Vortech 1994-1995 Ford 5.0 Mustang User Manual

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.

ii

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

iii

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.

iv

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

v

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

vi

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

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

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

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

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

FIREWALL

REMOVE HOSE

FROM

TEMPERATURE

SENDER/INTAKE

MANIFOLD

FROM WATER HOSE

VALVE COVER

(RIGHT SIDE)

WATER TUBE LEADING TO FIREWALL

WATER NECK

REMOVE HOSE

WATER

PUMP

1. PREPARATION/REMOVAL

A. Disconnect the battery negative cable. B. Remove all of the components that lead to the

throttle body including the mass air ow (MAF) sensor, air lter assembly and rubber bellows. Separate the MAF sensor from the air lter assembly and set aside.

C. Remove the air temperature sensor from the bel-

lows.

D. Loosen the crank pulley and water pump pulley

bolts. E. Remove the accessory belt. F. Remove the relay box that is mounted next to

the radiator recovery tank. Carefully remove the

electrical plug and set aside. G. Remove the water pump pulley. H. Drain approximately one gallon of coolant from the

radiator. Remove the upper radiator hose and set

aside. I. Remove the belt tensioner assembly. J. Unplug the wire connections and remove the

alternator assembly (make sure the battery is

disconnected). K. Remove the smog pump hoses from the smog

pump. L. Remove the smog pump and alternator brackets

with the smog pump still attached. M. Remove the smog pump from the bracket. N. Remove the 5/8" heater hose that runs from the

water pump to the manifold tube assembly, next

to the water temperature sender (see Fig. 1-a). O. Remove the distributor shield and the passenger

side spark plug wires at the distributor and set

aside. P. Disconnect the water temperature sensor plug. Q. Carefully cut the steel tube that runs along the

intake manifold (the tube where the hose was pre-

viously removed). Remove approximately 3-1/4"

and discard the cut off piece (see Fig. 1-b). R. Remove the radiator cover by using a Lisle door up-

holstery remover tool and a phillips screwdriver. S. For component clearance, it is necessary to remove

the air conditioning line clamps on the frame and

tuck the hose on top of the frame rail. T. Remove the "S" shaped coolant hose that runs

from the rewall to the steel tube above the in-

take manifold that was previously shortened (see

Fig. 1-c).

NOTE: Refer to your Mustang Owner's Guide for

helpful illustrations and descriptions of particular components.

Fig. 1-a

MODIFIED WATER

TUBE END

Fig. 1-b

Fig. 1-c

1

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

P/N: 4FG020-010

SENDER

1/4” NPT x 45o ELBOW

1/4” NPT x -4

1/4” NPT TEE

1/4” NPT TEE 10 O’CLOCK POSITION

1/4” x 45o ELBOW

SENDER

1/4” NPT x 45o ELBOW

1/4” NPT x -4

OIL PRESSURE SENDER BOSS

1/4” NPT NIPPLE

1/4” NPT TEE

ENGINE BLOCK

2. OIL FEED LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGERS SKIP AHEAD TO STEP 4)

A. Remove the oil lter for access to the oil pres-

sure sender. Remove the oil pressure sender and install the tee tting so that it points up and forward, towards the radiator at the 10 o' clock position.

B. Install 45° elbow into the end of the tee tting

positioned as shown in the graphic. Reinstall the oil pressure sending unit and wiring.

C. Thread the oil feed line onto the TEE and route

towards the engine oil ll port.

D. Fit a 24" length of the 1/2" ex loom onto the oil

line for abrasion protection.

NOTE: Cover the end of the tting with a plastic bag

to keep debris from entering the system.

WARNING: DO NOT use any sealant or sealing

tape on oil feed lines. Use ONLY engine oil on oil line threads or damage to the supercharger is possible and the warranty will be void!

Fig. 2-a / Front View

Fig. 2-b / Driver's Side View

2

FRONT

1/2" REAR FROM FIRST BOLT ON SIDE

1-1/4"

BELOW

PAN LIP

ENGINE BLOCK

PAN

FIREWALL

STOCK

FUEL

RETURN

FITTING

FMU

SHOCK TOWER

FRONT

3. OIL DRAIN (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGERS SKIP AHEAD TO STEP 4)

A. To provide an oil drain for the supercharger, it is

necessary to make a hole in the oil pan. Locate and mark hole as 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 the 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 approximately

1/4" 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

and thread in the oil drain assembly. 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. FUEL MANAGEMENT UNIT

A. Disconnect the fuel rail return line behind the shock

tower and at the manifold fuel rail with spring lock disconnect tool. Remove the fuel line. The return line does not have a pressure test tting on it. (It is the smaller of the two lines).

B. Attach the supplied 14" fuel line to the center tting

on the management unit (FMU). Mount the FMU against the passenger side inner fender panel in between the shock tower and the rewall using sheet metal screws. Coil the units 14" return line upward, forming a loop back down to the stock return line. (See Fig. 4-a.)

C. Connect the FMU input hose from the tting on

D. Using the stock hose mount on the shock tower,

the side of the FMU to the return line coming from the fuel rail regulator tting as shown in Figs. 4-b, 4-c on the following page.

secure the fuel lines away from the exhaust manifold with the tie wraps provided.

3

Fig. 4-a

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

P/N: 4FG020-010

4. FUEL MANAGEMENT UNIT, cont'd.

3-1/2"

VACUUM TREE

LOCATED ON INTAKE

MANIFOLD

28"

3"

FACTORY FUEL

REGULATOR

CONNECT TO MANIFOLD VACUUM/PRESSURE

INLET (FUEL LINE FROM STOCK REGULATOR)

OUTLET

(FUEL FROM HERE

RETURNS TO TANK)

FUEL FEED LINE

FUEL RETURN LINE

ON FIREWALL

FUEL

MANAGEMENT

UNIT (FMU)

T-REX HIGH-

OUTPUT ONLY

NEW FUEL FITTING

FUEL TANK

FUEL

PUMP

FILTER

ENGINE

E. Attach the 5/32" vacuum hose assembly to

the vacuum tree on the intake manifold (see Fig. 4-d). The assembly will form a TEE in between the tree and the fuel regulator.

F. Route the assembly to the tting on top of

the FMU.

NOTE: Make sure all connections are sealed

properly with the cable ties provided to avoid vacuum leaks.

G. Reuse the fuel retainer clips from the stock

return fuel line at the manifold.

Fig. 4-b

Fig. 4-d

4.1 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.

4

Fig. 4-c

Fig. 4-e / FMU

4.1 FUEL MANAGEMENT UNIT RECALIBRATION, cont'd.

1/2”

PLASTIC RADIATOR COVER

2”

DRILL 1/4" HOLES 5/8" BACK FROM EXISTING HOLES

5/8"

1/2"

REMOVE 1/2"

1-1/4"

RADIATOR

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).

5. FAN RELAY BOX RELOCATION

A. Modify the relay mount by removing 1/2"

from the front end of the bracket that mounts to the radiator core support. Mark and drill two 1/4" holes located 5/8" towards the back of the original mounting holes (see Fig. 5-a).

B. Trim a 2" x 1/2" section off of the plastic ra-

diator cover piece to clear repositioned relay (see Fig. 5-b). Align relay and shroud.

C. Reroute the electrical fan and coolant

overow wiring underneath the fan relay processor bracket for belt clearance.

Fig. 5-a

6. RADIATOR HOSE/AIR CONDITIONING LINE

A. Trim 1-1/4" of hose from the radiator end of the

upper radiator hose (straight portion) (see Fig. 6-a).

B. Remove the air conditioning line support clamps

near the radiator outlet so that the air conditioning lines may be bent. Reconnect the mounting tabs.

C. Slightly bend the high pressure air conditioning

line (the line with the pressure switch located on it) towards the radiator and around the radiator hose for clearance of the supercharger pulley and belt system. (See Figs. 6-b, 6-c.)

NOTE: Air conditioning lines are under high pressure and the uid is highly toxic; therefore, use extreme caution

when bending the line to avoid kinking or breaking the line. Support the assembly as much as possible while bending for clearance.

Fig. 5-b

Fig. 6-a

5

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

P/N: 4FG020-010

6. RADIATOR HOSE/AIR CONDITIONING LINE, cont'd.

RADIATOR

D. Notch the radiator bracket to the frame for clear-

ance of the air conditioning line. (See Fig. 6-d.)

E. Reinstall fan relay, bracket and radiator cover

piece.

Fig. 6-b

Fig. 6-c / Air Conditioning Line

Fig. 6-d / Right Side View

6

7. SMOG PUMP HOSES

DIVERTER VALV E

1-3/4”

DIVERTER

VALV E

EXIT HOSE

1-3/4”

CHECK VALVE HOSE

TO AIR

PUMP

AIR CONTROL VALV E

1-1/4”

1”

A. Separate the check valve hose and exit hose from

the diverter valve. (See Fig. 7-a.)

B. Remove 1-3/4" from the end of the diverter valve

exit hose and check valve hose.

C. Trim 1" from the opposite end of the check valve

hose.

D. Remove 1-1/4" from the smog pump hose. E. Secure the hoses as shown using the stock clamps

and supplied #16 clamps.

8. IGNITION MODULE RELOCATION

A. To ensure proper clearance for the intake duct,

the TFI ignition module must be rotated. Carefully unwrap the wire loom running to the grey TFI module plug. Lengthen the wire assembly by pulling the TFI loom out of the main harness (approximately 7") until it meets the air temp and MAF connector (in main harness).

B. Using the 7" length of 3/8" ex loom provided,

rewrap the unwrapped wiring and connector.

C. Using the original threaded hole closest to the

shock tower, rotate the ignition module 180° and mount with the bolt and sheet metal screw provided (see Fig. 8-a).

Fig. 7-a

7

Fig. 8-a

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

P/N: 4FG020-010

ALTERNATOR BRACKET

3/8-16 x 4" (THROUGH ALTERNATOR)

5/16-18 x 1"

7/16-14 x 2-1/4"

MOUNTING BRACKET

3/8-16 x 2-1/4"

3/8-16 x 1-1/2"

3/8-16 x 1-1/4"

3/8-16 x 1"

3/8-16 x 5"

AND NUT

.189" SPACER

(BEHIND PLATE)

MOUNTING PLATE

9. CRANKSHAFT AND WATER PUMP PULLEYS

A. Remove the crankshaft pulley. B. Place the Vortech crank pulley onto the crank

balancer and secure with the four supplied grade 8 bolts and washers.

C. Install the Vortech water pump pulley using stock

fasteners.

NOTE: Tighten bolts progressively and evenly in a

crisscross pattern so that pulleys align properly.

10. MAIN BRACKET AND SUPERCHARGER MOUNTING PLATE

A. Sandwich the smog pump between the casting and

front supercharger mounting plate using the ve 3/816 x 1" bolts and AN washers. On the upper smog pump bolt hole use the 3/8-16 x 5" bolt, 3/8" nut and AN washer with .189 spacer behind the front plate and the 3/8-16 x 1-1/4" bolt and AN washer on the lower mount of the smog pump.

B. Install the assembled bracket onto the engine using

one 7/16-14 x 2-1/4" bolt and two 3/8-16 x 2-1/4" and one 3/8-16 x 1-1/2" bolt and AN washer.

C. Connect the smog pump diverter inlet hose to the

smog pump discharge.

D. Mount the triangular shaped alternator bracket using

two 5/16-18 x 1" bolts and AN washers as shown.

E. Using the factory mounting

bolt, mount the accessory belt tensioner onto the Vortech main bracket.

8

Fig. 10-a

11. COOLANT HOSE REROUTING AND ENGINE COMPONENT REASSEMBLY

1/4-20 NUTS AND WASHERS

INSIDE

RIGHT FRONT

PASSENGER

FENDERWELL

FRONT

A. Attach the supplied 5/8" coolant hose with the

molded elbow end to the heater tting on the rewall. Secure with a hose clamp.

B. Carefully route the coolant hose along the shock

tower and fuel lines next to the oil ll pipe and secure with cable ties.

C. Attach the coolant hose to the front supercharger

mounting plate using the supplied #15 adel clamp and the 3/8" bolt as shown in the graphic. Install coolant hose and clamp onto the water pump tting. Trim if necessary.

NOTE: Make sure that the hoses are routed smoothly

with no kinks or sharp bends and away from all heat sources.

D. Reconnect the spark plug wires to the distributor.

Carefully rotate the temperature sender to allow as much clearance for the alternator as possible, reconnect the temperature sensor plug.

Fig. 11-a

12. MASS AIR FLOW SENSOR RELOCATION

A. Remove the mass air ow (MAF) sensor and

air temperature connector loom from the main harness.

B. Cut the air temperature sensor wires 3" to 4"

away from the air temperature connector. Using the supplied wiring, solder wire extensions (make sure the color of the wires match the main harness wire colors) to the cut harness. Slip two of the supplied one inch shrink sleeves onto each of the cut wires.

C. Reattach the air temperature sensor connector

by soldering it to the extended harness. Position the shrink sleeve sections over each of the solder joints. Gently heat until the tube seals the joint.

D. Cover the wire assembly with the 18" ex

loom.

E. Remove the two 1/4-20 washers and nuts from

the right lower fender valance and mount the MAF bracket on the existing studs using the same washers and nuts to fasten to the inner fender. (See Fig. 12-a.)

Fig. 12-a

9

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

P/N: 4FG020-010

INLET DUCT

12. MASS AIR FLOW SENSOR RELOCATION cont'd.

F. Slide the 3-1/8" x 1" sleeve onto the stock mass

air sensor. Slide the ex hose and #52 hose clamp over the assembly.

G. Mount the hose and mass air assembly onto the

mounting bracket using the four 1/4-20 bolts, washers and nylock nuts.

H. Screw the air temperature sensor into the bracket

and plug in the electrical connector for the MAF and the air temp sensor.

I. Slide the air lter and clamp assembly onto the

bracket and secure.

13. SUPERCHARGER MOUNTING AND ASSEMBLY, HOSE DRAIN AND INLET DUCT

A. Slide the inlet duct along with the T-type clamp

onto the supercharger inlet. (See Fig. 13-a.)

B.* 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.

C.* Feed the oil drain hose around the side of the

smog pump and down towards the oil pan tting while lowering the supercharger into position.

D. Secure the supercharger with four (4) 3/8-16 x 1"

bolts and AN washers.

E.* Connect the lower end of the oil drain hose to the

tting on the pan and secure with a hose clamp. Drain must be routed downhill with no kinks or dips. Trim hose if necessary.

F. Place the supercharger belt idler assembly on the

supercharger using the 12mm bolts and washers. Position the thin head bolt in the tensioner plate nearest the idler pulley.

G. Attach the 3-1/2" elbow assembly and 3-1/2 x 2"

sleeve to the supercharger inlet duct using the #56 clamps. Route the ex hose end through the opening in the fender apron and attach to the MAF sensor outlet. Secure hose to MAF with the supplied #52 clamp.

H.**Secure the remote drain hose away from the belt

and other hoses using tie-wraps.

Fig. 13-a

* Applies to "engine oil-fed" units only. V-3 applications skip these steps.

** Applies to V-3 applications only

10

ALTERNATOR

IDLER

POWER

STEERING

WATER PUMP

A/C

SMOG PUMP

CRANK

NOTE: SPACERS ARE LOCATED BEHIND ALTERNATOR STAY

5/16"SPACER

SUPERCHARGER

MOUNTING PLATE

SUPERCHARGER

MOUNTING BOSS

14. ALTERNATOR AND MAIN ACCESSORY BELT INSTALLATION

A. Mount the alternator to the alternator bracket

and main bracket using a 3/8-16 x 4" bolt and washer. Reconnect the two wiring plugs and battery lug to the alternator.

B.* Thread the oil feed line onto the supercharger

tting.

C. Route the coolant hose over the oil tting/hose

assembly.

D. Mount the alternator stay to the supercharger

and supercharger mounting plate using two 3/8-16 x 1-1/2" bolts and washers, 5/8" spacer and 5/16" spacer. Place the 5/8" spacer in between the upper supercharger mounting bolt hole and the alternator stay. Place the 5/16" spacer in between the upper supercharger mounting plate hole and the alternator stay (see Fig. 14-b). Bolt the alternator to the upper alternator stay slot using the 3/8-16 x 1-3/4" bolt, washer, lock washer and nut.

E. Install the main accessory belt using a 3/8"

breaker bar to rotate the tensioner clockwise, allowing the belt to t over all of the pulleys. (See Fig. 14-a.)

F. Mount the supercharger belt on the crank pul-

ley and supercharger pulley with the tensioner routed according to the graphic. Tighten the belt using a 1/2" breaker bar, a 3/4" tappet or a 19mm thin wrench to tighten the bolts.

Fig. 14-a

* Applies to "engine oil-fed" units only. V-3 applications skip these steps.

Fig. 14-b

11

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

P/N: 4FG020-010

15. DISCHARGE DUCT INSTALLATION

DISCHARGE

TUBE

3-1/2" x 1" HOSE

VACUUM HOSE

2-1/2" x 1" HOSE

INLET DUCT

TO VACUUM TEE

HIGH OUTPUT

KIT ONLY

TO BYPASS

VALVE

20"

4"

OIL

STOCK PVC HOSE

3/8” HOSE MENDER

3/8” HOSE

TO INLET DUCT

A. Fit the 3" x 2" sleeve onto the throttle body and

secure with the supplied #48 clamp. Loosely slide the remaining clamp onto the sleeve.

B. Slide the 2-3/4" x 2" sleeve and clamps onto the

discharge tube assembly.

C. Fit the discharge tube onto the throttle body tube

and slide the 2-3/4" x 2" sleeve onto the supercharger discharge port, tighten down the #44 clamps on both sides.

D. Using the 3/8" hose mender and length of 3/8"

hose supplied, t into the stock PCV hose and route to the barb tting on the inlet duct of the supercharger. (See Fig. 15-a.)

NOTE: In some instances you may have to trim or shorten

these ducts for t and ease of installation due to

differences in components.

Fig. 15-a

16. BYPASS VALVE INSTALLATION (High-Output System Kit Only)

A. Slide the 1" x 3-1/2" hose onto the bypass

valve. Secure with #16 hose clamps. (See Fig. 16-b.)

B. Slide the 1" x 2-1/2" hose onto the discharge

duct and bypass valve. Secure with hose clamps. Trim hose length if necessary.

C. Route the 5/32" vacuum line to the bypass

valve and FMU TEE as shown (See Fig. 16- a.)

D. Using the supplied TEE and length of hose,

cut the hose 4" from the FMU.

E. Install the tee tting and connect the hose to

the bypass valve.

Fig. 16-bFig. 16-a

12

17. IGNITION/BOOST CONTROL INSTALLATION (High-Output and Cobra Systems Only)

BOOST

RETARD

0

1

2

3

SUPERCHARGERS

Ignition/Boost

Contr

ol

MANUFACTURED FOR

VORTECH SUPERCHARGERS

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

IGNITION BOOST RETARD

BYPASS VALVE

FMU

MANIFOLD

VACUUM

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 bypass valve vacuum pressure hose. (See Fig. 17-a.)

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 con-

nector 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.

Fig. 17-a

Fig. 17-b

13

NOTE: Wiring diagram for MSD Retard Unit

ONLY.

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

P/N: 4FG020-010

18. T-REX® FUEL PUMP INSTALLATION (High-Output System Only)

A. Remove spare tire, etc. from trunk. B. Trim "Cut-Out" from the template provided in the kit and

place over spare tire hold-down. Centerpunch and drill the four 3/16" holes in the trunk oor.

C. Jack up the rear of the car and support with jack stands. D. Mount the T-Rex fuel pump to the underside of the tire

well with the rubber mounts, adel clamps and fasteners provided. Refer to the graphic on the following page.

E. Remove the hose assembly and tting that connects the

fuel tank to the fuel lter inlet. Carefully rotate the stock hose assembly previously disconnected from the lter downward 90°.

F. Connect the T-Rex inlet hose assembly to the stock female

supply hose tting by gently pushing the ttings together and making sure they are locked.

G. Fasten the extended feed line clear of the lter by looping

the two 11" cable ties through the front slot on the fuel lter mount, being careful not to kink the line.

H. Plug the female connector onto the fuel lter inlet making

sure the hose assembly clears all exhaust tubing and sharp objects.

NOTE: Use extreme caution when routing fuel lines. Make sure fuel

lines are located away from hot exhaust pipes and sharp edges

on vehicle underbody.

I. Mark and drill a 1/8" hole and mount the relay inside the

trunk in position as shown in the template. Use the sheet metal screw provided.

J. From relay terminal #85, tap the yellow wire into the stock

fuel pump harness in the trunk near the right tail light. Tap into the purple wire with the supplied scotch lock. (On some model years, wire may be brownish-green.)

K. Connect the short red wire on relay terminal #8 to the (+)

terminal on the fuel pump.

L. Connect the longer black wire from the (-) terminal on the

fuel pump to a clean ground.

M. Connect the short black wire to a clean ground from relay

terminal #86 (relay screw mount works well).

N. Route the remaining long red wire from relay terminal #30

up to the high current fuse panel located in the engine compartment. Using a solderless connector, connect the supplied fuse holder and fuse to the end of the wire. Crimp the fuse wire to the large ring terminal and attach the accessory (+) battery lug.

14

18. T-REX® FUEL PUMP INSTALLATION cont'd.

T- REX

®

MAGNIFICATION OF RELAY WIRING

86

GROUND

RELAY

30

87A

85

87

(+)T-REX FUEL PUMP

RED/PURPLE WIRE IN STOCK HARNESS

LUG FROM BATTERY TO FUSE PANEL UNDER HOOD

Route the red power lead from the relay #30 under the car through the drive shaft tunnel and secure with ties! Take care to avoid sharp edges and not damage the wire insulation. Mount relay in the right rear corner of the spare tire well. Make sure all wires are connected as per the relay schematic below. Provide a good ground connection free of rust and paint for both the pump and relay.

(Check with test light when key is turned to “ON” position. Test light should illuminate for 2-3 seconds, then it should turn “OFF” automatically.)

-

+

5/16" x 16-1/2" HOSE

MAGNIFICATION - UNDERSIDE VIEW

FUEL TANK STRAP

T-REX FUEL PUMP

3/8" x 22" HOSE

11" CABLE TIES

CABLE TIE

FLEX LOOM

FROM FUEL

TANK

FRONT OF CAR

STOCK HOSE

ASSEMBLY

FROM TANK

FLOW

STOCK FUEL FILTER

AND BRACKET

FLOW

FRONT

OF CAR

20 AMP

INLINE

FUSE

HIGH CURRENT FUSE PANEL WITH POWER LUG FROM BATTERY

DRIVE

SHAFT

TUNNEL

SPARE

TIRE WELL

Pump is mounted below the tire well, under the car.

Secure wires with adhesive anchors and tie wraps.

NOTE: Make sure everything is secure and away from all moving parts

or 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.

Fig. 18-a

15

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

P/N: 4FG020-010

WARNING: Do not attempt to operate the vehicle until

®

ALL components are installed and ALL

operations are completed including the nal

check.

19. 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(s) is lled with 92 octane or higher fuel before commencing test drive.

E. Start engine and allow to idle a few minutes,

then shut off.

F. 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.

G. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without ALL the subassemblies completely and properly installed may cause

FAILURE OF MAJOR COMPONENTS. H. Test drive the vehicle. I. The supercharger drive belt stretches ini-

tially and will require adjustment between

250 and 400 miles.

J. Read the STREET SUPERCHARGER

SYSTEM OW NER'S MANUAL AND

RETURN WARRANTY REGISTRATION

FORM within thirty (30) days of purchasing

your supercharger system to qualify.

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 supercharger unit it seats.

3. Once the dipstick has seated, remove the dipstick from the unit.

Fluid should register in the cross-

hatched area on the dipstick.

4. DO NOT OVERFILL!!! Drain excess fluid 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.

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