5.2/5.9 Durang L Dodge o Superc /Dakota/R har ger am Syst Install at 1996-1 ion Instructio 999 ns 49 State Model Year s Smog L e em gal* *Legal in California only for ra cing veh icles whic h may ne ver be u sed upon a highwa y. ® ENGINEERING, INC. 1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 P/N: 4CE020-010 © 2000 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 18AUG00 V 2.1 (Dodge 5.
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 possible installers in your area. © 2000 VORTECH ENGINEERING, INC. All rights reserved.
Table Of Contents FOREWORD ........................................................................................................................... i TABLE OF CONTENTS .......................................................................................................... ii NOTICE................................................................................................................................... iii SPECIAL NOTICE-CRANE IGNITION SYSTEM ....................................................
NOTICE 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, Inc.
SPECIAL NOTICE CONCERNING THE CRANE IGNITION SYSTEM The ignition system, manufactured by Crane Electronics, included in this kit is serviced exclusively by the manufacturer. Crane Electronics warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warranty.
1996-1999 5.2/5.9L Dodge Durango, Dakota and Ram Installation Instructions for Part No. 4CE218-010SQ/018SQ/020SQ/028SQ, 4CD218-040SQ/048SQ/050SQ/058SQ 49 State Smog Legal Congratulations on selecting the best performing and best backed automotive supercharger available today...
1997-1999 5.9L Dodge Durango/Dakota Part No. 4CE218-010SQ/018SQ ® PARTS LIST ENGINEERING, INC. IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-140 2E128-140 2A037-312 4FA016-150 7J012-092 7U100-070 2A040-011 7B375-110 7K375-040 SUPERCHARGER ASSEMBLY V-2 SQ Supercharger Supercharger pulley, 3.
1997-1999 5.2L Dodge Durango/Dakota Part No. 4CE218-020SQ/028SQ ® PARTS LIST ENGINEERING, INC. IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-140 2E128-140 2A037-312 4FA016-150 7J012-092 7U100-070 2A040-011 7B375-110 7K375-040 SUPERCHARGER ASSEMBLY V-2 SQ Supercharger Supercharger pulley, 3.
1996 5.2L Dodge Dakota, 1996-1999 5.2 Dodge Ram Part No. 4CD218-040SQ/048SQ ® PARTS LIST ENGINEERING, INC. IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-140 2E128-140 2A037-312 4FA016-150 7J012-092 7U100-070 2A040-011 7B375-110 7K375-040 SUPERCHARGER ASSEMBLY V-2 SQ Supercharger Supercharger pulley, 3.
1996 5.9L Dodge Dakota, 1996-1999 5.9L Dodge Ram Part No. 4CD218-050SQ/058SQ ® PARTS LIST ENGINEERING, INC. IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-140 2E128-140 2A037-312 4FA016-150 7J012-092 7U100-070 2A040-011 7B375-110 7K375-040 SUPERCHARGER ASSEMBLY V-2 SQ Supercharger 3.
1. PREPARATION/REMOVAL A. Disconnect the negative side of the battery. B. Remove the accessory drive belt. C. Remove the belt tensioner assembly, separate it from the mounting bracket and set aside. Remove tensioner mounting bracket. D. Disconnect and remove the crankcase breather hose. E. Remove the entire air filter/inlet assembly. F. Remove the ignition coil and bracket. Set aside. G. Remove the front plastic splash shield, if equipped. 2. OIL DRAIN A.
2. OIL DRAIN, cont'd. G. Thoroughly clean the threaded area. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the male threads of the 3/8" NPT x 45° street elbow and secure in the hole. Position the fitting so that it points up toward the top/front of the vehicle at approximately a 45° angle (see Figure 2-c). Make sure a seal is formed all around the fitting. Thread the 3/8" NPT x 1/2" barb fitting into the 45° street elbow using a small amount of pipe sealer. H.
4. MAIN MOUNTING BRACKET AND PLATE A. It is necessary to provide clearance between the dipstick and accessory drive belt. Remove the bolt holding the dipstick tube. Hold the tube approximately two inches from the top and gently bend rearward and inward about one inch. Resecure with the existing fastener after the bracket installation. B. Mount the cast aluminum main mounting bracket onto the front of the engine right cylinder head using the fasteners provided, as shown in the graphic on the next page.
4. MAIN MOUNTING BRACKET AND PLATE, cont'd. 1997-99 Dakota/Durango GROUND TO ALTERNATOR MOUNTING BOLT NOTE: Slight bending of the factory 3/8" aluminum air conditioning line (running to the firewall) is required before mounting plate can be installed (see photo below). MAIN MAIN HARNESS E. Secure the plate and tensioner as an assembly to the cast bracket. (See Figure 4-c.) F. Remove the right side exhaust manifold heat shield. Remove the second bolt (from the front) mounting the manifold to the head.
5. OIL FEED LINE A. Disconnect and remove the oil pressure sender from the engine. The sender is found at the rear of the intake manifold to the right side of the distributor. B. Install the supplied nipple and tee fitting into the block and place the sending unit in the upper end. Install the 45° fitting in the side port and orient the assembly so that it points forward and slightly outward towards the passenger's side (see Figure 5-a). Reconnect the pressure sender connector.
7. SUPERCHARGER MOUNTING A. Attach the oil drain hose to the drain fitting on the bottom of the supercharger and secure with the clamp provided. Make sure to position the clamp housing to the side so that it does not interfere with the mounting plate. B. Set the supercharger in place on the plate and secure with the five 3/8-16 x 1" bolts and washers. NOTE: The forward A/C line requires slight bending for supercharger pulley clearance. ➔ Figure: 7-a - Idler Pulley C.
9A. IGNITION/BOOST CONTROL INSTALLATION (1997-99 Dakota/Durango only) A. Remove the four phillips head screws attaching the plastic tray (located beneath the tilt-up console cover) to the armrest/console located between the two front seats. Remove the six console mounting screws with an 8mm socket and lift the center console out of the vehicle (four screws are located underneath the two cup holder mats in the armrest/console).
9A. IGNITION/BOOST CONTROL INSTALLATION, cont'd. (1997-99 Dakota/ Durango only) H. Refering to Figure 9A-c, drill a #25 hole through the floor. Remove all paint from around the hole, ensuring a good electrical connection. Attach a 12 GA eyelet terminal to the supplied 2' black 12 GA wire. Secure this wire to the previously drilled hole on the vehicle's floor using #12 hardware. I.
9B. IGNITION/BOOST CONTROL INSTALLATION (1996 Dakota/1996-1999 Ram only) A. Mount the ignition box in the engine compartment onto the flat area between the fuse box and driver's side firewall. Secure the ignition box with the four #8 sheet metal screws supplied (see Figure 9B-a). Mount the map sensor next to the ignition box. B. Route the heavy black cable to a clean ground. Route the heavy red cable to the (+) positive terminal located on the front side of the underhood fuse box. C.
9B. IGNITION/BOOST CONTROL INSTALLATION, cont'd. Figure: 9B-c P/N: 4CE020-010 © 2000 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 18AUG00 V 2.1 (Dodge 5.
10. IGNITION/BOOST CONTROL UNIT OPERATION Example 5 psi at 3° per lb. DEGREES OF RETARD A. The Ignition/Boost Control unit is designed to retard ignition in relation to boost. B. The unit is adjustable from 0° of ignition retard to 4°of ignition retard for each pound of boost, up to a maximum of 20° C. Using the middle position (knob pointing straight up) as a starting place, adjust the ignition retard knob until just beyond the point of detonation. Use third gear for testing in a safe area or road.
11B. SUPERCHARGER AIR INLET DUCT (1996 Dakota/1997-99 Ram only) A. Slide the supplied 3-1/2" silicone sleeve and two #56 clamps onto the supercharger inlet. Insert the short leg of the supplied aluminum air inlet duct into the silicone sleeve. B. Attach the supplied 5/8" hose to the barb on the air inlet duct and route over to the left side valve cover breather location. Attach the 5/8" hose to the breather fitting and secure with the supplied #8 clamp (trim hose length if necessary). C.
12. PLENUM AND DISCHARGE INSTALLATION, cont'd. H. Attach the bypass valve to the discharge and inlet (see Figure 12-a). I. Secure discharge and bypass assemblies. DISCHARGE TUBE 2-1/2" x 1" HOSE Figure: 12-d INLET DUCT 3-1/2" x 1" HOSE VACUUM HOSE Figure: 12-a Figure: 12-e 13A. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED SYSTEM (1997-99 Dakota/Durango only) A.
13A. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED SYSTEM (1997-99 Dakota/Durango only), cont'd. D. Thread the supplied plug with an O-ring into the front of the fuel rail. Thread the 1/4" NPTF O-ring adapter fitting into the rear of the fuel rail. Use light oil on the O-rings. Do not overtighten fittings. Thread the 1/4" NPT x 90° fitting into the installed adapter fitting at the rear of the fuel rail (use a small amount of Teflon paste on the pipe threads only.
13B. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED SYSTEM (1996 Dakota/1996-99 Ram only) A. Using the four supplied #8 x 1/2" screws, attach the fuel rail mounting tabs to the supplementary fuel rail in the orientation shown (see Figure 13B-a). Use thread locking compound on the bolt threads for safety. B. Lightly oil the O-rings on both ends of the supplied fuel injectors.
13B. SUPPLEMENTARY FUEL INJECTION COMPUTER (SFIC) AND RELATED SYSTEM, cont'd. (1996 Dakota/1996-99 Ram only) H. From the engine compartment, remove (pull out) the grommet in the firewall that surrounds the transmission gear select cable. Use a razor blade to carefully slit the grommet and temporarily remove it from the cable. I. Cut the center of the grommet out to make room for the vacuum line and harness that must attach to the Vortech SFIC which will be located under the dash (see Figure 13B-d). J.
WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check. 14. FINAL CHECK A. Reconnect the battery. B. If your vehicle has gone over 10,000 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.
® ENGINEERING, INC. 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 18 P/N: 4CE020-010 © 2000 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 18AUG00 V 2.1 (Dodge 5.
