User's Manual

P/N: 4HS020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
27JUL04 v2.0 S2000 (4HSv2.0)
battery. Following Fig. 12-g, route the wire up
along the factory wires.
L. Remove the factory heater motor relay located in
the underhood fusebox and modify to accept the
electrical power tap as shown in
Fig. 12-h . Re-
install the relay with the power tap. Connect the
yellow wire to the power tap.
M. Attach the black wire from the supplied relay to a
suitable ground.
N. Route the red wire from terminal #87 on the
supplied relay down to the water pump. Install a
female insulated slide connector onto the wire
and connect to the blue/green (positive) wire on
the water pump.
O. Cut the supplied fuse holder wire and install the
12 GA ring terminal on one end and the 12 GA.
solderless connector onto the other. Connect the
#30 wire on the supplied relay to the solderless
connector attached to the fuse holder. Connect
the ring terminal to the positive side of the battery
and install the provided fuse.
P. Cut approximately 40" off of the supplied length
of Ø3/4" hose. Install one end onto the water
pump discharge and the other onto the 90° fitting
on the water cooler, routing it forward toward the
front facia. (See
Fig. 12-i .) Be sure there are no
kinks or sharp bends in the hose. Secure both
ends with the provided clamps.
Use a tape measure to correctly check the proper
length and hose routing between each hose con-
nection prior to actually cutting the hose.
Q. Temporarily install the water tank mounting
bracket onto the water reservoir using the 1/4"
hardware (see
Fig. 12-j ). Mock the water reser-
voir up as shown and mark the location on the
vehicles frame (passenger side, outer frame rail)
where the #10 self-tapping screws are to be
located. Remove the 1/4" hardware attaching the
bracket to the reservoir. Secure the bracket to
the vehicle using the self-tapping screws. (See
Fig. 12-k .)
R. Install the two remaining 90° brass fittings into
the water reservoir using a small amount of
thread sealant. Attach one end of the remaining
Ø 3/4" hose to the top of the water reservoir and
secure with a clamp.
S. Permanently attach the water reservoir to the
mounting bracket using the 1/4" hardware.
T. Route the upper reservoir hose into the engine
compartment (
Figs. 12-j, 12-l ) under the radiator
fan and then up between the radiator fan and the
condenser fan finally connecting it to the passen-
ger side fitting on the charge air cooler. Secure
the hose with one of the provided clamps.
U. Measure between the bottom of the reservoir
water outlet and the pump inlet and cut an
appropriate section of hose and set aside.
12. CHARGE AIR COOLER INSTALLATION, cont’d.
Fig. 12-e
Fig. 12-f
UPPER WATER
COOLER BRACKET
Fig. 12-g
28
WATER PUMP
OUTLET HOSE
UPPER WATER COOLER BRACKET
Fig. 12h
MODIFY HERE