Vortech 1994-2000 Ford 3.8 Mustang User Manual

Ford 3.8L V-6 Mustang

Supercharger System

Installation Instructions

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

1994-2000 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

(94-00 3.8L Mus.(4FF V2.1))

ENGINEERING, LLC

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of

prior

this instruction manual you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

to beginning the installation to determine if

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

of Vortech Engineering, LLC.

(94-00 3.8L Mus.(4FF V2.1))

TABLE OF CONTENTS

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

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

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

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

PARTS LIST - 1994-1998 3.8L V-6 MUSTANG ................................................................................ vi

PARTS LIST - 1999-2000 3.8L V-6 MUSTANG ................................................................................vii

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

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

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

4. FUEL MANAGEMENT UNIT (94-98 ONLY)......................................................................... 4

5. FUEL PUMP INSTALLATION (94-98 ONLY) ....................................................................... 6

6. MAIN MOUNTING BRACKET/SUPERCHARGER PLATE ASSEMBLY ................................ 8

7. A/C LINE MODIFICATIONS ................................................................................................ 9

8. FUEL INJECTOR REPLACEMENT (99-00 ONLY) .............................................................. 12

9. EGR TUBE MODIFICATION (99-00 ONLY)........................................................................ 12

10. SUPERCHARGER MOUNTING/HOSE DRAIN/INLET DUCT ............................................. 15

11. AIR INLET........................................................................................................................... 17

12. AIR DISCHARGE................................................................................................................ 18

13. FINAL CHECK.................................................................................................................... 19

iii

09JUN03 V2.1

P/N: 4FF020-010

(94-00 3.8L Mus.(4FF V2.1))

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.

1999-2000 Models

This kit requires ECM modification and the installation of a Vortech ECM Module. The ECM must be sent directly to Vortech by the installing customer (the charge for this service with module installation has been included in the purchase price).

• Included in this kit is a prepaid next-day air shipping box and a credit tag for one Vortech ECM Module.

• The modules are made specifically for each individual vehicle with respect to the factory ECM calibration.

• Simply contact the Vortech Service Department at 805 247-0226 to request a Return Authorization Number (see ECM Module Credit Tag for more details).

—Mail to Vortech the enclosed "ECM Module Credit Tag" (send original tag

photocopies will not be accepted) and ECM in the supplied box.

—Turnaround time will be 1-2 days (each application varies). Vortech will give an

estimate at the time of your order.

Your Vortech ECM Module comes with a twelve month limited warranty from the original date of purchase of your supercharger system (see Owner's Manual for details).

(94-00 3.8L Mus.(4FF V2.1))

1994-2000

FORD 3.8L MUSTANG

Installation Instructions

50 State Smog Legal 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 and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 3035% and horsepower of 35-45% can be expected with the boost levels specified 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 modified 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

resolved.

5. Perform an oil and filter 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 filter 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 3 years or 30,000 miles with

original heat range plugs as specified by the manufacturer and reset timing to factory specifications (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 30,000 miles and spark plug wires every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS

A/C system drain and recharge required - Procedure to be performed properly by a trained technician.

• Factory Repair Manual

• 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

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

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 3/32", 5/16", 7/16", 9/16" (96-98 models), 37/64 Drill Bits

• Ford Springlock 3/8" Fuel Fitting Disconnect Tool

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

• 5 Quarts SF Rated Quality Engine Oil

• Oil Filter and Wrench

• 9/16" ROTA-BROACH

• T55 Torx Bit

• Power Steering Pulley Puller/Installer (94-95 models)

• Tubing Cutter (ø5/8" Tube)

• Grinder

If your vehicle has in excess of 30,000 miles since its last spark plug change, then you will also need:

• Spark plug socket • NEW spark plugs

09JUN03 V2.1

P/N: 4FF020-010

(94-00 3.8L Mus.(4FF V2.1))

1994-1998 3.8L V-6 Mustang

Part No. 4FF218-010SQ/018SQ

ENGINEERING, LLC

IMPORTANT:

Before beginning installation, verify that all parts are included in the kit. Report any

shortages or damaged parts immediately.

Part Number Description Quantity

4FF111-021 MOUNTING BRACKET ASSEMBLY 1

4FF011-021 Mounting bracket 1 4FF010-034 Mounting plate 1

7C010-066 10mm x 1.5 x 65 bolt 3 7C080-065 8mm x 1.25 x 65 1

7J375-044 3/8" Washer 3 7K312-001 5/16" Washer 1 7A375-100 3/8" - 16 x 1" Screw 5 7A375-075 3/8" - 16 x 3/4" Screw 5 7K375-040 3/8" Flat washer 10

7G010-175 12mm x 1.75 nut 1

2A046-114 Belt 1

4FA016-170 Idler pulley 1 4FD017-011 Idler spacer 1

7C012-050 12mm x 1.75 x 50mm Hex 1

4FA016-171 Dust shield 1

7J012-092 12mm Flat washer 2

2E228-250

4FF101-003 A/C LINE SUPPLEMENT 1

5W018-020 18 Gauge std. black wire (1.333 ft.) 1 5W018-050 18 Gauge std. yellow wire (1.333 ft.) 1 5W018-070 18 Gauge std. green wire (1.667 ft.) 1 5W018-080 18 Gauge std. blue wire (1.667 ft.) 1 5W001-012 Solderless connector, 22 red gauge 8 5W001-007 3/16" Heat-shrunk tube (1.00 ft.) 1

7P375-039 5/8 x 90° Barb 1 7P625-016 5/8 Union 1 7U034-100 5/8 A/C hose (.312 ft.) 1 7R002-010 #10 Clamp 3

4FF112-020 DISCHARGE ASSEMBLY 1

7R002-044 #44 Hose clamps 4 7R002-016 #16 Hose clamps 4 7S275-200 2-3/4” x 2” Sleeve 2 8D001-001 Bypass valve 1 7U034-016 1" Heater hoses (.416 ft.) 1 7U034-016 1" Heater hoses (.229 ft.) 1

4FF012-020 Discharge tube 1

4FF130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” Oil feed hose (3.16 ft.) 1 7P250-066 #4 Swivel x 1/4” hose barb fitting 4 7P525-067 .525 Crimp ferrules 4 7U100-055 Tie wrap, 6" nylon 2 7P250-144 1/4" NPT x #8 fitting 1 7P250-082 1/4" NPT x #4 90° fitting 1 7P125-103 #4 x 45° Male elbow 1/8" NPT 1 7P250-034 1/4 NPT Strt., Tee 1 7U030-026 1/4" Oil feed hose (1.58 ft.) 1

V2SQ SUPERCHARGER ASSEMBLY

PARTS LIST

Part Number Description Quantity

4FF238-068 FMU (with lines) 1

6Z110-112 10:1 Fuel management unit 1 4FF145-010 Male fuel assy., 3.8 (from rail) 1 4FF145-012 Female line assy., 3.8 (to tank) 1

7U030-046 5/32" Vacuum line (6 ft.) 1 7P156-082 5/32" TEE 2 7U100-055 Tie wrap, 6" nylon 4

4FF130-036 OIL DRAIN ASSEMBL Y 1

7U030-036 1/2” x 19” Oil drain hose (1.667 ft.) 1 7P375-017 3/8” NPT x 1/2” Bead straight barb 1 7R001-008 #8 Stainless hose clamps 2 7P375-045 45° Street elbow, 3/8" NPT 1

4FF112-010 AIR INTAKE ASSEMBLY 1

4FG112-022 Inlet duct w/ ring 1

7U035-001 3-1/2" Flex hose (1.33 ft.) 1 7R002-056 #56 Hose clamps 2 7R002-052 #52 Hose clamps 2 8H040-030 Air filter 1

7J250-001 1/4" SAE washers 8

7F250-021 1/4"-20 Nylock nuts 4 7A250-075 1/4"-20 x 3/4" Socket head cap screw 4 7S325-100 3.25 x 1 Sleeve 1 7S350-200 3-1/2 x 2 Sleeve 1

4FA012-012 90° Intake elbow 1

7U030-056 3/8" PCV hose (1.250 ft.) 1 7P250-045 1/4 NPT x 3/8 ID fitting 1 7R005-001 208-91 T-bolt clamp 3.75" 1

4FG110-050 MAF bracket assy. 1

7P375-016 3/8 Pipe plug 1 7U100-052 7/16 Rubber grommet 1

4FF101-002 FUEL PUMP ASSEMBLY 1

8F001-002 155 Inline fuel pump 1 8F101-200 T-Rex wir ing assy. 1

5W001-010 16-14 Gauge female slide, insulated 3

7R004-003 14.5 Stepless clamps 2 7R001-004 #4 Hose clamps 2 7U030-050 12mm Fuel hose (2.41 ft.) 1 7U031-018 5/16 Fuel hose (2 ft.) 1 7R003-024 Adel clamp, 1-1/2 ID 1 7E010-075 #12 x 3/4" Sheet metal, hex only 2 7P312-003 5/16" Female fuel connector 1 7P500-004 1/2" fuel adapter fitting 1 7C008-032 #8-32 Hex lock nut 1

7J008-001 #8 Flat washer 1

5W001-001 Wire tap 1

7U100-055 Tie wrap, 6" nylon 5 5W001-002 Fuse tap 1 5W001-015 Blade type fuse, 20 amp 1 5W001-014 #10 Fuse holder 1 5W001-019 Solderless connector, 12-10 gauge 1 5W001-011 16-14 Gauge eyelet, .25" bolt 1

7U375-135 Mounting pad 5

7U100-044 Tie wrap 5

7S625-000 Fire sleeve 1 ft.

(94-00 3.8L Mus.(4FF V2.1))

1999-2000 3.8L V-6 Mustang

Part No. 4FF218-020SQ/028SQ

ENGINEERING, LLC

IMPORTANT:

Before beginning installation, verify that all parts are included in the kit. Report any

shortages or damaged parts immediately.

Part Number Description Quantity

4FF218-020SQ 99-01 MUST 3.8 V6 KIT 1

4FF111-021

4FF011-021 Mounting bracket 1 4FF010-034 Mounting plate 1

7C010-066 10mm x 1.5 x 65 bolt 3 7C080-065 8mm x 1.25 x 65 1

7J375-044 3/8" Washer 3 7K312-001 5/16" Washer 1 7A375-100 3/8" - 16 x 1" Screw 5 7A375-075 3/8" - 16 x 3/4" Screw 5 7K375-040 3/8" Flat washer 10 7G010-175 12mm x 1.75 nut 1 2A046-114 Belt 1

4FA016-170 Idler pulley 1 4FD017-011 Idler spacer 1

7C012-050 12mm x 1.75 x 50mm Hex 1

4FA016-171 Dust shield 1

7J012-092 12mm Flat washer 2

2E228-350

4FF130-026 OIL FEED ASSY 1

7U030-026 1/4” Oil feed hose (3.16 ft.) 1 7P250-066 #4 swivel x 1/4” hose barb fitting 4 7P525-067 .525 Crimp ferrules 4 7U100-055 Tie wrap, 6" nylon 2 7P250-144 1/4" NPT x #8 fitting 1 7P250-082 1/4" NPT x #4 90° fitting 1 7P125-103 #4 x 45° Male elbow 1/8" NPT 1 7P250-034 1/4 NPT Strt., Tee 1 7U030-026 1/4" Oil feed hose (1.58 ft.) 1

4FF130-036 OIL DRAIN ASSY 3.8 V6 1

7U030-036 1/2” x 19” Oil drain hose (1.667 ft.) 1 7P375-017 3/8” NPT x 1/2” Bead straight barb 1 7R001-008 #8 Stainless hose clamps 2 7P375-045 45° Street elbow, 3/8" NPT 1

4FF112-010 AIR INTAKE ASSY 3.8 V6 1

4FG112-022 Inlet duct w/ ring 1

7U035-001 3-1/2" Flex hose (1.33 ft.) 1 7R002-056 #56 Hose clamps 2 7R002-052 #52 Hose clamps 2 8H040-030 Air filter 1

7J250-001 1/4" SAE washers 8 7F250-021 1/4"-20 Nylock nuts 4 7A250-075 1/4"-20 x 3/4" Socket head cap screw 4 7S325-100 3.25 x 1 Sleeve 1 7S350-200 3-1/2 x 2 Sleeve 1

4FA012-012 90° Intake elbow 1

MOUNTING BRACKET ASSY 3.8 V6

V2SQ SUPERCHARGER ASSY 3.8 V6

PARTS LIST

Part Number Description Quantity

7U030-056 3/8" PCV hose (1.250 ft.) 1 7P250-045 1/4 NPT x 3/8 ID fitting 1 7R005-001 208-91 T-bolt clamp 3.75" 1

4FG110-050 MAF bracket assy. 1

7P375-016 3/8 Pipe plug 1 7U100-052 7/16 Rubber grommet 1

4FF101-003 A/C LINE SUPPLEMENT 1

7P375-039 5/8 x 90° Barb 1 7P625-016 5/8 Union 1 7U034-100 5/8 A/C hose (.312 ft.) 1 7R002-010 #10 Clamp 3

4FF112-130 DISCHARGE ASSY 99-01 V6 MUSTANG 1

4FF112-030 Duct, disch 99-01 V6 mustang 1

7P156-082 5/32 TEE 1 7R002-016 #16 Goldseal hose clamp 4 7R002-044 #44 Goldseal hose clamp 4 7S275-200 2-3/4 x 2 sleeve 2 7U030-046 5/32" vacuum line 1.333' 7U034-016 1" GS hose .708' 7U100-055 Tie wrap, 6" nylon 4 7U133-090 Rubber elbow, ø1.0" x 90° 1 8D001-001 Std comp bypass valve 1 7P375-106 PCV valve 1

4FL120-025 ECM CHIP PACKAGE 99-01 V6 1 5A101-016 MAF VOLTAGE CLAMP ASSY 1 4FF101-003 A/C LINE SUPPLEMENT 1 4FF014-030 FLEXIBLE EGR TUBE 1 5W001-051 JUMPER HARNESS 6 7P500-626 1/2" F NPT-5/8" TUBE CONN S.S. 2 8F060-038 FUEL INJECTOR, 38 LBS RAIL 6 2A046-113 BELT, K061130-GATES 1

vii

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(94-00 3.8L Mus.(4FF V2.1))

This Page Left Intentionally Blank

(94-00 3.8L Mus.(4FF V2.1))

viii

1. PREPARATION/REMOVAL

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

throttle body including the mass air flow (MAF) sensor, air filter assembly and rubber bellows. Separate the MAF sensor from the air filter assembly and set aside.

C. Remove the air temperature sensor from the inlet

duct.

D. Remove the factory accessory drive belt. E. It is necessary to remove the refrigerant from

the air conditioning system. This should be

performed by a qualified technician using a refrigerant recycling system. Releasing refrigerant into the atmosphere is environmentally irresponsible and should be avoided.

F. Unplug the A/C compressor and the A/C line

electrical connectors. Using a springlock disconnect tool, disconnect both ends of the A/C line that runs from the condensor to the firewallmounted canister. Remove the screw mounting the A/C line junction block to the compressor and remove the line from the vehicle.

G. Remove the A/C compressor from the factory

bracket.

H. Using a T55 Torx bit, remove the belt tensioner

from the factory bracket.

I. Remove the factory A/C bracket including

mounting hardware from the engine.

(1999-2000 Models Only)

J. Remove (if equipped) the exhaust gas recirculation

(EGR) tube (one end connects to the passenger side exhaust manifold). Note the orientation of the pressure differential sensor.

K. Remove the passenger side front kick panel from

the interior of the vehicle. Remove the sound deadening material (if any) that is covering the ECM. Remove the plastic ECM hold-bracket.

L. Using the 10mm socket or wrench, remove the

harness and plug from the ECM (as you loosen the screw, the connector will slowly release). Remove the ECM from the vehicle.

M. Contact the Vortech Sevice Department for a

return authorization number. Send both ECM and supplied credit tag to Vortech using the enclosed shipping box.

09JUN03 V2.1

P/N: 4FF020-010

(94-00 3.8L Mus.(4FF V2.1))

+ 19 hidden pages

Vortech 1994-2000 Ford 3.8 Mustang User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual