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GM VORTEC 4.3L V-6
S-10/Sonoma/Jimmy/Blazer
Supercharger System
Installation Instructions
1996-1999 MODEL YEARS*
50 STATE SMOG LEGAL PER CARB EO #D-213-17
*1999 models Legal in California only for racing vehicles which may never be used upon a highway.
®
ENGINEERING, LLC
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226
FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST
P/N: 4GD020-010
©2001 Vortech Engineering, LLC
All Rights Reserved. Intl. Copr.
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FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area. © 2003 VORTECH ENGINEERING, LLC All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into a
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Table Of Contents FOREWORD .....................................................................................................................................ii TABLE OF CONTENTS ....................................................................................................................iii NOTICE.............................................................................................................................................iv TOOL & SUPPLY REQUIREMENTS ......................
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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
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1996-1999* GM VORTEC 4.3L V-6 S-10/Sonoma/Jimmy/Blazer Installation Instructions 50 State Smog Legal as per CARB EO #D-213-17 *1999 models Legal in California only for racing vehicles which may never be used upon a highway. Congratulations on selecting the best performing and best backed automotive supercharger available today... ® ® the VORTECH V-2 supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Super- charger System Owner's
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1996-1999 GM VORTEC 4.3L V-6 Part No. 4GD218-050/058SQ ® PARTS LIST ENGINEERING, INC. LLC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-280 Supercharger Assembly 1 4GD112-020 Air Discharge Assembly 1 2E128-280 V-2 SQ Supercharger 1 7R002-044 #44 Hose Clamps 4 2A036-312 Supercharger Pulley 3.125" 6 groove 1 8D001-001 Bypass Valve 1 7
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1. COMPONENT REMOVAL A. Disconnect the negative battery cable from the battery. B. Remove and set aside the following components: - The entire air inlet/filter box assembly, including the throttle body resonator and all hardware including the throttle body mounting bolts. - The crankcase vent tube from the passenger side valve cover. - The accessory drive belt. - The tensioner and idler from the alternator mounting bracket. - The alternator and bracket. - The 3/8" stud protruding from the righ
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2. OIL DRAIN, cont'd. 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. E. Thoroughly clean the threaded area. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the supplied 3/8" NPT x 1/2" barb fitting. Install the fitting into the pan. Make sure a seal is formed around the entire fitting. F. Drain the engine oil, install a new filter and refill with fresh oil. G. Reattach anti-roll bar and
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4. MAIN BRACKET A. To accommodate the relocation of the alternator onto the new main bracket, the brown field wire must be extended approximately 12”. Proceed by cutting the wire approximately 4” from the factory plug that attaches to the alternator. Splice the supplied piece of brown wire into the cut wire by soldering. Use the supplied piece of heat shrink tubing to seal the joints. Re-wrap the wire/ harness with the supplied length of plastic flex-loom. B. The transmission cooler lines may
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4. MAIN BRACKET, cont'd J. Reattach the field wire and positive wire to the alternator (make sure that the large positive wire has the factory rubber boot properly secured to prevent arcing to the heat shield). Using the supplied 3/8-16 x 2.75” bolts and washers, attach the alternator to the main bracket. Secure all alternator wiring from heat and sharp objects. K. Align the supercharger mounting plate with the bracket and secure with the supplied 3/8-16 x 3/4” bolts and AN washers. Fig. 4-e 5.
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6. SUPERCHARGER/ACCESSORY DRIVE BELT A. Mount the supplied automatic belt tensioner onto the main bracket. Rotate the unit so that the small alignment pin falls into the corresponding hole in the bracket. Secure the tensioner to the bracket using the suppplied socket head bolt and 7/16" AN washer. B. Route the supplied belt as shown (see Fig. 6-a). Belt installation is easiest when the water pump is the last pulley to be mounted (the radius on the edge of the water pump pulley allows the edge o
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D AR 7 . COIL RELOCATION/IGNITION INSTALLATION A. Remove ignition coil and bracket from the factory SUPPLIED location. COIL B. Separate the coil and module from factory mounting BRACKET bracket. C. Install the coil and module to the supplied bracket using the supplied hardware (see Fig. 7-b). D. Mount the coil and bracket assembly to the intake manifold. Use the factory studs and nuts to secure the coil. (See Fig. 7-c.) E. Remove the interior center console (between the two front seats). Mount
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7 . COIL RELOCATION/IGNITION INSTALLATION, cont'd. PICKUP TRUCK MODELS 2. SUV models (Blazer/Jimmy) CENTER a. The suggested mounting location is in the RETARD CONSOLE storage box located next to the back seat on KNOB the passenger side of the vehicle. b. The retard knob and MAP sensor can mount in MAP the center console as the pickup trucks do (see SENSOR Fig. 7-f). The brown retard wire and thin red power wire must be run over to the remote VACUUM LINE/ HOLE mounted ignition box. WIRING THROU
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8 . SUPERCHARGER DISCHARGE A. Install the supplied discharge plenum using studs, spacers, nuts and washers (see Fig. 8-b). B. Thread the three supplied studs into the factory throttle body mounting holes (into the intake manifold). The shortest of the three studs belongs at the rear of the throttle body. Insert the four spacers into their proper location (see Fig. 8-c). C. Slide the supplied O-ring around the top flange of the throttle body. Use a light amount of oil on the O-ring to allow easy
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9. SUPERCHARGER AIR INLET A. Install the supplied plastic 3/4” x 90° vent adapter into the factory rubber grommet located on the right side valve cover. Rotate the vent adapter so that it points toward the rear of the vehicle. Attach the supplied 3/4” x 20” hose to the installed adapter. B. The oil fill riser must be modified to allow for fitment of the new air inlet duct (see Fig. 9-a). Begin by removing the plastic oil fill riser and cap located on the right side valve cover. Cut the riser in
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9. SUPERCHARGER AIR INLET, CONT'D. I. Slide the supplied 3” orange sleeve onto the outlet of the MAF meter. Connect the previously installed steel supercharger inlet duct to the MAF meter oultet using the supplied section of flex hose and #52 clamps (see Fig. 9-f). J. Check to see that there is adequate clearance between the factory mounted underhood light and the supercharger kit by slowly closing the hood. Remove light if necessary. Fig. 9-d Fig. 9-e Fig. 9-f P/N: 4GD020-010 ©2001 Vortech Eng
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10. FUEL MANAGEMENT UNIT A. Following the Fig. 10-a, position the fuel management unit (FMU) on the inside of the vehicle frame, underneath the driver's seat. Mark and drill two #16 holes. Secure the FMU using the supplied #12 hex head screws. NOTE: Some earlier model trucks are not equipped with quick disconnect fittings and will require the use of compression fittings and alternate fuel lines. Proper lines and fittings are supplied to work with both versions of this vehicle. Refer to Fig- ure
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11. SUPPLEMENTARY FUEL PUMP AND HARNESS NOTE: Some earlier model trucks are not equipped with quick disconnect fittings and will require the use of compression fittings and alternate fuel lines. Proper lines and fittings are supplied to work with both versions of this vehicle. Refer to the graphic below to verify the vehicle you are modifying. QUICK DISCONNECT TYPE FITTINGS ONLY A. Using a fuel line disconnect tool, separate the supply line from the oulet of the fuel filter. B. Attach the suppl
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11. SUPPLEMENTARY FUEL PUMP AND HARNESS, cont'd. H. Following the diagram (see Figs. 11-c, 11d), wire the fuel pump and relay. Use the supplied tie wraps to run the wire and keep it away from heat/abrasion. Use the supplied 8mm nut to connect the main power lead on the relay to the factory fuse/power box underhood (the factory has provided two open power lugs under the power box cover). Tap the yellow relay wire (terminal #87) into the solid gray wire in the harness running along the driver's s
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12. FINAL REASSEMBLY AND CHECK WARNING: Do not attempt to operate the vehicle un- til ALL components are installed and ALL operations are completed including the final check. A. 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. B. 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. M
