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HOLDEN COMMODORE VZ V6 ALLOYTEC 3.6L (2004-2007)
VORTECH ENGINE BELT DRIVE
SUPERCHARGER KIT INSTALLATION MANUAL
For any further technical information contact:
Centrifugal Air Pumps Australia Pty Ltd 20 Verrall Cres, Berri SA 5343, Australia
Email [email protected] Phone 08 8582 3499 (Intl. +61 8 8582 3499)
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INTRODUCTION
Congratulations on selecting the best performing and best backed automotive supercharger available today. Before beginning this installation please read this instruction booklet thoroughly. CAPA Supercharger Systems are a performance improving device. This product is intended for use on healthy and well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine and or the supercharger. CAPA IS NOT RESPONSIBLE FOR ANY DAMAGES RESULTING FROM THE USE OF THIS KIT. For best performance and durability please take note of the following key points: 1. Use minimum of 96-98 RON unleaded fuel 2. The engine must have stock compression ratio. 3. If the motor has been modified in any way, check with CAPA prior to installation. 4. Change your oil and oil filter. Refill with the best synthetic oil available. 5. Check that all components of the ignition system are in top condition. 6. Cold Starts - never race your engine when your engine is cold. Allow water temperature to
rise up to operating range before driving above 2500 r.p.m. Engine damage may result in high r.p.m. and boost conditions when cold.
7. Always listen for signs of deterioration (pinging) and discontinue hard use (no boost) until the problem is resolved.
8. Change oil and oil filter every 5,000km. OVER FILL OIL BY 0.5 LITRE WHEN KIT IS FITTED. 9. Always use an air-filter. 10. Never strike the supercharger pulley with a hammer or other tools. (Evidence of such force
will void warranty). 11. Retention belt after 500-600km, if not sooner, because the belt will stretch during initial
brake in period. Tighten belt only enough to stop slippage (the belt must still have some flex), over tension of the belt is the cause of input bearing failure
12. Never over-rev supercharger. Internal step up on a Vortech V-3 Supercharger is 1.0 to 3.60. Impeller speed must not exceed 50,000r.p.m (Sealed Vortech). Impeller speed calculated as below:
Vortech V-2 / V-3 Supercharger
Crank Pulley Diameter Supercharger Pulley Diameter
13. Never hold RPM on Rev Cut as this will cause damage to the Engine by detonation.
NOTE: The reason for grooved belts to move over one or more grooves or come off completely is always due to an alignment problem. Misalignment can also be caused by over-tightening of the belt - which may damage the drive system.
x 3.60 x Engine RPM = Impeller Speed
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GLOSSARY
COMPRESSOR HOUSING The housing, which makes up the enclosure portion of the compressor. Also referred to as the volute, scroll or snail. COMPRESSOR SURGE The phenomenon that occurs when the pressure ratio is too high for a given flow, or impeller speed. All centrifugal compressors can experience it. In automotive use it is most often found during decelerations when the engine speed is still high and the throttle is closed. DETONATION The uncontrolled rapid expansion or explosion of the air/fuel mixture in the combustion chamber. GAUGE PRESSURE The measure of pressure above atmospheric pressure. IMPELLER The bladed wheel inside the compressor housing that accelerates the air. INDUCER The air inlet portion of the compressor. NATURALLY ASPIRATED An engine without a supercharger. PRESSURE, BOOST The difference in pressure between barometric and intake manifold absolute pressure on a supercharged engine (read as gauge pressure). PRESSURE, ABSOLUTE The sum of gauge pressure and atmospheric pressure. One standard atmosphere = 29.92 in. of mercury (Hg) = 14.696 lbs./in.2 (psi) PRESSURE RATIO Manifold absolute pressure divided by standard barometric pressure. P.R. = gauge pressure + atmospheric pressure absolute pressure STOICHIOMETRIC The correct chemical mixture of air and fuel to yield complete combustion.
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KITS PARTS LIST Quantity Checked
SUPERCHARGER ASSEMBLY:
Vortech Sealed Supercharger, Filled w/180cc Special Oil 1 Oil Reservoir Bottle 1 250mm Length Oil Drain Hose 1 Clamps 2 3.8” Supercharger Pulley, 6 Rib 1
MOUNT / DRIVE SYSTEM:
6PK3032 Belt 1 Supercharger Bracket 1 1 ¼” x 3/8” Allen Head Bolts, Spring and Flat Washers 5 Supercharger Bracket to Engine Brace 1 10mm x 25mm Bolt, Spring and Flat Washer 1 Hexagonal Bracket Spacer, 108mm Long 1 49mm Idler and Sleeve Assy 1
69.5mm Steel Idler and Sleeve Assy 1 10mm x 30mm Bolt & Flat Washer 1 8mm x 140mm Bolt & Flat Washer 2 8mm x 110mm Bolt, Flat and Spring Washer 1 8mm x 50mm Bolt & Flat Washer 1 Spacer 80mm Long with 8mm Hole 1 Supercharger Brace Bracket 1 10mm x 30mm Bolt, Flat and Spring Washer 1 12mm x 30mm Bolt, Flat and Spring Washer 1
AIR INLET & DISCHARGE
2.75” - 3” 90° Silicon Bend, Cut to Suit 1 3 – 3.5” Silicon Joiner (Airflow Meter) 1
2-Bolt MAF Flange / Bolts & Nuts 1 Plastic Blowoff Valve 1 1000mm Vacline & T-Piece 1 1200mm 1” BOV Hose 1 BOV Sock & Cable Tie 1 HS 12 Clamps 1 HS 48 Clamps 4 HS 60 Clamps 4 Supercharger Discharge Steel Tube w / BOV Grommet 1 CAPA Air Filter, Tapered Large with PCV Fitting 1 One Way Valve, Red 1 1000mm x 10mm PCV Breather Hose 1
Parts List Continued on Next Page…
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KITS PARTS LIST, CONTINUED Quantity Checked
POWER STEERING RELOCATION
Aluminium power steering reservoir shield 1 Modified Power Steering Reservoir Bracket 1 6mm x 25mm Bolt 1 14mm Spacer 1 22mm Saddle Clamp 1
M6 Bolts, Nuts & Flat Washers 2 380mm 5/8 High Pressure Fuel Hose and Conduit 1 500mm 3/8 Fuel Hose and Conduit 1 HS 12 Clamps 2 MH 16 Clamps 2
FUEL MANAGEMENT
525cc ¾ Length Injectors 6 255lph Fuel Pump Module Optional
Important before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.
PREPARATION & PART REMOVAL
1. Remove Left and Right Hand Engine Covers 2. Remove Air Box, Ducting and Airflow Meter 3. Remove Front Bumper Bar 4. Remove Left Hand Headlight 5. Remove Front Radiator Grille 6. Remove Engine Accessory Drive Belt 7. Disconnect Battery
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INSTALLATION 1. Relocating Power Steering Reservoir
Remove power steering reservoir (place catch tray under vehicle to collect fluid from reservoir). Remove existing hoses from reservoir and discard. Remove reservoir mounting bracket and discard. Relocate power steering reservoir to left hand inner wheel arch using two existing studs on side of shocker tower. Mount modified original bracket, L shaped mounting bracket and drip tray (supplied in kit fully assembled) to both studs using two 8mm nuts and spring washers. Plumb Reservoir to pump using Blue 5/8” hose and 10mm hose supplied in kit. Secure both new hoses with hose clamps. NOTE: Air Conditioner Canister will need to be bent to allow routing of hoses.
Photos 1a & 1b: Power Steering Reservoir Relocation
2. Power Steering Pressure Hose Modification High pressure hose will need to be modified to fit. Remove power steering pipe from power steering pump. Ensure drip tray under vehicle collects any spillage. Top steel section of hose has to be modified by bending it 60° using tube bender as per photo. Resecure Pipe to Power Steering Pump.
Photo 2: Power Steering Pipe Modification
Drip Tray Mounting Studs
60° Bend
StandardModified
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3. Remove air conditioner compressor top mounting bolt and discard. Fit hexagon supercharger bracket spacer to this hole using new 140mm x 8mm bolt, flat and spring washer.
Photo 3: Supercharger Bracket Spacer Fitment 4. Remove timing cover bolt located between power steering pulley and automatic tensioner
pulley, discard bolt.
Photos 4a and 4b: Timing Cover Bolt Location 5. To mount supercharger bracket, start by mounting bracket to hexagonal spacer using 35 x
8mm bolt, flat and spring washer. To previously discarded timing cover bolt hole fit 19mm thick x 80mm long spacer securing with 110 x 8mm bolt, flat and spring washer as per photos 4a and 4b.
140mm
110mm 140mm
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6. Mount 49mm idler pulley and support bracket to top hole of supercharger bracket. Fit support bracket and idler to spacer bolt supplied then fit spacer to bolt and mount to bracket with 30 x 10mm Bolt, flat and spring washer.
Photos 5a and 5b: Idler Location and Exploded View 7. Fit top bracket mount bolt. Fit an 80mm idler pulley to machined spacer then fit sleeve
outer spacer. Fit assembly to vehicle with sleeve side towards bracket and secure to existing bolt hole in front lower corner of LH side tappet cover using a 140 x 8mm bolt, flat and spring washer.
Photo 6a & 6b: Idler Pulley mounted to Tappet Cover and Exploded View
Bracket
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8. Secure power steering hose to supercharger bracket using 22mm D Saddle Clamp, 14mm thick spacer and 25 x 6mm bolt, flat and spring washer.
Photo 7: Power Steering Hose secured to bracket. 9. Fit supercharger to bracket - Secure using five 1¼ x 3/8 UNC Allen head bolts and flat
washers. Fit all bolts loosely first, care should be taken not to cross thread any bolts. Once all bolts are started they can be tightened.
10. Fitment of supercharger brace bracket – Brace bolts to existing spare hole in side of LH
cylinder head, just forward of oil filter housing using 30 x 10mm bolt, flat and spring washer. Secure to bottom supercharger bolt hole using 30 x 12mm bolt, flat and spring washer. Please Note: Some Models May Not Have This Hole You Will Have To Drill And Tap To Fit.
Photo 8: Supercharger Brace Bracket 11. Mount supercharger oil bottle to bracket to guard bolt using M-6 Nut supplied.
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12. Route belt as per layout diagram below.
NOTE: When fitting, top idler will need to be loose to allow fitment of belt over supercharger pulley as belt is tight. Once fitted in place tighten top idler securing bolt. Ensure all pulleys and idlers are tracking and aligned correctly.
Diagram 1: Belt Layout
13. To fit convoluted intake hose to supercharger a U shaped section of the lower LH headlight support panel will need to be cut out. This is to allow room for the convoluted tube to pass under headlight. See Photo 10a and 10b.
14. After section has been removed, fit pinch weld protector strip to U section to prevent hose
from being damaged.
Photos 10a and 10b: Section to be removed for Intake
PRECAUTION: The filter is mounted in this position to ensure it collects cold air without being affected from engine bay temperature. You will notice that it is lower on the car than the original mounting position. Take this into consideration when attempting water crossings as in extreme conditions the possibility exists of water entering the intake. Ensure all drivers are aware of this and take necessary precautions.
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15. Attach air filter to 500mm long convoluted tube using 45mm long steel sleeve as a joiner, clamp together with 2 clamps. To other end of tube, attach 70mm long steel sleeve with PCV fitting. Fit 250mm long convoluted hose to other end of this steel sleeve and clamp. Route hose assembly up under headlight and connect to back of supercharger with clamp. Convoluted hose will have to be squashed under headlight area to allow headlight re-fitment.
Photos 11a and 11b: Convoluted Tube and Air Filter Location 16. Using 10mm heater hose supplied in kit, join existing PCV plastic hose near throttle body to
plastic fitting on steel sleeve in air intake / Back of tapered Air Filter.
Intake PCV hose extension (Later kits utilise Tapered filter direct to S/C Intake)
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17. Fit one way valve to rear of right hand tappet cover, ensure the valve is fitted correctly, flowing from the tappet cover to the intake.
Photos 13a and 13b: PCV One Way Valve Fitment 18. Fit airflow meter to rubber 90° throttle body bend (ensure arrow of flow on airflow meter
faces throttle body). To supercharger side of airflow meter will need to be cut back flat, so it gets a flat face to seal against MAF adaptor flange provided. Fit this to the 3.5-3” Silicon Reducer Onto this hose fit black steel tube with 90° bend facing towards supercharger scroll outlet. Fit 55mm rubber joiner sleeve to supercharger end of tube. Align all joins to fit as per photo and secure all joints with clamps and tighten. Fit tube assembly to supercharger outlet and secure with clamp, then fit to throttle body and secure with clamp.
Photos 15a and 15b: Discharge Pipe Assembly 19. Install blow off valve to discharger pipe. Fit 1” BOV hose to blow off valve and route down
between sway bar and chassis square cross bar, cut to length. To end of hose secure sponge sock using cable tie.
20. Ensure all nuts, bolts and clamps are secure.
Airflow Meter Bypass Valve
Super Glue Joint
Flow
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21. To existing engine vacuum supply hose at the driver side rear of plenum chamber, fit a brass T piece 70mm from the chamber by cutting hose in half and fitting T piece. To spare port of T piece add 100mm of 4mm rubber hose supplied in kit. To end of hose fit another brass t piece. This leaves two spare ports on T piece. One side needs rubber hose routed along RH tappet cover under throttle body and up to BOV, attach to vacuum port on BOV. Cover vacuum hose with conduit supplied in kit and then secure in place with cable ties to prevent any damage to hose.
Photo 18: T Piece Fitment 22. Installation is now complete. Before starting your vehicle ensure all bolts, nuts and clamps
are tight and that no electrical cables, vacuum or fuel line will foul with drive belt or exhaust and cause damage. Power steering reservoir needs to be refilled with Dexron III Trans fluid, bleed system by turning wheels from lock to lock several times. This procedure needs to be repeated when engine is started. Top reservoir up to required level.
23. All parts removed prior to fitment can now be refitted.
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WARNING
1. DO NOT ATTEMPT TO OPERATE VEHICLE UNTIL ALL COMPONENTS ARE INSTALLED AND COMPLETE. SUPERCHARGER KITS EXTRUDE A HUGE AMOUNT OF HORSEPOWER FROM A STOCK ENGINE THEY ARE NOT INTENDED FOR CONTINUOUS OR EXTREME PERIODS OF MAXIMUM POWER OUTPUT. IT IS NOT OUR INTENTION TO CREATE RACE PROVEN HORSEPOWER BUT LEISURE ENDURING SYSTEMS.
2. WARRANTY POLICY FOR 12 MONTHS, UNLIMITED KILOMETRES COVERS FAULTY
COMPONENTS PROVIDED IN SUPERCHARGER KIT. POLICY DOES NOT INCLUDE LABOUR TO REPLACE FAULTY PARTS.
3. THE RESPONSIBILITY OF ADR COMPLIANCE AND INSURANCE FOR THIS KIT
FITTED TO A VEHICLE THAT IS ROAD REGISTERED AND DRIVEN IS THE RESPONSIBILITY OF THE VEHICLE OWNER.
4. RESPONSIBILITY FOR CORRECT FITMENT OF THE KIT IS THE REPONSABILITY OF
THE FITTER. 5. DAMAGES TO VEHICLE OR SURROUNDS IS THE RESPONSIBILITY OF THE VEHICLE
OWNER. PROVIDED THE KIT FITMENT IS CORRECT, ACCORDING TO THIS MANUAL.
GET OUT THERE & ENJOY...
