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Vortech HP500 EFI Installation Instructions Manual

Mercruiser supercharger system
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MERCRUISER
MARINEHP500EFI
Supercharger System

Installation Instructions

1998 - 2002
P/N: 4MB020-010
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0)

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Summary of Contents for Vortech HP500 EFI

  • Page 1: Installation Instructions

    MERCRUISER MARINEHP500EFI Supercharger System Installation Instructions 1998 - 2002 P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 2: Foreword

    Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area. © 2003 VORTECH ENGINEERING, LLC All rights reserved.

  • Page 3: Table Of Contents

    FUEL/WATER SEPARATOR INSTALLATION ..............14 FUEL COOLER INSTALLATION ..................15 CRANK PULLEY INSTALLATION ..................16 SUPERCHARGER MOUNTING ..................17 CHARGE COOLER/DISCHARGE DUCTING ..............22 FINAL CHECK ........................24 P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 4: Tool And Supply Requirements

    1. Use only premium grade fuel 91 octane or higher (R+M/2). 2. The engine must have stock or lower than stock compression ratio. 3. If the engine has been modified in any way, check with Vortech prior to using this product.

  • Page 5: Notice

    ECM. An ECM core charge has been included into the purchase price of this supercharger kit and will be refunded upon the return of the stock ECM to Vortech. Fill out the supplied "ECM Credit Tag" and contact Vortech.

  • Page 6: Parts List - Hp500

    Mercruiser Marine HP500 EFI Part No. 4MB218-010/018 PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 8N201-100/108 PWR COOLER ASSY. MARINE EFI...
  • Page 7 Mercruiser Marine HP500 EFI Part No. 4MB218-010/018 PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 4MB010-001 Plt. Fuel/H...
  • Page 8 P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured viii 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 9: Preparation/Removal

    M. Remove the 7/16" stud in the port side head using the two provided 7/16-20 nuts locked against each other. (See Fig. 1-c.) Fig. 1-c P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 10: Supercharger Oil Drain

    Use silicone sealer under each screw head and washer. E. Reinstall the valve cover. NOTE: The drain hose must be routed downhill without any dips or kinks. P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 11: Supercharger Oil Feed

    E. Temporarily plug the open end of the oil feed line to keep debris out. STOCK OIL PRESSURE TRANSDUCER Fig. 3-a / Supercharger Oil Feed P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 12: Mounting Brackets

    C. Following the diagram (see Fig. 4-b), install two 3/8-16 x 4-1/4" HHCS with washers into the backside of the cast bracket. Attach the Vortech cast bracket to the upper holes located on the cylinder head using two 7/16-14 x 2" and one 7/16-14 x 4-1/2"...
  • Page 13 (Ø7/8" O.D. x 13/32" I.D. x 39/64" length) behind it. Use the stock 5/16-18 screw. (See Fig. 4-d.) Fig. 4-d P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 14 4. MOUNTING BRACKETS, Cont'd. CUT HERE DRILL HOLE OUT Ø13/32" SCALE - 1:1 P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 15 H. Remove the engine's stock water pump pulley (located above the crank pulley) and replace with the one provided. (See Fig. 4-e.) POWER STEERING PUMP SPACER PLATE Fig. 4-d Fig. 4-e P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 16: Fuel Injector Replacement

    Orient the fitting so that when the fuel rail is installed the fitting will be pointing toward the starboard side. Fig. 5-b Fig. 5-c P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 17 If the regulator on your engine is the .090" unit, it must be replaced with a .120" unit for proper fuel bypass. FACTORY REGULATOR Fig. 5-d P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 18: Fuel System Upgrade

    Keep lines away from any moving parts or hot surfaces. Use a small amount of clean engine oil to lubricate all of the O-rings in the fuel system prior to installation. P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 19 6. FUEL SYSTEM UPGRADE, cont'd. P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 20: Computer And Map Sensor Sensor

    G. Reconnect the new plug to the MAP sensor. Fig. 7-b P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 21: Thermostat Replacement/Exhaust Manifold Modifications

    If the water tube makes contact with the cast bracket it will have to be shortened. (See Fig. 8-c.) Fig. 8-b Fig. 8-c P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 22: Fuel/Water Separator Installation

    ENGINE’S HEAD STARBOARD SIDE SUPPLIED FUEL/WATER SEPARATOR HOUSING .236" SPACERS FRONT OF ENGINE .423" SPACERS MODIFIED COOL FUEL BRACKET FRONT VIEW SIDE VIEW Fig. 9-a P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 23: Fuel Cooler Installation

    7U133-125 HOSE Ø1.25" x 90° LONG LEG REUSE STOCK 7P375-002 HOSE CLAMP 3/8 PIPE PLUG 7R002-024 #24 HOSE CLAMP Fig. 10-a / Fuel Cooler P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 24: Crank Pulley Installation

    STOCK HARMINIC SUPPLIED 10-RIB PULLEY DAMPER (BALANCER) SUPPLIED CRANK PULLEY 3/8-16 x 4-3/4” HHCS 3/8 LOCK WASHER 3/8 SAE WASHER Fig. 11-a P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 25: Supercharger Mounting

    Oil drain hose must always maintain a “downhill” slope. Tight bends or drain flow restrictions may cause su- percharger failure. Fig. 12-c P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 26 12mm washers must be placed 7K375-030 3/8" Washers in between the support plate and the super- charger cover as spacers. Install the remain- Fig. 12-d P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 27 Spacer, Pilot 7A375-277 3/8-16 x 2.75 SHCS 7J012-092 M12 Washer 7C012-020 M12 x 20 Bolt 7B375-250 3/8-24 x 2.50 SHCS 7a 7b Fig. 12-e P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 28 Spacer Ø1.00 x 1.536 SUPERCHARGER MOUNTING SUPPORT PLATE PLATE FACTORY IDLER IDLER SPACER #1 IDLER SPACER #2 Fig. 12-h Fig. 12-f P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 29 3/8-24 x 2-3/4" HHCS and M12 x 25mm HHCS. (See Fig. 12-j.) The stock steering bracket will have to be cut and welded to the oil filter bracket. (See Fig. 12-k.) Fig. 12-j Fig. 12-k P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 30: Chargecooler/Discharge Ducting

    Make sure that the O-ring is properly seated into the O- Fig. 13-b ring groove. Fig. 13-c P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)
  • Page 31 MOUNTED WATER OPTION #2: VORTECH PICKUP (NOT SUPPLIED TEE SUPPLIED) (CUT AND SPLICE INTO PUMP DISCHARGE LINE) RAW WATER PUMP DISCHARGE LINE Fig. 13-f P/N: 4MB020-010 ©2003 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 06DEC02 V1.0(4MB HP500 v1.0)

  • Page 32: Final Check

    Mercruiser fuel pump may need re- placement. Contact Vortech for further assis- tance if required. E. Read the Vortech Supercharger Limited War- ranty and Owner's Manual. 1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226 FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST P/N: 4MB020-010 ©2003 Vortech Engineering, LLC...

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