GM ALPHA H3 HUMMER. Supercharger System Installation Instructions. 50 State Smog Legal per CARB EO #D Model Years ENGINEERING, LLC

Transcription

1 GM ALPHA H3 HUMMER Supercharger System Installation Instructions 2008 Model Years 50 State Smog Legal per CARB EO #D ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands CA Phone: Fax: M-F 8:00AM - 4:30PM (PST) D - v2.0 10/20/08

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 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 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 (2008 H3 HUMMER).... vi 1. PREPARATION/REMOVAL OIL DRAIN INSTALLATION (OIL FED MODELS ONLY) OIL FEED INSTALLATION (OIL FED MODELS ONLY) FUEL INJECTOR REPLACEMENT MOUNTING BRACKET AND SUPERCHARGER INSTALLATION RADIATOR HOSE MODIFICATION CHARGE COOLER INSTALLATION AIR INLET INSTALLATION AIR INLET INSTALLATION "TEMPLATE" PCV VALVE INSTALLATION FINAL CHECKOUT iii

4 HUMMER H3 IMPORTANT NOTES 2008 Models This kit requires the installation of a Vortech ECU Reflash. The ECU must be sent directly to Vortech by the installing customer (the charge for this service with reflash installation has been included in the purchase price). Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1) Vortech ECU Reflash. An ECU reflash is created specifically for each individual vehicle with respect to the factory ECU calibration. Simply contact the Vortech Service Department at (805) to request a Return Authorization Number (See ECM Module Credit Tag for more details). - Mail to Vortech the enclosed "ECU Reflash" (send original tag - no photocopies will be accepted) and ECU in the supplied box. - Turnaround time will be 1-2 days (each application varies). Vortech will give an estimate at the time of your order. Your Vortech ECU Reflash comes with a twelve (12) month limited warranty from the original date of purchase of your supercharger system (see Owner's Manual for details). Note: Vortech Engineering is not responsible for engine or ECU damage due to an improperly installed/mishandled ECU. 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 GM 2008 H3 Hummer Installation Instructions 50-State Smog Legal, as per CARB EO # D 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 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 manufacture-rated, high grade engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result. 6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every 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 1/2" Socket and Drive Set: SAE & Metric 3/8" NPT Tap, 1/4-20 Tap and Handle Adjustable Wrench Open End Wrenches: 3/8", 7/16", 1/2", 9/16", 7/8, 10mm Center Punch and a 5/8" Tapered Punch 3/8 Springlock Fuel Fitting Disconnect Tool 5 Quarts manufacturer specified Engine Oil Oil Filter and Wrench Flat #2 Screwdriver Phillips #2 Screwdriver Heavy Grease Silicone Sealer Drill Motor 1/8", 3/16", 27/64" Drill Bits 5/16" Allen Wrench Wire Strippers and Crimpers Utility Knife Power Steering Pulley/Puller & Installer ENGINEERING, LLC If your vehicle has in excess of 15,000 miles since its last spark plug change, then you will also need: Spark Plug Socket NEW Spark Plugs v

6 ENGINEERING, LLC GM 2008 H3 Alpha Hummer Part No. 4GN L PARTS LIST IMPORTANT: 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. 2F V3 SC-TRIM,CW,CRVD,STN,H3-A 1 2A S/C PULLEY 3.33" 6 GROOVE 1 4GN ASSY, MNTG BRKT H3 ALPHA 1 4GN BRKT, S/C MNT H3 ALPHA 1 4GN BRKT, SPRT H3 ALPHA 1 4GN SPACER, S/C MNT TOP H3 ALPHA 1 4GN SPACER, S/C MNT LWR H3 ALPHA 1 2A SPACER, 1"OD X.406"ID X 2.992" 1 2A SPACER,.875"OD X.406"ID X A SPACER,.625"OD X.375"ID X.025" 1 7C M X 25MM HXCSP 1 7C M10 X 1.5 X 110 HXHD, ZINC 1 7C M10 X 1.5 X 120 HXHD, ZINC 1 7C M10 X 1.50 X 130 HEX HEAD 1 7A /8-16 X 1-1/4 HHCS, G5, PLATED 4 7A /8-16 X 3.5" HX HD GR8 1 7A /8-16 X 3/4 GR5 HXHD ZINC 1 7A /8-16 X 4" BOLT HXHD GR8 3 7A /8-16 X 4.25" HX HD GR8 1 7K /8 AN960 FLAT WASHR PLATED 13 4FR STEEL IDLR PLY, 3" 6 RIB SMOOTH 1 4FH IDLER PULY, 6RIB 3" FLANGD 1 2A SPACER, Ø.875 X W/PLT 1 2A PILOT, 6203/5 BRG, 3/8 SCREW 1 2A BELT, K GATES 4.6 2V 1 7J SPACER,.375/M10 IMPELLER NUT 1 7J SHIM, Ø.692" ID X.030" THK X 1 8N CHARGE COOLR ASY, 08, H3 ALPHA 8N WELDED CORE ASSY, H3 ALPHA 1 8N PLASTIC CAP, SURGE TANK 1 7R #44 SAE TYPE F SS HOSE CLAMP 2 7S SLEEVE, 2.75" X 5.00"L, BLUE 1 7S SLEEVE, 3" X 3", BLUE 1 4GN DUCT, DISC. H3 ALPHA 1 4GL ELBOW,3.88"-3.0" X 90 GM TRK 1 7R #48 SAE TYPE F SS HOSE CLAMP 3 7R #60 SAE TYPE F SS HOSE CLAMPS 1 8F PUMP, WATER, PIERBURG 1 7R ADEL CLAMP,1-11/16" 2 7E #12 X 3/4" SHT METL SCRW HEX 2 7U /32" VACUUM LINE 1.5 8D STD COMPRESS BYPASS VALVE 1 7U " GS HEATER HOSE R #16 SAE TYPE F SS HOSE CLAMP 4 8N BRKT, UPR SPRT SETRAB H3 1 8N BRKT, SETRAB MNT H3 1 8N WATER COOLR, SETRAB SINGLE PASS 1 7P /2NPT X 3/4 BARB 90 BRASS 1 7P /2NPT X 3/4 HOSE FIT STRT 3 7P /4" HOSE BARB UNION, BRASS 1 7U HOSE,3/4"DIA 90,4X12 LEGS 2 7U HOSE, 3/4"X150 MOLDED HOSE 1 4GV WATER PIPE, L BEND 1 7U /4" HEATER HOSE R NYLON RATCHET CLAMP 1-1/8" 10 5W FUSE, BLADE TYPE 20 AMP 1 5W FUSE HOLDER,16GA WIRE 1 5W GA STRD WIRE BLK, UL W MINI ATC FUSE TAP 1 5W FEM SLIDE,INSUL,MINI,22-16AWG 1 5W GA BUTT CONN RED INSUL 1 7C M8 X 1.25 X 16 HXHD 1 5W GA RING TERM.33" HOLE 1 4GN AIR INLET ASSY, H3 ALPHA 4GN AIR CLEANER COVER, H3 1 4GN BRACKET, AIR FILTER CVR SPRT 1 7S SLEEVE, 3-1/2 X 2, BLUE 2 8H AIR FILTER, 4.0FLG X 7.0L 1 7F MM NYLOCK NUT 1 7A /4-20 X.63 HHCS SS 2 7S ELBOW,Ø3.5" 90 DEG W/BUNG 1 4FA INTAKE ELBOW,90 DEG W/O BOSSES 1 7R #56 SAE TYPE F SS HOSE CLAMP 4 8A MAF, 2008 H3 ALPHA Ø3.44" ID 1 7C M4-.7X8MM SCHD SS 2 7A /4-20 X.75 HHCS PLTD 2 7A /4-20 X 1 HHCS ZINC PLTD 1 7J /4 WASHER, SAE, PLTD 6 7U /2" FLEX HOSE R #52 SAE TYPE F SS HOSE CLAMP 2 7U /8" EFI FUEL HSE HI-PSR 1 7P /8" HOSE UNION, BRASS 1 7P /8 NPT MALE X 3/8 HSE BARB 90º 1 4GN SHIELD, SPUND SPR 1 4GN SOUND ABS. MAT 1 4GN PCV MOD ASSY, H3 ALPHA 1 7P PCV VALVE, FORD, 3/8" HOSE 1 7P REDUCER, 5/8 BARB TO 3/8 BARB 1 7R #8 STNLS HOSE CLAMP 1 7R STEPLESS CLAMP, U HOSE, 5/8"ID CLASS 1 EMISSIONS FUEL GN COOLANT PIPE ASSY. H3 ALPHA 1 7R #20 SAE TYPE F SS HOSE CLAMP 2 4GN RAD. PIPE Ø1.375, H3 ALPHA 1 4GN TUBE ASSY.,Ø.75 X 2.5 X 4.5 X U /8"MOLDED ELBOW HSE, 24" 1 7U HOSE,3/4"DIA 90,4X12 LEGS 1 7P /4" HOSE BARB UNION, BRASS 1 7P /8" HOSE UNION, BARBED ENDS 1 7R ADEL CLAMP, 1.0" 1 7R #8 STNLS HOSE CLAMP 4 8F FUEL INJ 47LB, DELPHI MULTEC 3.5 SHORT 8 4GN INSTR MAN, H3 ALPHA HUMMER SMALL SILVER DIE CUT DECAL LICENSE PLATE FRAME, VORTECH S/C STRT INFO PKG ASSY VORT LUBE ASSY 1 vi

7 1. PREPARATION/REMOVAL A. Disconnect the negative battery cable, and remove the plastic engine cover. NOTE: 1. Locate the vehicles ECU and TCM modules behind the washer fluid/coolant reservoir assembly passenger side firewall. 2. Temporarily loosen the washer fluid/coolant reservoir assembly to gain adequate access to the modules. 3. Unplug the four factory harness connections and remove the modules from the vehicle. 4. Contact the Vortech Service Department for a Return Authorization Number. Send both the ECU and TCM and supplied credit tag to Vortech using the enclosed shipping materials. B. Disconnect the MAF electronics harness connection from the meter. (See Fig. 1-a) C. Disconnect the passenger side valve cover vent line fom the valve cover. Remove the 90 rubber elbow and set aside to be reused in a later step. D. Using a 5/16 nut driver, loosen the hose clamp securing the inlet duct to the throttle body. Remove the air filter lid and inlet duct to the throttle-body. (See Fig. 1-b) E. Disconnect the MAF harness from the lower half of the air box. Using a 13mm socket and long extension remove the fasteners retaining the lower portion of the air filter enclosure to the inner fender. Set the air box aside, it will not be reused. F. Remove the MAF electronics from the previously removed air filter assembly and set aside to be reused in a later step. (See Fig. 1-a) G. Using a 15mm wrench detention the factory belt tensioner and remove the accessory belt. H. Remove the three 15mm headed retainers securing the factory belt tensioner to the water pump. I. Remove the front skid plate and set aside. Drain the engine coolant into a clean container and set aside to be reused in a later step. Once the coolant is drained remove the retainer securing the heater hose support bracket to the front of the passenger side cylinder head. (See Fig. 1-c & 1-d) Fig. 1-a Fig. 1-b Fig. 1-c 1

8 1. PREPARATION/REMOVAL, cont d. J. Disconnect the 1/4" coolant line from the heater hose assembly. Disconnect the heater hoses where they attach to the water pump and fire wall on the passenger side. Remove the heater hose assembly and set aside. (See Fig. 1-d & 1-e) K. Remove the stud that formerly retained the front drivers side corner of the engine cover and discard. (See Fig. 1-f) 1/4" LINE HEATER HOSE SUPPORT BRACKET Fig. 1-d Fig. 1-e STUD Fig. 1-f 2

9 2. OIL DRAIN INSTALLATION (ENGINE oil-fed kits only. applications with v3 superchargers skip ahead to step 4) NOTE: To provide an oil drain for the supercharger, it is necessary to make a hole in the oil pan. A. Locate and remove the fasteners that secure the factory transmission cooler to the front cross-member. Push the cooler up and temporarily secure out of the way. (See Fig. 2-a) B. Remove the 10mm headed fastener that secures the plastic wire loom to the front of the oil pan. (See Fig. 2-b) C. Mark the hole location as shown on the front of the pan. Center punch the hole location to be drilled. (See Fig. 2-c) D. Drill an 1/8 pilot hole at the previously marked location. Locate the oil drain assembly (4GN ). Use the supplied 9/16 cutter to enlarge the pilot hole, making sure to break through easily. Do not stop the drill motor until the cutter has been extracted so that the cutout does not fall into the pan. It may help to pack the cutting tool with grease to help prevent any stray chips from entering the oil pan. E. Thread the hole with a 3/8 NPT tap to approximately 1/2" deep or until the fitting can be started. Pack the flutes of the tap with grease to minimize the amount of debris that gets into the engine. Access is restricted so inserting the tap in a socket and then using a ratchet to rotate it is helpful. NOTE: When tapping the hole be careful not to bottom out the tap. If the tap does bottom before the thread is large enough you will need to trim the end of the tap to facilitate a deep enough thread cut. F. Thoroughly clean the threaded area and the interior of the engine. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8 NPT MALE X.5 FEMAL INVERTED FLARE hose fitting and secure in the hole. Make sure a seal is formed all around the fitting. (See Fig. 2-d) G. Loosely install the TUBE NUT ASSEMBLY into the previously install fitting. The supercharger oil drain hose connection will be made in a later step. Leave the transmission cooler and wire loom loose until then. (See Fig. 2-d) H. Drain the engine oil and change the filter. 2 5/8" TRANSMISSION COOLER Fig. 2-a Fig. 2-b 1.5" Fig. 2-c Fig. 2-d 3

10 3. oil FEED INSTALLATION (ENGINE oil-fed kits only. applications with v3 superchargers skip ahead to step 4) A. Install the 1/8 NPT x 90-4 fitting into the supplied oil feed adaptor as seen in figure 3-a. B. Locate the factory oil passage cover just above the oil filter on the driver s side of the engine. Using a 10mm socket remove the factory retainers and discard. C. Using the new gaskets and 6mm hardware provided reinstall the factory oil passage cover and oil feed adapter. The 90 fitting should be facing the front of the vehicle. (See Fig. 3-b) D. Attach one end of the supplied 4 stainless steel oil line to the previously installed 4 x 90 fitting and secure. (See Fig. 3-b) E. Route the line toward the front of the engine and up to where it will be attached to the supercharger oil feed. Using the supplied cable ties secure the line away from hot, sharp or moving parts. (See Fig. 3-c) F. Cover the open end of the line to prevent contamination until the connection to the supercharger is made in a later step. Fig. 3-a Fig. 3-b OIL FEED LINE Fig. 3-c 4

11 4. FUEL INJECTOR REPLACEMENT NOTE: Caution should be used when working on the fuel system. Fuel may be under high pressure. Fuel injector replacement should be performed in a well ventilated area free of any possible ignition source. It is recommended that you have a fire extinguisher nearby. A. Relieve the fuel system pressure. B. Disconnect the eight fuel injector wiring clips and retainers from the injectors. C. Remove the four 8mm bolts securing the fuel rails to the intake manifold. Lift up on the rails evenly, removing all eight injectors. Separate and set aside the factory injectors as they will not be re-used. D. Using a small amount of clean motor oil, lightly lubricate the O-rings on both ends of the supplied fuel injectors. E. Install the new fuel injectors into the fuel rails and secure using the factory retaining clips. NOTE: The injector plug connections must face outwards. F. Carefully lower the fuel rail-injector assembly down onto the intake manifold. Check to see that each injector has been seated properly into the manifold. G. Secure the fuel rail assembly using the original hardware and attach the wiring clips to the injector terminals. 5

12 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION NOTE: For the following section, refer to Fig 5-l & Fig. 5-m on page 10 and 11, for screw and spacer location. Do not tighten until instructed to. A. B. C. D. E. F. G. Locate the supercharger mounting bracket assembly (4GN ) Clearance (grind) the end of the passenger side valve cover flush with the head surface. (See Fig. 5-a) Install the support bracket to the passenger side cylinder head using the M10 X 25mm screw and washer. Make sure the head surface is clean and no wires or hoses are between the bracket and mounting surface. Loosely install one of the factory tensioner mounting retainers in the lower cylinder head hole location as a guild. Tighten the previously installed M10 screw. Remove the tensioner retainer used as a guild. (See Fig. 5-b) Using two 3/8-16 x 4 screws and the lower bracket spacer, loosely install the supercharger mounting bracket. Install one of the Ø1.0 x spacer using the M10 x 110mm screw, do not use a washer when installing this fastener as tensioner bracket interference will result. (See Fig. 5-c) Using a one of the factory tensioner retainers, M10 x 120mm, and 3/8-16 x 4 retainers and washers install the upper (three hole) spacer between the supercharger bracket and the previously installed support bracket. Tighten all hardware installed to this point. (See Fig. 5-c) Locate the factory spring tensioner and supplied mounting hardware: Place the thick washer onto the M10 x 130mm screw and insert it through the factory spring tensioner. Insert the 3/8-16 x 4.25 screw and washer through the tensioner. Place the two Ø.875 x 1.98 spacers on the previously installed hardware. Insert the 3/8-16 x.75 screw and washer through the remaining tensioner hole and place the.025 spacer on it. Carefully install this assembly. The M10 screw will go through the support bracket and into the head. The 3/8-16 x 4.25 screw secures to the support bracket. And the 3/816 x.75 screw secure to the supercharger mounting bracket. (See Fig. 5-d, 5-l, 5-m) Fig. 5-a M10 x 25mm Fig. 5-b M10 x 110mm Fig. 5-c Fig. 5-d 6

13 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d. H. I. J. Remove the 15mm headed screw securing the ribbed tensioner pulley to the tensioner arm. Install the supplied 3 steel smooth idler and secure using the factory hardware and Ø.692" I.D x.030" thick spacer. Locate the coolant pipe assembly (4GN114020). Secure the Ø3/4 x 90 and Ø5/8 x 90 molded hoses to their corresponding water pump ports using the factory hose clamps from the previously removed hose assembly. (See Fig. 5-e) Using the supplied adel clamp secure the Ø5/8 hose to the coil (front passenger side) retainer. Route the hose to the heater core connection at the firewall. Locate and cut the factory heater hose assembly to obtain the factory clip connectors (leave yourself extra hose and trim as necessary) set the 3/4" connector aside. Connect the factory 5/8 clip connector to the heater core. Use the supplied Ø5/8 union and hose clamps to connect the previously installed mold hose to the factory heater hose (trim as necessary for best fit). (See Fig. 1-f, 5-f & 5-g) Ø 5/8" HOSE Ø 3/4" HOSE Fig. 5-e COIL ADEL CLAMP Fig. 5-f FACTORY 5/8" HOSE UNION 5/8" HOSE Fig. 5-g 7

14 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d. K. Install the Ø3/4 aluminum 105 tube into the open end of the previously installed Ø3/4 molded 90 hose (the 1/4" barb should face slightly forward). Connect the factory 3/4" clip connector to the heater core. Insert the open end of the 105 aluminum tube into the open end of the factory 3/4" hose. Secure all hose connections with the provided hose clamps. Secure the factory 1/4" bleed hose to the 1/4" barb on the 105 aluminum tube. (See Fig. 5-h) L. (OIL-FED MODELS ONLY) Using one of the supplied #6 hose clamps secure the provided 1/2" oil drain hose to the 1/2" oil drain fitting on the bottom of the supercharger. (See Fig. 5-i) M. Mount the supercharger to the supercharger bracket using the four 3/8-16 x 1.25 screws and washers. Attach the supplied 3 flanged smooth idler to the mounting bracket using the Ø.875 x piloted spacer, 3/8-16 x 3.5 screw, and pilot washer. (See Fig. 5-j, & 5-k, 5-l) N. (OIL-FED MODELS ONLY) Install the 1/8 NPT x 90 x 4 fitting into the supercharger oil feed port and orient so it faces down. (See Fig. 5-j) FACTORY Ø 3/4" HOSE 105 ALUMINUM TUBE Ø 3/4" MOLDED 90 HOSE Fig. 5-h 1/4" BLEED HOSE Fig. 5-i 1/8 NPT x 90 x -4 3" FLANGED SMOOTH IDLER Fig. 5-j 8

15 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d. O. (OIL-FED MODELS ONLY) Connect the 1/2" oil drain hose from the S/C to the 1/2" tube assembly previously installed in the oil pan and secure. Using a cable tie secure the line to the A/C line away from the A/C pulley NOTE: Ensure that the hose does not have any dips or kinks in the routing. Supercharger failure may be the result of a restricted drain path. P. (OIL-FED MODELS ONLY) Connect the open end of the 4 stainless steel oil feed line to the 4 x 90 fitting on the supercharger. Q. Install the supplied drive belt as shown. (See Fig. 5-k) S/C 3 FLANGED IDLER ALT. IDLER TENSIONER WATER PUMP POWER STEERING CRANK Fig. 5-k 9

16 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d. 3/8-16 X 3.5 WITH PILOT WASHER 3/8-16 X4 M X120MM FACTORY TENSIONER RETAINER M X25MM 4X3/8-16 X1.25 3/8-16 X4.25 3/8-16 X4 3/8-16 X.75 3/8-16 X4 Fig. 5-l M X 130MM & THICK WASHER M x 110MM NO WASHER 10

17 5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont d. UPPER (3 HOLE) SPACER LOCATED BETWEEN S/C BRACKET AND SUPPORT BRACKET Ø.625 X.025 SPACER LOCATED UNDER TENSIONER MOUNTING BOSS LOWER (2 HOLE) SPACER LOCATED BETWEEN S/C BRACKET AND SUPPORT BRACKET Ø1.0 X SPACER LOCATED BETWEEN S/C BRACKET AND SUPPORT BRACKET Fig. 5-m Ø0.875 X 1.98 SPACERS LOCATED UNDER TENSIONER MOUNT BOSSES 11

18 6. RADIATOR HOSE MODIFICATION A. Locate the upper radiator hose. B. Cut the hose after the 45 leaving as much straighht section as possible (approximately 1"). See Fig. 6-a. C. Make a second cut approximately 2" before the 90 bend. See Fig. 6-a. D. Install the provided stainless steel radiator tube and secure using the supplied #20 hose clamps. See Fig. 6-b. NOTE: Adjust the hose ends as necessary to provide the best possible drive belt and idler pulley clearance. Fig. 6-a Fig. 6-b 12

19 7. charge cooler installation Refer to Fig.7-h for assistance throughout this manual. A. Remove the four screws and two nuts that secure the grill to the core support. B. Pull forward on the ends of the grill to release the push clips holding the grill in place. C. Locate the Charge Air Cooler assembly (8N ). D. Install one 1/2"NPT x 3/4" barb 90 brass elbow and one 1/2"NPT x 3/4" barb straight fitting into the supplied heat exchanger and orient as shown*. (See Fig. 7-h.) E. Remove the two 13mm headed screws and two 10mm headed screws securing the hood latch support assembly to the core support. Unclip the wire harness that runs behind the support. Set the support aside to be reinstalled later. (See Fig. 7-a.) F. Secure the heat exchanger bracket (8N010240) to the heat exchanger using the 1/4-20 x.75" screws, washers and Nyloc nuts provided. Loosely install the heat exchanger assembly into position. (See Fig. 7-a, 7-h.) G. Reinstall the hood latch support (the heat exchanger bracket is between the core support and the hood latch support) secure using the factory hardware. Feed the sensor leads through their respective sides and reconnect to the sensors. 90 HOSE 150 MOLDED HOSE Fig. 7-a NOTE: Careful not to pinch wires between the brackets. H. I. Fig. 7-b Place the supplied piece of 1/8" x 4" tape foam on the heat exchanger. It may be necessary to trim the tape to fit. Install the upper heat exchanger bracket and secure using a 1/4-20 x.75" screw, washer and Nyloc nut provided. (See Fig. 7-b.) Using the supplied Adel clamps, self-tapping screws and washers, secure the provided water pump, to the cooling fan shroud. (See Fig. 7-c.) NOTE: Orient the pump discharge so that it points to the front passenger side of the vehicle. J. K. Latch Support Secure the supplied Ø2.75" X 5" sleeve to the supercharger discharge using a #44 hose clamp. (See Fig. 7-d.) Using the supplied Ø3.88 to Ø3.0 reducer elbow and Ø3.0 x 3 sleeve, install the discharge duct between the CAC and the throttle body, secure using the #48 & #60 hose clamps provided. See Fig 7-d) HOSE FROM CAC 150 HOSE WATER PUMP Fig. 7-c * Use pipe sealant on tapered pipe threads. 13

20 7. charge cooler installation, cont d. L. M. N. O. Install the two 1/2" NPT x 3/4" barb fittings into the charge air cooler (CAC*). Cut a piece of the supplied Ø3/4" rubber hose (7U ) approximately 24" long. Connect the cut hose between the CAC discharge (bottom driver s side fitting) and the water pump inlet as shown. (See Figs. 7-c, 7-d 7-h.) Connect the supplied 150 x Ø3/4" molded rubber hose between the water pump discharge and the heat exchanger inlet (passenger s side fitting). (See Figs. 7-a, 7-c, 7-h.) Attach the short end of the supplied molded 90 rubber hose (7U ) to the straight fitting previously installed in the heat exchanger (driver s side fitting). (See Fig. 7-a, 7-h.) Fig. 7-d NOTE: Trim the hose as necessary. P. Q. Trim the long end of the previously installed hose to about 1.5". Connect the long end of the formed 150 aluminum tube to the open end of the previously installed 90 molded hose. (See Figs. 7-f, 7-h.) Connect the long eng of the remaining 90 rubber hose to the aluminum tube. Install the supplied hose union to the open end of the hose. Attach a section (approximately 36 long) of the supplied Ø3/4 heater hose to the previously installed union. Connect the open end of the Ø3/4 hose to the CAC inlet (top passenger side fitting). (See Fig. 7-e, 7-f & 7-h) Fig. 7-e Fig. 7-f * Use pipe sealant on tapered pipe threads. 14

21 7. CHARGE COOLER INSTALLATION, cont d R. Secure all hose connections at this time using the supplied nylon ratchet clamps. Make sure that all hoses are routed and secured away from hot or moving parts. S. Using the supplied butt connector, attach the supplied length of wire to the poitive (green) wire on the water pump. Route the wire to the power distribution box (PDB) located on the driver side. Trim the wire so that it just reached the PDB. Connect the supplied fuse holder to the end of the wire. Attach the trimmed piece of wire to the opposite side of the fuse holder. Locate the fuel pump relay. Using the mini ATC fuse tap and the supplied femal spayed connector attach the wire to terminal #87 on the relay. (see Fig. 7-g) T. Attach the supplied ring terminal to the water pump ground wire. Secure the ground wire to the inner fender using the supplied M8 fastener. U. Fill the CAC coolant using a 25%/75% antifreeze/water mix. Fill through the surge tank fill port located on the CAC. Fig. 7-g 15

22 7. CHARGE COOLER INSTALLATION, cont d CHARGE AIR COOLER 1/2 NPT TO 3/4 HOSE BARB (7P ) (7U ) 90 A X 12 FORMED HOSE WATER PUMP (8F ) MOUNTED WITH TWO ADEL CLAMPS TO FAN SHROUD (7U ) 150 MOLDED HOSE 3/4 HOSE (7U ) CUT TO FIT APPROXIMATELY 23 WATER COOLER (8N ) 3/4 HOSE UNION BARBED (7P ) 3/4 HOSE (7U ) CUT TO FIT APPROXIMATELY 26 (7U ) 90 A X 12 FORMED HOSE (TRIMMED TO APPROX 4.5 X 1.5 (4GV ) FORMED ALUMINUM TUBE 90 1/2 NPT TO 3/4 HOSE BARB (7P ) 1/2 NPT TO 3/4 HOSE BARB (7P ) (FRONT VIEW) (8N ) HEAT EXCHANGER MOUNTING BRACKET MOUNTED BETWEEN CORE SUPPORT AND HOOD LATCH SUPPORT Fig. 7-h 16

23 8. AIR INLET INSTALLATION A. Locate the MAF mounting hole template in this manual. Remove and cut the template as shown. Place the template on the passenger side inner fender and mark the three hole positions to be drilled. Drill the previously marked hole locations using a 1/4" drill. B. Install the MAF meter into the air filter cover. Place the supplied air filter on to the meter and secure. (See Fig. 8-a.) C. Install the air filter assembly into the vehicle. Secure the MAF meter and the sound suppressor shield to the previously drilled holes in the inner fender using the 1/4-20 hardware provided (the shield goes inside the fender opposite the MAF) (See Figure 8-d.). D. Secure the forward edge of the air filter housing to the front core support using the supplied 90 bracket, 1/4-20 hardware and M6 Nyloc nut. (See Fig. 8-b). E. Install the previously removed MAF electronics into the supplied meter housing and secure using the supplied hardware. Connect the MAF electronics harness to the MAF. (See Figure 8-d) F. Locate the 3.5 x 90 duct with bosses and install the 3/8 NPT x 3/8 barb x 90 fitting. Secure the 3.5 x 90 duct to the supercharger inlet using the Ø3.5 x 2 sleeve and two #56 hose clamps provided. Secure the 90 duct w/out bosses to the previously installed MAF meter using the remaining Ø3.5" x 2" sleeve and two #56 hose clamps. (See Fig. 8-c, 8-d) G. Connect the provided length of Ø3/8 hose to the previously installed 3/8 barb x 90 fitting. Insert the supplied Ø3/8 hose union into the open end of the hose. Attach the factory 90 molded hose to the previously installed union. Connect the open of the 90 hose to the barb located on the passenger side valve cover. (See Fig. 8-c) MAF METER FACTORY MOLDED 90 Ø3.5" X 90 DUCT Fig. 8-a SUPPORT BRACKET Fig. 8-b Fig. 8-c AIR FILTER FILTER COVER Ø3/8" HOSE 3/8" NPT X 3/8" BARB 90 NOTE: Trim the 3/8" hose to the best fit. Retain the extra hose to use in a later step. H. Connect the two 90 inlet ducts using the Ø3.5 x 10" flex hose and secure using the remaining #52 hose clamps provided. (See Fig. 8-d.) I. Cut a piece of the supplied Ø1.0 rubber hose approximately 4 long and secure it to the Ø1 port on the previously installed CAC using the #16 hose clamp provided ELBOW w/ BOSSES ELBOW w/o BOSSES Fig. 8-d MAF METER 17

24 This Page Left Intentionally Blank 18

25 8. AIR INLET INSTALLATION TEMPLATE EXISTING HOLE DRILL THREE 1/4 HOLES TEMPLATE INNER FENDER 19

26 8. AIR INLET INSTALLATION, cont d K. Insert the inlet side of the supplied by-pass valve into the open end of the previously installed hose and orient it so that the open end faces forward and secure using the #16 hose clamp provided. (the vacuum port should be facing down). L. Using the remaining section of Ø1.0 rubber hose connect the open end of the by-pass valve to the Ø1.0 barb on the previously installed Ø3.5 x 90 duct and secure using the remaining #16 hose clamps provided. M. Connect the supplied piece of 5/32 vacuum line to the vacuum port on the by-pass valve. Route the line up to the manifold. Locate the vacuum port on the passenger side of the manifold. Cut the sealing tab off the end of the factory vacuum port. Insure that the port is open and free of any debris left from the cutting process. Connect the open end of the previously installed vacuum line to the vacuum port. (See Fig. 8-e) N. Reinstall the grill in the reverse order removed, using the factory harware. SEALING TAB VACUUM PORT Fig. 8-e 20

27 9. PCV VALVE INSTALLATION A. Locate the valve cover vent hose attached between the intake manifold and the rear of the valve cover. B. Remove the factory 45 molded rubber elbow from the valve cover end of the factory vent tube. (See Fig. 9-a) C. Cut the factory vent tube just after the 90 bend, leave enough straight section to install the PCV valve. (See Fig. 9-b) D. Install the 3/8 end of the PCV valve into the open end of the factory vent tube (heating the end of the tube slightly will make inserting the valve easier, use care not the melt the material). (See Fig. 9-b, 9-c) E. Using the section of Ø5/8 hose provided, attach the 5/8 x 3/8 reducer fitting to the end of the previously installed PCV valve. (See Fig. 9-b) F. Attach the supplied section of Ø3/8 hose (left over from the intake assembly) to the reducer fitting. Install the provided Ø3/8 hose union into the end of the Ø3/8 hose. Using the factory 45 molded rubber elbow connect the Ø3/8 hose to the barb on the drivers side valve cover. (See Fig. 9-a) 45 MOLDED ELBOW Fig. 9-a FACTORY TUBE PCV VALVE Ø5/8" HOSE REDUCER UNION Ø3/8" HOSE Fig. 9-b Fig. 9-c 21

28 10. FINAL CHECK NOTE: Once the Re-flashed ECU and TCM are received back from Vortech, reinstall them in the reverse order removed. Take care not to damage the harness connectors or ECU/TCM connection pins. Re-secure the washer fluid/coolant reservoir assembly. WARNING: Do not attempt to operate the vehicle until all components are installed and all operations are completed including the final check. A. 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. B. Check all fitting, 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 91 octane or higher fuel before commencing test drive. D. Start the engine and allow to idle a few minutes, then shut-off. H.O. Charge Cooled Kits Only NOTE: Check to see that CAC coolant is flowing through the surge tank. If coolant is not flowing, remove the 3/4 rubber hose from the side of the CAC and apply light suction in an attempt to pass any trapped air in the system. Reconnect the hose and recheck coolant flow. E. Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts. Look also for any signs of fluid leakage. F. PLEASE TAKE SPECIAL NOTE: operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS. 22

29 10. FINAL CHECK, cont d G. Test drive the vehicle. H. Always listen carefully for engine detonation. Discontinue heavy throttle usage if detonation is heard. I. 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 internally lubricated V3 units only This supercharger has been factory pre-filled with special Vortech synthetic lubricant. Oil does not need to be added to a brand new unit; however a fluid level check should be performed. Prior to operating the supercharger on the vehicle and after installation onto the vehicle: Remove the factory installed flat-head brass shipping plug (not the dipstick) from the top of the supercharger case. Replace the sealed shipping plug with the supplied vented plug. Do not operate the supercharger without it. Check the supercharger fluid level. Fluid level checking procedure: 1. Ensure that the.06 copper sealing washer is located on the dipstick base. 2. Thread the clean dipstick into the unit until it seats. 3. Once the dipstick has seated, remove the dipstick from the unit. Fluid should register in the crosshatched area on the dipstick. 4. DO NOT OVERFILL!!! Drain excess fluid from the unit if it is above the maximum level on the dipstick. Check the fluid level using the dipstick at least every 2,500 miles. Initial supercharger fluid change must be performed at 2,500 miles. The supercharger fluid must be changed at least every 7,500 miles. Drain the fluid, refill the unit with 4 oz. of Vortech V3 lubricating fluid and then confirm proper oil level using the dipstick. DO NOT OVERFILL!!! WARNING: Use of any other fluid other than the special Vortech lubricant will void the warranty and may cause component failure. 23

30 ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands CA Phone: Fax: M-F 8:00AM - 4:30PM (PST) D - v2.0 10/20/08