Transcript
5.2L Je e Superc p Cheroke har ger e Insta Sy stem
llat ’93-’95 ion Instructio 5.2L Je ns for 50 State e Smog L egal per p Cherok ee C 1996 5 .2L Jee ARB EO # D-213-1 6 pC 49 State Smog L herokee egal
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ENGINEERING, INC. 1 6 5 0 PA C I F I C AV E N U E • C H A N N E L I S L A N D S , C A 9 3 0 3 3 - 9 9 0 1 © 1997 VORTECH® all rights reserved. International Copyrights Secured 1-3-1994
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. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, Inc.
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ENGINEERING, INC. 1650 Pacific Avenue, Channel Islands, CA 93033 • (805) 247-0226 FAX (805) 247-0669 • http://www.vortecheng.com • M-F 8AM - 4:30PM (PST)
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. If found to be defective as mentioned above, it will be repaired or replaced if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Crane Electronics and/or Vortech Engineering, Incorporated. To the extent permitted by law, the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall Crane Electronics and/or Vortech Engineering, Incorporated, be liable for labor charges, special or consequential damages. When returning this unit for service, proof of purchase must be supplied for warranty verification. After the warranty period has expired, repair service is charged between a minimum and maximum charge. In either case, please send the unit prepaid with proof of purchase to the attention of: Crane Electronics Customer Service Department 530 Fentress Boulevard Daytona Beach, Florida, 32114 (904) 258-6167 (904) 258-6174 Fax www.cranecams.com The repaired unit will be returned as soon as possible after receipt, COD for any charges. Be sure you include a detailed account of any problems experienced, the type of vehicle and any modifications. Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Incorporated, directly at (805) 247-0226.
® ENGINEERING, INC.
Installation Instructions for 5.2L Jeep Cherokee - 50 State Smog Legal per CARB EO # D-213-16 Part No. 4CJ218-020S 1996 5.2L Jeep Cherokee - 49 State Smog Legal
Part No. 4CJ218-010S ‘93-’95
Congratulations on selecting the best performing and best backed automotive supercharger available today... the VORTECH® V-1S® 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 and return envelope. Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30 to 35% and horsepower of between 35 and 45% can be expected with the boost levels specified by Vortech Engineering. 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 as well as the supercharger. Vortech Engineering is not responsible for engine damage. Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed. For best performance and continued durability, please take note of the following key points: 1. Use only premium grade fuel 92 octane or higher (R+M/2). 2. The engine must have stock compression ratio. 3. If the engine has been modified in any way, check with Vortech prior to using this product. 4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is resolved. 5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer's claims, as potential damage to the supercharger may result. 6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every 15,000 miles and spark plug wires every 50,000 miles or earlier. TOOL & SUPPLY REQUIREMENTS Factory Repair Manual 3/8" Drive and Socket Set: SAE and Metric 1/2" Drive and Socket Set: SAE and Metric 3/8" NPT Tap and Tap Handle Adjustable Wrench Open End Wrenches: 5/16", 3/8", 7/16", 1/2", 9/16" Center Punch and a 5/8" Tapered Punch 3/8" Fuel Fitting Disconnect Tool 5 quarts SF Rated Quality Engine Oil, Oil Filter, and Wrench Flat #2 Screwdriver Phillips #2 Screwdriver Heavy Grease Silicone Sealer Drill Motor 3/32" Drill Bit Oil Sender Socket, Snap-on® # A120 Rivet Gun If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need: Spark Plug Socket NEW Spark Plugs 4CJ218-010S-3
1993-95 5.2 Jeep Cherokee Part No. 4CJ218-010S ®
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
2A228-140 2A128-140 2A037-312 4FA016-150 7J012-092 8R101-001
SUPERCHARGER ASSEMBLY V-1S Supercharger 3.125” Supercharger Drive Pulley Smooth Pulley Tensioner 12 mm Flat Washer 6 Rib Pulley Retainer Assembly
1 1 1 1 1 1
4CJ111-021 4CB010-010 4CB010-034 4CB011-021 2A047-104 7A312-351 7A375-100 7A375-300 7A375-375 7F375-016 7J375-044 7K375-040 7U100-055 4CB017-011 7A312-450
MOUNTING BRACKET ASSEMBLY Mounting Bracket Support Mounting Plate Mounting Bracket Belt 5/16-18 x 3-1/2” Bolt 3/8-16 x 1” Bolts 3/8-16 x 3" Cap Screw 3/8-16 x 3-3/4” HH Bolt 3/8-16 Hex Nut 3/8” SAE Washers 3/8” AN960 Flat Washers 6" Nylon Tie Wraps 1/2" Spacer 5/16-18 x 4.5" Stainless HXHD
1 1 1 1 1 1 10 1 1 1 10 5 2 1 1
4CJ130-026 7U030-026 7P125-103 7P250-066 7P525-067 7P125-026 7P125-104 7P125-106
OIL FEED ASSEMBLY 1/4” x 33” Oil Feed Hose 1/8" NPT -4 x 45° Male Elbows #4 Swivel x 1/4” Hose Barb Fittings .525 Crimp Ferrules 1/8" NPT x #4 90° Fitting 1/8" NPT Female Tee 1/8" NPT x 3" Nipple
1 1 2 2 2 1 1 1
4CJ112-010 4FG112-022 7R001-056 8H040-040 7P375-020 7U033-000
AIR INTAKE ASSEMBLY Inlet Duct #56 Hose Clamp Air Filter 3/8" NPT x 5/8" Straight Hose Barb 5/8" x 42" PVC Hose
1 1 1 1 1 1
4CJ112-020 4FG012-030 7S275-200 7S300-200 7R002-044 7R002-048 8D001-001 7P750-100 7U034-016 7R002-016 7P156-082 7U030-046 4CJ050-010 4GB040-060 7J250-001 7F250-030
AIR DISCHARGE ASSEMBLY Discharge Tube 2-3/4” x 2” Sleeve 3" X 2" Sleeve #44 Hose Clamps #48 Hose Clamps Bypass Valve 3/4" NPT x 1" Straight Hose Fitting 1" x 7" Heater Hose #16 Hose Clamps 5/32" Tee 5/32" x 24" Vacuum Line Air/Plenum Air/Plenum Gasket 1/4" SAE Washers 1/4-20 Acorn Nut
1 1 1 1 2 2 1 1 1 4 1 1 1 1 3 1
4CJ101-003 8F001-002 7C011-075 7F010-032 7J010-001 7P250-082 7P250-036 4CJ145-010 4CJ145-020 5W001-010 5W018-020 5W001-011 5W001-001 5W001-017 8F101-400 7E010-050 7U031-018 7P250-034 7P312-002 7P250-037 7R003-023 7R001-004
FUEL PUMP ASSEMBLY 200 Inline Fuel Pump 10/32" x 3/4" HH Cap Screw 10-32 Nylock Nut #10 Flat Washers 1/4" NPT x -4 90° Fitting 1/4" NPT #4 Flares Male Fuel Line Female Fuel Line 16-14GA Female Slides 12" 18GA Black Wire 16-14GA Eyelets Wire Tap Large Ring Terminals Pump Wiring Assembly #12 x 1/2" Sheet Metal Screw 5/16" x 4" Fuel Hose 1/4" NPT x 1/4" NPT Straight Tee 5/16" x 1/4" NPT Barbs #4 Male Run Tee Adel Clamp #4 Hose Clamps
1 1 1 1 3 1 3 1 1 3 1 2 1 2 1 1 2 1 2 1 1 4
4CJ238-068 6Z110-111 4CJ145-030 4CJ145-040 7U030-046 7U100-055
FMU (with lines) 12:1 Fuel Management Unit Fuel Line (FMU In) Fuel Line (FMU Out) 5/32” x 25” Vacuum Line 6” Nylon Tie Wraps
1 1 1 1 1 2
4CJ110-010 4CJ010-040 7A250-103 7F250-021 5W022-040 5W022-090 5W001-007 7A312-125 7K312-001 4CJ017-021 5W001-005
COIL RELOCATE ASSEMBLY Coil Bracket 1/4-20 x 1" SH Cap Screws 1/4-20 Nylock Nuts 30" 22GA Green Wire 30" Grey Wire 3/16" x 8" Heat-Shrink Tubing 5/16-18 x 1-1/4" HH Bolts 5/16" AN Washers 5/8" Coil Spacer 3/8" x 40" Plastic Wire Loom
1 1 2 2 1 1 1 2 2 1 1
5A101-009 5A001-009 5W001-001 5W001-009 5W001-010 5W001-011 5W001-017 7E010-048 7U375-002 7U375-001 7U030-046 7P156-082 7U100-050 7U100-055
HI-6 TR ASSEMBLY HI-6 TR Ignition System Wire Taps 16-14GA Male Slides 16-14GA Female Slides 16-14GA Eyelets Large Ring Terminals #10 x 3/4" HH Bolts 3.6" Velcro Latch 3.6" Velcro Hook 5/32" x 36" Vacuum Line 5/32" Tee 5/8" Grommet 6" Nylon Tie Wrap
1 1 2 6 6 2 2 4 1 1 1 1 1 1
4CJ120-010 4CJ010-060 7U100-025 7E010-075
FUSE BOX RELOCATION ASSEMBLY Fuse Box 1/8" Dia. x 1/4" Rivets #12 x 3/4" HH Sheet Metal Screws
1 1 5 3
4CJ130-036 7U030-036 7P375-017 7R001-008 7P375-045
OIL DRAIN ASSEMBLY 1/2” x 18” Oil Drain Hose 3/8” NPT x 1/2” Straight Hose Barb #8 Stainless Hose Clamps 3/8" NPT x 45° Street Elbow
1 1 1 2 1
4CJ150-012 4CJ010-070 7A375-351 7F375-017 4CJ017-031 5W013-000 5W013-001 5W001-027 5W001-028 5W001-029 7U100-055 7R003-008 7E010-050 7J375-044 7P437-375 5W001-030
BATTERY RELOCATE ASSEMBLY Battery Tray 3/8-16 x 3-1/2" SH Flat Screws 3/8-16 Nylock Nuts 2-5/8" Battery Tray Spacers 82" 1 Gauge Red Cable 30" 1 Gauge Black Cable 3-Way Splice Battery Post Terminals Lug End Terminals 6" Nylon Tie Wraps 1/2" Adel Clamps #12 x 1/2" Sheet Metal Scews 3/8" SAE Washers 7/16-20 x 3/8" Set Screws 1-1/2" x 8" Heat-Shrink Tubing
1 1 3 3 3 1 1 1 2 2 10 3 3 3 2 1
1996 5.2 Jeep Cherokee Part No. 4CJ218-020S ®
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
2A228-140 2A128-140 2A037-312 4FA016-150 7J012-092 8R101-001
SUPERCHARGER ASSEMBLY V-1S Supercharger 3.125” Supercharger Drive Pulley Smooth Pulley Tensioner 12 mm Flat Washer 6 Rib Pulley Retainer Assembly
1 1 1 1 1 1
4CJ111-021 4CB010-010 4CB010-034 4CB011-021 2A047-104 7A312-351 7A375-100 7A375-300 7A375-375 7F375-016 7J375-044 7K375-040 7U100-055 4CB017-011 7A312-450
MOUNTING BRACKET ASSEMBLY Mounting Bracket Support Mounting Plate Mounting Bracket Belt 5/16-18 x 3-1/2” Bolt 3/8-16 x 1” Bolts 3/8-16 x 3" Cap Screw 3/8-16 x 3-3/4” HH Bolt 3/8-16 Hex Nut 3/8” SAE Washers 3/8” AN960 Flat Washers 6" Nylon Tie Wraps 1/2" Spacer 5/16-18 x 4.5" Stainless HXHD
1 1 1 1 1 1 10 1 1 1 10 5 2 1 1
4CJ130-026 7U030-026 7P125-103 7P250-066 7P525-067 7P125-026 7P125-104 7P125-106
OIL FEED ASSEMBLY 1/4” x 33” Oil Feed Hose 1/8" NPT -4 x 45° Male Elbows #4 Swivel x 1/4” Hose Barb Fittings .525 Crimp Ferrules 1/8" NPT x #4 90° Fitting 1/8" NPT Female Tee 1/8" NPT x 3" Nipple
1 1 2 2 2 1 1 1
4CJ112-010 4FG112-022 7R001-056 8H040-040 7P375-020 7U033-000
AIR INTAKE ASSEMBLY Inlet Duct #56 Hose Clamp Air Filter 3/8" NPT x 5/8" Straight Hose Barb 5/8" x 42" PVC Hose
1 1 1 1 1 1
4CJ112-020 4FG012-030 7S275-200 7S300-200 7R002-044 7R002-048 8D001-001 7P750-100 7U034-016 7R002-016 7P156-082 7U030-046 4CJ050-010 4GB040-060 7J250-001 7F250-030 4CJ110-010 4CJ010-040 7A250-103 7F250-021 5W022-040 5W022-090 5W001-007 7A312-125 7K312-001 4CJ017-021 5W001-005
AIR DISCHARGE ASSEMBLY Discharge Tube 2-3/4” x 2” Sleeve 3" X 2" Sleeve #44 Hose Clamps #48 Hose Clamps Bypass Valve 3/4" NPT x 1" Straight Hose Fitting 1" x 7" Heater Hose #16 Hose Clamps 5/32" Tee 5/32" x 24" Vacuum Line Air/Plenum Air/Plenum Gasket 1/4" SAE Washers 1/4-20 Acorn Nut Coil Relocate Assembly Coil Bracket 1/4-20 x 1" SH Cap Screws 1/4-20 Nylock Nuts 30" 22GA Green Wire 30" Grey Wire 3/16" x 8" Heat-Shrink Tubing 5/16-18 x 1-1/4" HH Bolts 5/16" AN Washers 5/8" Coil Spacer 3/8" x 40" Plastic Wire Loom
1 1 1 1 2 2 1 1 1 4 1 1 1 1 3 1 1 1 2 2 1 1 1 2 2 1 1
4CJ101-004 8F001-200 4CJ145-050 4CJ145-030 4CJ145-020 7U032-016 7P250-122 7P250-036 7P250-045 7P250-050 7P250-082 7P312-002 7R001-008 7U031-018 7R003-023 7C010-075 7F010-024 7J010-001 7U100-055 7R003-008 7R001-004
FUEL PUMP ASSEMBLY 200 Inline Fuel Pump Fuel Line FMU Out Fuel Line FMU In Female Fuel Line 3/8" x 36" Fuel Hose 1/4" Pipe Thread Tee 1/4" NPT #4 Flares 1/4" NPT x 3/8" Fitting 1/4" NPT Male Branch Tee 1/4" NPT x -4 90° Fittings 5/16" x 1/4" NPT Barb #8 Hose Clamps 5/16" x 2-1/2" Fuel Hose 1.8" Adel Clamps 10-24 x 3/4" SHCS 10-24 Nylock Nuts #10 Flat Washers 6" Nylon Tie Wraps 1/2" Adel Clamps #4 Hose Clamps
1 1 1 1 1 1 1 2 1 1 2 1 4 2 2 2 2 4 10 2 4
4CJ238-068 6Z110-111 4CJ145-030 4CJ145-040 7U030-046 7U100-055
FMU (with lines) 12:1 Fuel Management Unit Fuel Line (FMU In) Fuel Line (FMU Out) 5/32” x 25” Vacuum Line 6” Nylon Tie Wraps
1 1 1 1 1 2
5A101-009 5A001-009 5W001-001 5W001-009 5W001-010 5W001-011 5W001-017 7E010-048 7U375-002 7U375-001 7U030-046 7P156-082 7U100-050 7U100-055
HI-6 TR ASSEMBLY HI-6 TR Ignition System Wire Taps 16-14GA Male Slides 16-14GA Female Slides 16-14GA Eyelets Large Ring Terminals #10 x 3/4" HH Bolts 3.6" Velcro Latch 3.6" Velcro Hook 5/32" x 36" Vacuum Line 5/32" Tee 5/8" Grommet 6" Nylon Tie Wrap
1 1 2 6 6 2 2 4 1 1 1 1 1 1
4CJ120-010 4CJ010-060 7U100-025 7E010-075
FUSE BOX RELOCATION ASSEMBLY Fuse Box 1/8" Dia. x 1/4" Rivets #12 x 3/4" HH Sheet Metal Screws
1 1 5 3
4CJ130-036 7U030-036 7P375-017 7R001-008 7P375-045
OIL DRAIN ASSEMBLY 1/2” x 18” Oil Drain Hose 3/8” NPT x 1/2” Straight Hose Barb #8 Stainless Hose Clamps 3/8" NPT x 45° Street Elbow
1 1 1 2 1
4CJ160-010 7P125-107 5W018-010 5W018-020 5W001-007 5W001-032 4CJ010-080
1996 SUPPLEMENT ASSEMBLY 1/8" NPT x 2" Nipple 60" 18 Ga. Red Wire 60" 18 Ga. Black Wire 3/16" x 8" Heat Shrink Tube 18 Ga. Solderless Connectors 1996 Fuse Box Bracket
1 1 1 1 1 4 1
4CJ150-012 4CJ010-070 7A375-351 7F375-017 4CJ017-031 5W013-000 5W013-001 5W001-027 5W001-028 5W001-029 7U100-055 7R003-008 7E010-050 7J375-044 7P437-375 5W001-030
BATTERY RELOCATE ASSEMBLY Battery Tray 3/8-16 x 3-1/2" SH Flat Screws 3/8-16 Nylock Nuts 2-5/8" Battery Tray Spacers 82" 1 Gauge Red Cable 30" 1 Gauge Black Cable 3-Way Splice Battery Post Terminals Lug End Terminals 6" Nylon Tie Wraps 1/2" Adel Clamps #12 x 1/2" Sheet Metal Scews 3/8" SAE Washers 7/16-20 x 3/8" Set Screws 1-1/2" x 8" Heat-Shrink Tubing
1 1 3 3 3 1 1 1 2 2 10 3 3 3 2 1
1. PREPARATION/REMOVAL A. Disconnect the battery, remove the battery box and battery tray. Set aside. Separate the vacuum canister from the bottom of the tray. B. Remove the accessory drive belt. C. Remove the belt tensioner assembly, separate it from the mounting bracket and set aside. D. Disconnect and remove the crankcase breather hose. E. Remove the entire air filter/inlet assembly. F. Remove the windshield washer reservoir and set aside. G. Remove the ignition coil and bracket. Set aside. H. Remove the front skid plate, if equipped. 2. OIL DRAIN A. To provide an oil drain for the supercharger, it is necessary to make a hole in the oil pan. The best way to provide this hole is to punch the hole rather than drill. B. Rotate the engine until the mark on the damper is aligned with the TDC (top dead center) tag on the front of the engine. To aid you in this, remove the distributor cap and watch the ignition rotor. It should end up between #5 and #7 electrodes as shown in the graphic. C. Locate and mark hole per diagram. Remove paint around the hole area. Layout the hole center per the diagram. D. Use a small center punch to perforate the pan and expand the hole. Switch to a larger diameter punch and expand the hole further to approximately 9/16" diameter. Most punches are made from hexagon material and may be placed in a socket with an extension to make this procedure easier. NOTE: Use extreme caution not to hit the crankshaft while punching the pan. If a clearance problem exists, rotate the crankshaft until clearance is obtained.
ROTATE ENGINE TO DISPLAYED POSITION IGN. ROTOR
TDC
DOWN 1-3/4" 2"
E. Tap the hole with a 3/8" NPT tap approximately 1/4" deep. Pack the flutes of the tap with heavy grease to hold chips. Use a small magnet to check for any stray chips.
OIL PAN
PUNCH HOLE THROUGH
NOTE: This method of rolling over the lip of the hole and tapping it works very well if carefully done and should cause no problems.
1
2. OIL DRAIN, cont'd. F. 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. 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. G. Drain engine oil and change filter. H. The drain hose will be attached to the fitting in later steps. If your installation is going to be over several days we suggest that you cover the fitting to protect it from dirt.
45° ANGLE UPWARD
3. POWER DISTRIBUTION CENTER A. Remove the plastic power distribution center (PDC) (main fuse box located underhood on the passenger side) from its mounting bracket. Remove bracket from vehicle. B. Drill the rivets out of the PDC mounting bracket. Retain the upper portion and discard lower. C. Re-rivet the upper bracket to the lower bracket provided in the kit. See graphic.
RIVET BRACKETS TOGETHER
NOTE: Due to different vehicle applications, two mounting brackets are supplied in each kit. 1995 and earlier models will use the bracket with four mating holes (see graphic) and 19961997 models will use the bracket with three mating holes. D. Disconnect the positive battery cable from the PDC. Carefully remove about one inch of the tape and wire cover over the wire loom going into the power distribution center. E. Place the new PDC bracket against the passenger side inner fenderwell, allowing enough space for the power distribution center to slide into its forwardmost position with the positive terminal cover on. (See photo above.) F. Mark mounting hole location. Drill and secure with supplied sheetmetal screws. 2
VORTECH SUPPLIED BRACKET
(1996-1997 bracket appears slightly different)
4. VACUUM RESERVOIR VACUUM RESERVOIR
A. Remove the vacuum reservoir from the bottom of the battery tray. B. Place the vacuum reservoir in the forward most corner of the passenger side fenderwell. See graphic. C. Using the existing mounting flanges, drill and secure with the provided sheetmetal screws. D. Reattach the vacuum hose.
PDC
NEW BRACKET
5. MAIN MOUNTING BRACKET AND PLATE A. It is necessary to provide clearance between the dipstick and accessory drive belt. Remove the bolt holding the dip stick tube. Hold the tube approximately two inches from the top and gently bend rearward and inward about one inch. Resecure with the existing fastenera after the bracket installation. B. Mount the cast aluminum main mounting bracket on the front of the engine right cylinder head using the fasteners provided, as shown in the graphic on the next page. NOTE: Before mounting the main bracket, the vehicle wiring harness must be shifted so that it rests in between the timing chain cover and the supercharger mounting bracket for exhaust clearance.
WIRING HARNESS
3
5. MAIN MOUNTING BRACKET AND PLATE, cont'd. C. Please note that the 3-3/4" bolt also holds the supercharger mounting plate. This fastener must be threaded into its hole loosely as a pilot while securing the cast bracket with the other two, then removed for installation of the supercharger mounting plate. Reinstall the bolt after mounting the plate and before attaching the spring tensioner. D. Attach the stock belt tensioner to the front of the supercharger mounting plate as shown. Make sure the indexing tab is engaged in the slot. E. Secure the plate and tensioner as an assembly to the cast bracket. F. Attach the support strut between the supercharger mounting plate and the second exhaust manifold stud. Secure with the supplied stainless steel bolt. G. Attach the 3 loose ground connections from the main harness (near the supercharger mounting bracket) to the existing alternator mounting bolt and secure.
GROUND TO ALTERNATOR MOUNTING BOLT
MAIN HARNESS
MAIN MOUNTING BRACKET ATTACH TO EXHAUST MANIFOLD
5/16-18 x 4-1/2" 5/16-18 X 3.5 SUPPORT
HEAT SHIELD
3/8-16 x 1.0 1" 3/8-16 X
.60 SPACER
5/16" BOLT 3/8-16 x 3.0 3" 3/8-16 X
EXHAUST MANIFOLD
3/8-16X 3-3/4"xx3-3/4" 3/8-16 3.75 (BOLT MUST BE INSTALLED BEFORE SPRING TENSIONER IS MOUNTED.)
SUPERCHARGER GEARCHARGER MOUNTING PLATE MOUNTING PLATE
3/8-16 Xx 3.0 3" 3/8-16
.25 SPACER 3/8-16 3/8-16Xx 1.0 1"
VORTECH SUPPORT STOCK TENSIONER
4
6. 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. C. Attach the plastic idler pulley (arrow) to the inner most threaded boss on the supercharger. Use the supplied large washer as a spacer in between the pulley and the supercharger. NOTE: Drain hose must be routed downhill with no kinks or sharp turns. Supercharger life will be affected by an improperly routed drain hose. D. Route the supercharger drain hose downhill towards the drain fitting in the pan. Trim hose if necessary and secure to fitting with the supplied #8 hose clamp.
7. SUPERCHARGER/ACCESSORY DRIVE BELT A. The new, longer accessory S/C DRIVE drive belt is routed the same PULLEY as the original belt except for accommodation of the supercharger and a idler pulley. B. Route the belt around the outside of the supercharger drive pulley then around the inside of the idler as shown. C. The stock tensioner is used as originally intended in its relocated position.
A/C ALT
P/S PULLEY WATER PUMP
CRANK
5
8. 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. (1995 and earlier models will use the 3" long nipple, while 1996-1997 models will use the 2" nipple.) Install the 45° fitting in the side port and orient the assembly so that it points forward and slightly outward towards the passenger side. Reconnect the pressure sender connector.
OIL SENDING UNIT 45° x 1/8" FITTING
NOTE: It is essential that the supercharger oiling orifice not be plugged; therefore, do not use Teflon tape or other sealant that could possibly cause blockage. Use engine oil. C. Attach the preassembled oil hose onto the fitting. Route the hose forward along the inside of the right valve cover. Be careful not to rest the oil hose or ignition wires on the EGR tube at the rear of the head. (On 1996-1997 models, no EGR is present). D. Before connecting the other end of the hose to the supercharger, briefly crank over the engine in order to purge the line with oil and remove any contaminants from the line. Use a drain pan or coffee can to catch the oil. E. Place the 45° union fitting into the supercharger fitting. Connect the hose to the 45° fitting.
6
STOCK OIL PRESSURE SENDING UNIT 1/8" NPT NIPPLE 45° x 1/8" FITTING
1/8" NPT NIPPLE
ENGINE BLOCK
9a. BATTERY RELOCATION NEW TRAY
A. Loosen the power steering lines on the power steering pump and pivot them toward the radiator approximately 2". This will provide enough clearance for the battery in its new location. Retighten fittings. B. Remove the two nut clips from the original battery tray and attach them to the provided tray. C. Using the three existing holes in the lower plane of the drivers side inner fenderwell (the previous position of the air filter assembly), mount the new battery tray parallel to the head light assembly. See photo. D. 1996-1997 models are equipped with a battery temperature sensor. This unit must be relocated to the new battery tray using the supplied red and black wire extensions. E. Place the battery on the tray and secure with the original retaining parts.
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NUT CLIPS
9b. NEGATIVE BATTERY CABLE A. Disconnect the negative battery cable from the inner fenderwell ground location. B. Cut the engine ground cable as close as possible to the battery terminal end. Strip the end of the cut cable and attach the eyelet connector provided. Reconnect the new engine ground and all previously removed ground wires to the original fenderwell location. C. Remove the lower power steering pump bracket bolt (on the drivers side) and attach the eyelet end of the new negative battery cable provided. D. Secure the cable with the tie straps provided. Trim as necessary. Connect the negative cable end to the battery.
1"
9c. POSITIVE BATTERY CABLE A. Cut both positive cables as close as possible to the battery terminal end and discard terminal. B. Strip cable cover back about one inch. Connect both ends to the provided splice connector. C. Attach the provided length of cable to the opposite end of the splice. Slide the heat shrinkable tube over the splice. Apply heat with heat gun or hair dryer until tube shrinks snugly around connector and cable end assembly. D. Route the cable under the radiator to the new battery location. Secure the cable with the tie straps and adel clamps. Trim as necessary. E. Connect the cable end to the battery. Reinstall the skid plate. (If equipped.)
1"
SPLICE CONNECTOR
WARNING: It is imperative that the cable is carefully routed and secured so that no sharp edges or moving parts can damage the insulation.
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10A. AUXILIARY FUEL PUMP (1993-1995 Models Only) A. An additional fuel pump is supplied to insure that sufficient fuel is available to the engine. This pump is mounted on the left side inner fenderwell beneath the windshield washer reservoir and the brake master cylinder. B. Open, then close the fuel filler cap to vent any residual pressure. Disconnect the stock fuel supply hose where it enters the fuel rail. WARNING: Take great care to minimize fuel spillage and always have a second person stand by with a fire extinguisher as a precaution. C. Following the graphic on the next page, insert hose assembly "A" into the factory feed line until it snaps into place. Route the hose assembly along the rear firewall near the base of the brake booster. D. Attach the Vortech fuel pump to the vehicle with the outlet pointing forward using the supplied adel clamp and #10 hardware. See photo at right. AUXILIARY FUEL PUMP
NOTE: On ABS equipped vehicles, the pump mounting position may vary slightly. E. Use the supplied length of short black wire to ground the fuel pump. F. Mark and drill a 1/8" hole and mount the supplied relay on the passenger side inner fenderwell near the fuse box. Connect the short black wire from the relay terminal #86 to ground. G. From relay terminal #85, route the yellow wire to the bottom of the underhood fuse box. Tap the yellow relay wire into the factory fuel pump relay wire connected to pin #87 on the factory fuel pump relay (the wire can be various colors but usually is green with a white stripe) using the supplied wire tap. Double check the wire choice by using a test light to confirm that when the key is initially turned on, the wire has power for 4-8 seconds and then turns off. H. Connect the long red wire from relay terminal #87 to the (+) terminal on the fuel pump.
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FUEL MANAGEMENT UNIT
(+) FUEL PUMP
86
GROUND
87 87A
30
RELAY
85
GREEN/WHITE @ PIN #87 OF FACTORY FUEL PUMP RELAY LUG FROM BATTERY TO FUSE PANEL UNDERHOOD
10A. AUXILIARY FUEL PUMP, cont'd. (1993-1995 Models Only) I. Connect the short red wire from relay terminal #30 to the external fuse box (+) lug. J. Assemble the brass fittings and hoses as shown in the graphic. Make sure hose "B" makes a positive snap connection onto the fuel rail. K. Using the supplied tie wraps, secure all hoses from sharp edges, moving parts or chaffing. L. Activate the fuel pump and check all fittings, connections and hoses for leaks.
1/4" NPT x 45° FLARE 3/8" x 1/4" NPT 3/8" x4" FUEL HOSE
1/4" x 5" HOSE FUEL PUMP
5/16" x 4" FUEL HOSE
1/4" x 28" HOSE
#4 MALE RUN TEE
HOSE ASSEMBLY "B"
1995 AND EARLIER MODELS ONLY 10
10B. AUXILIARY FUEL PUMP (1996-1997 Models Only) A. An additional fuel pump is supplied to ensure that sufficient fuel is available to the engine. The pump is mounted underneath the new battery tray. B. Open, then close the fuel filler cap to vent any residual pressure. Disconnect the stock fuel supply hose where it enters the fuel rail. WARNING: Take great care to minimize fuel spillage and always have a second person stand by with a fire extinguisher as a precaution. C. Following the graphic on the next page, insert hose assembly A into the factory feed line until it snaps into place. Loop the hose assembly around and into the 1/4" tee assembly. D. Attach the Vortech fuel pump to the bottom of the battery tray using the supplied #10 hardware and adel clamps. See graphic. E. Use the supplied length of short black wire to ground the fuel pump. F. Mark and drill a 1/8" hole and mount the supplied relay on the passenger side inner fenderwell near the fuse box. Connect the short black wire from the relay terminal #86 to ground. G. From relay terminal #85, route the yellow wire to the bottom of the underhood fuse box. Tap the yellow relay wire into the factory fuel pump relay wire connected to pin #87 on the factory fuel pump relay (the wire can be various colors but usually is green with a white stripe) using the supplied wire tap. Double check the wire choice by using a test light to confirm that when the GROUND key is initially turned on, the wire has power for 4-8 seconds and then turns off. H. Connect the long red wire from relay terminal #87 to the (+) terminal on the fuel pump. I. Connect the short red wire from relay terminal #30 to the external fuse box (+) lug. J. Assemble the brass fittings and hoses as shown in the graphic. Make sure hose "B" makes a positive snap connection onto the fuel rail. K. Using the supplied tie wraps, secure all hoses from sharp edges, moving parts or chaffing. L. Activate the fuel pump and check all fittings, connections and hoses for leaks.
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FLOW
FRONT OF VEHICLE
FUEL PUMP MOUNTED UNDERNEATH BATTERY TRAY
(+) FUEL PUMP
86
87 87A
30
RELAY
85
GREEN/WHITE @ PIN #87 OF FACTORY FUEL PUMP RELAY LUG FROM BATTERY TO FUSE PANEL UNDERHOOD
10B. AUXILIARY FUEL PUMP, cont'd. (1996-1997 Models Only) 1996-1997 FUEL SYSTEM FACTORY FEED LINE
1/4" NPT x #4 FLARE
1/4" x 20" MALE LINE ASSEMBLY "A"
1/4" NPT x #4 FLARE
1/4" NPT FEMALE TEE
1/4" NPT x 3/8" BARB
1/2" ADEL CLAMP
1/4" x 20" HOSE CONNECT TO MANIFOLD VACUUM/PRESSURE
3/8" x 35" FUEL HOSE FMU INLET
FUEL PUMP (ATTACH TO BOTTOM OF BATTERY TRAY)
FLOW
OUTLET
T-REX ®
1/2" ADEL CLAMP
1/4" x 28" HOSE 1/4" x 30" FEMALE LINE ASSEMBLY "B"
5/16" x 2-1/2" FUEL HOSE
5/16" x 1/4" NPT FEMALE BARB
1/4" NPT x 90° FLARE
1/4" NPT x 90° FLARE 1/4" NPT BRANCH TEE
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11. FUEL MANAGEMENT UNIT A. Using the photo on page 9 as a reference, place the fuel management unit (FMU) on the firewall. Mark and drill two 3/32" holes and secure the unit with the sheet metal screws provided. (Temporarily placing the washer reservoir back into its original location will help reference proper FMU placement.) B. Connect the FMU inlet hose (the hose running to the 90° fitting on the side of the FMU) to the brass tee fitting on the exit side of the secondary fuel pump. C. Connect the FMU outlet hose to the brass #4 flare fitting located before the secondary pump inlet. D. Attach the supplied vacuum line from the fitting on top of the FMU to the small vacuum fitting on the driver's side of the intake manifold. See graphic. E. Use tie wraps to secure the lines. F. Reinstall wiper washer reservoir, lines and wire connections. FUEL RAIL FUEL INJECTORS INTAKE MANIFOLD
ATTACH FMU TO SMALL VACUUM CONNECTION
DRIVER'S SIDE
IGNITION COIL
12. IGNITION COIL RELOCATION A. Remove the ignition coil from its original mounting bracket. B. Locate the two 5/16" threaded bosses on the intake manifold between the throttle body and rear of the air conditioning unit. C. Attach the supplied coil bracket and 1/4-20 hardware to the ignition coil. Secure the coil assembly to the intake manifold using the supplied spacer, 5/16" bolts and washers. The distributor lead must point toward the rear of the vehicle.
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13. IGNITION/BOOST CONTROL INSTALLATION A. Mount the ignition box in the engine compartment onto the flat area near the fuse box and passenger side headlight. Use the supplied #10 sheet metal screws to secure. (See graphic.) 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 under hood fuse box. C. Locate the ignition coil plug-in connector (grey and green wires) on the vehicle wiring harness near the original spring tensioner location. Cut the connector from the harness leaving 2-3" of wire remaining on the connector.
FUSE BOX
PASSENGER SIDE ENGINE COMPARTMENT
(+) TERM
VACUUM RESERVOIR
FRAME RAIL
(–) TERM GROUND
RANE HI-6TR C cams ®
NOTE: 1996-1997 models have a slightly different coil plug location and do not need wire extensions.
CAPACITIVE DISCHARGE IGNITION WITH AUTO-SEQUENCE REV LIMITER
FRONT OF VEHICLE (VIEW FROM TOP)
D. Extend the wires on the coil connector using the supplied grey and green wires. Connect the grey and green extensions to the black and orange wires from the ignition box. Connect the remaining wires following the diagram on the following page. E. Mount the timing retard control knob and the map sensor in the drivers compartment underneath the dash. The knob control must be in an accessible position from the drivers seat. F. Attach one end of the supplied 5/32" vacuum line to the map sensor. Route the red and blue (or brown) wires along with the vacuum line through the firewall. G. Connect vacuum line and wiring harness following graphic on the next page.
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13. IGNITION/BOOST CONTROL INSTALLATION, cont'd. NOTE: 1996-1997 models do not require extensions to properly wire ignition assembly.
IGNITION COIL CONNECTOR
GREY GREEN
MAIN WIRING HARNESS
GREEN GREY SOLDER AND SHRINK SLEEVE CONNECTORS
WHITE RED
GREY GREEN
TO BATTERY +
30" SUPPLIED WIRE EXTENSIONS
HEAVY RED
CAPACITIVE DISCHARGE IGNITION WITH AUTO-SEQUENCE REV LIMITER
GREEN TACH (TAPE UP) GREY MAGNETIC TRIGGER HARNESS (TAPE UP) SUPPLIED MAP SENSOR
3 WIRE HARNESS MANIFOLD VACUUM
RED
®
BLUE OR BROWN (RETARD INPUT)
RANE HI-6TR C cams
RED WHITE BLACK ORANGE
C RANE
ELECTRONICS
YELLOW (TAPE UP) BLACK (GROUND) R
ET AR D
HI-6TR TIMING RETARD CONTROL
15
BLACK
WIRE TAP
ORANGE
HEAVY BLACK TO GROUND
14. IGNITION/BOOST CONTROL UNIT OPERATION Example [5 psi at 3° per per lb.] [7 psi at 2° per per lb.]
MaximumRetard Retard==15° 20° Maximum
15 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. Adjust the retard according to changes in altitude and fuel quality.
10 [10 psi at 1/2° per per lb.] 5
5 7 10 psi Boost
Caution: It is extremely important that the boost retard never be turned to 0° using pump fuel. It is recommended that in stock street applications, the knob be at no less than 1°/lb.
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15. PLENUM AND DISCHARGE INSTALLATION A. Remove the tab holding down the factory air cleaner mounting stud. Use the two (2) supplied 1/4" washers as spacers underneath the mounting stud tab. Reattach the assembly to the throttle body. (See graphic.) B. Place the gasket and plenum onto the throttle body. Secure with plenum nut. C. Fit the 3" x 2" silicone sleeve onto the plenum and slide on the two #48 clamps. D. Slide the 2-3/4" x 2" sleeve onto the supercharger discharge. Secure with #44 clamps. E. Install the discharge tube between the plenum and supercharger and secure with clamps.
FACTORY AIR CLEANER MOUNTING STUD
(2) 1/4" WASHERS THROTTLE BODY SIDE VIEW
16. BYPASS VALVE INSTALLATION A. Slide the 1" x 3-1/2" hose onto the bypass valve. Secure with #16 hose clamps. (See the graphic on the next page.) B. Slide the 1" x 2-1/2" hose onto the discharge duct and bypass valve inlet. Secure with hose clamps. C. Route the 5/32" vacuum line to the bypass valve and FMU tee as shown in the graphic on the next page. D. Using the supplied tee and length of hose, cut the hose 4" from the FMU. E. Install the tee fitting and connect the hose to the bypass valve.
17
16. BYPASS VALVE INSTALLATION, cont'd. DISCHARGE TUBE
TO BYPASS VALVE
FMU
2-1/2" x 1" HOSE
TO INTAKE MANIFOLD INLET DUCT 3-1/2" x 1" HOSE VACUUM HOSE
17. SUPERCHARGER INLET A. Slide the inlet duct and T-bolt clamp onto the supercharger inlet. B. Route the new 5/8" hose from the drivers side valve cover breather, around the rear portion of the intake manifold and attach to the corresponding hose barb on the air inlet duct. C. Connect the bypass assembly to the 1" barb on the air inlet. D. Mount the air filter and secure with supplied hose clamp.
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WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check. 18. 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. Make sure all wires and lines are properly secured with clamps or tie wraps. D. Check all fluid levels, making sure that your tank(s) is filled with 92 octane or higher fuel before commencing test drive. E. Start engine and allow to idle a few minutes, then shut off. F. Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts and for signs of any fluid leakage. Check ignition timing to make sure it is set to stock specifications before commencing test drive. G. PLEASE TAKE SPECIAL NOTE: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS. H. Test drive the vehicle. I. Read the STREET SUPERCHARGER SYSTEM OWNER'S MANUAL AND WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify.
®
ENGINEERING, INC. ®
© 1994 VORTECH ENGINEERING, INC. all rights reserved
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