1992-1996 5.7L LT1 Corvette

1992-1996 5.7L LT1 Corvette

Corvette L

Super

T1

®

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.

®

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)

ATTENTION

CORVETTE OWNERS!

The 3-Year Unlimited Mileage Warranty is automatically included with the purchase of your

Corvette kit. However, you must still fill out the

Warranty Registration Form along with a copy of the original purchase receipt and mail it back to Vortech Engineering within 30 days from time of purchase so that we can activate your warranty. Thank you for choosing Vortech

Engineering!

®

ENGINEERING, Inc.

SPECIAL NOTICE CONCERNING THE

Carroll Supercharging

MAF Signal Massager

Some 1996 LT1 Corvettes 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. warrants this product to be free from defects in material and workmanship under normal use and if properly installed for 90 days. 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 Carroll Supercharging Co., INC. 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 Carroll

Supercharging Co., INC. 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. Please send the unit prepaid with proof of purchase to the attention of:

Carroll Supercharging Co., INC.

Customer Service Department

14 Doty Rd.

Haskell, NJ 07420

(973) 835-1705

(973) 835-1660 Fax www. carrollsupercharging.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, M-F 8AM-4:30PM

(PST).

®

ENGINEERING, 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. 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) 258-6174

(904) 258-6167 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, M-F 8AM-4:30PM (PST).

®

ENGINEERING, INC.

Installation Instructions for

1992 - 1996 Corvette LT1 -

50 State Smog Legal, as per CARB EO #D-213-16

Congratulations on selecting the best performing and best supported automotive supercharger available today... the VORTECH

®

V-1

®

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, Inc. 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, Inc. 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 either a high grade SF rated engine oil or a high quality synthetic lubricant, 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 outlined in 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 sooner.

TOOL & SUPPLY REQUIREMENTS

Factory repair manual

3/8" socket and drive set: SAE & metric

1/2" breaker bar and 4" extension

Flat #2 screwdriver

Phillips #2 screwdriver

Adjustable wrench

Open end wrenches:

Center punch and 5/8" taper punch

3/8" x 2" swivel extension

2 gallons 50/50 coolant and water mix

Tubing cutter

Hose cutter or knife

Loctite ® threadlocker

Drill motor

#7 drill bit

3/8", 7/16", 9/16", 5/8", 3/4", 7/8", 15mm

5/32" allen wrench

1992-1993 Models:

1-3/16" crow's foot tool

1994-1995 Models:

1-1/16" crow's foot tool

1/2"-20 die

5 quarts 20w/50 synthetic motor oil

T-15 torx screwdriver

Spring-lock fitting disconnect tool

3/8" NPT tap

Note: If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will need:

Spark plug socket

8 - new OE heat range spark plugs

4GV020-010-10

1992-93 CORVETTE LTI 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. Attach the pink and white wires to the red and white wires on the supplied ignition box.

3. Reattach the grey connector to the coil (leave the black connector disconnected). Using the supplied male and female connectors, attach the pink wire on the grey connector to the orange wire on the supplied ignition box and attach the white wire to the black wire on the ignition box.

VORTECH

®

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

C RANE

ELECTRONICS

R

ETARD

HI-6TR

TIMING RETARD CONTROL

*NOTE: CABLE CONTAINS RED AND BLACK LEADS.

MAKE SURE LEADS DO NOT CONTACT EACH

OTHER AND SHORT UNIT WHEN TAPING UP.

®

ENGINEERING, INC.

© 1995 VORTECH

®

ENGINEERING, INC. all rights reserved

1994-1996 CORVETTE LTI 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. Reattach the grey connector to the coil (leave the black connector disconnected). Using the supplied male and female connectors, attach the pink wire on the grey connector to the orange wire on the supplied ignition box and attach the white wire to the black wire on the ignition box.

VORTECH

®

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

C

RANE

ELECTRONICS

R

ETARD

HI-6TR

TIMING RETARD CONTROL

*NOTE: CABLE CONTAINS RED AND BLACK LEADS.

MAKE SURE LEADS DO NOT CONTACT EACH

OTHER AND SHORT UNIT WHEN TAPING UP.

®

ENGINEERING, INC.

© 1994 VORTECH

®

ENGINEERING, INC. all rights reserved

®

ENGINEERING, INC.

1992-1993 Corvette LT1

Part No. 4GV218-078S

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.

Part Number

2A229-018

2A129-028

2A036-312

8R101-001

4GV101-004

4GV010-060

7R005-003

4GV014-040

7E010-050

4GV101-002

4GV010-050

8F101-300

7R001-004

7U100-055

8F060-024

7R004-002

7P375-050

7C060-025

7C011-075

7F010-032

7J010-001

7C008-032

7F008-032

7J008-001

5W001-014

5W001-015

5W001-012

5W001-001

7J006-093

5W001-017

7U032-016

8F001-200

7R004-001

4GV111-021

4GV011-021

4GV010-034

4GV010-010

4GV010-040

4GV017-011

4GV017-021

4FA016-170

7A375-075

7A375-100

7A375-425

7A375-525

7J375-044

7F375-016

7K375-040

7A375-375

7U125-000

7P375-050

7U030-056

7U030-000

7R001-004

7R001-008

7U100-055

7A250-100

7F250-021

7A375-224

4GV114-020

4GV055-010

4GV014-010

4GV014-020

4GV014-030

4GV014-051

7R002-024

7C010-050

7R003-022

7R001-008

7J010-001

7P250-074

7F250-021

7J250-001

4GV130-036

7U030-036

7P375-033

7P375-017

7R001-008

7U100-055

7U100-066

Description

SUPERCHARGER ASSEMBLY

V-1S supercharger

Supercharger 3.125" drive pulley

6 rib pulley retainer assembly

MOUNTING BRACKET ASSEMBLY

Mounting bracket

Mounting plate

Attachment plate

Coil mount bracket

Idler spacer

Coil mount spacer

Wide idler pulley

3/8-16 x 3/4" bolts

3/8-16 x 1" bolts

3/8-16 x 4-1/4" bolt

3/8-16 x 5-1/4" bolt

3/8" SAE washers

3/8-16 nuts

3/8" AN960 washers

3/8-16 x 3-3/4" bolt

6" heat sleeves

3/8" hosemender

3/8" x 7-1/4" hose

5/8" x 10" hose

#4 hose clamps

#8 hose clamps

6" nylon tie wraps

1/4-20 x 1" flat head screw

1/4-20 nut

3/8-16 x 2-1/4" bolts

A/C LINE ASSEMBLY

A/C drier bracket

200-87 T-bolt clamp

A/C lines with ends

#12 x 1/2" sheet metal screw

FUEL PUMP ASSEMBLY

Pump mounting bracket

Pump wiring assembly

#4 hose clamps

6" nylon tie wraps

Fuel injectors

17.0 stepless clamps

3/8" hosemender

M6 x 1.00 x 25mm bolts

10/32" x 3/4" bolt

10-32 nylock nut

#10 flat washers

8-32 x 3/4" bolts

8-32 nylock nuts

#8 flat washers

Fuse holder

Blade type 20A fuse

Solderless connector

Wire tap

6mm washer

Large ring terminal

3/8" x 28" fuel hoses

200 inline fuel pump

15.7 stepless clamp

WATER LINE ASSEMBLY

Water tank

Water pipe, L bend

Water pipe, S bend

Water pipe, Z bend

Radiator pipe, polished

#24 hose clamps

10-24 x 1/2" socket heads

1-3/8" adel clamps

#8 stainless hose clamps

#10 flat washers

1/4-20 x 3/4" HXHD cap screw

1/4-20 nylock nut

1/4 SAE washer

OIL DRAIN ASSEMBLY

1/2" x 35" oil drain hose

3/8" NPT x 3/8" NPT street elbow

3/8" NPT x 1/2" straight hose barb

#8 hose clamps

6" nylon tie wraps

11" tie wraps

Quantity

1

1

1

1

2

1

1

1

1

1

1

1

1

4

8

2

4

1

1

1

2

10

8

2

1

2

1

1

1

1

1

1

1

6

1

2

2

1

3

1

1

7

1

7

2

3

1

1

1

8

2

1

1

1

1

1

1

1

1

1

2

2

1

2

1

1

1

1

1

1

8

2

2

1

1

1

1

2

4

4

Description

AIR INTAKE ASSEMBLY

Air filter

Air filter mount tube

3" 90

°

rubber elbow

200-84 T-bone clamps

Air inlet tube

208-91 T-bone clamp

6" nylon tie wraps

3/8" vacuum cap

5/8" x 50" PVC hose

Mass air tube

Air filter tube bracket

#8 hose clamp

#40 hose clamp

3-1/2" x 2" sleeve

#56 hose clamps

3/4 NPT x 1" hose fitting

AIR DISCHARGE ASSEMBLY

Discharge tube, polished

4" x 2" sleeve

#44 hose clamps

Bypass valve

2-3/4" x 2" sleeve

7/8" x 20" heater hose

#16 hose clamps

5/32" x 46" vacuum line

5/32" x 1.5" vacuum line

5/32" tee

#64 hose clamps

FUEL MANAGEMENT UNIT (w/lines)

Fuel management unit, 10:1

29" male fuel line assembly

45" female fuel line assembly

5/32" x 36" vacuum line

5/32" tee

#10 flat washer

6" nylon tie wraps

HI-6TR ASSEMBLY

Crane HI-6TR ignition system

GM wiring harness

Wire tap

16-14GA male slides

16-14GA female slides

16-14GA eyelets

22-GA red solderless connectors

Fuse holder

20A blade type fuse

Large ring terminals

12-10GA solderless connectors

3/4" x 35" plastic wire loom

72" 12GA red wire

24" 12GA black wire

18" 18GA red wire

18" 18GA black wire

18" 18GA orange wire

50" 18GA green wire

18" 18GA white/yellow wire

78" 22GA blue wire

#8 x 3/4" sheet metal screws

5/32" tee

5/32" x 60" vacuum line

6" nylon tie wraps

9" Velcro ® hook

9" Velcro ® latch

Map sensor

OIL FEED ASSEMBLY

1/8" NPT x 1/8" NPT street tee

1/8" NPT straight fitting

90

°

1/8" NPT x #4 flare fitting

.500 crimp ferrules

1/4" x 54" fuel hose

6" nylon tie wraps

#4 swivel x 1/4" hose barb

BELT TENSIONER ASSEMBLY

Belt tensioner

Idler-ribbed pulley

10mm x 1.5" nylock nut

DAMPENER PULLEY ASSEMBLY

Harmonic balancer

Goodyear belt

7/16-14 x 1.75 belts

4GV238-068

6Z110-119

4GV145-156

4GV146-166

7U030-046

7P156-082

7J010-001

7U100-055

5A101-007

5A001-009

5A002-001

5W001-001

5W001-009

5W001-010

5W001-011

5W001-012

5W001-014

5W001-015

5W001-017

5W001-019

5W001-020

5W012-000

5W012-010

5W018-010

5W018-020

5W018-060

5W018-070

5W018-240

5W022-060

7E010-046

7P156-082

7U030-046

7U100-055

7U375-001

7U375-002

5A002-006

4GV130-026

7P125-034

7P125-027

7P125-026

7P525-067

7U030-016

7U100-055

7P250-066

4GV111-042

4GV011-032

4GV016-150

7GL10-150

4GV116-021

4GV016-021

2A046-510

7A437-176

Part Number

4GV112-010

8H040-030

4GV012-031

7S300-000

7R005-002

4GV012-011

7R005-001

7U100-055

7U375-052

7U033-000

4GV012-041

4GV011-034

7R001-008

7R002-040

7S350-200

7R002-056

7P750-100

4GV112-020

4GV012-028

7S400-200

7R002-044

8D001-002

7S275-200

7U136-020

7R002-016

7U030-046

7U030-046

7P156-082

7R002-064

1

1

1

1

1

1

2

4

1

1

1

1

1

1

1

1

11

15

2

6

1

1

1

2

6

1

1

1

1

1

1

1

1

1

1

6

1

1

1

1

1

1

1

3

1

4

1

2

2

1

1

1

Quantity

1

2

1

1

1

1

1

1

1

2

1

2

1

1

1

1

1

3

1

1

1

1

2

1

1

2

1

1

1

®

ENGINEERING, INC.

1994-1996 Corvette LT1

Part No. 4GV218-088S

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.

Description

SUPERCHARGER ASSEMBLY

V-1S supercharger

Supercharger 3.125" drive pulley

6 rib pulley retainer assembly

MOUNTING BRACKET ASSEMBLY

Wide idler pulley

Attachment plate

Mounting plate

Coil mount bracket

Mounting bracket

Idler spacer

Coil mount spacer

3/8-16 x 3/4" bolts

3/8-16 x 1" bolts

3/8-16 x 4-1/4" bolt

3/8-16 x 5-1/4" bolt

3/8" SAE washers

3/8-16 nuts

3/8" AN960 washers

3/8-16 x 3-3/4" bolt

6" heat sleeves

3/8" hosemender

3/8" x 7-1/4" hose

5/8" x 10" hose

#4 hose clamps

#8 hose clamps

6" nylon tie wraps

1/4-20 x 1" flat head screw

1/4-20 nut

3/8-16 x 2-1/4" stainless bolts

BELT TENSIONER ASSEMBLY

Belt tensioner

Idler-ribbed pulley

10mm x 1.5" nylock nut

WATER LINE ASSEMBLY

Water tank

Water pipe, L bend

Water pipe, S bend

Water pipe, Z bend

Radiator pipe, polished

#24 hose clamps

10-24 x 1/2" socket heads

1-3/8" adel clamps

#8 stainless hose clamps

#10 flat washers

1/4-20 x 3/4" HXHD cap screw

1/4-20 nylock nut

1/4 SAE washer

AIR INTAKE ASSEMBLY

Air filter tube bracket

Air inlet tube

Air filter mount tube

22 GA solderless connectors

3/16" x 6" shrink tube

3/8" x 36" flex loom

36" 18GA standard red wire

36" 18GA standard black wire

36" 18GA standard yellow wire

3/4 NPT x 1" straight hose fitting

#8 hose clamp

#40 hose clamp

#56 hose clamps

208-91 3.75" T-bone clamp

200-84 T-bone clamps

3" 90

°

rubber elbow

3-1/2" x 2" sleeve

6" nylon tie wraps

5/8" x 50" PVC hose

3/8" vacuum cap

3/4" breather

Air filter

FUEL MANAGEMENT UNIT (w/lines)

Fuel management unit, 10:1

29" male fuel line assembly

45" female fuel line assembly

5/32" x 36" vacuum line

5/32" tee

#10 flat washer

6" nylon tie wraps

A/C LINE ASSEMBLY

A/C drier bracket

A/C line, with ends

#12 x 1/2" sheet metal screw

200-87 T-bolt clamp

Part Number

2A229-018

2A129-028

2A036-312

8R101-001

4GV111-021

4FA016-170

4GV010-010

4GV010-034

4GV010-040

4GV011-021

4GV017-011

4GV017-021

7A375-075

7A375-100

7A375-425

7A375-525

7J375-044

7F375-016

7K375-040

7A375-375

7U125-000

7P375-050

7U030-056

7U030-000

7R001-004

7R001-008

7U100-055

7A250-100

7F250-021

7A375-224

4GV111-042

4GV011-032

4GV016-150

7GL10-150

4GV114-020

4GV055-010

4GV014-010

4GV014-020

4GV014-030

4GV014-051

7R002-024

7C010-050

7R003-022

7R001-008

7J010-001

7P250-074

7F250-021

7J250-001

4GV112-030

4GV011-034

4GV012-011

4GV012-031

5W001-012

5W001-067

5W011-010

5W118-035

5W118-037

5W118-038

7P750-100

7R001-008

7R002-040

7R002-056

7R005-001

7R005-002

7S300-000

7S350-200

7U100-055

7U033-000

7U375-052

8H040-022

8H040-030

4GV238-068

6Z110-119

4GV145-156

4GV146-166

7U030-046

7P156-082

7J010-001

7U100-055

4GV101-006

4GV010-060

4GV114-045

7E010-050

7R005-003

5A101-007

5A001-009

5A002-001

5W001-001

5W001-009

5W001-010

5W001-011

5W001-012

5W001-014

5W001-015

5W001-017

5W001-019

5W001-020

5W012-000

5W012-010

5W018-010

5W018-020

5W018-060

5W018-070

5W018-240

5W022-060

7E010-046

7P156-082

7U030-046

7U100-055

7U375-001

7U375-002

5A002-006

4GV101-005

4GV010-070

5W001-001

5W001-012

5W001-014

5W001-015

5W001-017

7C008-032

7C011-075

7F008-032

7F010-032

7J006-093

7J008-001

7J010-001

7P375-050

7R001-004

7R004-002

7U100-055

7U032-016

8F001-200

8F101-300

4GV130-036

7U030-036

7P375-033

7P375-017

7R001-008

7U100-055

7U100-066

Part Number

4GV112-020

4GV012-020

7S400-200

7R002-044

8D001-002

7S275-200

7U136-020

7R002-016

7U030-046

7U030-046

7P156-082

7R002-064

4GV116-021

4GV016-021

2A047-510

7A437-176

4GV130-026

7P125-034

7P125-027

7P125-026

7P525-067

7U030-016

7U100-055

7P250-066

Quantity

1

1

1

1

3

1

7

1

1

1

7

2

1

2

1

1

1

1

8

1

1

1

1

2

6

1

2

1

1

3

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Description

AIR DISCHARGE ASSEMBLY

Discharge tube, polished

4" x 2" sleeve

#44 hose clamps

Bypass valve

2-3/4" x 2" sleeve

7/8" x 20" heater hose

#16 hose clamps

5/32" x 46" vacuum line

5/32" x 1.5" vacuum line

5/32" tee

#64 hose clamps

DAMPENER PULLEY ASSEMBLY

Harmonic balancer

Goodyear belt

7/16-14 x 1.75 belts

OIL FEED ASSEMBLY

1/8" NPT x 1/8" NPT street tee

1/8" NPT straight fitting

90

°

1/8" NPT x #4 flare fitting

.500 crimp ferrules

1/4" x 54" fuel hose

6" nylon tie wraps

#4 swivel x 1/4" hose barb

FUEL PUMP ASSEMBLY

Fuel pump bracket

Wire tap

Solderless connector

Fuse holder

Blade type 20A fuse

Large ring terminal

8-32 x 3/4" bolts

10/32" x 3/4" bolts

8-32 nylock nuts

10-32 nylock nuts

6mm washer

#8 flat washers

#10 flat washers

3/8" hosemender

#4 hose clamps

17.0 stepless clamps

6" nylon tie wraps

3/8" x 28" fuel hoses

200 inline fuel pump

Pump wiring assembly

HI-6TR ASSEMBLY

Crane HI-6TR ignition system

GM wiring harness

Wire tap

16-14GA male slides

16-14GA female slides

16-14GA eyelets

22-GA red solderless connectors

Fuse holder

20A blade type fuse

Large ring terminals

12-10GA solderless connectors

3/4" x 35" plastic wire loom

72" 12GA red wire

24" 12GA black wire

18" 18GA red wire

18" 18GA black wire

18" 18GA orange wire

50" 18GA green wire

18" 18GA white/yellow wire

78" 22GA blue wire

#8 x 3/4" sheet metal screws

5/32" tee

5/32" x 60" vacuum line

6" nylon tie wraps

9" Velcro ® hook

9" Velcro ® latch

Map sensor

OIL DRAIN ASSEMBLY

1/2" x 35" oil drain hose

3/8" NPT x 3/8" NPT street elbow

3/8" NPT x 1/2" straight hose barb

#8 hose clamps

6" nylon tie wraps

11" tie wraps

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11

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Quantity

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1

1. COMPONENT REMOVAL

A. It is necessary to remove the refrigerant from the air conditioning system. This should be performed by a qualified

technician using a Refrigerant Recycling System.

Releasing refrigerant into the atmosphere is environmentally irresponsible and should be avoided.

B. Disconnect the battery (negative lead).

C. Remove the air inlet. Pull out the intake air temperature

(IAT) sensor but leave it connected to the harness. Remove the bellows, air filter cover and the entire assembly forward of the throttle body. (If the vehicle is a 1994 model or later, the mass air meter must be removed and set aside by unplugging the wiring connection and cutting the clamps fastening it to intake bellows).

D. Remove the radiator overflow tank underneath the right

(passenger) side headlight.

E. Remove the accessory drive belt and harmonic balancer.

(Do not remove the hub from the crankshaft.)

F. Drain coolant from the radiator. The drain fitting is located on the bottom of the right tank.

G. Remove the radiator hose from the right side.

H. Remove the power steering reservoir and its related brackets and hardware. Use a small container to catch the fluid when the hoses are removed.

I.

Remove the ignition coil and all of its mounting hardware on the right side.

J. Number and remove the spark plug wires from the right bank of the distributor. Place the wires out of the way.

K. Remove the right side injector cover.

1

2. POWER STEERING LINE MODIFICATION

A. Remove the rubber hose and the two fasteners from the 5/8" steel power steering reservoir return line located on the front of the engine. It is not necessary to remove the line from the pump.

B. Use the tubing cutter to cut the steel reservoir line 1-1/2" from the lower tab as shown in the graphic and photo.

C. Use the 3/8" hose splice fitting, #4 clamps and the section of 3/8" x 7-1/4" rubber hose to extend the small rubber reservoir line.

Extend the 5/8" steel line with the 5/8" x 10" rubber hose and the #8 clamps provided.

D. Reattach the 5/8" steel line to the engine block using the tab and original fastener.

E. Slide a 6" section of heat protectant sleeve over the end of each of the rubber power steering lines. The lines should be positioned as low and tight to the block as possible to make room for the mounting bracket. The

3/8" rubber line, which runs back over the crossmember, should be held tightly to the frame horizontally and brought up next to the 5/8" line. Refer to the photo. (Use tie wraps to hold it to the frame and parallel to the 5/8" reservoir line.)

F. Slide the third heat sleeve over all four (4) of the spark plug wires located to the right and reconnect them to the distributor.

TO RESERVOIR

DISCARD

THIS END

1-1/2"

5/8" POWER STEERING

STEEL RESERVOIR

RETURN LINE

TO PUMP

HEAT SLEEVES

HEAT

PROTECTANT

SLEEVE

5/8" x 10" RUBBER HOSE

3/8" x 7-1/4" RUBBER HOSE

3/8" ORIGINAL HOSE

CONNECTED TO POWER

STEERING RESERVOIR

2

3. HARMONIC BALANCER

A. Be sure that both of the mating surfaces of the crank and balancer are clean and free from rust and dirt.

B. Slide the new harmonic balancer onto the crankshaft hub.

C. Rotate the balancer on the crankshaft to find the proper bolt hole alignment. Use the supplied 7/16" x 1-3/4" bolts with

Loctite ® and start all three bolts; then torque to 60 ft./lbs.

4. 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. The return is a gravity drain and must have a gradual drop connecting to the oil pan and away from suspension components or exhaust pipes.

WARNING: The oil system contains a small orifice that is easily plugged. DO NOT use any type sealant on any of the threads.

Instead, use clean engine oil. Disassemble and blow out entire line if you have any doubts.

OIL

SENDING

UNIT

B. Remove the factory oil pressure sending unit located at the rear of the intake manifold with a 1-3/16" crow's foot tool

(1994-1995 models need a 1-1/16" crow's foot tool).

C. Install the supplied 1/8" NPT street tee pointing to the right side of the vehicle. (Refer to the graphic at right.)

D. Install the oil sending unit into the top of the tee.

E. Install the straight #4 flare into the remaining branch in the tee, pointing toward the right side.

F. Install the black oil feed line onto the #4 flare. Cover the end of the oil feed line to protect it from dirt and place it on top of the manifold for later connection.

1/8" NPT

STREET

TEE

ENGINE BLOCK

#4 FLARE

PASSENGER

SIDE

5. OIL DRAIN FITTING

A. To provide an oil drain for the supercharger, it is necessary to make a hole in the oil pan. It is best to punch the pan rather than drill. Remove paint around the hole area so that it does not flake into the pan.

B. Make a mark on the driver's side of the oil pan ahead of the oil filter. The mark must be 2-3/4" below the oil pan mounting flange and rearward of the fifth bolt (from the front) 3/4".

5TH BOLT FROM

THE FRONT

2-3/4"

3

3/4"

5. OIL DRAIN FITTING, cont'd.

C. Use a small center punch to perforate the pan and expand 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.

CAUTION: Use care so as not to strike internal engine components when punching oil pan.

D. 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.

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.

E. Thoroughly clean the threaded area. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8" NPT street elbow and secure in hole (elbow must point toward the front of the vehicle). Make sure a seal is formed all around the fitting. Thread the

3/8" NPT x 1/2" barb fitting into the fitting installed in the pan using pipe sealer.

F. Change the engine oil and filter.

6. FUEL MANAGEMENT UNIT INSTALLATION

A. Attach the Fuel Management Unit (FMU) to the

FMU bracket with the flare fittings pointing down and toward the front of the vehicle as shown in the graphic.

B. Install the FMU and bracket assembly in the space between the heater blower and coolant surge tank. Sandwich one end of the bracket between the blower motor and the relay bracket. Use the #8 washer as a spacer in the rear relay hole. Secure the inboard end at the surge tank bracket. Use the original bolts. (Refer to the photos on next page.)

4

CONNECT TO MANIFOLD

VACUUM/PRESSURE

FMU BRACKET

OUTLET (FUEL

FROM HERE

RETURNS TO TANK)

INLET (FUEL LINE

FROM STOCK

REGULATOR)

6. FUEL MANAGEMENT UNIT INSTALLATION, cont'd.

C. Using a spring-lock fitting disconnect tool, disconnect the return line (the line closest to the front of the car) from the fuel rail (at the top rear of the intake manifold).

D. Install the supplied 45" fuel line by connecting the female spring-lock end onto the fuel rail. Run the line parallel to the feed line and then downward behind the wheel well to the FMU. The flare end will be connected to the 90

°

inlet fitting on the FMU.

E. Fit the 28" male fuel line into the braided tank return line. Route the braided tank return line assembly forward to form a smooth radius pointing downward. Use tie wraps to hold the line in position.

Route the flared end of the line downward behind the wheel well with the other FMU line to the FMU. Connect the line to the center fitting.

NOTE: Make sure you have routed all fuel lines away from all moving parts, sharp edges, exhaust pipes and manifold. Secure the fuel lines with the tie wraps.

FUEL

MANAGEMENT

UNIT (FMU)

TO MANIFOLD PRESSURE

TO FMU

OUTLET

TO FMU

INLET

FUEL

RETURN

LINE

FUEL

FEED

LINE

ADDITIONAL

FUEL PUMP

ENGINE

STANDARD

PUMP

FUEL

TANK

5

7. COOLANT LINE MODIFICATIONS

A. Radiator hose

1) Modify the previously removed radiator hose as shown in the graphic at right. Cut a 2" piece from the upper end for the thermostat housing.

2) Remove a 1-1/2" section where the hose attaches to the radiator and discard.

Reconnect the modified hose.

3) Cut and discard the portion of the bottom section as shown in the graphic.

B. Surge tank hose

NOTE: On 1992 LT1 models the coolant hoses are slightly different. Remove the upper coolant lines and modify according to the diagram on page

7. The throttle body coolant hose must be routed near the valve cover using the "Z" bend 3/4" diameter tube. Disregard points 1 and 2 in section B.

1) Cut the hoses at the left and right sides of the plastic tee in the surge hose (refer to the graphic on page 7, 1993-1994 models;

1995-1996 models do not have a tee located in the surge tank hose line).

2) Discard the short portions and reconnect the modified hoses to the plastic tee with the original clamps.

3) Cut a 2" section off the end that connects to the water pump and reconnect one of the ends with the OEM clamp.

4) Cut off the remaining portion as shown in the graphic on page 8 and install the "S" shaped aluminum tube with the short end into the 2" hose on the water pump.

DISCARD

SAVE THIS

PORTION

2"

SAVE FOR

THERMOSTAT

HOUSING

CUT AT END OF

STRAIGHT PORTION

1-1/2"

DISCARD

RADIATOR

'S' BEND

ALUMINUM TUBE

'L' BEND

ALUMINUM TUBE

(HEATER CORE HOSE)

6

C. HEATER CORE HOSE

NOTE: For 1992 LT1 models, disregard the following five points. There are no lower water pump hoses to modify.

1) Remove the heater core hose from the water pump

(refer to the graphic on page 7). Cut off the last 4" of hose at the water pump end. Set aside for now.

2) Cut off 2-1/2" of hose at the restrictor end.

3) Assemble the short end of the "Z" shaped aluminum tube into the 2-1/2" hose on the restrictor with a #8 clamp.

4) Slide the 4" connector piece that was previously set aside and the #8 clamps onto the long end of the remaining single "L" curve aluminum tube. Slide the "L" bend assembly onto the "Z" bend. Connect the hoses as shown in the graphic on the next page.

5) Using the rubber "S" shaped coolant hose cut from the original heater core hose and #8 clamps, connect the single "L" curved aluminum tube to the water pump.

1992 MODELS ONLY

VALVE COVER

"Z" BEND

ALUMINUM TUBE

DISCARD

2"

2"

"S" BEND

ALUMINUM

TUBE HERE

THROTTLE

BODY HOSE

SURGE TANK

OUTLET HOSE

7

1993-1996 MODELS ONLY

TO

WATER

PUMP

2"

USE "S" BEND

ALUMINUM

TUBE HERE

DISCARD

THIS PORTION

TO THROTTLE BODY

RADIATOR SURGE TANK HOSE

NOTE: 1995 MODELS DO NOT

HAVE A THROTTLE BODY

HOSE AND PLASTIC TEE. DO

NOT CUT MAIN COOLANT

HOSE.

USE

THIS

PORTION

1-3/4"

1-1/4"

CUT AND

DISCARD

TOP VIEW

HEATER CORE HOSE

RESTRICTOR

DISCARD

THIS PORTION

2-1/2"

USE

THIS

PORTION

UP

"Z" BEND

ALUMINUM

TUBE

CUT AT END

OF STRAIGHT

PORTION

CUT AT END

OF STRAIGHT

PORTION

USE

THIS

PORTION

LOWER

WATER

PUMP

4" (USE FOR

CONNECTOR)

"L" BEND

ALUMINUM

TUBE

NOTE: THE "Z/L"BEND WATER

TUBE ASSEMBLY NEEDS TO

BE ROUTED DOWN ON TOP OF

THE VEHICLE FRAME AND

UNDER THE PIVOT OF THE

RIGHT SIDE CONTROL ARM.

4"

CONNECTOR

8

8A. AIR INLET (1992-1993 Models)

A. Trim the fiberglass splash guard as shown in the graphic.

B. Install the air filter mounting tube and bracket into the right side front headlight well (ahead of the wheel) where the coolant reservoir was originally located. Use the original holes and bolts to secure the bracket.

C. Install the rubber 90

°

elbow with a #200-84 band clamp onto the air inlet on the engine compartment side.

D. Use a #40 clamp to attach the filter tube to the mounting bracket. Install the 3-1/2" sleeve and

#56 clamps, attaching one of the clamps to the bracket as shown.

E. Install the air filter extension and clamp onto the air inlet tube inside of the right side headlight pocket

(1992-1993 models only). Attach air filter.

VIEW FROM

BOTTOM

8B. AIR INLET (1994-1996 Models)

A. Follow steps 8A-D above.

B. Locate the MAF sensor connector in the vehicle wiring harness and cut all three wires approximately 2" away from the connector.

C. Extend the MAF connector by using the supplied

36" wires and shrink sleeve. Soldering is recommended. Crimp connectors have been supplied for applications where soldering is not possible.

NOTE: Double check the wire to wire (MAF and harness) relationship before soldering and sealing.

TOP VIEW

AIR FILTER TUBE

D. Attach the MAF meter to the air filter tube as shown. Route the MAF connector down into the headlight well and attach to the air meter. 3/8" flex loom has been provided to protect the extended harness. Attach the supplied air filter to the air meter inlet.

AIR FILTER

TUBE BRACKET

1992-1993

AIR FILTER

EXTENSION

1994-1995

MAF METER

RUBBER ELBOW

AIR INLET DUCT

RIGHT

FRONT

TIRE

FRONT

HEADLIGHT

WELL

BRACKET

RIGHT

FRONT

TIRE

#40 CLAMP

#56 CLAMPS 3-1/2" X 2" SLEEVE

9

9. COOLANT RECOVERY TANK

A. Install the supplied coolant reservoir into the right side front headlight well (next to the air inlet). Use the existing hole and supplied fasteners to attach the reservoir to the fender well (see photo).

B. Carefully bend the original overflow line around the fender well and connect to the new reservoir.

C. Attach the 5/32" vent line to the top fitting on the reservoir and route out of the engine compartment.

AIR FILTER

COOLANT

RECOVERY TANK

10. AIR CONDITIONING ACCUMULATOR RELOCATION

A. Remove the air conditioning line from the accumulator to the evaporator (right side).

B. Remove the air conditioning line clamp and screw located on the frame crossmember in front of the water pump near the accumulator.

C. Use the mounting hole and bolt to line up the supplied "T" bracket (refer to the graphic). Mount the adel clamp and air conditioning line on top of the "T" bracket. Drill a hole with a #12 drill in the frame using the remaining hole in the bracket for a template. Install the supplied #12 sheet metal screw.

D. Carefully bend the outermost line at the air conditioning compressor outward slightly to pull the accumulator into position onto the bracket. Use a second hand to support the line at the compressor, being careful not to kink the line (refer to the photo).

E. Position the accumulator onto the bracket and secure with the band clamp provided.

F. Install the supplied aluminum air conditioning line making sure the

O-rings are in place at the ends of each fitting.

TOP VIEW

FRAME

EXISTING HOLE,

SCREW IN CLAMP

CLAMP

CANISTER

FRONT

AIR CONDITIONING LINE

"T" BRACKET

DRILL HOLE #12

USE #12

SHEET METAL SCREW

ACCUMULATOR

10

11. INTAKE AIR TEMPERATURE (IAT)

SENSOR THREADING

A. Disconnect the IAT sensor from the harness.

B. With a file, remove the ridges from the sensor and thread the sensor to 1/2"-20 with a die.

C. Install the threaded sensor into the supercharger discharge duct and secure.

REMOVE RIDGES

USE A 1/2"-20 DIE TO

THREAD THIS PORTION

12. MOUNTING BRACKET

A. Mount the spring tensioner to the mounting bracket with the supplied hardware. Place the bolt through the center hole in the bracket and position it so that the alignment stud fits into the hole.

B. Fasten the mounting bracket to the engine block and heads using three (3) 3/8-16 x 2-1/4" bolts, one (1)

3/8-16 x 4-1/4" bolt, and four (4) 3/8" flat washers. Make sure that the power steering lines and plug wires are safely secured behind the bracket and the three sections of heat sleeve are positioned properly, staying clear of the exhaust.

C. Modify the power steering bracket by cutting the existing tab to mirror the opposite side of the bracket (refer to graphic).

D. Attach the power steering reservoir to the appropriate hoses with the supplied clamps.

E. Using the dimple as a location point, drill a .25" through hole. Countersink to .40".

F. Attach the modified power steering reservoir bracket to the backside of the mounting bracket with the 1/4-20 x

1" flat head screw, locking nut and flat washer. Refer to graphic on following page for further reference.

CUT

DRILL OUT

DIMPLE TOP .25"

COUNTERSINK

TO .40"

11

POWER

STEERING

RESERVOIR

MOUNT

SPRING

TENSIONER

MOUNTING

BOLT

SPRING

TENSIONER

ALIGNMENT

STUD

12. MOUNTING BRACKET

3/8-16 x 5-1/4"

ATTACHMENT

PLATE

1/4-20 x 1"

FLATHEAD

3/8-16 x 3/4"

TUBE SPACER

MOUNTS TO

SUPERCHARGER

3/8-16 x 2-1/4"

3/8-16 x 4-1/4"

3/8-16 x 2-1/4"

SMOOTH IDLER

PULLEY

PULLEY

SPACER

3/8-16 x 2-1/4"

3/8-16 x 1"

3/8" AN WASHER

SPRING TENSIONER

RIBBED TENSIONER

PULLEY

3/8-16 x 1"

3/8" AN WASHER

3/8-16 x 3-3/4"

3/8" AN WASHER

12

13. SUPERCHARGER MOUNTING PLATE

A. Place the supercharger belt around the crank pulley and under the spring tensioner.

B. Make sure the belt routes around the large riser on the mounting bracket (passenger side, above the spring tensioner), as shown in the graphic, BEFORE the mounting plate is put into position.

C. Place the smooth idler pulley and spacer onto the bracket (make sure that the belt is routed underneath the idler pulley). Place the plate into position with a 3/8-16 x 3-1/2" bolt and 3/8" AN washer through the plate to hold the pulley and spacer in position.

Fasten down the plate with the remaining two (2) 3/8-16 x 1" bolts and 3/8" AN washers to the bracket.

SUPERCHARGER

PULLEY

RISER

14. SUPERCHARGER INSTALLATION

A. Attach the air inlet duct to the supercharger inlet with the

#208-91 clamp. Position the inlet so that it points downward, parallel to the drain fitting. Leave the clamp loose so that the air inlet duct can be rotated for adjustment.

B. Attach the 36" drain hose and clamp to the fitting on then bottom of the supercharger. Make sure that the clamp is rotated so that it will not interfere with the mounting plate when installed.

C. Slide a #200-84 clamp onto the 90

°

rubber inlet elbow.

D. Lower the supercharger/air inlet duct assembly down onto the supercharger plate. Rotating the air inlet duct and supercharger slightly to clear the radiator and mounting plate bolts will ease installation. Feed the oil drain downward and toward the left side.

E. Install the four (4) 3/8-16 x 3/4" bolts and 3/8" AN washers into the supercharger through the bracket underneath, using a 9/16" socket and 1/4" drive ratchet with swivel.

F. Use the 3/8-16 x 5-1/4" bolt, 3/8" washer, 4 hole attachment plate (use the single hole in the middle with the upper single hole offset toward the throttle body) and the tube spacer (in the same order) to connect the upper portion of the supercharger to the supercharger bracket.

13

14. SUPERCHARGER INSTALLATION (cont'd.)

G. Mount the spacer/bolt assembly onto the main mounting bracket with the two (2) 3/8-16 x 3/4" bolts and washers.

Thread the 5-1/4" bolt into the supercharger (refer to the photo).

H. Tighten the air filter mount to the 90

° elbow. Tighten the air inlet duct onto the supercharger.

I.

Mount the short end of the coil-mount bracket to the throttle body (remove the upper right bolt from the throttle body) and the other end to the coil

(refer to the graphic). Mount the opposite end of the coil to the attachment plate. Fasten with the two

(2) 3/8-16 x 3/4" bolts, nuts and washers.

J. Route the supercharger belt around the crank pulley on the rear set of grooves and underneath both the spring tensioner and smooth idler pulley. From the left side, place a

15mm box wrench on the spring tensioner hex. Pull up to provide room for the belt to slip onto the supercharger pulley. Release tension and install the accessory belt following the factory procedure.

K. Install the 90

°

1/8" NPT fitting into the supercharger oil feed with the flare pointing to the right side.

L. Fasten the oil feed line to the flare fitting on the supercharger.

WARNING: The oil system contains a small orifice that is easily plugged. DO NOT use any type sealant on any of the threads. Instead, use clean engine oil. Disassemble and blow out entire line if you have any doubts.

THROTTLE

BODY

COIL-MOUNT BRACKET

(SHORT STRAIGHT END)

3/8-16 x 3/4" BOLT

COIL

3/8-16 x 3/4"

BOLT

TUBE

SPACER

5-1/4-16 x 3/8" BOLT

4 HOLE

ATTACHMENT

PLATE

TOP VIEW

PASSENGER SIDE

FRONT

3/8-16 x 3/4" BOLT

SUPERCHARGER

DISCHARGE

DUCT

14

15. DRAIN LINE

NOTE: It is important that the supercharger oil drain line be routed gradually downward without dips, away from heat, sharp objects and moving parts.

A. Route the supercharger drain hose downward behind the front frame crossmember.

Using tie wraps, secure the drain hose to the steel power steering pressure line located on the steering rack. See fig. A.

B. Route the drain hose around the front of the crank pulley to the driver's side of the engine.

Make sure that the hose maintains smooth downhill routing.

C. Use tie wraps to secure the hose to the rear power steering line, away from the crank pulley and accessory belt. See fig. A and B.

D. Attach the end of the drain hose to the 1/2" drain fitting barb in the oil pan and secure with the supplied #8 hose clamp. Trim the hose length if necessary.

16. RADIATOR PIPE

A. Install the previously cut radiator hoses on the radiator and water neck with OEM clamps.

B. Install the supplied stainless coolant pipe and #24 clamps.

C. Install the two adel clamps, #10-24 x 1/2" screws and #10 washers to hold the coolant pipe in place on top of the air inlet duct.

FROM

SUPERCHARGER

VIEW FROM FRONT

FRAME

CRANK

PULLEY

OIL PAN

POWER STEERING RACK

ROUTE THE DRAIN HOSE AROUND THE CRANK

PULLEY AND BACK TO THE 1/2" BARB IN THE PAN

FIG. A

DAMPENER PULLEY

OIL DRAIN HOSE

TIE WRAP

TO POWER

STEERING LINE

FIG. B

OIL PAN

17. DISCHARGE TUBE

A. Using the #44 clamps, place the 2-3/4" blue sleeve onto the supercharger discharge. Place the large sleeve onto the throttle body using #72 clamps.

B. Install the discharge tube and secure with the clamps to the supercharger and throttle body.

C. Hook up the IAT sensor connector.

D. Connect the length of 7/8" hose from the bypass valve to the barb on the air inlet duct with the #16 hose clamps. Trim the hose, if necessary.

15

18. VACUUM AND BREATHER LINES

A. Remove the fuel regulator vacuum connection from the manifold. Place the 1-1/2" length of 5/32" tubing and a 5/32" vacuum tee on the manifold vacuum spout. Connect the tee to the original fuel regulator line and the 32" vacuum line to the bypass valve.

B. Connect the 36" FMU vacuum line from the FMU to the bypass vacuum line by using a 5/32" tee to splice the lines together.

C. Remove the breather line that connects the throttle body to the valve cover. Place a 1/2" vacuum cap on the nipple at the throttle body. Take the plastic 90

°

breather line and cut as shown in the graphic at right.

D. Install the supplied 5/8" breather line from the fitting on the air filter tube to the 90

°

valve cover breather.

E. On 1994-1995 models, remove the 3/4" air pump inlet hose and section out a straight 4" piece. Install the supplied breather in one hose end and install the other end onto the pump inlet.

NOTE: On some 1994/1995 models there is a 5/32" vacuum line running from the spark distributor module to the throttle body air inlet hose. Reroute the end originally connected to the air inlet hose to the new inlet duct located in between the MAF and the supercharger.

INTAKE

THROTTLE

BODY

BYPASS

VALVE

TO MSD

TO

REGULATOR

VALVE COVER

5/32" VACUUM LINE

FMU

POWER

STEERING

RESERVOIR

SUPERCHARGER

5/8" VALVE COVER

BREATHER LINE

6"

16

AIR FILTER

19. IGNITION/BOOST CONTROL INSTALLATION

A. Mount the Ignition/Boost Control unit above the radiator shroud using Velcro

®

strips (see photo).

B. Route the heavy black cable to a clean ground.

Route the heavy red cable to the battery. Using a solderless connector, connect the supplied fuse holder and fuse to the end of the wire. Set the wire aside for now (do not connect to the battery).

D. Install the Ignition/Boost Control wiring harness following the graphic on the next page. Use the supplied wire and connectors to extend some of the wires, if needed.

E. Locate the tachometer filter in the factory coil harness. (Note: 1994 and 1995 models are not equipped with tach filters. In this case, ignore step "E".) Cut the thin white wire located near the filter. Splice the supplied length of wire and connectors into the thin white wire and run to the green tach output wire on the Ignition/Boost

Control unit.

F. Mount the timing control knob in an easily accessible position from the drivers seat. Attach the black wire to a clean ground and the red wire to a keyed on 12V power source or the red wire from the Vortech ignition box. Tape up the end of the yellow wire to prevent contact with a metal surface. Route the three-wire harness out into the engine compartment near the battery.

Connect the supplied GM-style map sensor to the three-wire harness and secure.

G. Route a vacuum line from the supplied map sensor to the bypass/vacuum line assembly using a 5/32" tee.

17

19. IGNITION/BOOST CONTROL INSTALLATION, cont'd.

FACTORY GM

HARNESS

(UNPLUGGED

FROM COIL)

TO BATTERY +

TO GROUND

HEAVY RED

HEAVY BLACK

VORTECH

®

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN TACH OUTPUT

GREY MAGNETIC TRIGGER

HARNESS (TAPE UP)

SUPPLIED

MAP SENSOR

WIRE TAP

RED

WHITE

BLACK

ORANGE

IGNITION COIL

GM ADAPTER

HARNESS

NO CONNECTIONS

AT GREY TERMINAL

BLACK

TERMINAL

YELLOW (TAPE UP)

BLACK (GROUND)

CRIMP

CONNECTOR

MANIFOLD

VACUUM

CUT THIN WHITE WIRE AND

SPLICE INTO SUPPLIED

WIRE TO TACH OUTPUT

HEAVY WHITE

HEAVY BLACK

3 WIRE

HARNESS

TACH

FILTER

C

RANE

ELECTRONICS

R

ETARD

HI-6TR

TIMING RETARD CONTROL

18

20. IGNITION/BOOST CONTROL OPERATION

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 1

°

per pound position as a starting point, 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.

15

10

5

Example of Ignition Retard vs. Boost:

[5 psi at 3

°

per per lb.]

[7 psi at 2

°

per per lb.]

Maximum Retard = 20

Maximum Retard = 15

°

°

[10 psi at 1/2

°

per per lb.]

5 7 10 psi Boost

Caution: It is extremely important that the boost retard never be turned to 0

°

. It is recommended that in stock street applications, the knob be at no less than 1

°

/lb.

21. AUXILIARY FUEL PUMP INSTALLATION

A. Remove the license plate and frame, gas door, gas cap and rubber fuel overflow catch.

B. Using a 3/4" socket, lower the spare tire and cover assembly.

C. Install the wiring harness/relay assembly into the spare tire well area on the inside of the bumper (underneath the car).

Use one of the square holes in the seam of the fuel tank, a #10 screw and nylon locking nut to secure the relay assembly. On some models, a hole for the relay mount may have to be drilled. Make sure the relay is positioned well inside the spare tire well to eliminate possible spare tire and fuel overflow contact.

D. Secure the fuel pump/lines assembly onto the steel mounting bracket with the provided clamps and #8 fasteners in the direction shown in the graphic on page 21.

19

21. AUXILIARY FUEL PUMP INSTALLATION, cont'd.

NOTE: On 1994-1996 Models disregard step E. Install the fuel pump assembly onto the vehicle through the license plate opening. Use the supplied 10-

32 hardware to mount the pump assembly to the existing hole in the aluminum rear section. See photo.

E. Remove the 6mm bolt that holds the spare tire bracket in position (threads from the front). Install the fuel pump assembly onto the vehicle through the license plate opening.

Use the spare tire bracket hole and supplied 6mm x 25mm bolt to line up the left side fuel pump bracket hole. Use the corresponding hole in the fuel tank seam to mount the right side pump bracket. Use the supplied 6mm screw, nylon locking nuts and washers to secure (see photo).

F. Disconnect the factory fuel supply hose and connect the new hoses as shown in the graphic on the next page. Use the supplied tie wraps to keep the fuel lines away from sharp objects. Make sure the lines are routed in such a way that they make gradual turns with no sharp kinks or bends.

G. Wire the negative terminal on the pump and the #86 relay terminal to a clean ground, free from rust and paint.

H. Using the yellow wire from the #85 relay and a wire tap, splice into the grey wire in the factory fuel pump harness.

I.

Connect the #87 red wire on the relay to the positive terminal on the T-Rex ® fuel pump.

J. Run the remaining long red wire up to the battery, using tie wraps to keep the wire away from heat and moving parts.

Using a solderless connector, connect the supplied fuse holder and fuse to the end of the wire. Using the large ring terminal, crimp both the ignition/boost control fuse wire and the fuel pump fuse wire together (in the same terminal).

Connect the ring terminal to the (+) positive battery post.

K. Replace the license plate and frame, gas door, fuel overflow catch and gas cap.

L. Refer to the graphic on the next page to confirm that all wires are routed correctly. Replace the spare tire and cover, making sure that the wires and relay are not contact with the spare tire and mounting fasteners.

20

21. AUXILIARY FUEL PUMP INSTALLATION (cont'd.)

RELAY

86

87

87A

85

(+) TERMINAL ON

T-REX FUEL PUMP

GROUND

30

(+) BATTERY

TERMINAL

3/8" x 28"

GREY

PURPLE

BLACK

WIRE TAP

FUEL WIRING

CONNECTOR

RETURN

3/8" HOSE MENDER

3/8" x 28"

+

-

M6 x 1.00 x 25 mm HEX HEAD

NOTE: 1994-95 MODELS

DO NOT HAVE A LEFT SIDE

MOUNTING PLATE HOLE

1994-95 MODELS

ORIGINAL TANK

OUTLET

#8-32 x 3/4"

#8 LOCKNUT (4x)

#8 WASHERS (4x)

®

T-REX

®

FLOW

FUEL PUMP

MOUNTING PLATE

1992-93 MODELS

M6 x 1.00 x 25mm HEX HEAD

M6 LOCK NUT

M6 WASHERS (2)

OR

1994-95 MODELS

10-32 X 3/4" HEX HEAD

10-32 LOCK NUT

#10 WASHERS (2)

21

22. FUEL INJECTOR REPLACEMENT

(1992-1993 Models only)

A. Remove the right side injector cover.

B. Disconnect the eight (8) fuel injector wiring connectors and retainers from the injectors.

C. Remove the four (4) 10mm bolts holding down the fuel rail on the intake manifold. Lift up on the rails evenly, removing all eight (8) 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. Install the new injectors into the fuel rails with the terminals facing outward. Attach the injector retainers into the top injector groove.

F. Carefully lower the fuel/rail injector assembly down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

G. Tighten down the fuel rail assembly with the original bolts and attach the wiring connectors to the injector terminals.

H. Replace the left and right side injector covers.

NOTE: Make sure injector retainers are secure and properly installed. Recheck after cycling fuel system.

23. FINAL ASSEMBLY AND CHECK

A. Make sure that the pan fitting is tight and the engine is filled with factory specified synthetic oil.

B. Fill the coolant surge tank with a 50/50 coolant/water mix.

C. Fill the overflow tank approximately one quarter full.

D. Reconnect the battery.

E. 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.

F. 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.

G. Check all fluid levels, making sure that your tank is filled with

92 octane or higher fuel before commencing test drive.

NOTE: Do not attempt to operate the air conditioning until a qualified air conditioning technician has performed the necessary steps to purge and recharge the air conditioning system.

22

23. FINAL ASSEMBLY AND CHECK (cont'd.)

H. Start the engine and bleed the cooling system at the water neck until a steady stream of coolant comes out of the fitting. Retighten the bleed screw.

I.

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.

J. Test drive the vehicle.

K. Recheck the coolant and oil level.

L. Read the STREET

SUPERCHARGER SYSTEM

OWNER'S MANUAL AND

WARRANTY REGISTRATION FORM

within thirty (30) days of purchasing your supercharger system to qualify.

NOTE: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE

OF MAJOR COMPONENTS.

WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including final check.

23

®

ENGINEERING, INC.

© 1997 VORTECH

®

ENGINEERING, INC. all rights reserved

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