Vortech 1994-2000 Ford 3.8 Mustang User Manual

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Page 1

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

Page 2

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))

Page 3

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

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

Page 4

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))

Page 5

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))

Page 6

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))

Page 7

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

09JUN03 V2.1

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

Page 8

This Page Left Intentionally Blank

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

viii

Page 9

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))

Page 10

2. OIL FEED

NOTE:

IMPORTANT:

The supercharger uses engine oil for lubri-

cation and must have an oil feed line connected to a filtered oil access on the engine.

Use only clean engine oil on the pipe threads. Teflon tape or pipe sealant is not recommended as it might loosen and cause blockage of the small oil feed orifice resulting in possible supercharger failure.

1994-1995 Models only

1. Remove the vehicle's power steering pump pulley. Remove the screws that fasten the power steering/alternator bracket to the head. Pull the assembly away from the engine temporarily to gain access to the oil pressure sending unit. Remove the factory pressure sending unit. Thread the supplied 1/4" NPT street TEE and 1/4" NPT x 90° x #4 flare into the previous pressure sending unit location. Install pressure sending unit into the street TEE. (See

Fig. 2-a

2. Connect the supplied 19" (2 different hose lengths are supplied) oil feed line to the flare fitting and route up to supercharger location. Secure the hose with the tie wraps provided, routing it away from chaffing and/or sharp objects. Temporarily cover the open end from debris until the connection is made to the supercharger in Step 7.

1996-2001 Models only

1. Remove the factory #8 O-ring plug located on the engine oil filter boss. Replace the plug with the supplied #8 O-ring x 1/4" NPT adapter fitting. Thread the supplied 1/4" NPT x 90° x #4 flare fitting into the adapter fitting. Orient the 90° fitting as shown in

Fig. 2-b

2. Connect the supplied 38" (2 different hose lengths are supplied) oil feed line to the flare fitting and make a gentle upward loop around the power steering pump. Secure the hose with the tie wraps provided, routing it away from exhaust heat, chaffing and/or sharp objects. Temporarily cover the open end from debris until the connection is made to the supercharger in Step 7.

1994-1995 MODELS

OIL FEED FITTING & ADAPTER

Fig. 2-a

1996-2001 MODELS

OIL FEED FITTING & ADAPTER OIL FEED HOSE

Fig. 2-b

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

Page 11

3. OIL DRAIN

1.2”

OIL PAN

FRONT/PASSENGER SIDE

CORNER OF OIL PAN

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

Figs. 3-a and 3-b

B. Carefully drill a pilot hole (the same diameter as

the Rota-Broach pilot) into the marked spot on the oil pan (this procedure may also be done by removing the oil pan if you are unsure of your ability to perform the following steps properly). Drill slowly as to catch most of the aluminum chips from the hole being drilled. Using the 9/16" Roto-Broach, very slowly machine a hole in the pan (use the previously drilled hole as a guide). Stop machining just before the tool breaks through into the oil pan. Using a scribe or a small screwdriver, remove the remaining disc-shaped oil pan piece (allowing you to remove the pan slug before it falls into the oil pan and keeps most of the aluminum chips out).

C. Tap the hole with a 3/8" NPT tap approximately

1/4" deep. Pack the flutes of the tap with heavy grease to hold the chips. Thoroughly clean the threads in the hole with acetone or lacquer thinner.

D. Using a small amount of silicone sealer, install the

3/8 NPT x 45° elbow into the oil pan. Thread the supplied 3/8" NPT x 1/2" barb fitting into 45° elbow. (Orient the fittings as shown in Temporarily cap the fitting until the drain hose is connected in Step 7.

E. Drain the engine oil and change the filter. Refill

engine with factory specified weight oil. Vortech recommends the use of synthetic oil.

Fig. 3-b

Fig. 3-a

Fig. 3-b

09JUN03 V2.1

P/N: 4FF020-010

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

Page 12

4. FUEL MANAGEMENT UNIT (1994-1998 Models only)

A. Position the FMU onto the right side inner fender

and secure with the supplied sheet metal screws. (See

Fig. 4-a.

B. Disconnect and discard the factory rubber fuel

return line running from the fuel rail (note that the return line DOES NOT have pressure test fitting on it) to the steel return line (the smaller of the two) located behind the right side shock tower using a springlock disconnect tool.

C. Connect the FMU inlet hose (the hose that goes

to the 90° fitting on the side of the FMU) to the return side of the factory fuel regulator. Make sure the hose end is securely “snapped” onto the factory connector. (See page.)

D. Connect the FMU outlet hose (attaches to the

center fitting on the bottom of the unit) to the steel return line running to the tank. Make sure the hose end is securely "snapped" onto the factory fuel line.

E. Secure the fuel lines away from abrasion and

exhaust with the tie wraps provided.

F. Attach the supplied length of 5/32" vacuum hose

to the fitting on top of the FMU. Connect the opposite end of the hose to the factory fuel regulator vacuum connection using the 5/32" TEE provided. (See graphic on the next page.) Trim hose length as necessary.

)

Fig 4-b

on the next

Fig. 4-a

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

Page 13

4. FUEL MANAGEMENT UNIT (1994-1998 Models only), cont'd.

FACTORY VACUUM HOSE

FUEL MANAGEMENT

UNIT (FMU)

VACUUM LINE

SUPPLIED TEE

OUTLET

INLET

FACTORY QUICKDISCONNECT FITTING

FUEL RETURN LINE

FACTORY SPRINGLOCK

CONNECTOR

FILTER

VORTECH

FUEL PUMP

FUEL FEED LINE

ENGINE

FACTORY REGULATOR

FUEL TANK

Fig. 4-b

09JUN03 V2.1

P/N: 4FF020-010

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

Page 14

5. FUEL PUMP INSTALLATION (1994-1998 Models only)

A. Remove the spare tire, etc. from the trunk. B. Jack up the rear of the car and support with jack

stands.

C. Mount the fuel pump to the underside of the spare

tire well with the adel clamp and #8 fasteners provided. Refer to

Figs. 5-a and 5-b

D. Remove the factory female hose end connected

to the fuel filter inlet.

E. Insert the supplied 1/2" fuel pump inlet hose

adapter fitting into the factory female supply hose fitting by gently pushing the fittings together and making sure they are locked.

F. Attach the supplied 1/2" fuel hose to the pump

inlet and the inlet hose adapter fitting. Use the supplied #4 clamps to secure both ends. Cut hose length if necessary.

G. Fasten the extended pump inlet line clear of the

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

H. Plug the female connector located on the pump

discharge line onto the fuel filter 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 the 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 fuse panel located under the dash. Using a solderless connector, connect the supplied fuse holder and fuse to the end of the wire. Crimp the fuse wire to the supplied female slide and fuse tap. Attach fuse tap and wire to fuse #17.

Fig. 5-a

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

Page 15

5. FUEL PUMP INSTALLATION (1994-1998 Models only), cont'd.

Mount relay in the right rear corner of the spare tire well. Make sure 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. Connect the red power lead from the relay position #30 to fuse #17 in the under dash fuse panel. Route the wire underneath the rear seat and carpet. Take care to avoid sharp edges and not damage the wire insulation.

MAGNIFICATION - UNDERSIDE VIEW

UNDERDASH

FUSE BOX

20 AMP

INLINE

FUSE

5/16" x 24" HOSE

FUEL PUMP

CABLE

TIE

STOCK FUEL FILTER AND BRACKET

FLEX

LOOM

FUEL TANK

STRAP

GROUND

FRONT

OF CAR

SPARE

TIRE WELL

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

Secure wires with adhesive anchors and tie wraps.

MAGNIFICATION OF RELAY WIRING

(+) FUEL PUMP

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.)

HEATER/A/C FUSE AT INTERIOR FUSE BOX

87A

FLOW

1/2” x 29" HOSE

FRONT OF CAR

FUEL LINE

FROM TANK

FLOW

STOCK HOSE

11" CABLE TIES

NOTE: 1998 Mustangs have 7 or 8 wires in the harness. Use the brown wire with pink stripe. Double check with test light.

ASSEMBLY FROM TANK

RELAY

Fig. 5-b

09JUN03 V2.1

P/N: 4FF020-010

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

Page 16

6. MAIN MOUNTING BRACKET/SUPERCHARGER PLATE ASSEMBLY

A. Using a grinder, remove the casting boss on the

factory water pump. (See

Figs. 6-a, 6-b.

)

B. Using the supplied 12mm nut, washer and factory

tensioner screw, secure the factory belt tensioner to the Vortech mounting bracket.

C. Mount the factory A/C compressor to the Vortech

mounting bracket (without the A/C line) using the factory alignment dowels and hardware.

D. Temporarily remove the two passenger side coil

screws from the coil.

E. Attach the Vortech mounting bracket assembly to

the engine using the supplied 10mm x 1.5 socket head screws and single 8mm x 1.25 hex head screw using a washer with each fastener. (See

Fig. 6-c.

)

F. Attach the Vortech mounting plate to the bracket

using the supplied 3/8" - 16 x 3/4" screws and AN washers.

G. The coil capacitor must be relocated to the front

Fig. 6-a

passenger side coil bolt for supercharger compressor clearance (see

Fig.6-c

). The two previously removed coil screws should be reinstalled now.

BEFORE

BOSS

REMOVAL

Fig. 6-b

AFTER

BOSS

REMOVAL

NEW CAPACITOR

LOCATION

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

VORTECH MOUNTING

BRACKET INSTALLED

Fig. 6-c

Page 17

7. A/C LINE MODIFICATIONS

NOTE:

Modified air conditioning (A/C) lines may

be purchased from Vortech or the installer may perform the modifications by following the steps below.

Modify the A/C suction lines as shown. Note that the 1994-95 models require slightly different modifications than the 1996-98 models.

A. Cut off the suction line flush with the junction

block (See

Fig 7-a

). Enlarge the exposed junction block hole by using a 37/64” drill (preferably mounted in a milling machine or drill press to ensure that the hole is round and properly sized). Thread the hole with a 3/8” NPT tap. Properly clean all chips and lube out of the hole. It is very important that no debris be allowed to enter the A/C compressor.

B. Following the graphic, thread the 3/8” NPT x 90°

fitting into the A/C junction block. Tighten the fitting so that it will point in the proper direction when finished.

C. Take the cut-off section of A/C line (separated

from the junction block in step 1) and remove the remaining muffler and tube starting where the ferrule meets with the rubber portion of the line (see

Figs. 7-b, 7-c, 7-d

). Discard muffler/steel tube portion. Clean out the remaining rubber hose/spring lock connector line. Slightly bend the remaining muffler tube following the full scale template on the next page.

D. Assemble the open end of the cut-off rubber hose

assembly onto the 90° junction block fitting. 1994- 95 models require a union and an extra length of rubber A/C hose (supplied). Connect these pieces as shown. Temporarily install the assembled A/C line onto the vehicle. Allow the hoses to rotate so that proper alignment is achieved. Mark the hose rotation and remove the line assembly from the vehicle.

E. Secure hose junction(s) with the supplied #10

hose clamps and permanently install the complete A/C line onto the vehicle. Make sure that both O-rings on the A/C line junction block are properly located and that both of the springlock connectors snap properly into place.

F. Extend the wires for the A/C compressor and A/C

line pressure sensor switch with the supplied wire extensions and heat shrink sleeves.

A/C LINE CUT

MODIFICATIONS

CUT

HERE

REMOVE

AND

DISCARD

CUT HERE

Fig. 7-a

09JUN03 V2.1

P/N: 4FF020-010

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

Page 18

7. A/C LINE MODIFICATIONS, cont'd.

STOCK POSITION

SIDE VIEW (PASSENGER’S SIDE)

MODIFIED (BENT) POSITION

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

FULL SCALE BEND TEMPLATE

Fig. 7-b

Page 19

7. A/C LINE MODIFICATIONS, cont'd.

FITTING CLOCKING (TOP VIEW)

TO FIREWALL MOUNTED CANISTER

FACTOR Y 5/8" RUBBER A/C HOSE

FACTORY TUBE/ FERRULE

ORIGINAL FERRULE

1994-1995

& 1999-2000 MODELS

FACTORY HOSE

CUT AT END OF

Fig. 7-c

ATTACH #10

HOSE CLAMPS

TO HEAT EXCHANGER

(FRONT OF RADIATOR)

5/8" X 3.75

LONG A/C HOSE

(SUPPLIED)

5/8" HOSE BARB UNION

STOCK

POSITION

3/8" NPT X 5/8" ELBOW

CUT OFF STEEL TUBE HERE-THEN DRILL AND TAP 3/8” NPT

SIDE VIEW (PASSENGER SIDE)

MODIFIED (BENT) POSITION

TO FIREWALL MOUNTED CANISTER

FACTORY TUBE/ FERRULE

1996-98 MODELS

ATTACH #10 HOSE CLAMP

5/8" RUBBER A/C HOSE

FACTORY HOSE CUT AT END

OF ORIGINAL FERRULE

STOCK POSITION

TO HEAT EXCHANGER (FRONT OF RADIATOR)

Fig. 7-d

FITTING CLOCKING (TOP VIEW)

3/8" NPT X 5/8" ELBOW

CUT OFF STEEL TUBE HERE-THEN DRILL AND TAP 3/8” NPT

SIDE VIEW (PASSENGER SIDE)

MODIFIED POSITION

09JUN03 V2.1

P/N: 4FF020-010

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

Page 20

8. FUEL INJECTOR REPLACEMENT, (1999-2000 models only)

A. Remove the plastic clips holding the ignition wires

to the upper manifold. Disconnect the throttle cable and cruise control cable. Remove the 12 screws securing the upper manifold. Disconnect all hose/line and electrical connections and noting their routing. Remove the coil pack, throttle cable bracket and EGR solenoid bracket wiring harness. Unsnap the wiring loom from the back of the upper manifold.

B. Lift the upper manidold carefully off of the lower

manifold. Cover the lower manifold with a clean cloth or rag to help prevent debris from falling into the engine.

C. Disconnect the wiring harness from each injector

and clips securing the injectors to the fuel rail.

D. Remove the four fuel rail screws (two per side).

Lift the fuel rails up and remove the injectors.

E. Lube the O-rings on the new injectors and install

into the fuel rails first, then install the fuel rail assembly into the manifold. Reinstall the retainer clips onto the injectors and fuel rail.

NOTE:

New injectors have two grooves. Use the

upper groove which is closest to the O-ring.

F. Reinstall the four fuel rail retainer screws. Install

the supplied jumpers onto the new injectors and connect the wiring harness to each one.

G. Reinstall the previously removed components in

reverse order.

9. EGR TUBE MODIFICATION (1999-2000 VEHICLES EQUIPPED WITH AN EGR TUBE)

A. The EGR tube must be modified to allow proper

clearance for the air inlet ducting. Using a tubing cutter, cut the EGR tube just before the 90° bend downward and just after the 90° bend that heads to the exhaust manifold. Use the supplied flexible tube to gauge the proper amount of tubing to be removed, cut and discard section. (See

Fig. 9-a.

)

B. Remove any burrs remaining on the EGR tube.

Install the two 1/2" NPT x 5/8 tubing connectors on to each end of the flexible tube and tighten. (See

Fig. 9-b.

)

C. Slide one end of the flexible tube assembly over

each end of the EGR tube and tighten the compression fittings. (See

Fig. 9-c.

)

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

Page 21

TO INTAKE MANIFOLD

NOTE PRESSURE DIFFERENTIAL TUBES

MAY BE LOCATED NEAR EXHAUST MANIFOLD

CUT HERE

TO EXHAUST MANIFOLD

9. EGR TUBE MODIFICATION (1999-2000 VEHICLES EQUIPPED WITH AN EGR TUBE), cont'd.

Fig. 9-a

09JUN03 V2.1

P/N: 4FF020-010

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

Page 22

9. EGR TUBE MODIFICATION (1999-2000 VEHICLES EQUIPPED WITH AN EGR TUBE), cont'd.

EGR TUBE

FLEXIBLE EGR TUBE

1/2” NPT - 5/8 TUBE

CONNECTION

Fig. 9-b

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

Fig. 9-c

Page 23

10. SUPERCHARGER MOUNTING/HOSE DRAIN/INLET DUCT

A. Place the oil drain hose onto the supercharger

drain fitting and secure with the supplied #8 clamp. Arrange the clamp housing so that it will not interfere with the mounting plate when installed.

B. Lower the supercharger down onto the mounting

plate while routing the drain hose through the mounting bracket and around the A/C compressor. Secure the supercharger to the mounting plate using the supplied 3/8-16 x 1" screws and AN washers.

C. Connect the lower end of the drain hose to the

fitting in the drain pan. Hose routing must be downhill with smooth bends and must not have kinks, sharp bends or uphill sections. Trim hose length if necessary. Secure drain hose to the oil pan fitting with the supplied #8 clamp.

D. Attach the 1/8 NPT x 45° brass fitting to the

supercharger oil feed fitting. Use a 1/2” wrench to hold the feed fitting while tightening the 45° fitting. Attach the previously installed oil feed hose to the supercharger.

E. Attach the supplied idler pulley to the supercharger

using the supplied spacer, dust shield and M12 x

VALVE COVER BREATHER HOSE (SEE SECTION 8)

50mm screw (place the spacer in between the supercharger and the idler pulley). (See

Fig. 10-c

for idler location.)

SUPERCHARGER

INLET DUCT

Fig. 10-a

NOTE:

F. Install the drive belt following

routing, on the next page.

Fig. 10-d,

belt

VORTECH IDLER PULLEY

(1994-1998 mounting location shown)

Fig. 10-b

99-01 MODELS - IDLER

MOUNTING LOCATION

Fig. 10-c

94-98 MODELS - IDLER MOUNTING LOCATION

09JUN03 V2.1

P/N: 4FF020-010

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

Page 24

10. SUPERCHARGER MOUNTING/HOSE DRAIN/INLET DUCT, cont'd.

FACTORY IDLER

ALTERNATOR

WATER

PUMP

POWER

STEERING

CRANK

FACTORY

TENSIONER

A/C

SUPERCHARGER PULLEY

VORTECH IDLER

94-98 MOUNTING

LOCATION

VORTECH IDLER

99-01 MOUNTING

LOCATION

BELT ROUTING

Fig. 10-d

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

Page 25

11. AIR INLET

NOTE:

1999-2000 models. Install the MAF voltage clamp using the supplied instructions.

A. Using the supplied 1/4-20 hardware, mount the

MAF meter to the Vortech MAF bracket and secure. (See

Fig. 11-a

for orientation.) Remove the factory MAF screen before attaching the meter to the new bracket.

B. Slide the supplied orange sleeve onto the MAF

outlet to function as a spacer for the 3-1/2" blue sleeve.

C. Attach the supplied K & N air filter, 3-1/2” sleeve,

90° 3-1/2” elbow and #56 hose clamps to the MAF and secure.

D. AIR INTAKE TEMPERATURE SENSOR:

• 1994-95 Models:

Thread the temperature

sensor into the Vortech MAF bracket.

• 1996-1998 Models:

Plug the Vortech MAF sensor threads with the supplied 3/8 NPT plug. Drill a 9/16" hole into the side of the plastic air inlet elbow (see

Fig. 11-a

). Insert the factory temperature sensor and supplied grommet into the 9/16" hole. Lubricate for easier fit.

• 1999-2000 Models:

Plug the Vortech MAF

sensor threads with the supplied 3/8"NPT plug.

E. Working from beneath the vehicle, remove the

two factory nuts and washers from the right side lower fender valence. Mount the MAF/bracket assembly onto the existing studs using the same washers and nuts originally removed. (See

11-a.

)

F. Using a #52 hose clamp, connect the piece of

3-1/2” flex hose to the elbow attached to the MAF meter and route it through the opening in the right side inner fender toward the supercharger. Make sure the 3-1/2” flex hose does not contact or rub on the edge of the inner fender opening. Eventual hose failure will result if hose is not properly routed. (See

Fig. 11-b

G. Route the factory temperature sensor and MAF

sensor connectors out through the inner fender opening. Reattach the connectors to the relocated sensors.

1996-1998 Models:

Attach the supplied piece of rubber 3/8" hose to the end of the factory valve cover breather tube (plastic). Into the end of the rubber breather hose, insert the factory 3/8" x 90° plastic breather fitting to allow connection of the tube assembly to the supercharger air inlet duct. (See

Fig. 11-c

1996-1998 Models:

Using a short piece of 3/8" rubber hose, join the plastic 90° elbow to the 3/8" brass barb on the supercharger air inlet duct.

1999-2000 Models:

Attach the supplied piece of 3/8" rubber hose to the factory valve cover breather, located on the passenger side valve cover. Connect the other end of the previously installed hose to the 3/8" brass barb on the supercharger air inlet duct.

Fig.

FACTORY AIR

TEMPERATURE

SENSOR

(1996-1998 Models)

3-1/2" ELBOW SLEEVE

#56 CLAMPS FACTORY

STUDS & NUTS

VIEW FROM

INSIDE ENGINE

COMPARTMENT

(Steel inner fender

not shown for ease

of description)

INSIDE

RIGHT FRONT

PASSENGER

FRONT

FACTORY AIR TEMPERATURE SENSOR

1994-1995 MODELS (1996-2001 USE PIPE PLUG)

FENDERWELL

Fig. 11-a

Fig. 11-b

VALVE COVER BREATHER HOSE

(19941998 Models)

Fig. 11-c

09JUN03 V2.1

P/N: 4FF020-010

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

Page 26

12. AIR DISCHARGE

A. Attach the discharge duct between the

supercharger and the throttle body using the supplied 2.75” sleeves and #44 hose clamps.

1994-1998 Models only

1. Following Fig. 12-a, connect the 1" x 5" and 1" x 2.75" hoses to the supplied supercharger bypass valve and secure with #16 hose clamps. Attach the bypass valve/hose assembly to the bung located on the discharge duct and to the 1" barb located on the plastic molded inlet elbow (make sure the bypass valve nipple is pointing down when installed). Secure with #16 hose clamps.

2. Cut the 5/32” FMU vacuum hose near the shock tower and insert one of the supplied brass TEEs into the hose to allow a branch for the air bypass valve connection. Run the supplied piece of 5/32” vacuum hose from this TEE to the nipple located on the bottom of the supercharger bypass valve. (See

12-a

1999-2000 Models only

1. Following

Fig. 12-b

, connect the 1” x 8.5” and 1” x 90° hoses to the supplied supercharger bypass valve and secure with #16 hose

Fig.

DISCHARGE DUCT

VACUUM HOSE

1” x 2.75” HOSE

1” x 5” HOSE

1994 - 1998

INLET DUCT

VACUUM SOURCE

clamps. Attach the bypass valve/hose

assembly to the bung located on the discharge duct and to the 1” barb located on the plastic molded inlet elbow (make sure that the bypass valve nipple is pointing down when installed). Secure with #16 hose clamps.

2. Insert the supplied brass TEE into the vacuum hose connecting the top of the manifold, near the throttle body. Route the supplied piece of 5/32" vacuum hose from the previously mentioned TEE to the nipple located on the bottom of the supercharger bypass valve.

3. Remove the factory PCV valve from the driver's side valve cover and replace with the one provided.

TEE INTO PREVIOUSLY INSTALLED FMU VACUUM LINE

Fig. 12-a

DISCHARGE DUCT

1” x 90°ELBOW

1” x 8.5” HOSE

VACUUM HOSE

FMU

INLET DUCT

1999 - 2001

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

VACUUM SOURCE

Fig. 12-b

Page 27

WARNING:

Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check.

13. FINAL CHECK

A. Reconnect the battery. B. If your vehicle has gone over 30,000 miles since

its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

C. Check all fittings, 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 fluid levels, making sure that your

tank(s) is filled 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 fluid leakage.

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. Read the STREET SUPERCHARGER SYSTEM

OWNER'S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within

thirty (30) days of purchasing your supercharger system to qualify for the 3 year limited warranty.

Fig. 12-a

NOTE:

Do not attempt to operate the air condi-

tioning until a qualified air conditioning technician has performed the necessary steps to purge and recharge the air conditioning system.

09JUN03 V2.1

P/N: 4FF020-010

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

Page 28

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