GM FB Supe o d r c harge y LT1 Insta r Sys llatio t n Ins truct em ions 50 St ate S 1993-199 mog Lega 7 Model Y l per e CARB ars EO #D-21 3-17 ® 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 P/N: 4GH020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 05NOV01 v1.2(4GH V1.
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. © 2001 VORTECH ENGINEERING, LLC All rights reserved.
Table Of Contents FOREW0RD ............................................................................................................ i TABLE OF CONTENTS .......................................................................................... ii IMPORTANT NOTICES ........................................................................................... iii 1993 GM LT1 F-BODY SUPPLEMENT ................................................................... iv 1994-95 GM LT1 F-BODY SUPPLEMENT...............
GM F-BODY LT1 IMPORTANT NOTICES 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.
1993 GM LT1 F-BODY SUPPLEMENT HARDWIRING INSTRUCTIONS FOR KITS NOT EQUIPPED WITH A GM WIRING HARNESS 1. Unplug the grey and black connectors from the coil. Cut the connectors off from the main harness approximately 2" from the end. 2. Attach the supplied male and female connectors to lengthen the white and pink wires previously cut from the coil connectors. Connect the two pink wires together to one red wire and the two white wires to the supplied single white wire.
1994-95 GM LT1 F-BODY SUPPLEMENT HARDWIRING INSTRUCTIONS FOR KITS NOT EQUIPPED WITH A GM WIRING HARNESS 1. Unplug the grey and black connectors from the coil. Cut the connectors off from the main harness approximately 2" from the end. 2. Attach the supplied male and female connectors to lengthen the white and pink wires previously cut from the coil connectors. Connect the two pink wires together to one red wire. Attach the pink and white wires to the red and white wires on the supplied ignition box. 3.
1996-97 GM LT1 F-BODY SUPPLEMENT HARDWIRING INSTRUCTIONS FOR KITS NOT EQUIPPED WITH A GM WIRING HARNESS 1. Unplug the two-wire harness from the coil. Cut the connectors off from the main harness approximately 2" from the end. 2. Attach the supplied male and female connectors to the green and pink wires previously cut from the coil connector. Connect the pink wire to the red wire and the green wire to the white wire coming from the supplied ignition box. 3. Reattach the grey connector to the coil.
SPECIAL NOTICE CONCERNING THE Carroll Supercharging MAF Signal Massager 1996-97 LT1 F-Bodies may require the Carroll Supercharging MAF Signal Massager to prevent OBD-II trouble codes from being set. This part is available separately at an additional cost under P/N 4GM020-030 direct from Vortech Engineering, Inc. The MAF Signal Massager, manufactured by Carroll Supercharging Co., Inc., is serviced exclusively by the manufacturer. Carroll Supercharging Co., 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.
1993 - 1997 GM LT1 F-Body Installation Instructions 50 State Smog Legal per CARB EO #D-213-16 Congratulations on selecting the best performing and best supported automotive supercharger available today... the VORTECH® V-2® Supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty Registration form.
1993 GM LT1 F-Body Part No. 4GH218-050SQ ® 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 Number Description Quantity Part Number Description Quantity 2E228-120 2E128-120 4GH038-333 8R101-002 SUPERCHARGER ASSEMBLY V-2 SQ Supercharger 3.
1994-1997 GM LT1 F-Body Part No. 4GH218-060SQ ® 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 Number Description Quantity Part Number Description Quantity 2E228-120 2E128-120 4GH038-333 8R101-002 SUPERCHARGER ASSEMBLY V-2 SQ supercharger 3.
1. PREPARATION/REMOVAL A. Disconnect the negative cable at the battery. B. Jack up the front of the vehicle and secure with jack stands or use a lift. C. Crank the engine over just until the arrow on the crankshaft pulley points in the 6 o'clock position (straight down). D. Disconnect and set aside the anti-roll bar. E. Drain the radiator completely by removing the radiator cap and opening the petcock on the lower passenger's side. Catch the coolant in a clean container to reuse or dispose of properly. F.
2. OIL COOLER LINE MODIFICATIONS NOTE: On vehicles not equipped with external oil cooler lines, skip the steps below and move onto steps 2-H, 2-J and 2-K. A. Remove the engine oil filter. B. With both coolant lines disconnected from the radiator and water pump, remove the clamp securing the cooler line assembly to the oil pan. Spreading the clamp slightly may be necessary. C. Remove the bolt securing the oil cooler line assembly to the oil filter base.
2. OIL COOLER LINE MODIFICATIONS, cont'd. I. Install the 5/8" x 20" long heater hose onto the upper oil cooler line fitting. Slide the supplied 12" long heat sleeve over the heater hose to protect it from exhaust heat. Route the hose up and around to the 90° fitting on the water pump. (The hose will run near the exhaust manifold.) Secure both ends of the hose with clamps provided. (See Figure 2-e.) J.
3. CRUISE CONTROL RELOCATION Fig. 3-a ➔ A. Using the template on page 5, mark the splash guard located in the front lower left side of the vehicle. B. Remove the splash guard and cut out the marked area for air inlet tube clearance. (See Figure 3-a.) C. Locate the cruise control box below the driver's side front frame rail, and remove by disconnecting the electrical connection and fasteners. D.
TEMPLATE SPLASH GUARD 1993-1997 LT1 F-BODY UP FRONT OF VEHICLE CUT OUT CUT OUT TEMPLATE AND PLACE ON SPLASH GUARD AS A GUIDE ® ® ENGINEERING,LLC INC. ENGINEERING, © VORTECH ENGINEERING 1997 ALL RIGHTS RESERVED 5 P/N: 4GH020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 05NOV01 v1.
4.1 AIR PUMP MODIFICATION AND RELOCATION (1993 MODELS) HOSE REMOVED A. Unplug the wiring assembly, clamps and FROM ORIGINAL hoses from the air pump. AIR PUMP INLET B. Remove the unit from the mount by removing the mounting nuts. Remove the pump mount and spark plug wire hold-down from the vehicle. C. Remove the 90° rubber elbow from the ROTATE 5/8" x 23" check valve and TEE on the driver's side TEE 180° HOSE exhaust manifold. Rotate the TEE 180°.
4.2 AIR PUMP MODIFICATION AND RELOCATION (1994-97 MODELS) A. Unplug the wiring assembly, clamps and hoses from the air pump. B. Remove the unit from the mount by removing the mounting nuts. Remove the pump mount and spark plug wire hold-down from the vehicle. C. Using a tubing cutter or hacksaw, cut the 5/ 8" steel air line that runs from the passenger's side exhaust manifold to the driver's side exhaust manifold. Make the cut in the area shown in Figures 4-c, 4-d (approximately 2" off of the crank). D.
4.2 AIR PUMP MODIFICATION AND RELOCATION (1994-97 MODELS) cont'd. H. Place the air pump relocation bracket near the driver's side inner fender panel (former air filter assembly location). Position the pump bracket so that the pump discharge and inlet tubes face the engine. Mark and drill holes and mount the bracket using the #12 x 1" sheet metal screws provided. (See Figure 4-g.) I. Using the three 1/4-20 x 1" bolts, nylock nuts and washers, secure the air pump to the relocation bracket. J.
5. OIL FEED LINE A. The supercharger uses engine oil for lubrication and must have an oil feed line connected to a filtered oil access on the engine and an oil return or drain. The return is a gravity drain and should be routed so a gradual drop is provided and connected to the pan above oil level and away from suspension components or exhaust headers or pipes. WARNING: The oil system contains a small orifice that is easily plugged. DO NOT USE any type sealant on any of the threads.
5. OIL FEED LINE cont'd. G. Attach one end of the feed hose assembly to the 90° flare previously mounted in the block. Route the line around the oil filter mount, along the oil cooler tubing and out to the front of the engine block. Take care to tie wrap and protect the line from kinking, abrasion and high heat areas. (See Figure 5-c.) H. Temporarily cover the end of the hose and protect it from dirt until connecting to the supercharger. OIL PAN FRONT Figure: 5-c 6. OIL DRAIN LIN E A.
7. SUPERCHARGER MAIN BRACKETS A. Install the lower mounting bracket to the front driver's side of the engine block using two 3/8-16 x 1-1/4" socket head bolts supplied. (See Figures 7-a, 7-b.) B. Install the upper mounting bracket to the cylinder head and engine block using the two 3/8-16 x 2-1/2" and 3/8-16 x 1-1/4" socket head bolt. (See Figure 7-c.) Figure: 7-a UPPER MOUNTING BRACKET HOLES LOWER MOUNTING BRACKET HOLES LOWER MOUNTING BRACKET UPPER MOUNTING BRACKET Figure: 7-b Figure: 7-c 8.
8. SUPERCHARGER MOUNTING, cont'd D. Attach mounting plates A and B together (see Figure 8-b) using two 5/16-18 x 1" bolts and 5/16" nuts, washers and lock washers. E. Fasten the supercharger plate assembly to the supercharger unit using the four supplied 3/8-16 x 1" bolts and washers. F. From beneath the car, carefully guide the supercharger and mounting plate assembly up and onto the two mounting brackets. G.
10. AIR INLET DUCT A. Attach the appropriate fitting into the 1/8" NPT bung on the plastic air inlet tube: a. 1993-94 models - 1/8" NPT plug b. 1995-97 models - 1/8" NPT x 5/32" 90° fitting B. Slip the 3-1/2" x 2" sleeve onto the supercharger inlet using the supplied #56 clamps. Slide the short end of the 3-1/2" plastic elbow into the sleeve. Rotate the elbow so that it points downward in approximately the five o'clock position (viewed from the front). C.
10. AIR INLET DUCT, cont'd. I. Reinstall the plastic splash guard (previously trimmed) into the lower left fenderwell. 11. OIL DRAIN HOSE A. Connect the 1/2" x 9" drain hose from the supercharger to the 1/2" barb in the oil pan. Make sure that there are no dips or kinks in the drain hose. Trim if necessary. B. Secure both ends with the supplied #8 clamps. 12. OIL FEED HOSE CONNECTION A. Route the oil feed line up to the supercharger and connect to the supercharger oil feed. B.
13. COIL RELOCATION AND IGNITION BOX MOUNTING, cont'd. C. Mount the coil and bracket assembly to the AIR PUMP upper supercharger mounting bracket. Use the two 3/8-16 x 1-1/4" bolts previously installed on the supercharger bracket to mount the coil assembly. TOP VIEW D. Reinstall the upper radiator and coolant hoses. E. Mount the supplied ignition control box onto the vehicle in the flat area behind the headlight, next to the air pump. (See Figure 13-b.) F. Route the heavy black cable to a clean ground.
13. COIL RELOCATION AND IGNITION BOX MOUNTING cont'd.
15. SUPERCHARGER DISCHARGE ASSEMBLY A. Install the 2-3/4" x 2" sleeve and #44 clamps onto the supercharger discharge. Place the 4" x 2" sleeve and #64 clamps onto the throttle body. B. Connect the Vortech discharge tube and aluminum discharge elbow together using the 3-1/2" x 3" sleeve and #56 clamps. Orient the discharge tube so that the 1" barb points toward the front of the vehicle. C. Install the discharge tube assembly onto the throttle body and supercharger.
18. FUEL MANAGEMENT UNIT (FMU) INSTALLATION A. Remove the two center bolts that secure the driver's side valve cover. B. Install the FMU with the fittings pointing upward (towards the center of the engine) using the valve cover bolts. C. Disconnect the fuel return line at the fuel rail (smaller line) using a spring lock disconnect tool. D. Connect the 1/4" x 14" fuel line to the center fitting on the FMU and then snap into the return line running to the tank. (See Figure 18-c.) E.
19. BREATHER HOSE REROUTING 1/2" BREATHER HOSE A. Remove the valve cover breather assembly from the vehicle. Disconnect the plastic valve cover fitting and attach it to the supplied length of 1/2" x 58" long hose. B. Thread the supplied 1/2" barb into the 3/8" NPT bung on the inlet duct. C. Route the hose from the valve cover forward along the fender apron, down near the air conditioning compressor and then along the front frame K-member to the 1/2" barb on the inlet duct. Secure with a #8 clamp.
20. T-REX FUEL PUMP INSTALLATION, cont'd. I. Secure the fuel pump/line assembly to the vehicle with the supplied rubber isolators, nylock nuts, and hardware. (See Figure 20-c.) J. Reinstall rear carpet and seats. K. Route the T-Rex inlet hose around the front of the fuel filter to form a smooth, gradual bend to the pump. Attach into the 3/8" barb in the factory feed line. Secure the connection with a #8 hose clamp. (See Figure 20-a.) L.
20. T-REX FUEL PUMP INSTALLATION, cont'd. FRAME/CROSS MEMBER STOCK RELAY BOX ATTACH YELLOW VORTECH RELAY WIRE TO FACTORY GREY WIRE.
21. FUEL INJECTOR REPLACEMENT (1993 MODELS ONLY) A. Disconnect the eight fuel injector wiring clips and retainers from the injectors. B. Remove the four 10mm bolts holding down the fuel rail on the intake manifold. Lift up on the rails evenly, removing all eight injectors. C. Using a small amount of clean motor oil, lightly lubricate the O-rings on both ends on the Vortech supplied fuel injectors. D. Install the new injectors into the fuel rails with the terminals facing outward.
22. FINAL ASSEMBLY AND CHECK A. Reinstall cooling fan if removed in step 1. B. Make sure that the pan fitting is tight and the engine is filled with factory specified synthetic oil. C. Fill the coolant surge tank with a 50/50 coolant/water mix. D. Fill the overflow tank to the proper level. E. Reconnect the battery. F. 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. G.
® ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone (805) 247-0226 Fax (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30PM (PST) P/N: 4GH020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 05NOV01 v1.2(4GH V1.
