NOTICE This supercharger mounting kit is sold with NO supercharger head unit and is intended for use with Vortech supercharger head units exclusively. DO NOT attempt to adapt any other manufacturer s supercharger onto this kit, for safety purposes. The Vortech head units that are compatible with this mounting kit are V1 Series, V2 Series and V7 (YSi trim only) series. If you need assistance with selecting the proper head unit please email us at techsupport@rtmods.com The installation of this kit requires some automotive mechanical experience; please review this instruction manual THOROUGHLY PRIOR to attempting any installation. After reviewing the manual you can determine if you should seek the assistance of an automotive professional/technician to do the installation. RELEASE OF LIABILITY R/Tmods.com and all of its providing vendors assume no financial responsibility to persons or property by the installation of this supercharger mounting kit. Mounting this kit is at your own risk!! R/Tmods.com assumes no liability for supercharger use on public roadways; is not deemed legal for use in that capacity, it is intended for race use only! Please observe all precautions when driving a supercharged vehicle, the power increases are drastic and the vehicle may tend to act violent driving under boosted conditions. SUPERCHARGER TUNING As previously mentioned there is no head unit included with this kit, it is a mounting kit only. There are also NO tuning aids included with this kit, tuning is the sole responsibility of the purchasing party. PLEASE DO NOT attempt to drive your truck without having a proper tuning system in place. R/Tmods.com accepts no responsibility for motor damage by using this mounting kit, purchaser understands that additional items are REQUIRED above and beyond the mounting kit to ensure safe & reliable vehicle operation. YOU WILL BLOW YOUR MOTOR UP IF YOU MOUNT A SUPERCHARGER TO THIS KIT AND DRIVE AWAY WITHOUT INTEGRATING A RELIABLE TUNING METHOD!!!!!! Some suggested tuning options: - FAST Standalone Systems - Megasquirt Standalone Systems - Accel DFI Standalone Systems - Big Stuff 3 Standalone Systems - SCT Flash (PCM remapping software) TOOLS & SUPPLIES NEEDED Factory Repair Manual 3/8" Drive and Socket Set: SAE and Metric 1/2" Drive and Socket Set: SAE and Metric 3/8" NPT Tap and Tap Handle Adjustable Wrench Open End Wrenches: 5/16", 3/8", 7/16", 1/2", 9/16" Center Punch and a 5/8" Tapered Punch 5 quarts SF Rated Quality Engine Oil, Oil Filter, and Wrench Flat #2 Screwdriver Phillips #2 Screwdriver Heavy Grease Silicone Sealer, Thread Sealant & Teflon Tape Oil Sender Socket, Snap-On #A120 NGK V-Power spark plugs (BKR6E) If you have more than 10K miles since your last plug change Spark Plug Socket - 1 -
PARTS LIST Item Assembly Assembly Pieces QTY. Mounting Bracket Intake Tube Discharge Tube Airhat Air Filter Belt Bypass Valve Oil Feed Oil Drain Supercharger Mounting Plate 1 Main Mounting Bracket (To Mount Plate) 1 3/8"-16 X 1" Hex Head Stainless Bolt 9 3/8"-16 X 3" Hex Head Stainless Cap Screw 1 3/8"-16 X 3 3/4" Hex Head Stainless Bolt 1 3/8" SAE Washers 6 3/8" AN 960 Flat Washers 5 Idler Pully Spacer 1 Idler Pully Dust Cover 1 Idler Pully (90mm or 3.5" X 1" wide) 1 M12 X 1.75 X 45mm Hex Head Stainless Bolt 1 M12 Stainless Washer 1 Intake Tube - OEM Vortech Cast Aluminum 3.5" J-Tube 1 3.5" Silicon Connector (Intake) 1 4" (3.78"-4.09") Stainless T-Clamp 1 Discharge Tube - OEM Vortech Cast Aluminum 2.75" to 3" 1 2.75" Silicon Connector (Discharge) 1 3" (2.90"-3.21") Stainless T-Clamp 2 3" Silicon Connector (Discharge) 1 3.5" (3.28"-3.59") Stainless T-Clamp 2 Aluminum 3" Outlet Airhat 1 3.5" Air Filter (Blue & Chrome) 1 113" Gatorback Serpentine Belt (AC) 1 OR 103.75" Gatorback Serpentine Belt (Non-AC) 1 Billet Bosch Style BOV 1 1" Silicon Connector (Bypass Valve Connector) 1 11/16"-1 1/4" Band Clamp 2 5/32 Vacuum Hose (Per Foot - 2 Feet) 2 Barbed 90 Plastic Tube Fitting 1 Brass Female Pipe x Male Pipe T (1/8" NPT) 1 45 1/8" NPT Male X -4AN Flare Male 2 90 1/4" Barb Male Pushlock X -4AN Flare Female 1 Straight Pushlock Swivel -4NA Female X 1/4" Hose Barb 1 1/4" Black Pushlock Hose (Per Foot) 3 3/8" NPT X 45 Street Elbow 1 3/8" NPT X 1/2" Straight Hose Barb 1 1/2" Black Pushlock Hose (Per Foot) 2 7/16"-29/32" Stainless Hose Clamp 1-2 -
SECTION A: PREPARATION Prior to install you will need to complete the following: 1.) Disconnect the negative battery terminal and make sure it is removed from the post and out of the way. 2.) Remove the stock accessory drive belt. 3.) Remove the belt tensioner assembly. Once that is off remove the backing nut from the tensioner and separate it from the black cupped mounting bracket. 4.) Remove the stock air box or any aftermarket cold air systems that are currently installed. 5.) Remove the stock ignition coil and bracket assembly (you will have to lengthen the wires and relocate wherever you wish for your desired aesthetic appearance of the motor compartment). If you already run an aftermarket coil in a different location, please disregard this step. 6.) Remove the plastic splash shield next to the radiator if your vehicle is equipped so as to aid the supercharger air filter assembly in getting the coolest air possible). SECTION B: OIL DRAIN Vortech Supercharger head units require an oil drain be installed into the oil pan. The best way to tap the pan is with a punch NOT a drill. This section will outline how to install oil drain fitting per Vortech recommendations. 1.) SECURE passenger side of vehicle on jackstands SAFETY FIRST DO NOT RELY ON A JACK!!!! 2.) Remove passenger side front wheel. 3.) Rotate engine until damper is aligned with TDC (top dead center) on the front of the engine. A helpful visual aid to make sure you are in the right spot is to remove the distributor cap and make sure it is between #5 and #7 electrodes refer to figure B-1 to see the orientation of the rotor. 4.) Using figure B-2 as a guide mark the correct location for the CENTER of the hole being put into the oil pan. Make sure to remove any paint/debris from around the hole location with a wire wheel on a drill or some sand paper. 5.) Use a small center punch to perforate the pan at location you marked in step 4. 6.) Use a bigger punch to open the hole to approximated 9/16 in diameter. TIP: Most punches are designed to slip over a socket in an extension to make this process easier WARNING: USE EXTREME CAUTION TO NOT HIT THE CRANKSHAFT IF YOU NEED ADDITIONAL CLEARANCE ROTATE THE MOTOR A TAD MORE TO GET ADEQUATE CRANKSHAFT CLEARANCE 7.) Once the hole is punched tap it with a 3/8 NPT tap approximately 1/4 deep. REMEMBER TO PACK THE FLUTES OF THE TAP WITH HEAVY GREASE TO CATCH THE METAL CHIPS/SHAVINGS. ALSO USE A MAGNET AROUND THE HOLE TO SNAG ANY STRAY CHIPS!!! 8.) Thoroughly clean the new threaded area of the oil pan & apply a coat of silicon sealer to the threads in the pan 9.) Take the supplied 45 o 3/8 NPT street elbow & apply silicon sealer to the threads. Put into the oil pan and aim towards the top/front of the vehicle at a 45 degree angle. Refer to figure B-3 to view orientation. Make sure a nice seal is visible around the whole fitting where it mates to the pan. 10.) Insert the supplied 3/8 NPT X 1/2" barb fitting into the street elbow. Use a small amount of pipe thread sealant on the fitting before inserting into the street elbow. 11.) Drain the engine oil thoroughly (let it drip for 10-15 minutes) & replace oil filter. 12.) The drain hose will be attached during the supercharger head unit installation if installation is going to take more than 1 day it is recommended that the fitting in the oil pan be covered to prevent dirt & unwanted debris from getting in there. 13.) Reinstall passenger front tire and torque to proper specifications remember to re-torque after a few miles of driving!!! - 3 -
SECTION B: OIL DRAIN (REFERENCE IMAGES) FIGURE B-1 FIGURE B-2 FIGURE B-3 SECTION C: MAIN BRACKET / SUPERCHARGER PLATE ASSEMBLY 1.) Now is a good time to relocate your ignition coil if you haven t done so already. Some fabrication might be necessary to come up with a bracket or alternate mounting location. This is not included in the kit because a good portion of the owners have already gone to aftermarket coils and relocated already; others are picky about the looks of the wiring, so we left this step up to the individual vehicle owner. 2.) You will need to add clearance between the dipstick tube and accessory drive belt. First remove the bolt that is holding the dipstick tube in place. Then hold the top of the tube and GENTLY bend it up under the alternator about 1. You can mock up the main supercharger bracket to see if you have given it enough clearance. Refasten the dipstick tube bolt. See figure C-2 for how the bent dipstick should look. TIP: Once you install the accessory drive belt you will need tweak the top of the dipstick tube as well to clear the path of the belt this will be later in the install process. 3.) Mount the billet aluminum main bracket to the passenger side head as shown in Figure C-3 on the next page. Use the provided stainless hardware for fastening. Make sure all bolts are snug! 4.) Take the supercharger mounting plate and slide the 3 3/4 stainless bolt through the plate, refer to Figure C-3 for bolt placement. 5.) Bolt the stock tensioner to the plate as seen in Figure C-1. Use the factory nut you removed earlier as the fastening hardware. MAKE SURE the indexing tab is engaged on the slot in the mounting plate!!! 6.) Mount the supercharger plate to the main bracket with the supplied stainless hardware. Refer to Figure C-3 for mounting diagram. Make sure to snug all bolts! FIGURE C-1 FIGURE C-2-4 -
FIGURE C-3-5 -
SECTION D: OIL FEED ASSEMBLY 1.) Locate the oil pressure sending unit on the back side of the engine block behind the intake manifold, it sits on the passenger side of the distributor. 2.) Undo the electrical connector on top of the sending unit. 3.) Remove the sending unit from the block. TIP: Snap on makes an oil pressure sending socket for Chrysler motors, it is part #A120 4.) Install the supplied T fitting into the block where the oil pressure sender was located. Use some Teflon tape or pipe thread sealant on the threads. Make sure to get it at least 5 turns into the block, it is time consuming to get it in there but better than a leaky fitting. See Figure D-1 for a diagram. 5.) Install the 45 1/8 NPT X -4AN fitting into the side of the T fitting. Again use Teflon tap or pipe thread sealant on the threads of the fitting before inserting it into the T. Make sure to get it snug into the T so it doesn t leak. See figure D-1 for diagram. 6.) Slide one end of the 1/4 push-lok hose onto the supplied 90-4AN swivel fitting. TIP: DO NOT use tape or sealant on the AN side of any of the fittings, they are flared to seal with no leaks!!! Using tape may cause the fitting to leak!!! 7.) Attach the swivel to the 45 fitting that you put in the T fitting. See figure D-2 for an installed view of the oil feed assembly. 8.) Reinstall the oil pressure sending unit into the top of the T fitting. Use tape or sealant on the threads of the pressure sender. BE SURE to reattach the electrical connector. 9.) Slide the other end of the 1/4 push-lok hose onto the supplied straight -4AN swivel fitting. 10.) Insert the other 45 fitting into the feed inlet of the supercharger head unit; angle it upwards in a 1-2 O clock position. This is where the other side of the 1/4 push-lok hose will attach once the supercharger head unit is install later in the process. See figure D-3 to view how it will hook up later in the install process. FIGURE D-1 FIGURE D-2 FIGURE D-3-6 -
SECTION E: SUPERCHARGER HEAD UNIT MOUNTING 1.) Attach 1/2 push-lok hose to the fitting on the bottom of the supercharger with the supplied hose clamp. TIP: Make sure the hose clamp is facing sideways with the bolt tucked in towards the supercharger. If the supercharger will not sit on the mounting plate correctly this clamp is most likely in the way and you do not have it on correctly. 2.) Set supercharger on the mounting plate. Attach with (5) 3/8-16 X 1 bolts & use the provided AN-960 washers on each bolt. 3.) Attach provided plastic idler pulley to the inner most supercharger mounting hole using the provided spacer, dust cover, M12 stainless bolt and M12 stainless washer. See figure E-1 for pulley mounting location. 4.) Now attach the oil feed line from Section D. Refer to figure D-3 for a view of the oil feed hook up to the supercharger. 5.) Now route the oil drain line down to the fitting install in the pan. It is a push-lok hose so just push it on there, no clamps needed. FIGURE E-1 SECTION F: DISCHARGE TUBE & AIRHAT ASSEMBLY 1.) Insert the plastic 90 fitting from the blow off valve assembly into the bottom of the supercharger discharge tube at this time. It is easier to do this before installing the discharge tube!! 2.) Attach the cast aluminum air hat to the throttle body with the outlet pointed towards the passenger side. See Figure F-1 for a completed pic of this section. TIP: If you haven t already, you should make an S-Bolt from 1/4"-20 rod and get a nut & washer. 3.) Using the supplied 2.75 silicon couplers on the supercharger side and the 3 silicon couplers on the air hat side. Attach the discharge using the supplied 3 T-Clamps (for the 2.75 connectors) & 3.5 T- Clamps (for the 3 connectors). See Figure F-1 for a completed pic of this section. BE SURE TO PUT THE CLAMPS OVER THE TUBE FIRST!! FIGURE F-1-7 -
SECTION G: BLOW OFF VALVE ASSEMBLY 1.) Slide the 1 X 2.5 silicon hose onto the plastic fitting under the discharge tube. Fasten with provided stainless hose clamp. See Figure G-1 for diagram. 2.) Slide the bottom of the billet blow off valve into the other end of the silicon hose. Fasten with provided stainless hose clamp. Refer again to figure G-1 for diagram. TIP: If the blowoff turns out to be too loud after you get the vehicle running, put a crankcase breather filter made by K&N onto the blowoff 3.) Attach the provided vacuum line to the nipple on the blow off valve. The other end of the line will need a vacuum source off the M-1 (most people run M-1 manifolds). If you do not run an M-1 or have no extra nipples on your intake manifold you will need to T one of the stock vacuum sources (parts not included for that procedure). FIGURE G-1 SECTION H: AIR INTAKE ASSEMBLY 1.) Attach the supercharger intake tube to the intake of the supercharger using the provided 3.5 silicon hose coupler and 4 T-Clamps (For 3.5 I.D. silicon tube). See Figure H-1 for completed view. 2.) Slide the air filter on to the other end of the intake tube and fasten with hose clamp provided in the air filter box. See Figure H-1 for completed view. FIGURE H-1-8 -
SECTION I: DRIVE BELT ASSEMBLY 1.) Now is the time to install your supercharger drive belt. Use the supplied Gatorback back belt (113 if you ordered AC kit and 103.75 if you ordered Non-AC kit). 2.) Route the belt per the diagram, Figure I-1. FIGURE I-1 SECTION J: FINAL PROCEDURES & CHECKS 1.) Re-install the negative battery terminal. 2.) Now is a good time to replace your spark plugs if yours have more than 10K miles on them. NGK V- Power BKR6E plugs work well in blown applications on these trucks. 3.) Make sure your REFILLED engine oil. 4.) Check all other fluids. 5.) Make sure all fittings, bolts, nuts, etc. are tightened down. 6.) Start engine and let it idle. 7.) Check for any leaks around all the oil fittings. 8.) Feel around all the silicon fittings and air hat to make sure you have no air leaks. 9.) Shut motor off and check to make sure all hoses and bolts are still tight. 10.) Make sure there are no obstructions (AC lines, dipstick tube, etc.) in the way of the drive belt. 11.) You are now ready to get the vehicle tuned. IF YOU DRIVE IT WITH NO TUNE YOU CAN DAMAGE THE MOTOR. IF YOU MUST DRIVE IT TO GET IT TUNED DO NOT GO OVER 3K RPMS AND USE A GENTLE FOOT AT ALL TIMES!!!!!!!!!!!!! WE RECOMMEND FLAT BEDDING IT TO THE TUNER!!!!! WARRANTY This supercharger mounting kit is warrantied for parts and craftsman ship for 60 days after date of purchase. Please keep your original paypal receipt for any warranty issues that may arise during the given warranty period. If you have a warranty related issue please contact our technical support department via email at techsupport@rtmods.com - 9 -