Vortech 1986-1993 Ford 5.0L Mustang User Manual

Maxflow® Power Cooler

Installation Instructions

™

1986 - 1993 Ford 5.0 Mustang

Part# 8N301-010 CARB E.O.# D-213-15

P/N: 8N201-010??
©1997, 1999 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
16JAN00 V 1.0

This product may not be legal for use on public roads in all 50 states.

®

ENGINEERING, INC.

®

ENGINEERING, INC.

NOTICE

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 whole or part, abstractly or fundamentally,

intentionally or fortuitously, nor shall any design, dimension, or other

information be incorporated into any product or apparatus without

prior written consent of Vortech Engineering, Inc.

Vortech Engineering, Inc. • 1650 Pacific Avenue • Channel Islands, CA 93033-9901

Voice: [phone] • Fax: [phone] • M-F 8AM - 4:30PM (PST)

vortechsuperchargers.com

© 1997, 2000 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

®

Vortech

Maxflow

1986 - 1993 Ford 5.0 Mustang

®

Power Cooler

®

Installation Instructions

Congratulations on selecting the best performing and most

efficient aftercooler today... the Vortech ® Maxflow

®

Power Cooler ™!

Before beginning this installation,

please read through this entire instruction booklet

The Vortech ® Maxflow ® Power Cooler ™ System was designed as a street/strip oriented aftercooler,
specifically for use on 1986 - 1993 Ford 5.0 Mustangs vehicles equipped with a Vortech Supercharger
producing up to approximately 580 hp. The Maxflow Power Cooler System will fit and work equally
well with other brands of centrifugal superchargers as well as turbochargers, with minor modifications.

As with any power enhancing product, this system is intended for use on healthy, well-maintained
engines. Vortech Engineering is not responsible for engine damage. Installation on new vehicles
will not harm or adversely affect the break-in period so long as factory break-in procedures are
followed.

For best performance and continued durability, please take a note of the following key points:

1. Use only premium grade fuel 92 octane or higher (R+M/2).

2. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until
problem is resolved.

IMPORTANT NOTE: If the vehicle still has the battery located in the factory position, it must be
relocated into the trunk to make room for the water tank assembly. Vortech part no. 8N150-010
is a Heavy-Duty Battery Relocation Kit that may be purchased separately. Commonly available
“universal” relocation kits may be used but they will most likely contain smaller cable. Additional
fabrication may also be necessary when using a “universal” kit.

TOOL & SUPPLY REQUIREMENTS

• Adjustable Wrench

• Open End Wrenches
(5/16”, 7/16”, 1/2”, 9/16”, 3/4”, 7/8” and 18mm)

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Pipe Tape (Teflon®)

• Wire Cutters

• Wire Strippers

• Hack Saw

• Round File

• 1” Hole Saw

• Tape Measure

• Drill Motor

• Utility Knife

• 3/8” Ratchet

• 7/16”, 1/2”, 9/16”, 8mm,
and 10mm Sockets

• 3/16” Allen Wrench

• 1/2” Breaker Bar

• Soldering Gun

• Hammer

• 1/4” NPT Tap

• 7/16” Drill Bit

• Valve Cover Gaskets (optional)

© 1997, 2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

FORCEPOWER™ PARTS Basic Limited Warranty

Vortech Forecepower Parts carry a Ninety (90) Day LIMITED WARRANTY from the date of purchase
from your dealer or Vortech. The part(s) must be used in the manner intended by Vortech. Any
component found to be defective in either material or workmanship, will be replaced or repaired at
our option, at no charge to the customer. This warranty does not included any part that is used for
racing. This warranty is nontransferable and is extended to original purchasers residing within
the United States or Canada only. The warranty excludes hoses and sleeves, as well as all electronic
support components manufactured by any other company.

Vortech Engineering, Inc. agrees to honor any warranty claim at its sole discretion and only after
inspection by Vortech engineers at the Vortech factory. No warranty will be honored if any
Forcepower part being submitted for inspection is found to have been tampered with, improperly
installed, or mishandled in any way. Claims for freight damage must be held against the freight
company. NOTE: THE DURATION OF ANY AND ALL WARRANTIES ON FORCEPOWER PARTS ARE
LIMITED TO NINETY (90) DAY DURATION OF THE EXPRESS WARRANTY. IN NO EVENT WILL
VORTECH BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

If you require any additional details regarding Vortech warranties, please call at [phone],
M - F, 8:00-4:30 Pacific Time.

WARRANTY/REPAIR PROCEDURE

If the product should fail within the ninety (90) day warranty period as outlined above, follow the procedures below completely:

1. Phone Vortech directly [phone] and be prepared with the following information:
A. Copy of the invoice on which the part was purchased.
B. Year, make, model, vehicle mileage and engine specifications of vehicle in which part is installed.
C. Description of perceived problem.
D. Mileage on Voretch product(s) - where applicable.

2. Once the information is given to Vortech as outlined in Warranty/Repair Procedure item 1 above, Vortech will either:
A. Issue you a RETURN AUTHORIZATION NUMBER or;
B. Offer suggestions to aid you in additional troubleshooting.

NO RETURNS WILL BE ACCEPTED WITHOUT A RETURN AUTHORIZATION NUMBER APPEARING ON THE OUTSIDE OF THE RETURN CARTON.

3. Once you are assigned a RETURN AUTHORIZATION NUMBER, you must box and carefully “safety package” the Vortech product(s) being

returned. “Safety Package” means to pack each product within the box in such a way so that it will not hit other product(s) components, or
the side of the box during shipping. The box must be strong enough to easily hold the weight of the product(s) plus the packaging and sturdy
enough to maintain its shape during shipping.

CLEARLY MARK THE RETURN AUTHORIZATION NUMBER IN 2” HIGH ALPHANUMERIC CHARACTERS IN 2 LOCATIONS ON THE BOX WITH A BOLD
BLACK MARKER.

4. Include within the box the following six (6) items:
A. A copy of the original invoice or receipt.
B. Your name, address and daytime phone number.
C. A description of the year, make, model and specification of the engine (noting ALL modification in detail), where applicable.
D. A description of the perceived problem or defect.
E. The RETURN AUTHORIZATION NUMBER.
F. The address to which the product is to be return shipped after inspection by Vortech.

5. Ship the properly safety packaged and marked box by UNITED PARCEL SERVICE (UPS),

being returned for inspection, to the Vortech factory at:

Vortech Engineering, Inc.
Warranty Dept.
1650 Pacific Ave.
Channel Islands, CA 93033-9901

6. If Vortech’s limited warranty applies, your product(s) will be repaired or replaced at Vortech’s option and returned to you freight prepaid, via

UPS ground service. If the limited warranty does not apply, we will advise you of the specific reason for denial and tell you the costs involved in
repairing your product(s). After relating such information we will, at your option, either proceed with repairs as quoted or return your product(s) to
you in the state they are in at the time of inspection for warranty evaluation by UPS COD insured for the new retail replacement value. This means
that you must pay any disassembly and/or inspection charges, return shipping and insurance charges if the Vortech limited warranty does not apply.

NINETY (90) DAY LIMITED WARRANTY

prepaid and insured for the retail value of the product(s)

© 1997, 2000 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

Vortech

®

Maxflow

®

Power Cooler

™

Part No. 8N301-010

1986 - 1993 Ford 5.0 Mustang

PARTS LIST

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

Air/Water Aftercooler Assembly (8N201-010)

PART NUMBER DESCRIPTION QUANTITY

8N101-010 Air/Water Aftercooler 1
7P500-078 1/2” NPT x 3/4” Hose Fitting 1
7P500-026 1/2” NPT to 3/4” 90° Barb 1
7P750-100 3/4” NPT x 1” Straight Hose Fitting 1
7P250-048 1/4” NPT x 5/8” 90° Barb 1
7U030-065 3/4” 90° Hose 1
7P375-075 3/4” Hose Barb 1
8N103-010 Oil Filler Assembly 1
8N102-010 Idler Air Control 1

Oil Filler Assembly (8N103-010)

PART NUMBER DESCRIPTION QUANTITY

7U100-054 Crank Vent Grommet 1
7U100-056 90° Vent Tube 1
7U100-053 Oil Fill Cap 1
7U030-060 3/4” x 5/8” x 180° Hose 1
7U100-055 6” Nylon Tie Wraps 4
7P250-048 1/4” NPT to 5/8” 90° Barb 1
7U033-000 5/8” x 4” PCV Hose 1
7P625-002 5/8” Hose Barb 1

Water Cooler Assembly (8N106-010)

PART NUMBER DESCRIPTION QUANTITY

8N006-010 Water Cooler 1
8N100-001 Nylon Mounting Kit 1
8N010-010 Pump Support 1
7A250-050 1/4” - 20 x 1/2” SHCS 2
7F250-021 1/4” - 20 Nylock Nuts 2
7J250-022 1/4” Washers 2
7C010-075 10-24 x 3/4” SHCS 2
7F010-024 10-24 Nylock Nuts 2
7J010-001 #10- Flat Washers 2

Water Tank Assembly (8N155-010)

PART NUMBER DESCRIPTION QUANTITY

8N105-010 Water Tank 1
7U038-000 3/4” x 14 Feet Heater Hose 1
7U100-055 6” Nylon Tie Wraps 10
5W001-009 16-14GA Male Slides 2
5W001-010 16-14GA Female Slides 3
5W001-011 16-14GA Eyelet 1
5W001-002 Fuse Tap 1
5W014-010 6 ft. 14GA Red Wire 1
5W014-030 2 ft. 14GA Black Wire 1
7R007-001 Nylon Clamp, 1-1/8” 12
5W001-015 Fuse Blade 1
5W001-014 Fuse Holder 1
5W001-019 Solderless Connector, 10-12 1
5W001-040 12- 10 GA, Female Slide 1

Idle Air Control Assembly (8N102-010)

PART NUMBER DESCRIPTION QUANTITY

8N004-011 Adapter 1
7A250-102 1/4-20 x 1” SHCS 2
8N005-020 Adapter Gasket 1
7J006-093 6mm Washers 2
7P250-048 1/4” NPT to 5/8” 90° Barb 1
7U033-000 5/8” x 15” PCV Hose 1
7U034-016 1” x 12” Gas Hose 1
5W001-007 3/16” x 8” Heat-shrink tube 1
5W018-010 18 GA Strd. Wire, Red 1
5W018-024 18 GA Strd. Wire, White/Yellow 1
5W001-006 3/8” Heat Shrink Tubing 1
7R001-008 #8 Hose Clamps 2

© 1997, 2000 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

1. Preparation and Removal

A. Disconnect and remove the battery (if located

in the factory position).

B. Remove the supercharger discharge tube and

bypass valve assembly.

C. Remove and set aside the supercharger inlet

elbow and flex tube.

D. Remove the belt tensioner, the supercharger

drive belt and supercharger. Set aside.

NOTE: Temporarily cap oil feed and oil drain
to protect your engine from foreign particles.

E. Remove the FMU, disconnect the lines noting

their position for assembly.

F. Remove the idle air control unit and throttle

body linkage from the intake manifold.

G. Remove the upper intake manifold and both

valve covers.

NOTE: The stock valve cover gaskets may
have small metal spacers that could become
dislodged from the gasket during removal.
Check carefully to ensure that they are all
accounted for.

H. Remove the front bumper cover and headlight

assembly (optional).

NOTE: Removal of the bumper cover is not
required but will allow easier installation of
the water cooler/pump assembly.

© 1997, 2000 Vortech Engineering, Inc.

1

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

2. Valve Cover Modification

NOTE: It is imperative that the supplied
rubber grommets are fitted during the
fabrication process and material is removed
carefully.

Passenger side valve cover modification
A. With a hack saw or a die grinder carefully cut

off the oil filler tube shown.

B. You should have approximately 1/16” of lip

remaining.

C. With a hammer, carefully fold the remaining

1/16” lip inward until a secure grommet fit is
achieved.

D. Grind or file the remaining oil filler flange

square as shown in the graphic. Deburr and
remove sharp edges.

E. Thoroughly clean the valve cover ensuring that

the there are no chips or shavings in the internal
oil baffle.

90° Vent Tube

REMOVE OIL
FILLER TUBE

1/16"

Passenger Side Front View

1/4” NPT x 5/8” Barb

F. Install the supplied rubber grommet and the

90° plastic crankcase vent tube, pointing toward
the distributor. (See Photo)

G. Using the new gasket (or old gasket if in good

condition), reinstall the valve cover.

Drivers’ side valve cover modification
A. To provide a hole for the new oil fill cap it is

necessary to drill a hole in the top of the valve
cover.

B. Measure and mark the location to be drilled.

NOTE: The valve cover MUST BE HELD
SECURELY or the hole saw will walk, creating
an oval shaped hole, preventing a proper
seal for the oil fill cap.

Photo - 1

Rubber Grommet

© 1997, 2000 Vortech Engineering, Inc.

2

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

2. Valve Cover Modification

(continued)

C. Using a 1” hole saw, carefully drill into the top

of the valve cover as shown in the graphic.
Carefully finally fit the hole to the new oil cap
using a round file. Bevel the opening, removing
all burrs and sharp edges.

D. Thoroughly clean the valve cover.

E. Using a new gasket (or old gasket if in good

condition), reinstall the valve cover.

F. Reinstall the upper manifold, throttle body and

throttle linkage. Inspect and replace gaskets
as needed.

1.180 DIA.

1.250

1.650

© 1997, 2000 Vortech Engineering, Inc.

3

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

3. Inlet Elbow Modification

A. Carefully mark the inlet elbow as shown.

B. Drill a 7/16” hole in the specified location, tap

1/4” NPT and install the 1/4” NPT x 5/8” barb
x 90°.

C. Orient the fitting as shown to approximately

the one o’clock position.

2.600

© 1997, 2000 Vortech Engineering, Inc.

4

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

4. Supercharger Reclocking and Reinstallation

A. Loosen and remove the six (6) 1/4-20 cap

screws and retaining plates that hold the
compressor housing to the gearcase.

B. Carefully rotate the supercharger volute to the

specified location as shown.

NOTE: If the compressor housing does not
rotate freely relative to the gearcase, DO
NOT FORCE IT. SERIOUS SUPERCHARGER
DAMAGE MAY OCCUR. The machined mating
surfaces are designed to prevent pressurized
air from escaping and have minimal
tolerances. If the housing will not move or
is very tight, contact Vortech Engineering
immediately at [phone] and ask for
our service department for further assistance.

C. Evenly retighten the six (6) cap screws, torque

to 5 ft./lbs.

Rotate until retainer

stops against gearcase

D. Reinstall the supercharger, securing the oil

drain, oil feed and the air inlet elbow. The air
inlet elbow must be rotated down to the
8 o’clock position to allow proper clearance
for the aftercooler.

E. Install the large end of the rubber 180°

crankcase vent hose to the 3/4” plastic vent
tube located in the passenger side valve cover
and the opposite end to the 5/8” fitting located
in the air inlet elbow. (See photo in step 2,
page 2)

F. Secure the hose ends with the 6” tie wraps

provided.

© 1997, 2000 Vortech Engineering, Inc.

5

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

5. Idle Bypass Solenoid Relocation and Wire Extension

A. Using the original 6mm bolts and gasket, install

the cast aluminum Vortech idle air adapter in
the position previously occupied by the factory
idle air controller on the throttle body. The
5/8” fitting must be pointing downward.

B. From the 5/8” barbed fitting, temporarily route

the 5/8” x 15” hose to the rear of the passenger
shock tower and position out of the way.

C. The idle air controller plug harness must be

extended to accommodate relocation onto the
aftercooler. Carefully remove approximately
6” of the factory wire wrap.

D. Extend the connector by cutting the wires and

soldering on the matching 12” extensions.
Use the supplied shrink tubing to protect the
soldering joints. Slip the tubing over wire
before soldering and gently heat until tube
seals joint.

© 1997, 2000 Vortech Engineering, Inc.

6

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

6. Aftercooler and Idle Air Bypass Controller Mounting

A. With the supplied gasket and 1/4-20 hardware,

mount the idle air controller to the aftercooler
as shown.

B. Cut the supplied 1” hose into 2-1/2” and 9”

lengths and attach to the supercharger air
bypass valve (See graphic). Secure the
assembly to the air inlet elbow with #16 clamps.

C. Remove the silicone sleeves and clamps from

the original discharge tube.

D. Reinstall the 2-3/4” diameter silicone sleeve

onto the supercharger discharge tube, slide
the sleeve back as far as possible, leaving the
two #44 hose clamps loose.

AFTERCOOLER

E. Slide the 3” diameter silicone sleeve onto the

aftercooler discharge, leaving the two #48 hose
clamps loose.

F. Secure the 1” supercharger air bypass hose

assembly to the plastic 1” fitting on to
aftercooler discharge.

G. Slide aftercooler into the position and secure

the silicone sleeves and clamps.

H. Secure the 5/8” hose with the #8 hose clamp

onto the 5/8” x 90° fitting located on the

®

Maxflow

Power Cooler™.

1" HEATER
HOSE

BYPASS
VALV E

CONNECT TO
MANIFOLD VACUUM

2-1/2"

VIEW FROM
PASSENGER SIDE

9"

1" HEATER HOSE

© 1997, 2000 Vortech Engineering, Inc.

7

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

7. Water Tank Mounting/Plumbing Schematic

A. Place the water tank in the tray previously

occupied by the battery. (See Photo)

B. Cut 66” length of 3/4” hose and temporarily

attach to the water return fitting on the tank.
Route back against the firewall and over the
passenger side shock tower.

NOTE: Do not secure the water return hose
until the system has been purged of air. See
step 9E (NOTE).

C. Attach the smaller of the two 3/4” 90° hose

bends to the forward most aftercooler fitting.
Following the diagram, join the 90° hose bend
to the return line using a hose union and secure
with clamps.

D. Use the stock battery hold-down block and bolt

to secure the water tank.

RETURN WATER FROM

AFTERCOOLER CORE

COOLED

CHARGE AIR

INTAKE

MANIFOLD

®

™

COOLED WATER

MOLDED

WATER

TANK

DRAINCOCK

(-)

(+)

BOSCH
WATER

PUMP

WATER

FLOW

SUPERCHARGER

DISCHARGE

WATER

COOLER

(located in front of vehicle radiator)

8

© 1997, 2000 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

8. Water Cooler Assembly Mounting

NOTE: To avoid damage to the water cooler and the
air conditioning core, it is recommended that the
entire front bumper skin be removed for easy access
prior to the installation of the water cooler assembly.

A. Using the provided nylon mounting rods, mount the

water cooler to the front of the radiator/air conditioning
core and secure. Make sure that the cooler is
positioned so that it will receive unobstructed air from
the front of the vehicle.

B. Cut and attach a 42” section of 3/4” hose to the pas-

senger’s side fitting on the water cooler and route to
the 90° fitting on the aftercooler. Trim ends appropri­ately and secure both ends with the nylon ratchet clamps.

C. Connect the wiring harness to the water pump. Following

the diagram, position the water pump and bracket on
the inner frame rail, as far forward as possible. Using
the mounting bracket as a guide, mark the positions
on the frame rail that are to be drilled. Drill the mounting
holes and attach the water pump with bracket to the
frame with the supplied #12 hardware. NOTE: See new

supplement diagram.

D. Attach the 3/4” 90° hose bend to the pump inlet. Cut

a piece of the 3/4” hose approximately 8” in length and
connect one end to the lower 90° fitting on the water
tank. Install a 3/4” hose union into the opposite end
and connect to the previously installed hose bend on
the water pump.

E. Cut a 54” length of 3/4” hose and attach to the outlet

of the water pump. Route line toward front of vehicle
and connect to the driver’s side of the water cooler
assembly and secure with clamps.

F. Secure hoses with provided tie wraps.

NOTE: Hoses must not be kinked or restricted, route
away from moving parts and direct engine heat.

G. After all hoses have been connected and secured,

remount the FMU in a new position to clear all water
lines and fittings.

© 1997, 2000 Vortech Engineering, Inc.

9

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

9. Water Pump Wiring

A. Using the factory ground lug between the inner

fenderwell and the water tank, ground the black
wire coming from the water pump.

B. Route the red wire through the firewall to the

fuse panel.

NOTE: Do not attach the red wire to power
until the water tank is full of water, running
the water pump without water will lead to
premature failure and void your warranty.

C. With a test light find 20 amp, fused, key-on

power. Remove the fuse and install the
provided fuse tap on fused side and reinstall
the fuse, check again for power. (The heater
blower motor fuse works well.)

D. Fill water tank with 25% antifreeze and 75%

water up to approximately 3” from the top.

E. Turn the ignition key to the “on” position and

check that water is flowing through the system.

Fill tank to one inch below filler ring.

NOTE: In many cases, the water pump must
be primed on initial start-up. This may be
accomplished by turning on the pump,
removing the RETURN line from the tank and
providing light suction on the hose to remove
the air in the system.

10

© 1997, 2000 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0

10. Final Check

WARNING: Do not attempt to operate the
vehicle until ALL components are installed
and ALL operations are completed including
the final check.

A. Check all fittings, hoses and clamps for

tightness and leaks. Make sure all wires and
lines are properly secure with clamps or tie
wraps.

B. Make sure all wires and hoses are routed away

from hot, moving or sharp objects.

C. Double check to ensure water is flowing through

the system.

11

© 1997, 2000 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

24JAN00 V 1.0