Vortech 1994-1995 Ford 5.0 Mustang User Manual

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Ford 5.0L Mustang

Supercharger System

Installation Instructions

50 SMOG STATE LEGAL PER CARB EO #D-213-17

1994-1995 MODEL YEARS

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

FOREWORD

STOP

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 call Vortech Engineering for installers in your area.

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-modified, OEM) vehicles. The

PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified 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 the 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 modifications such as, but not lim-

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

or translated into another language in any form, by any means without written permission

of Vortech Engineering, LLC.

Table Of Contents

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

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

NOTICE ............................................................................................................................................. iv

TOOL & SUPPLY REQUIREMENTS ................................................................................................ v

PARTS LIST - 94-95 HIGH OUTPUT MUSTANG .............................................................................vi

PARTS LIST - 94-95 HIGH OUTPUT MUSTANG, V-3 ......................................................................vii

MSD IGNITION SYSTEM .................................................................................................................. viii

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

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

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

4. FUEL MANAGEMENT UNIT ................................................................................................ 3

4.1 FUEL MANAGEMENT UNIT RECALIBRATION ................................................................... 4

5. FAN RELAY BOX RELOCATION .........................................................................................5

6. RADIATOR HOSE/AIR CONDITIONING LINE ..................................................................... 5

7. SMOG PUMP HOSES .......................................................................................................... 7

8. IGNITION MODULE RELOCATION ..................................................................................... 7

9. CRANKSHAFT AND WATER PUMP PULLEYS ...................................................................8

10. MAIN BRACKET AND SUPERCHARGER MOUNTING PLATE .......................................... 8

11. COOLANT HOSE REROUTING AND ENGINE COMPONENT

REASSEMBLY ......................................................................................................................9

12. MASS AIR FLOW SENSOR RELOCATION .........................................................................9

13. SUPERCHARGER MOUNTING AND ASSEMBLY, HOSE DRAIN

AND INLET DUCT ................................................................................................................10

14. ALTERNATOR AND MAIN ACCESSORY BELT INSTALLATION ......................................... 11

15. DISCHARGE DUCT INSTALLTION ......................................................................................12

16. BYPASS VALVE INSTALLATION (High Output Kit Only) ..................................................... 12

17. IGNITION/BOOST CONTROL INSTALLATION (High Output and Cobra

Systems Only) ...................................................................................................................... 13

18. T-REX FUEL PUMP INSTALLATION (High Output Systems Only) ...................................... 14

19. FINAL CHECK ......................................................................................................................16

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04NOV08 V2.0(94-95 5.0 Mus.(4FG V2.0))

P/N: 4FG020-010

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, LLC. 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.

1994-1995

FORD 5.0L MUSTANG

Installation Instructions

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

Congratulations on selecting the best performing and best backed automotive supercharger

available today... the VORTECH® V-2® Supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program, the Warranty Registration form and return envelope.

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 92 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 the problem

is resolved.

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 every 3,000 miles or less. 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 at least 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

• Timing light

• 3/8" Socket and Drive Set: SAE and metric

• 1/2" Socket and Drive Set: SAE and metric

• 3/8" and 1/2" Breaker Bars, 4" Extension

• 3/8"NPT Tap, 3/8-16 Tap and Handle

• Adjustable Wrench

• 1-1/16" Oil Sending Unit - Socket

• Ford Springlock 3/8" Fuel Fitting Disconnect Tool

or Lisle A/C and Fuel Disconnect Tool Set #37000

• Lisle Door Upholstery Remover #35400 (Lisle tools available at Sears or Trak Auto)

• 5 Quarts SF Rated Quality Engine Oil

• Oil Filter and Wrench

• Open End Wrenches: 3/8", 7/16", 1/2", 9/16"

• "Slimline" 19mm - Snap-On #LTAM1719

or Craftsman 3/4" Tappet Wrench #44474

• Center Punch and a 5/8" Tapered Punch

• Large Screwdriver or Pry Bar

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 3/32", or 5/16", 7/16" Drill Bits

• #45 Torx Bit

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

• Spark plug socket

• NEW spark plugs

04NOV08 V2.0(94-95 5.0 Mus.(4FG V2.0))

P/N: 4FG020-010

1994-95 High Output Mustang

Part No. 4FG218-020SQ

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

2e328-110 V-2 suPercharger assembly 1

4Fg111-021 mouNtiNg bracket assembly 1

4FG011-021 MOUNTING BRACKET 1 4FG010-033 MOUNTING PLATE 1 4FG015-013 ALTERNATOR STAY 1 4FG015-023 ALTERNATOR BRACKET 1 7A375-100 3/8-16 x 1" BOLTS 9 7K375-040 3/8"AN960 FLAT WASHERS 18 7L375-075 3/8" LOCK WASHERS 2 7F375-016 3/8-16 NUTS 2 7K312-001 5/16"AN WASHERS 2 7K437-001 7/16"AN WASHER 1 4FG017-011 ALTERNATOR STAY SPACER 1 4FG017-021 LOWER ALTERNATOR STAY SPACER 1 7A375-150 3/8-16 x 1-1/2" BOLTS 3 7A375-175 3/8-16 x 1-3/4" BOLT 1 7A375-224 3/8-16 x 2.25" BOLTS 3 7A437-225 7/16-14 x 2-1/4" BOLT 1 7A375-400 3/8-16 x 4" BOLT 1 7A312-100 5/16-18 x 1" BOLTS 2 4FG017-031 SMOG PUMP SPACER 1 7A375-500 3/8-16 x 5" BOLT 1 7A375-124 3/8-16 x 1-1/4" BOLT 1 4FG150-012 IGNITION MODULE RELOCATION 1 7E010-100 #12 x 1.0" SHEET METAL SCREW 1

4Fa111-042 belt teNsioNer assembly 1

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

8F202-265 t-rex® assembly 1

7F008-032 8-32 LOCK NUTS 8 7J008-001 #8 FLAT WASHERS 8 7P312-003 5/16" FEMALE FUEL CONNECTOR 1 7P312-001 FUEL FITTING ADAPTER 1 7R004-002 17.0 STEPLESS CLAMPS 2 7U314-001 #8 LORD MOUNTS 4 5W001-001 WIRE TAP 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 8F002-265 T-REX INLINE 90° 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 6 7R004-001 15.7 STEPLESS CLAMPS 3 7U032-016 3/8" x 22" FUEL HOSE 1 7U031-018 5/16" x 16.5" FUEL HOSE 1

4Fg114-023 raDiator hose assembly 1

7U133-048 5/8" MOLDED ELBOW HOSE 1 7U100-066 11" TIE-WRAPS 4 7R001-008 #8 HOSE CLAMPS 2 7R003-015 15/16" ADEL CLAMP 1

4Fg130-036 oil DraiN assembly 1

7U030-036 1/2" x 19" OIL DRAIN HOSE 1 7P375-017 3/8"NPT x 1/2" STRAIGHT HOSE BARB 1 7R001-008 #8 STAINLESS HOSE CLAMPS 2

Part Number DescriPtioN QuaNtity

4Fg112-030 Discharge assembly 1

7R002-044 #44 HOSE CLAMPS 2 7R002-048 #48 HOSE CLAMPS 2 7S275-200 2-3/4" x 2" SLEEVE 1 7S300-200 3" x 2" SLEEVE 1 7P156-082 5/32" TEE 1 7R002-016 #16 HOSE CLAMPS 4 8D001-001 BYPASS VALVE 1 7U100-055 6" NYLON TIE-WRAPS 6 7U030-046 5/32" x 36" VACUUM LINE 1 7U034-016 1" x 3.5" HEATER HOSES 2 4FG012-011 DISCHARGE DUCT 1

4Fg116-021 craNk Pulley assembly 1

4FG018-031 CRANK PULLEY 1 4FG016-081 WATER PUMP PULLEY 1 7A375-126 3/8-16 x 1.25" BOLTS 4 7J375-044 3/8"SAE WASHERS 4 7L375-075 3/8" LOCK WASHERS 4 2A046-031 ACCESSORY BELT 1 2A048-575 SUPERCHARGER BELT 1

4Fg130-026 oil FeeD assembly 1

7U030-026 1/4" x 29" OIL FEED HOSE 1 7P125-103 1/8"NPT -4 x 45° MALE ELBOW 1 7P250-066 #4 SWIVEL x 1/4" HOSE BARB FITTING 1 7P250-067 1/4" BARB TO 1/4"NPT 1 7P250-075 1/4"NPT 45° STREET ELBOW 1 7P250-122 1/4" PIPE THREAD AN917 TEE 1 7P250-123 1/4"NPT x 1-1/2" NIPPLE 1 7P525-067 .500" CRIMP FERRULES 1 7R003-003 14.5 STEPLESS CLAMP 1 5W011-008 1/2" x 24" WIRE LOOM 1

4Fg238-068 Fmu (with liNes) 1

6Z110-116 12:1 FUEL MANAGEMENT UNIT 1 4FG135-056 MALE FUEL LINE ASSEMBLY 1 4FG135-057 FEMALE FUEL LINE ASSEMBLY 1 7U030-046 5/32" x 34" VACUUM TUBE 1 7P156-082 5/32" TEE 1 7U100-055 6" NYLON TIE-WRAP 1 6Z170-040 10:1 RING SPACER ASSEMBLY 1

4Fg112-011 air iNtake assembly 1 4FG112-022 AIR INLET DUCT 1

7U035-000 3-1/2" x 10" FLEX HOSE 1 7R002-056 #56 HOSE CLAMPS 3 7R002-052 #52 HOSE CLAMP 1 8H040-030 AIR FILTER 1 7A250-101 1/4-20 x 1" CAP SCREWS 4 7J250-001 1/4"SAE WASHERS 8 7F250-021 1/4-20 NYLOCK NUTS 4 7S325-100 3.25" x 1" SLEEVE 1 7P375-050 3/8" HOSEMENDER 1 7U030-056 3/8" x 1" PVC HOSE 1 7P250-045 1/4"NPT x 3/8" FITTING 1 4FA012-012 90° INTAKE ELBOW 1 7S350-200 3-1/2" x 2" SLEEVE 1 5W122-025 12" 22GA GREY WIRE 1 5W122-026 12" 22GA BLACK WIRE 1 4FG110-050 MAF BRACKET ASSEMBLY 1 5W001-087 3/16" x 8" SHRINK TUBE 1

5a101-003 staND aloNe assembly 1

7P156-082 5/32" TEE 1 5A002-002 WIRING HARNESS 1 5A001-001 STAND ALONE IGNITION RETARD 1 7U030-046 5/32" x 36" VACUUM LINE 1 7U375-001 2' x 5" VELCRO-HOOK 1 7U375-002 2' x 5" VELCRO-LATCH 1 5W001-009 16-14GA MALE SLIDE 1

1994-95 High Output Mustang, V-3

Part No. 4FG218-020L

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

2F328-050 V-3 suPercharger assembly 1

4Fg111-021 mouNtiNg bracket assembly 1

4Fa111-042 belt teNsioNer assembly 1

8F202-265 t-rex® assembly 1

4Fg114-023 raDiator hose assembly 1

7U133-048 5/8" MOLDED ELBOW HOSE 1 7U100-066 11" TIE-WRAPS 4 7R001-008 #8 HOSE CLAMPS 2 7R003-015 15/16" ADEL CLAMP 1

Part Number DescriPtioN QuaNtity

4Fg112-030 Discharge assembly 1

4Fg116-021 craNk Pulley assembly 1

4Fg238-068 Fmu (with liNes) 1

4Fg112-011 air iNtake assembly 1 4FG112-022 AIR INLET DUCT 1

5a101-003 staND aloNe assembly 1

4Fg112-011 air iNtake assembly 1

009035 V-3 lube 1

vii

04NOV08 V2.0(94-95 5.0 Mus.(4FG V2.0))

P/N: 4FG020-010

SPECIAL NOTICE CONCERNING THE

MSD IGNITION SYSTEM

The MSD Boost Timing Master, manufactured by Autotronic Controls Corporation, 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 date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Autotronic Controls Corporation and/or Vortech Engineering, LLC. 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, LLC, 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

This Page Left Intentionally Blank

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, LLC, directly at (805) 247-0226.

viii

+ 16 hidden pages

Vortech 1994-1995 Ford 5.0 Mustang User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual