GM FSuper BODY Insta charger LS1 lla S tion I ystem n struc 1998 -2002 tions Mode l Yea rs* *Legal in Cali fornia only fo r racin g vehic les wh ich ma y neve r be us ed upo n a hig hway. ® ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone (805) 247-0226 Fax (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST) P/N: 4GK020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 09JUN03 v3.2(FBodyLS1(4GK v3.
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.
TABLE OF CONTENTS FOREWORD ........................................................................................................................................... ii TABLE OF CONTENTS .......................................................................................................................... iii IMPORTANT NOTES ............................................................................................................................. iv CAMARO SS HOOD MODS ................................
1998-2002 GM F-BODY LS1 IMPORTANT NOTES (Read before installation is started) This kit requires ECM programming. The hand-held ECM programmer is not included in the kit box and must be ordered directly from Vortech by the installing customer (the charge for this unit has been included in the purchase price). Included in this kit is a credit tag for one (1) hand-held programmer. The programmers are made specifically for each individual vehicle with respect to the factory ECM calibration and VIN.
98-02 CAMARO HOOD MODIFICATIONS (SS ONLY) 4 5 3.5" 2 3 3.5" 3.5" 1 NOTE: Be very careful not to cut through the top of the hood. 1. Areas to be removed. 2. Align with hood hinge and cut perpendicularly through the air duct using a pneumatic cutting wheel. 3. Align for the second cut straight down from the first cut. 4. Cut this section symmetrically to the other using the same points of reference. 5. Measure 3.5" from the indented line in ram air. Cut perpendicularly through the air duct.
1998 - 2002 GM F-Body LS1 Installation Instructions Congratulations on selecting the best performing and best supported automotive supercharger available today... the VORTECH ® Supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual and Automotive Limited Warranties Program. Vortech supercharger systems are performance improving devices.
1998-2002 GM F-Body LS1 Standard Part No. 4GK218-010SQ ® PARTS LIST ENGINEERING, 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 2D228-110 SUPERCHARGER ASSY, LS1 FBODY STD, 98-00 2A038-370 3.
1998-2000 GM F-Body LS1 w/Charge Air Cooler Part No. 4GK218-060SQ ® PARTS LIST ENGINEERING, 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 2D228-100 2A038-312 2A038-495 SUPERCHARGER ASSY, 1998 LS1, W/COOLER 3.12 Drive Pulley Belt 1 1 1 MOUNTING BRACKET ASSEMBLY Mounting Bracket Support Spring Tensioner, 5.
1998-2000 GM F-Body LS1 w/Charge Air Cooler Part No. 4GK218-060SQ ® PARTS LIST ENGINEERING, 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 Mtg. Tab, LS1 Fbody 3/8 x 3/8 x 1/4 Male Barb TEE 1/8 NPT - 90° to 1/4 Barb 1/4" Vacuum Hose Tie Wrap, 6" Nylon Tie wrap, 4" Nylon 1/4-20 SHCS, 1/2 Long 6mm Washer, Plated 1 1 1 1.
2001-2002 GM F-Body LS1 w/Charge Air Cooler Part No. 4GK218-080SQ ® PARTS LIST ENGINEERING, 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 2D228-100 2A038-312 2A038-495 SUPERCHARGER ASSY, 1998 LS1, W/COOLER 3.12 Drive Pulley Belt 1 1 1 MOUNTING BRACKET ASSEMBLY Mounting Bracket Support Spring tensioner, 5.
2001-2002 GM F-Body LS1 w/Charge Air Cooler Part No. 4GK218-080SQ ® PARTS LIST ENGINEERING, 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 Tab A, Coil Relocation 6mm Tab B, Coil Relocation M6 x 1.
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1. COMPONENT REMOVAL A. Disconnect the negative cable at the battery. B. Remove all ducting between the air filter cover and the throttle body (set aside MAF meter, taking care to protect the wire elements inside). C. Remove the air temperature sensor and grommet from ducting (set aside). D. Remove and discard the hose that connects the passenger's side valve cover breather to the throttle body. E. Cap off the throttle body nipple with the supplied 3/8" vacuum cap. F.
2. SUPERCHARGER MOUNTING BRACKET A. For 1999-2002 vehicles, the driver’s side coil mounting bracket must be relocated 1” to make room for the supercharger inlet. Follow the steps in the coil relocate schematic (see Fig. 2a, 2-b) using the supplied 6mm hardware unless noted. Only four of the original mounting holes are utilized. B. Unbolt the coil bracket from the valve cover (5 stud bolts). VORTECH TAB INSTALLED Fig.
3. OIL DRAIN LINE A. To provide an oil drain for the supercharger, it is necessary to make a hole in the front of the oil pan. Locate and centerpunch the hole. This hole should be centered .40” from the bottom of the oil pan lip between the last bolt and the driver’s side of the oil pan. (See Fig. 3-a.) B. Drill the 1/8” pilot hole at the center location. C. Use the supplied 9/16” Rotabroach to drill a hole in oil pan. Break through the pan easily so that the cut out piece does not go into the oil pan. D.
4. OIL FEED LINE A. Spray the nuts securing the driver’s side catalytic converter with penetrating oil and remove. Use caution not to shear off the exhaust manifold studs! B. Remove the two bolts holding the small casting located just above the oil filter. C. Drill through the existing hole in the casting neck with an “R” drill bit and tap 1/8” NPT. Thoroughly clean the neck with solvent to remove metal clips. D.
6. RADIATOR HOSE MODIFICATION A. The object of this section is to route the radiator hose as close to the radiator as possible to provide room for the supercharger belt and spring tensioner. B. Drain the coolant system until the upper radiator hose can be removed. C. Leaving the straight legs as long as possible, trim the supplied hose per Fig. 6-a. D. (Vehicles with power steering cooler) Remove the radiator hose connecting the engine to the power steering cooler.
7. POWER STEERING INSTALLATION, cont'd. H. Install the assembly on the supercharger mounting bracket. Install two 5/16 socket head cap screws through the supercharger support into the mounting bracket. I. To ensure that the power steering supply fitting remains seated, pry the small fitting retaining bracket downward and tighten the 1/4” screws. J. Attach the supplied 1/2” hose to the pump fitting and secure with a hose clamp.
8. FUEL INJECTOR REPLACEMENT, cont'd. 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 clips to the injector terminals. 9. SUPERCHARGER INSTALLATION TO SUPERCHARGER VOLUTE A. Attach the supplied 1/2" oil drain hose to the supercharger and tighten clamp. B. Install the supercharger loosely onto the bracket.
10. CHARGE AIR COOLER ASSEMBLY INSTALLATION, (for non-charge air cooled standard supercharger kit installation, go to step 11) A1. 1998-2000 - EGR removal, relocation/heat shield installation 1. Remove EGR valve. Using thread sealer, install 1/8" NPT plugs in the EGR relocation plate. 2. Using the new supplied gasket, bolt the EGR valve to the relocation plate using 5/16” bolts and washers. 3. Install EGR relocation plate and heat shield using new gasket and supplied 8mm bolts.
10. CHARGE AIR COOLER ASSEMBLY INSTALLATION, cont'd. 3. Place the #52 hose clamp over the raised tab on the A/C canister anchor. A/C line support clamp may need to be removed for ease of installation. Tighten the clamp until the A/C canister is seated tightly against its anchor. Tighten the bolt securing the anchor to the strut tower. Tighten the factory clamp-on A/C canister bracket. C. Water reservoir assembly 1.
10. CHARGE AIR COOLER ASSEMBLY INSTALLATION, cont'd. TO BYPASS VALVE ® SUPERCHARGER DISCHARGE ™ 1/4” HOSE COOLED CHARGE AIR SURGE TANK TO RADIATOR OVERFLOW HOSE MOLDED WATER TANK 3/4” HOSE WATER PUMP )-( )+( WATER COOLER (Located In Front Of Vehicle Radiator) Fig. 10-f Charge Air Cooler Schematic P/N: 4GK020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 09JUN03 v3.2(FBodyLS1(4GK V3.
10. CHARGE AIR COOLER ASSEMBLY INSTALLATION, cont'd. 4. Connect the hose previously routed into the fender well to the fitting on the top of the reservoir. Install the clamp. 5. Remove horn bracket assembly. Using supplied 8mm bolt, attach water pump bracket to vehicle using original horn bracket mounting hole. Install original horn bracket retaining bolt through second water pump mounting bracket hole and tighten.
10. CHARGE AIR COOLER ASSEMBLY INSTALLATION, cont'd. 6. Install the supplied TEE and connect the remaining barb on the TEE to the barb on the surge tank using 1/4" hose. 7. Secure the hose with tie wraps. H. Charge air cooler radiator installation 1. Remove the plastic push connectors holding the bumper fascia on either side of the center connector. 2. From above, install 5/16" bolts through holes and radiator brackets and start nuts. 3.
11. STANDARD KIT DISCHARGE DUCT INSTALLATION, (for charge air cooler kit installation skip step 11 and go to step 12) A. Loosely install the supplied sleeves on both ends of the discharge duct. Put the discharge duct into position and slide the sleeves onto the supercharger and the throttle body. B. Tighten clamps on both ends of the discharge duct. 12. SUPERCHARGER BYPASS VALVE INSTALLATION A. Thread 1" NPT plastic fitting into charge air cooler inlet manifold. (Charge air cooled vehicles only) B.
13. FUEL PUMP INSTALLATION A. Inside the vehicle, remove the rear paneling, fold the carpet forward and flip the rear seats forward. Remove the rear driver's side seat. B. Locate the fuel relay box underneath the vehicle rear seat floor pan. Disconnect the two plugs entering the box. Trim the "cut-out" from the supplied template on page 16 (see Fig. 13-b) and place over the fuel relay. Center punch and drill the two holes 17/64" in diameter. Reinstall the factory relay plugs . C.
13. FUEL PUMP INSTALLATION, cont'd. D. Reinstall rear carpet and seats. E. Loosen the tank filler cap to vent any residual pressure. F. Disconnect the original plastic fuel feed hose to the fuel filter inlet. G. Route the fuel pump inlet hose around the front of the fuel filter to form a smooth, gradual bend to the pump. Attach the hose to the factory supply line from the tank. H. Attach the pump discharge line to the inlet of the fuel filter. Use wraps to keep all fuel lines tight against the underbody.
13. FUEL PUMP INSTALLATION, cont'd. TEMPLATE FUEL PUMP KIT CENTER PUNCH AND DRILL TWO 17/64” HOLES CUT OUT PATTERN AND PLACE OVER FUEL SYSTEM RELAY AS A GUIDE UP CUT OUT (RELAY) RELAY LOCATED UNDERNEATH THE REAR SEAT FLOORPAN IN THE DRIVER’S SIDE OF THE VEHICLE NOTE: ENSURE WIRES INSIDE CAR ARE TUCKED DOWN AWAY FROM POSSIBLE CONTACT WITH DRILL BIT WHEN DRILLING. Fig. 13-b STOCK RELAY BOX ATTACH YELLOW VORTECH RELAY WIRE TO FACTORY GREY WIRE.
13. FUEL PUMP INSTALLATION, cont'd. RELAY (+) TERMINAL ON FUEL PUMP 87 86 87A GREY PURPLE 85 BLACK GROUND 30 (+) BATTERY TERMINAL FACTORY FUEL WIRING CONNECTOR Fig. 13-e 14. INLET DUCT INSTALLATION A. Install the supplied grommet and 3/8” elbow into the 180° inlet duct hole. B. Attach short leg of large duct to supercharger with 3-1/2" sleeve and clamps. C. Attach MAF to long end of 180° inlet duct using 3-1/2” sleeve and clamps.
15. REFLASH COMPUTER MICRO TUNER 2001 VEHICLE PROGRAMMING INSTRUCTIONS IMPORTANT! To ensure trouble-free programming of your vehicle's computer: • Make sure the vehicle's battery is sufficiently charged. • Turn off all accessories and close doors to prevent unnecessary drain on the battery. • Do not attempt to program your vehicle while a battery charger is connected. • Improper battery voltage will result in failure of the programming process.
16. FINAL ASSEMBLY AND CHECK, cont'd B. For a vehicle equipped with an automatic transmission, make sure that the automatic transmission cooling lines will not contact the crank pulley when the vehicle is in operation. Secure as necessary. C. Fill the factory radiator and the factory coolant surge tank with a 50/50 coolant/water mix. D. If your vehicle has gone over 20,000 miles since its last spark plug change, you will need to change the spark plugs now before test-driving the vehicle. E.
® ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone (805) 247-0226 Fax (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST) P/N: 4GK020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 09JUN03 v3.2(FBodyLS1(4GK V3.
