Instruction manual

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4GR020-010 v1.7 — 11/25/09

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

CHEVROLET

CORVETTE

Supercharger System

Installation Instructions

1997-2003 Model Years

50 State Smog Legal per CARB EO #D-213-19

2004 Model Year*

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

Summary of content (40 pages)

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CHEV R CORV OLET E TTE Supe rch Insta a llatio rger Syst n Ins em 1997 t 50 Sta r uctio -20 te Sm ns og Le 03 Model gal pe Years 2004 M r CARB EO #D odel Y -213-1 ear* 9 *Legal in Cali fornia only for rac ing veh icles w hich m ay never be use d upon a high way. ® ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226 Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST) 4GR020-010 v1.
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FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area. © 2004 VORTECH ENGINEERING, LLC All rights recerved.
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TABLE OF CONTENTS FOREWORD �� ii TABLE OF CONTENTS �� iii IMPORTANT NOTES �� iv TOOL & SUPPLY REQUIREMENTS ��
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GM Chevrolet Corvette IMPORTANT NOTES This kit requires ECM programming. The hand-held ECM programmer is not included in the kit box and must be ordered directly from Vortech by the installing customer (the charge for this unit has been included in the purchase price). Included in this kit is a credit tag for one hand-held programmer. The programmers are made specifically for each individual vehicle with respect to the factory ECM calibration and VIN.
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CHEVROLET CORVETTE Installation Instructions 1997-2004 Congratulations on selecting the best performing and best supported 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 and Automotive Limited Warranties Program. Vortech supercharger systems are performance improving devices.
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2001-2004 Corvette LS6 Z06 Part No. 4GR218-010SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. Description 2E229-020 V2SQ ASSY, C5 SATIN 4GR033-034 S/C PULLEY, 34-TOOTH, C5 2A042-080 BELT, GATES 640-8MGT-20 4GR111-021 MTG BRKT ASSEMBLY 4GR011-021 MTG BRKT,S/C,C5 MACH 7C010-025 M10-1.5" x 25mm HXCSP 7C010-035 M10-1.
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2001-2004 Corvette LS6 Z06 Part No. 4GR218-010SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: Part No. Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Description 8N301-150 POWER COOLER ASSY, C5 CORVETTE 8N201-150 DISCHARGE ASSY, C5 CORVETTE 8N101-150 AFTERCOOLER ASSY, C5 CORVETTE 4GL012-030 ELBOW, 3.88" - 3.
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1997-1998 Corvette LS1 C5 Part No. 4GR218-030SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. Description 2E229-040 V2SQ ASSY, C5 SATIN 4GR033-030 S/C PULLEY, 30-TOOTH, C5 2A042-080 BELT, GATES 640-8MGT-20 4GR111-021 MTG BRKT ASSEMBLY 4GR011-021 MTG BRKT,S/C,C5 MACH 7C010-025 M10-1.5" x 25mm HXCSP 7C010-035 M10-1.
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1999-2000 Corvette LS1 C5 Part No. 4GR218-040SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: Part No. Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Description 2E229-040 V2SQ ASSY, C5 SATIN 4GR033-030 S/C PULLEY, 30 TOOTH, C5 2A042-080 BELT, GATES 640-8MGT-20 4GR111-021 MTG BRKT ASSEMBLY 4GR011-021 MTG BRKT, S/C, C5 MACH 7C010-025 M10-1.5" x 25mm HXCSP 7C010-035 M10-1.
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2001-2004 Corvette LS1 C5 Part No. 4GR218-020SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. Description 2E229-020 V2SQ ASSY, C5 SATIN 4GR033-032 S/C PULLEY, 32-TOOTH, C5 2A042-080 BELT, GATES 640-8MGT-20 4GR111-021 MTG BRKT ASSEMBLY 4GR011-021 MTG BRKT, S/C, C5 MACH 7C010-025 M10-1.5" x 25mm HXCS P 7C010-035 M10-1.
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1997-2004 C5 Corvette Tuner Base Kit Part No. 3GR218-010 PARTS LIST ® ENGINEERING, LLC IMPORTANT: Part No. Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Description 3GR111-021 MTG BRKT ASSEMBLY 4GR011-021 MTG BRKT, S/C, C5 MACH 7C010-025 M10-1.5" x 25mm HXCS P 7C010-035 M10-1.
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1. PREPARATION/REMOVAL A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Disconnect the negative cable at the battery. Remove all ducting between air filter cover and throttle body. Remove the air temperature sensor (if equipped) and grommet from factory air inlet duct and set aside. Remove both of the coil/fuel rail covers (plastic) on top of the engine and set aside. Remove the valve cover breather hose from the passenger side of the throttle body and set aside temporarily.
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2. HARMONIC DAMPER DOWEL PIN INSTALLATION NOTE: A. B. C. D. E. F. G. H. The purpose of this section is to provide access to the harmonic damper bolt area so that the crankshaft can be pinned to the damper to prevent the damper from spinning on the crank shaft. The following steps will work on all or most applications.
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2. HARMONIC DAMPER DOWEL PIN INSTALLATION, cont’d. NOTE: L. M. N. O. P. 3. If it is necesary to rotate the engine to install the remaining dowel pins, tap the installed dowel pin flush with the surface, remove the socket head screw, remove the flywheel holding tool (if installed), install the old damper retaining screw and rotate the damper to the desired position. Remove the socket-head cap screw and drill guide.
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F. G. H. I. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8" NPT nipple, elbow and hose barb and secure in hole. Make sure seal is formed all around the fitting. Install elbow and barb fitting pointing up and towards the driver side frame rail. (See Fig. 3-b.) Temporarily cover oil drain barb fitting to keep out debris. Drain the engine oil, install a new filter and refill with fresh oil. Re-attach the steering rack and ball joints.
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5. SURGE TANK RELOCATION The factory surge tank will be spaced up about 3/4" in order to clear the new alternator mounting location cap on some vehicles - this may cause hood misalignment. If hood alignment is unacceptable, the surge tank may have to be lowered and clearance to the alternator re-checked. A. B. C. D. E. F. G. Attach the supplied small metal tab onto the bottom of the engine coolant surge tank using the supplied M6 bolt, nut and washers as shown in Fig. 5-a.
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6. AUTOMATIC TRANSMISSION COOLING LINE MODIFICATION (Vehicles equipped with Automatic Transmissions only) A. B. C1. C2. Disconnect the upper automatic transmission cooler line from the top passenger side of the radiator. Cut the hard line off of the radiator side of the transmission line. Leave the amount of hose attached to the transmission line as long as possible. 1997-2000 M.Y. Vehicles: Install the supplied tube so that it points downward.
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7. ALTERNATOR RELOCATION, cont’d. E. F. G. H. I. J. tor off of the alternator power wire and use the supplied wire, butt connector and ring terminal connector to extend the factory power wire. Use the supplied heat shrink tubing to protect each connection after crimping. Route the extended wires across the front of the engine (underneath and behind the throttle body) to the new alternator location.
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7. ALTERNATOR RELOCATION, cont’d K. L. dust shield onto the spring tensioner using the supplied 25mm screw with a washer. Install the spring tensioner onto the alternator plate in the position shown in fig. 7-g. Tighten all of the screws. Verify that the spring tensioner does not hit the water pump when rotated down. If contact occurs, remove the tensioner and sand additional material off of the back of it until there is minimal clearance. MODIFIED AREA Fig. 7-f Fig. 7-g P/N: 4GR020-010 v1.
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8. SUPERCHARGER MOUNTING BRACKET INSTALLATION NOTE: A. B. C. D. E. The mounting bracket and power steering pump can be installed in the manner in which the stock mounting bracket was removed. The following steps apply to a 2002 ZO6, which has the ABS module directly in front of the power steering pump. For vehicles with the ABS module mounted elsewhere, it may be easier to leave the power steering pump connected to the power steering hose but loose until after the mounting bracket is installed.
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8. SUPERCHARGER MOUNTING BRACKET INSTALLATION, cont’d. I. J. K. L. M. N. hub of the power steering pulley is flush with the end of the power steering pump input shaft. Install the supplied flanged plastic idler with dust cover onto the lower idler pilot. Install the factory idler (without rear dust cover) from the stock mounting bracket onto the upper idler pilot. Tighten both idlers using the supplied M10 x 25 mm screws. With the supplied 6-rib belt encircling it as shown in Fig.
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9. ABS MODULE RELOCATION (1999-2000 Model vehicles only, all others proceed with step 10.) NOTE: A. B. C. D. E. The following steps reposition the ABS module upside down so that there will be room for the supercharger. It is very important to spend as much time as necessary to ensure that the brake lines are sound (not kinked or bent repeatedly), routed away from moving parts, and protected from abrasion wherever they touch non-moving parts or each other.
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10. RADIATOR HOSE MODIFICATION A. The object of this section is to route the radiator hose as close to the radiator as possible to provide room for the supercharger components. Trim the supplied hose so that it turns down as quickly as possible when connected to the radiator with factory clamp. Install the new hose onto the radiator. (See Fig 10-a.) Cut the original radiator hose and the newly installed radiator hose so that they will connect with the supplied 1-3/8" hose mender.
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11. C. D. E. F. POWER STEERING RESERVOIR INSTALLATION, cont’d. Use factory clamps on each end of the hose mender and supplied clamps on pump (already completed) and reservoir. Use the supplied 3/8" hose mender, hose, and #6 clamps to lengthen the reservoir return line (from the power steering cooler). Route the lengthened hose against the fan shroud and along the driver’s side frame rail to the power steering reservoir. Attach the hose to the reservoir.
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13. A. CHARGE AIR COOLER INSTALLATION Reservoir and water pump assembly and installation 1. Attach the water pump to the water reservoir using the supplied adel clamp and screw in the position shown in Fig. 13-a. 2. Cut off the electrical plug on the water pump leaving as much wire connected to the pump as possible. Install the supplied 1/4" eyelet on the water pump ground wire (brown wire). Install a male slide connector onto the water pump positive wire (green wire). 3.
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13. B. C. CHARGE AIR COOLER INSTALLATION, cont’d 12. Connect the supplied long red wire to the water pump power wire using a female slide connector. Route the water pump power wire up to and across the cowl below the windshield and secure using zip ties Water pump wiring 1. Drill out the relay mounting hole to 1/4" and mount the supplied relay using the forward most screw on the passenger side hood latch. (See Fig 13-d.) 2. Connect the water pump power wire up to the relay terminal #87. 3.
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13. D. E. CHARGE AIR COOLER INSTALLATION, cont’d Charge air cooler radiator install 1. Install the supplied cooler radiator, with no fittings installed, in the radiator opening (just behind the spring base pins). Position so that it is roughly perpendicular to the adjacent panels. (See Figs. 13-i, 13-j.) 2. Mark the position of the radiator water inlet and outlet ports onto the upper plastic panel. Also mark the location of one of the 1/4" slots on each side of the cooler radiator onto the lower air dam.
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13. CHARGE AIR COOLER INSTALLATION, cont’d 4. Temporarily disconnect the small radiator bleed hose from the radiator. (See Fig 13-l.) Loosen the nut securing the factory harness plug to the front passenger’s side frame rail. Rotate the plug toward the outside of the vehicle for cooler clearance. Tighten the nut. (See Fig. 13-m.) Note: 5. 6. 7. 8. 9. If there is insufficient space for the CAC (all automatic cars with clutched alternator pulleys), trim the upper edge of the radiator fan shroud.
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14. A. SUPERCHARGER INSTALLATION Install the supplied T-bolt clamp onto the aluminum supercharger inlet duct oriented so as to be accessible after the supercharger is installed. Slide the inlet duct onto the supercharger so that the cast contour lines up with the discharge section of the volute. (See Fig. 14-a.) Note: B. C. D. E. Install the 1/8 NPT x -4 x 90° fitting into the supercharger oil feed nozzle. (See Fig. 14-b.
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14. I. J. K. SUPERCHARGER INSTALLATION, cont’d. manifold) with the supplied tie wraps. Route the toothed belt around the supercharger pulley. Install the supplied 3/8-16 x 3.25" idler bolt through two washers, the flanged aluminum idler and the idler spacer and into the slot in the top of the supercharger mounting bracket. (The bearing retainer snap ring on the idler must be pointing toward the idler spacer.
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15. A. B. C. D. E. SUPERCHARGER BYPASS VALVE INSTALLATION Connect the supplied 3-1/2" length of Ø1" hose from the barb on the supercharger discharge duct to the inlet of the bypass valve. (See Fig. 14-a.) Attach the short leg of the molded 1" x 90° hose to the bypass valve discharge and point it up to where it will attach to the plastic air inlet duct. Tighten the hose clamps on each connection. Cut brake booster vacuum hose as shown (see Fig. 14-b) and insert the supplied plastic Tee fitting.
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16. A. B. INLET DUCT INSTALLATION Install the supplied grommet and 3/8" elbow in inlet duct hole (if not already completed). If the vehicle is equipped with a separate air temperature sensor, drill an 11/16" hole in the plastic inlet duct and install the air temperature sensor and grommet in the hole. (See Fig. 16-a.) Note: C. D. E. F. G. The air temperature sensor should be installed up stream of the valve cover breather.
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17. A. B. C. D. E. F. G. H. FUEL PUMP VOLTAGE BOOSTER INSTALLATION (Tuner or H.O. kits only - All others Proceed to Step 18) Note: Fuel pump or voltage booster components are not included in the Vortech systems. These are accessories that can be purchased separately. Note: The purpose of the voltage booster is to raise the voltage to the factory fuel pump when the vehicle is in boost. This will raise the fuel flow in order to maintain fuel pressure on high horsepower applications.
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18. REFLASH COMPUTER For 1999-2003 Chevrolet Corvettes - ( Those with 1997-1998 models — skip to “MICRO TUNER 2001 VEHICLE PROGRAMMING INSTRUCTIONS”. ) A. GM requires that a tool be installed into a wiring connector beneath the passenger’s side floor floor kick panel during ANY PROGRAMMING PROCESS (this includes performance programming and programming back to stock). B. Once visible, you will notice there are two identical connectors to the immediate left.
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18. REFLASH COMPUTER, cont’d. i. The 2241 is keyed, like the two caps you removed. ii. Make sure the 2241 is inserted straight & aligned with the key. c. Leave the top connector open (i.e. with the make cap removed) 5. Follow the normal procedure for programming (see “Microtuner 2001 Vehicle Programming Instructions” on the following page). 6. When complete, remove the Micro Tuner and shut the ignition off. 7.
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18. REFLASH COMPUTER, cont’d. IMPORTANT! To ensure trouble-free programming of your vehicle's computer: • Make sure the vehicle's battery is sufficiently charged. • Turn off all accessories and close doors to prevent unnecessary drain on the battery. • Do not attempt to program your vehicle while a battery charger is connected. • Improper battery voltage will result in failure of the programming process. • Do not disconnect the cable or turn off the ignition during programming. C. D. E. F. G. H. I.
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19. A. B. C. D. E. F. G. H. I. FINAL ASSEMBLY AND CHECK If your vehicle has gone over 20,000 miles since its last spark plug change, it is a good idea to change the spark plugs now, before test-driving. Make sure that oil drain to oil pan fitting is tight and that the engine is filled with factory specified oil. Make sure radiator and overflow tank are filled with 50/50 coolant/water mix. Make sure that the vehicle is filled with 91 octane or higher fuel before commencing test drive.
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19. N. O. P. FINAL ASSEMBLY AND CHECK, cont’d. Test drive vehicle by gradually working up to full throttle and paying close attention to any abnormal sounds or engine detonation. Install both of the engine covers by trimming the passenger side to clear the alternator and the driver side to clear the idler if necessary.
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® ENGINEERING, LLC 1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226 FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST 4GR020-010 v1.