Jeep

Grand
6.1L S Cherokee
Supe
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Inst a rge r
allati
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50 St
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2005
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-2010
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CARB
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-213-
31

ENGINEERING, INC
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: 4CK020-010 v6.0, 02/17/2012
©2012 Vortech Engineering, Inc
All Rights Reserved, Intl. Copr. Secured
i
 FOREWORD

T
his manual provides information on the installation, maintenance and service
of the Vortech supercharger kit expressly designed for this vehicle. All infor-
mation, illustrations and specifications contained herein are based on the lat-
est product information available at the time of this publication. Changes to the
manual may be made at any time without notice. Contact Vortech Engineering for
any additional information regarding this kit and any of these modifications at (805)
247-0226 8:00am-4:30pm PST.

Take note of the following before proceeding:

1. Proper installation of this supercharger kit requires general auto-
STOP motive 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 contact your dealer or Vortech Engineering for
possible installers in your area.
2. This product was designed for use on stock (un-modified, OEM) vehicles.
The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must
be stock. If the vehicle or engine has been modified in any way, check with
Vortech prior to installation and use of this product.
3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).
4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard
use (no boost) until the problem is resolved.
5. Vortech is not responsible for any clutch, transmission, drive-line or engine
damage.
Exclusions from Vortech warranty coverage considerations
include, but not limited to:
1. Neglect, abuse, lack of maintenance, abnormal operation or improper installa-
tion.
2. Continued operation with an impaired vehicle or sub-system.
3. The combined use of Vortech components with other modifications such as, but
not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party
PCM programming or other such changes.

©2012 VORTECH ENGINEERING, INC

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated
into another language in any form, by any means without written permission of Vortech Engineering, Inc.

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
ii
 TABLE OF CONTENTS
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
UPDATE ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
TOOL & SUPPLY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
PARTS LIST (4CK218-020L, Complete System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
PARTS LIST (4CK218-120L, Tuner KIt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
1. Preparation and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Harmonic Damper Dowel Pin Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Fuel Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Supercharger Mounting Plate Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Supercharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Engine Coolant Hose Modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.A. Charge Air Cooler (CAC) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.B. CAC Reservoir and Water Pump Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . 9
7.C. CAC Radiator Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8. Supercharger Discharge Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9. Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10. Voltage Booster Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11. Reflash Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12. Final Assembly and Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc
All Rights Reserved, Intl. Copr. Secured
iii
 COPYRIGHT 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,
LLC. 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, LLC.

TRACTION CONTROL NOTICE

When driving the vehicle aggressively, excessive wheel spin may activate the ve-
hicles' OEM traction control system. The traction control feedback may temporar-
ily cause the vehicles' engine to operate erratically at heavy throttle inputs. This
condition can be eliminated by temporarily defeating the vehicles' traction control
(refer to the vehicle manufacturers' guidelines). Vortech does not recommend dis-
abling the OEM traction control system. Use caution when operating the vehicle
with a disabled traction control system, as loss of vehicle control may result.

SPARK PLUG NOTICE

When driving the vehicle on "non-public roads", Vortech strongly recommends
reducing the factory spark plug gap down to .032" (off-road applications such as
racing / high RPM operation).

RADIATOR CAP NOTICE

In supercharged and non-supercharged applications, Vortech has observed short-
comings in the OEM engine cooling radiator cap's ability to properly seal. Vortech
recommends replacement of the OEM radiator cap with a quality aftermarket ver-
sion, such as the Stant #11334, which is available at most local auto parts retail-
ers for around $5.00.

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
iv
 ATTENTION
BEFORE STARTING INSTALLATION,
PLEASE NOTE THE FOLLOWING:
Your vehicle’s ECM may need to be updated. With the programmer powered up and connected,
This can be determined by locating the supplied and the main menu screen being displayed:
Diablosport programmer and plugging it into the
vehicle’s OBD2 port. • Type the following into your web browser:
vortechsuperchargers.com/dsinstaller
Once the programmer is powered up and is at • Save the installer to your desktop. It should
the main menu screen, there will be four options place an installer icon on your desktop.
to choose from:

• Performance tune
• Diagnostics
• Options
• Tool information

Select performance tune and follow the screen • Double-click on the DS Downloader installer
for instructions. on the desktop to start the installation pro-
cess. Follow the prompts to install.
If you are prompted to update the vehicle’s cali- • Once the installer has completed, locate the
bration, disconnect the Diablosport programmer new icon that the installer has placed on your
and follow these steps: desktop. (See Fig)
• With the programmer powered up and con-
Tools required: Diablosport U7778 Interface Kit. nected to your computer, double-click on the
DSDownloader icon. You should see an
In the event you are unable to purchase or option to download calibration update.
locate a U7778 Interface Kit, this process can • Select the update and allow the program to
be accomplished by using the vehicle for the connect to Diablosport’s website. This may
power source (by plugging the programmer take a few minutes.
into the vehicles OBD2 port) and by purchas- • Once the programmer has updated, discon-
ing a USB to serial cable (RS232) (Note: if nect it from the power source and the com-
your computer has a serial cable outlet plug puter.
then just a serial cable will be needed). • Plug the programmer into the vehicles OBD2
port and follow the main menu screen (as
If you are unable to use the vehicle as the described in section 10).
power source, a power supply will be required.

The requirement for the power supply:

Input 120 VAC 60Hz 30W output 12 VDC
1000 Ma, with a 5.5 x 2.5 mm tip, positive
center.

Depending on the model year of the vehicle, new OEM radiator core support brackets may
be required (P/N: 55394098AE). See step 7.C.1 for details.

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc
All Rights Reserved, Intl. Copr. Secured
v
 Jeep Grand Cherokee
Installation Instructions
Congratulations on selecting the best performing and best backed 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 which includes the Automotive Limited Warranties Program
and the Warranty Registration form.
Vortech supercharger systems are performance improving devices. In most cases, increases in torque of
30‑35% and horsepower of 35-45% 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 91 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. 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 at least 15,000 miles and spark plug wires at least every 50,000 miles.
TOOL & SUPPLY REQUIREMENTS:
• Factory Repair Manual
• 3/8” Socket and Drive Set: SAE & Metric
• 1/2” Socket and Drive Set: SAE & Metric
• Adjustable Wrench
• Open End Wrenches: 3/8”, 7/16”, 1/2”, 9/16”
• Flat #2 Screwdriver
• Phillips #2 Screwdriver
• Drill Motor
®

• 1/8”, 3/16”, 1/4”, 27/64” Drill Bits INE

ERI
NG,
LLC

• 3/16” Allen Wrench ENG

• Wire Strippers and Crimpers

• Utility Knife
If your vehicle has in excess of 15,000 miles since its
last spark plug change, then you will also need:
• Spark Plug Socket
• NEW Spark Plugs

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
vi
 2006-2010 Jeep Grand Cherokee
Part No. 4CK218-020L/-028L
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 NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY
008110 SMALL SILVER DIE CUT DECAL 2 4CK112-010* AIR INLET ASSY, HEMI JGC 1
008130 LICENSE PLATE FRAME, VORTECH 1 *SEE PAGE viii FOR ASSEMBLY COMPONENTS
008341 POWERCOOLER DECAL 1 4CK112-020* AIR DISCHARGE ASSY, HEMI JGC 1
*SEE PAGE viii FOR ASSEMBLY COMPONENTS
008447 S/C STREET PACKAGE ASSEMBLY 1
4CL110-110* ASSY, DAMPER PIN HEMI 1
009035 S/C LUBE, BOTTLED, VORT 3-PACK 1 *SEE PAGE viii FOR ASSEMBLY COMPONENTS
2A046-975 BELT K060975, JEEP HEMI 1 8D204-010(06) RACE BYPASS VALVE-BLACK 1
2F329-190(8) S/C ASSY, V3 CCW SI STR 1 8N301-270(8) WELDED CLR ASSY, HEMI JGC 1
4GR033-032 PULLEY, SC, C5, 20MM, 32T 1
7A312-125 5/16-18 X 1 1/4 GR5 HHCS, ZINC 2 4CK110-100 FUEL SYSTEM ASSY, JGC 1
4GS012-030(8) DUCT, CAC TO TBODY, C6 1 4CK010-080 BRKT, MAP MOUNT, JGC 1
7J312-000 5/16 FLAT WASHER-SAE 2 4CL010-030 MAP SENSOR BLOCK, 07 CHARGER 1
7R005-001 CLAMP, T-BOLT, 208-91 1 4FR017-061 SPCR, H20 PIPE ASY, 03 MACH 1
5A002-017 MAP SENSOR, 07 CHARGER SC 1
4CK020-010 MANUAL, JEEP GRAND HEMI 1 7C010-077 10-24X3/4 BUTTON HD,CAP SCREW 2
4CK110-044 S/C MTG BRKT ASSY, JGC 1 7E010-150 #10 X 1.5" SHEET METAL SCREW 4
008725 CAP, TAMPER PROOF, VORT S/C 2 7F006-093 6MM NYLOCK NUT 1
2A017-093 SPACER, S/C PULLEY, .093" 1 7J250-001 1/4 WASHER, SAE, PLTD 1
2A017-102-181 SPACER, 1"OD X .406 ID X 1.809 1 7P062-187 1/16NPT X 3/16 HOSE BARB 1
2A017-105-197 SPACER,1"OD,.328"ID,1.974"L 6 7P250-045 1/4 MALE NPT X 3/8 MALE BARB 2
2A017-105-198 SPACER,1"OD,.328" ID,1.974"L,STEPPED 1 7R001-006 #6 STNLS HOSE CLAMP, NARROW 5
2A017-105-290 SPACER,1.00" O.D. X .328" I.D. AL 2 7U031-016 5/16" PCV/VAC RUBBER HOSE 2'
2A017-154 SPACER, .154", IDLER BRG 1 7U032-016 3/8" EFI FUEL HSE HI-PSR 4'
2A017-375 SPACER, .375, C6, IDLER 2 8F060-008 FUEL INJ, 07 CHARGER SC 8
2A036-333 S/C PULLEY 3.33" 6 GROOVE 1 5A003-050 DIABLO PREDATOR, HEMI 1
2A040-051 PLY RETAINER, TAMPER PRF CAP 2
2A040-061 RETAINER CUP, VORT S/C PLY 2 5A102-032 ASSY, VOLT BOOST JEEP SRT8 G3 1
2A042-080 BELT, GATES 20MM, 80 TOOTH 1 5A002-031 VOLT BOOSTER HEMI G3 1
2D070-159 LARGE BEARING,EXTENDED DRIVE 2 5W001-021 1/2" SPLIT PLASTIC WIRE LOOM 7'
2D070-171 JACKSHAFT, C5, H900 1 5W001-005 3/8" SPLIT PLASTIC WIRE LOOM 11'
4CJ017-021 SPACER, .625" COIL 3 5W001-032 1/4" SPLIT PLASTIC WIRE LOOM 5'
4CK010-010 PLATE, HEAD MTG, 08 JGC 1 5W010-000 10GA RED STRANDED WIRE 19'
4CK010-020 BRKT, LOWER, IDLER-SC PLT, 08 JGC 1 5W012-010 12GA BLACK STRANDED WIRE 9'
4CK010-030 BRKT, UPPER, WTR PMP-SC PLT, 08 JGC 1 5W012-080 12GA ORANGE STRANDED WIRE 9'
4CK010-044 PLATE,SC MTG, 08 JGC 1 5W014-010 14GA RED STRANDED WIRE 9'
4GR032-032 PULLEY,JACKSHAFT,C5,20MM,32T 1 7U030-024 1/8" NYLON INSTRUMENT TUBING 20'
4GR116-300 IDLER ASSY, 20MM BELT 2 7P156-082 5/32" TEE 1
4NZ030-041 BRG HSG, 350Z 1 7U030-109 7/64" VAC HOST .5'
7A312-152 5/16-18 X 1.5 SHCS, ZN PLT 4 7U100-044 4" NYLON TIE WRAPS 10
7A312-300 5/16-18 X 3" HXHD 1 7U100-055 7.5" NYLON TIE WRAPS 10
7A312-401 5/16-18 X 4" HXHD 2 5W001-014 FUSE HOLDER 10GA WIRE 1
7A312-675 5/16-18 X 6.75" STUD 2 7E010-048 #10 SHEET METAL PHILLIPS HEAD 3
7A375-300 3/8-16 X 3" HXCSG5P 1 7E010-075 #12 SHEET METAL HEX HEAD 2
7B375-075 3/8-24 X 3/4" GR8 HXHD BOLT 1 5W001-007 3/16 HEAT SHRINK .75'
7B375-150 3/8-24X 1-1/2 GR8 HX 1 5W001-038 1/4 HEAT SHRINK .75'
7C010-025 M10-1.5X25MM HXCP 1 5W001-043 10-12GA 1/4" YELLOW RING TERMINAL 1
7C010-162 M10 X 160MM STUD 1 5W001-041 10-12GA YELLOW SLIDE CONNECTOR MALE 2
7C012-022 M12 X 1.75 X 20MM THIN HD 3 5W001-040 10-12GA YELLOW SLIDE CONNECTOR FEMALE 3
7C012-065 M12 X 1.75 X 65MM HX 1 5W001-019 10-12GA YELLOW BUTT CONNECTOR 2
7C080-020 M8 X 1.25 X 20 HXHD, PLTD 1 5W001-009 14-16GA BLUE SLIDE CONNECTOR MALE 2
7C080-090 M8 X 1.25 X 90 HXHD CL10.9 1 5W001-010 14-16GA BLUE SLIDE CONNECTOR FEMALE 3
7C080-100 M8 X 1.25 X 100 HXHD Zn PLT 1 5W001-013 14-16GA BLUE BUTT CONNECTOR 1
7F312-018 5/16-18 NUT USS PLTD 2 5W001-011 14-16GA BLUE RING TERMINAL 2
7G010-175 12MM X 1.75 NUT 1
7GL10-150 10M X 1.5 NUT NYLOCK 1
7J012-092 12MM WASHER, FLAT 2
7J312-000 5/16 FLAT WASHER-SAE 8
7J375-044 3/8 SAE WASHER, PLTD 3
7U100-069 KEY, 3/16 SQUARE X .73 LONG 1
7U100-073 KEY, 3/16 SQUARE X 1.375 LONG 1
7U100-084 SNAP RING,V9 1
7X100-027 WAVE WASHER-LARGE (V-2) 1

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc
All Rights Reserved, Intl. Copr. Secured
vii
 2006-2010 Jeep Grand Cherokee
Part No. 4CK218-020L/-028L
parts list, CONT'D
®

ENGINEERING, INC

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

8N006-020 WATER COOLR, FLDYN DUAL PASS 1

8N105-270* WATER TANK MTG ASSY, JGC 1
4CK010-050 BRKT, CAC RAD MTG, JGC 2
4CK010-060 BRKT, WATER TANK, JGC 1
4CK010-070 BRKT, JGC PWR STR CLR, JGC 2
7A250-051 1/4-20 X .50 HHCS ZINC PLTD 8
7E010-075 #12 X 3/4" SHT METL SCRW HEX 4
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 5
7J250-001 1/4 WASHER, SAE, PLTD 15
7J250-150 1/4" FENDER WASHER ZN PLTD 4
8N055-030 TANK, WATER, TRIANGLE SHAPE 1
7E010-100 #12 X 1.0" SHEET METAL SCREW 2
7U030-065 3/4"X90 RUBBER HOSE, SHORT 1
7P500-075 1/2NPT X 3/4 HOSE FIT STRT NICKEL 1
7A250-050 1/4-20 X .50 SHCS ZINC PLTD 5
7P500-026 1/2NPT X 3/4 BARB 90° BRASS 1
7P500-078 1/2NPT X 3/4 HOSE FIT STRT 1
7R007-001 NYLON RATCHET CLAMP 1-1/8" 12
7U038-000 3/4" HEATER HOSE 10'
8N107-190 WATER PUMP MTG ASSY, 07 CHGR 1
5W001-011 16-14 GA RING TERM .26" HOLE 1
5W001-013 14-16 GA BUTT CONN BLU INSUL 3
5W001-024 MINI ATC FUSE TAP 1
5W001-025 FEMALE SLIDE,INSULATED,MINI 1
5W001-054 18 GA FUSE HOLDER 1
5W014-030 14GA STRD WIRE BLACK 7'
7R003-027 ADEL CLAMP,1-11/16" 1
8F001-402 PUMP, WATER, PIERBURG 1
4CK101-001 FUEL PUMP ASSY, JGC GSS 342 1
5W001-013 14-16 GA BUTT CONN BLU INSUL 2
5W001-052 HARNESS, GSS 317 FUEL PUMP 1
7R004-001 STEPLESS CLAMP, 15.7-70 2
7R004-002 STEPLESS CLAMP, 17.0-70 1
7U032-018 3/8" SUBMERSIBLE EFI FUEL HOSE 12"
8F001-342 FUEL PUMP W/SCREEN,GSS 342 1
5W001-009 MALE SLIDE 2
5W001-010 FEMALE SLIDE 2
7P100-121 SEALING NUT 1
7P375-036 BULKHEAD FITTING 1
7U012-013 13X2MM O-RING 1

P/N: 4CK020-010 v6.0, 02/17/2012

©2012 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
viii
 2006-2009 Grand Cherokee Tuner Kit
Part No. 4CK218-120L/-128L
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 NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY
008110 SMALL SILVER DIE CUT DECAL 2
008130 LICENSE PLATE FRAME, VORTECH 1
008341 POWERCOOLER DECAL 1
008447 S/C STREET PACKAGE ASSEMBLY 1
009035 S/C LUBE, BOTTLED, VORT 3-PACK 1
2A046-975 BELT K060975, JEEP HEMI 1
2F329-190(8)** S/C ASSY, V3 CCW SI STR 1
**SEE PREVIOUS BOM FOR ASSEMBLY COMPONENTS
4CK020-010 MANUAL, JEEP GRAND HEMI 1
4CK110-044** S/C MTG BRKT ASSY, JGC 1
**SEE PREVIOUS BOM FOR ASSEMBLY COMPONENTS
4CK112-010 AIR INLET ASSY, HEMI JGC 1
4FU013-010 COVER, AIR FILTER, 05 MUST GT 1
4GR012-011 DUCT, S/C INTAKE, MACH 1
7P500-009 1/2" X 90 HOSE BARB UNION 1
7R002-056 #56 SAE TYPE F SS HOSE CLAMP 2
7S350-300 SLEEVE, 3-1/2 X 3, BLUE 1
7U030-036 1/2" OIL DRAIN HOSE 6'
8H040-050 AIR FILTER 3.5"FLG X 7"L 1
4CK112-020 AIR DISCHARGE ASSY, HEMI JGC 1
7R002-044 #44 SAE TYPE F SS HOSE CLAMP 3
7R005-001 CLAMP, T-BOLT, 208-91 1
7S275-192 ELBOW, 2.75 X 90 SILICONE TRIMMED 1
7S350-278 ELBOW, 3.5x2.75 x 180º SILICONE 1
7U030-046 5/32" VACUUM LINE 5'
7U100-065 GROMMET,.5"ID,.812"OD,.187"GRV 1
8H040-175 FILTER,1-3/4"I.D.,MFRB 1
8N055-050 PLASTIC CAP, SURGE TANK 1
4CL110-110 ASSY, DAMPER PIN HEMI 1
4GR010-110 GUIDE, DWL PIN IST, C5 1
7C014-095 M14-1.5 X 95 MM SHCS 1
7U250-019 DOWEL PIN,1/4D X 1/2L 1
7U250-026 DRILL BUSHING, 1/4ID,.375OD 1
8D204-010(06) RACE BYPASS VALVE-BLACK 1
8N301-270(8) WELDED CLR ASSY, HEMI JGC 1
8N006-020 WATER COOLR, FLDYN DUAL PASS 1
8N105-270 WATER TANK MTG ASSY, JGC 1
4CK010-050 BRKT, CAC RAD MTG, JGC 2
4CK010-060 BRKT, WATER TANK, JGC 1
4CK010-070 BRKT, JGC PWR STR CLR, JGC 2
7A250-051 1/4-20 X .50 HHCS ZINC PLTD 8
7E010-075 #12 X 3/4" SHT METL SCRW HEX 4
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 5
7J250-001 1/4 WASHER, SAE, PLTD 15
7J250-150 1/4" FENDER WASHER ZN PLTD 4
8N055-030 TANK, WATER, TRIANGLE SHAPE 1
7E010-100 #12 X 1.0" SHEET METAL SCREW 2
7U030-065 3/4"X90 RUBBER HOSE, SHORT 1
7P500-075 1/2NPT X 3/4 HOSE FIT STRT NICKEL 1
7A250-050 1/4-20 X .50 SHCS ZINC PLTD 5
7P500-026 1/2NPT X 3/4 BARB 90° BRASS 1
7P500-078 1/2NPT X 3/4 HOSE FIT STRT 1
7R007-001 NYLON RATCHET CLAMP 1-1/8" 12
7U038-000 3/4" HEATER HOSE 10'
8N107-190** WATER PUMP MTG ASSY, 07 CHGR 1
**SEE PREVIOUS BOM FOR ASSEMBLY COMPONENTS
4CK101-001 FUEL PUMP ASSY, JGC GSS 342 1
**SEE PREVIOUS BOM FOR ASSEMBLY COMPONENTS

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ix
P/N: 4CK020-010 v6.0, 02/17/2012
©2012 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
x
1. PREPARATION AND REMOVAL

NOTE: It is recommended that this installation be performed

when fuel level is below a quarter tank as the fuel tank
will be removed in a later step.

A. Disconnect negative cable at the battery.

B. Remove the plastic engine cover and set
aside.
C. Remove the valve cover breather hose from
the factory air inlet duct. Remove the air filter
and all ducting up to the throttle body.
Unplug the IAT (Inlet Air Temperature) sensor
and remove it from the air filter housing. Set
it aside for later use.
Fig. 1-a
NOTE: For early model year vehicles whose coolant reservoir
tops are black colored, a reservoir adjustment is
required for proper installation clearance.
- Use the supplied spacer and M6 nut with
washer located in fuel system assembly to
space the fender mount tab away from the
inner fender (See Fig. 1-a).
- Drill another 3/16" mounting hold in the shock
tower to secure the relocated reservoir (See
Fig. 1-b).

D. Remove the radiator grille from the vehicle

(only the 6 plastic fasteners on top of the
radiator core support need to be removed to
accomplish this).
E. Remove the accessory drive belt.
Fig. 1-b

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1
 2. HARMONIC DAMPER DOWEL PIN INSTALLATION

NOTE: The purpose of this section is to provide access to the har-

monic damper bolt area so that the crankshaft can be pinned
to the damper to prevent the damper from spinning on the
crankshaft. The following steps will work on all or most appli-
cations. If it is not possible to get adequate clearance by per-
forming the following steps, follow the manufacturer’s steps
for removing the harmonic damper until there is sufficient
room to work in.

A. Remove the crankshaft damper bolt. (A fac-

tory tool may be used to keep the engine
from rotating or carefully use a pry tool to
keep the damper from rotating.)
B. Install the supplied drill guide with the raised
section piloting in the damper bore. Secure
in place by installing the supplied socket head Fig. 2-a
cap screw. Do not over-tighten the screw as
it may distort the drill guide (its purpose is just
to hold the guide in place while drilling). See
Fig. 2-a.
C. Using a small drill motor (right angle pneu-
matic works well), mark a 1/4” drill bit with
electrical tape or a drill stop so that the hole 1” MINIMUM
will be deep enough for the supplied 1/2” long
dowel pin. See Fig. 2-b.
D. Drill hole in damper/crankshaft.
E. Remove the socket head cap screw.
F. Clean area of metal chips and install the sup-
plied dowel pin in the drilled hole making sure
that it does not protrude past the damper
face.
G. Install and tighten the crankshaft damper bolt
to 129 ft-lbs (176 Nm). Fig. 2-b

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2
3. FUEL INJECTOR REPLACEMENT

A. Relieve the fuel system pressure

B. Disconnect the eight fuel injector plugs and
retaining clips from the injectors.
C. Remove the four screws that hold down the
fuel rail on the intake manifold. Lift up on the
rails evenly and remove all eight injectors.
D. Using a small amount of clean motor oil, light-
ly lubricate the O-rings on both ends of the
Vortech supplied fuel injectors. Install the fac-
tory injector retaining clips.
E. Install the new injectors into the fuel rails with
the terminals facing outward.
F. Carefully lower the fuel rail/injector assembly
down onto the intake manifold.
G. Check to see that each injector has been
seated properly into the intake manifold.
H. Re-install both driver side fuel rail bolts and
the front passenger side bolt. Set aside the
remaining bolt as it will be used in a later
step. Attach the injector plugs to the injectors.

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 4. SUPERCHARGER MOUNTING PLATE INSTALLATION
A. Drain the engine coolant into a clean pan for
later use.
B. Remove the two bolts securing the thermostat
housing and set all aside.
C. Remove the alternator bolt. Loosely install
the supplied M10 stud in its place.
D. Cut off plastic wire loom push connector and
discard (see Fig. 4-a).
E. Loosen the wire loom on top of the valve
cover so that the primary mounting plate can
be installed flush with the front face of the
head. Fig. 4-a
F. Temporarily unplug the wires to the alternator
if necessary. Cut the wire loom and separate
the alternator wires so that they will reach the spacer in front of plate - .45" spacer between plate
and head at this location only
alternator.
G. Loosely attach the primary mounting plate to
the head with the recess pointed back using Spacer with flat
the supplied 8mm hardware as shown in Fig. (Shown placed in
4-b. position)
H. With the cog belt encircling the cog pulley,
slide the slotted portion of the supercharger
M8 x 20mm (Tighten
mounting plate assembly onto the 100mm fully at this time)
bolt already installed and loosely attach it to
the primary mounting plate using the 8mm M8 x 100MM (Install
loosely for plate
hardware as shown in Fig. 4-d. alignment)
I. Sandwich the supplied 1.97” spacers between
the two plates at every location where there is Fig. 4-b
a hole in the primary mounting plate. Note
that one of the spacers has a flat and must
be used in the lowermost hole to clear the
water pump housing (See Fig. 4-b, 4-c).
J. Be sure to keep alt wiring loom below bracket
and spacers to prevent from contacting cog
drive. Use the supplied 5/16 x 6.75” long
studs and 2.9" spacers at the location shown
in Fig. 4-e.

Fig. 4-c

Primary Mounting
5/16X6.75" Studs go thru Plate
both plates with a 1.97"
spacer in between
(2.9" spacers not shown)
Supercharger
Mounting Plate

Fig. 4-e Fig. 4-d

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4
K. Loosely install the upper mounting bracket
support using two .45” long spacers as shown
in Fig. 4-f.
L. Tighten the fasteners that go all the way 1.97" Spacers
through into the head first and then tighten
the rest.
.45" Spacers
M. Remove factory tensioner and replace with
the supplied replacement tensioner in your
kit.
N. Per Fig. 4-h, install the supplied .15" thick
spacer, one of the supplied aluminum idlers
(with snap ring facing rearward), and one of
the supplied .38" spacers onto the previously Upper MOUNTING
installed 10mm alternator stud. BRACKET SUPPORT
O. Install the lower mounting bracket support
over the three previously installed studs as Fig. 4-f
shown in Fig. 4-i.
P. Recheck and tighten all of the mounting
bracket hardware.
Q. Retract the belt tensioner and install the six
rib belt. Release belt tensioner.

.15" spacer (pilot .38" spacer (pilot

points forward) points rearward)

Fig. 4-g

LOWER MOUNTING
aluminum idler (snap BRACKET SUPPORT
M10 Stud shown off ring side faces rear of
vehicle for clarity vehicle)

2.9" Spacer
Fig. 4-h

Fig. 4-i
Fig. 4-j

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5
 5. SUPERCHARGER INSTALLATION
A. Loosen the two bolts installed behind the
supercharger pulley by hand until the bolt M12 Thin head with-
heads contact the supercharger pulley. Slide out washer
the bolt shoulders into the receiving slots in
the supercharger mounting plate keeping the
washers next to the bolt heads. Guide the
cog belt around the supercharger pulley.
B. Install the three 12mm thin-head bolts
through the plate and into the lower part of
the supercharger. Do not use washers.
C. Install the 3/8" X 3" long bolt through the
supercharger mounting plate, a 1.81" spacer 3/8 Bolt installed in
and into the supercharger gearcase using the counterbored hole
supplied washer (See Fig. 5-a).
D. Tighten all six supercharger mounting bolts. Fig. 5-a (Shown off the vehicle for clarity)
E. Verify that the bearing snap ring on the sup-
plied aluminum idler is pointing towards the
mounting plate and the .375” spacer. Secure
it to the slot in the supercharger mounting
plate using the supplied 12mm hardware.
F. Verify that the supplied cog belt is routed
around both cog pulleys and above the
smooth idler and tighten the idler so that the
gilmer belt is snug (See Fig. 5-a).
G. Secure the remote drain hose away from the
belt and hoses using tie-wraps.
H. Remove 3 forward most plastic rivets and the
forward most reusable rivet holding passen-
ger side inner fender liner to fender. Bend
back inner fender liner to gain access to
wheel well area.
I. Be sure the supplied inlet duct to the super-
charger inlet is oriented properly and tighten
T-bolt clamp (See Fig. 5-b)
NOTE: Use caution when rotating the aluminum inlet duct.
Careful heating with a propane torch will allow for easi-
er rotation without galling the aluminum mating surfac-
es.

J. Using the supplie d 90° barbed fitting, attach Fig. 5-b

the supplied ½” breather hose to the hole in
the end-cap of the air filter. Route the ½”
hose to the driver side valve cover and attach
to the breather port.
K. Install the air filter and air filter shield onto the
long end of 3.5-inch pipe and install using 2
#56 clamps and 3.5-inch coupler to air inlet
duct, orient for best clearance and tighten
clamps on each connection.

Fig. 5-c

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6
6. ENGINE COOLANT HOSE MODIFICATION

A. Remove the upper radiator hose from the

thermostat housing. Rotate these
clamps up as
B. While the upper radiator hose is detached, shown
rotate the two hose clamps on the short sec-
tion so that they are pointed away from the
drive assembly and bracket (See Fig. 6-a).
C. Relocate upper A/C line to reside above radi-
ator hose by first releasing it from support on
front of water pump and then routing the
upper radiator hose below it before re-attach-
ment to the thermostat housing (See Fig. 6-b,
6-c).
D. Re-install the upper coolant hose if removed. Fig. 6-a

NOTE: Rotation of the rubber coolant hose and elbow may be Reroute A/C Line
required for adequate clearance to the drive belt and above radiator
assembly. Double check that hose clearance is ade- hose
quate after clamps have been secured..

E. Remove coolant “bleed” plug.

F. Re-fill coolant system remembering to plug
the “bleed” as soon as coolant comes out of
it.
G. Using the supplied 5/16” rubber line, route
radiator overflow tube around supercharger
and away from the blower drive pulley.
Fig. 6-b

Fig. 6-c

bleed plug

Fig. 6-d

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7
 7.A CHARGE AIR COOLER (CAC) INSTALLATION

1. Install a 1” long piece of the supplied ¾” hose

over the end of the passenger side fuel rail
(See Fig. 7A-a).
2. Using pipe thread sealant, install two 1/2"
NPT X 3/4" barbed straight fittings into the
upper and lower holes on the CAC end tank.
3. Install the supplied grommet into the hole in
the CAC discharge tank, install IAT sensor,
and plug it in.
4. Lower the CAC into place over the passenger
side valve cover and loosely attach it to the
supercharger and throttle body using the sup-
plied silicone elbows. Using the 2.75 90°
elbow, connect the short leg to the super-
charger discharge and the other end to the Fig. 7A-a
left air tank on the CAC. Connect the 2.75-
inch end of the 180° silicone hose to the right
air tank on the CAC and the 3.5-inch end to
the throttle body. Install the bypass valve
using a gasket and the supplied hardware.

Fig. 7A-b

Fig. 7A-c

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8
7.B CAC RESERVOIR AND WATER PUMP ASSEMBLY AND INSTALLATION
1. Using thread sealant, install 1/2" NPT 90° to
3/4 hose barb fitting into the Bottom of the
reservoir and one straight 1/2" NPT to 3/4
hose barb fitting into the top of the supplied
plastic reservoir.
2. Attach the water reservoir bracket to the res-
ervoir using 1/4-20 x .5" cap screws.
3. Attach pump to reservoir using the supplied
clamp and ¼-20 screw in the orientation
shown in Fig. 7B-e. Attach pump inlet to the
bottom reservoir fitting using the supplied 90°
hose and two nylon clamps.
4. Position the reservoir on the passenger side Fig. 7B-a (2008-2009)
frame rail below the old air box location.
5. With the tank as far forward as possible mea-
sure 3 inches up from the bottom of the rail
and mark the hole for drilling.
6. Drill two 11/64" holes for the supplied #12
sheet metal screws, install and tighten.
7. Cut off pump plug leaving as much wire con-
nected to the pump as possible. Locate
ground (brown) wire and attach a length of
supplied black wire. Attach wire to sheet
metal screw used to mount reservoir using
the supplied ring terminal.
8. Connect a section of hose to the top of the Fig. 7B-b (2005-2007)
reservoir and run it to the straight fitting
installed in the upper hole of the CAC.
9. Connect the supplied fuse holder (lengthened
with the supplied wire if necessary) to the
water pump power wire using a butt connec-
tor. Route the water pump power wire across
the bottom of the radiator and up to the fuse
box and connect to fuse pictured in appropri-
ate figure, using the supplied fuse tap and
slide connector (if vehicle does not have a
fuse in this area, or the water pump does
not function, connect the power wire to
any keyed power source).

Fig. 7B-c

Fig. 7B-e Fig. 7B-d

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9
 1. Remove the hood latch, core support brack-
ets and power steering cooler from in front of
the radiator. Pull firmly on the power steering
cooler mounting clips until they come off.
NOTE: Early model year cars with core support brackets that
do not bend in an arc will need to be replaced with new
support bars available from your local dealer.
(Ref PN 55394098AE). (See Fig. 7C-d)

2. Remove lower power steering hose from

cooler and route below wiring harness.
Re-install line to cooler using factory clamp.
3. Relocate the power steering cooler behind
the bumper using the supplied brackets. Use
the ¼” hardware to connect the brackets to Fig. 7C-a
the power steering cooler.
4. Mark and drill 11/64” holes in the top of the
metal bumper. Secure with #12 sheet metal
screws.
5. Attach the supplied brackets to the CAC core
using ¼” x ½” long screws and washers.
Remove the screws securing the ac condens-
er and mount CAC core using these screws
in the middle hole in the bracket. Make sure
that CAC core is mounted with passenger
side outlet at the highest point.

Fig. 7C-b

Fig. 7C-c

Late model style is required for S/C Kit install

(May need to be purchased from Dealer)

Early Model won't

fit

Fig. 7C-d

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10
6. Install the supplied ¼” hardware in the pas-
senger side upper hole where it lines up with
the vehicle (See Fig. 7C-e).
7. Re-install the hood latch and core support
brackets checking for clearance.
8. Connect the water pump discharge to the bot-
tom hose barb on the CAC radiator using the
supplied hose.
9. Connect the upper hose barb on the cooler
radiator to the water inlet fitting in the bottom
of the CAC core using the supplied hose. Be
sure hose sweeps evenly as not to kink (see
Fig. 7C-g).
10. Temporarily remove the hose from the top of
Fig. 7C-e
the CAC core and fill hose with 25%/75%
coolant/water mix until water comes out the
fitting on the CAC core.
11. Re-attach hose, tighten clamps on all connec-
tions and check for leaks.
12. Re-install the front grille.

Fig. 7C-f

Fig. 7C-g

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11
 7.C CHARGE AIR COOLER RADIATOR INSTALLATION, CONT'D

 

 
 








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12
8. SUPERCHARGER DISCHARGE ASSEMBLY INSTALLATION

A. Using pipe thread sealants, thread the two

1/4 NPT to 3/8 barb fittings in either end of
the map sensor block and the 1/16 barb fitting
in appropriate hole.
B. Assemble the supplied MAP sensor and MAP
sensor bracket into the block using 10-24
screws. Unplug the factory MAP sensor and
plug in the supplied MAP sensor. Factory
MAP sensor is located at the back of the
intake manifold and is most easily removed
from the driver side.
C. Attach map sensor assembly to the top of the
rear passenger side fuel rail mount.
D. Remove the 3/8” vacuum line from the brake
booster fitting. Re-route the hose towards the
passenger side of the motor and connect the Fig. 8-a
line to the rear facing fitting on the map sen-
sor. Connect the other fitting on the MAP sen-
sor block back to the brake booster using the
supplied 3/8” rubber hose. Install a supplied
hose clamp on each connection.
E. Connect 5/32” vacuum line from the bypass
valve to the map sensor block fitting.
F. Tighten clamps on the supplied Ø2.75” 90º
elbow that attaches the supercharger dis-
charge to the CAC.
G. Tighten clamps on the supplied Ø2 ¾” to 3 ½”
180º elbow that attaches the CAC to the
throttle body (see Fig. 8-b for reference).
H. It may be necessary to trim the vehicles plas-
tic radiator shroud to provide proper clear-
ance for the 180º silicone elbow. Fig. 8-b

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13
 9. Fuel pump INSTALLATION

NOTE: This section is easier when the tank is less than half full.

A. Start by disconnecting the fuel supply and

fuel vapor lines located just in front of the fuel
tank. Disconnect by pushing connector for-
ward slightly, and then while depressing the
retainer clip tab as shown pull the connector
back and off the hard metal line.
(See Fig. a, Fig. b).

NOTE: Always use caution and use of safety goggles is rec-

ommended when disconnecting fuel lines that may be
under pressure. Fuel will escape from connection. Fig. a
Take care to keep heat sources away.

B. At the rear of the tank disconnect the two

lines that go to the fuel vapor canister ( white
connector and black connector with yellow
clip). Disconnect the fill tube from the tank by
loosening the clamp and separating the hose.
(See Fig. c, Fig. d)

Fig. b

Fig. d Fig. c

P/N: 4CK020-010 v6.0, 02/17/2012

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C. Detach and unplug the fuel pump wiring har-
ness located just above the center section of
the rear axle.
D. Support the tank using a transmission jack or
equivalent. (See Fig. e)
E. Locate and remove the six bolts mounting the
fuel tank to the body. Disconnecting the drive-
shaft from the rear pinion flange by removing
the 4 bolts will make removal of the tank easi-
er. (See Fig. f)
F. Carefully lower the tank down. Ensure that the
fuel tank support brackets don’t get hung up
on the drive shaft. Some maneuvering of the
tank is required.
G. Once the tank is out make sure it is on stable
surface. Dust off and clean up around the top
of the fuel pump canister hole so that dirt
doesn’t get into the tank during the following
steps.
H. Disconnect the wiring harness at the top of the
fuel pump canister. (See Fig. g)

Fig. e

Fig. f

Fig. g
P/N: 4CK020-010 v6.0, 02/17/2012
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15
 I. Using a brass or similar non-sparking metal
punch or equivalent and hammer, tap the
retaining ring in a counter clockwise direction.
(See Fig. j1)
J. Once the retaining ring is loose, disconnect
the fuel feed line from the top of the fuel pump
canister along with the retaining ring and set
aside. (See Fig. j2.)

Fig. j1

Fig. j2

P/N: 4CK020-010 v6.0, 02/17/2012

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16
K. Remove the pump assembly from the tank
being careful not to damage or lose the rubber
O-ring or the fuel level float and arm. (See
Fig. k)
L. Remove the electrical connection from the
underside of the top of the canister(See Fig. l,
Fig. m)

Fig. k

Fig. l

Fig. m

P/N: 4CK020-010 v6.0, 02/17/2012

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 M. Separate the two green signal wires from the
side of the canister and make loose for sepa-
ration of the canister. (See Fig. n)
N. Separate the canister by gradually working
around the unit, gently prying each snap clip
until the two halves can be split. Be careful
not to pull on the green wires to the fuel level
sensor. (See Fig. o, Fig. p)

Fig. n

Fig. o

Fig. p

P/N: 4CK020-010 v6.0, 02/17/2012

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18
O. Using a flat screwdriver, carefully separate the
filter from the bottom of the fuel pump. This
filter will be reused on the new pump at a later
step. (See Fig. q, Fig. r)
P. Detach the black corrugated fuel line that con-
nects the fuel pump to the canister at the can-
ister side by gently slitting the line along the
barbs as shown with a razor blade. (See Fig.
s.)

Fig. q

Fig. r

Fig. s

P/N: 4CK020-010 v6.0, 02/17/2012

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19
 Q. Separate the top lid from the center section of
the fuel pump canister by carefully disengag-
ing the retainer tab on the two flat arms con-
necting them. (See Fig. t, Fig. u)
R. Remove the factory pump from the canister by
first pushing up on the bottom of the stock
pump. Push it out of its cavity using a small
screwdriver. If necessary, disconnect the ter-
minal connections at the top of the pump.
(See Fig. v, Fig. w)

Fig. v

Fig. t

Fig. w

Fig. u

P/N: 4CK020-010 v6.0, 02/17/2012

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20
S. Locate the supplied fuel pump. (See Fig. x)
T. Modification to the bottom of the pump is
required for it to sit properly in the canister.
Keeping the dust cap in place, carefully
remove the two of the four plastic tabs closest
to the fuel pickup port, by either shaving them
flush with a razor blade or with a small die
grinder. (See Fig. y.)

Fig. x

Fig. y

P/N: 4CK020-010 v6.0, 02/17/2012

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21
 U. Slide the two supplied 15.7 stepless clamps
onto the one end of the supplied submersible
rubber fuel hose and then slide the end over
the fuel pump discharge. Secure the 15.7
stepless clamps as shown. (See Fig. ac1,
ac2)

Fig. ac1

Fig. ac2

P/N: 4CK020-010 v6.0, 02/17/2012

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22
AA. On underside of fuel pump canister lid, locate
the square recess as depicted in fig ag1.
AB. Mark the square recess as depicted in fig ag2
and drill through with an 1/8” drill bit. See fig
ag3.

Fig. ag1

Fig. ag2

Fig. ag3

P/N: 4CK020-010 v6.0, 02/17/2012

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23
 AC. On the top side of the lid the previously drilled
hole should appear as shown in fig ag4. Using
a fine grit/grade file or grinder, remove the
webbing surrounding the hole so that a flat
and smooth surface remains. See fig ag5.

Fig. ag4

Fig. ag5

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24
AD. Enlarge the 1/8” pilot hole to 43/64” stepping
up in gradual increments and taking care not
to crack the lid. Using cutters, carefully
remove the surrounding webbing from the
underside of the lid so the supplied bulkhead
sealing nut can sit flush. See fig ag6.
AE. Insert the bulkhead through the top of the lid
and secure it by installing and tightening the
bottom nut as seen in fig. ag7.

Fig. ag6

Fig. ag7

P/N: 4CK020-010 v6.0, 02/17/2012

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25
 AF. Locate supplied pump connector and pass the
wires through the bulkhead. Loosen top nut on
bulkhead to allow adjustment of pump plug
wire length (See fig ag8). Attach a male slide
connector to the end of the red wire and a
female slide to end of the black wire.
AG. Locate factory pump plug on underside of lid
and cut the red power wire as close to the
plug as possible (See fig ag9). Trim black fuel
pump ground wire just below where the small-
er black wire tees into the larger black wire.
See fig ag10.

Fig. ag8

Fig. ag9

Fig. ag10
P/N: 4CK020-010 v6.0, 02/17/2012
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26
AH. Install the fuel pump into the center cavity of
the canister being sure to orient the fuel inlet
as shown. Install the previously removed filter
by pressing it on to the new pump inlet. Attach
the new electrical connector into the top of the
pump. After plug is attached to pump, tighten
top nut on bulkhead. (See Fig. ai, Fig. ak, Fig.
al, Fig. am)

Fig. al

Fig. ai

Fig. am

Fig. ak

P/N: 4CK020-010 v6.0, 02/17/2012

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27
 AI. Re-assemble the top lid to the canister, and
the lower bucket to the middle section of the
fuel pump canister being sure that the fuel fil-
ter pad is positioned appropriately. Make sure
that the o-ring is installed on the middle sec-
tion of the discharge and aligned properly with
the riser located in the bucket during reassem-
bly. Lubricate the o-ring with a drop of clean
motor oil to ensure the o-ring doesn't tear or
bind during re-assembly.
(See Fig. ao, Fig. ap)
NOTE: It is important to be sure that the o-ring is properly
seated and sealed during re-assembly of the bucket
as failure to do so may result in insufficient fuel pres-
sure at wide open throttle.
Fig. ap

Fig. ao

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28
AJ. Re-connect the factory electrical connector to
the underside of the fuel canister lid using
dielectric grease on the plug terminals.
AK. Onto the free end of the new fuel line slide a
stepless 17.0 clamp. Install fuel line to the barb
located on the middle section of the fuel canister
and tighten clamp (See Fig. as). Trim rubber
hose for best fit.
AL. Compress the lid down and make sure that the
fuel lines and wires will be free of kinks once the
canister is re-installed.
AM. Re-install the newly assembled fuel pump canis-
ter back into the tank using the original o-ring
gasket. Be sure to orient the unit so that the
locating tab lines up with the arrow and the fuel
connection points towards the appropriate side
of the tank. (See Fig. aw)

Fig. as

Fig. aw

P/N: 4CK020-010 v6.0, 02/17/2012

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29
 AN. While pressing down on the lid, re-install the
canister retaining ring using a brass or similar
non-sparking metal punch and hammer.
AO. Tap the retaining ring in a clockwise direction
until the raised notches are located with the
appropriate raised notch of each of the tanks
brackets. (See Fig. p, Fig. q)
AP. Squeeze a small amount of dielectric grease
into each pin location of the connector that con-
nects to the external receiver of the fuel pump
canister lid.
AQ. Connect the fuel feed line to the top of the pump
canister unit.

Fig. p

Fig. q

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30
10. Fuel pump voltage booster installation

A. Be sure the battery is disconnected.

B. Remove front driver side wheel and remove 2
rear most plastic rivets and rear most reusable
rivet securing plastic inner fender liner. Bend
inner fender liner forward.
C. Gain access to the firewall right below the
brake master cylinder booster. (See Fig. b)

Fig. a

Fig. b

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31
 D. Open rear hatch door of vehicle to gain
access to FPB mounting location. Remove the
bottom plastic trim panel piece along bottom
edge at latch. Remove two 10mm nuts and lift
up subfloor to gain access to FPB mounting
location.
E. Place FPB in the mounting location lowering
subfloor to confirm location and fit. Mark
mounting location and cut away insulation
mat. (See Fig. c)
F. Position the FPB unit as shown in Fig. 10-d
and mark the three mounting holes for drilling.
G. Using a drill with a 9/64” drill, drill 3 mounting
holes.
H. Mount the FPB unit to the floor using the three Fig. c
#10 sheet metal Phillips head screws. (See
Fig. e)

Fig. d

Fig. e

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32
I. Locate the 1/8” nylon Instrument tubing, 10ga.
red wire, 12ga.orange wire, 14ga. red wire,
and install it into the 1/2” plastic split loom
making a harness assembly.
J. Locate the rubber plug shown in Fig. f and
Fig. g. Using a sharp knife or blade cut the
bottom out of the plug to provide through
access for ½” harness assembly.
K. From the underside of the vehicle route the
harness assembly up through the modified
plug to the FPB previously installed. Secure
the loom with provided tie wraps in Fig. f.
L. Locate the 11’ piece of 3/8” plastic split loom
and install the 1/8” nylon instrument tube and
red 10ga. power wire. Continue routing the Fig. f
harness assembly loom (See Fig. h, Fig. i)
through the factory fuel line supports along the
inside of the underbody and secure with zip
ties as needed. Leave the 12ga. orange and
14ga. red wire hanging as shown in Fig. h to
be used in a later step.

Fig. g

Fig. i Fig. h

P/N: 4CK020-010 v6.0, 02/17/2012

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33
 M. Continue routing harness along transmission
cross member, (See Fig. j, Fig. k, Fig l) and
continue routing the harness further forward
up and through the oblong hole under the
brake booster in the firewall and up and into
the engine bay. (See Figs. m)

NOTE: Crimp on connectors are provided but it is recommend-

ed that all of the wire connections be soldered and Fig. j
insulated.

NOTE: Refer to the fuel pump wiring diagram that is provided

for further explanation if needed.

Fig. k

Fig. l Fig. m

P/N: 4CK020-010 v6.0, 02/17/2012

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34
N. Continue running the red 10ga. power wire to
the Power Distribution Center. Locate the pro-
vided fuse holder and cut the center of the
wire loop. Attach one end to the red 10ga.
power wire from FPB. Use the supplied ¼”
yellow ring terminal crimp, solder, and attach
to factory power lug. (See Fig. n) Install the
supplied 40amp fuse into fuse holder after all
connections are complete and cover the wire
with a piece of ¼” plastic split loom. (Refer to
wiring diagram).
O. Run the 1/8” instrument tube vacuum line from
the FPB to the passenger side of the engine.
Locate the supplied 7/64” vacuum hose and
cut off a 2” piece. Slide approx. 1” onto the
1/8” nylon instrument tube. Fig. n
P. Using the supplied brass fitting, connect the
FPB vacuum line to the line between the MAP
sensor and bypass valve. (See Fig. o, and
Fig. p). Cover with ¼” plastic split loom and
secure with the provided tie wraps. This will
be used for boost reference.

Fig. o

Fig. p

P/N: 4CK020-010 v6.0, 02/17/2012

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35
©2012 Vortech Engineering, Inc.
P/N: 4CK020-010 v6.0, 02/17/2012


All Rights Reserved, Intl. Copr. Secured

  









 

 
  


 

 
 

 
   
 
  

36




 
Wiring Diagram









 

Q. On the FPB box locate the red 10ga. wire with
a fuse holder. Connect this wire to the 10ga.
red wire in the harness assembled back in
step I. (See Fig. d). Connect the 10ga. orange
wire from the FPB to the 12ga. orange wire in
the harness. Connect the 14ga. red wire from
the FPB to the 14ga. red wire in the harness.
Locate the 7/64 vacuum hose provided in the
kit and cut a 2” piece and install one end on
the 1/8” nylon tube and the other end to the
vacuum port on the FPB. This will be used for
boost reference. Locate the black 12ga.
ground wire from the FPB and install a ¼” ring
terminal. Using a drill with a 9/64” bit, drill a
hole and attach the black ground wire to a
suitable ground as shown in Fig. q, and r. Fig. q
(Refer to wiring diagram). Install the supplied
40amp fuse into fuse holder.
R. Reassemble the subfloor and plastic trim
panel. (See Fig s)

Fig. r

Fig. s

P/N: 4CK020-010 v6.0, 02/17/2012

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37
 S. Locate the factory fuel pump wiring harness
disconnected from the fuel pump canister in
step 9-H. Peel back the electrical tape toward
the end that plugs into the pump canister. Cut
the orange wire with the red tracer roughly 3
inches from the plug (see Fig. t).
T. Bundle wires together and wrap with electrical
tape (See Fig t). Refer to wiring diagram for
final installation.
U. Trim the FPB red and orange wires left hang-
ing (shown in Fig. h, page 33) so that there is
adequate length to connect to fuel tank during
re-assembly. Attach the 14ga. red wire from
the FPB to the end of the orange with red
trace wire going to the OEM wiring harness.
(Refer to wiring diagram). Attach a female Fig. t
slide connector to the 12ga. orange wire from
the FPB. This wire will power the fuel pump.
V. Locate the 3 foot piece of 12ga. black ground
wire supplied in your kit. Attach a male slide
connector to one end and a ¼” ring terminal to
the other end. Attach the ring terminal to the
chassis using the supplied sheet metal screw.
(See Fig. u)

INSTALL FUEL TANK

AA. Re-support tank on transmission jack or equiv-

alent and carefully raise tank back up into the
cavity of the car. Connect the harness that
was spliced into the FPB wires to the fuel
pump canister. Connect the orange FPB wire
to the red pump wire and black ground wire to Fig. u
the black pump ground wire. Raise the tank all
the way. Some maneuvering is required if the
driveshaft was not disconnected.
AB. Secure with original six bolts.
AC. Reconnect the fuel tank filler tube with original
clamp, the two push lock connectors at the
rear of the tank to the fuel vapor canister
(white connector and black connector with yel-
low clip)
AD. Reconnect the electrical connector located
above the rear differential center section.
AE. Reconnect the two push lock connectors
located at the front of the tank. (Fuel supply
and fuel vapor lines)
AF. Re-secure inter fenders and re-install front
wheel.
AG. Connect the battery. After reconnecting the
battery you should key on listening for the
pump to prime and check all fuel connections
for leaks.

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38
11. REFLASH COMPUTER

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.
• Do not disconnect the cable or turn off the ignition during programming.

A. Reconnect the battery.

B. Locate the vehicles OBD2 connector locat-
ed below the dash on the driver’s side of
the vehicle.
C. Attach the OBD2 connector from the Flash
tool that is provided in the kit to the vehicle’s
OBD2 port. Make sure this connector is
seated all the way in the vehicle’s OBD2
port. You do not want this connector coming
out during programming or damage may
occur to the vehicle’s ECM.
D. The Reflash tool should power up and dis-
play three parameters.
1. Performance Tune
2. Diagnostics
3. Options
E. Select “Performance Tune” and press the
enter button in the middle of the arrow keys.
F. Read the disclaimer entirely, then select
agree and press enter.
G. At this point follow the instructions on the
screen displayed on the reflash tool. If you
have any questions, either refer to the man-
ual that is provided with the reflash tool or
contact our service department for further ESCAPE
assistance. ARROWKEYS
H. Turn the ignition on (do not start the vehi-
cle). Set the parking brake and press the ENTER
enter button to continue. OR
SELECT
NOTE: Do not disturb the cable, or turn the ignition off during
this time. If the programming is disrupted, the comput-
er will not start or run your vehicle!

I. SELECT TUNE will be displayed at the top Fig. a

of the screen. Use the arrow keys to select
the appropriate tune for your vehicle and
press the enter button. You will have a
choice of two to choose from:
1. Vortech (used for installing kit)
2. Original Backup
J. Continue to follow the screen and when fin-
ished, unplug the reflash tool from the vehi-
cle’s OBD2 port.

P/N: 4CK020-010 v6.0, 02/17/2012

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39
 12. Final Assembly and Check

NOTE: This supercharger has been factory

pre-filled with special synthetic lubri-
cant. Oil does not need to be added to a
brand new unit. However the following
fluid level check should be performed.

A. Remove the factory installed flat head brass

shipping plug (not the dipstick) from the top of
the supercharger case.
B. Replace the sealed shipping plug with the
supplied “vented” plug. Do not operate the
supercharger without it.
C. Ensure that the .06” copper sealing washer is
located on the dipstick base.
D. Thread the clean dipstick into the supercharg-
er until it seats.
E. Once the dipstick has seated, remove the
dipstick from the unit. Fluid should register in
the crosshatched area on the dipstick.
F. DO NOT OVERFILL!! Drain excess fluid from
the unit if it is above the maximum level on
the dipstick. Install and tighten the dipstick in
the gearcase.
G. If your vehicle has gone over 20,000 miles
since its last spark plug change, it is a good
idea to change the spark plugs now, before
test-driving.
H. Make sure that the vehicle is filled with 91
octane or higher fuel before commencing test
drive.
I. With key on, make sure charge air cooler
water pump is operating and that water is
flowing through the surge tank. Fill as neces-
sary. If water is not flowing, remove the hose
from the bottom of the surge tank and lower
until water flows out of hose. This should
prime the pump. Reconnect hose, verify
water flow and top off surge tank. Do not run
the water pump for extended periods (30 sec-
onds or more) without water flow.
J. Check all fittings, nuts, bolt and clamps for
tightness.
WARNING: Do not attempt to operate the vehicle until ALL compo-
nents are installed and ALL operations are completed includ-
ing final check. Failure to do so may cause PREMATURE
FAILURE OF MAJOR COMPONENTS.

K. At this point it is OK to start the vehicle.

L. With engine running, check power steering
hose connections for leakage. Let engine run
for two minutes. Turn steering wheel in both
directions.

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©2012 Vortech Engineering, Inc.
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40
Verify:
• Smooth power assist
• Noiseless operation
• Proper fluid level
• No system leaks
• No bubbles, foam or discoloration in fluid
M. Verify that the gilmer belt is running smoothly.
If wear is detected on the side of the belt, it is
probably too tight. If it is vibrating excessively,
tighten until there is minimal movement.
N. Turn off vehicle and recheck all fluid levels
and verify that no hoses, wires, etc. are near
exhaust headers or moving parts and that
there is no fluid leakage.
O. Be sure both front fender liners are secured w/
supplied pull lock pins.
P. Test drive vehicle by gradually working up to
full throttle and paying close attention to any
abnormal sounds or engine detonation.

NOTE: Read the STREET SUPERCHARGER SYSTEM OWNER’S

MANUALAND RETURN THE WARRANTY REGISTRATION
FORM within thirty (30) days of purchasing your supercharger
system to qualify for the 3 year limited warranty.

P/N: 4CK020-010 v6.0, 02/17/2012

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41
 For Internally Lubricated V-3 Units Only

Important Information About

Supercharger Maintenance:
Long term maintenance and care:
· CAUTION: Use of any fluid other than the
Vortech supplied synthetic lubricating fluid
will void the warranty and may cause com-
ponent failure.
· Replacement Vortech V-3 lubricating fluid
part number: 009035 - Package of three 4
oz. bottles
· Check the fluid level using the dipstick at
least every 2,500 miles.
Initial supercharger fluid change must be
performed at 2,500 miles. The supercharger
fluid must then be changed at least every
7,500 miles.
1. Drain the fluid, re-fill the unit only with 4
oz. of Vortech supplied synthetic lubri-
cating fluid.
2. Confirm proper oil level using the dip-
stick. DO NOT OVERFILL!! (See steps
12-C through 12-F)

Supercharger fluid level checking procedure:

1. Ensure that the .06” copper sealing washer is
located on the dipstick base.
2. Thread the clean dipstick into the supercharger
unit it seats.
3. Once the dipstick has seated, remove the dip-
stick from the unit. Fluid should register in the
crosshatched area on the dipstick.
4. DO NOT OVERFILL!!! Drain excess fluid the
unit if it is above the maximum level on the dip-
stick.

P/N: 4CK020-010 v6.0, 02/17/2012

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All Rights Reserved, Intl. Copr. Secured
42
 ®

ENGINEERING, INC
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: 4CK020-010 v6.0, 02/17/2012

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43