Vortech 1997-2004 C5 Corvette - Manual (Page 38)

P/N: 4GR020-010 v1.7, 2009-11-25
©2009 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
26
A. If your vehicle has gone over 20,000 miles
since its last spark plug change, it is a good
idea to change the spark plugs now, before
test-driving.
B. Make sure that oil drain to oil pan fitting is
tight and that the engine is filled with factory
specified oil.
C. Make sure radiator and overflow tank are
filled with 50/50 coolant/water mix.
D. Make sure that the vehicle is filled with 91
octane or higher fuel before commencing test
drive.
E. Follow the brake bleeding procedure in the
factory shop manual using Dot 3 brake fluid.
F. Re-install the wheels and torque the lug nuts
to factory specs.
G. With key on, make sure charge air cooler
water pump is operating and that water is
flowing through the surge tank. Fill as neces-
sary. If water is not flowing, remove the hose
from the bottom of the surge tank and lower
until water flows out of hose. This should
prime the pump. Reconnect hose, verify
water flow and top off surge tank. Do not run
the water pump for extended periods (30 sec-
onds or more) without water flow.
H. Check all fitting, nuts, bolt and clamps for
tightness.
I. At this point it is OK to start the vehicle.
J. With engine running, check power steering
hose connections for leakage. Let the engine
run for two minutes. Turn steering wheel in
both directions.
Verify:
• Smooth power assist
• Noiseless operation
• Proper fluid level
• No system leaks
• No bubbles, foam or discoloration in fluid
K. Turn off vehicle and recheck all fluid levels,
verify that no hoses, wires, etc. are near
exhaust headers or moving parts and that
there is no fluid leakage.
L. Verify that the belt, where it passes over the
spring tensioner idler, has a gap between the
edge of the belt and the flange on the plastic
idler. If the belt is touching the flange on the
spring tensioner idler, it is a result of spring
19. FINAL ASSEMBLY AND CHECK
Fig. 19-a
WARNING: Do not attempt to operate the vehicle until
ALL components are installed and ALL
operations are completed including final
check. Failure to do so may cause
PREMATURE FAILURE OF MAJOR
COMPONENTS.
tensioner wear. Either the spring
tensioner must be replaced with a
new one, or the following steps
must be taken:
• The top of the spring tensioner will
be moved towards the back of the
vehicle by shortening its spacer.
Loosen the sleeves on the charge
cooler core and move forward as
far as possible for bolt head
access. Remove the accessory
drive belt from the alternator.
• Remove the spring tensioner idler
and loosen all of the bolts secur-
ing the spring tensioner and alter-
nator support plate except the
upper alternator mounting bolt.
• Rotate the pieces up and remove
the spacer from behind the upper
spring tensioner mount. On a
lathe, remove .040" from the
length of the spacer.
• Place a 10mm washer between
the spring tensioner and the alter-
nator support plate/bushing and
reassemble.
• Verify that the belt is tracking
properly with the vehicle running.
M. Install a fuel pressure gauge on
the vehicle and verify that the fuel
pressure stays above 50 psi
(especially at redline). If the fuel
pressure drops below this level a
voltage booster must be connect-
ed to the fuel pump and adjusted
until the fuel pressure reads at
least 55 psi under full throttle near
redline
NOTE: Make it a habit to check the belt at
each oil change and correct an
improperly tracking belt before it is
damaged.