Unive rsal GM L SX Sup ercha rger T Insta uner llatio Kit n Ins tr uct ions Legal in Cali forn ia only for rac ing vehicle s whic h may never be use d upon a high wa y. ® 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) i P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr.
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 INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v TOOL & SUPPLY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COPYRIGHT 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, LLC.
IMPORTANT INSTALLATION NOTES This kit should only be installed by qualified mechanics. It is imperative that the correct air/fuel mixture be maintained at all times. This kit is to be supplied to competent engine tuners for their completion by the addition of, and tuning of, appropriate fuel and ignition control components. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine.
Serpentine: • • • • • • • • • • • • Vortech # 2A031-250: 2.50" Diameter 10-rib driven pulley Vortech # 2A031-275: 2.75" Diameter 10-rib driven pulley Vortech # 2A031-295: 2.95" Diameter 10-rib driven pulley Vortech # 2A031-312: 3.12" Diameter 10-rib driven pulley Vortech # 2A031-333: 3.33" Diameter 10-rib driven pulley Vortech # 2A031-347: 3.47" Diameter 10-rib driven pulley Vortech # 2A031-360: 3.60" Diameter 10-rib driven pulley Vortech # 2A031-370: 3.
UNIVERSAL GM LSX Installation Instructions Congratulations on selecting the best performing and best backed 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 which includes the Automotive Limited Warranties Program and the Warranty Registration form. Vortech supercharger systems are performance improving devices.
UNIVERSAL LSX KIT, YSi, 10-Rib Part No. 4GE218-130 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 QTY 008110 SMALL SILVER DIE CUT DECAL 2 008130 LICENSE PLATE FRAME, VORTECH 1 008443 S/C RACE INFO PKG ASSY VORT 1 2A258-070 S/C ASY, V7 YSi, 2010 CAMARO 1 4GE110-044 MTG BRKT ASSY 1 2A017-875-23 SPACER, .875 OD X .404 ID X 2 3 2A017-875-24 SPACER, .875 OD X .
UNIVERSAL LSX KIT, YSi, 50mm Part No. 4GE218-140 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 QTY 008110 SMALL SILVER DIE CUT DECAL 2 008130 LICENSE PLATE FRAME, VORTECH 1 008443 S/C RACE INFO PKG ASSY VORT 1 2A158-060 S/C, V7 YSi, CW STRT, SATIN 1 4GE110-044 MTG BRKT ASSY 1 2A017-875-23 SPACER, .875 OD X .404 ID X 2 3 2A017-875-24 SPACER, .875 OD X .
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1. Preparation/Removal A. Release the tension from the 6-rib belt with the OEM belt tensioner as shown in Fig. 1A. Remove the belt and set aside for reinstallation in a later step. B. Remove any accessories mounted to the front face of the driver side cylinder head. C. Remove the three (3) 15mm-headed bolts securing the cast power steering bracket to the cylinder head. The cast bracket and fasteners will not be reused. Fig 1A D. Remove the 15mm-headed screw from the alternator shown in Fig. 1C.
E. Remove the 4-rib A/C belt. For configurations without a tensioner, remove the stretch belt by rotating the crankshaft clockwise with a 15/16” or 24mm socket while pushing the belt toward the rear of the vehicle as shown in Fig. 1D. NOTE: P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured Be sure to place manual transmission cars in neutral.
F. Lock the engine from rotating and remove the OEM damper pulley bolt. NOTE: Automatic transmission cars can lock the engine through the trans dust cover with an open end wrench to one of the torque converter mounting bosses on the flex plate. Manual transmission cars place car in 6th gear with wheels on the ground and apply parking brake. G. Remove the crank pulley/damper assembly using the appropriate tool as shown in Fig. 1E. Fig 1E 3 P/N: 4GE020-015 v1.
2. Damper & PULLEY InstallATION A. Assemble the supplied ATI Super Damper assembly as follows: i. Insert the hub into the back of the damper making sure to line up the “OFFSET HOLE” in the hub and damper as shown in Fig. 2A. This hole is labeled on the damper sticker, and there is also an indicator machined into both the damper and the hub. NOTE: ii. Make sure that all mating surfaces of the parts are clean.
iii. B. Temporarily assemble the aluminum A/C pulley onto the back of the hub with the pulley’s “snout” facing toward the damper. Insert the three (3) 3/8-16 x 2.5” 12-pt cap screws (supplied with damper) into the three unthreaded holes passing through the hub and thread them into the three (3) 3/8-16 holes in the A/C pulley. Do not tighten. See Fig. 2D. Transfer the OEM rubber seal from the OEM damper assembly to the corresponding location on the new damper assembly as shown in Figures 2E & 2F.
C. Install the supplied damper onto the crankshaft using a proper damper installation tool with thrust bearing. See Fig 2G, 2H. NOTE: DO NOT use the crank bolt to “pull” the damper onto the crankshaft. Use only an appropriate damper installation tool such as ATI kit part number 918999 with 918999SC extension. Fig 2G Fig 2H P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr.
D. After the new damper is fully seated, remove the installation tool. E. F. Install the supplied drill guide with the raised section piloting in the damper bore. Temporarily secure in place by installing the supplied socket head cap screw. Do not over-tighten the screw as it may distort the drill guide (its purpose is just to hold the guide in place while drilling). DRILL BIT MARKED AT 3.85" FROM TIP Mark the supplied ¼” drill bit with tape or use a drill stop at a point 3.
H. Remove the socket head cap screw and drill guide. Carefully remove any metal chips from the area with compressed air. The drilled 1/4" hole should appear as in Fig. 2K. I. Install the supplied Ø1/4" x 1/2" long dowel pin into the drilled hole with the chamfered end pointed toward the front of the vehicle. J. Verify that the dowel pin is recessed slightly from the damper face. K. Install the supplied new damper retaining bolt as follows: L. i.
SERPENTINE DRIVE SYSTEMS (Cog Drive Installations Skip STEP 2.M. BELOW) M. Assemble the supplied crank pulley spacer and 10-rib crank pulley onto the front of the newly installed damper. See Figures 2M and 2N. NOTE: Apply 1 drop of blue threadlocker onto the threads of each fastener prior to final assembly. Fig 2M NOTE: Make sure that the damper decal does not interfere with proper seating of the pulley spacer. Cut away the damper decal if necessary. i.
COG DRIVE SYSTEMS (Serpentine Drive Installations Skip STEP 2.N. BELOW) N. Assemble the supplied crank pulley spacer and 50mm Cog drive pulley onto the front of the newly installed damper. See Figure 2P. i. Secure the pulley and spacer to the dampner using the three supplied 3/8-16 X 3.25" screws with washers. The 3.25" long screws will pass through the entire assembly and thread into the A/C pulley. ii. Thread the previously removed 3/8-16 X 2.
O. Automatic Transmission: “Unlock” the engine from turning by removing the previously-installed wrench holding the flex plate and replace the dust cover. Manual Transmission: Place the transmission in Neutral. P. Reinstall the 4-rib A/C stretch belt as follows (See Fig. 2P): i. Route the belt over and then behind the crank pulley. ii. Route the belt securely onto the A/C compressor pulley. iii. Start the belt onto the top of the corresponding 4-rib A/C pulley that is part of the new damper assembly.
3. OIL FEED INSTALLATION (ENGINE Oil-FED Units Only) 1. Disconnect the charging wire and plug located on the back side of the alternator. Remove alternator and alternator bracket (the factory mounting stud must be removed to allow removal of alternator). See Fig 3A, 3B. 2. Remove oil galley plug located next to the timing chain cover on the front driver side of the engine block. Set aside plug, as it will not be reused. See Fig 3C. Fig 3A Fig 3B Fig 3C P/N: 4GE020-015 v1.
3. Install supplied M16 X 1/8 NPT fitting into oil galley hole using supplied sealing washer. Tighten fitting. See Fig 3D. 4. Install 1/8NPT to -4 90° fitting into previously installed fitting. Clock the fitting so that it points towards the rear of the vehicle. Tighten fitting. See Fig 3D. NOTE: Use only clean engine oil on the pipe threads. Teflon tape or pipe sealant is not recommended as it might loosen and cause blockage of the small oil feed orifice resulting in possible supercharger failure. 5.
4. OIL DRAIN INSTALLATION (ENGINE Oil-FED Units Only) 1. To provide an oil drain for the supercharger, it is necessary to make a hole in the side of the oil pan. The drain fitting location MUST allow the oil to drain back ABOVE the oil level in the pan. 2. Locate the forward-most oil pan bolt on the driver side of the engine block. 3. From the center of that bolt, measure 2.5” toward the rear of the pan and mark the pan for the oil return line fitting. See Fig 4A.
5. Mounting Bracket and Supercharger Installation A. B. Locate the 4GE110-044 supercharger mounting bracket assembly. M10 X 90MM BUTTON HEAD Install the supplied M10-1.5 x 90mm button head screw into the upper alternator screw location from which the OEM screw was previously removed. See Fig. 5A. C. Make sure that the front face of the driver side cylinder head is clean and smooth. Mount the cylinder head plate to this face using four (4) M10 x 30mm screws and washers in the locations shown in Fig. 5B.
D. Locate the P/S support plate, three (3) 2.981” long spacers, one (1) M10 x 120mm screw, one 3/8-16 x 4.0” screw, and one (1) 3/8-16 x 4.5” screw and their associated washers. See Fig. 5C. E. F. Position the P/S plate and screws as shown and secure plate by tightening only M10 x 120mm and 3/8-16 x 4.0” screws. Leave the remaining 3/8-16 x 4.5” screw loosely installed. 3/8 X 4.0L M10 X 120MM P/S SUPPORT PLATE 3/8 X 4.5L Install the P/S pump using the OEM fasteners. If appl. cable See Fig. 5D.
3/8-16X3" BOLT LOOSELY INSTALLED 3/8-16 X 4.5" 3/8-16X4.5 BOLT WITH .085" SPACER 3/8-16X6.25 LOOSELY INSTALLED Fig 5E G. Locate the S/C mounting plate and one .085" long spacer, six 3.566" long spacers, five 3/8-16 x 4.5” screws, one 3/8-16 x 3” screw, one 3/8-16 x 6.25" screw, and their associated washers. Position the hardware and spacers in the plate as shown. See Fig 5E. H. Remove loosely installed 3/8-16 x 4.5” screw from prior installation of P/S bracket. I.
J. K. Make sure to sandwich the two (2) .085” spacers between the steel bracket and the aluminum P/S bracket at either end of the C-shaped section of the steel bracket that fits around the P/S pulley. See Figures 5F & 5G. 3/8-16X4.5 BOLT WITH .085" SPACER Tighten the six 3/8-16 x 4.5” screws, leaving the remaining hardware loose for the next step. Fig 5F .085" SPACERS Fig 5H 5 x 3.566" SPACERS Fig 5G Fig 5I P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl.
L. Use three (3) 3/8-16 x 1.25” screws with washers to mount the supercharger to the S/C plate using the three holes closest to the center of the arc (see Fig. 5J), and tighten these screws. M. Reinstall the OEM 6-rib accessory drive belt following the original belt routing. There is a diagram in the owner’s manual for reference. 3/8-16 X 1.25 Fig 5J 19 P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr.
N. Locate the front tensioner support plate with the following (see Figures 5K, 5L, 5M): i. Nine (9) 1.434” spacers ii. Two (2) 3/8-16 x 2.75” screws with washers iii. One (1) M12-1.75 x 20mm screw (no washer) iv. Three (3) M10-1.5 x 55mm screws with washers v. One (1) M10-1.5 x 120mm screw with washer (from the drive assembly) vi. One (1) M10-1.5 x 110mm screw with washer (from the drive assembly) 3 X 2.981" SPACERS 9 X 1.434" SPACERS 6 X 3.566" SPACERS Fig 5K P/N: 4GE020-015 v1.
O. Remove the one (1) 3/8-16 x 3” and one (1) 3/8-16 x 6.25” screw previously loosely installed. Take care not to lose the .085” spacer sandwiched between the steel plate and the aluminum P/S bracket in the location of the 3” screw. Install the front tensioner support plate using all of the hardware and spacers in the previous step. Reinstall the one (1) 3/8-16 x 3” and one (1) 3/8-16 x 6.25” screw, again taking care not to lose the .085” spacer. 21 P/N: 4GE020-015 v1.
SPRING TENSIONER MOUNTING HOLES M12-1.75 X 20MM 3/8-16 X 3" BOLT, 1.434" AND .085" SPACERS 3/8-16 X 2.75 BOLTS AND 1.434" SPACERS M10-1.5 X 110MM BOLT, 1.434" SPACER 3/8-16 X 6.25" BOLT, 1.434" AND 3.566" SPACERS M10-1.5 X 55MM BOLTS AND 1.434" SPACERS Fig 5L P. Tighten all fasteners with the exception of the M10-1.5 x 120mm and M10-1.5 x 110mm screws. See Figures 5L & 5M. .085" SPACER M10-1.5 X 55MM 3/8-16 X 3" 3/8-16 X 2.75 M10-1.5 X 110MM 3/8-16 X 6.25" M10-1.
Q. Oil Drain: i. Self-Contained units only: Route the end of the remote drain line from the bottom of the supercharger to a location where it can be conveniently be accessed to perform oil changes. Use zip ties to secure the line away from moving parts, hot surfaces, and sharp edges. ii. Oil-Fed units only: Route the oil drain hose down to the ½” fitting previously installed into the oil pan.
6.1 Belt & Drive System Installation (SERPENTINE) SERPENTINE DRIVE SYSTEMS ONLY (ALL OTHERS CONTINUE TO 6.2) A. B. Assemble the supplied smooth idler, M10-1.5 x 110mm screw, idler pilot spacer, and idler pilot washer with the head of the screw on the snap ring side of the idler as shown in Fig. 6P. Install the idler assembly into the lower left-hand hole in the tensioner support plate as shown in Figure 6.1A. FIXED IDLER PULLEY Fig 6.1A Remove temporarily installed M10-1.
C. Using a ½” ratchet or breaker bar, de-tension the spring tensioner and install the supplied 10-rib belt as follows: i. Around the 10-rib crank pulley. ii. Under the spring tensioner. iii. Around the supercharger pulley. iv. On top side of the fixed idler. See Fig 6.1D, 6.1E, 6.1F. Fig 6.1D Fig 6.1E Fig 6.1F 25 P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr.
6.2 Belt & Drive System Installation (COG DRIVE) COG DRIVE SYSTEMS ONLY (ALL OTHERS SKIP THIS SECTION) NOTE: A. B. Do NOT hammer, press, or pry etc. on either of the pulleys when installing or removing them. Lightly heat the pulley with a propane torch until the pulley slides onto the input shaft/crank pulley spacer pilot. Locate the two supplied M10-1.5X55mm bolts and washers. Fig 6.2A Replace the temporarily installed M10-1.5 X 120MM and M10-1.5 X 110mm bolts with M10-1.
D. Locate the following parts: 7B500-325 tensioner arbor, 7PA375-500 adjustment screw, 4PFA010-031 adjustment screw bracket, two 7A250-100 ¼-20 flat allen screws. E. Apply a liberal amount of anti seize to the threads of the adjustment screw (7PA375500) F. Feed the shaft of the tensioner arbor through the slot of the front plate from the back. See Fig 6.2D. Fig 6.2D G. Start to thread the adjustment screw into the head of the tensioner arbor. H.
I. Slide the supplied idler spacer over the shaft of the tensioner arbor. J. Next install the supplied larger aluminum idler onto the arbor followed by the piloting washer and ½”-20 hex nut. Install only finger tight while still allowing for movement with the adjustment screw. Fig 6.2G Fig 6.2H Fig 6.2I P/N: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr.
K. Make sure the tensioner arbor is adjusted to the highest position and install the supplied cog belt around the crank first and then the supercharger pulley. L. With the belt routing underneath the tensioner idler pulley, adjust the tensioner by turning the tensioner screw counter-clockwise so that idler pulley is lowered onto the belt applying tension. M.
7. FINAL INSTALLATION NOTE: This tuner kit does not include supercharger inlet / filter or discharge / CAC components. It is important that properly sized components are selected by the installer / tuner. Contact Vortech technical department if assistancce is required. A. Configure air inlet piping and filter to supercharger inlet. B. Configure discharge ducting from supercharger discharge to throttle body/Carburetor. C. Integrate a properly sized charge air cooler and bypass valve as needed.
8. FINAL RE-ASSEMBLY AND CHECK WARNING: Do not attempt to operate the vehicle until all components are installed and all operations are completed including final check. A. Reconnect the battery. B. If your vehicle has gone over 15,000 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.
® 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: 4GE020-015 v1.0, 2010-05-24 ©2010 Vortech Engineering, LLC All Rights Reserved, Intl. Copr.
