GM 4.8/5 Ligh .3/6 . t 0 Sup T L e r rcha u Inst c rger k alla tio Sy 50 S tat s n In str u tem ctio ns 1 e Sm 999-20 06 og L ega Model l Pe r CA Years RB E O #D -213 -26 ® 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: 4GL020-010 v5.
FOREWORD T his manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for this vehicle. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice.
Table Of Contents FOREWORD............................................................................................................... ii TABLE OF CONTENTS.............................................................................................. iii IMPORTANT NOTES................................................................................................. iv TOOL & SUPPLY REQUIREMENTS........................................................................... v PARTS LISTS 1999 GM 4.8/5.3/6.
1999-2007 GM 4.8/5.3/6.0 Light Truck IMPORTANT NOTES 2002 4.8L / 2000-2002 5.3L / 2000, 2003-2004 6.0L Models 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.
GM 1999-2006 4.8/5.3/6.0 Light Truck Installation Instructions Congratulations on selecting the best performing and best backed 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 Automotive Limited Warranties Program and the Warranty Registration form. Vortech supercharger systems are performance improving devices.
1999 GM 4.8/5.3/6.0L Truck Part No. 4GL218-030/038SQ 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 2E228-300 V2SQ SC TRIM, GM TRUCK 2A036-333 S/C PULLEY 2A046-113 BELT, K061130-GATES 2A046-140 Belt K061140 Gates 7C012-050 12mm x 1.
2000-2002 GM 4.8/5.3 Part No. 4GL218-010/018SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: PART NO.
2001-2003 GM 6.0L Truck ® Part No. 4GL218-020/028, 4GL218-040/048SQ 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 QTY 2E228-300 V2SQ SC TRIM, GM TRUCK 1 2A036-333 S/C PULLEY 1 2A046-113 BELT, K061130-GATES 1 2A046-140 Belt K061140 Gates 1 7C012-050 12mm x 1.
2003 GM 4.8/5.3 Truck Part No. 4GL218-050/058SQ PARTS LIST ® ENGINEERING, LLC IMPORTANT: PART NO. 2E228-300 2A036-333 2A046-113 2A046-140 7C012-050 4FA016-171 4FH016-150 2A017-462 7A375-224 7J375-044 4GL011-021 Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. DESCRIPTION V2SQ SC TRIM, GM TRUCK S/C PULLEY BELT, K061130-GATES Belt K061140 Gates 12mm x 1.
2004-2005 GM 4.8L/5.3L Truck Part No. 4GL218-120/128SQ ® 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 4GL011-021 MOUNTING BRACKET 4GL130-026 OIL FEED ASSY, GM TRK 4GL010-020 ADAPTER, ESCALADE OIL FEED 4GL010-030 GASKET, ESCALADE OIL ADAPTER 4GL010-040 GASKET, 5.3 OIL ADAPTER 5C060-050 M6 x 1.
1. COMPONENT REMOVAL A. Drain sufficient coolant to remove the upper radiator hose and clamps. B. Disconnect the negative battery cable at the battery. C. Remove all ducting between the MAF meter and the throttle body. D. Remove the upper fan shroud and the radiator hose. (If the vehicle has an electric fan, skip to step E.) E. Remove the accessory drive belt. (Keep in vehicle as a spare.) F. Remove the two bolts holding the alternator fusible link junction box and set aside.
2. COMPUTER RELOCATION (2003 5.3L Only) A. Remove the plastic cover protecting the vehicle ECM. Unsnap the ECM from the bracket securing it to the inner fender. Temporarily move the ECM to the side to aid in the bracket relocation. B. Remove the two screws securing both the battery tray bracket and the upper tab of the ECM bracket. Remove the final screw securing the bottom of the ECM bracket. Remove the ECM bracket from the vehicle. C.
3. SUPERCHARGER MOUNTING BRACKET A. Install the original alternator bushings into the supercharger mounting bracket with the flanged portion pointed back. (See Figs. 3-a, 3-b.) B. Clean the driver’s side head of debris. C. Bolt the supplied Vortech supercharger mounting bracket to the head and block using the original mounting bolts. Make sure the mounting bracket is seated directly on a machined surface on the head and that no wires are pinched. D. Tighten the four mounting bolts to 37 ft-lbs (50 N-m). E.
4. SUPERCHARGER INSTALLATION *A. Attach the oil drain hose to the supercharger and tighten the clamp. B. Loosely install the supercharger onto the Vortech bracket. Start all five 3/8-16 x 2-1/4” supercharger mounting screws with washers. C. Tighten the supercharger mounting screws in a rotating pattern to 18 ft-lbs (25 N-m). D. Install the Vortech supplied M12 x 50mm bolt, dust cover, idler pulley and spacer onto the supercharger cover as shown in Figs. 4‑a, 4-b. E.
5. OIL DRAIN LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGER SKIP AHEAD TO STEP 7) A. To provide an oil drain for the supercharger, it is necessary to make a hole in the oil pan. Locate and centerpunch the hole per Fig. 5‑a. Drill a 1/8” pilot hole at center location. B. Use the supplied 9/16” rotobroach to drill the hole in the oil pan. Take care to break through the pan gently and remove the cut out. C. Pack the flutes of a 3/8 NPT tap with grease.
6. OIL FEED LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGER SKIP AHEAD TO STEP 7) A. Remove the two screws holding the small casting or oil cooler block located directly above the oil filter. (Vehicles with oil coolers will appear the same as depicted in Fig. 6-a.) B. Using engine oil on the threads, install 1/8”NPT to #4 x 90° fitting into the supplied oil feed adapter. C.
7. FUEL INJECTOR REPLACEMENT (1999, 2003 and 2004-06 Models Only/2000-2002 models Go To Step 8) A. Relieve the fuel system pressure. B. Disconnect the eight fuel injector wiring clips and retainers from the injectors. C. Remove the four 10mm bolts holding down the fuel rail on the intake manifold. Lift up on the rails evenly, and remove all eight injectors. D. Using a small amount of clean motor oil, lightly lubricate the O-rings on both ends on the Vortech supplied fuel injectors. E.
8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION (2000-2002 Models Only) A. Mount the supplied FMU as shown in Fig. 8-a using the existing studs on the firewall as follows: 1. Remove the nuts securing the factory ground straps. 2. Install the FMU over the studs. NOTE: Not all vehicles have the studs in the same location. Drill an additional 1/4” hole in the FMU bracket as required. See Fig. 8-a. 3. Loosely reinstall the nuts on top of the FMU bracket. B.
8.1 FUEL MANAGEMENT UNIT RECALIBRATION (2000 Models, 2002 4.8L Only) WARNING: For 2000 model year 5.3 & 6.0L and 2002 4.8L vehicles, complete Section 7 (previous step). Perform this step then proceed with Section 8 in the instruction manual A. Remove the six allen head screws on top of the fuel management unit (FMU). (See Fig. 8.1‑a.) WARNING: Do not remove the four screws holding the valve body. Once taken apart the valve would have to be replaced. B. Remove the diaphram and 10:1 disk (2.47” O.D.
9. FUEL PUMP WIRING AND INSTALLATION (All 2000-2002 Models and 2003 6.0L Models Only) A. Mount the supplied fuel pump relay onto the FMU bracket as shown in Fig. 9-a. B. Connect the red 12-gauge wire from terminal #30 to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt to the fuse box power supply terminal as shown in Fig. 9-b.
9. FUEL PUMP WIRING AND INSTALLATION (All 2000-2002 Models and 2003 6.0L Models Only), cont’d. F. Remove the fuel line from the outlet (front) of the fuel filter. Remove the tube from the plastic retainer holding it so that it can be rotated freely. Some models may vary from the photo slightly. Follow the same procedure, taking care to mount the pump so that the hard line is not stressed. G.
10.A INLET DUCT INSTALLATION (99-03 Models) A. Install the supplied 3-1/2” x 3” sleeve onto the MAF sensor outlet. B. Reinstall the upper fan shroud with the exception of the top two bolts. C. Remove any plastic clips that are no longer used to secure the radiator hose. D. Slide the entry of the large plastic inlet duct (see Fig. 10-d) into the sleeve installed on the MAF. Lower the inlet duct onto the top of the radiator shroud.
10.B INLET DUCT INSTALLATION (2004 - 2006 4.8L / 5.3L Models) A. Install the supplied 3-1/2” x 3” sleeve onto the MAF outlet, and the 3-1/2” x 2” sleeve on the inlet of the supercharger. B. Reinstall the upper fan shroud with the exception of the top two bolts. NOTE: If the vehicle is supplied with electric fans from the factory, refer to Fig. 10.b-a to modify the plastic shrouding for the Vortech supplied brackets to mount. C. Remove any plastic clips that are no longer used to secure the radiator hose.
11 RADIATOR TUBE INSTALLATION A. Cut the supplied hose as shown in Fig. 11a. B. Using the two original clamps and the two supplied #24 hose clamps, attach the previously trimmed hose pieces to each end of the supplied radiator tube, radiator and water pump. (See Figs. 11-a, 11‑b.) C. Orient the radiator tube and hoses for best fit and tighten all clamps. D. Use the supplied adel clamp and 1/4-20 x 1/2” screw and washer to secure the radiator tube to the insert on the large plastic inlet duct. (See Fig.
12. DISCHARGE DUCT INSTALLATION NOTE: This section only applies to standard output kits. A. Install the supplied 2-3/4” sleeve and rubber elbow onto the cast discharge duct. Put the discharge duct into position and slide the sleeves onto the supercharger and the throttle body. B. Install and tighten the #64, #48 and the two #44 hose clamps. Fig. 12-a 15 P/N: 4GL020-010 ©2008 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 08OCT08 v5.0(99-07 GM Trk (4GLv5.
13. SUPERCHARGER BYPASS VALVE INSTALLATION A. Connect a 3” length of 1” hose from the barb on the supercharger inlet duct to the outlet of the bypass valve. B. Using the supplied #16 hose clamps, connect the barb on the aluminum discharge duct to the inlet of the bypass valve using the supplied 1” hose. (See Fig. 13‑a.) SUPERCHARGER DISCHARGE TUBE AIR INLET DUCT NOTE: Some vehicles may require trimming of the engine cover to clear various components.
14.A Reflash computer, SUPERCHIPS EQUIPPED KITS 2002 4.8L / 2000-2002 5.3L / 2003 6.0L MODELS ONLY 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.
14.B Reflash computer, DIABLO PREDATOR EQUIPPED KITS IMPORTANT! To ensure trouble-free programming of your vehicle’s computer: • All model years up to 2002: Locate “interior” fuse panel and remove Qty 2 SEO labeled fuses. Locate “exterior” fuse panel ane remove Qty 2 SEO labeled fues. • 2003-2005 model year vehicles” Locate “exterior” fuse panel and remove Qty 1 INFO, Qty 1 RADIO and Qty 1 RADIO AMP labeled fuses. • Turn off all accessories and close doors to prevent unnecessary drain on the battery.
15. SUPERCHIPS NOTICE (2002 4.8L / 2000-2002 5.3L / 2003 6.0L Only) Regarding all GM vehicles with “ON-STAR” and Microtuner 2001. It has come to our attention that GM vehicles equipped with “ON-STAR” communications may have trouble being programmed with a Superchips Microtuner 2001. It appears the “ON-STAR” system interrupts communications between the Microtuner 2001 unit and the vehicle’s PCM. In most cases this results in the following message being displayed on the Microtuner 2001 “No response from PCM.
16. FINAL ASSEMBLY AND 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. Make sure all wires and lines are properly secured with clamps or tie wraps. (See Fig. 16-a.) D.
16. FINAL ASSEMBLY AND CHECK, CONT'D For internally lubricated V3 units only This supercharger has been factory pre-filled with special Vortech synthetic lubricant. Oil does not need to be added to a brand new unit; however a fluid level check should be performed. Prior to operating the supercharger on the vehicle and after installation onto the vehicle: Remove the factory installed flat-head brass shipping plug (not the dipstick) from the top of the supercharger case.
® 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: 4GL020-010 ©2008 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 08OCT08 v5.0(99-07 GM Trk (4GLv5.
