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

Lexus 3.
0L I S300 Supe Insta rcharge r ll
ation Syste m Instru 2001 ction -2005 Mode s l Yea r
*Legal in Cali fornia only fo r racin g vehic les wh ich ma y
never be use d upon
a high way.
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.
Take note of the following before proceeding:
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.
2007 VORTECH ENGINEERING, LLC

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, LLC.
P/N: 4LA020-010 2007 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 11JUL07 v1.1 Lexus(4LAv1.1)
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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 (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
2001-2005 3.0L Lexus IS300 IMPORTANT NOTE
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.
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2001-2005 3.0L Lexus IS300

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 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
LLC G, RIN EE GIN EN
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
2002-2005 3.0L Lexus

Part No. 4LA218-010SQ/018SQ
ENGINEERING, LLC IMPORTANT:

PART NO.
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
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2002-2005 3.0L Lexus, contd Part No. 4LA218-010SQ/018SQ
ENGINEERING, LLC IMPORTANT:

PART NO. 8F101-350 5W001-005 5W001-010 5W001-016 5W001-040 5W001-046 5W001-054 5W014-010 5W014-030 5W014-030 6Z170-040
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
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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
LEAVE CONNECTED TO HARD LINE
Fig. 1-c
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
TUBE PREVIOUSLY CONNECTED TO PRESSURE SOLENOID
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.
CUT LOOM HERE
Fig. 1-e
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.
REMOVE 10mm HEADED SCREW PREVIOUSLY SECURED LOOM BRACKET
L.
M.
Fig. 1-f
REMOVE
N.
BOLT SECURING LOOM BRACKET ALT. BOLT LOWER W/P BOLT
Fig. 1-g
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
Fig. 2-a (View From Below)

1/8"NPT x #4 FLARE
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.
1/8"NPT STRT TEE
Fig. 2-b
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.
INTERMEDIATE OIL PAN
LOWER OIL PAN
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.
INTERMEDIATE OIL PAN
OIL PAN
Fig. 3-b
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.
SPOT WELDS DRILLED THROUGH
NEW HOLE LOCATION
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
FRONT EDGE OF BRACKET FACTORY STUD
BOTTOM EDGE OF BRACKET
Fig. 4-b
LINES SLIGHTLY BENT
RELOCATED ABS MODULE
ABS HARNESS
Fig. 4-c
5.
A. B.
MOUNTING BRACKET AND SUPERCHARGER INSTALLATION

Locate the S/C mounting bracket assembly (4LA111-044.) Using the M8 x 40mm socket-headed screw, loosely attach the mounting bracket support block (4LA010-021) to the side of the water pump. (See Fig. 5-a.)
NOTE: For the following section, refer to Fig. 5-b for screw and spacer location. Do not tighten until all hardware is in place.
LOWER BRACKET SUPPORT (4LA010-021)
M8-1.25" x 40mm (7C080-040)
Fig. 5-a
3/8-16 x 1.75" SCREW, WASHER, & .895" SPACER (2A017-875-13)
M10-1.25 x 15mm
4LA010-010 UPPER SUPPORT BRACKET
3/8-16 x 1" SCREW, WASHER, NYLOC NUT
.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 1" SCREW & WASHER
3/8-16 x 2.75" SCREW, WASHER, DUST SHIELD, 3" SPOOTH IDLER, AND IDLER SPACER (4LA017-011)
NO SPACER/FACTORY ALT. BOLT (M10-1.25 x 50mm)
Fig. 5-b
5.
C.
MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, contd

Using Fig. 5-b as a guide and working from the bottom up, install all the applicable hardware and spacers into position as follows: 1. With the mounting bracket in position, place the M8-1.25 x 80mm screw and washer through the mounting bracket, 1.437" spacer and into the lower water pump mounting hole. 2. Then install the factory alternator bolt (M10-1.25 x 50mm) through the mounting bracket and into the alternator mount. 3. Next, install the M6-1.0 x 70mm screw and washer through the mounting bracket support spacer (4LA010-021) and into the water pump. 4. Install the 3/8-16 x 2.75" screw and washer through the dust shield, 3" smooth idler, 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 the support spacer (4LA010-021). 6. Install the M6-1.0 x 70mm screw and washer through the mounting bracket, 1.538" long spacer and into the upper water pump location. 7. Tighten the previously installed hardware. Make sure all mounting surfaces seat flat against one another and no lines or wire, etc. are being pinched. Loosely install the upper support bracket (4LA010-010) to the S/C bracket using the two 3/8-16 x 1.0" screws, washers and Nylock nuts. Install the M10-1.25 x 16mm screw through the support bracket and into the cylinder head. (See Fig. 5-c.) Evenly tighten the previously installed hardware. Ensure the bracket is supported, but not pulled or the location of the S/C bracket is not changed. Remove the blue plastic dust cap located on the 1/2" oil drain fitting at the bottom of the supercharger. Attach the supplied 1/2" fabric braided oil drain hose to the supercharger drain fitting. Secure with a #8 hose clamp. Secure the supercharger to the main bracket using the five 3/8-16 x 1.75" screws, washers, and .896" long spacers. (See Fig. 5-b, 5-c.) Reinstall the factory water pump pulley and secure using the factory hardware.
M10-1.25 x 15mm SCREW UPPER SUPPORT BRACKET .895" LONG SPACER
SEPARATE MAF HARNESS HERE
Fig. 5-c
D.
E.
F.
G.
H.
5.
I.
MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, contd

Install a 12mm-1.75 x 40mm screw through the dust shield, 3" smooth idler, idler spacer (.462" long piloted), and into the middle supercharger mounting boss. (See Fig. 5-d.) Remove the blue plastic dust cap located on the brass oil feed nozzle on the side of the supercharger. Thread the supplied 1/8"NPT x 90 fitting into the oil feed nozzle. Carefully tighten and clock the fitting as shown. (See Fig.5-e.) Use caution when tightening the oil feed fitting, as the nozzle may break if care is not exercised. Connect the previously installed oil feed line to the 90 fitting as shown. (See Fig. 5-e.)
NOTE: Use clean engine oil to lubricate fitting threads. Pipe tape, paste, or other types of sealant are not recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure.
J.
3" SMOOTH IDLER IN MIDDLE POSITION
Fig. 5-d
90 END OF SUPPLIED OIL LINE
K.
Install the supplied drive belt as shown. (See Fig. 5-f.)
1/8"NPT x 90
Fig. 5-e
SUPERCHARGER
IDLER
POWER STEERING WATER PUMP
IDLER
TENS.
A/C ALT. CRANK
Fig. 5-f
6.
A. B.
CHARGE COOLER INSTALLATION

Locate the discharge assembly 8N201-330. Use Fig. 6-a as reference. Remove the 10mm headed screws securing the plastic splash shield to the bottom of the car and set aside. Using a 2.5 x 25 sleeve and #40 clamps provided, secure Tube A onto the supercharger discharge. (See Figs. 6-a, 6-b.) Secure the supplied bypass valve to Tube A using the 1" x 90 elbow and two #16 hose clamps provided. Orient as seen in Fig. 6-b and install the supplied 1"ID filter. Attach a length of 5/32" vacuum hose to the bypass valve and route to the vacuum port on the intake manifold. Remove the factory vacuum cap from the manifold port and attach the previously routed vacuum line. (See Fig. 6-c.)
TUBE E TUBE B
TUBE C TUBE A CHARGE COOLER
C.
D.
TUBE D
Fig. 6-a
2.5" x 25 SLEEVE
BYPASS VALVE
TUBE A
Fig. 6-b
VACUUM LINE TO BYPASS VALVE
VACUUM PORT
Fig. 6-c
10
6.
E.
CHARGE COOLER INSTALLATION, contd

Attach Tube B using a 2.5" x 25 sleeve and #40 clamps provided to Tube A as shown. (See Fig. 6-d.) A 4.5" hole will need to be cut in the drivers side splash panel to provide a path for the CAC discharge tube. Using a 4.5" hole saw or tool of choice, mark and drill the hole location shown. (See Fig. 6-e.)
F.
2.5" x 25 SLEEVE
OIL PAN
TUBE B
Fig. 6-d
TUBE B CAC 2.5" x 25 SLEEVE
4.5" HOLE IN SPLASH PANEL
2.5" x 25 SLEEVE
TUBE C
Fig. 6-e
2.5 x 25 SLEEVE CAC TUBE C
Fig. 6-f
11
6.
G.

Remove the three retaining screws at the top of the grill. Unclip the bottom edge of the grill. Remove the grill and set aside. Locate and remove the two 10mm headed screws that secure the P/S cooler to the front core support. Disconnect the rubber P/S hoses from the steel P/S line assembly located near the P/S reservoir. Remove the power steering cooler and the steel P/S line assembly located on the drivers side of the radiator and discard. (See Fig. 6-g.) To gain access to the assembly on the drivers side, you will first need to temporarily remove the three 10mm headed retaining screws that secure the ECU enclosure and pull the enclosure upward to gain access to the 10mm headed screw that retains the line bracket to the top of the frame rail. Once you remove the line bracket, re-secure the ECU enclosure using the factory hardware. (See Fig. 6-h.)
NOTE: Leave the rubber lines connected to the power steering pump.
H.
POWER STEERING COOLER PREVIOUSLY ATTACHED TO CORE SUPPORT
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
12
6.
K.

Secure the CAC (Charge Air Cooler) bracket 8N010-210 to the passengers side frame rail using the factory hardware as shown. (See Fig. 6-j.) Loosely install the charge cooler into its location. (See Figs. 6-j,6-k.) Using the supplied 1/4-20 x .50 " hardware, loosely attach the CAC to the mounting bracket. Reinstall the A/C condenser, and secure using the factory hardware. Install one of the provided 2.5-25 sleeves onto the CAC inlet and secure using #40 hose clamps. (See Fig. 6-e.) Using a 2.5" x 25 sleeve and #40 clamps provided, secure Tube C to the open end of Tube B and the 25 sleeve previously installed onto the CAC. (See Figs. 6-e, 6-f.) To provide a path for the discharge ducting, you must cut a 3" hole through the inner fender behind the passengers side headlight. Using the provided template, mark and drill the location. Take care not to damage the headlight assembly or wiring harnesses in this area. (See Fig. 6-l, 6-m.) Install one of the 2.5" x 25 elbow onto the CAC discharge (passengers side outlet) and secure using the provided #40 hose clamp. (See Fig. 6-m.)
CAC MOUNTING BRACKET 8N010-210
L.
M. N.
FACTORY HARDWARE
O.
Fig. 6-j
P.
Q.
Fig. 6-k
Fig. 6-l
13
14
Template
15
16
6.
R.

Install the straight section of discharge duct D up through the previously cut 3" hole. Attach the curved end to the previously installed elbow and secure using the provided #40 hose clamp. (See Fig. 6-m.)
NOTE: Rotate the previously installed 25 elbow to allow best tube engagement and core support clearance.
TUBE B TUBE D 2.5" x 25 ELBOW
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
6.
V.

Connect the previously installed sleeves using discharge duct E and two #44 hose clamps. (See Fig. 6-p.) Locate the factory MAF harness. Carefully split the plastic flex-loom exposing the wire to the sensor connector. Separate enough length to reach the new MAF sensor location, and re-wrap the flex-loom. Reconnect the harness plug to the MAF sensor.
TUBE E
W.
3" x 2.75" REDUCER
3" x 2.75" REDUCER
Fig. 6-p
18
7.
A. B.
AIR INLET INSTALLATION

Locate the 4LA112-010 Air Inlet Assembly. Loosely install the supplied air filter onto the supercharger inlet. Mark the two hole locations to be drilled in the filter. One hole approximately 5/16" in the center of the filter. The other hole should be approximately 1/2" and offset to clear the ABS lines. (See Fig. 7-a.)
NOTE: Thoroughly clean the inside of the filter and inspect to make sure no material is left from the drilling process.
SUPPLIED AIR FILTER 1/2" UNION
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.)
LINE TO PRESSURE SOLENOID
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
RELOCATED ABS MODULE
Fig. 7-c
19
7.
H.
AIR INLET INSTALLATION, contd

Using the supplied union and length of 1/2" hose provided, connect the valve cover breather hose (previously connected to the factory air box) to the union previously installed in the supplied air filter. (See Figs. 7-a, 7-g.) Attach the length of 5/32" vacuum hose to the bypass valve and route to the vacuum port on the intake manifold. Remove the factory vacuum cap from the manifold port and attach the previously routed vacuum line.
VALVE COVER BREATHER
I.
1/2" UNION
1/2" HOSE
1/2" UNION
Fig. 7-g
20
8.1
FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003 Auto)

NOTE: This step applies to Model Year 2003 automatic vehicles only! For all others, skip the following and proceed with Section 8.2.
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
22
8.2
FUEL PUMP AND FMU INSTALLATION

NOTE; The following step should be completed in a well ventilated area free of any ignition source.
STEERING LINKAGE TRANSMISSION
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.
DRIVERS SIDE FRAME RAIL
FUEL LINE TO BE 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
FMU MOUNTING BRACKET
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
SUPPLIED FUEL PUMP
GROUND WIRE
Fig. 8-d
23
8.2
FUEL PUMP AND FMU INSTALLATION, contd

4. Verify that all line connections have been made properly. Adjust all previously installed hoses and fittings so the lines route smoothly and are kept away from any sharp or moving parts. Tighten securely, all previously installed clamps at this time. Connect the supplied length of 5/32" vacuum line to the pressure port on the FMU. Route the line up underneath the intake manifold to the vacuum port on the intake manifold. Using the supplied 5/32" vacuum TEE, connect the line to the previously installed line going to the by-pass valve. (See Fig. 8-g.)
FACTORY FUEL LINE TO INTAKE MANIFOLD
5.
Fig. 8-e
5/32" HOSE (CONNECTED TO MANIFOLD PRESSURE) INLET
FACTORY SUPPLY LINE FROM FUEL TANK
OUTLET
5/16" HOSE BARB TEES
RED POWER WIRE (FROM FUEL PUMP RELAY)
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 LINE TO BYPASS VALVE
VACUUM PORT
Fig. 8-g
24
8.2
F.
FUEL PUMP AND FMU INSTALLATION, contd

Mount the supplied fuel pump relay as seen in Fig. 8-h using factory hardware. Using one of the supplied ring-terminals, connect the provided fuse holder to the (+) battery terminal. Connect terminals #85 and #30 to the fuse holder previously connected to the battery. Route the long black wire from terminal #87 to the postive (+) terminal on the previously installed fuel pump. Terminal #86 will be connected in a later step. (See Fig. 8-i RELAY WIRING SCHEMATIC for correct wiring.)
Fig. 8-h (+) TERMINAL ON SUPPLIED FUEL PUMP
87 86 85
87a
CONTROL BOX
30
(+) BATTERY TERMINAL
RELAY WIRING SCHEMATIC

Fig. 8-i
25
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
26
10.
A.
ELECTRONIC CONTROL BOX INSTALLATION

Locate the factory ECU enclosure. Using a 10mm socket, remove the three retaining screws. Set the enclosure cover and hardware aside to be reinstalled later. (See Fig. 10-a.) Disconnect the ECU harness connectors located next to the ECU. To make room for the supplied ECU interface, you will need to remove the plastic connector cradle and discard. (See Fig. 10-b.) Reconnect the harness connectors. (See Fig. 10-c.) Locate the supplied plug and play harness connection. (See Fig. 10-d.) Make the appliicable ECU connections. Each connector plug is different from the others so there is only one possible location for each. (See Fig. 10-e.)
ECU ENCLOSURE
B.
C.
10mm HEADED RETAINING SCREWS
Fig. 10-a
HARNESS CONNECTOR PLASTIC CRADLE
Fig. 10-b
Fig. 10-c
PLUG & PLAY HARNESS CONNECTION
Fig. 10-d
27
10.
D.
ELECTRONIC CONTROL BOX INSTALLATIION. contd

Once the connections have been made, gently push the unit down into the factory ECU housing next to the ECU. (See Fig.10-e.) Locate the factory ECU cover previously removed and cut a hole approximately 1/2" in the cover to allow the small 24-pin connector harness to pass through. Install the 24-pin connector harness through the ECU cover. Reinstall the ECU cover using the factory hardware. Using the supplied Velcro installation strip, install the control module to the ECU cover. (See Figs. 10-f, 10-g.) Connect the 16-pin and 24-pin connectors to the control module. Install the provided ring terminal onto the brown wires on the 16-pin harness. Route the brown wire to the location shown (see Fig. 10-f) and ground to chassis. Route the red and white wire to the fuel pump relay previously installed and connect to terminal #86 as shown previously in the RELAY WIRING SCHEMATIC. (See Fig. 8-i. on page 23)
FACTORY ECU
E.
F.
SUPPLIED PLUG & PLAY HARNESS
Fig. 10-e
Fig. 10-f
CONTROL MODULE 16-PIN CONNECTOR
BROWN GROUND WIRE
24-PIN CONNECTOR
FUEL PUMP TRIGGER WIRE
Fig. 10-g
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
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

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

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

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Lexus 3.

0L I S300 Supe Insta rcharge r ll

ation Syste m Instru 2001 ction -2005 Mode s l Yea r

*Legal in Cali fornia only fo r racin g vehic les wh ich ma y

never be use d upon

Take note of the following before proceeding:

2007 VORTECH ENGINEERING, LLC

2001-2005 3.0L Lexus IS300 IMPORTANT NOTE

2001-2005 3.0L Lexus IS300

LLC G, RIN EE GIN EN

2002-2005 3.0L Lexus

ENGINEERING, LLC IMPORTANT:

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

ENGINEERING, LLC IMPORTANT:

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LEAVE CONNECTED TO HARD LINE

TUBE PREVIOUSLY CONNECTED TO PRESSURE SOLENOID

CUT LOOM HERE

REMOVE 10mm HEADED SCREW PREVIOUSLY SECURED LOOM BRACKET

BOLT SECURING LOOM BRACKET ALT. BOLT LOWER W/P BOLT

Fig. 2-a (View From Below)

1/8"NPT STRT TEE

INTERMEDIATE OIL PAN

LOWER OIL PAN

INTERMEDIATE OIL PAN

SPOT WELDS DRILLED THROUGH

NEW HOLE LOCATION

FRONT EDGE OF BRACKET FACTORY STUD

BOTTOM EDGE OF BRACKET

RELOCATED ABS MODULE

MOUNTING BRACKET AND SUPERCHARGER INSTALLATION

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

4LA010-010 UPPER SUPPORT BRACKET

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

3/8-16 x 1" SCREW & WASHER

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

MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, contd

SEPARATE MAF HARNESS HERE

MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, contd

3" SMOOTH IDLER IN MIDDLE POSITION

Install the supplied drive belt as shown. (See Fig. 5-f.)

POWER STEERING WATER PUMP

A/C ALT. CRANK

CHARGE COOLER INSTALLATION

TUBE C TUBE A CHARGE COOLER

VACUUM LINE TO BYPASS VALVE

CHARGE COOLER INSTALLATION, contd

4.5" HOLE IN SPLASH PANEL

CHARGE COOLER INSTALLATION, contd

POWER STEERING COOLER PREVIOUSLY ATTACHED TO CORE SUPPORT

CHARGE COOLER INSTALLATION, contd

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This Page Left Intentionally Blank

CHARGE COOLER INSTALLATION, contd

CHARGE COOLER INSTALLATION, contd

3" x 2.75" REDUCER

3" x 2.75" REDUCER

AIR INLET INSTALLATION

LINE TO PRESSURE SOLENOID

RELOCATED ABS MODULE

AIR INLET INSTALLATION, contd

FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003 Auto)

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