Vortech Superchargers 1992-1996 5.7L LT1 Corvette Installation guide

Brand: Vortech Superchargers

Model: 1992-1996 5.7L LT1 Corvette

Category: Cable clamps

Type: Installation guide

Corvette LT1

Supercharger System

Installation Instructions

1992-1996 MODEL YEARS

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

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901

VORTECH

ENGINEERING, INC.

This product is protected by state common law,

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.

NOTICE

1650 Pacific Avenue, Channel Islands, CA 93033 • (805) 247-0226

FAX (805) 247-0669 • http://www.vortecheng.com • M-F 8AM - 4:30PM (PST)

ENGINEERING, INC.

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!

VORTECH

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 pre-

paid 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 pre-

paid 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.

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:

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

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

Congratulations on selecting the best performing and best supported automotive

supercharger available today... the VORTECH® V-1® Supercharger!

Installation Instructions for

1992 - 1996

Corvette LT1 -

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

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

1/2"-20 die

5 quarts 20w/50 synthetic motor oil

T-15 torx screwdriver

Spring-lock fitting disconnect tool

3/8" NPT tap

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.

ENGINEERING, INC.

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

VORTECH

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

*NOTE: CABLE CONTAINS RED AND BLACK LEADS.

MAKE SURE LEADS DO NOT CONTACT EACH

OTHER AND SHORT UNIT WHEN TAPING UP.

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 con-

nectors 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. Con-

nect the two pink wires together to one red wire. Attach the pink

and white wires to the red and white wires on the supplied igni-

tion box.

3. Reattach the grey connector to the coil (leave the black connec-

tor disconnected). Using the supplied male and female connec-

tors, 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.

ENGINEERING, INC.

RANE

ELECTRONICS

HI-6TR

TIMING RETARD CONTROL

VORTECH

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

*NOTE: CABLE CONTAINS RED AND BLACK LEADS.

MAKE SURE LEADS DO NOT CONTACT EACH

OTHER AND SHORT UNIT WHEN TAPING UP.

Part Number Description Quantity

2A229-018 SUPERCHARGER ASSEMBLY 1

2A129-028 V-1S supercharger 1

2A036-312 Supercharger 3.125" drive pulley 1

8R101-001 6 rib pulley retainer assembly 1

4GV111-021 MOUNTING BRACKET ASSEMBLY 1

4GV011-021 Mounting bracket 1

4GV010-034 Mounting plate 1

4GV010-010 Attachment plate 1

4GV010-040 Coil mount bracket 1

4GV017-011 Idler spacer 1

4GV017-021 Coil mount spacer 1

4FA016-170 Wide idler pulley 1

7A375-075 3/8-16 x 3/4" bolts 8

7A375-100 3/8-16 x 1" bolts 2

7A375-425 3/8-16 x 4-1/4" bolt 1

7A375-525 3/8-16 x 5-1/4" bolt 1

7J375-044 3/8" SAE washers 7

7F375-016 3/8-16 nuts 2

7K375-040 3/8" AN960 washers 7

7A375-375 3/8-16 x 3-3/4" bolt 1

7U125-000 6" heat sleeves 3

7P375-050 3/8" hosemender 1

7U030-056 3/8" x 7-1/4" hose 1

7U030-000 5/8" x 10" hose 1

7R001-004 #4 hose clamps 2

7R001-008 #8 hose clamps 2

7U100-055 6" nylon tie wraps 6

7A250-100 1/4-20 x 1" flat head screw 1

7F250-021 1/4-20 nut 1

7A375-224 3/8-16 x 2-1/4" bolts 3

4GV101-004 A/C LINE ASSEMBLY 1

4GV010-060 A/C drier bracket 1

7R005-003 200-87 T-bolt clamp 1

4GV014-040 A/C lines with ends 1

7E010-050 #12 x 1/2" sheet metal screw 1

4GV101-002 FUEL PUMP ASSEMBLY 1

4GV010-050 Pump mounting bracket 1

8F101-300 Pump wiring assembly 1

7R001-004 #4 hose clamps 2

7U100-055 6" nylon tie wraps 10

8F060-024 Fuel injectors 8

7R004-002 17.0 stepless clamps 2

7P375-050 3/8" hosemender 1

7C060-025 M6 x 1.00 x 25mm bolts 2

7C011-075 10/32" x 3/4" bolt 1

7F010-032 10-32 nylock nut 1

7J010-001 #10 flat washers 2

7C008-032 8-32 x 3/4" bolts 4

7F008-032 8-32 nylock nuts 4

7J008-001 #8 flat washers 8

5W001-014 Fuse holder 1

5W001-015 Blade type 20A fuse 1

5W001-012 Solderless connector 1

5W001-001 Wire tap 1

7J006-093 6mm washer 1

5W001-017 Large ring terminal 1

7U032-016 3/8" x 28" fuel hoses 2

8F001-200 200 inline fuel pump 1

7R004-001 15.7 stepless clamp 1

4GV114-020 WATER LINE ASSEMBLY 1

4GV055-010 Water tank 1

4GV014-010 Water pipe, L bend 1

4GV014-020 Water pipe, S bend 1

4GV014-030 Water pipe, Z bend 1

4GV014-051 Radiator pipe, polished 1

7R002-024 #24 hose clamps 2

7C010-050 10-24 x 1/2" socket heads 2

7R003-022 1-3/8" adel clamps 2

7R001-008 #8 stainless hose clamps 8

7J010-001 #10 flat washers 2

7P250-074 1/4-20 x 3/4" HXHD cap screw 1

7F250-021 1/4-20 nylock nut 1

7J250-001 1/4 SAE washer 2

4GV130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2" x 35" oil drain hose 1

7P375-033 3/8" NPT x 3/8" NPT street elbow 1

7P375-017 3/8" NPT x 1/2" straight hose barb 1

7R001-008 #8 hose clamps 2

7U100-055 6" nylon tie wraps 4

7U100-066 11" tie wraps 4

Part Number Description Quantity

4GV112-010 AIR INTAKE ASSEMBLY 1

8H040-030 Air filter 1

4GV012-031 Air filter mount tube 1

7S300-000 3" 90° rubber elbow 1

7R005-002 200-84 T-bone clamps 2

4GV012-011 Air inlet tube 1

7R005-001 208-91 T-bone clamp 1

7U100-055 6" nylon tie wraps 3

7U375-052 3/8" vacuum cap 1

7U033-000 5/8" x 50" PVC hose 1

4GV012-041 Mass air tube 1

4GV011-034 Air filter tube bracket 1

7R001-008 #8 hose clamp 1

7R002-040 #40 hose clamp 1

7S350-200 3-1/2" x 2" sleeve 1

7R002-056 #56 hose clamps 2

7P750-100 3/4 NPT x 1" hose fitting 1

4GV112-020 AIR DISCHARGE ASSEMBLY 1

4GV012-028 Discharge tube, polished 1

7S400-200 4" x 2" sleeve 1

7R002-044 #44 hose clamps 2

8D001-002 Bypass valve 1

7S275-200 2-3/4" x 2" sleeve 1

7U136-020 7/8" x 20" heater hose 1

7R002-016 #16 hose clamps 2

7U030-046 5/32" x 46" vacuum line 1

7U030-046 5/32" x 1.5" vacuum line 1

7P156-082 5/32" tee 1

7R002-064 #64 hose clamps 2

4GV238-068 FUEL MANAGEMENT UNIT (w/lines) 1

6Z110-119 Fuel management unit, 10:1 1

4GV145-156 29" male fuel line assembly 1

4GV146-166 45" female fuel line assembly 1

7U030-046 5/32" x 36" vacuum line 1

7P156-082 5/32" tee 1

7J010-001 #10 flat washer 1

7U100-055 6" nylon tie wraps 6

5A101-007 HI-6TR ASSEMBLY 1

5A001-009 Crane HI-6TR ignition system 1

5A002-001 GM wiring harness 1

5W001-001 Wire tap 1

5W001-009 16-14GA male slides 11

5W001-010 16-14GA female slides 15

5W001-011 16-14GA eyelets 2

5W001-012 22-GA red solderless connectors 6

5W001-014 Fuse holder 1

5W001-015 20A blade type fuse 1

5W001-017 Large ring terminals 2

5W001-019 12-10GA solderless connectors 4

5W001-020 3/4" x 35" plastic wire loom 1

5W012-000 72" 12GA red wire 1

5W012-010 24" 12GA black wire 1

5W018-010 18" 18GA red wire 1

5W018-020 18" 18GA black wire 1

5W018-060 18" 18GA orange wire 1

5W018-070 50" 18GA green wire 1

5W018-240 18" 18GA white/yellow wire 1

5W022-060 78" 22GA blue wire 1

7E010-046 #8 x 3/4" sheet metal screws 2

7P156-082 5/32" tee 1

7U030-046 5/32" x 60" vacuum line 1

7U100-055 6" nylon tie wraps 6

7U375-001 9" Velcro® hook 1

7U375-002 9" Velcro® latch 1

5A002-006 Map sensor 1

4GV130-026 OIL FEED ASSEMBLY 1

7P125-034 1/8" NPT x 1/8" NPT street tee 1

7P125-027 1/8" NPT straight fitting 1

7P125-026 90° 1/8" NPT x #4 flare fitting 1

7P525-067 .500 crimp ferrules 2

7U030-016 1/4" x 54" fuel hose 1

7U100-055 6" nylon tie wraps 4

7P250-066 #4 swivel x 1/4" hose barb 2

4GV111-042 BELT TENSIONER ASSEMBLY 1

4GV011-032 Belt tensioner 1

4GV016-150 Idler-ribbed pulley 1

7GL10-150 10mm x 1.5" nylock nut 1

4GV116-021 DAMPENER PULLEY ASSEMBLY 1

4GV016-021 Harmonic balancer 1

2A046-510 Goodyear belt 1

7A437-176 7/16-14 x 1.75 belts 3

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.

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.

Part Number Description Quantity

4GV112-020 AIR DISCHARGE ASSEMBLY 1

4GV012-020 Discharge tube, polished 1

7S400-200 4" x 2" sleeve 1

7R002-044 #44 hose clamps 2

8D001-002 Bypass valve 1

7S275-200 2-3/4" x 2" sleeve 1

7U136-020 7/8" x 20" heater hose 1

7R002-016 #16 hose clamps 2

7U030-046 5/32" x 46" vacuum line 1

7U030-046 5/32" x 1.5" vacuum line 1

7P156-082 5/32" tee 1

7R002-064 #64 hose clamps 2

4GV116-021 DAMPENER PULLEY ASSEMBLY 1

4GV016-021 Harmonic balancer 1

2A047-510 Goodyear belt 1

7A437-176 7/16-14 x 1.75 belts 3

4GV130-026 OIL FEED ASSEMBLY 1

7P125-034 1/8" NPT x 1/8" NPT street tee 1

7P125-027 1/8" NPT straight fitting 1

7P125-026 90° 1/8" NPT x #4 flare fitting 1

7P525-067 .500 crimp ferrules 2

7U030-016 1/4" x 54" fuel hose 1

7U100-055 6" nylon tie wraps 4

7P250-066 #4 swivel x 1/4" hose barb 2

4GV101-005 FUEL PUMP ASSEMBLY 1

4GV010-070 Fuel pump bracket 1

5W001-001 Wire tap 1

5W001-012 Solderless connector 1

5W001-014 Fuse holder 1

5W001-015 Blade type 20A fuse 1

5W001-017 Large ring terminal 1

7C008-032 8-32 x 3/4" bolts 4

7C011-075 10/32" x 3/4" bolts 2

7F008-032 8-32 nylock nuts 4

7F010-032 10-32 nylock nuts 2

7J006-093 6mm washer 1

7J008-001 #8 flat washers 8

7J010-001 #10 flat washers 4

7P375-050 3/8" hosemender 1

7R001-004 #4 hose clamps 2

7R004-002 17.0 stepless clamps 3

7U100-055 6" nylon tie wraps 10

7U032-016 3/8" x 28" fuel hoses 2

8F001-200 200 inline fuel pump 1

8F101-300 Pump wiring assembly 1

5A101-007 HI-6TR ASSEMBLY 1

5A001-009 Crane HI-6TR ignition system 1

5A002-001 GM wiring harness 1

5W001-001 Wire tap 1

5W001-009 16-14GA male slides 11

5W001-010 16-14GA female slides 15

5W001-011 16-14GA eyelets 2

5W001-012 22-GA red solderless connectors 6

5W001-014 Fuse holder 1

5W001-015 20A blade type fuse 1

5W001-017 Large ring terminals 2

5W001-019 12-10GA solderless connectors 4

5W001-020 3/4" x 35" plastic wire loom 1

5W012-000 72" 12GA red wire 1

5W012-010 24" 12GA black wire 1

5W018-010 18" 18GA red wire 1

5W018-020 18" 18GA black wire 1

5W018-060 18" 18GA orange wire 1

5W018-070 50" 18GA green wire 1

5W018-240 18" 18GA white/yellow wire 1

5W022-060 78" 22GA blue wire 1

7E010-046 #8 x 3/4" sheet metal screws 2

7P156-082 5/32" tee 1

7U030-046 5/32" x 60" vacuum line 1

7U100-055 6" nylon tie wraps 6

7U375-001 9" Velcro® hook 1

7U375-002 9" Velcro® latch 1

5A002-006 Map sensor 1

4GV130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2" x 35" oil drain hose 1

7P375-033 3/8" NPT x 3/8" NPT street elbow 1

7P375-017 3/8" NPT x 1/2" straight hose barb 1

7R001-008 #8 hose clamps 2

7U100-055 6" nylon tie wraps 4

7U100-066 11" tie wraps 4

Part Number Description Quantity

2A229-018 SUPERCHARGER ASSEMBLY 1

2A129-028 V-1S supercharger 1

2A036-312 Supercharger 3.125" drive pulley 1

8R101-001 6 rib pulley retainer assembly 1

4GV111-021 MOUNTING BRACKET ASSEMBLY 1

4FA016-170 Wide idler pulley 1

4GV010-010 Attachment plate 1

4GV010-034 Mounting plate 1

4GV010-040 Coil mount bracket 1

4GV011-021 Mounting bracket 1

4GV017-011 Idler spacer 1

4GV017-021 Coil mount spacer 1

7A375-075 3/8-16 x 3/4" bolts 8

7A375-100 3/8-16 x 1" bolts 2

7A375-425 3/8-16 x 4-1/4" bolt 1

7A375-525 3/8-16 x 5-1/4" bolt 1

7J375-044 3/8" SAE washers 7

7F375-016 3/8-16 nuts 2

7K375-040 3/8" AN960 washers 7

7A375-375 3/8-16 x 3-3/4" bolt 1

7U125-000 6" heat sleeves 3

7P375-050 3/8" hosemender 1

7U030-056 3/8" x 7-1/4" hose 1

7U030-000 5/8" x 10" hose 1

7R001-004 #4 hose clamps 2

7R001-008 #8 hose clamps 2

7U100-055 6" nylon tie wraps 6

7A250-100 1/4-20 x 1" flat head screw 1

7F250-021 1/4-20 nut 1

7A375-224 3/8-16 x 2-1/4" stainless bolts 3

4GV111-042 BELT TENSIONER ASSEMBLY 1

4GV011-032 Belt tensioner 1

4GV016-150 Idler-ribbed pulley 1

7GL10-150 10mm x 1.5" nylock nut 1

4GV114-020 WATER LINE ASSEMBLY 1

4GV055-010 Water tank 1

4GV014-010 Water pipe, L bend 1

4GV014-020 Water pipe, S bend 1

4GV014-030 Water pipe, Z bend 1

4GV014-051 Radiator pipe, polished 1

7R002-024 #24 hose clamps 2

7C010-050 10-24 x 1/2" socket heads 2

7R003-022 1-3/8" adel clamps 2

7R001-008 #8 stainless hose clamps 8

7J010-001 #10 flat washers 2

7P250-074 1/4-20 x 3/4" HXHD cap screw 1

7F250-021 1/4-20 nylock nut 1

7J250-001 1/4 SAE washer 1

4GV112-030 AIR INTAKE ASSEMBLY 1

4GV011-034 Air filter tube bracket 1

4GV012-011 Air inlet tube 1

4GV012-031 Air filter mount tube 1

5W001-012 22 GA solderless connectors 6

5W001-067 3/16" x 6" shrink tube 1

5W011-010 3/8" x 36" flex loom 1

5W118-035 36" 18GA standard red wire 1

5W118-037 36" 18GA standard black wire 1

5W118-038 36" 18GA standard yellow wire 1

7P750-100 3/4 NPT x 1" straight hose fitting 1

7R001-008 #8 hose clamp 1

7R002-040 #40 hose clamp 1

7R002-056 #56 hose clamps 2

7R005-001 208-91 3.75" T-bone clamp 1

7R005-002 200-84 T-bone clamps 2

7S300-000 3" 90° rubber elbow 1

7S350-200 3-1/2" x 2" sleeve 1

7U100-055 6" nylon tie wraps 3

7U033-000 5/8" x 50" PVC hose 1

7U375-052 3/8" vacuum cap 1

8H040-022 3/4" breather 1

8H040-030 Air filter 1

4GV238-068 FUEL MANAGEMENT UNIT (w/lines) 1

6Z110-119 Fuel management unit, 10:1 1

4GV145-156 29" male fuel line assembly 1

4GV146-166 45" female fuel line assembly 1

7U030-046 5/32" x 36" vacuum line 1

7P156-082 5/32" tee 1

7J010-001 #10 flat washer 1

7U100-055 6" nylon tie wraps 6

4GV101-006 A/C LINE ASSEMBLY 1

4GV010-060 A/C drier bracket 1

4GV114-045 A/C line, with ends 1

7E010-050 #12 x 1/2" sheet metal screw 1

7R005-003 200-87 T-bolt clamp 1

1. COMPONENT REMOVAL

A. It is necessary to remove the refrigerant from the air condi-

tioning system. This should be performed by a qualified

technician using a Refrigerant Recycling System.

Releasing refrigerant into the atmosphere is environ-

mentally 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 brack-

ets 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.

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.

1-1/2"

TO RESERVOIR

TO PUMP

DISCARD

THIS END

5/8" POWER STEERING

STEEL RESERVOIR

RETURN LINE

HEAT

PROTECTANT

SLEEVE

3/8" ORIGINAL HOSE

CONNECTED TO POWER

STEERING RESERVOIR

5/8" x 10" RUBBER HOSE

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

••

HEAT SLEEVES

•

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.

5. OIL DRAIN FITTING

A. To provide an oil drain for the super-

charger, 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".

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.

ENGINE BLOCK

OIL

SENDING

UNIT

#4 FLARE

PASSENGER

SIDE

1/8" NPT

STREET

TEE

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.

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.

5TH BOLT FROM

THE FRONT 3/4"

2-3/4"

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 approxi-

mately 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.

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.

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.

CAUTION: Use care so as not to strike

internal engine components when punch-

ing oil pan.

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.

CONNECT TO MANIFOLD

VACUUM/PRESSURE

INLET (FUEL LINE

FROM STOCK

REGULATOR)

OUTLET (FUEL

FROM HERE

RETURNS TO TANK)

FMU BRACKET

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.)

6. FUEL MANAGEMENT UNIT INSTALLATION, cont'd.

TO FMU

OUTLET

TO FMU

INLET

•

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

FEED

LINE

FUEL

TANK

STANDARD

PUMP

ADDITIONAL

FUEL PUMP

FUEL

RETURN

LINE

FUEL

MANAGEMENT

UNIT (FMU)

ENGINE

TO MANIFOLD PRESSURE

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.

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

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.

1-1/2"

DISCARD

SAVE FOR

THERMOSTAT

HOUSING

RADIATOR

CUT AT END OF

STRAIGHT PORTION

SAVE THIS

PORTION DISCARD

'S' BEND

ALUMINUM TUBE 'L' BEND

ALUMINUM TUBE

(HEATER CORE 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.

C. HEATER CORE HOSE

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.

NOTE: For 1992 LT1 models, disregard the

following five points. There are no lower

water pump hoses to modify.

THROTTLE

BODY HOSE

"S" BEND

ALUMINUM

TUBE HERE

DISCARD

1992 MODELS ONLY

"Z" BEND

ALUMINUM TUBE

SURGE TANK

OUTLET HOSE

VALVE COVER

CUT AT END

OF STRAIGHT

PORTION

RADIATOR SURGE TANK HOSE

HEATER CORE HOSE

TO THROTTLE BODY

WATER

PUMP

CUT AT END

OF STRAIGHT

PORTION

USE "S" BEND

ALUMINUM

TUBE HERE

USE

THIS

PORTION

RESTRICTOR

1-3/4" 1-1/4"

2-1/2"

LOWER

WATER

PUMP

(USE FOR

CONNECTOR)

DISCARD

THIS PORTION

CONNECTOR

USE

THIS

PORTION

"Z" BEND

ALUMINUM

TUBE

CUT AND

DISCARD

"L" BEND

ALUMINUM

TUBE

USE

THIS

PORTION

DISCARD

THIS PORTION

TOP VIEW

1993-1996 MODELS ONLY

NOTE: 1995 MODELS DO NOT

HAVE A THROTTLE BODY

HOSE AND PLASTIC TEE. DO

NOT CUT MAIN COOLANT

HOSE.

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.

BRACKET

HEADLIGHT

WELL

AIR FILTER TUBE

RUBBER ELBOW

AIR INLET DUCT

RIGHT

FRONT

TIRE

TOP VIEW

FRONT

VIEW FROM

BOTTOM

RIGHT

FRONT

TIRE

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.

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 approxi-

mately 2" away from the connector.

C. Extend the MAF connector by using the supplied

36" wires and shrink sleeve. Soldering is recom-

mended. Crimp connectors have been supplied

for applications where soldering is not possible.

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.

NOTE: Double check the wire to wire (MAF

and harness) relationship before soldering

and sealing.

#40 CLAMP

#56 CLAMPS

AIR FILTER

TUBE BRACKET

1992-1993

AIR FILTER

EXTENSION 1994-1995

MAF METER

3-1/2" X 2" SLEEVE

•ACCUMULATOR

AIR FILTER

COOLANT

RECOVERY TANK

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 CONDITIONING LINE

CLAMP

FRAME

FRONT

TOP VIEW

DRILL HOLE #12

USE #12

SHEET METAL SCREW

"T" BRACKET

EXISTING HOLE,

SCREW IN CLAMP

CANISTER

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.

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Vortech Superchargers 1992-1996 5.7L LT1 Corvette Installation guide

Brand: Vortech Superchargers

Model: 1992-1996 5.7L LT1 Corvette

Category: Cable clamps

Type: Installation guide

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Vortech Superchargers 1992-1996 5.7L LT1 Corvette Installation guide

Vortech Superchargers 1992-1996 5.7L LT1 Corvette Installation guide

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