Vortech HP500 EFI User manual

P/N: 4MB020-010
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0)
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)
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
© 2003 VORTECH ENGINEERING, LLC
All rights reserved. No parts 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.
ii

P/N: 4MB020-010
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All Rights Reserved, Intl. Copr. Secured
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
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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.
iv

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06DEC02 V1.0(4MB HP500 v1.0)
v
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
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All Rights Reserved, Intl. Copr. Secured
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
vi
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
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
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
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All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0) viii

P/N: 4MB020-010
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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.)
1
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

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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
2
Fig. 2-a
NOTE: The drain hose must be routed downhill
without any dips or kinks.

P/N: 4MB020-010
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06DEC02 V1.0(4MB HP500 v1.0)
3
3. SUPERCHARGER OIL FEED
Fig. 3-a / Supercharger Oil Feed
A. Remove the stock oil pressure transducer lo-
cated behind the power steering cooler on the
portsideof the engineblock. Remove thelarger
of the two pressure transducers.
B. Install in its place the provided 1/8" street TEE
(see Fig. 3-a). Reinstall the previously removed
pressure transducer into the bottom of the TEE
fitting.OrienttheTEEfittingsothatthehorizontal
female port is pointed toward the transom.
C. Threada1/8" NPTx#4x 90°fittingintotheopen
port on the TEE fitting.
D. Attach the oil feed line to the previously installed
#4 fitting and tighten.
E. Temporarilyplugtheopenendoftheoilfeedline
to keep debris out.
CAUTION: Improper application of pipe sealants
suchasTeflontapeandpastetooilsys-
temfittingsmaycauseoilsystemblock-
age and/or failure which could lead to
severe supercharger and engine dam-
age. Use any sealants on the oil feed
system sparingly!
7P125-026 FITTING,
1/8 NPT x #4 X 90°
4MA145-020
OIL FEED HOSE
STOCK OIL PRESSURE
TRANSDUCER
STOCK OIL FITTING
& TRANSDUCER
7P125-034 1/8
NPT x 1/8 NPT
STREET TEE

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06DEC02 V1.0(4MB HP500 v1.0) 4
A. Referring to Fig. 4-a and using the provided
template(seetemplate onPg.6),mark andcut
thestockpowersteeringandalternatorbracket
as shown. Using a Ø13/32" drill bit and motor,
enlargetheproperholeperthediagram.These
modifications will leave the bracket exposed to
theoutsideelementsandthereforethisbracket
should be treated with paint or rust preventa-
tive.
B. Reattach the modified alternator bracket to the
engine using the stock hardware. Install a 3/8-
16 x 3/4" HHCS with washer into the hole
previously enlarged and tighten.
C. Followingthediagram(seeFig.4-b),installtwo
3/8-16 x 4-1/4" HHCS with washers into the
backsideofthecastbracket.AttachtheVortech
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" SHCS.
4. MOUNTING BRACKETS
Fig. 4-a
DESCRIPTION
Supercharger Mounting Bracket
7/16-14 x 2" SHCS
7/16-14 x 4-1/2" SHCS
3/8-16 x 4-1/2" HHCS
3/8 AN Flat Washers
QTY.
1
2
1
2
2
PART #
4MB011-011
7A437-200
7A437-450
7A375-450
7K375-030
N0.
1
2
3
4
5
Fig. 4-b
2
3
1
5
4

P/N: 4MB020-010
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06DEC02 V1.0(4MB HP500 v1.0)
5
NOTE: Due to manufacturing differences in the ex-
haust manifold, the water tube may come
into contact with the cast bracket. (See Fig.
4-c.) If this occurs, the water tube will have
tobeshortenedorseriousmisalignmentand
failure of the accessories and supercharger
will occur. Removal and cutting of the ex-
haust manifold will be required. See the
"Thermostatchange/exhaustmanifold" sec-
tion for modification details (Pg. 13).
4. MOUNTING BRACKETS, Cont'd.
Fig. 4-d
D. Toalign thebracketproperly,threadthe 7/16-14
x 4-1/2" socket head cap screw into the third
threaded hole on the cylinder head. Tighten the
two 7/16-14 x 2" socket head screws. Remove
the 7/16-14 x 4-1/2" socket head cap screw and
put aside. (See Fig. 4-b.)
E. Slide the supplied power steering pump spacer
plate onto the two 3/8-16 x 4.5" HHCS screws
that were previously installed into the backside
of the cast bracket. (Note that the plate is NOT
symmetrical and may need to be turned over to
provide proper fit). (See Fig. 4-d.)
F. Install the alternator onto the modified stock
bracket using two spacers (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-c
SPACERS

P/N: 4MB020-010
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06DEC02 V1.0(4MB HP500 v1.0)
4. MOUNTING BRACKETS, Cont'd.
6
CUT HERE
DRILL HOLE OUT Ø13/32"
SCALE - 1:1

P/N: 4MB020-010
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06DEC02 V1.0(4MB HP500 v1.0)
7
Fig. 4-d
Fig. 4-e
G. Slide the power steering pump onto the power
steeringpumpspacerplate andbolts.Orientthe
pumpso thatthe inletispointingtothe portside.
Secure the pump with the stock nylock nuts and
washers. (See Fig. 4-d.)
H. Remove the engine's stock water pump pulley
(located above the crank pulley) and replace
with the one provided. (See Fig. 4-e.)
4. MOUNTING BRACKETS, Cont'd.
POWER STEERING
PUMP SPACER PLATE

P/N: 4MB020-010
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06DEC02 V1.0(4MB HP500 v1.0) 8
5. FUEL INJECTOR REPLACEMENT
A. Disconnect the wiring connecting to the throttle
position sensor (TPS), manifold air pressure
(MAP) and the idle air controller (IAC)
B. Removeall thescrews securingtheuppermani-
fold to the lower manifold.
C. Carefully lift the upper manifold off of the lower.
Note that the throttle cable may stay attached if
the upper manifold is tilted over onto its side.
Cover each of the ports of the lower manifold to
prevent debris from falling in. (See Fig. 5-a.)
D. Removethestockfuelfilterandhardlinelocated
at the back of the manifold. (See Fig. 5-b.)
E. Removethefourscrewssecuringthefuelrailsto
the lower intake manifold.
F. Markeachoftheinjectorconnectors(withmask-
ingtapeand apen)corresponding toeachcylin-
der/port. This will aid in reinstallation.
G. Disconnecteachoneoftheelectricalconnectors
from each injector by pressing down on the
springclipandpullingup.Donotpullonthewires
as this could cause an open circuit.
H. Remove the fuel rails with the injectors still at-
tached to it. (See Fig. 5-c.) Look into each
injectorport forany looseO-rings thatmay have
come off of the injectors. Remove the clips
securing the injectors to the fuel rail. Remove
each injector from the fuel rails and look for any
loose O-rings in the fuel rail. (See Fig. 5-e.)
I. Removethe #6fittingon thefuel railand replace
with the provided #8 x 3/8 NPT x 45°fitting.
Orient the fitting so that when the fuel rail is
installed the fitting will be pointing toward the
starboard side.
Fig. 5-a
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)
9
Fig. 5-e
Fig. 5-f
J. Remove the stock fuel regulator and cut the
upper portion off of the regulator using a fine
tooth hacksaw or an abrasive cutoff wheel as
shown in Fig. 5-d. Clean the regulator out and
make sure that there are no loose chips or
debris. Install the adjustable top.
K. Remove the sealing nut at the bottom of the
regulator and remove the brass plug from the
inside (this may require air to be blown into the
open end to force out the brass plug). Install the
fittingontothe bottom ofthe regulator andmake
sure the O-ring is still there and tighten. Re-
attachtheregulatortothefuelrail.(SeeFig.5-f.)
L. Installthenewinjectorsintothefuelrailfirstusing
a small amount of oil to lubricate the O-rings.
Reinstall the injector retaining clips.
M. Install the rail assembly into the lower manifold
and secure with the stock hardware. Reconnect
each one of the electrical connectors to each
injector.
N. Installthefuellinestothefuelrailbeforereinstall-
ing the upper manifold.
O. Remove the stock PCV valve and replace with
the one provided.
5. FUEL INJECTOR REPLACEMENT, cont'd.
TOP OF FUEL
REGULATOR
TO BE DISCARDED
1/4”
FACTORY
REGULATOR
Fig. 5-d
NOTE: Twotypes of regulators are supplied by
Mercruiser from the factory. The exit
orificewillmeasureeither.090"or.120"
If the regulator on your engine is the
.090" unit, it must be replaced with a
.120" unit for proper fuel bypass.
ADAPTER FITTING w/MODIFIED
REGULATOR INSTALLED

P/N: 4MB020-010
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0) 10
6. FUEL SYSTEM UPGRADE
A. Disconnect the fuel lines connecting to the
mechanical fuel pump.
B. Remove the mechanical fuel pump and plug the
vacuum port on the manifold that has a vacuum
line running to it. Use the provided fuel pump
block-off plate and gasket along with the stock
hardware to cover the exposed area. (See
Fig.6-a .)
C. Disconnect the fuel lines from the fuel water
separator and remove the fuel/water separator
mount and filter.
D. Disconnect and remove all fuel lines.
E. Remove the cool fuel pump assembly located
below the crank pulley and both water lines
connecting to it.
F. Removethe coolfuel bracketassemblyfromthe
bracket.
G. Mock up the new fuel pump and filter on the
bracket to check for clearance.
H. Using the new fuel pump as a guide, center the
fuelpump(seeFig.6-b)onthebracketandmark
thefourholesontothebracket.Usingaletter"K"
(Ø.281") drill bit and drill motor, drill out the
previously marked holes. Secure the fuel pump
to the bracket using the four 1/4-20 x 1" SHCS,
1/4" washers and nylock nuts.
I. Supplied in this kit is ten feet of #8 and eight feet
of #6 fuel line, 5 #8 and 4 #6 female swivel
fittings. Measure the distances between each of
thefuelsystemcomponentsandwritethelengths
next to each fuel line on the diagram. It is impor-
tanttomaintainafuellineroutingthatisnotnear
movingparts,havingexcessivelengthorunusu-
ally tight bends that will inhibit the proper opera-
tion of the fuel system.
Fig. 6-b
NOTE: The inlet of the fuel pump should point to-
ward the starboard side when mounted.
NOTE: Cutallhosessquarewithafinetoothhacksaworabrasivecut-offwheel.
Lubricatethenippleofthe female swivels with oil to aid installation and
all O-rings to avoid pinching of chafing. Clean all fuel lines prior to
installation as any debris in the fuel line may cause complete or partial
fuelsystemfailure.Hoseassembliesshouldbe testedhydrostaticallyat
twice the recommended working pressure of the hose (150 psig). All
fuel system components must be completely and properly installed
into hoses or death may occur. Route each fuel line per Fig.5-c. As-
semble the ends with their associated fuel system hardware fittings.
When routing fuel lines be sure not to kink or have any tight bends in
thelines. Keeplinesawayfrom anymovingparts or hotsurfaces.Use a
small amount of clean engine oil to lubricate all of the O-rings in the
fuel system prior to installation.
Fig. 6-a
NOTE: Some engine systems do not have a me-
chanical fuel pump.

P/N: 4MB020-010
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0)
11
6. FUEL SYSTEM UPGRADE, cont'd.
Fig. 6-c
4
10
1
16
3
2
15 5
1
7
12
86
9
18
11
16
16 11 13 17 17 14 17 13
17 10
FUEL COOLER
(SEE ALSO FIG. 10-a)
MODIFIED
FACTORY
REGULATOR
ATTACHED TO
FUEL RAIL
119
SOME APPLICATIONS MAY REQUIRE A 90°FITTING FOR CLEARANCE PURPOSES
TO FUEL
RAIL
CONNECT STOCK FUEL LINE HERE
NOTE: SHOWN IS A COMPLETE FUEL SYSTEM,
BUT DUE TO MANUFACTURERS DIFFERENCES
THIS SYSTEM MAY REQUIRE SOME MODIFICATION.
ADAPTER
FITTING
LOCATION DESCRIPTION PART NO. QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
#6 HOSE END 37°
3/8 PIPE PLUG
3/8 NPT x #8 x 45°37°JIC
1/2” HOSE UNION
1/2 NPT x #6
1/2 NPT x #6 x 90°37°JIC
1/2 NPT x #8 37°JIC
1/2 NPT x #8 x 90 37JIC
1/2" PIPE PLUG
#8 x 45°HOSE END 37°
#8 HOSE END 37°
#8 x 90°AL. HOSE END
#10 x #8 HOSE UNION 37°
#10 UNION
#6 USCG FUEL HOSE
1/2" FUEL LINE
#10 O-RING
FILTER MOUNT FUEL SEPARATOR
FUEL COOLER 5"
7P250-138
7P375-002
7P375-111
7P500-001
7P500-024
7P500-027
7P500-028
7P500-029
7P500-030
7P500-064
7P500-083
7P500-500
7P625-015
7P625-022
7U030-051
7U037-030
7U100-043
8J050-020
4MA014-030
4
1
1
1
2
1
1
1
1
2
2
1
2
1
8'
10'
4
1
1

P/N: 4MB020-010
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0) 12
7. COMPUTER AND MAP SENSOR REPLACEMENT
A. Disconnect the two connectors that connect to
the engines computer located next to the dis-
tributor on the starboard side.
B. Remove the computer and install the new one.
(See Fig. 7-a.) Reconnect the two connectors.
C. Using a Phillips screwdriver, remove the two
screws securing the MAP sensor to the upper
intake manifold (the MAP sensor is located on
the top port side of the manifold). Carefully
remove the MAP sensor from the manifold.
D. RemovetherubbergrommetfromthestockMAP
sensor and install it on the one provided.
E. Install the new MAP sensor back onto the mani-
fold using the stock hardware.
F. Using a GM pin removal tool (purchased sepa-
rately) Remove the three pins from the stock
connector and install the new connector. (See
Fig. 7-b.)
G.Reconnect the new plug to the MAP sensor.
Fig. 7-a
Fig. 7-b
NOTE: Write down the color combination with re-
gards to pin location or remove only one
pinat a time to avoid improperinstallation.