Vortech 1997-2004 C5 Corvette User Manual

Page 17

P/N: 4GR020-010 v1.7, 2009-11-25

Fig. 5-b

Fig. 5-c

Fig. 5-a

A. Attach the supplied small metal tab onto the

bottom of the engine coolant surge tank using

the supplied M6 bolt, nut and washers as

shown in Fig. 5-a.

B. Install the M6 x 50 mm bolt (the bolt is to be

installed from the bottom of the fender) and

.85" long spacer in the rear hole on the inner

fender.

C. Install the M6 x 45 mm bolt (the bolt is to be

installed from the bottom of the fender) and

.7" long spacer in the front hole on the inner

fender.

D. Use the remaining factory nuts to secure the

surge tank at all three of its original mounting

locations. (See Fig. 5-b.)

The 3/4" hose connecting the surge tank to

the thermostat housing (on the engine’s water

pump) must be extended to provide clear-

ance for the Vortech Charge Air Cooler

(CAC). Remove the hose that connects the

coolant reservoir to the thermostat housing

and cut off the last bend on the water pump

side. Connect the cut end of the remaining

U-shaped hose to the surge tank and insert

the supplied 3/4" brass hose mender in the

open end. Using the supplied 90° hose, con-

nect the short end to the water pump. Cut the

long end so that it mates to the hose mender

and allows the hose to be tucked next to the

frame allowing room for the CAC. (See Fig.

5-c for finished modifications.) Secure the

hose ends with the two nylon ratchet clamps

provided.

The hose coming out of the water pump and

going towards the firewall must be routed on

top of the A/C line. Disconnect the end

attached to the water pump. Route it on top

of the 3/8" aluminum A/C line and re-attach.

G. The A/C line must be bent up to clear the

hoses coming out of the CAC and then down

and towards the passenger side to clear the

alternator.

5. SURGE TANK RELOCATION

The factory surge tank will be spaced up about 3/4"

in order to clear the new alternator mounting location

cap on some vehicles - this may cause hood mis-

alignment. If hood alignment is unacceptable, the

surge tank may have to be lowered and clearance to

the alternator re-checked.