vortech super charger install 2001-2005 lexus is300 (4la020-010v1.1)

8/2/2019 Vortech Super Charger Install 2001-2005 Lexus IS300 (4LA020-010v1.1)

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DP/N: 4LA020-010 - v1.1 07/10/07

1650 Pacific Avenue, Channel Islands CA 93033-9901 Phone: 805 247-0226Fax: 805 247-0669 www.vortechsuperchargers.com M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

Lexus3.0LIS300SuperchargerSystemInstallationInstructions

2001-2005ModelYear

*LegalinCaliforniaonlyforracingvehicleswhichmayneverbeuseduponahighway.


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2007 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured11JUL07 v1.1 Lexus(4LAv1.1) ii

FOREWORD

2007 VORTECH ENGINEERING, LLCAll rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translatedinto another language in any form, by any means without written permission of Vortech Engineering, LLC.

Take note of the following before proceeding:

1. Proper installation of this supercharger kit requires general automotivemechanic knowledge and experience. Please browse through each step ofthis instruction manual prior to beginning the installatlion to determine if youshould 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. ThePCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. Ifthe vehicle or engine has been modified in any way, check with Vortech prior to installa-tion 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 (noboost) 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, butnot limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Vortech components with other modifications such as, but not limit-ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM program-ming or other such changes.

STOP

This manual provides information on the installation, maintenance and service of the

Vortech supercharger kit expressly designed for this vehicle. All information, illustra-tions and specifications contained herein are based on the latest product information

available at the time of this publication. Changes to the manual may be made at any timewithout notice. Contact Vortech Engineering for any additional information regarding this kitand any of these modifications at (805) 247-0228 8:00am-4:30pm PST.

NOTICEDue to variances in each vehicle, Vortech recommends that the vehicle geta custom tune from a local, reputable tuner.

This kit is supplied with a universal fuel and ignition timing calibration. Thiscalibration is intended to allow the vehicle to start and operate at part throt-tle, and is not optimized for full throttle performance. Do not operate the

vehicle at heavy throttle or high RPM until a custom calibration tailored foryour specific vehicle can be obtained from a competent tuner. A wide-band exhaust oxygen sensor must be used to confirm proper air/fuel ratio.Vortech suggests a proper WOT air/fuel ratio range of 10.8-11.0:1 for 91octane fuel.


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TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

PARTS LIST (2002-2005 3.0L Lexus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

1. PREPARATION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4. ABS RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION . . . . . . .7

6. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

7. AIR INLET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

8.1 FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003Automatic Models Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

8.2 FUEL PUMP AND FMU INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .23

9. POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

10. ELECTRONIC CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . .27

11. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29


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This product is protected by state common law, copyright and/or patent. Alllegal rights therein are reserved. The design, layout, dimensions, geometry,and engineering features shown in this product are the exclusive propertyof Vortech Engineering, LLC. This product may not be copied or duplicatedin whole or part, abstractly or fundamentally, intentionally or fortuitously, nor

shall any design, dimension, or other information be incorporated into anyproduct or apparatus without prior written consent of Vortech Engineering,LLC.

IMPORTANT NOTE

2001-2005 3.0L Lexus IS300


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Before beginning this installation, please read through this entire instruction booklet and theStreet Supercharger System Owners Manual which includes the Limited Warranty Program,the Warranty Registration form and return envelope.

Vortech supercharger systems are performance improving devices. In most cases, increases intorque of 30-35% and horsepower between 35-45% can be expected with the boost levels specifiedby 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 ofthe engine as well as the supercharger. Vortech Engineering is not responsible for enginedamage.

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. Perform an oil and filter change upon completion of this installation and prior to test driving

your vehicle.Thereafter, always use a high grade SF rated engine oil or a high quality syn-thetic, and change the oil and filter at least every 3,000 miles. Never attempt to extend theoil change interval beyond 3,000 miles, regardless of oil manufacturers claims aspotential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1-year or 15,000

miles with original heat range plugs as specified by the manufacturer and reset timing to fac-tory specifications (follow the procedures indicated within the factory repair manual and/or asindicated on the factory underhood emissions tag). Do not use platinum spark plugsunless they are original equipment. Change spark plugs every 20,000 miles.

TOOL & SUPPLY REQUIREMENTS

Factory repair manual 3" hole saw 1/2" socket and drive set: SAE & metric 3/8-18 tap & handle Adjustable wrench Open end wrenches: 3/8", 7/16", 1/2", 9/16",

10mm, 12mm

Metric Allen wrench set Center punch and a 5/8" tapered punch Fractional drill bit set Grinder (electric right-angle) 6 quarts (or what is specified in your owners manual)

SF rated quality engine oil, oil filter and wrench

If it has been 20,000 miles or more since your vehicles last spark plug change, then you will also need:

Spark plug socket

NEW spark plugs

2001-2005 3.0L Lexus IS300Installation Instructions

Congratulations on selecting the best performing and best backed automotivesupercharger available today... the VORTECH supercharger!

ENGIN

EERING

, LLC


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008110 SMALL SILVER DIE-CUT DECAL 2

008130 LICENSE PLATE FRAME, VORTECH 1

008444 S/C STRT INFO PKG ASY VORT 1

2E248-080 SUPERCHARGER V-5F SQ CW, LEXUS IS300 1

4LA020-010 INSTRUCTION MANUAL, IS300 1

4LA110-010 POWER STEERING COOLR ASY 18N006-025 COOLER, P/S 4-PASS PERMA/CL 18N100-001 NYLON MOUNTING KIT 17P375-312 3/8" BARB x 5/16" BARB REDUCER 27R004-003 STEPLESS CLAMP, 14.5-70 47U031-018 5/16" EFI FUEL HOSE HI-PSR 4'

4LA111-044 S/C MOUNT BRKT ASY, LEXUS IS300 12A017-462 SPACER, IDLER SMOOTH 6-RIB 12A017-501-153 SPACER, .50"OD x 1.538"L ALUM 1

2A017-750-08 SPACER, .75"OD x .1.437"L 12A017-875-13 SPACER, .875"OD x .895"L 52A046-100 BELT, GATES K061010 14FA016-171 DUST COVER (IDLER PULLEY) 24FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 24LA010-010 BRKT, SUPPORT IS300 14LA010-021 BRKT, LOWER SUPPORT IS300 14LA010-044 BRKT, 5/16" S/C MOUNT IS300 14LA017-011 SPACER, IDLER, 1.060"L IS300 17A375-100 3/8-16 x 1" G5 HHCS PLT 27A375-100 3/8-16 x 1" G5 HHCS PLT 17A375-178 3/8-16 x 1-3/4" HXHD G8 57A375-276 3/8-16 x 2-3/4" HXHD ZINC 17C010-016 M10-1.25 x 16mm, FLG HD, 10.9 17C012-040 M12-1.75 x 40mm HXHD BOLT, CL10.9 17C060-070 M6-1.00 x 70mm HXHD CL8.8 PLT 27C080-040 M8-1.25 x 40mm, SHCS, CL12.9 17C080-081 M8-1.25 x 80mm, HXHD, CL10.9 17E010-075 #12 x 3/4" SHT METAL SCRW, HEX 3

7F375-017 3/8-16 NYLOCK NUT 27J006-094 6mm WASHER SS 27K312-001 5/16"AN WASHER, PLATED 17K375-040 3/8"AN960 FLAT WASHER PLATED 12

4LA112-010 INLET ASY, LEXUS IS3008H040-035 AIR FILTER, 3.5" FLANGE, G35 OFFSET 17U030-036 1/2" OIL DRAIN HOSE 0.75'7P500-001 1/2" HOSE UNION 27R001-006 #6 STNLS HOSE CLAMP, NARROW 37U031-016 5/16" PCV/VAC RUBBER HOSE 2.5'7R004-003 STEPLESS CLAMP, 14.5-70 47P312-050 5/16" HOSE MENDER 17P312-060 ELBOW, PLASTIC 5/16" x 90 UNION 1

4LA130-026 OIL FEED LINE ASY, IS300 17P125-004 1/8"NPT x 90 x -4 JIC FTG STL 17P125-005 1/8"NPT STR x -4 JIC FTG STL 17P125-034 1/8"NPT x 1/8"NPT STRT T 17P125-125 FTG, 1/8"NPT FEM x 1/8"BSPT MALE 1

7U100-055 TIE-WRAP, 7.5" NYLON 57U250-090-320 OIL FEED HOSE, 32" x -4 x 90 1

4NZ101-068 FUEL PUMP ASY, INLINE 350Z 15W001-045 16-14GA RING TERM., .17" HOLE 15W001-032 1/4" WIRE LOOM 10'5W001-011 16-14GA RING TERM. .26" HOLE 15W014-030 14GA STRD WIRE BLACK .5'7E010-075 #12 x 3/4" SHT METAL SCREW, HEX 27P312-017 5/16" HOSE BARB TO M10 x 1.0mm 17P312-082 5/16" TEE HOSE BARB 27R003-027 ADEL CLAMP, 1-11/16" 27R004-001 STEPLESS CLAMP, 15.7-70 8

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

7U031-0018 5/16" EFI HOSE, HI-PSR 5.5'7U100-044 TIE-WRAP, 4" NYLON 107U100-055 TIE-WRAP, 7.5" NYLON 58F001-068 WALBRO INLINE FUEL PUMP, 68 GP 1

4NZ130-036 OIL DRAIN LINE ASY, 350Z 17P375-017 3/8"NPT x 1/2" BEADED HSE BARB 17R001-008 #8 STNLS HOSE CLAMP 27T560-001 CUTTER, 9/16" ROTABROACH 17T560-002 ARBOR, ROTABROACH 17U030-036 1/2" OIL DRAIN HOSE 1.5'7U100-066 TIE-WRAP, 11" NYLON 5

4NZ238-088 FMU, 8:1 w/LINES, w/SPRING, 3 16Z010-101 FMU HOUSING (BLUE ANODIZED) 16Z010-111 FMU VALVE BODY (BLUE ANODIZED) 16Z010-131 COVER, FMU - GM 4.3 16Z020-130 SML DIAPHRAGM, FLUORO 1

6Z020-140 LRG DIAPHRAGM, FLOURO 16Z030-150 BRACKET, FMU 16Z040-160 PISTON, FMU 16Z050-191 FMU WASHER, 8:1 PLATED 16Z060-181 SHIM, FMU 16Z070-030 FMU 8:1 RING SPACER 16Z080-011 RETAINER, FMU SPRING GM 4.3 16Z090-010 SPRING, FMU GM 4.3 17C010-050 10-24 x .50" SHCS GR8 PLT 67C010-075 10-24 x 3/4" SHCS GR5 ZINC 47C024-025 10-24 x 1/4" PHILL HD 37E010-075 #12 x 3/4" SHT MTL SCRW, HEX 27P125-025 1/8"NPT x 5/32" HOSE, 90 17P125-031 1/8"NPT x 90 x 5/16" BARB 17P125-032 1/8"NPT-STR, 5/16" BARB 17P156-082 5/32" TEE 17P312-005 5/16" FEM FUEL CNCT, STEEL 17P312-007 FUEL FTG, 5/16" GM x 5/16" HSE 17R004-001 STEPLESS CLAMP, 15.7-70 4

7U030-046 5/32" VACUUM LINE 7'7U031-018 5/16" EFI FUEL HSE, HI-PSR 2.5'7U031-018 5/16" EFI FUEL HSE, HI-PSR 1.25'7U100-030 O-RING, FMU 17U100-096 ROLL PIN, 3/16" x 1/2" SS 1

5A003-130 ECU, UNICHIP QT, '02-'05 IS300 SAFE TUNE 1

8N201-330 CHARGE COOLR ASY, LEXUS IS300 14LA010-061 BRKT, HOOD LATCH SPRT IS300 14LA012-010 TUBE A S/C DISCHARGE IS300 14LA012-020 TUBE B S/C DISCHARGE IS300 14LA012-040 TUBE D S/C DISCHARGE IS300 14LA012-050 TUBE E S/C DISCHARGE IS300 14NZ012-020 TUBE, COOLER INLET, 350Z 17A250-074 1/4-20 x .75" HHCS PLTD 17A312-050 1/4-20 x 1/2" HXHD GR5 ZINC 27C008-050 #8-32 x 1/2" SHCS, ZINC 27E010-049 #10 x 3/4" HXHD SLF DRL SHT MTL 27F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1

7J006-094 6mm WASHER SS 47P156-082 5/32" TEE 17R002-016 #16 SAE TYPE F SS HOSE CLAMP 27R002-040 #40 SAE TYPE F SS HOSE CLAMP 127R002-044 #44 SAE TYPE F SS HOSE CLAMP 27S250-025 ELBOW, 2.5"ID x 25 BLUE 57U030-046 5/32" VACUUM LINE 3'7U133-090 RUBBER ELBOW, 1.0" x 90 18D001-001 STD COMPRESS BYPASS VALVE 18H040-075 1" AIR FILTER BYPASS 18N010-210 BRKT, CLR MNT, IS300 18N101-350 CHARGE AIR COOLER, 350Z 17S300-275 REDUCER, 3.00" x 2.75" 2

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

2002-2005 3.0L LexusPart No. 4LA218-010SQ/018SQ

ENGINEERING, LLC PARTS LIST


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8F101-350 RELAY ASY, 350Z FUEL PUMP 15W001-005 3/8" PLASTIC WIRE LOOM 8'5W001-010 16-14GA FEMALE SLIDE INSULATED 25W001-016 RELAY, BOSCH 15W001-040 12-10GA FEMALE SLIDE INSULATED 25W001-046 16-14GA RING TERM. .33" HOLE 25W001-054 16GA FUSE HOLDER WITH WIRE 15W014-010 14GA STRD WIRE, RED, UL1015 7'5W014-030 14GA STRD WIRE BLACK 1'5W014-030 14GA STRD WIRE BLACK 7'

6Z170-040 10:1 RING SPACER ASY 1

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

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

2002-2005 3.0L Lexus, contdPart No. 4LA218-010SQ/018SQ

ENGINEERING, LLC PARTS LIST


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A. Disconnect the negative battery cable.

B. Remove the four 10mm headed fastenerssecuring the plastic engine cover and setaside.

C. Disconnect the valve cover vent hose fromthe air inlet assembly but leave it attached tothe valve cover.

D. Using a 10mm socket and ratchet, removethe factory air filter enclosure, air scoop, andducting leading to the throttle-body and setaside. (See Fig. 1-a.)

E. Remove the MAF electronics from the previ-ously removed intake ducting and set aside tobe reused in a later step. (See Fig. 1-b.)

F. Detach the pressure solenoid from the plasticair filter enclosure (a single 10mm headscrew). Set solenoid and screw aside to bereinstalled in a later section. (See Fig. 1-c.)

1. PREPARATION/REMOVAL

Fig. 1-a

Fig. 1-b

Fig. 1-c

NOTE: It is a good idea to label the line connec-tions to prevent confusion later.

G. Disconnect the ABS module harness plugfrom the module. Using a 10mm wrench,loosen the ABS module retaining nuts.Remove the module from its mounting brack-et. Using a 12mm wrench, remove the hard-ware securing the ABS module bracket.Remove the module mounting bracket fromthe frame rail and set aside. Be careful not tolose the rubber stud mounts or the rubber

bushing on the bottom of the module.

MAF ELECTRONICS

LEAVE CONNECTEDTO HARD LINE


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H. Drain the engine coolant into a clean contain-er and set aside. Remove the lower radiatorhose located on the passengers side of theengine. Trim approximately 1" from the end ofthe hose that was attached to the radiator,and set aside. Remove the upper radiator

hose and set aside to be reinstalled in a laterstep. Remove the thermostat housing. Rotatethe thermostat housing 180 and reinstall.Disconnect the fans power connectors, radia-tor overflow bottle and remove the fan mount-ing hardware. Remove the engine fan assem-bly and set aside. Remove the upper radiatormounts/hardware and set aside. Remove theradiator and set aside. (See Fig. 1-d.)

I. Remove the four 5mm socket-head screwsretaining the cam sprocket cover and set thecover and hardware aside. Locate the plasticwire loom channel on the passengers side ofthe engine. Remove the wire loom from thechannel. Remove the 5mm socket-head fas-tener securing the channel to the cylinderhead. Cut the channel as shown. (See Fig.1-e.) Install the supplied piece of flex loomonto the exposed section of wire and wrapwith electrical tape. Reinstall the cam sprock-

et cover using the factory hardware.

NOTE: Automatic transmission vehicleswillneed to disconnect the cooler lines run-ning to the radiator. Cover any open lineconnections to avoid possible fluid con-

tamination.

Fig. 1-e

Fig. 1-d

1. PREPARATION/REMOVAL, contd

THERMOSTAT HOUSINGROTATED 180

TUBE PREVIOUSLYCONNECTED TO

PRESSURE SOLENOID

CUT LOOM HERE


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Fig. 1-f

J. Remove the wire loom bracket secured to thetop of the water pump and discard. (See Fig.1-f.) Remove the 10mm headed screw locat-ed just above and to the drivers side of thepreviously removed bracket as shown. (SeeFig. 1-g.)

K. Remove the 12mm headed bolt and wire har-ness on the side of the water pump and dis-card. (See Fig. 1-g.)

L. Cut the small black cross-over tube locatedjust above the water pump where indicated.(See Fig. 1-f.)

M. Loosen the four water pump pulley retainers.Un-tension the accessory drive belt andremove. Remove the water pump pulleyretainers and pulley, setting them aside to bereinstalled in later step.

N. Remove the bolt securing the alternator to

the water pump. Remove the 12mm headedbolt just to the right (drivers side) and downfrom the previously removed alternator bolt.Remove the 10mm headed bolt just abovethe alternator. (See Fig. 1-g.)

Fig. 1-g

1. PREPARATION/REMOVAL, contd

BOLT SECURINGLOOM BRACKET

LOWERW/P BOLTALT. BOLT

REMOVE

CUT TUBE HERE

PREVIOUSLYSECURED

LOOMBRACKET

REMOVE10mm HEADED

SCREW


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A. The supercharger uses engine oil for lubrica-tion and must have an oil feed line connectedto a filtered oil access on the engine.

B. Locate the oil pressure sending unit on thedrivers side of the engine, just in front of andabove the engine mount. (See Fig. 2-a.)

C. Disconnect and remove the pressure senderand set aside to be re-installed later.

D. Locate the supplied oil feed assembly(4LA130-026).

E. Install the supplied 1/8"BSP adapter into thehole previously occupied by the oil pressuresender. Install the supplied 1/8"NPT streetTEE into the BSP adapter. Orient the branchof the TEE so that it faces up. Thread the fac-tory sending unit into the TEE as shown.(See Fig. 2-b.)

2. OIL FEED

Fig. 2-a (View From Below)

Fig. 2-b

OIL PRESSURESENDER

OIL PAN

1/8"NPT x#4 FLARE

FACTORY OILPRESSURE SENDER

1/8"NPT STRT TEE

BSP

ADAPTER

NOTE: The factory wiring harness may need tobe unclipped from the engine block togain the necessary length to reach therepositioned sending unit.

NOTE: Pipe tape, paste or other sealant is notrecommended as it may loosen andcause blockage of the oil feed orificeresulting in supercharger failure. Useengine oil on the threads.

F. Install the supplied 1/8"NPT x #4 flare fittinginto the previously installed TEE. (See Fig.2-b.)

G. Attach the straight end of the supplied oil feedline to the #4 flare fitting previously installedand route up and over the engine valve cover.

H. Temporarily cover the open oil feed line end

to keep out debris until the connection ismade to the supercharger in a later step.

I. Reconnect the factory oil pressure senderwire.


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A. To provide an oil drain for the supercharger, itis necessary to make a hole in the intermedi-ate oil pan.

B. Locate the factory oil drain boss on the pas-sengers side of the engine as shown. (SeeFig. 3-a.)

C. Drill a 1/8" pilot hole into the center of theboss. Using the supplied 9/16" rota-broachcutter and arbor, carefully machine a through-hole into the intermediate pan.

D. Tap the previously machined hole approxi-mately 1/4" deep using a 3/8"NPT tap. Packthe flutes of the tap with heavy grease to holdthe chips.Thoroughly clean the threads andhole with acetone or lacquer thinner.

E. Using a small amount of silicone sealer,install the 3/8"NPT x 1/2" barb fitting into thepreviously tapped hole. Temporarily cap thefitting until the drain hose is connected in alater step. (See Fig. 3-b.)

F. Drain the engine oil and change the oil filter.

3. OIL DRAIN

Fig. 3-a

Fig. 3-b

NOTE: Pack the cutter with heavy grease andDO NOT stop the drill motor until therota-broach has been extracted from the

pan This will help retain the cut out piecein the cutting tool.

NOTE: Automatic transmission vehicles only:It may be necessary to temporarilyremove the transmission cooler lines(see Fig. 3-a) from their mounting brack-et to provide a clear path for drilling.

INTERMEDIATEOIL PAN

OIL DRAIN LOCATION

LOWEROIL PAN

3/8"NPT x 1/2"BARB FITTING

INTERMEDIATEOIL PAN

OIL PAN

ENGINEBLOCK


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Fig. 4-a

Fig. 4-b

TOP OF FRAME RAIL

BOTTOM EDGEOF BRACKET

FRONT EDGEOF BRACKET

FACTORYSTUD

3.5" '02-'05 MODEL YRS

2" '01 MODEL YR

2.4" '02-'05MODEL YRS

1-5/8" '01MODEL YR

Fig. 4-c

A. Locate the ABS module bracket removed inSection 1. Remove the three spot welds thathold the side support to the main cradle.Separate the side support from the main cra-dle and discard. Drill the two lower spot weldlocations to 3/16" and add an annitional3/16" hole as shown. (See Fig. 4-a.)

B. (2001 Model Year Only, 2002 and LaterSkip to B-2.)

1. Measure 2" back from the stud that previ-ously secured the bottom of the ABSbracket and make a mark. At the previ-ously marked location, measure down 1-5/8" from the top of a frame rail and make

a second mark. Align the front and bottomedges of the bracket where the two marksintersect. Using the modified bracket as atemplate (see Fig 4-a) to mark the threehole locations on the frame rail. Drill thehole locations using a 1/8" drill bit. Securethe ABS bracket to the frame rail usingthe supplied selt-tapping hardware. Cutthe factory stud that previously securedthe ABS bracket flush wiith the frame.(See Fig. 4-b.)

(2002-2005 Model Years Only),2. Measure 3.5" back from the stud that pre-

viously secured the bottom of the ABS

bracket and make a mark. At the previous-ly marked location, measure down 2.4"from the top of the frame rail and make asecond mark. Align the front and bottomedges of the bracket where the two marksintersect. Using the modified bracket as atemplate (see Fig. 4-a) to mark the threehole locations on the frame rail. Drill thehole locations using a 1/8" drill. Secure theABS bracket to the frame rail using thesupplied self-tapping hardware. Cut thefactory stud that previoisly secured theABS bracket flush with the frame. (SeeFig. 4-b.)

C. Remove the 10mm headed screw thatsecures the plastic brake line separator anddiscard. Remove the brake lines from theirplastic separator located on the frame rail.Slightly bend the lines running to the ABSmodule so that it may be repositioned to itsnew location. Secure the module to the relo-cated bracket using the factory hardware.

4. ABS RELOCATION

NOTE: Use caution when bending these lines.Make bends as large as possible toavoid kinking.

NOTE: The preferred method of removing aspot weld is the use of a spot weld cut-ting tool. However in this application,the use of an approximate sized drill ora right-angle grinder is acceptable.

D. Locate the ABS module harness.Carefully split the plastic flex-loomexposing the wires from the ABSconnector to the main harness onthe shock tower. Separate enoughlength to reach the relocated ABSmodule and re-wrap the flex-loom.Reconnect the harness plug to theABS module. (See Fig. 4-c.)

LINES SLIGHTLY BENT

RELOCATEDABS MODULE

ABS HARNESS

SPOT WELD

NEW HOLELOCATION

SPOT WELDSDRILLED

THROUGH


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SPACER, LOWERSUPPORT(4LA010-021)

M6-1.0 x 70mmSCREW & WASHER

.50" x 1.538" SPACER(2A017-501-153)M6-1.0 x 70mmSCREW & WASHER

.875" x 1.437" SPACERM8-1.25 x 80mmSCREW & WASHER

NO SPACER/FACTORY ALT. BOLT(M10-1.25 x 50mm)

3/8-16 x 2.75" SCREW, WASHER, DUSTSHIELD, 3" SPOOTH IDLER, AND IDLER

SPACER (4LA017-011)

3/8-16 x 1" SCREW

& WASHER

3/8-16 x 1.75" SCREW, WASHER,& .895" SPACER (2A017-875-13) M10-1.25 x 15mm

4LA010-010UPPER SUPPORT

BRACKET

3/8-16 x 1" SCREW,WASHER, NYLOC NUT

Fig. 5-b

A. Locate the S/C mounting bracket assembly(4LA111-044.)

B. Using the M8 x 40mm socket-headed screw,loosely attach the mounting bracket supportblock (4LA010-021) to the side of the waterpump. (See Fig. 5-a.)

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION

NOTE: For the following section, refer to Fig.5-b for screw and spacer location. Donot tighten until all hardware is in place.

LOWER BRACKETSUPPORT (4LA010-021)

M8-1.25" x 40mm(7C080-040)

Fig. 5-a


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C. Using Fig. 5-bas a guide and working fromthe bottom up, install all the applicable hard-ware and spacers into position as follows:

1. With the mounting bracket in position,place the M8-1.25 x 80mm screw andwasher through the mounting bracket,

1.437" spacer and into the lower waterpump mounting hole.

2. Then install the factory alternator bolt(M10-1.25 x 50mm) through the mountingbracket and into the alternator mount.

3. Next, install the M6-1.0 x 70mm screwand washer through the mounting bracketsupport spacer (4LA010-021) and into thewater pump.

4. Install the 3/8-16 x 2.75" screw and wash-er through the dust shield, 3" smoothidler, idler spacer, and into the support

spacer (4LA010-021).5. Install the 3/8-16 x 1" screw and washer

through the mounting bracket and into thesupport spacer (4LA010-021).

6. Install the M6-1.0 x 70mm screw andwasher through the mounting bracket,1.538" long spacer and into the upperwater pump location.

7. Tighten the previously installed hardware.Make sure all mounting surfaces seat flatagainst one another and no lines or wire,etc. are being pinched.

D. Loosely install the upper support bracket(4LA010-010) to the S/C bracket using thetwo 3/8-16 x 1.0" screws, washers andNylock nuts. Install the M10-1.25 x 16mmscrew through the support bracket and intothe cylinder head. (See Fig. 5-c.)

E. Evenly tighten the previously installed hard-ware. Ensure the bracket is supported, butnot pulled or the location of the S/C bracket isnot changed.

F. Remove the blue plastic dust cap located onthe 1/2" oil drain fitting at the bottom of thesupercharger. Attach the supplied 1/2" fabric

braided oil drain hose to the superchargerdrain fitting. Secure with a #8 hose clamp.

G. Secure the supercharger to the main bracketusing the five 3/8-16 x 1.75" screws, washers,and .896" long spacers. (See Fig. 5-b, 5-c.)

H. Reinstall the factory water pump pulley andsecure using the factory hardware.

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, contd

Fig. 5-c

UPPER SUPPORTBRACKET

M10-1.25 x15mm SCREW

.895" LONGSPACER

SEPARATE MAF HARNESS HERE


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5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, contd

I. Install a 12mm-1.75 x 40mm screw throughthe dust shield, 3" smooth idler, idler spacer(.462" long piloted), and into the middlesupercharger mounting boss. (See Fig. 5-d.)

J. Remove the blue plastic dust cap located onthe brass oil feed nozzle on the side of the

supercharger.Thread the supplied 1/8"NPT x90 fitting into the oil feed nozzle. Carefullytighten and clock the fitting as shown. (SeeFig.5-e.) Use caution when tightening the oilfeed fitting, as the nozzle may break if care isnot exercised. Connect the previouslyinstalled oil feed line to the 90 fitting asshown. (See Fig. 5-e.)

K. Install the supplied drive belt as shown. (SeeFig. 5-f.)

Fig. 5-d

Fig. 5-e

POWERSTEERING

A/C

CRANK

TENS.

ALT.

IDLERWATERPUMP

SUPERCHARGER

IDLER

Fig. 5-f

3" SMOOTH IDLERIN MIDDLE POSITION

90 END OF SUPPLIED OIL LINE

1/8"NPT x 90

NOTE: Use clean engine oil to lubricate fittingthreads. Pipe tape, paste, or other typesof sealant are not recommended as itmight loosen and cause blockage of theoil feed orifice, resulting in supercharger

failure.


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6. CHARGE COOLER INSTALLATION

Fig. 6-a

Fig. 6-b

Fig. 6-c

A. Locate the discharge assembly 8N201-330.Use Fig. 6-aas reference.

B. Remove the 10mm headed screws securingthe plastic splash shield to the bottom of thecar and set aside.

C. Using a 2.5 x 25 sleeve and #40 clamps

provided, secure Tube A onto the super-charger discharge. (See Figs. 6-a, 6-b.)

D. Secure the supplied bypass valve to Tube Ausing the 1" x 90 elbow and two #16 hoseclamps provided. Orient as seen in Fig.6-band install the supplied 1"ID filter. Attacha length of 5/32" vacuum hose to thebypass valve and route to the vacuum port onthe intake manifold. Remove the factory vacu-um cap from the manifold port and attach thepreviously routed vacuum line. (See Fig. 6-c.)

TUBE A

TUBE BTUBE E

TUBE D

CHARGE COOLER

TUBE C

2.5" x 25 SLEEVE

BYPASS VALVE TUBE A

VACUUM LINETO BYPASS

VALVE

VACUUM PORT


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6. CHARGE COOLER INSTALLATION, contd

Fig. 6-e

Fig. 6-f

Fig. 6-d

TUBE B

TUBE C

2.5" x 25SLEEVE4.5" HOLE IN

SPLASH PANEL

2.5" x 25SLEEVE

CAC

CAC

TUBE C2.5 x 25SLEEVE

E. Attach Tube B using a 2.5" x 25 sleeveand #40 clamps provided to Tube A asshown. (See Fig. 6-d.)

F. A 4.5" hole will need to be cut in the driversside splash panel to provide a path for theCAC discharge tube. Using a 4.5" hole saw

or tool of choice, mark and drill the hole loca-tion shown. (See Fig. 6-e.)

2.5" x 25 SLEEVE

TUBE BOIL PAN


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POWER STEERING COOLER PREVIOUSLYATTACHED TO CORE SUPPORT

ECU ENCLOSURE10mm HEADEDSCREW

LINE BRACKET

CUT HERE


Fig. 6-g

Fig. 6-h

Fig. 6-i

G. Remove the three retaining screws at the topof the grill. Unclip the bottom edge of the grill.Remove the grill and set aside.

H. Locate and remove the two 10mm headedscrews that secure the P/S cooler to the frontcore support. Disconnect the rubber P/S

hoses from the steel P/S line assembly locat-ed near the P/S reservoir. Remove the powersteering cooler and the steel P/S line assem-bly located on the drivers side of the radiatorand discard. (See Fig. 6-g.) To gain accessto the assembly on the drivers side, you willfirst need to temporarily remove the three10mm headed retaining screws that securethe ECU enclosure and pull the enclosureupward to gain access to the 10mm headedscrew that retains the line bracket to the topof the frame rail. Once you remove the linebracket, re-secure the ECU enclosure using

the factory hardware. (See Fig. 6-h.)

NOTE: Leave the rubber lines connected to thepower steering pump.

I. Remove the two retainers securing the top ofthe A/C condenser. Tilt the condenser backtoward the engine (be careful not to damagethe condenser).

J. Remove the bolt securing the hood latchassembly to the core support. Cut approxi-mately 9" from the bottom of this mount.(See Fig. 6-i.)


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Fig. 6-j

Fig. 6-k

Fig. 6-l

CAC MOUNTING BRACKET8N010-210

FACTORY HARDWARE

K. Secure the CAC (Charge Air Cooler) bracket8N010-210 to the passengers side frame railusing the factory hardware as shown. (SeeFig. 6-j.) Loosely install the charge cooler intoits location. (See Figs. 6-j,6-k.)

L. Using the supplied 1/4-20 x .50 " hardware,

loosely attach the CAC to the mountingbracket.

M. Reinstall the A/C condenser, and secureusing the factory hardware.

N. Install one of the provided 2.5-25 sleevesonto the CAC inlet and secure using #40hose clamps. (See Fig. 6-e.)

O. Using a 2.5" x 25 sleeve and #40 clampsprovided, secure Tube C to the open end ofTube B and the 25 sleeve previouslyinstalled onto the CAC. (See Figs. 6-e, 6-f.)

P. To provide a path for the discharge ducting,

you must cut a 3" hole through the innerfender behind the passengers side headlight.Using the provided template, mark and drillthe location. Take care not to damage theheadlight assembly or wiring harnesses inthis area. (See Fig. 6-l, 6-m.)

Q. Install one of the 2.5" x 25 elbow onto theCAC discharge (passengers side outlet) andsecure using the provided #40 hose clamp.(See Fig. 6-m.)


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Template


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Fig. 6-m

Fig. 6-n

Fig. 6-o

TUBE D

2.5" x 25ELBOW

TUBE A

TUBE B

2.75"-3" REDUCER SLEEVE

TUBE E MAF ELECTRONICS

R. Install the straight section of discharge ductD up through the previously cut 3" hole.Attach the curved end to the previouslyinstalled elbow and secure using the provided#40 hose clamp. (See Fig. 6-m.)

S. Install one of the provided 3" x 2.75"reducer sleeve onto the open end of duct Dand secure using the provided #40 clamps.

T. Secure the remaining 3" x 2.75" reducersleeve to the throttle body using the supplied#40 hose clamp. (See Fig. 6-n.)

U. Secure the previously removed MAF electron-ics to Tube E using the supplied 8-32 x .50"hardware. (See Fig. 6-o.) Make sure theOEM O-ring is in place and is undamaged.

NOTE: Rotate the previously installed 25elbow to allow best tube engagementand core support clearance.


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Fig. 6-p


V. Connect the previously installed sleevesusing discharge duct E and two #44 hoseclamps. (See Fig. 6-p.)

W. Locate the factory MAF harness. Carefullysplit the plastic flex-loom exposing the wire tothe sensor connector. Separate enough

length to reach the new MAF sensor location,and re-wrap the flex-loom. Reconnect theharness plug to the MAF sensor.

TUBE E

3" x 2.75"REDUCER

3" x 2.75"REDUCER


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Fig. 7-c

A. Locate the 4LA112-010 Air Inlet Assembly.

B. Loosely install the supplied air filter onto thesupercharger inlet. Mark the two hole loca-tions to be drilled in the filter. One holeapproximately 5/16" in the center of the fil-ter.The other hole should be approximately

1/2" and offset to clear the ABS lines. (SeeFig. 7-a.)

7. AIR INLET INSTALLATION

Fig. 7-b

Fig. 7-a

SUPPLIED AIR FILTER

1/2" UNION

5/16" 90 ELBOW

LINE TO PRESSURE SOLENOID

LINE TO MOLDED FACTORY HOSE

PRESSURESOLENOID

LINE TO FILTER

MOLDED FACTORY HOSE

5/16" HOSEMENDER

5/16" HOSE TOPRESSURESOLENOID

RELOCATED

ABS MODULE

C. Install the two fittings into the end of the airfilter and re-install onto the supercharger inletand secure. (See Fig. 7-a.)

D. Locate the pressure solenoid removed fromthe plastic air filter enclosure in a previousstep.

E. Secure the solenoid to the top of the passen-gers side frame rail using the factory retaineras shown. (See Fig. 7-b.)

F. Using the supplied union and length of5/16" hose provided, connect the formedrubber hose (previously connected betweenthe filter enclosure and the solenoid) to thevacuum port as shown. (See Figs. 7-b, 7-c.)

G. Connect the remaining portion of the 5/16"hose between the 5/16" x 90 fitting previ-ously installed into the air filter and open vac-uum port on the pressure solenoid. (See

Figs. 7-a, 7-b.)

NOTE: Thoroughly clean the inside of the filterand inspect to make sure no material isleft from the drilling process.


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Fig. 7-g

7. AIR INLET INSTALLATION, contd

VALVE COVER BREATHER

1/2" UNION 1/2" HOSE 1/2" UNION

H. Using the supplied union and length of 1/2"hose provided, connect the valve coverbreather hose (previously connected to thefactory air box) to the union previouslyinstalled in the supplied air filter. (See Figs.7-a, 7-g.)

I. Attach the length of 5/32" vacuum hose tothe bypass valve and route to the vacuumport on the intake manifold. Remove the fac-tory vacuum cap from the manifold port andattach the previously routed vacuum line.


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8.1 FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003 Auto)

NOTE: This step applies to Model Year 2003 automatic vehicles only! For allothers, skip the following and proceed with Section 8.2.

A. Remove the six allen-head screws on top ofthe fuel management unit (FMU).

B. Remove the diaphragm and 8:1 disk and

ring from inside of the FMU.WARNING: Do not remove the four

screws holding the valvebody. Once taken apart,the valve would have tobe replaced.

C. Install the replacement 10:1 ring (withthe notched part facing FMU body)around the four screws inside the FMU.(The 10:1 components are larger indiameter than the 8:1).

D. Place the 10:1 disk inside the ring next to thepiston.

E. Install the new diaphragm and carefully lineup the holes to the body.

F. Place the spring retainer in the center of thediaphragm with the spring between it and thecover. (See Fig. 8.1-a.)

G. Reinstall the FMU cover with the six allen-head screws. Do not over-tighten the screws.The correct torque is 24 in/lb (2ft/lb).

8:1 RING SPACER

8:1 WASHER (2.270")

LARGE DIAPHRAM

SPRING RETAINER

SPRINGFCU COVER

Fig. 8.1-a


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Fig. 8-a

A. Locate the rubber section of the fuel supplyline on the drivers side frame rail as shown.(See Fig. 8-a.)

B. Cut the fuel line in approximately the middleof its length. (See Figs. 8-a, 8-b.)

C. Using the FMU and mounting bracket as atemplate, position the FMU as shown. (SeeFig. 8-c.) Mark the two hole locations. Drill1/8" pilot holes in the previously marked holelocations. Install the FMU using the provided

#12 sheet-metal screws as shown. (See Fig.8-c.) Cut the spring lock fittings off of the sup-plied FMU lines as close to the fitting as pos-sible and discard.

D. Position the supplied fuel pump as shown.(See Fig. 8-d.) Mark and drill the two pilotholes in the sub-frame support brace. Securethe fuel pump and fuel pump ground wire tothe sub-frame support brace using the sup-plied adel clamps and #12 sheet metal

screws. (See Fig. 8-d.)E. (See Figs. 8-e, 8-ffor reference.)

1. Attach the two supplied 5/16" hose barbTEEs to the open ends of the previouslycut factory fuel line.

2. Connect the hose from the FMU inlet porton the previously installed FMU to the

TEE connected to the line from the fueltank. Connect a length of supplied hosefrom the branch of the same TEE to thefuel pump inlet port.

3. Connect the length of hose from the out-let on the side of the FMU to the TEEattached to the line going to the fuel railon the manifold. Connect a length of sup-plied hose from the branch of the sameTEE to the fuel pump outlet.

NOTE; The following step should be completed in awell ventilated area free of any ignition source.

NOTE; Spring lock fittings are not used in thisapplication

NOTE; When installing the fuel lines in this step,install the supplied clamps simultaneous-ly. However, do not clamp until all con-nections have been made and verified.

NOTE; Using a pair of locking pliers to pinch thefuel line on the fuel tank side of your cutlocation to avoid draining the fuel tank.Use caution as there will be fuel drainagefrom the engine side of the cut.

Fig. 8-b

Fig. 8-c

Fig. 8-d

8.2 FUEL PUMP AND FMU INSTALLATION

TRANSMISSION

DRIVERS SIDEFRAME RAIL

STEERINGLINKAGE

FUEL LINE TO BE CUT

FMU

FMU MOUNTING BRACKET

SUPPLIED FUEL PUMP

1-11/16" ADEL CLAMPS

FUEL LINE FROM TANK

FLOW

GROUND WIRE


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4. Verify that all line connections have beenmade properly. Adjust all previouslyinstalled hoses and fittings so the linesroute smoothly and are kept away fromany sharp or moving parts. Tightensecurely, all previously installed clamps at

this time.5. Connect the supplied length of 5/32"

vacuum line to the pressure port on theFMU. Route the line up underneath theintake manifold to the vacuum port on theintake manifold. Using the supplied5/32" vacuum TEE, connect the line tothe previously installed line going to theby-pass valve. (See Fig. 8-g.)

Fig. 8-e

8.2 FUEL PUMP AND FMU INSTALLATION, contd

Fig. 8-f

Fig. 8-g

VACUUM LINETO BYPASS

VALVE

VACUUM PORT

5/32" HOSE (CONNECTEDTO MANIFOLD PRESSURE)

FACTORY FUEL LINETO INTAKE MANIFOLD

RED POWER WIRE(FROM FUEL PUMP RELAY)

MARK AND DRILL HOLESINSTALL THE SUPPLIED SHEET-METAL SCREWS TO

HOLD THE FUEL MANAGEMENT UNIT AND FUEL PUMP

SUPPLIED

FUEL PUMP

5/16" HOSEBARB TEES

INSTALL AND TIGHTEN CLAMPSUSING STEPLESSCLAMP PLIERS

INLET

OUTLET

(VERIFY THAT COPPER

WASHERS ARE INSTALLEDAND FITTINGS ARE TIGHT)

FACTORY SUPPLYLINE FROM FUEL

TANK


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F. Mount the supplied fuel pump relay as seenin Fig. 8-husing factory hardware. Using oneof the supplied ring-terminals, connect theprovided fuse holder to the (+) battery termi-nal. Connect terminals #85 and #30 to thefuse holder previously connected to the bat-

tery. Route the long black wire from terminal#87 to the postive (+) terminal on the previ-ously installed fuel pump. Terminal #86 will beconnected in a later step. (See Fig. 8-iRELAY WIRING SCHEMATIC for correctwiring.)

Fig. 8-h

Fig. 8-i

87a

87

8586

RELAY WIRING SCHEMATIC

CONTROLBOX

(+) BATTERYTERMINAL

(+) TERMINAL ONSUPPLIED FUEL PUMP

30

8.2 FUEL PUMP AND FMU INSTALLATION, contd


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A. Locate the power steering cooler relocationassembly (4LA110-010). (See Fig. 9-a.)

B. Attach the supplied 5/16" rubber hoses tothe power steering cooler and secure usingthe stepless clamps provided.

C. Secure the power steering cooler to the A/C

condenser using the supplied nylon mountingkit. (See Fig. 9-b.)

D. Route the hoses around the drivers side ofthe radiator and towards the factory P/Shoses.

E. Using the supplied 3/8" to 5/16" barbedreducers, two factory clamps and two step-less clamps provided, connect and secure therubber lines to the factory P/S hoses. (SeeFig. 9-c.)

F. Top off the power steering system reservoirusing the factory recommended power steer-

ing fluid.G. Using the factory hardware, reinstall the radi-

ator and fan assembly. Install the upper andmodified lower factory radiator hoses andsecure using the original clamps. Refill theengine coolant system using the coolantdrained in a previous step (provided it is ingood condition). Automatic transmission vehi-cles reconnect the factory transmissiion cool-er lines, you will need to wait until the install-tion is complete before checking fluid level.

9. POWER STEERING

Fig. 9-a

Fig. 9-b

Fig. 9-c


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A. Locate the factory ECU enclosure. Using a10mm socket, remove the three retainingscrews. Set the enclosure cover and hard-ware aside to be reinstalled later. (See Fig.10-a.)

B. Disconnect the ECU harness connectors

located next to the ECU. To make room forthe supplied ECU interface, you will need toremove the plastic connector cradle and dis-card. (See Fig. 10-b.) Reconnect the harnessconnectors. (See Fig. 10-c.)

C. Locate the supplied plug and play harnessconnection. (See Fig. 10-d.) Make the appli-icable ECU connections. Each connector plugis different from the others so there is onlyone possible location for each. (See Fig.10-e.)

10. ELECTRONIC CONTROL BOX INSTALLATION

Fig. 10-a

Fig. 10-b

Fig. 10-c

Fig. 10-d

ECU ENCLOSURE

10mm HEADEDRETAINING SCREWS

HARNESS CONNECTOR

PLASTIC CRADLE

PLUG & PLAY

HARNESS CONNECTION


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D. Once the connections have been made, gen-tly push the unit down into the factory ECUhousing next to the ECU. (See Fig.10-e.)

E. Locate the factory ECU cover previouslyremoved and cut a hole approximately 1/2"in the cover to allow the small 24-pin connec-

tor harness to pass through. Install the 24-pinconnector harness through the ECU cover.Reinstall the ECU cover using the factoryhardware. Using the supplied Velcro installa-tion strip, install the control module to theECU cover. (See Figs. 10-f, 10-g.)

F. Connect the 16-pin and 24-pin connectors tothe control module. Install the provided ringterminal onto the brown wires on the 16-pinharness. Route the brown wire to the locationshown (see Fig. 10-f) and ground to chassis.Route the red and white wire to the fuel pumprelay previously installed and connect to ter-

minal #86 as shown previously in the RELAYWIRING SCHEMATIC. (See Fig. 8-i. onpage 23)

10. ELECTRONIC CONTROL BOX INSTALLATIION. contd

Fig. 10-e

Fig. 10-f

Fig. 10-g

FACTORY ECU

SUPPLIED PLUG &PLAY HARNESS

CONTROLMODULE

16-PINCONNECTOR

24-PINCONNECTOR

BROWNGROUND WIRE

FUEL PUMPTRIGGER WIRE


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Fig. 11-a

A. Reconnect the battery.

B. If your vehicle has gone over 20,000 milessince its last spark plug change, you will needto change the spark plugs now beforetestdriving the vehicle.

C. Check all fittings, nuts, bolts and clamps for

tightness. Pay particular attention to oil andfuel lines around moving parts, sharp edgesand exhaust system parts. Make sure allwires and lines are properly secured withclamps or tie-wraps. (See Fig. 11-a.)

D. Check all fluid levels, making sure that yourtank(s) is/are filled with 91 octane or higherfuel before commencing test drive.

E. Start engine and allow to idle a few minutes,then shut off.

F. Recheck to be sure that no hoses, wires, etc.are near exhaust headers or moving partsand for signs of any fluid leakage.

G. PLEASE TAKE SPECIAL NOTE: Operatingthe vehicle without ALL the subassembliescompletely and properly installed may causeFAILURE OF MAJOR COMPONENTS.

H. Recheck all fluid levels following the factoryrecommended procedures at this time.

I. Test drive the vehicle by gradually working upto full throttle and paying close attention toany abnormal sounds or engine detonation. Ifdetonation is heard, discontinue heavy throt-tle usage until the necessary adjustment orrepairs are made.

J. Read the Street Supercharger SystemOwner's Manual and RETURN THEWARRANTY REGISTRATION FORM withinthirty (30) days of purchasing your super-charger system to qualify.

11. FINAL CHECK

WARNING: Due to variances in each vehicle,Vortech recommends that the vehicleget a custom tune from a local, rep-utable tuner.This kit is supplied with a universalfuel and ignition timing calibration. Thiscalibration is intended to allow the vehi-cle to start and operate at part throttle,and is not optimized for full throttleperformance. Do not operate the vehicleat heavy throttle or high RPM until acustom calibration tailored for yourspecific vehicle can be obtained from acompetent tuner. A wide-bandexhaust oxygen sensor must be used toconfirm proper air/fuel ratio. Vortechsuggests a proper WOT air/fuel ratiorange of 10.8-11.0:1 for 91 octane fuel.

WARNING:Never operate your engine at fullthrottle when the engine is cold.Always allow plenty of time for the oilto reach full operating temperaturebefore running above 2,500 RPM. Fullsupercharger operating temperature isgenerally achieved only after theengine water temperature has been atthe normal indicated operating rangefor two or three minutes.


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vortech super charger install 2001-2005 lexus is300 (4la020-010v1.1)

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