Vortech 1986-1993 Ford 5.0 Mustang User Manual

Ford 5.0L Mustang

®

Supercharger System

Installation Instructions

(CARB E0 # not applicable to Renegade Kit P/N: 4FA218-100/108)

50 State Smog Legal per CARB EO #D-213-17

1986-1993 MODEL YEARS

ENGINEERING, LLC

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

FOREWORD

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 specications 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 modications 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-modied, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire

O.D. must be stock. If the vehicle or engine has been modied 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 modications such as, but not lim-

ited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

into another language in any form, by any means without written permission of Vortech Engineering, LLC.

ii

TABLE OF CONTENTS

FOREWORD .....................................................................................................................................ii

TABLE OF CONTENTS ....................................................................................................................iii

IMPORTANT NOTICE ....................................................................................................................... iv

TOOL & SUPPLY REQUIREMENT...................................................................................................v

PARTS LIST - 1986-1993 MUSTANG (Internally Lubricated) ...........................................................vi

PARTS LIST - 1986-1993 HIGH-OUTPUT MUSTANG .....................................................................vii

PARTS LIST - 1986-1993 HIGH-OUTPUT MUSTANG (Internally Lubricated) ................................. viii

PARTS LIST - 1986-1993 RENEGADE MUSTANG..........................................................................ix

PARTS LIST - 1986-1993 SUPER HIGH-OUTPUT MUSTANG .......................................................x

MSD IGNITION SYSTEM .................................................................................................................. xii

1. PREPARATION/REMOVAL .................................................................................................. 1

2. CRANKSHAFT PULLEY .......................................................................................................1

3. OIL DRAIN ............................................................................................................................ 2

4. OIL FEED LINE .................................................................................................................... 2

5. FUEL MANAGEMENT UNIT ................................................................................................ 3

5.1 FUEL MANAGEMENT UNIT RECALIBRATION ................................................................... 4

6. T-REX FUEL PUMP (High Output and Cobra Systems Only) .............................................. 5

7. MAIN BRACKET ASSEMBLY ............................................................................................... 8

8. SMOG PUMP HOSES .......................................................................................................... 9

9. RADIATOR HOSE ................................................................................................................10

10. ACCESSORY BELT TENSIONER MOUNTING BRACKET .................................................10

11. SUPERCHARGER MOUNTING ........................................................................................... 11

12. SUPERCHARGER DRIVE BELT .......................................................................................... 11

13. AIR FILTER ASSEMBLY ......................................................................................................13

14. IGNITION/BOOST CONTROL INSTALLATION ....................................................................13

15. IGNITION/BOOST CONTROL UNIT OPERATION .............................................................. 14

16. VORTECH BYPASS VALVE (High Output and Cobra Systems Only) ................................15

17. FINAL CHECK ......................................................................................................................16

iii

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

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, 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 modications.

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.

iv

1986 - 1993

FORD 5.0L MUSTANG

Installation Instructions

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 amplication 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 Maxow 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 specied 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 modied 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 specied by the manufacturer and reset timing to factory specications (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:

• Spark plug socket

• NEW spark plugs

• Large screwdriver or pry bar

• Flat #2 screwdriver

• Phillips #2 screwdriver

• Heavy grease

• Silicone sealer

• Drill motor

• 3/32", R or 5/16", 7/16" drill bits

v

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

1986-1993 Mustang

®

Part No. 4FA218-010L

ENGINEERING, LLC

PARTS LIST

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

PART NUMBER DESCRIPTION QUANTITY

2F338-040 V-3 SCi SUPERCHARGER ASSY 1

4FA111-032 SUPERCHARGER BELT 1 TENSIONER ASSEMBLY

7J012-092 12mm FLAT WASHERS 3 4FA011-032 BELT TENSIONER PLATE 1 7C012-050 12mm x 1.75" x 50mm BOLT 1 4FA016-150 SMOOTH PULLEY TENSIONER 1 2A017-010 IDLER PULLEY SPACER 1 7C012-020 12mm x 1.75" x 20mm BOLTS 2 7C012-022 12mm x 1.75" x 22mm THIN HEAD BOLT 1 7G010-175 12mm x 1.75" NUT 1

4FA112-010 AIR INTAKE ASSEMBLY 1

7S350-200 3-1/2" x 2" SLEEVE 1 4FA012-012 90° INTAKE ELBOW 1 4FA013-010 AIR CLEANER COVER 1 7J006-093 6mm WASHERS 2 7P375-097 3/8"NPT x 3/8" BARB 1 7S300-100 3" x 1" SLEEVE 1 7E010-046 #8 x 3/4" SHEET METAL SCREWS 2 8H040-010 AIR FILTER 1 7R002-056 #56 HOSE CLAMPS 2 7R002-052 #52 HOSE CLAMPS 2 7U035-000 3-1/2" x 12" FLEX HOSE 1

4FA112-020 AIR DISCHARGE ASSEMBLY 1

4FA012-020 DISCHARGE TUBE 1 7S275-200 2-3/4" x 2" SLEEVE 1 7S300-200 3" x 2" SLEEVE 1 7R002-044 #44 HOSE CLAMPS 2 7R002-048 #48 HOSE CLAMPS 2

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

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

PART NUMBER DESCRIPTION QUANTITY

4FA110-011 SPRING TENSIONER 1

MOUNTING ASSEMBLY

4FA010-011 TENSIONER MOUNTING BRACKET 1 7A375-100 3/8-16 x 1" BOLTS 2 7J375-044 3/8"SAE WASHERS 3 7F375-016 3/8-16 NUT 1 7A500-350 1/2-13 x 3-1/2" CARRIAGE BOLT 1 7F500-013 1/2-13 NUT 1 7J012-092 12mm FLAT WASHER 1

4FA114-023 RADIATOR HOSE ASSEMBLY 1

4FA014-011 RADIATOR PIPE 1 7R002-024 #24 HOSE CLAMPS 2

4FA111-021 MOUNTING BRACKET ASSEMBLY 1

4FA011-021 MOUNTING BRACKET 1 4FA010-034 MOUNTING PLATE 1 4FA015-015 ALTERNATOR STAY 1 4FA017-021 SMOG PUMP SPACER 1 7A375-625 3/8-16 x 6-1/4" BOLTS 2 7A375-700 3/8-16 x 7" BOLT 1 7A437-175 7/16-14 x 1-3/4" BOLT 1 7A375-175 3/8-16 x 1-3/4" BOLT 1 7A375-650 3/8-16 x 6-1/2" BOLT 1 7A375-200 3/8-16 x 2" BOLT 1 7A375-075 3/8-16 x 3/4" BOLT 1 7F375-016 3/8-16 NUTS 2 7A375-100 3/8-16 x 1" BOLTS 7 7K375-040 3/8"AN960 FLAT WASHERS 5 7J375-044 3/8"SAE WASHERS 10 7J012-092 12mm FLAT WASHER 1

4FA116-011 CRANK PULLEY ASSEMBLY 1

4FA016-011 6" CRANK PULLEY 1 7A375-208 3/8-16 x 2" CAP SCREWS 4 7J375-044 3/8"SAE WASHERS 4 2A046-527 BELT 1

009035 V-3 OIL LUBE PACKET 1

vi

1986-1993 High-Output Mustang

®

Part No. 4FA218-040SQ

ENGINEERING, LLC

PARTS LIST

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

PART NUMBER DESCRIPTION QUANTITY

2E428-010 SUPERCHARGER ASSEMBLY 1

2E128-010 V-2 SUPERCHARGER 1 2E038-333 8-GR 3.33" SUPERCHARGER DRIVE PULLEY 1 8R101-002 8 & 10-RIB PULLEY RETAINER ASSEMBLY 1

4FA111-021 MOUNTING BRACKET ASSEMBLY 1

4FA011-021 MOUNTING BRACKET 1 4FA010-034 MOUNTING PLATE 1 4FA015-015 ALTERNATOR STAY 1 4FA017-021 SMOG PUMP SPACER 1 7A375-625 3/8-16 x 6-1/4" BOLTS 2 7A375-700 3/8-16 x 7" BOLT 1 7A437-175 7/16-14 x 1-3/4" BOLT 1 7A375-175 3/8-16 x 1-3/4" BOLT 1 7A375-650 3/8-16 x 6-1/2" BOLT 1 7A375-200 3/8-16 x 2" BOLT 1 7A375-075 3/8-16 x 3/4" BOLT 1 7F375-016 3/8-16 NUTS 2 7A375-100 3/8-16 x 1" BOLTS 7 7K375-040 3/8"AN960 FLAT WASHERS 5 7J375-044 3/8"SAE WASHERS 10 7J012-092 12mm FLAT WASHER 1

4FA110-011 SPRING TENSIONER 1 MOUNTING ASSEMBLY

4FA010-011 TENSIONER MOUNTING BRACKET 1 7A375-100 3/8-16 x 1" BOLTS 2 7J375-044 3/8"SAE WASHERS 2 7F375-016 3/8-16 NUT 1 7A500-350 1/2-13 x 3-1/2" CARRIAGE BOLT 1 7F500-013 1/2-13 HEX NUT 1 7J012-092 12mm FLAT WASHER 1

4FA111-042 SUPERCHARGER 1 BELT TENSIONER ASSEMBLY

7J012-092 12mm FLAT WASHERS 3 4FA011-032 BELT TENSIONER PLATE 1 7C012-020 12mm x 1.75" x 20mm BOLTS 3 7G010-175 12mm x 1.75" NUT 1 4FA016-170 WIDE IDLER PULLEY 1 2A017-011 8-RIB IDLER SPACER 1 7C012-065 12mm x 1.75" x 65mm BOLT 1

4FA116-041 CRANK PULLEY ASSEMBLY 1

4FA018-021 8-GR 6.0/6.87 CRANK PULLEY 1 7A375-178 3/8-16 x 1-3/4" BOLTS 4 7J375-044 3/8"SAE WASHERS 4 7L375-075 3/8" LOCK WASHERS 4 2A048-545 BELT 1

4FA238-068 FMU (WITH LINES) 1

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

4FA130-026 OIL FEED ASSEMBLY 1

7P525-067 .500" CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4" HOSE BARB FITTINGS 2 7P125-027 1/8" STRAIGHT FITTING 1 7P125-103 1/8"NPT -4 x 45° MALE ELBOW 1 7U030-026 1/4" x 25" OIL FEED HOSE 1 7P250-121 3" NIPPLE 1 7P250-122 1/4" TEE 1 7P250-075 45° ELBOW 1 7P250-082 90° FLARE 1

PART NUMBER DESCRIPTION QUANTITY

4FA130-036 OIL DRAIN ASSEMBLY 1

7R001-008 #8 STAINLESS HOSE CLAMPS 2 7P375-017 3/8"NPT x 1/2" STRAIGHT HOSE BARB 1 7U030-036 1/2" x 28" OIL DRAIN HOSE 1

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

4FA114-023 RADIATOR HOSE ASSEMBLY 1

4FA014-011 RADIATOR PIPE 1 7R002-024 #24 HOSE CLAMPS 2

5A101-001 STAND ALONE ASSEMBLY 1

7P156-082 5/32" TEE 1 5A002-002 FORD EFI WIRING HARNESS 1 5A001-001 STAND ALONE IGNITION RETARD 1 7U030-046 5/32" x 24" VACUUM LINE 1

4FA112-030 DISCHARGE ASSEMBLY 1

4FA012-030 ALUMINUM DISCHARGE TUBE 1 7S275-200 2-3/4" x 2" SLEEVE 1 7S300-200 3" x 2" SLEEVE 1 7R002-044 #44 HOSE CLAMPS 2 7R002-048 #48 HOSE CLAMPS 2 8D001-001 BYPASS VALVE 1 7P750-100 3/4"NPT x 1” STRAIGHT HOSE FITTING 1 7U134-145 1" x 4-1/2" HEATER HOSE 1 7U134-130 1" x 3" HEATER HOSE 1 7R002-016 #16 HOSE CLAMPS 4 7P156-082 5/32" TEE 1 7U030-046 5/32" x 24" VACUUM LINE 1

4FA112-015 AIR INTAKE ASSEMBLY 1

7S350-200 3-1/2" x 2" SLEEVE 1 4FA012-013 90° INTAKE ELBOW 1 4FA013-010 AIR CLEANER COVER 1 8H040-040 AIR FILTER 1 7J006-093 6mm WASHERS 2 7P375-097 3/8"NPT x 3/8" BARB 1 7S300-100 3" x 1" SLEEVE 1 7E010-046 #8 x 3/4" SHEET METAL SCREWS 2 7R002-056 #56 HOSE CLAMPS 2 7U035-000 3-1/2" x 12" FLEX HOSE 1 7R002-052 #52 HOSE CLAMPS 2 7P750-102 3/4"NPT x 1" 90° HOSE FITTING 1

8F201-265 T-REX® PUMP ASSEMBLY 1

7F008-032 8-32 HEX LOCK NUTS 8 7J008-001 #8 FLAT WASHERS 8 7P312-003 5/16" FEMALE FUEL CONNECTORS 2 7P312-001 FORD FUEL FITTING ADAPTER 1 7R004-002 17.0 STEPLESS CLAMPS 2 7R004-001 15.7 STEPLESS CLAMPS 3 7R001-004 #4 HOSE CLAMPS 2 7U314-001 #8 LORD MOUNTS 4 5W001-001 WIRE TAP 1 7U032-016 3/8" x 6" FUEL HOSE 1 7E010-050 #12 x 1/2" SHEET METAL SCREW 1 7U375-135 ADHESIVE MOUNTING PADS 4 7U100-055 6" NYLON TIE-WRAPS 6 4FA020-030 T-REX PUMP TEMPLATE 1 8F101-200 T-REX WIRING ASSEMBLY 1 7U031-018 5/16" x 24" HP FUEL HOSE 1 8F002-265 90° T-REX INLINE FUEL PUMP 1 5W001-010 16-14GA FEMALE SLIDE 1 5W001-002 FUSE TAP 1 5W001-011 16-14GA EYELETS 2 7U100-044 4" NYLON TIE-WRAPS 4 7U031-018 5/16" " 30" MPI HOSE 1

vii

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

1986-1993 High-Output Mustang

®

Part No. 4FA218-040L/048L

ENGINEERING, LLC

PARTS LIST

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

PART NUMBER DESCRIPTION QUANTITY

2F328-010 V3-SI SUPERCHARGER ASSEMBLY 1

2E038-333 8-GR 3.33" SUPERCHARGER DRIVE PULLEY 1 8R101-002 8 & 10-RIB PULLEY RETAINER ASSEMBLY 1

4FA111-021 MOUNTING BRACKET ASSEMBLY 1

4FA011-021 MOUNTING BRACKET 1 4FA010-034 MOUNTING PLATE 1 4FA015-015 ALTERNATOR STAY 1 4FA017-021 SMOG PUMP SPACER 1 7A375-625 3/8-16 x 6-1/4" BOLTS 2 7A375-700 3/8-16 x 7" BOLT 1 7A437-175 7/16-14 x 1-3/4" BOLT 1 7A375-175 3/8-16 x 1-3/4" BOLT 1 7A375-650 3/8-16 x 6-1/2" BOLT 1 7A375-200 3/8-16 x 2" BOLT 1 7A375-075 3/8-16 x 3/4" BOLT 1 7F375-016 3/8-16 NUTS 2 7A375-100 3/8-16 x 1" BOLTS 7 7K375-040 3/8"AN960 FLAT WASHERS 5 7J375-044 3/8"SAE WASHERS 10 7J012-092 12mm FLAT WASHER 1

4FA110-011 SPRING TENSIONER 1 MOUNTING ASSEMBLY

4FA010-011 TENSIONER MOUNTING BRACKET 1 7A375-100 3/8-16 x 1" BOLTS 2 7J375-044 3/8"SAE WASHERS 2 7F375-016 3/8-16 NUT 1 7A500-350 1/2-13 x 3-1/2" CARRIAGE BOLT 1 7F500-013 1/2-13 HEX NUT 1 7J012-092 12mm FLAT WASHER 1

4FA111-042 SUPERCHARGER 1 BELT TENSIONER ASSEMBLY

7J012-092 12mm FLAT WASHERS 3 4FA011-032 BELT TENSIONER PLATE 1 7C012-020 12mm x 1.75" x 20mm BOLTS 3 7G010-175 12mm x 1.75" NUT 1 4FA016-170 WIDE IDLER PULLEY 1 2A017-011 8-RIB IDLER SPACER 1 7C012-065 12mm x 1.75" x 65mm BOLT 1

4FA116-041 CRANK PULLEY ASSEMBLY 1

4FA018-021 8-GR 6.0/6.87 CRANK PULLEY 1 7A375-178 3/8-16 x 1-3/4" BOLTS 4 7J375-044 3/8"SAE WASHERS 4 7L375-075 3/8" LOCK WASHERS 4 2A048-545 BELT 1

4FA238-068 FMU (WITH LINES) 1

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

4FA114-023 RADIATOR HOSE ASSEMBLY 1

4FA014-011 RADIATOR PIPE 1 7R002-024 #24 HOSE CLAMPS 2

5A101-001 STAND ALONE ASSEMBLY 1

7P156-082 5/32" TEE 1 5A002-002 FORD EFI WIRING HARNESS 1 5A001-001 STAND ALONE IGNITION RETARD 1 7U030-046 5/32" x 24" VACUUM LINE 1

4FA112-030 DISCHARGE ASSEMBLY 1

4FA012-030 ALUMINUM DISCHARGE TUBE 1 7S275-200 2-3/4" x 2" SLEEVE 1 7S300-200 3" x 2" SLEEVE 1 7R002-044 #44 HOSE CLAMPS 2 7R002-048 #48 HOSE CLAMPS 2 8D001-001 BYPASS VALVE 1 7P750-100 3/4"NPT x 1” STRAIGHT HOSE FITTING 1 7U134-145 1" x 4-1/2" HEATER HOSE 1 7U134-130 1" x 3" HEATER HOSE 1 7R002-016 #16 HOSE CLAMPS 4 7P156-082 5/32" TEE 1 7U030-046 5/32" x 24" VACUUM LINE 1

4FA112-015 AIR INTAKE ASSEMBLY 1

7S350-200 3-1/2" x 2" SLEEVE 1 4FA012-013 90° INTAKE ELBOW 1 4FA013-010 AIR CLEANER COVER 1 8H040-040 AIR FILTER 1 7J006-093 6mm WASHERS 2 7P375-097 3/8"NPT x 3/8" BARB 1 7S300-100 3" x 1" SLEEVE 1 7E010-046 #8 x 3/4" SHEET METAL SCREWS 2 7R002-056 #56 HOSE CLAMPS 2 7U035-000 3-1/2" x 12" FLEX HOSE 1 7R002-052 #52 HOSE CLAMPS 2 7P750-102 3/4"NPT x 1" 90° HOSE FITTING 1

8F201-265 T-REX® PUMP ASSEMBLY 1

7F008-032 8-32 HEX LOCK NUTS 8 7J008-001 #8 FLAT WASHERS 8 7P312-003 5/16" FEMALE FUEL CONNECTORS 2 7P312-001 FORD FUEL FITTING ADAPTER 1 7R004-002 17.0 STEPLESS CLAMPS 2 7R004-001 15.7 STEPLESS CLAMPS 3 7R001-004 #4 HOSE CLAMPS 2 7U314-001 #8 LORD MOUNTS 4 5W001-001 WIRE TAP 1 7U032-016 3/8" x 6" FUEL HOSE 1 7E010-050 #12 x 1/2" SHEET METAL SCREW 1 7U375-135 ADHESIVE MOUNTING PADS 4 7U100-055 6" NYLON TIE-WRAPS 6 4FA020-030 T-REX PUMP TEMPLATE 1 8F101-200 T-REX WIRING ASSEMBLY 1 7U031-018 5/16" x 24" HP FUEL HOSE 1 8F002-265 90° T-REX INLINE FUEL PUMP 1 5W001-010 16-14GA FEMALE SLIDE 1 5W001-002 FUSE TAP 1 5W001-011 16-14GA EYELETS 2 7U100-044 4" NYLON TIE-WRAPS 4 7U031-018 5/16" " 30" MPI HOSE 1 009035 LUBE ASSY 1

viii

1986-1993 Renegade Mustang

®

Part No. 4FA218-100

ENGINEERING, LLC

PARTS LIST

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

PART NUMBER DESCRIPTION QUANTITY

2A258-010 SUPERCHARGER ASSEMBLY 1

4FA111-021 MOUNTING BRACKET ASSEMBLY 1

4FA011-021 MOUNTING BRACKET 1 4FA010-034 MOUNTING PLATE 1 4FA015-015 ALTERNATOR STAY 1 4FA017-021 SMOG PUMP SPACER 1 7A375-625 3/8-16 x 6-1/4" BOLTS 2 7A375-700 3/8-16 x 7" BOLT 1 7A437-175 7/16-14 x 1-3/4" BOLT 1 7A375-175 3/8-16 x 1-3/4" BOLT 1 7A375-650 3/8-16 " 6-1/2" BOLT 1 7A375-200 3/8-16 x 2" BOLT 1 7A375-075 3/8-16 x 3/4" BOLT 1 7F375-016 3/8-16 NUTS 2 7A375-100 3/8-16 x 1" BOLTS 7 7K375-040 3/8"AN960 FLAT WASHERS 5 7J375-044 3/8"SAE WASHERS 10 7J012-092 12mm FLAT WASHER 1

4FA110-011 SPRING TENSIONER 1 MOUNTING ASSEMBLY

4FA010-011 TENSIONER MOUNTING BRACKET 1 7A375-100 3/8-16 x 1" BOLTS 2 7J375-044 3/8"SAE WASHERS 2 7F375-016 3/8-16 NUT 1 7A500-350 1/2-13 x 3-1/2" CARRIAGE BOLT 1 7F500-013 1/2-13 HEX NUT 1 7J012-092 12mm FLAT WASHER 1

4FA130-026 OIL FEED ASSEMBLY 1

7P525-067 .500" CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4" HOSE BARB FITTINGS 2 7P125-027 1/8" STRAIGHT FITTING 1 7P125-103 1/8"NPT -4 x 45° MALE ELBOW 1 7U030-026 1/4" x 25" OIL FEED HOSE 1 7P250-121 3" NIPPLE 1 7P250-122 1/4" TEE 1 7P250-075 45° ELBOW 1 7P250-082 90° FLARE 1

4FA130-036 OIL DRAIN ASSEMBLY 1

7R001-008 #8 STAINLESS HOSE CLAMPS 2 7P375-017 3/8"NPT x 1/2" STRAIGHT HOSE BARB 1 7U030-036 1/2” x 28" OIL DRAIN HOSE 1

4FA112-070 AIR INLET ASSEMBLY 1

4FA112-060 4" INLET DUCT WITH BUNG 1 7S400-200 4" x 2" SLEEVE 2 7R002-064 #64 HOSE CLAMP 4 7S00-325 2" x 3.25" SLEEVE 1 7R002-032 #32 HOSE CLAMP 2

4FA114-023 RADIATOR HOSE ASSEMBLY 1

4FA014-011 RADIATOR PIPE 1 7R002-024 #24 HOSE CLAMPS 2

PART NUMBER DESCRIPTION QUANTITY

8E018-300 PULLEY PACKAGE, RENEGADE 1

2A038-300 SUPERCHARGER PULLEY 3" 8 GROOVE 1 7A375-158 3/8-16 x 1.5" SOC HD 4 7K375-040 3/8" WASHER 4 7L375-075 3/8" LOCK WASHER 4 4FA018-027 8" 8-GV CRANK PULLEY 1 8R101-002 PULLEY RETAINER ASSY, 8-RIB 1 4FA1110042 S/C BELT TENSIONER ASSY, H.O. 1 2A048-565 BELT 1

4FA212-050 V-7 DISCHARGE WITH BYPASS 1

7S003-200 3" x 2" SLEEVE 1 7S300-275 REDUCER, 3.00" - 2.75" 1 7R002-052 #52 HOSE CLAMP 2 7R002-048 #48 HOSE CLAMP 2 8D103-001 MAXFLOW MONDO BYPASS VALVE 1 4FA012-041 DISCHARGE TUBE, RACE 1 7S325-200 3.25" x 2" SLEEVE 1

ix

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

1986-1993 5.0 S.H.O. V-7 Mustang

®

Part No. 4FA218-200

ENGINEERING, LLC

PARTS LIST

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

PART NUMBER DESCRIPTION QUANTITY

2A258-020 SUPERCHARGER, YSI, 3.33" 10-RIB 1

4FA111-031 MNTG BRCKT ASSY, S.H.O. 1

4FA010-045 ALUM. MTG PLATE, BILLET 5.0 1 4FA011-021 MOUNTING BRACKET 1 4FA015-015 ALTERNATOR STAY-PLATED 1 4FA017-021 SPACER, SMOG PUMP 1 7A375-075 3/8-16 x 3/4" GR5 HXHD 1 7A375-100 3/8-16 x G5 HXHD PLT 8 7A375-175 3/8-16 x 1-3/4 HXHD 1 7A375-200 3/8-16 x 2 GR5 PLTD 1 7A375-625 3/8-16 x 6-1/4 HXHD 2 7A375-675 3/8-16 x 6.75" HXHD GR8 ZINC 1 7A375-751 3/8-16 x 7.5" HXHD GR8 ZINC 1 7A437-175 7/16-14 x 1-3/4" HXHD 1 7F375-016 3/8-16 HX NUT 2 7J012-092 12mm WASHER, FLAT 1 7J375-044 3/8"SAE WASHER, PLTD 6 7K375-040 3/8"AN960 FLAT WASHER 12

4FA116-150 CRK PLY ASSY, 10RIB V-7 KIT 1

7B375-150 3/8-24 x 1-1/2" GR8 HX 1 7A375-178 3/8-16 x 1-3/4" HXHD G8 4 7J375-044 3/8"SAE WASHER, PLTD 4 7L375-075 3/8 LOCK WASHER 4 2A041-545 BELT, CUSTOM 545, 10-RIB SERP 1 4FA018-023 4.75/6.87 10-GR CKPLY 1 4FA017-051 FAN SPACER 5.0" 1 7U313-021 5/16-24 x 1.5" STUD 4 7F312-021 5/16-24 NUT 4 7J312-000 5/16" FLAT WASHER-SAE 4

4FA238-068 FMU 12:1 W/LINES 1

6Z110-111 FUEL MGMT UNIT, 12:1 1 4FA145-010 FUEL LINE 5.0-MALE 1 4FA145-020 FUEL LINE 5.0-FEMALE 1 7U030-046 5/32" VACUUM LINE 4.5 7U100-055 TIE-WRAP, 6" NYLON 2

4FA130-027 OIL FEED ASSEMBLY 1

7P125-027 FITTING, STRGT, 1/8"NPT 1 7P125-103 -4 x 45° FITTING 1 70000 INSPECTOR NUMBER 0 7P250-121 1/4"NPT STEEL NIPPLE 1 7P250-122 1/4" PIPE THRD AN917 TEE 1 7P250-075 1/4"NPT 45° STRT ELBOW 1 7P250-082 1/4"NPT x -4 90° FITTING 1 4FA145-030 OIL FEED HOSE ASSY 5.0 86-93 1

4FA130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2" OIL DRAIN HOSE x 28" 1 7P375-017 3/8"NPT x 1/2" HOSE BARB 1 7R001-008 #8 STNLS HOSE CLAMP 2

4FA114-011 RADIATOR HOSE ASSEMBLY 1

4FA014-011 RADIATOR PIPE-POLISHED 1 7R002-024 #24 GOLDSEAL HOSE CLAMP 2

PART NUMBER DESCRIPTION QUANTITY

4FA112-090 DISCH. ASSY S.H.O. V-7 KIT-SATIN 1

4FA012-041 DISCHARGE TUBE, RACE 1 7S300-200 3" x 2" SLEEVE 1 7S325-200 3.25" x 2" SLEEVE 1 7R002-052 #52 GOLDSEAL HOSE CLAMP 2 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 8D204-001 MAXFLOW RACE BYPASS 1 7P250-030 1/4" BARBED MALE TEE 1 7U030-030 1/4" VACUUM HOSE 2'

4FA112-080 4" AIR INLET ASSY, 5.0 S.H.O. 1

4FA112-080 4" ELBOW, W/BUNG 1 7S400-200 4" x 2" SLEEVE 1 7R002-064 #64 GOLDSEAL HOSE CLAMP 2 7S175-400 Ø1.75" x 4" SLEEVE 1 7R002-028 #28 GOLDSEAL HOSE CLAMP 2 7U030-056 3/8" PCV HOSE x 1.5" 1 7P250-047 1/4"NPT TO 3/8" BARB 90° 1

8F201-265 T-REX PMP ASSY, 86-93 5.0 1

5W001-001 WIRE TAP 1 5W001-002 FUSE TAP 1 5W001-040 12-10GA FEMALE SLIDE 1 5W001-042 12-10GA 3/16" RING TERMINAL 2 4FA020-030 TEMPLATE, T-REX PUMP 0 7E010-050 #12 x 1/2" SHEET METAL SCREW 1 7F008-032 8-32 HEX LOCK NUT 8 7J008-001 #8 FLAT WASHER 8 7P312-001 ADAPTER, FUEL FITTING 1 7P312-003 5/16" FEMALE FUEL 2 7R001-004 #4 HOSE CLAMP 2 7R004-003 14.5 STEPLESS CLAMP 3 7R004-002 17.0 STEPLESS CLAMP 2 7U100-044 TIE-WRAP, 4" NYLON 4 7U100-055 TIE-WRAP, 6" NYLON 6 7U031-018 5/16" FUEL HOSE HI-PSR x 2" 1 7U031-018 5/16" FUEL HOSE HI-PSR x 2.5" 2.1 7U032-016 3/8" FUEL HOSE HI-PSR x 6" .1 7U314-001 #8 LORD MOUNTS 4 7U375-135 ADHES MTNG PAD 4 8F002-265 T-REX FUEL PUMP-INLINE 90° 1 8F101-200 T-REX WIRING ASSY MUSTANG 1 5W001-014 FUSE HOLDER 10GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-019 SOLDERLESS CONNECTOR 10-12 1

8F110-011 SPRING TENS. MOUNT 1

4FA010-011 TENS. BRKT.-MACH 1 7A375-100 3/8-16 x 1" G5 HXHD PLT 2 7A500-350 1/2-13 x 3-1/2" CARRIAGE 1 7F375-016 3/8-16 HEX NUT 1 7F500-013 1/2-13 HEX NUT 1 7J012--92 12mm WASHER, FLAT 1 7J375-044 3/8"SAE WASHER, PLTD 3

x

1986-1993 5.0 S.H.O. V-7 Mustang, cont'd.

®

Part No. 4FA218-200

ENGINEERING, LLC

PARTS LIST

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

PART NUMBER DESCRIPTION QUANTITY

4FA111-062 S/C BELT TENSNR ASSY, S.H.O. 1

4FA011-042 BELT TENSIONER PLATE 1 2A017-012 SPACER, 10-RIB IDLER 1 7C012-065 12mm x 1.75" x 20mm PLD 3 7C012-065 12mm x 1.75" x 65mm HX 1 7G010-175 12mm x 1.75" NUT 1 7J012-092 12mm WASHER, FLAT 3 4FA016-171 DUST COVER (WIDE IDLER) 1 4FA016-170 IDLER PULLEY, WIDE 1

8H140-000 FENDER MOUNT MAF KIT 86-93 1

8H040-030 AIR FILTER 3-1/2" CYL 1 7S350-300 3-1/2" x 3" SLEEVE 1 7S350-200 3-1/2" x 2" SLEEVE 1 4FA012-012 INTAKE ELBOW, 90° 2 7R002-056 #56 GOLDSEAL HOSE CLP 4 7C060-016 M6 x 1.00" x 16 HXHD 3 7J006-093 6mm WASHER, PLATED 3 5W001-007 3/16" HEAT-SHRINK TUBE .666' 5W018-020 18GA STRD WIRE BLK 1' 5W018-010 18GA STRD WIRE RED 1' 5W018-060 18GA STRD WIRE ORANGE 1' 5W018-070 18GA STRD WIRE GREEN 1' 4FA020-020 TEMPLATE, MASS AIR 0 7U035-001 3-1/2" FLEX HOSE 1

2A046-888 BELT, K060888 1

xi

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

SPECIAL NOTICE CONCERNING THE

MSD IGNITION SYSTEM

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 verication. 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 modications.

Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Inc. directly at (805) 247-0226.

xii

NEW ADDITIONAL PULLEY

BOLTS: 3/8-16x2"

RENEGADE/HIGH-OUTPUT PULLEY

STANDARD PULLEY

HIGH-OUTPUT BOLTS:

3/8-16x2-3/4"

RENEGADE BOLTS:

3/8-16x1-1/2"

1. PREPARATION/REMOVAL

FRAME

RELOCATED EVAPORATIVE CANISTER ASSY.

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.

1

Fig. 2-a

Fig. 2-b

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

3. OIL DRAIN (Engine oil fed kits only. V3 kits, skip

ENGINE BLOCK

1/2” REAR FROM FIRST BOLT ON SIDE

FRONT

1-3/4”

BELOW

PAN LIP

3” NIPPLE

1/4” TEE

45°ELBOW

ahead to section 5)

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 oroce, 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.

Fig. 4-a

2

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/R S/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.

Fig. 5-b

Fig. 5-c

3

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

5.1 FUEL MANAGEMENT UNIT RECALIBRATION

(For Cobra models or vehicles equipped with 24

lb. injectors only.)

WARNING: Do not remove the four screws

holding the valve body. Once taken apart, the valve would have to be replaced.

A. Remove the six allen head screws on top of

the fuel management unit (FMU). (See Fig. 4-e.)

B. Remove the diaphragm and disk (and the ring,

if equipped) from inside of the FMU.

C. Install replacement ring (with the notched part

facing down) around the four screws inside the FMU.

D. Place the new disk inside the ring on top of

the piston.

E. Install the new diaphragm and carefully line

up holes to the body.

F. Reinstall the FMU cover with the six allen head

screws. Do not overtighten the screws. The correct torque is 24 in/lbs (2 ft/lbs).

Fig. 5.1-e / FMU

4

6. T-REX® FUEL PUMP (H.O., S.H.O. and Cobra Systems Only)

ADAPTER FITTING

3/8”x6” FUEL HOSE

RELAY #87

GROUND

5/16”x24” FUEL HOSE

EXISITING FUEL LINE

STOCK FUEL FILTER

RETURN

REPLACE THE FACTORY FEED LINE WITH THE VORTECH SUPPLIED PIECE

FUEL

TANK

NOTE: Make sure that the fuel level is below 1/4 tank for

easier installation.

A. Remove spare tire, etc. from trunk. B. Trim "cut-out" from template and place over spare tire hold-

down. Centerpunch and drill holes 3/16" diameter.

C. Jack up the rear of the car and support with jack stands. D. Drop down the fuel tank by loosening the ller neck and the

two tank mounting straps. (There is no need to disconnect any of the wiring or to completely remove the tank.)

E. Disconnect and remove the original rubber fuel line running

from the tank to the fuel lter. Remove the 90° plastic tting from the feed hose and set aside.

F. Attach one end of the supplied fuel line with connections to

the fuel tank pickup (see below). Route the hose around to the front of the tank in the factory manner.

G. Place the Vortech supplied fuel adapter tting, located in the

T-Rex pump inlet hose, into the new feed line coming from the tank. Make sure that the white plastic retainer clip is in place.

H. Reinstall the fuel tank and ller tube. Take care to route the

fuel lines and vent lines away from exhaust pipes and provide room so that lines are not crushed between the oor pan and the tank.

T-REX FUEL PUMP ASSEMBLY

Fig. 6-a

5

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

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.

6

87

87a

30

85

86

FUSE BOX

SPARE TIRE WELL

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

.)

RELAY WIRING SCHEMATIC

SECURE WIRES WITH ADHESIVE ANCHORS AND TIE WRAPS

20A INLINE FUSE

PUMP IS MOUNTED BELOW TIRE WELL

(UNDER CAR)

SCHEMATIC (H.O., S.H.O. and Cobra systems only)

VORTECH T-REX WIRING AND PLACEMENT GUIDE

Fig. 6-a

Fig. 6-b

7

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

3/8-16x1"

MOUNTING PLATE

3/8-16X1-3/4"

7/16-14x1-3/4"

3/8-16x6-1/2"

3/8-16x7"

3/8-16x6-1/4" install from rear

ALTERNATOR

ALTERNATOR STAY

3/8-16x1"

3/8-16x3/4"

3/8-16x2"

3/8-16x61/4" install from rear place .920" spacer

SMOG PUMP

& PULLEY

3/8-16x61/4” and place .920 spacer

between plate and pump

install from rear

(6-3/4” *)

(7-1/4” *)

MOUNTING BRACKET

7. MAIN BRACKET ASSEMBLY

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.

Fig. 7-a

* V-7 application with aluminum

mounting plate requires 6-3/4" and 7-1/4" bolts.

NOTE: Remember to place the .920"

spacer between the smog pump and mounting plate.

S.H.O./RENEGADE V-7

KIT ONLY

Fig. 7-b

8

7. MAIN BRACKET ASSEMBLY (cont'd.)

SMOG PUMP

DIVERTER VALVE ALVEAIR CONTROL V

SHORTEN THIS HOSE 1-1/2”

E. Attach the Vortech alternator brace between

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 modication 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.

clamps.

line after the supercharger is in place.

9

Fig. 8-a

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

9. RADIATOR HOSE

2"

3"

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. Rell 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

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 modications.

* 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.

Fig. 13-a

11

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

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 bafed 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 bafed 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"

sleeve.

Fig. 13-b

Front View

Fig. 13-c

Right Side View

12

13. AIR FILTER ASSEMBLY, cont'd.

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.

13

Fig. 14-a

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

14. IGNITION/BOOST CONTROL INSTALLATION

BOOST

RETARD

0

1

2

3

SUPERCHARGERS

Ignition/Boost

Control

MANUFACTUREDFOR

VORTECHSUPERCHARGERS

BY

MSD

¨

BLACK

WHITE

RED

ORANGE

BLACK

WHITE

RED

ORANGE

IGNITION COIL

FROM FACTORY COIL HARNESS

MAGNETIC PICKUP CONNECTOR (NOT USED)

BOOST

RETARD

CONNECTOR

GROUND

TO MANIFOLD

VACUUM

15

10

5

5 psi at 3° per lb. 7 psi at 2° per lb.

10 psi at

1/2° per lb.

MAX. RETARD=15°

DEGREES OF RET ARD

5

7

10

PSI BOOST

(High Output and Cobra systems only) cont'd.

15. IGNITION/BOOST CONTROL UNIT OPERATION (High Output and Cobra Systems only)

A. The Ignition/Boost Control unit is designed

to retard ignition in relation to boost.

B. The unit is adjustable from 0° of ignition

retard to 3° of ignition retard for each pound of boost, up to a maximum of 15°.

C. Using the 1° per pound position as a starting

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

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

line.

15

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

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 specications 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, rell the unit with 4 oz. of Vortech V3 lubricating uid and then conrm 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.

16

17

16APR09 v4.1(86-93 5.0 Mus (4FA v4.1))

P/N: 4FA020-010

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

®

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

ENGINEERING, LLC

18