his manual provides information on the installation, maintenance and service of the
Vortech supercharger kit expressly designed for this vehicle. All information, illustra-
T
tions and specications contained herein are based on the latest product information
available at the time of this publication. Changes to the manual may be made at any time
without notice. Contact Vortech Engineering for any additional information regarding this kit
and any of these modications at (805) 247-0228 8:00am-4:30pm PST.
Take note of the following before proceeding:
1. Proper installation of this supercharger kit requires general automotive
mechanic knowledge and 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 contact your
dealer or Vortech Engineering for possible installers in your area.
2. This product was designed for use on stock (un-modied, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire
O.D. must be stock. If the vehicle or engine has been modied in any way, check with
Vortech prior to installation and use of this product.
3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).
4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no
boost) until problem is resolved.
5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.
Exclusions from Vortech warranty coverage considerations include, but not limited to:
1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.
2. Continued operation with an impaired vehicle or sub-system.
3. The combined use of Vortech components with other modications such as, but not lim-
ited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.
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, LLC.
This Vortech 5.0 supercharger kit was designed for installation and use on Mass
Air Flow (MAF) equipped vehicles. The model years include 1988 California and
all 1989-1993 models. All other years not equipped with MAF systems (factory or
aftermarket) require the installation of a MAP sensor check valve assembly (Vortech
part number 4FD113-010). This allows proper function of early (1986-1988) models
equipped with speed density processors.
RENEGADE 5.0L KIT
The factory water pump pulley may require removal and replacement with an
aftermarket unit for proper supercharger drive belt clearance. Also, an aftermarket
electric fan is recommended, although the factory mechanical fan may still be
retained with minor clearance modications.
1993 5.0 L COBRA APPLICATIONS
Underdrive crank pulley P/N 4FA018-022 and FMU calibration kit P/N 6Z170-040
may be required and are not included in this system. Please call your Vortech
sales representative for details.
Congratulations on selecting the best performing and best backed automotive supercharger available today...
50 State Smog Legal, as per CARB EO #D-213-17 (not applicable to P/N: 4FA218-100/108)
the VORTECH® supercharger!
Before beginning this installation, please read through this entire instruction booklet and the Street
Supercharger System Owner's Manual (Race Owner's Manual for the Renegade kit) which includes the
Limited Warranty Program, the Warranty Registration form and return envelope.
1986-93 RENEGADE 5.0L MUSTANG KIT ONLY 4FA218-100/108
IMPORTANT NOTE: This kit does not supply any of the required fuel and ignition system support assemblies.
This kit was designed for racing/off-road use only.
IGNITION: An ignition amplication unit will be required above 10 psig manifold pressure. Crane HI-6/7 or MSD 6/7
are the most popular choices. A high output coil is also suggested. Spiral core, low resistance, suppression spark plug
wires will also be required. Vortech part number 5A002-005 is a 10.4mm premium wire set manufactured by Taylor, with
pre-cut lengths for the 5.0 Mustang.
FUEL SYSTEM: A high output fuel system will be required when horsepower levels reach approximately 400 or above.
Vortech produces a variety of fuel system combinations including the Maxow Renegade system which is a complete
fuel system from the tank pickup to the fuel rails and will support up to 1000 hp (wiring harness is included).
Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35%
and horsepower between 35-45% can be expected with the boost levels specied by Vortech Engineering. This
product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine
is not recommended and may result in failure of the engine as well as the supercharger. 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 note of the following key points:
1. Use only premium grade fuel 91 octane or higher (R+M/2).
2. The engine must have stock compression ratio.
3. If the engine has been modied 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 re-
solved.
5. Perform an oil and lter change upon completion of this installation and prior to test driving your vehicle.
Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and
lter at least every 3,000 miles. Never attempt to extend the oil change interval beyond 3,000 miles,
regardless of oil manufacturer's claims as potential damage to the supercharger may result.
6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original
heat range plugs as specied by the manufacturer and reset timing to factory specications (follow the
procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs
every 15,000 miles and spark plug wires at least every 50,000 miles.
TOOL & SUPPLY REQUIREMENT
• Factory repair manual
• Timing light
• 3/8" socket and drive set: SAE & metric
• 1/2" socket and drive set: SAE & metric
• 1/2" breaker bar and 4" extension
• 1/8" NPT tap, 3/8" NPT tap, 3/8-16 tap & handle
• Adjustable wrench
• Open end wrenches: 3/8", 7/16", 1/2", 9/16"
"Slimline" 19 mm - Snap-On #LTAM1719
• Center punch and a 5/8" tapered punch
• Ford springlock 3/8" fuel tting disconnect tool
• 5 quarts SF rated quality engine oil, oil lter and wrench
If it has been 10,000 miles or more since your vehicle's last spark plug change,
then you will also need:
8H040-020 3/8" INLINE FILTER 1
7U375-052 3/8" VACUUM CAP 1
7U030-056 3/8" x 22" FUEL HOSE 1
4FA238-068 FMU (WITH LINES) 1
6Z110-111 12:1 BLACK FUEL MANAGEMENT UNIT 1
4FA145-010 MALE FUEL LINE ASSEMBLY 1
4FA145-020 FEMALE FUEL LINE ASSEMBLY 1
7U030-046 5/32" x 54" VACUUM LINE 1
7E010-046 #8 x 3/4" SHEET METAL SCREWS 2
7U100-055 6" NYLON TIE WRAPS 2
6Z110-111 12:1 BLACK FUEL MANAGEMENT UNIT 1
4FA145-010 MALE FUEL ASSEMBLY 1
4FA145-020 FEMALE FUEL LINE ASSEMBLY 1
7U030-046 5/32" x 54" VACUUM LINE 1
7E010-046 #8 x 3/4" SHEET METAL SCREWS 2
7U100-055 6" NYLON TIE-WRAPS 2
6Z110-111 12:1 BLACK FUEL MANAGEMENT UNIT 1
4FA145-010 MALE FUEL ASSEMBLY 1
4FA145-020 FEMALE FUEL LINE ASSEMBLY 1
7U030-046 5/32" x 54" VACUUM LINE 1
7E010-046 #8 x 3/4" SHEET METAL SCREWS 2
7U100-055 6" NYLON TIE-WRAPS 2
PART NUMBER DESCRIPTION QUANTITY
4FA139-096 PCV BYPASS KIT 1
8H040-020 3/8" INLINE FILTER 1
7U375-052 3/8" VACUUM CAP 1
7U030-056 3/8" x 22" FUEL HOSE 1
The MSD Boost Timing Master, manufactured by Autotronic
Controls Corporation, that may be included in this kit, is
serviced exclusively by the manufacturer. Autotronic Controls
Corporation warrants this product to be free from defects in
material and workmanship under normal use and if properly
installed for a period of one (1) year from the date of purchase.
In case of malfunction, this unit will be repaired free of charge
according to the terms of the warranty. If found to be defective
as mentioned above, it will be repaired or replaced if returned
prepaid along with proof of purchase. This shall constitute the
sole remedy of the purchaser and the sole liability of Autotronic
Controls Corporation and/or Vortech Engineering, Inc. To the
extent permitted by law, the foregoing is exclusive and in lieu
of all other warranties or representations whether expressed
or implied, including any implied warranty of merchantability or
tness. In no event shall Autotronic Controls Corporation and/
or Vortech Engineering, Inc. be liable for labor charges, special
or consequential damages.
When returning this unit for service, proof of purchase must
be supplied for warranty verication. After the warranty period
has expired, repair service is charged between a minimum and
maximum charge. In either case, please send the unit pre-paid
with proof of purchase to the attention of:
Autotronic Controls Corporation
Customer Service Department
12120 Esther Lama
Suite #114
El Paso, Texas, 79936
Phone: (915) 855-7123
Fax: (915) 857-3344
www.msdignition.com
The repaired unit will be returned as soon as possible after
receipt, COD for any charges. Be sure you include a detailed
account of any problems experienced, the type of vehicle and
any modications.
Should you have any technical or installation questions
regarding this unit, contact Vortech Engineering, Inc. directly
at (805) 247-0226.
A. Disconnect the battery negative cable.
B. Remove the accessory drive belt. Super High-Output (S.H.O.)
V-7 installations also require removal of the shroud and fan
from the vehicle.
C. Remove the radiator fan assembly and carefully place it in
the fan shroud, out of the way.
D. Remove all components that lead to the throttle body including
air lter assembly, rubber bellows, mass air ow (MAF) sensor
and bracket with rubber mounts and resonator from inner
fender. Separate the MAF sensor from the mounting bracket
and set aside.
E. The ground wire attached to the radiator support must be
rerouted so as to pass through the hole behind the right
headlight and secured from the front. Make sure to clean
away any paint that would insulate the end of the ground
wire from the grounding point on the vehicle.
F. Drain approximately one gallon of coolant. Remove upper
radiator hose and set aside.
G. Remove the crankcase vent tube from between oil lter and
throttle body.
H. Remove belt tensioner assembly.
I. Unplug wire connections and remove alternator assembly
(make sure the battery is disconnected).
J. Remove brace from between the smog pump and front engine
cover.
K. Disconnect hoses and remove smog pump and cast mounting
bracket.
L. Relocate the evaporative canister forward (at a slight angle)
by using only the front bolt in the bracket rear hole. (See Fig.
1-a.)
Fig. 1-a
2. CRANKSHAFT PULLEY
A. Remove crankshaft pulley.
B. For the standard output system, place the cast
Vortech crank pulley into the stock pulley as
shown and secure with the longer bolts and
washers as a unit.
C. For the Vortech High Output, S.H.O. or V -7
Renegade system, remove the factory crank
pulley and replace with the new high output
crank pulley; secure with the supplied bolts
and washers.
NOTE: Tighten bolts progressively and
evenly in a crisscross pattern
so that pulleys align properly.
A. To provide an oil drain for the supercharger, it is necessary
to make a hole in the oil pan. Locate and mark hole per
diagram. It is best to punch the hole rather than drill.
B. Remove paint around the hole area.
C. Use a small center punch to perforate the pan and expand
hole. Switch to a larger diameter punch and expand the hole
further to approximately 9/16" diameter. Most punches are
made from hexagon material and may be placed in a socket
with an extension to make this procedure easier.
D. Tap the hole with a 3/8" NPT tap approximately1/4" deep.
Pack the utes of the tap with heavy grease to hold chips.
Use a small magnet to check for any stray chips.
NOTE: This method of rolling over the lip of the hole and
tapping it works very well if carefully done and
should cause no problems.
E. Thoroughly clean the threaded area. Apply a small amount
of silicone sealer to the new threads. Apply more sealer to
the 3/8" NPT hose tting and secure in hole. Make sure a
seal is formed all around the tting.
F. Drain the engine oil and change the lter.
Fig. 3-a
4. OIL FEED LINE (Engine oil fed kits only. V3
kits, skip ahead to section 5)
A. Remove the oil pressure sender and mounting
boss tting from the engine. These are found on
the engine's left side just ahead of the oil lter.
B. Thread the supplied 3" x 1/4" NPT nipple into the
block using engine oil on the threads. Pipe tape,
paste or other sealant is not recommended as it
might loosen and cause blockage of the oil feed
oroce, resulting in supercharger failure.
C. Thread the supplied 1/4" female TEE into the
nipple. Rotate the TEE so that the center leg
points toward the front of the vehicle. Thread
the 45° elbow into the leg of the TEE pointing
toward the side of the vehicle.
D. Install the factory sending unit into the 45°
elbow.
E. Thread the supplied are tting into the remaining
leg of the TEE.
F. Connect the red oil feed line to the tting at the
pressure sender and route it behind the A/C
mounting plate to the supercharger location.
Cover the end of the hose with a clean plastic
bag. Connect the line to the supercharger with
the are tting provided.
5. FUEL MANAGEMENT UNIT (skip this step for Renegade applications)
FMU
RELAY
SHOCK TOWER
CONNECT TO
MANIFOLD
VACUUM/PRESSURE
INLET
FUEL LINE
FROM
STOCK
REGULATOR
OUTLET
(FUEL FROM HERE
RETURNS TO TANK)
B/RS/C
REMOVE VACUUM CAP
AND ATTACH FMU LINE HERE
A. Relocate the relay using the stock screw.
B. Locate the fuel management unit against the inner fender
panel ahead of the shock tower about an inch from the
top. Drill holes and secure with the sheet metal screws
provided. (See Fig. 5-a.)
C. Disconnect the fuel rail return line at the rubber hose
on the engine's lower right side with a 3/8" spring lock
disconnect tool. The return line does not have the
pressure test tting on it.
Fig. 5-a
D. Connect the Fuel Management
E. Connect the unit’s return hose
F. Secure the fuel lines away from
G. Connect the top tting on the FMU
Unit (FMU) input hose (the hose
that goes to the 90° tting on the
side of the FMU) to the return line
coming from the fuel rail regulator
as shown in Fig. 5-b.
(that connects to the center tting)
to the stock return hose.
the exhaust header with the tie
wraps provided.
to the multi-branch tting located
on the driver's side rewall using
the supplied 5/32" hose. Use the
port with the "B/R" designation.
(See Fig. 5-c.)
NOTE: Add on inline fuel pump
with unit provided if installing high output system.
6. T-REX® FUEL PUMP (H.O., S.H.O. and Cobra Systems Only) cont'd.
I.Mount pump to the underside of the tire well with rubber
mounts, adel clamps and fasteners.
J.Connect the hoses to pump inlet and outlet. This operation
is completed at the Vortech factory for most models.
K. Place the 90° fuel connector (removed from stock line) into
the end of the 5/16" outlet hose from the pump.
L. Connect the 90° end to the inlet side of the fuel lter. Use
cable ties to keep lines up against underbody.
M. Mark and drill a 1/8" hole and mount relay inside trunk in
position as shown in template.
N. From relay terminal #85, tap the yellow wire into the stock
fuel harness in trunk near the right tail light. Tie into red/
purple wire with a scotch lock. (On some model years, wire
may be brownish-green.)
O. Connect the short red wire to the (+) terminal at the fuel pump
relay terminal #87.
P. Connect the longer black wire from the (-) terminal at the fuel
pump to a clean ground.
Q. Connect the short black wire to the ground from relay terminal
#86 (relay screw mount works well).
R. Connect the long red wire from relay terminal #30 to the fuse
box with supplied fuse tap and inline fuse. (The fused side
of the cigarette lighter is the preferred location.)
S. Check over the job and make sure everything is secure and
away from all moving parts and exhaust pipes. Make sure
no wires will rub on sharp edges. After you have activated
the pump, check for any leaks and correct if necessary.
ROUTE RED POWER LEAD FROM FUSE BOX UNDER CARPET ON
DRIVER SIDE WITH STOCK WIRE HARNESS. TAKE CARE TOAVOID
SHARP EDGES AND NOT TO DAMAGE WIRE INSULATION.
MOUNT RELAYIN RIGHT REAR CORNER OF SPARE TIRE WELL.
MAKE SURE WIRES ARE CONNECTED AS PER RELAY SCHEMATIC
PROVIDEAGOOD GROUND CONNECTION FOR BOTH THE PUMP
AND RELAY THATIS FREE OF RUST OR PAINT.
(+) T-REXª FUEL PUMP
GROUND
FUSE BOX AT CIGAR LIGHTER TAP
(FUSED SIDE)
RED/PURPLE WIRE IN STOCK HARNESS
(Check with test light. When key is turned to “ON”
position, test light should illuminate for 2-3 seconds
& then should turn “OFF” automatically
Assemble the main bracket, plate and other
parts necessary to relocate the alternator
and smog pump and make room for the
supercharger. For 1992 and later vehicles,
please review points A through H before
starting.
A. Measure the length of the pivot boss on
the alternator and record. It should be very
close to 3".
B. In a similar manner, measure the boss on
the smog pump. When combined with the
.920" spacer, it should be 4.050". Record
these measurements so that in the event
of a belt alignment problem, Vortech can
properly advise you.
1986-93 S.H.O./RENEGADE
V-7 KITS ONLY
NOTE: The upper mounting bolt boss
on the smog pump (if equipped)
requires grinding to allow for
tment of the V-7 compressor
(see Fig. 7-b).
C. Place the smog pump and alternator on
the large aluminum mounting bracket as
shown. After making sure the 6 1/4" bolts
have a washer on them, enter the cast
mounting bracket from the rear (coming
towards you). Place the .920" tube spacer
over the bolt on the smog pump. Lower
supercharger mounting plate over bolts.
The idea is to sandwich the alternator
and smog pump between the mounting
bracket and plate. Place washers and nuts
on the 6-1/4" bolts and nger tighten. For
vehicles equipped with alternators having
larger 7/16" pivot bolts, it will be necessary
to enlarge the corresponding hole in the
plate.
D. Start the 3/8-16 x 1" fastener with a washer
at the top of the bracket and nger tighten.
Insert the 6-1/2" and 7" bolts. These bolts
will later hold assembly to engine.
the boss on the smog pump and alternator
with the 3/8-16 x 1" bolts. On 1992 and later
Mustangs, it may be necessary to drill and
tap the "blanked" hole in the smog pump.
To accomplish this use an R size bit and a
3/8-16 size tap.
F. Tighten all fasteners in the bracket/accessory
assembly.
G. Lower the entire assembly into position and
start all four fasteners that hold it to the
engine. Tighten all fasteners in a progressive
manner.
H. Reconnect alternator wires and use a tie
wrap to secure the wires.
8. SMOG PUMP HOSES
1986-93 RENEGADE
5.0L KIT ONLY
NOTE: Due to the location of the Vortech
Mondo bypass valve, removal of
the air injection hose assemblies
is required for proper bypass valve
installation. This modication is for
off-road use only. Disregard the following steps A thru E.
A. Separate the short hose and bent hose from the
B. Connect the air control valve to the short hose.
C. Trim approximately 1-1/2", or as necessary, off
D. Secure the hose as shown with the stock
E. It may be necessary to reroute the vacuum control
air control valve and place the shorter hose on
the diverter valve (the valve closest to the rewall)
as shown.
the longer straight portion of the bent hose for
proper t.
A. From the stock radiator hose, make two 90° elbows by trimming as
shown. The rst is with 3" long legs for the thermostat housing end.
The second, with 2" long legs, is from the middle of the stock hose and
attaches to the radiator.
NOTE: S.H.O. V-7 APPLICATIONS - The
10-rib supercharger pulley supplied in
this kit ts close to the upper radiator
hose. More trimming than shown in
Fig. 9-a may be required.
B. Place the stainless water pipe between the
two hoses placing the shorter leg nearer the
radiator.
C. Position the hoses and tube so there is ample
overlap for sealing and secure with provided clamps.
D. Rell radiator and coolant bottle.
NOTE: Make sure the cooling system
is completely full. Air is often
trapped in 5.0 systems.
Fig. 9-a
10. ACCESSORY BELT TENSIONER MOUNTING BRACKET
A. Secure the factory spring tensioner assembly
to the Vortech belt tensioner mounting bracket
using the 1/2" carriage bolt.
B. Replace the locking type nut on the A/C
mounting bracket stud closest to the water
pump with a standard nut.
C. Dep e n ding on For d 's m a nufactur i n g
tolerances, it may be necessary to trim
about 1/8" off the edge of the ange on the
A/C mounting bracket to provide room for
the tensioner mounting bracket.
D. Install the tensioner mounting bracket
with tensioner between the supercharger
mounting plate and A/C bracket stud using
two standard at washers as a spacer. Secure
with two 3/8-16 x 1" bolts and washers and
a 3/8-16 nut.
E. Reinstall radiator shroud and fan assembly.
(Slight shroud trimming may be required on
S.H.O. applications.)
NOTE: On S.H.O. applications, a fan
spacer, studs and nuts have been
F. Reinstall stock accessory belt. (On S.H.O.
applications, use the supplied 888 belt for
the accessory drive.)
supplied. Install these items before installing the fan
10
NOTE: Check the accessory belt ten-
sioner pulley alignment. It may
be necessary to add or remove
a washer to the stud behind the
tensioner bracket.
Fig. 10-a
Page 23
11. SUPERCHARGER MOUNTING
*A. Place the oil drain hose onto the supercharger drain tting and
secure with a hose clamp. Arrange the clamp screw housing so it
will not interfere with the mounting plate when installed.
*B. Feed the oil drain hose over the top of the smog pump and down
towards the oil pan tting while lowering the supercharger into
position.
C. Secure the supercharger with ve 3/8-16 x 1" bolts and AN
washers.
*D. Connect the lower end of the oil drain hose to the tting on the pan
and secure with a hose clamp.
**E. Secure the remote drain hose away from the belt and other hoses
using tie-wraps.
12. SUPERCHARGER DRIVE BELT
1986-93 RENEGADE 5.0L KIT ONLY
NOTE: The factory water pump pulley must be re-
moved and replaced with an aftermarket unit
for proper supercharger drive belt clearance.
Also, an aftermarket electric fan is recommended, although the factory mechanical fan
may still be retained with minor clearance
modications.
* Engine oil fed kits only
** V3 kits only
A. Place the supercharger belt idler assembly on the
supercharger using the 12mm bolts and washers.
Position the thin head bolt nearest pulley.
B. Fit the supercharger drive belt over the new crank
pulley and supercharger pulley.
C. Tension the belt by rotating the tensioner plate
and secure.
Fig. 12-a
13. AIR FILTER ASSEMBLY (skip to step I for Renegade applications
and step J for S.H.O. applications)
A. Place the Vortech air lter cover against the inner fender just
behind the right headlight. Use it as a template to mark and
drill two 3/32" holes. Do not install the cover at this time.
B. Insert the mass air ow (MAF) sensor into the back of the air
lter cover. Place the air lter with clamp, from the inside,
over the protruding MAF and the air lter ange. Rotate
the MAF so that the connector runs parallel to the top as
shown. Tighten the clamp.
C. Mount the air lter assembly behind the headlight and secure
with sheet metal screws provided.
D. Attach the 3” molded elbow to the supercharger with the
sleeve and clamps.
E. Connect the 3” ex tube to the molded elbow and the back
of the MAF with the 3" x 1" adapter sleeve on the MAF (as
a spacer) and secure with clamps.
F. Connect the air discharge tube to the throttle body and
supercharger with the sleeves and clamps provided.
13. AIR FILTER ASSEMBLY (skip to step I for Renegade applications)
cont'd.
NOTE: If kit is a High Output or Cobra model refer to step
16, and Step J for S.H.O. applications.
G. Clamp the provided rubber cap onto the vent tting on
the throttle body.
H. With the 3/8” rubber hose, route blowby to the air lter
cover through the inline lter provided.
I.1986-93 RENEGADE 5.0L KIT ONLY:Install the supplied 4” aluminum elbow onto the
supercharger inlet using the silicone sleeve and #64
clamps. The inlet elbow is supplied with cast-in bosses
that can be drilled and threaded for a valve cover breather
tting (Note: The engine valve cover vent MUST be
properly bafed or else the supercharger may pull in
oil from the engine). The aluminum elbow can then be
attached to the vehicles’ MAF and air inlet lter. Vehicles
equipped with an Anderson Power Pipe can be easily
adapted to the Vortech inlet elbow by using the supplied
4” silicone sleeve and #64 clamps.
J.
S.H.O. V-7 KITS ONLY: INNER FENDER AIR INLET KIT
1.Thread the supplied 3/8 x 90" x 1/4 NPT tting into
the 4" aluminum inlet elbow.
2.Install the elbow onto the supercharger inlet using
the supplied silicone sleeve and #64 clamps.
3.Route the supplied 3/8" blowby hose from the valve
cover to the supercharger inlet elbow tting and trim
if necessary. (Note: The engine valve cover vent
MUST be properly bafed or else the supercharger
may pull in oil from the engine).
4.Cut out the Vortech provided template. Using the
template, mark and drill the hole patterm into the
fender apron.
5.Remove the round plastic cover at the rear of the
oval opening on the inner fender.
6.Remove the plastic fender lining from the right
fender.
7.Attach the lter to the mass air ow (MAF) sensor
and secure with the clamp. Place the MAF in the
fender from the outside and secure with fasteners
provided from the engine compartment side.
8.Attach the short sleeve to the MAF and slip one of
the elbows inside the sleeve facing rearward (see
diagram).
9.Connect the 3" long sleeve to the rearward facing
elbow. Slip the second elbow through the round hole
to the engine compartment and secure into the 3"
10. In the engine compartment, connect the ex hose from
the elbow extending through the hole to the elbow on
the supercharger.
11. Cut the MAF wires 3" to 4" away from the MAF
connector.
12. Slip 1" long sections of the supplied shrink tubing over
each wire before soldering.
13. Using the supplied wiring, solder wire extensions for the
MAF and connector through the fender well. Position
shrink tube over the solder joint and gently heat until
the tube seals the joint.
14. Replace the inner fender lining.
14. IGNITION/BOOST CONTROL INSTALLATION
(High Output and Cobra systems only)
A. The Ignition/Boost Control unit has been prewired for
installation convenience. Installation is a simple matter of
disconnecting the stock connector at the ignition coil and
plugging in the new adapter. Then plug the stock connector
into the adapter.
B. The next step is to provide a good ground for the black wire
and mounting the box in as cool a place as possible under
the hood. The box should be mounted with the aluminum
cover on the bottom.
C. Using the supplied 5/32" hose and 5/32" tee, connect the vent
on the control unit to the FMU vacuum/pressure hose
(see graphic at right).
D. Route the Ignition/Boost Control wires through the rewall
from the interior side. Mount the knob in an easily accessible
place.
E. Connect the wires to the plastic oval wiring connector on
the Ignition/Boost Control unit using the snap-on connector
supplied in the Ignition/Boost Control kit.
NOTE: The wiring to the boost/control knob can be
matched to either of the corresponding wires in
the boost retard connector.
place, adjust the ignition retard knob until just
beyond the point of detonation. Use third gear
for testing in a safe area or road. Adjust the
retard according to changes in altitude and
fuel quality.
CAUTION: It is extremely important
that the boost retard never
be turned to 0°. It is recommended that in stock street
applications, the knob be
positioned at 1° per lb. to
start.
Fig. 14-b
14
Example of Ignition Retard vs. Boost:
Fig. 15-a
Page 27
16. VORTECH BYPASS VALVE (H.O. and Cobra Systems Only. Skip to
step H. for S.H.O. V-7 and Renegade applications)
A. Install the 90° inlet tube onto the
supercharger with the tting pointing
down.
B. Place the hoses as shown on the
valve and secure it with the clamps
provided.
C. Attach one end of the small vacuum
line onto the valve.
D. Install the valve and hoses onto the
inlet elbow tting and secure with the
clamps.
E. Install the aluminum discharge tube
(between the t hrottle body a nd
supercharger) while guiding the hose
onto the valve. Secure hoses with the
clamps.
F. Route the supplied 5/32" vacuum line
and TEE so that you can splice into the
FMU vacuum/pressure line.
G. Make sure everything is secure and
that no fuel lines or wires have been
accidentally moved into harm's way.
H. 1986-93 S.H.O. V-7 AND
RENEGADE 5.0L KIT ONLY:
BYPASS
VALVE
DISCHARGE
TUBE
Fig. 16-a
FMU
INLET
ELBOW
1.Mount the supplied bypass valve to the
aluminum discharge tube using the gasket
and hardware.
2.Connect the supplied 1-3/4" or 2" diameter
silicone sleeve to the outlet of the bypass
valve.
3.Mount the aluminum discharge tube and valve
assembly to the vehicle using the supplied
silicone sleeves and clamps.
4.Align the bypass outlet sleeve to the inlet
elbow boss located on the supercharger inlet
elbow.
NOTE: MAF equipped applicaions require
the bypass discharge air to be
routed back into the air inlet so
that proper air sampling can take
place.
5.Align the discharge tube properly and tighten
all clamps.
6.Route the supplied 1/4" vacuum line and TEE
so that it is spliced into the FMU/vacuum
WARNING: Do not attempt to operate the vehicle until
ALL components are installed and ALL
operations are completed including the
nal check.
17. FINAL CHECK
A. Reconnect the battery.
B. If your vehicle has gone over 10,000 miles
since its last spark plug change, you will
need to change the spark plugs now before
test driving the vehicle.
C. Check all ttings, nuts, bolts and clamps
for tightness. Pay particular attention to
oil and fuel lines around moving parts,
sharp edges and exhaust system parts.
Make sure all wires and lines are properly
secured with clamps or tie wraps.
D. Check all uid levels, making sure that
your tank is lled with 91 octane or higher
fuel before commencing test drive.
E. Visually inspect the fan, belts and shroud
for clearance before running the vehicle.
Pay special attention to the upper radiator
hose-to-belt and pulley clearance.
F. Start engine and allow to idle a few minutes,
then shut off.
G. Recheck to be sure that no hoses, wires,
etc. are near exhaust headers or moving
parts and for signs of any uid leakage.
Check ignition timing to make sure it is set
to stock specications before commencing
test drive.
H. PL EASE TAK E SPECI A L NO TE:
Operating the vehicle without ALL the
subassemblies completely and properly
installed may cause FAILURE OF MAJOR
COMPONENTS.
I. Test drive the vehicle.
J. The supercharger drive belt stretches
initially and will require adjustment
between 250 and 400 miles.
K. Read the STREET SUPERCHARGER
SYSTEM OWNER'S MANUAL (RACE
OW N E R ' S MA N U A L FO R TH E
RENEGADE KIT) AND RETURN THE
WARRANTY REGISTRATION FORM
within thirty (30) days of purchasing your
supercharger system to qualify (Renegade
systems are designed for racing and come
with a standard 6 month warranty).
For internally lubricated V3 units only
This supercharger has been factory pre-lled with
special Vortech synthetic lubricant. Oil does not need
to be added to a brand new unit; however a uid level
check should be performed.
Prior to operating the supercharger on the vehicle and
after installation onto the vehicle:
Remove the factory installed at-head brass shipping
plug (not the dipstick) from the top of the supercharger
case. Replace the sealed shipping plug with the supplied “vented” plug. Do not operate the supercharger
without it. Check the supercharger uid level.
Fluid level checking procedure:
1. Ensure that the .06” copper sealing washer
is located on the dipstick base.
2. Thread the clean dipstick into the unit until
it seats.
3. Once the dipstick has seated, remove the
dipstick from the unit. Fluid should register
in the crosshatched area on the dipstick.
4. DO NOT OVERFILL!!! Drain excess uid from
the unit if it is above the maximum level on
the dipstick.
Check the uid level using the dipstick at least every
2,500 miles.
Initial supercharger uid change must be performed at
2,500 miles. The supercharger uid must be changed
at least every 7,500 miles.
Drain the uid, rell the unit with 4 oz. of Vortech V3
lubricating uid and then conrm proper oil level using
the dipstick. DO NOT OVERFILL!!!
WARNING: Use of any other uid other than the
special Vortech lubricant will void the
warranty and may cause component
failure.