-WRAP, 4" NYLON 10 7U TIE-WRAP, 7.5" NYLON 5 8F WALBRO INLINE FUEL PUMP, 68 GP 1 4NZ OIL DRAIN LINE ASY, 350Z 1 7P /8"NPT x 1/2" BEADED HSE BARB 1 7R #8 STNLS HOSE CLAMP 2 7T CUTTER, 9/16" ROTABROACH 1 7T ARBOR, ROTABROACH 1 7U /2" OIL DRAIN HOSE 1.5' 7U TIE-WRAP, 11" NYLON 5 4NZ FMU, 8:1 w/lines, w/spring, 3 1 6Z FMU HOUSING (BLUE ANODIZED) 1 6Z FMU VALVE BODY (BLUE ANODIZED) 1 6Z COVER, FMU - GM Z SML DIAPHRAGM, FLUORO 1 6Z LRG DIAPHRAGM, FLOURO 1 6Z BRACKET, FMU 1 6Z PISTON, FMU 1 6Z FMU WASHER, 8:1 PLATED 1 6Z SHIM, FMU 1 6Z FMU 8:1 RING SPACER 1 6Z RETAINER, FMU SPRING GM Z SPRING, FMU GM C x.50" SHCS GR8 PLT 6 7C x 3/4" SHCS GR5 ZINC 4 7C x 1/4" PHILL HD 3 7E #12 x 3/4" SHT MTL SCRW, HEX 2 7P /8"NPT x 5/32" HOSE, P /8"NPT x 90 x 5/16" BARB 1 7P /8"NPT-STR, 5/16" BARB 1 7P /32" TEE 1 7P /16" FEM FUEL CNCT, STEEL 1 7P FUEL FTG, 5/16" GM x 5/16" HSE 1 7R STEPLESS CLAMP, U /32" VACUUM LINE 7' 7U /16" EFI FUEL HSE, HI-PSR 2.5' 7U /16" EFI FUEL HSE, HI-PSR 1.25' 7U O-RING, FMU 1 7U ROLL PIN, 3/16" x 1/2" SS 1 5A ECU, UNICHIP QT, '02-'05 IS300 SAFE TUNE 1 8N CHARGE COOLR ASY, LEXUS IS LA BRKT, HOOD LATCH SPRT IS LA TUBE A S/C DISCHARGE IS LA TUBE B S/C DISCHARGE IS LA TUBE D S/C DISCHARGE IS LA TUBE E S/C DISCHARGE IS NZ TUBE, COOLER INLET, 350Z 1 7A /4-20 x.75" HHCS PLTD 1 7A /4-20 x 1/2" HXHD GR5 ZINC 2 7C #8-32 x 1/2" SHCS, ZINC 2 7E #10 x 3/4" HXHD SLF DRL SHT MTL 2 7F /4-20 NYLOCK NUT ZINC PLATED 1 7J mm WASHER SS 4 7P /32" TEE 1 7R #16 SAE TYPE F SS HOSE CLAMP 2 7R #40 SAE TYPE F SS HOSE CLAMP 12 7R #44 SAE TYPE F SS HOSE CLAMP 2 7S ELBOW, 2.5"ID x 25 BLUE 5 7U /32" VACUUM LINE 3' 7U RUBBER ELBOW, Ø1.0" x D STD COMPRESS BYPASS VALVE 1 8H " AIR FILTER BYPASS 1 8N BRKT, CLR MNT, IS N CHARGE AIR COOLER, 350Z 1 7S REDUCER, 3.00" x 2.75" 2 vi

7 IMPORTANT: ENGINEERING, LLC L Lexus, cont d Part No. 4LA SQ/018SQ PARTS LIST Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY. 8F RELAY ASY, 350Z FUEL PUMP 1 5W /8" PLASTIC WIRE LOOM 8' 5W GA FEMALE SLIDE INSULATED 2 5W RELAY, BOSCH 1 5W GA FEMALE SLIDE INSULATED 2 5W GA RING TERM..33" HOLE 2 5W GA FUSE HOLDER WITH WIRE 1 5W GA STRD WIRE, RED, UL1015 7' 5W GA STRD WIRE BLACK 1' 5W GA STRD WIRE BLACK 7' 6Z :1 RING SPACER ASY 1 vii

8 This Page Left Intentionally Blank viii

9 1. PREPARATION/REMOVAL A. Disconnect the negative battery cable. B. Remove the four 10mm headed fasteners securing the plastic engine cover and set aside. C. Disconnect the valve cover vent hose from the air inlet assembly but leave it attached to the valve cover. D. Using a 10mm socket and ratchet, remove the factory air filter enclosure, air scoop, and ducting leading to the throttle-body and set aside. (See Fig. 1-a.) E. Remove the MAF electronics from the previously removed intake ducting and set aside to be reused in a later step. (See Fig. 1-b.) F. Detach the pressure solenoid from the plastic air filter enclosure (a single 10mm head screw). Set solenoid and screw aside to be reinstalled in a later section. (See Fig. 1-c.) Fig. 1-a NOTE: It is a good idea to label the line connections to prevent confusion later. G. Disconnect the ABS module harness plug from the module. Using a 10mm wrench, loosen the ABS module retaining nuts. Remove the module from its mounting bracket. Using a 12mm wrench, remove the hardware securing the ABS module bracket. Remove the module mounting bracket from the frame rail and set aside. Be careful not to lose the rubber stud mounts or the rubber bushing on the bottom of the module. Fig. 1-b MAF ELECTRONICS LEAVE CONNECTED TO HARD LINE Fig. 1-c 1

10 1. PREPARATION/REMOVAL, cont d H. Drain the engine coolant into a clean container and set aside. Remove the lower radiator hose located on the passenger s side of the engine. Trim approximately 1" from the end of the hose that was attached to the radiator, and set aside. Remove the upper radiator hose and set aside to be reinstalled in a later step. Remove the thermostat housing. Rotate the thermostat housing 180 and reinstall. Disconnect the fan s power connectors, radiator overflow bottle and remove the fan mounting hardware. Remove the engine fan assembly and set aside. Remove the upper radiator mounts/hardware and set aside. Remove the radiator and set aside. (See Fig. 1-d.) TUBE PREVIOUSLY CONNECTED TO PRESSURE SOLENOID Fig. 1-d THERMOSTAT HOUSING ROTATED 180 NOTE: Automatic transmission vehicles will need to disconnect the cooler lines running to the radiator. Cover any open line connections to avoid possible fluid contamination. I. Remove the four 5mm socket-head screws retaining the cam sprocket cover and set the cover and hardware aside. Locate the plastic wire loom channel on the passenger s side of the engine. Remove the wire loom from the channel. Remove the 5mm socket-head fastener securing the channel to the cylinder head. Cut the channel as shown. (See Fig. 1-e.) Install the supplied piece of flex loom onto the exposed section of wire and wrap with electrical tape. Reinstall the cam sprocket cover using the factory hardware. Fig. 1-e CUT LOOM HERE 2

11 1. PREPARATION/REMOVAL, cont d J. Remove the wire loom bracket secured to the top of the water pump and discard. (See Fig. 1-f.) Remove the 10mm headed screw located just above and to the driver s side of the previously removed bracket as shown. (See Fig. 1-g.) K. Remove the 12mm headed bolt and wire harness on the side of the water pump and discard. (See Fig. 1-g.) L. Cut the small black cross-over tube located just above the water pump where indicated. (See Fig. 1-f.) M. Loosen the four water pump pulley retainers. Un-tension the accessory drive belt and remove. Remove the water pump pulley retainers and pulley, setting them aside to be reinstalled in later step. N. Remove the bolt securing the alternator to the water pump. Remove the 12mm headed bolt just to the right (driver s side) and down from the previously removed alternator bolt. Remove the 10mm headed bolt just above the alternator. (See Fig. 1-g.) PREVIOUSLY SECURED LOOM BRACKET CUT TUBE HERE Fig. 1-f REMOVE REMOVE 10mm HEADED SCREW BOLT SECURING LOOM BRACKET ALT. BOLT LOWER W/P BOLT Fig. 1-g 3

12 2. 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. Locate the oil pressure sending unit on the driver s side of the engine, just in front of and above the engine mount. (See Fig. 2-a.) C. Disconnect and remove the pressure sender and set aside to be re-installed later. D. Locate the supplied oil feed assembly (4LA ). E. Install the supplied 1/8"BSP adapter into the hole previously occupied by the oil pressure sender. Install the supplied 1/8"NPT street TEE into the BSP adapter. Orient the branch of the TEE so that it faces up. Thread the factory sending unit into the TEE as shown. (See Fig. 2-b.) NOTE: Pipe tape, paste or other sealant is not recommended as it may loosen and cause blockage of the oil feed orifice resulting in supercharger failure. Use engine oil on the threads. F. Install the supplied 1/8"NPT x #4 flare fitting into the previously installed TEE. (See Fig. 2-b.) G. Attach the straight end of the supplied oil feed line to the #4 flare fitting previously installed and route up and over the engine valve cover. H. Temporarily cover the open oil feed line end to keep out debris until the connection is made to the supercharger in a later step. I. Reconnect the factory oil pressure sender wire. BSP ADAPTER Fig. 2-a (View From Below) 1/8"NPT STRT TEE Fig. 2-b OIL PRESSURE SENDER OIL PAN 1/8"NPT x #4 FLARE FACTORY OIL PRESSURE SENDER NOTE: The factory wiring harness may need to be unclipped from the engine block to gain the necessary length to reach the repositioned sending unit. 4

13 3. OIL DRAIN A. To provide an oil drain for the supercharger, it is necessary to make a hole in the intermediate oil pan. B. Locate the factory oil drain boss on the passenger s side of the engine as shown. (See Fig. 3-a.) C. Drill a 1/8" pilot hole into the center of the boss. Using the supplied 9/16" rota-broach cutter and arbor, carefully machine a throughhole into the intermediate pan. OIL DRAIN LOCATION NOTE: Automatic transmission vehicles only: It may be necessary to temporarily remove the transmission cooler lines (see Fig. 3-a) from their mounting bracket to provide a clear path for drilling. INTERMEDIATE OIL PAN Fig. 3-a LOWER OIL PAN NOTE: Pack the cutter with heavy grease and DO NOT stop the drill motor until the rota-broach has been extracted from the pan This will help retain the cut out piece in the cutting tool. D. Tap the previously machined hole approximately 1/4" deep using a 3/8"NPT tap. Pack the flutes of the tap with heavy grease to hold the chips. Thoroughly clean the threads and hole with acetone or lacquer thinner. E. Using a small amount of silicone sealer, install the 3/8"NPT x 1/2" barb fitting into the previously tapped hole. Temporarily cap the fitting until the drain hose is connected in a later step. (See Fig. 3-b.) F. Drain the engine oil and change the oil filter. ENGINE BLOCK INTERMEDIATE OIL PAN Fig. 3-b 3/8"NPT x 1/2" BARB FITTING OIL PAN 5

14 4. ABS RELOCATION A. Locate the ABS module bracket removed in Section 1. Remove the three spot welds that hold the side support to the main cradle. Separate the side support from the main cradle and discard. Drill the two lower spot weld locations to Ø3/16" and add an annitional Ø3/16" hole as shown. (See Fig. 4-a.) NOTE: The preferred method of removing a spot weld is the use of a spot weld cutting tool. However in this application, the use of an approximate sized drill or a right-angle grinder is acceptable. B. (2001 Model Year Only, 2002 and Later Skip to B-2.) 1. Measure 2" back from the stud that previously secured the bottom of the ABS bracket and make a mark. At the previously marked location, measure down 1-5/8" from the top of a frame rail and make a second mark. Align the front and bottom edges of the bracket where the two marks intersect. Using the modified bracket as a template (see Fig 4-a) to mark the three hole locations on the frame rail. Drill the hole locations using a 1/8" drill bit. Secure the ABS bracket to the frame rail using the supplied selt-tapping hardware. Cut the factory stud that previously secured the ABS bracket flush wiith the frame. (See Fig. 4-b.) ( Model Years Only), 2. Measure 3.5" back from the stud that previously secured the bottom of the ABS bracket and make a mark. At the previously marked location, measure down 2.4" from the top of the frame rail and make a second mark. Align the front and bottom edges of the bracket where the two marks intersect. Using the modified bracket as a template (see Fig. 4-a) to mark the three hole locations on the frame rail. Drill the hole locations using a 1/8" drill. Secure the ABS bracket to the frame rail using the supplied self-tapping hardware. Cut the factory stud that previoisly secured the ABS bracket flush with the frame. (See Fig. 4-b.) C. Remove the 10mm headed screw that secures the plastic brake line separator and discard. Remove the brake lines from their plastic separator located on the frame rail. Slightly bend the lines running to the ABS module so that it may be repositioned to its new location. Secure the module to the relocated bracket using the factory hardware. D. Locate the ABS module harness. Carefully split the plastic flex-loom exposing the wires from the ABS connector to the main harness on the shock tower. Separate enough length to reach the relocated ABS module and re-wrap the flex-loom. Reconnect the harness plug to the ABS module. (See Fig. 4-c.) FACTORY STUD Fig. 4-a 2" '01 MODEL YR 3.5" '02-'05 MODEL YRS FRONT EDGE OF BRACKET Fig. 4-b TOP OF FRAME RAIL BOTTOM EDGE OF BRACKET 1-5/8" '01 MODEL YR 2.4" '02-'05 MODEL YRS LINES SLIGHTLY BENT RELOCATED ABS MODULE SPOT WELD SPOT WELDS DRILLED THROUGH NEW HOLE LOCATION NOTE: Use caution when bending these lines. Make bends as large as possible to avoid kinking. ABS HARNESS Fig. 4-c 6

15 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION A. Locate the S/C mounting bracket assembly (4LA ) B. Using the M8 x 40mm socket-headed screw, loosely attach the mounting bracket support block (4LA ) to the side of the water pump. (See Fig. 5-a.) LOWER BRACKET SUPPORT (4LA ) NOTE: For the following section, refer to Fig. 5-b for screw and spacer location. Do not tighten until all hardware is in place. M8-1.25" x 40mm (7C ) Fig. 5-a 3/8-16 x 1.75" SCREW, WASHER, &.895" SPACER (2A ) M x 15mm 4LA UPPER SUPPORT BRACKET 3/8-16 x 1" SCREW, WASHER, NYLOC NUT Ø.50" x 1.538" SPACER (2A ) M6-1.0 x 70mm SCREW & WASHER M6-1.0 x 70mm SCREW & WASHER SPACER, LOWER SUPPORT (4LA ) Ø.875" x 1.437" SPACER M x 80mm SCREW & WASHER 3/8-16 x 1" SCREW & WASHER 3/8-16 x 2.75" SCREW, WASHER, DUST SHIELD, 3" SPOOTH IDLER, AND IDLER SPACER (4LA ) Fig. 5-b NO SPACER/FACTORY ALT. BOLT (M x 50mm) 7

16 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d C. Using Fig. 5-b as a guide and working from the bottom up, install all the applicable hardware and spacers into position as follows: 1. With the mounting bracket in position, place the M x 80mm screw and washer through the mounting bracket, 1.437" spacer and into the lower water pump mounting hole. 2. Then install the factory alternator bolt (M x 50mm) through the mounting bracket and into the alternator mount. 3. Next, install the M6-1.0 x 70mm screw and washer through the mounting bracket support spacer (4LA ) and into the water pump. 4. Install the 3/8-16 x 2.75" screw and washer through the dust shield, Ø3" smooth idler, idler spacer, and into the support spacer (4LA ). 5. Install the 3/8-16 x 1" screw and washer through the mounting bracket and into the support spacer (4LA ). 6. Install the M6-1.0 x 70mm screw and washer through the mounting bracket, 1.538" long spacer and into the upper water pump location. 7. Tighten the previously installed hardware. Make sure all mounting surfaces seat flat against one another and no lines or wire, etc. are being pinched. D. Loosely install the upper support bracket (4LA ) to the S/C bracket using the two 3/8-16 x 1.0" screws, washers and Nylock nuts. Install the M x 16mm screw through the support bracket and into the cylinder head. (See Fig. 5-c.) E. Evenly tighten the previously installed hardware. Ensure the bracket is supported, but not pulled or the location of the S/C bracket is not changed. F. Remove the blue plastic dust cap located on the 1/2" oil drain fitting at the bottom of the supercharger. Attach the supplied 1/2" fabric braided oil drain hose to the supercharger drain fitting. Secure with a #8 hose clamp. G. Secure the supercharger to the main bracket using the five 3/8-16 x 1.75" screws, washers, and.896" long spacers. (See Fig. 5-b, 5-c.) H. Reinstall the factory water pump pulley and secure using the factory hardware. UPPER SUPPORT BRACKET.895" LONG SPACER M x 15mm SCREW SEPARATE MAF HARNESS HERE Fig. 5-c 8

17 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d I. Install a 12mm-1.75 x 40mm screw through the dust shield, Ø3" smooth idler, idler spacer (.462" long piloted), and into the middle supercharger mounting boss. (See Fig. 5-d.) J. Remove the blue plastic dust cap located on the brass oil feed nozzle on the side of the supercharger. Thread the supplied 1/8"NPT x 90 fitting into the oil feed nozzle. Carefully tighten and clock the fitting as shown. (See Fig.5-e.) Use caution when tightening the oil feed fitting, as the nozzle may break if care is not exercised. Connect the previously installed oil feed line to the 90 fitting as shown. (See Fig. 5-e.) 3" SMOOTH IDLER IN MIDDLE POSITION NOTE: Use clean engine oil to lubricate fitting threads. Pipe tape, paste, or other types of sealant are not recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure. Fig. 5-d 90 END OF SUPPLIED OIL LINE K. Install the supplied drive belt as shown. (See Fig. 5-f.) 1/8"NPT x 90 Fig. 5-e SUPERCHARGER IDLER POWER STEERING IDLER WATER PUMP TENS. ALT. CRANK A/C Fig. 5-f 9

18 6. CHARGE COOLER INSTALLATION A. Locate the discharge assembly 8N Use Fig. 6-a as reference. B. Remove the 10mm headed screws securing the plastic splash shield to the bottom of the car and set aside. C. Using a Ø2.5 x 25 sleeve and #40 clamps provided, secure Tube A onto the supercharger discharge. (See Figs. 6-a, 6-b.) D. Secure the supplied bypass valve to Tube A using the Ø1" x 90 elbow and two #16 hose clamps provided. Orient as seen in Fig. 6-b and install the supplied 1"ID filter. Attach a length of Ø5/32" vacuum hose to the bypass valve and route to the vacuum port on the intake manifold. Remove the factory vacuum cap from the manifold port and attach the previously routed vacuum line. (See Fig. 6-c.) TUBE E TUBE D Ø2.5" x 25 SLEEVE TUBE A CHARGE COOLER Fig. 6-a TUBE B TUBE C BYPASS VALVE TUBE A Fig. 6-b VACUUM LINE TO BYPASS VALVE VACUUM PORT Fig. 6-c 10

19 6. CHARGE COOLER INSTALLATION, cont d E. Attach Tube B using a Ø2.5" x 25 sleeve and #40 clamps provided to Tube A as shown. (See Fig. 6-d.) F. A Ø4.5" hole will need to be cut in the driver s side splash panel to provide a path for the CAC discharge tube. Using a Ø4.5" hole saw or tool of choice, mark and drill the hole location shown. (See Fig. 6-e.) Ø2.5" x 25 SLEEVE OIL PAN TUBE B Fig. 6-d TUBE B CAC Ø4.5" HOLE IN SPLASH PANEL Ø2.5" x 25 SLEEVE Ø2.5" x 25 SLEEVE TUBE C Fig. 6-e CAC Ø2.5 x 25 SLEEVE TUBE C Fig. 6-f 11

20 6. CHARGE COOLER INSTALLATION, cont d G. Remove the three retaining screws at the top of the grill. Unclip the bottom edge of the grill. Remove the grill and set aside. H. Locate and remove the two 10mm headed screws that secure the P/S cooler to the front core support. Disconnect the rubber P/S hoses from the steel P/S line assembly located near the P/S reservoir. Remove the power steering cooler and the steel P/S line assembly located on the driver s side of the radiator and discard. (See Fig. 6-g.) To gain access to the assembly on the driver s side, you will first need to temporarily remove the three 10mm headed retaining screws that secure the ECU enclosure and pull the enclosure upward to gain access to the 10mm headed screw that retains the line bracket to the top of the frame rail. Once you remove the line bracket, re-secure the ECU enclosure using the factory hardware. (See Fig. 6-h.) POWER STEERING COOLER PREVIOUSLY ATTACHED TO CORE SUPPORT 10mm HEADED SCREW Fig. 6-g ECU ENCLOSURE NOTE: Leave the rubber lines connected to the power steering pump. I. Remove the two retainers securing the top of the A/C condenser. Tilt the condenser back toward the engine (be careful not to damage the condenser). J. Remove the bolt securing the hood latch assembly to the core support. Cut approximately 9" from the bottom of this mount. (See Fig. 6-i.) LINE BRACKET Fig. 6-h CUT HERE Fig. 6-i 12

21 6. CHARGE COOLER INSTALLATION, cont d K. Secure the CAC (Charge Air Cooler) bracket 8N to the passenger s side frame rail using the factory hardware as shown. (See Fig. 6-j.) Loosely install the charge cooler into its location. (See Figs. 6-j,6-k.) L. Using the supplied 1/4-20 x.50 " hardware, loosely attach the CAC to the mounting bracket. M. Reinstall the A/C condenser, and secure using the factory hardware. N. Install one of the provided Ø sleeves onto the CAC inlet and secure using #40 hose clamps. (See Fig. 6-e.) O. Using a Ø2.5" x 25 sleeve and #40 clamps provided, secure Tube C to the open end of Tube B and the 25 sleeve previously installed onto the CAC. (See Figs. 6-e, 6-f.) P. To provide a path for the discharge ducting, you must cut a Ø3" hole through the inner fender behind the passenger s side headlight. Using the provided template, mark and drill the location. Take care not to damage the headlight assembly or wiring harnesses in this area. (See Fig. 6-l, 6-m.) Q. Install one of the Ø2.5" x 25 elbow onto the CAC discharge (passenger s side outlet) and secure using the provided #40 hose clamp. (See Fig. 6-m.) FACTORY HARDWARE Fig. 6-j CAC MOUNTING BRACKET 8N Fig. 6-k Fig. 6-l 13

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23 Template 15

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25 6. CHARGE COOLER INSTALLATION, cont d R. Install the straight section of discharge duct D up through the previously cut Ø3" hole. Attach the curved end to the previously installed elbow and secure using the provided #40 hose clamp. (See Fig. 6-m.) NOTE: Rotate the previously installed 25 elbow to allow best tube engagement and core support clearance. S. Install one of the provided Ø3" x Ø2.75" reducer sleeve onto the open end of duct D and secure using the provided #40 clamps. T. Secure the remaining Ø3" x Ø2.75" reducer sleeve to the throttle body using the supplied #40 hose clamp. (See Fig. 6-n.) U. Secure the previously removed MAF electronics to Tube E using the supplied 8-32 x.50" hardware. (See Fig. 6-o.) Make sure the OEM O-ring is in place and is undamaged. TUBE D TUBE A Fig. 6-m 2.75"-3" REDUCER SLEEVE Ø2.5" x 25 ELBOW TUBE B Fig. 6-n TUBE E MAF ELECTRONICS Fig. 6-o 17

26 6. CHARGE COOLER INSTALLATION, cont d V. Connect the previously installed sleeves using discharge duct E and two #44 hose clamps. (See Fig. 6-p.) W. Locate the factory MAF harness. Carefully split the plastic flex-loom exposing the wire to the sensor connector. Separate enough length to reach the new MAF sensor location, and re-wrap the flex-loom. Reconnect the harness plug to the MAF sensor. TUBE E Ø3" x Ø2.75" REDUCER Ø3" x Ø2.75" REDUCER Fig. 6-p 18

27 7. AIR INLET INSTALLATION A. Locate the 4LA Air Inlet Assembly. B. Loosely install the supplied air filter onto the supercharger inlet. Mark the two hole locations to be drilled in the filter. One hole approximately Ø5/16" in the center of the filter. The other hole should be approximately Ø1/2" and offset to clear the ABS lines. (See Fig. 7-a.) SUPPLIED AIR FILTER 1/2" UNION NOTE: Thoroughly clean the inside of the filter and inspect to make sure no material is left from the drilling process. 5/16" 90 ELBOW C. Install the two fittings into the end of the air filter and re-install onto the supercharger inlet and secure. (See Fig. 7-a.) D. Locate the pressure solenoid removed from the plastic air filter enclosure in a previous step. E. Secure the solenoid to the top of the passenger s side frame rail using the factory retainer as shown. (See Fig. 7-b.) F. Using the supplied union and length of Ø5/16" hose provided, connect the formed rubber hose (previously connected between the filter enclosure and the solenoid) to the vacuum port as shown. (See Figs. 7-b, 7-c.) G. Connect the remaining portion of the Ø5/16" hose between the Ø5/16" x 90 fitting previously installed into the air filter and open vacuum port on the pressure solenoid. (See Figs. 7-a, 7-b.) LINE TO PRESSURE SOLENOID Fig. 7-a LINE TO MOLDED FACTORY HOSE LINE TO FILTER Fig. 7-b MOLDED FACTORY HOSE PRESSURE SOLENOID 5/16" HOSE MENDER 5/16" HOSE TO PRESSURE SOLENOID RELOCATED ABS MODULE Fig. 7-c 19

28 7. AIR INLET INSTALLATION, cont d H. Using the supplied union and length of Ø1/2" hose provided, connect the valve cover breather hose (previously connected to the factory air box) to the union previously installed in the supplied air filter. (See Figs. 7-a, 7-g.) I. Attach the length of Ø5/32" vacuum hose to the bypass valve and route to the vacuum port on the intake manifold. Remove the factory vacuum cap from the manifold port and attach the previously routed vacuum line. VALVE COVER BREATHER 1/2" UNION 1/2" HOSE 1/2" UNION Fig. 7-g 20

29 8.1 FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003 Auto) NOTE: This step applies to Model Year 2003 automatic vehicles only! For all others, skip the following and proceed with Section 8.2. A. Remove the six allen-head screws on top of the fuel management unit (FMU). B. Remove the diaphragm and 8:1 disk and ring from inside of the FMU. WARNING: Do not remove the four screws holding the valve body. Once taken apart, the valve would have to be replaced. C. Install the replacement 10:1 ring (with the notched part facing FMU body) around the four screws inside the FMU. (The 10:1 components are larger in diameter than the 8:1). D. Place the 10:1 disk inside the ring next to the piston. E. Install the new diaphragm and carefully line up the holes to the body. F. Place the spring retainer in the center of the diaphragm with the spring between it and the cover. (See Fig. 8.1-a.) G. Reinstall the FMU cover with the six allenhead screws. Do not over-tighten the screws. The correct torque is 24 in/lb (2ft/lb). Fig. 8.1-a 8:1 RING SPACER 8:1 WASHER (Ø2.270") LARGE DIAPHRAM SPRING RETAINER SPRING FCU COVER 21

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31 8.2 FUEL PUMP AND FMU INSTALLATION NOTE; The following step should be completed in a well ventilated area free of any ignition source. A. Locate the rubber section of the fuel supply line on the driver s side frame rail as shown. (See Fig. 8-a.) B. Cut the fuel line in approximately the middle of its length. (See Figs. 8-a, 8-b.) DRIVER S SIDE FRAME RAIL STEERING LINKAGE TRANSMISSION NOTE; Using a pair of locking pliers to pinch the fuel line on the fuel tank side of your cut location to avoid draining the fuel tank. Use caution as there will be fuel drainage from the engine side of the cut. C. Using the FMU and mounting bracket as a template, position the FMU as shown. (See Fig. 8-c.) Mark the two hole locations. Drill 1/8" pilot holes in the previously marked hole locations. Install the FMU using the provided #12 sheet-metal screws as shown. (See Fig. 8-c.) Cut the spring lock fittings off of the supplied FMU lines as close to the fitting as possible and discard. FUEL LINE TO BE CUT Fig. 8-a NOTE; Spring lock fittings are not used in this application D. Position the supplied fuel pump as shown. (See Fig. 8-d.) Mark and drill the two pilot holes in the sub-frame support brace. Secure the fuel pump and fuel pump ground wire to the sub-frame support brace using the supplied adel clamps and #12 sheet metal screws. (See Fig. 8-d.) E. (See Figs. 8-e, 8-f for reference.) FUEL LINE FROM TANK Fig. 8-b FMU NOTE; When installing the fuel lines in this step, install the supplied clamps simultaneously. However, do not clamp until all connections have been made and verified. FMU MOUNTING BRACKET 1. Attach the two supplied Ø5/16" hose barb TEEs to the open ends of the previously cut factory fuel line. 2. Connect the hose from the FMU inlet port on the previously installed FMU to the TEE connected to the line from the fuel tank. Connect a length of supplied hose from the branch of the same TEE to the fuel pump inlet port. 3. Connect the length of hose from the outlet on the side of the FMU to the TEE attached to the line going to the fuel rail on the manifold. Connect a length of supplied hose from the branch of the same TEE to the fuel pump outlet. Fig. 8-c 1-11/16" ADEL CLAMPS FLOW SUPPLIED FUEL PUMP GROUND WIRE Fig. 8-d 23

32 8.2 FUEL PUMP AND FMU INSTALLATION, cont d 4. Verify that all line connections have been made properly. Adjust all previously installed hoses and fittings so the lines route smoothly and are kept away from any sharp or moving parts. Tighten securely, all previously installed clamps at this time. 5. Connect the supplied length of Ø5/32" vacuum line to the pressure port on the FMU. Route the line up underneath the intake manifold to the vacuum port on the intake manifold. Using the supplied Ø5/32" vacuum TEE, connect the line to the previously installed line going to the by-pass valve. (See Fig. 8-g.) Fig. 8-e FACTORY FUEL LINE TO INTAKE MANIFOLD 5/32" HOSE (CONNECTED TO MANIFOLD PRESSURE) INLET FACTORY SUPPLY LINE FROM FUEL TANK OUTLET 5/16" HOSE BARB TEES RED POWER WIRE (FROM FUEL PUMP RELAY) INSTALL AND TIGHTEN CLAMPS USING STEPLESS CLAMP PLIERS SUPPLIED FUEL PUMP MARK AND DRILL HOLES INSTALL THE SUPPLIED SHEET-METAL SCREWS TO HOLD THE FUEL MANAGEMENT UNIT AND FUEL PUMP (VERIFY THAT COPPER WASHERS ARE INSTALLED AND FITTINGS ARE TIGHT) Fig. 8-f VACUUM LINE TO BYPASS VALVE VACUUM PORT Fig. 8-g 24

33 8.2 FUEL PUMP AND FMU INSTALLATION, cont d F. Mount the supplied fuel pump relay as seen in Fig. 8-h using factory hardware. Using one of the supplied ring-terminals, connect the provided fuse holder to the (+) battery terminal. Connect terminals #85 and #30 to the fuse holder previously connected to the battery. Route the long black wire from terminal #87 to the postive (+) terminal on the previously installed fuel pump. Terminal #86 will be connected in a later step. (See Fig. 8-i RELAY WIRING SCHEMATIC for correct wiring.) Fig. 8-h (+) TERMINAL ON SUPPLIED FUEL PUMP a 85 CONTROL BOX 30 (+) BATTERY TERMINAL RELAY WIRING SCHEMATIC Fig. 8-i 25

34 9. POWER STEERING A. Locate the power steering cooler relocation assembly (4LA ). (See Fig. 9-a.) B. Attach the supplied Ø5/16" rubber hoses to the power steering cooler and secure using the stepless clamps provided. C. Secure the power steering cooler to the A/C condenser using the supplied nylon mounting kit. (See Fig. 9-b.) D. Route the hoses around the driver s side of the radiator and towards the factory P/S hoses. E. Using the supplied Ø3/8" to Ø5/16" barbed reducers, two factory clamps and two stepless clamps provided, connect and secure the rubber lines to the factory P/S hoses. (See Fig. 9-c.) F. Top off the power steering system reservoir using the factory recommended power steering fluid. G. Using the factory hardware, reinstall the radiator and fan assembly. Install the upper and modified lower factory radiator hoses and secure using the original clamps. Refill the engine coolant system using the coolant drained in a previous step (provided it is in good condition). Automatic transmission vehicles reconnect the factory transmissiion cooler lines, you will need to wait until the installtion is complete before checking fluid level. Fig. 9-a Fig. 9-b Fig. 9-c 26

35 10. ELECTRONIC CONTROL BOX INSTALLATION A. Locate the factory ECU enclosure. Using a 10mm socket, remove the three retaining screws. Set the enclosure cover and hardware aside to be reinstalled later. (See Fig. 10-a.) B. Disconnect the ECU harness connectors located next to the ECU. To make room for the supplied ECU interface, you will need to remove the plastic connector cradle and discard. (See Fig. 10-b.) Reconnect the harness connectors. (See Fig. 10-c.) C. Locate the supplied plug and play harness connection. (See Fig. 10-d.) Make the appliicable ECU connections. Each connector plug is different from the others so there is only one possible location for each. (See Fig. 10-e.) ECU ENCLOSURE 10mm HEADED RETAINING SCREWS Fig. 10-a HARNESS CONNECTOR PLASTIC CRADLE Fig. 10-b Fig. 10-c PLUG & PLAY HARNESS CONNECTION Fig. 10-d 27

36 10. ELECTRONIC CONTROL BOX INSTALLATIION. cont d D. Once the connections have been made, gently push the unit down into the factory ECU housing next to the ECU. (See Fig.10-e.) E. Locate the factory ECU cover previously removed and cut a hole approximately Ø1/2" in the cover to allow the small 24-pin connector harness to pass through. Install the 24-pin connector harness through the ECU cover. Reinstall the ECU cover using the factory hardware. Using the supplied Velcro installation strip, install the control module to the ECU cover. (See Figs. 10-f, 10-g.) F. Connect the 16-pin and 24-pin connectors to the control module. Install the provided ring terminal onto the brown wires on the 16-pin harness. Route the brown wire to the location shown (see Fig. 10-f) and ground to chassis. Route the red and white wire to the fuel pump relay previously installed and connect to terminal #86 as shown previously in the RELAY WIRING SCHEMATIC. (See Fig. 8-i.on page 23) FACTORY ECU Fig. 10-e SUPPLIED PLUG & PLAY HARNESS Fig. 10-f CONTROL MODULE 16-PIN CONNECTOR BROWN GROUND WIRE 24-PIN CONNECTOR FUEL PUMP TRIGGER WIRE Fig. 10-g 28

37 11. FINAL CHECK A. Reconnect the battery. B. If your vehicle has gone over 20,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle. C. 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. (See Fig. 11-a.) D. Check all fluid levels, making sure that your tank(s) is/are filled with 91 octane or higher fuel before commencing test drive. E. Start engine and allow to idle a few minutes, then shut off. F. Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts and for signs of any fluid leakage. G. PLEASE TAKE SPECIAL NOTE: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS. H. Recheck all fluid levels following the factory recommended procedures at this time. I. Test drive the vehicle by gradually working up to full throttle and paying close attention to any abnormal sounds or engine detonation. If detonation is heard, discontinue heavy throttle usage until the necessary adjustment or repairs are made. WARNING: Never operate your engine at full throttle when the engine is cold. Always allow plenty of time for the oil to reach full operating temperature before running above 2,500 RPM. Full supercharger operating temperature is generally achieved only after the engine water temperature has been at the normal indicated operating range for two or three minutes. Fig. 11-a WARNING: Due to variances in each vehicle, Vortech recommends that the vehicle get a custom tune from a local, reputable tuner. This kit is supplied with a universal fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your specific vehicle can be obtained from a competent tuner. A wide-band exhaust oxygen sensor must be used to confirm proper air/fuel ratio. Vortech suggests a proper WOT air/fuel ratio range of :1 for 91 octane fuel. J. 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. 29

38 ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands CA Phone: Fax: M-F 8:00AM - 4:30PM (PST) D - v1.1 07/10/07