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ENGINEERING, LLC
1650 Pacific Avenue, Channel Islands CA 93033-9901 Phone: 805 247-0226 Fax: 805 247-0669 www.vortechsuperchargers.com M-F 8:00AM - 4:30PM (PST)
DP/N: 4LA020-010 - v1.1 07/10/07
FOREWORD
his manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for this vehicle. All information, illustrations 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 time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0228 8:00am-4:30pm PST.
STOP
2.
3. 4. 5.
1. Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installatlion 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. 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. Use only premium grade fuel with a minimum of 91 octane (R+M/2). Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost) until the problem is resolved. 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 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 limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.
NOTICE
Due to variances in each vehicle, Vortech recommends that the vehicle get a custom tune from a local, reputable tuner. This kit is supplied with a universal fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your specific vehicle can be obtained from a competent tuner. A wideband 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 91 octane fuel.
ii
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 (2003 Automatic 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
iii
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
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.
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
iv
Before beginning this installation, please read through this entire instruction booklet and the Street 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 in torque of 30-35% and horsepower between 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. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturers claims as potential 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 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 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
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
PARTS LIST
QTY 2 1 1 1 1 1 1 1 2 4 4' 1 1 1 1 5 1 2 2 1 1 1 1 2 1 5 1 1 1 2 1 1 3 2 2 1 12 1 0.75' 2 3 2.5' 4 1 1 1 1 1 1 1 5 1 1 1 10' 1 .5' 2 1 2 2 8 PART NO. 7U031-0018 7U100-044 7U100-055 8F001-068 4NZ130-036 7P375-017 7R001-008 7T560-001 7T560-002 7U030-036 7U100-066 4NZ238-088 6Z010-101 6Z010-111 6Z010-131 6Z020-130 6Z020-140 6Z030-150 6Z040-160 6Z050-191 6Z060-181 6Z070-030 6Z080-011 6Z090-010 7C010-050 7C010-075 7C024-025 7E010-075 7P125-025 7P125-031 7P125-032 7P156-082 7P312-005 7P312-007 7R004-001 7U030-046 7U031-018 7U031-018 7U100-030 7U100-096 5A003-130 8N201-330 4LA010-061 4LA012-010 4LA012-020 4LA012-040 4LA012-050 4NZ012-020 7A250-074 7A312-050 7C008-050 7E010-049 7F250-021 7J006-094 7P156-082 7R002-016 7R002-040 7R002-044 7S250-025 7U030-046 7U133-090 8D001-001 8H040-075 8N010-210 8N101-350 7S300-275 DESCRIPTION 5/16" EFI HOSE, HI-PSR TIE-WRAP, 4" NYLON TIE-WRAP, 7.5" NYLON WALBRO INLINE FUEL PUMP, 68 GP OIL DRAIN LINE ASY, 350Z 3/8"NPT x 1/2" BEADED HSE BARB #8 STNLS HOSE CLAMP CUTTER, 9/16" ROTABROACH ARBOR, ROTABROACH 1/2" OIL DRAIN HOSE TIE-WRAP, 11" NYLON FMU, 8:1 w/LINES, w/SPRING, 3 FMU HOUSING (BLUE ANODIZED) FMU VALVE BODY (BLUE ANODIZED) COVER, FMU - GM 4.3 SML DIAPHRAGM, FLUORO LRG DIAPHRAGM, FLOURO BRACKET, FMU PISTON, FMU FMU WASHER, 8:1 PLATED SHIM, FMU FMU 8:1 RING SPACER RETAINER, FMU SPRING GM 4.3 SPRING, FMU GM 4.3 10-24 x .50" SHCS GR8 PLT 10-24 x 3/4" SHCS GR5 ZINC 10-24 x 1/4" PHILL HD #12 x 3/4" SHT MTL SCRW, HEX 1/8"NPT x 5/32" HOSE, 90 1/8"NPT x 90 x 5/16" BARB 1/8"NPT-STR, 5/16" BARB 5/32" TEE 5/16" FEM FUEL CNCT, STEEL FUEL FTG, 5/16" GM x 5/16" HSE STEPLESS CLAMP, 15.7-70 5/32" VACUUM LINE 5/16" EFI FUEL HSE, HI-PSR 5/16" EFI FUEL HSE, HI-PSR O-RING, FMU ROLL PIN, 3/16" x 1/2" SS ECU, UNICHIP QT, '02-'05 IS300 SAFE TUNE CHARGE COOLR ASY, LEXUS IS300 BRKT, HOOD LATCH SPRT IS300 TUBE A S/C DISCHARGE IS300 TUBE B S/C DISCHARGE IS300 TUBE D S/C DISCHARGE IS300 TUBE E S/C DISCHARGE IS300 TUBE, COOLER INLET, 350Z 1/4-20 x .75" HHCS PLTD 1/4-20 x 1/2" HXHD GR5 ZINC #8-32 x 1/2" SHCS, ZINC #10 x 3/4" HXHD SLF DRL SHT MTL 1/4-20 NYLOCK NUT ZINC PLATED 6mm WASHER SS 5/32" TEE #16 SAE TYPE F SS HOSE CLAMP #40 SAE TYPE F SS HOSE CLAMP #44 SAE TYPE F SS HOSE CLAMP ELBOW, 2.5"ID x 25 BLUE 5/32" VACUUM LINE RUBBER ELBOW, 1.0" x 90 STD COMPRESS BYPASS VALVE 1" AIR FILTER BYPASS BRKT, CLR MNT, IS300 CHARGE AIR COOLER, 350Z REDUCER, 3.00" x 2.75" QTY. 5.5' 10 5 1 1 1 2 1 1 1.5' 5 1 1 1 1 1 1 1 1 1 1 1 1 1 6 4 3 2 1 1 1 1 1 1 4 7' 2.5' 1.25' 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 4 1 2 12 2 5 3' 1 1 1 1 1 2
Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.
DESCRIPTION
008110 SMALL SILVER DIE-CUT DECAL 008130 LICENSE PLATE FRAME, VORTECH 008444 S/C STRT INFO PKG ASY VORT 2E248-080 SUPERCHARGER V-5F SQ CW, LEXUS IS300 4LA020-010 INSTRUCTION MANUAL, IS300 4LA110-010 POWER STEERING COOLR ASY 8N006-025 COOLER, P/S 4-PASS PERMA/CL 8N100-001 NYLON MOUNTING KIT 7P375-312 3/8" BARB x 5/16" BARB REDUCER 7R004-003 STEPLESS CLAMP, 14.5-70 7U031-018 5/16" EFI FUEL HOSE HI-PSR 4LA111-044 S/C MOUNT BRKT ASY, LEXUS IS300 2A017-462 SPACER, IDLER SMOOTH 6-RIB 2A017-501-153 SPACER, .50"OD x 1.538"L ALUM 2A017-750-08 SPACER, .75"OD x .1.437"L 2A017-875-13 SPACER, .875"OD x .895"L 2A046-100 BELT, GATES K061010 4FA016-171 DUST COVER (IDLER PULLEY) 4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 4LA010-010 BRKT, SUPPORT IS300 4LA010-021 BRKT, LOWER SUPPORT IS300 4LA010-044 BRKT, 5/16" S/C MOUNT IS300 4LA017-011 SPACER, IDLER, 1.060"L IS300 7A375-100 3/8-16 x 1" G5 HHCS PLT 7A375-100 3/8-16 x 1" G5 HHCS PLT 7A375-178 3/8-16 x 1-3/4" HXHD G8 7A375-276 3/8-16 x 2-3/4" HXHD ZINC 7C010-016 M10-1.25 x 16mm, FLG HD, 10.9 7C012-040 M12-1.75 x 40mm HXHD BOLT, CL10.9 7C060-070 M6-1.00 x 70mm HXHD CL8.8 PLT 7C080-040 M8-1.25 x 40mm, SHCS, CL12.9 7C080-081 M8-1.25 x 80mm, HXHD, CL10.9 7E010-075 #12 x 3/4" SHT METAL SCRW, HEX 7F375-017 3/8-16 NYLOCK NUT 7J006-094 6mm WASHER SS 7K312-001 5/16"AN WASHER, PLATED 7K375-040 3/8"AN960 FLAT WASHER PLATED 4LA112-010 INLET ASY, LEXUS IS300 8H040-035 AIR FILTER, 3.5" FLANGE, G35 OFFSET 7U030-036 1/2" OIL DRAIN HOSE 7P500-001 1/2" HOSE UNION 7R001-006 #6 STNLS HOSE CLAMP, NARROW 7U031-016 5/16" PCV/VAC RUBBER HOSE 7R004-003 STEPLESS CLAMP, 14.5-70 7P312-050 5/16" HOSE MENDER 7P312-060 ELBOW, PLASTIC 5/16" x 90 UNION 4LA130-026 OIL FEED LINE ASY, IS300 7P125-004 1/8"NPT x 90 x -4 JIC FTG STL 7P125-005 1/8"NPT STR x -4 JIC FTG STL 7P125-034 1/8"NPT x 1/8"NPT STRT T 7P125-125 FTG, 1/8"NPT FEM x 1/8"BSPT MALE 7U100-055 TIE-WRAP, 7.5" NYLON 7U250-090-320 OIL FEED HOSE, 32" x -4 x 90 4NZ101-068 FUEL PUMP ASY, INLINE 350Z 5W001-045 16-14GA RING TERM., .17" HOLE 5W001-032 1/4" WIRE LOOM 5W001-011 16-14GA RING TERM. .26" HOLE 5W014-030 14GA STRD WIRE BLACK 7E010-075 #12 x 3/4" SHT METAL SCREW, HEX 7P312-017 5/16" HOSE BARB TO M10 x 1.0mm 7P312-082 5/16" TEE HOSE BARB 7R003-027 ADEL CLAMP, 1-11/16" 7R004-001 STEPLESS CLAMP, 15.7-70
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
vi
PARTS LIST
QTY 1 8' 2 1 2 2 1 7' 1' 7' 1 PART NO. DESCRIPTION QTY.
Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.
DESCRIPTION RELAY ASY, 350Z FUEL PUMP 3/8" PLASTIC WIRE LOOM 16-14GA FEMALE SLIDE INSULATED RELAY, BOSCH 12-10GA FEMALE SLIDE INSULATED 16-14GA RING TERM. .33" HOLE 16GA FUSE HOLDER WITH WIRE 14GA STRD WIRE, RED, UL1015 14GA STRD WIRE BLACK 14GA STRD WIRE BLACK 10:1 RING SPACER ASY
vii
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
viii
1.
A. B.
PREPARATION/REMOVAL
Disconnect the negative battery cable. Remove the four 10mm headed fasteners securing the plastic engine cover and set aside. Disconnect the valve cover vent hose from the air inlet assembly but leave it attached to the valve cover. Using a 10mm socket and ratchet, remove the factory air filter enclosure, air scoop, and ducting leading to the throttle-body and set aside. (See Fig. 1-a.) Remove the MAF electronics from the previously removed intake ducting and set aside to be reused in a later step. (See Fig. 1-b.) Detach the pressure solenoid from the plastic air filter enclosure (a single 10mm head screw). Set solenoid and screw aside to be reinstalled in a later section. (See Fig. 1-c.)
NOTE: It is a good idea to label the line connections to prevent confusion later.
C.
D.
E.
Fig. 1-a
F.
G.
Disconnect the ABS module harness plug from the module. Using a 10mm wrench, loosen the ABS module retaining nuts. Remove the module from its mounting bracket. Using a 12mm wrench, remove the hardware securing the ABS module bracket. Remove the module mounting bracket from the frame rail and set aside. Be careful not to lose the rubber stud mounts or the rubber bushing on the bottom of the module.
MAF ELECTRONICS
Fig. 1-b
Fig. 1-c
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
1.
H.
PREPARATION/REMOVAL, contd
Drain the engine coolant into a clean container and set aside. Remove the lower radiator hose located on the passengers side of the engine. Trim approximately 1" from the end of the hose that was attached to the radiator, and set aside. Remove the upper radiator hose and set aside to be reinstalled in a later step. Remove the thermostat housing. Rotate the thermostat housing 180 and reinstall. Disconnect the fans power connectors, radiator overflow bottle and remove the fan mounting hardware. Remove the engine fan assembly and set aside. Remove the upper radiator mounts/hardware and set aside. Remove the radiator and set aside. (See Fig. 1-d.)
NOTE: Automatic transmission vehicles will need to disconnect the cooler lines running to the radiator. Cover any open line connections to avoid possible fluid contamination.
THERMOSTAT HOUSING ROTATED 180
Fig. 1-d
I.
Remove the four 5mm socket-head screws retaining the cam sprocket cover and set the cover and hardware aside. Locate the plastic wire loom channel on the passengers side of the engine. Remove the wire loom from the channel. Remove the 5mm socket-head fastener securing the channel to the cylinder head. Cut the channel as shown. (See Fig. 1-e.) Install the supplied piece of flex loom onto the exposed section of wire and wrap with electrical tape. Reinstall the cam sprocket cover using the factory hardware.
Fig. 1-e
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
1.
J.
PREPARATION/REMOVAL, contd
Remove the wire loom bracket secured to the top of the water pump and discard. (See Fig. 1-f.) Remove the 10mm headed screw located just above and to the drivers side of the previously removed bracket as shown. (See Fig. 1-g.) Remove the 12mm headed bolt and wire harness on the side of the water pump and discard. (See Fig. 1-g.) Cut the small black cross-over tube located just above the water pump where indicated. (See Fig. 1-f.) Loosen the four water pump pulley retainers. Un-tension the accessory drive belt and remove. Remove the water pump pulley retainers and pulley, setting them aside to be reinstalled in later step. Remove the bolt securing the alternator to the water pump. Remove the 12mm headed bolt just to the right (drivers side) and down from the previously removed alternator bolt. Remove the 10mm headed bolt just above the alternator. (See Fig. 1-g.)
CUT TUBE HERE
K.
L.
M.
Fig. 1-f
REMOVE
N.
Fig. 1-g
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
2.
A.
OIL FEED
The supercharger uses engine oil for lubrication and must have an oil feed line connected to a filtered oil access on the engine. Locate the oil pressure sending unit on the drivers side of the engine, just in front of and above the engine mount. (See Fig. 2-a.) Disconnect and remove the pressure sender and set aside to be re-installed later. Locate the supplied oil feed assembly (4LA130-026). Install the supplied 1/8"BSP adapter into the hole previously occupied by the oil pressure sender. Install the supplied 1/8"NPT street TEE into the BSP adapter. Orient the branch of the TEE so that it faces up. Thread the factory sending unit into the TEE as shown. (See Fig. 2-b.)
NOTE: Pipe tape, paste or other sealant is not recommended as it may loosen and cause blockage of the oil feed orifice resulting in supercharger failure. Use engine oil on the threads.
BSP ADAPTER FACTORY OIL PRESSURE SENDER OIL PRESSURE SENDER
B.
C. D. E.
OIL PAN
F.
G.
H.
I.
Install the supplied 1/8"NPT x #4 flare fitting into the previously installed TEE. (See Fig. 2-b.) Attach the straight end of the supplied oil feed line to the #4 flare fitting previously installed and route up and over the engine valve cover. Temporarily cover the open oil feed line end to keep out debris until the connection is made to the supercharger in a later step. Reconnect the factory oil pressure sender wire.
NOTE: The factory wiring harness may need to be unclipped from the engine block to gain the necessary length to reach the repositioned sending unit.
Fig. 2-b
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
3.
A.
OIL DRAIN
To provide an oil drain for the supercharger, it is necessary to make a hole in the intermediate oil pan. Locate the factory oil drain boss on the passengers side of the engine as shown. (See Fig. 3-a.) Drill a 1/8" pilot hole into the center of the boss. Using the supplied 9/16" rota-broach cutter and arbor, carefully machine a throughhole into the intermediate pan.
NOTE: Automatic transmission vehicles only: It may be necessary to temporarily remove the transmission cooler lines (see Fig. 3-a) from their mounting bracket to provide a clear path for drilling. Pack the cutter with heavy grease and DO NOT stop the drill motor until the rota-broach has been extracted from the pan This will help retain the cut out piece in the cutting tool.
OIL DRAIN LOCATION
B.
C.
Fig. 3-a
ENGINE BLOCK 3/8"NPT x 1/2" BARB FITTING
NOTE:
D.
E.
F.
Tap the previously machined hole approximately 1/4" deep using a 3/8"NPT tap. Pack the flutes of the tap with heavy grease to hold the chips. Thoroughly clean the threads and hole with acetone or lacquer thinner. Using a small amount of silicone sealer, install the 3/8"NPT x 1/2" barb fitting into the previously tapped hole. Temporarily cap the fitting until the drain hose is connected in a later step. (See Fig. 3-b.) Drain the engine oil and change the oil filter.
OIL PAN
Fig. 3-b
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
4.
A.
ABS RELOCATION
Locate the ABS module bracket removed in Section 1. Remove the three spot welds that hold the side support to the main cradle. Separate the side support from the main cradle and discard. Drill the two lower spot weld locations to 3/16" and add an annitional 3/16" hole as shown. (See Fig. 4-a.)
NOTE: The preferred method of removing a spot weld is the use of a spot weld cutting tool. However in this application, the use of an approximate sized drill or a right-angle grinder is acceptable.
D.
Locate the ABS module harness. Carefully split the plastic flex-loom exposing the wires from the ABS connector to the main harness on the shock tower. Separate enough length to reach the relocated ABS module and re-wrap the flex-loom. Reconnect the harness plug to the ABS module. (See Fig. 4-c.)
SPOT WELD
B.
C.
(2001 Model Year Only, 2002 and Later Skip to B-2.) 1. Measure 2" back from the stud that previously secured the bottom of the ABS bracket and make a mark. At the previously marked location, measure down 15/8" from the top of a frame rail and make a second mark. Align the front and bottom edges of the bracket where the two marks intersect. Using the modified bracket as a template (see Fig 4-a) to mark the three hole locations on the frame rail. Drill the hole locations using a 1/8" drill bit. Secure the ABS bracket to the frame rail using the supplied selt-tapping hardware. Cut the factory stud that previously secured the ABS bracket flush wiith the frame. (See Fig. 4-b.) (2002-2005 Model Years Only), 2. Measure 3.5" back from the stud that previously secured the bottom of the ABS bracket and make a mark. At the previously marked location, measure down 2.4" from the top of the frame rail and make a second mark. Align the front and bottom edges of the bracket where the two marks intersect. Using the modified bracket as a template (see Fig. 4-a) to mark the three hole locations on the frame rail. Drill the hole locations using a 1/8" drill. Secure the ABS bracket to the frame rail using the supplied self-tapping hardware. Cut the factory stud that previoisly secured the ABS bracket flush with the frame. (See Fig. 4-b.) Remove the 10mm headed screw that secures the plastic brake line separator and discard. Remove the brake lines from their plastic separator located on the frame rail. Slightly bend the lines running to the ABS module so that it may be repositioned to its new location. Secure the module to the relocated bracket using the factory hardware.
NOTE: Use caution when bending these lines. Make bends as large as possible to avoid kinking.
Fig. 4-a
TOP OF FRAME RAIL 2" '01 MODEL YR 3.5" '02-'05 MODEL YRS 1-5/8" '01 MODEL YR 2.4" '02-'05 MODEL YRS
Fig. 4-b
LINES SLIGHTLY BENT
ABS HARNESS
Fig. 4-c
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
5.
A. B.
Fig. 5-a
3/8-16 x 1.75" SCREW, WASHER, & .895" SPACER (2A017-875-13)
M10-1.25 x 15mm
.50" x 1.538" SPACER (2A017-501-153) M6-1.0 x 70mm SCREW & WASHER M6-1.0 x 70mm SCREW & WASHER
SPACER, LOWER SUPPORT (4LA010-021) .875" x 1.437" SPACER M8-1.25 x 80mm SCREW & WASHER
3/8-16 x 2.75" SCREW, WASHER, DUST SHIELD, 3" SPOOTH IDLER, AND IDLER SPACER (4LA017-011)
Fig. 5-b
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
5.
C.
Fig. 5-c
D.
E.
F.
G.
H.
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
5.
I.
J.
Fig. 5-d
90 END OF SUPPLIED OIL LINE
K.
1/8"NPT x 90
Fig. 5-e
SUPERCHARGER
IDLER
IDLER
TENS.
Fig. 5-f
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
6.
A. B.
C.
D.
TUBE D
Fig. 6-a
2.5" x 25 SLEEVE
BYPASS VALVE
TUBE A
Fig. 6-b
VACUUM PORT
Fig. 6-c
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
10
6.
E.
F.
2.5" x 25 SLEEVE
OIL PAN
TUBE B
Fig. 6-d
TUBE B CAC 2.5" x 25 SLEEVE
2.5" x 25 SLEEVE
TUBE C
Fig. 6-e
2.5 x 25 SLEEVE CAC TUBE C
Fig. 6-f
11
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
6.
G.
H.
Fig. 6-g
10mm HEADED SCREW ECU ENCLOSURE
I.
J.
Remove the two retainers securing the top of the A/C condenser. Tilt the condenser back toward the engine (be careful not to damage the condenser). Remove the bolt securing the hood latch assembly to the core support. Cut approximately 9" from the bottom of this mount. (See Fig. 6-i.)
LINE BRACKET
Fig. 6-h
CUT HERE
Fig. 6-i
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
12
6.
K.
L.
M. N.
FACTORY HARDWARE
O.
Fig. 6-j
P.
Q.
Fig. 6-k
Fig. 6-l
13
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P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
14
Template
15
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
16
6.
R.
S.
T.
U.
Install one of the provided 3" x 2.75" reducer sleeve onto the open end of duct D and secure using the provided #40 clamps. Secure the remaining 3" x 2.75" reducer sleeve to the throttle body using the supplied #40 hose clamp. (See Fig. 6-n.) Secure the previously removed MAF electronics to Tube E using the supplied 8-32 x .50" hardware. (See Fig. 6-o.) Make sure the OEM O-ring is in place and is undamaged.
TUBE A
Fig. 6-m
2.75"-3" REDUCER SLEEVE
Fig. 6-n
TUBE E MAF ELECTRONICS
Fig. 6-o
17
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
6.
V.
W.
Fig. 6-p
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
18
7.
A. B.
5/16" 90 ELBOW
C.
D.
E.
F.
G.
Install the two fittings into the end of the air filter and re-install onto the supercharger inlet and secure. (See Fig. 7-a.) Locate the pressure solenoid removed from the plastic air filter enclosure in a previous step. Secure the solenoid to the top of the passengers side frame rail using the factory retainer as shown. (See Fig. 7-b.) Using the supplied union and length of 5/16" hose provided, connect the formed rubber hose (previously connected between the filter enclosure and the solenoid) to the vacuum port as shown. (See Figs. 7-b, 7-c.) Connect the remaining portion of the 5/16" hose between the 5/16" x 90 fitting previously installed into the air filter and open vacuum port on the pressure solenoid. (See Figs. 7-a, 7-b.)
Fig. 7-a
LINE TO MOLDED FACTORY HOSE
PRESSURE SOLENOID
LINE TO FILTER
Fig. 7-b
MOLDED FACTORY HOSE 5/16" HOSE MENDER 5/16" HOSE TO PRESSURE SOLENOID
Fig. 7-c
19
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
7.
H.
I.
1/2" UNION
1/2" HOSE
1/2" UNION
Fig. 7-g
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
20
8.1
A. B.
C.
D. E. F. G.
Remove the six allen-head screws on top of the fuel management unit (FMU). Remove the diaphragm and 8:1 disk and ring from inside of the FMU. WARNING: Do not remove the four screws holding the valve body. Once taken apart, the valve would have to be replaced. Install the replacement 10:1 ring (with the notched part facing FMU body) around the four screws inside the FMU. (The 10:1 components are larger in diameter than the 8:1). Place the 10:1 disk inside the ring next to the piston. Install the new diaphragm and carefully line up the holes to the body. Place the spring retainer in the center of the diaphragm with the spring between it and the cover. (See Fig. 8.1-a.) Reinstall the FMU cover with the six allenhead 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 SPRING FCU COVER
Fig. 8.1-a
21
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P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
22
8.2
A.
B.
Locate the rubber section of the fuel supply line on the drivers side frame rail as shown. (See Fig. 8-a.) Cut the fuel line in approximately the middle of its length. (See Figs. 8-a, 8-b.)
NOTE; Using a pair of locking pliers to pinch the fuel line on the fuel tank side of your cut location to avoid draining the fuel tank. Use caution as there will be fuel drainage from the engine side of the cut.
Fig. 8-a
C.
Using the FMU and mounting bracket as a template, position the FMU as shown. (See Fig. 8-c.) Mark the two hole locations. Drill 1/8" pilot holes in the previously marked hole locations. Install the FMU using the provided #12 sheet-metal screws as shown. (See Fig. 8-c.) Cut the spring lock fittings off of the supplied FMU lines as close to the fitting as possible and discard.
NOTE; Spring lock fittings are not used in this application Fig. 8-b
FUEL LINE FROM TANK
D.
E.
Position the supplied fuel pump as shown. (See Fig. 8-d.) Mark and drill the two pilot holes in the sub-frame support brace. Secure the fuel pump and fuel pump ground wire to the sub-frame support brace using the supplied adel clamps and #12 sheet metal screws. (See Fig. 8-d.) (See Figs. 8-e, 8-f for reference.)
NOTE; When installing the fuel lines in this step, install the supplied clamps simultaneously. However, do not clamp until all connections have been made and verified.
FMU
Attach the two supplied 5/16" hose barb TEEs to the open ends of the previously cut factory fuel line. 2. Connect the hose from the FMU inlet port on the previously installed FMU to the TEE connected to the line from the fuel tank. Connect a length of supplied hose from the branch of the same TEE to the fuel pump inlet port. 3. Connect the length of hose from the outlet on the side of the FMU to the TEE attached to the line going to the fuel rail on the manifold. Connect a length of supplied hose from the branch of the same TEE to the fuel pump outlet. 1.
Fig. 8-c
1-11/16" ADEL CLAMPS
FLOW
GROUND WIRE
Fig. 8-d
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
23
8.2
5.
Fig. 8-e
OUTLET
INSTALL AND TIGHTEN CLAMPS USING STEPLESS CLAMP PLIERS SUPPLIED FUEL PUMP MARK AND DRILL HOLES INSTALL THE SUPPLIED SHEET-METAL SCREWS TO HOLD THE FUEL MANAGEMENT UNIT AND FUEL PUMP (VERIFY THAT COPPER WASHERS ARE INSTALLED AND FITTINGS ARE TIGHT)
Fig. 8-f
VACUUM PORT
Fig. 8-g
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
24
8.2
F.
87 86 85
87a
CONTROL BOX
30
25
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
9.
A. B.
POWER STEERING
Locate the power steering cooler relocation assembly (4LA110-010). (See Fig. 9-a.) Attach the supplied 5/16" rubber hoses to the power steering cooler and secure using the stepless clamps provided. Secure the power steering cooler to the A/C condenser using the supplied nylon mounting kit. (See Fig. 9-b.) Route the hoses around the drivers side of the radiator and towards the factory P/S hoses. Using the supplied 3/8" to 5/16" barbed reducers, two factory clamps and two stepless clamps provided, connect and secure the rubber lines to the factory P/S hoses. (See Fig. 9-c.) Top off the power steering system reservoir using the factory recommended power steering fluid. Using the factory hardware, reinstall the radiator and fan assembly. Install the upper and modified lower factory radiator hoses and secure using the original clamps. Refill the engine coolant system using the coolant drained in a previous step (provided it is in good condition). Automatic transmission vehicles reconnect the factory transmissiion cooler lines, you will need to wait until the installtion is complete before checking fluid level.
C.
D.
E.
Fig. 9-a
F.
G.
Fig. 9-b
Fig. 9-c
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
26
10.
A.
B.
C.
Fig. 10-a
HARNESS CONNECTOR PLASTIC CRADLE
Fig. 10-b
Fig. 10-c
PLUG & PLAY HARNESS CONNECTION
Fig. 10-d
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
27
10.
D.
E.
F.
Fig. 10-e
Fig. 10-f
CONTROL MODULE 16-PIN CONNECTOR
24-PIN CONNECTOR
Fig. 10-g
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
28
11.
A. B.
FINAL CHECK
Reconnect the battery. If your vehicle has gone over 20,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle. Check all fittings, nuts, bolts and clamps for tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie-wraps. (See Fig. 11-a.) Check all fluid levels, making sure that your tank(s) is/are filled with 91 octane or higher fuel before commencing test drive. Start engine and allow to idle a few minutes, then shut off. Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts and for signs of any fluid leakage. PLEASE TAKE SPECIAL NOTE: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS. Recheck all fluid levels following the factory recommended procedures at this time. Test drive the vehicle by gradually working up to full throttle and paying close attention to any abnormal sounds or engine detonation. If detonation is heard, discontinue heavy throttle usage until the necessary adjustment or repairs are made.
WARNING: Due to variances in each vehicle, Vortech recommends that the vehicle get a custom tune from a local, reputable tuner. This kit is supplied with a universal fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your 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 91 octane fuel. WARNING: Never operate your engine at full throttle when the engine is cold. Always allow plenty of time for the oil to reach full operating temperature before running above 2,500 RPM. Full supercharger operating temperature is generally achieved only after the engine water temperature has been at the normal indicated operating range for two or three minutes.
C.
D. E. F. G.
H. I.
Fig. 11-a
J.
Read the Street Supercharger System Owner's Manual and RETURN THE WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify.
29
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
ENGINEERING, LLC
1650 Pacific Avenue, Channel Islands CA 93033-9901 Phone: 805 247-0226 Fax: 805 247-0669 www.vortechsuperchargers.com M-F 8:00AM - 4:30PM (PST)
DP/N: 4LA020-010 - v1.1 07/10/07