Vortech Hp500 efi User manual

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

MERCRUISER

MARINEHP500EFI

Supercharger System

Installation Instructions

1998 - 2002

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

Properinstallationofthissystemrequiresgeneralautomotivemechanicknowledgeand

experience. 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.

FOREWORD

or translated into another language in any form, by any means without written permission

of Vortech Engineering, LLC.

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

iii

TABLE OF CONTENTS

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

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

TOOL AND SUPPLY REQUIREMENTS ...........................................................................................iv

NOTICE.............................................................................................................................................v

PARTS LIST - HP500........................................................................................................................vi

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

2. SUPERCHARGER OIL DRAIN ............................................................................................2

3. SUPERCHARGER OIL FEED..............................................................................................3

4. MOUNTING BRACKETS .....................................................................................................4

5. FUEL INJECTOR REPLACEMENT .....................................................................................8

6. FUEL SYSTEM UPGRADE..................................................................................................10

7. COMPUTER AND MAP SENSOR SENSOR .......................................................................12

8. THERMOSTAT REPLACEMENT/EXHAUST MANIFOLD MODIFICATIONS ......................13

9. FUEL/WATER SEPARATOR INSTALLATION......................................................................14

10. FUEL COOLER INSTALLATION..........................................................................................15

11. CRANK PULLEY INSTALLATION........................................................................................16

12. SUPERCHARGER MOUNTING ..........................................................................................17

13. CHARGE COOLER/DISCHARGE DUCTING......................................................................22

14. FINAL CHECK......................................................................................................................24

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

TOOL AND SUPPLY REQUIREMENTS:

•Factory Repair Manual

•Masking Tape

•Marking Pen

•GM Pin Tool P/N:12014012-1

•3/8" Drive and Socket Set: SAE and Metric

•1/2" Drive and Socket Set: SAE and Metric

•Adjustable wrenches

•Open End Wrenches: SAE and Metric

•8 Quarts SF Rated Quality Engine Oil

•Loctite Sealer #RC-609

•Oil Filter and Wrench

• Screwdrivers: Flat and Phillips

•Heavy Grease

• Silicone Sealer

• Drill Motor and Drill Bit Set

• Teflon Paste Sealant

• Zinc Chromate Spray

• Anti-seize

Thiskitshouldonlybeinstalledbyqualifiedmarinemechanics.Itisimperativethatthe

correct air/fuel mixture be maintained at all times. Before beginning this installa-

tion, please read through this entire instruction manual and the Owner's Manual

which includes the Vortech Supercharger Limited Warranty.

Thiskitshouldonlybeinstalledbyqualifiedmarineengineanddrivemechanicsthatcan

properly set correct air-to-fuel ratios, proper drive specifications and fuel systems.

This product is intended for use on healthy, well maintained engines. Installation on a

worn-outordamagedengineisnotrecommendedandmayresultinfailureoftheengine.

Vortech Engineering is not responsible for engine damage. Installation on new

engines will not harm or adversely affect the break-in period so long as factory break-

in procedures are followed.

Mercruiser Marine HP500 EFI

Installation Instructions

PLEASE READ CAREFULLY

Forbestperformanceandcontinueddurability,pleasetakenoteofthefollowingkey

points:

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.

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

operatingthevessel.Thereafter,alwaysuseahighgradeSFratedengineoilorahigh

quality synthetic, and change the oil and filter every 25 hours.

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

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, Inc. This product may not be copied or duplicated in

wholeorpart,abstractlyorfundamentally,intentionallyorfortuitously,norshall

any design, dimension, or other information be incorporated into any product

or apparatus without prior written consent of Vortech Engineering, LLC.

NOTICE

WARNING: DuetotheincreasedhorsepoweroutputoftheVortechsuperchargerkit,

itisimperativethat the fuel lines and tankswitchvalveallow adequate

flow to support the engine fuel requirements. Vortech recommends

the installation of larger fuel lines and an Imco type tank switch valve

if required.

After the boat is supercharged, use caution when making propeller

selection. Selecting a propeller which will allow the engine to con-

stantly "bump" against the engine speed limiter (the Vortech supplied

ECM is programmed for 5400 RPM rev-limit) will cause engine dam-

age. Vortech recommends the installation of an MSD-6M with rev-

limiter capacity if the engine speed will reach 5200+ RPM at maxi-

mum sustained vessel speed. The MSD unit limits engine speed by

cylindersparkeliminationratherthanfueleliminationastheECMdoes.

This is the safest way of limiting engine speed in supercharged appli-

cations that approach maximum engine speed on a consistent basis.

Proper operation of this supercharger kit requires the installation of a

reprogrammed 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.

NOTE: Additional fuel system components are required to complete the installation of this system.

•8F060-050 50 lb/hr fuel injectors (8 ea.)

•8F0130-040 Fuel Pressure Optimizer

•8F030-040 -6 Fuel Adapter Fitting

•8F001-300 Fuel Pump

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

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

parts immediately.

Mercruiser Marine HP500 EFI

PARTS LIST

Part Number Description Quantity Part Number Description Quantity

Part No. 4MB218-010/018

8N201-100/108 PWR COOLER ASSY. MARINE EFI 1

8N101-100 Weld Core Assy. Marine Clr 1

4MA012-061 Cooler Duct, Mach 1

8N002-041 Cap, Top, Marine Cooler 1

7U100-087 O-ring, Marine Cooler Cap 1

7A250-076 1/4-20 x 3/4 SCHS Stainless 8

7A312-451 5/16-18 x 4/5" S.S. SCHS 4

7P500-625 1/2 NPT x -10 45°Flare Ftg 2

7P625-020 Hose End, -10 Brass Push on 2

4MA040-010 Foam Seal, Merc Charge cooler 1

4MA018-040 TEE, Marine Charge cooler 1

7R002-020 #20 SAE Type F SS Hose Clamp 2

7U033-000 5/8" Fuel/PCV Hose 8

7P625-018 5/8" Thru-Hull Dump, Plstc 1

7R001-008 #8 Stnls Hose Clamp 2

2B228-080/088 S/C, V-4-J, HP500 W/PLY SATIN 1

4MA130-026 OIL FEED ASSY. BBC MARINE 1

7P125-034 1/8 NPT x 1/8 NPT Strt T 2

7P125-103 -4 Flare x 45°1/8 NPT 2

7P125-026 Fitting, 90°1/8 NPOT x #4 1

4MA145-020 Oil Feed Hose Assy. BBC Kit 1

7P250-036 -4 SAE Flare to 1/4 NPT 1

7P250-120 1/4 NPT Pipe Plug 1

4MA130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2" Oil Drain Hose 2.5'

7P375-017 3/8 NPT x 1/2 Beaded Hose Barb 1

7P375-045 45°Street Elbow 1

7R001-008 #8 Stnls Hose Clamp 2

7P500-090 Fitting, 1/2" Oil Drain Flange 1

7U100-088 O-ring, S/C Oil Drain Ftg 1

7P375-033 3/8 NPT x 3/8 NPT Srt El 1

7C011-051 10-32 x .50 SHCS Plated 2

7J010-001 #10 Flat Washer 2

4MB116-011 S/C DRIVE ASSY. HP500 1

2A041-618 Belt, 10 Rib 1

2A046-930 Belt, 6 Rib 1

4MA018-051 7" Crank Pulley, Universal 1

4MA016-001 Crank Pulley, HP500 Merc 1

7A375-475 3/8-16 x 4.75 HXHD GR8 Pltd 3

7J375-044 3/8 SAE Washer, Pltd 3

7L375-075 3/8 Lock Washer 3

4MB112-041/048 AIR INLET ASSY. HP500 1

4MB012-041/048 Air Inlet Duct, HP500 1

4MA010-088 Cover, A/F Marine S.C. Pol 1

4MA017-031 Standoff, A/F Marine 2

7A250-076 1/4-20 x 3/4 SHCS S.S. 2

7A250-105 1/4-20 x 1 Set Screw 2

7P250-124 1/4 NPT To 1/2 Barb 1

7P250-146 1/4 NPT Street Elbow 1

7R005-006 T-Bolt Clamp, Ø5.2" 1

8H040-160 Air Filter, Marine S.C. 1

4MB101-001 FUEL SYSTEM ASSY. HP500 1

4MA010-044 Fuel Pump Block Off 1

5W001-013 14-16 AWG, Solderless Connector 2

5W001-014 Fuse Holder 10 GA Wire 1

5W001-015 Fuse, Blade Type 20 Amp 1

5W001-017 12-10 GA x 3/8" RingTerminal 2

5W001-019 10-12 GA Butt Conn Insulated 2

5W001-043 12-10 GA x 1/4" RingTerminal 2

5W012-010 12 GA Wire, Black 8

7A250-102 1/4-20 x 1" SHCS SS 4

7F250-022 1/4-20 Nylock Nut, Stainless 4

7J250-022 1/4" Washer SAE, Stainless 8

7P250-138 #6 Hose End, 37°4

7P375-002 3/8 Pipe Plug, Steel, Znc Pltd 1

7P375-111 3/8 NPT x #8 x 45°, 37°JIC 1

7P500-001 1/2" Hose Union 1

7P500-024 1/2 NPT x #6 2

7P500-025 Nipple, Threaded 1

7P500-027 1/2 NPT x #6 x 90°, 37°JIC 1

7P500-028 1/2 NPT x #8, 37°JIC 1

7P500-029 1/2 NPT x #8 x 90°, 37°JIC 1

7P500-030 1/2" Pipe Plug 1

7P500-064 #8 x 45°Hose End, 37°JIC 2

7P500-083 #8 Hose End, 37°JIC 2

7P500-500 -8 x 90°Al.Hose End, Pshloc 1

7P625-015 #10 x #8 Male Hose Union, 37°JIC 2

7P625-022 -10 Union 1

7R002-024 #24 SAE Type F, SS Hose Clamp 4

7U030-051 -6 USCG Fuel Hose, Push-on 8

7U034-020 Hose, 1.25 Dia. Rubber Rad. 1

7U037-030 1/2" Fuel Line, Pushlock 10

7U100-043 #10 O-Ring 4

7U133-125 Ø1.25 Black Hose 1

7U375-050 1/4" Vac. Cap 1

8F101-200 T-Rex Wiring Assy. Mustang 1

8H040-080 Fuel Separator Filter 1

8J050-020 Fuel Separator 1

4MA014-030 Fuel Cooler, 5" 1

5A002-006 Map Sensor, 2 Bar 1

5A002-011 Map Sensor Harness 1

4MB112-020/028 DISCHARGE ASSY., HP500 1

4MB012-031/038 Discharge Tube "B" 1

7S400-200 4 x 2 Sleeve 1

7R002-064 #64 Goldseal Hose Clamp 2

7S350-200 3-1/2 x 2 Sleeve 2

7R002-056 #56 SAE Type F, SS Hose Clamp 4

4MB012-020/028 Duct, Disch. HP500 1

7A312-078 5/16-18 x 3/4, SS SHCS 4

4MB111-011 MOUNTING BRACKET ASSY. 1

2A017-042 Brkt Spacer A, 502 EFI 10 Rib 1

2A017-043 Brkt Spacer B, 502 EFI 10 Rib 1

4GD011-032 Spring Tensioner 1

4MA010-084 Mtng. Plate, Alumn. Merc. EFI 1

4MA010-094 Support Plate, Merc. EFI 1

4MA116-160 Idler Assy. Marine GEN2 1

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

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

parts immediately.

Mercruiser Marine HP500 EFI

PARTS LIST

Part No. 4MB218-010/018

Part Number Description Quantity

vii

Part Number Description Quantity

4MB010-001 Plt. Fuel/H2O Filter, HP500 1

4MB010-010 Brkt., Engine Oil Filter 1

4MB010-011 Brkt., Cooler Support 1

4MB011-001 Mtng. Brkt, HP500 1

4MB014-010 Thermostat, 120°F HP500 1

4MB016-002 Pulley, Eng. H20 Pmp, HP500 1

4MB017-002 Spcr, Plt Pwr Steering, HP500 1

4MB017-003 Spcr, Alt, HP500 2

4MB017-004 Spcr, Idler, HP500 1

4MB017-011 Spcr, Idler, #2 1

4MB017-021 Spcr, Raw H2O Pmp, HP500 2

4MB017-031 Spcr, Cool Fuel 1

4MB040-050 Gasket, Thermostat, HP500 1

7A312-152 5/16-18 x 1.5 SHCS, Znc Plt 2

7A312-250 5/16-18 x 2-1/2 HHCS 1

7A375-100 3/8-16 x 1 G5 HXHD Plt 1

7A375-101 3/8-16 x 1" SHCS Stnls 11

7A375-102 3/8-16 x 1" Flt Allen Znc Plt 1

7A375-103 3/8-16 x 1" HXHD Stnls 2

7A375-126 3/8-16 x 1.25 HXHD GR8 Plt 2

7A375-201 3/8-16 x 2" SHCS 2

7A375-226 3/8-16 x 2-1/4 SS HCS 1

7A375-277 3/8-16 x 2.75 SHCS Stnls 1

7A375-350 3/8-16 x 3-1/2 HXHD 1

7A375-450 3/8-16 x 4-1/2 SHCS S.S. 2

7A375-451 3/8-16 x 4.50 HXHD GR5, Znc 1

7A437-125 7/16-14 x 1.25 G8 SHCS 2

7A437-150 7/16-14 x 1-1/2 HXHD GR8 1

7A437-200 7/16-14 x 2" SHCS 2

7A437-201 7/16-14 x 2.00 HXHD Znc Plt 2

7A437-275 7/16-14 x 2-3/4 SHCS Znc 1

7A437-451 7/16-14x 4-1/2 HHCS 1

7B375-250 3/8-24 x 2.5 SHCS Stnls 1

7B375-275 3/8-24 x 2-3/4 HXHD 1

7C012-020 12mm x 1.75 x 20mm Plt 3

7C012-025 M12 x 1.75 x 25mm HXHD Plt 1

7C012-051 M12 x 1.75 x 50 L.H. Bolt 1

7F312-017 5/16-18 Nylock Nut 2

7F375-017 3/8-16 Nylock Nut 5

7F375-028 Press Nut, 3/8-24 x .50 1

7F437-000 7/16-14 Hex Nylock Nut 1

7F438-001 7/16-20 Jam Nut, Plt 4

7J012-092 12mm Washer, Flat 6

7J375-044 3/8 SAE Washer, Plt 3

7J438-081 7/16 SAE Washer, Plt 5

7K312-001 5/16" AN Washer, Plt 4

7K375-030 3/8 AN Flat Washer, Stnls 30

7K437-001 7/16 AN Washer 3

7U032-020 Hose, 3/8" ID S/Steering Ret (24") 24

7U033-010 Hose, 5/8" ID S/Steering Ret (17") 1

4FD017-011 Bearing Pilot, 12mm Bore 1

7P750-010 3/4" Pipe Plug 1

7P375-106 PCV Valve 1

4MB017-041 Idler Spacer #1, No P/S 1

4MB017-051 Idler Spacer #2, No P/S 1

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0) viii

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

A. Disconnect the batteries and/or switch.

B. Remove the stock flame arrestor and hardware

from the throttle body.

C. Remove the stock accessory belt.

D. Remove the crank pulley.

E. Removethe3/8"screwsecuringtheidlerbracket

to the engine water pump. Remove the idler

bracket assy. (See Fig. 1-a.)

F. Remove the nuts securing the raw water pump

bracket.

G. Remove the cooling hose. (See Fig. 1-b.)

H. Disconnect the water lines connecting to the

back of the raw water pump. Slide the raw water

pump (with the bracket still attached to it) off of

the engine.

I. Remove the three 7/16" studs from the front

starboard side of the engine.

J. Remove the power steering reservoir bracket

and the oil filter bracket assembly. Disconnect

the power steering lines.

K. Remove the alternator and the power steering

pump.

L. Remove the alternator/power steering pump

bracket.

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.)

NOTE: Itmaybedesirabletodraintheengineoil,cool-

ant and power steering systems to ease in-

stallation and minimize possible contamina-

tion.

1. PREPARATION/REMOVAL

Fig. 1-a

Fig. 1-b

Fig. 1-c

P/N: 4MB020-010

06DEC02 V1.0(4MB HP500 v1.0)

A. Place the provided oil drain tap on the port side

valvecoverandmock upthedrainlineto ensure

it does not come in contact with the exhaust

manifold.

B. Place the supplied adapter fitting as low as

possibleontotheoutsideofthevalvecoverinthe

place where it is to be mounted (see Fig. 2-a).

Mark three points onto the valve cover with a

markerorscribeusingtheadapterasatemplate.

Onepointwillbefortheoilpassageandtheother

two will be for the 10-32 screws to pass through

the valve cover and thread into the fitting.

C. Remove the engine's port side valve cover and

coverthe exposedvalvetrain witha cleanrag to

keepdebris out andprevent contamination.Drill

twoØ.203"holesthroughatthelocationsmarked.

Drill one Ø.391 hole through at the location

marked.

D. Make sure the outside O-ring sealing surface of

the valve cover is smooth and free from paint

chips. Clean the inside of the valve cover area

withacetoneormineralspirits.Attachtheadapter

and O-ring onto the outside of the valve cover.

Threadthetwo10-32x1/2"screwswithwashers

throughthevalvecoverandintotheadapterfrom

the inside out. Use silicone sealer under each

screw head and washer.

E. Reinstall the valve cover.

2. SUPERCHARGER OIL DRAIN

Fig. 2-a

NOTE: The drain hose must be routed downhill

without any dips or kinks.

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Vortech HP500 EFI User manual

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