1993-1996 5.2L Grand Cherokee

5.2L Je
e
Superc p Cheroke
har ger
e
Insta
Sy
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llat
’93-’95 ion Instructio
5.2L Je
ns for
50 State
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Smog L
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C
1996 5
.2L Jee ARB EO # D-213-1
6
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49 State
Smog L herokee
egal
®
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)
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.
7
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.
8
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.
9
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.
11
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
12
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.
13
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.
14
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.
16
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.
18
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
19