Vortech 1996-2004 Ford 4.6L Mustang GT User Manual

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Maxflow®Power Cooler

Installation Instructions

1996 - 2001 Ford 4.6 Mustang GT (2 Valve)

P/N: 8N301-030 CARB EO #D-213-15 (1996-1998 Models only)

1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone 805 247-0226

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

ENGINEERING, LLC

VORTECH

Page 2

FOREWORD

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.

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

of Vortech Engineering, Inc.

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iii

P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

Table Of Contents

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

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

NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

TOOL AND SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

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

2. SUPERCHARGER RECLOCKING AND REINSTALLATION . . . . . . . . .2

3. AFTERCOOLER AND DISCHARGE TUBE MOUNTING . . . . . . . . . . . .3

4. IDLE AIR CONTROL AND VALVE COVER VENT LINES . . . . . . . . . . . .4

5. WATER TANK MOUNTING (PLUMBING SCHEMATIC) . . . . . . . . . . . . .5

6. PLUMBING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

7. WATER COOLER AND PUMP INSTALLATION . . . . . . . . . . . . . . . . . . .7

8. WATER PUMP WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

9. FMU RECALIBRATION (1996-1998 Only) . . . . . . . . . . . . . . . . . . . . . . .9

10. FMU ASSEMBLY (1996-1998 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . .10

11. FMU MOUNTING (1996-1998 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . .11

12. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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If the vehicle still has the battery located in the factory position, it must be relocated into the trunk to make room for the water tank assembly. Vortech part number 8N150-010 is a Heavy-Duty Battery Relocation Kit that may be purchased separately. Commonly available “universal” relocation kits may be used but they will most likely contain a smaller cable. Additional fabrication may also be necessary when using a “universal” kit.

This product may not be legal for use on public roads in all 50 states.

NOTICES

(Read before installation is started)

Included in this kit is a smaller than originally supplied supercharger pulley. This new pulley is recommended to achieve the best performance results. Removal of the factory sealed pulley will reduce the supercharger warranty from three years to one year unless the supercharger unit (with the original pulley still attached) and new pulley are sent into Vortech for removal, installation and re-sealing. If the supercharger warranty is not a concern or if the supercharger warranty has expired, the pulley may simply be removed and replaced with the new part supplied. Hammering/prying etc. on the supercharger and/or pulley will cause damage to the parts. Light heating of the supercharger pulley with a propane torch (if the pulley is tight on the shaft) will aid removal. A return authorization number is required before the supercharger and pulley are sent into Vortech. Call the Vortech service department at (805) 247-0226 for a return authorization number. Return freight (ground) will be paid by Vortech.

This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry, and engineering features shown in this product are the exclusive property of Vortech Engineering, Inc. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, Inc.

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

Vortech Maxflow Power Cooler

Installation Instructions

1996 - 2001 Ford 4.6 Mustang GT (2 Valve)

Before beginning this installation,

please read through this entire instruction booklet

The Vortech Maxflow Power Cooler system was designed as a street/strip oriented aftercooler, specifically for use on 1996 - 2001 Ford 4.6 Mustang vehicles equipped with a Vortech supercharger producing up to approximately 580 horsepower.

As with any power enhancing product, this system is intended for use on healthy, well-maintained engines. Vortech Engineering is not responsible for engine dam- age. 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 a note of the following key points:

1. Use only premium grade fuel 92 octane or higher (R+M/2).

2. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost)

until problem is resolved.

TOOL & SUPPLY REQUIREMENTS:

• Open End Wrenches (7/16”, 9/16”, 5/8”, 11/16”)

• 3/8” Ratchet

• 8mm, 13mm, 9/16”and 18mm Sockets

• 5/32”, 3/16”, 9/16” Allen Wrenches

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Utility Knife

• Torque Wrench (in/lbs)

• Wire Cutters, Strippers and Crimpers

• Drill Motor

• 1/8”, #21 Drill Bits

• Tape Measure

• Ford Springlock 3/8” Fuel Fitting

Disconnect Tool

• Pipe Tape (Teflon)

• Adjustable Wrench

Congratulations on selecting the best performing and most

efficient aftercooler today... the Vortech Maxflow Power Cooler!

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

Vortech Maxflow Power Cooler

Part No. 8N301-030

1996 - 2001 Ford 4.6 Mustang GT (2 Valve)

PARTS LIST

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

Air/Water Aftercooler Assembly (8N201-030)

Water Cooler Assembly (8N106-030)

PART NUMBER DESCRIPTION QUANTITY 8N101-030 Air/Water Aftercooler 1

7P500-078 1/2” NPT x 3/4” Hose Fitting 2 8N012-050 Cooler Discharge Tube 4.6 2V 1 7S300-200 3” x 2” Sleeve 1 7R002-044 No. 44 Hose Clamps 2

PART NUMBER DESCRIPTION QUANTITY 8N006-010 Water Cooler 1

7P500-026 90° Brass Fittings 2 8N010-050 Mounting Tabs 2 7E010-075 #12 x 3/4 HXHD Sheet Metal 4 7J010-001 #10 Flat Washer 4 7A250-075 1/4-20 x 3/4 SHCS 5 7F250-021 1/4-20 Nylock 5 7J250-001 1/4” Flat Washer 10

Water Pump Assembly (8N107-020)

PART NUMBER DESCRIPTION QUANTITY 5W001-011 14-16 GA Eyelet 1

5W001-012 18-22 GA Butt Connector 1 5W018-010 18 GA Wire Red (99”) 1 5W001-019 12 GA Butt Connector 1 5W001-014 Fuse Holder 1 5W001-015 Fuse Blade Style 1 5W001-002 Fuse Tap 1 5W001-040 12-10 GA Female Slide 1 8F001-402 Pump, Water 1 7E010-075 #12 x 3/4” Sheet Metal Screw 2 7J010-001 #10 Flat Washer 2 7U133-060 3/4” x 90° Hose Elbow 1 7R003-027 Adel Clamp 1

Water Tank Assembly (8N105-030)

PART NUMBER DESCRIPTION QUANTITY 8N105-010 Water Tank w/Fittings 1

7U038-000 3/4” Heater Hose (228”) 1 7R007-001 Plastic Double Grip Clamps 7 7R003-016 15/16” Adel Clamps 3 7E010-075 #12 x 3/4 HXHD 3 7J010-001 #10 Flat Washer 3 7U100-044 Nylon Tie Wraps 4” 16 7U100-066 Nylon Tie Wraps 11” 6

Support Components (8N104-020)

PART NUMBER DESCRIPTION QUANTITY 4FH145-050 30” Male Fuel Line 1

7U030-046 5/32” Vac Line (30”) 1 7U133-024 5/8” x 24-90° (Modified) 1 7P625-002 5/8” Hose Mendor 1 7P375-075 3/4” Hose Mendor 1 7U030-065 3/4”90° (Modified) 1 7U100-030 O-Ring FMU 1 6Z020-130 Small Diaphragm 1 6Z060-181 Valve Disk 1 6Z170-020 8:1 Ring Spacer Assembly 1 2A036-333 3.33 Supercharger Pulley 1

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

1. Preparation and Removal

A. Disconnect and remove the battery (if located in

the factory position, the battery will need to be relocated to the trunk).

B. Remove the supercharger discharge tube and

bypass valve assembly.

C. Remove belt, supercharger and bracket.

Disassemble the bracket from the supercharger.

D. Disconnect lines from the air inlet that connects to

the idle air control and valve cover vent.

E. 1996-1998 Models Only: Remove the FMU from

the inner fender and disconnect the male fuel line from the fuel rail.

NOTE: Temporarily cap oil feed and oil drain to

protect your engine from foreign particles.

* Ignore these steps and refer to the supercharger kit

instruction manual if the Power Cooler is being installed at the same time as the supercharger kit.

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2. Supercharger Reclocking and Reinstallation

A. Loosen and remove the six (6) 1/4-20 cap screws

and retaining plates that hold the compressor housing to the gearcase.

B. Carefully rotate the supercharger volute to the

specified location as shown. (See Figure 2-a.)

C. Evenly retighten the six (6) cap screws, torque to

60 in/lbs (5ft/lbs).

D. Remove original 3.60” supercharger pulley from

the supercharger and install the supplied 3.33” pulley.

E. Reattach the supercharger onto the bracket and

then remount the assembly to the engine. Reconnect oil feed and drain lines.

NOTE: Included in this kit is a smaller than origi-

nally supplied supercharger pulley. This new pulley is recommended to achieve best performance results. Removal of the factory sealed pulley will reduce the supercharger warranty from three years to one year unless the supercharger unit (with the original pulley still attached) and new pulley are sent into Vortech for removal, installation and re-sealing. If supercharger warranty is not a concern or if the supercharger warranty has expired, the pulley may simply be removed and replaced with the new part supplied. Hammering/prying etc. on the supercharger and/or pulley will cause damage to the parts. Light heating of the supercharger pulley with a propane torch (if the pulley is tight on the shaft) will aid removal. A return authorization number is required before the supercharger and pulley are sent into Vortech. Call the Vortech service department at (805) 2470226 for return authorization number. Return freight (ground) will be paid by Vortech.

NOTE: If the compressor housing does not rotate

freely relative to the gearcase, DO NOT FORCE IT. SERIOUS SUPERCHARGER DAMAGE MAY OCCUR. The machined mating surfaces are designed to prevent pressurized air from escaping and have minimal tolerances. If the housing will not move or is very tight, contact Vortech Engineering immediately at (805) 2470226 and ask for our service department for further assistance.

Figure 2-a

NOTE: Ignore this section if the Power Cooler is

being installed at the same time as the supercharger kit.

Modified Clocking

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

3. Aftercooler and Discharge Tube Mounting

A. Install the bypass valve onto the 1” cooler inlet

barb using the original hose. Secure the assembly to the aftercooler.

B. Remove the silicone sleeves and clamps from the

original discharge tube.

C. Reinstall the 2-3/4” diameter silicone sleeve onto

the supercharger outlet and slide the sleeve back as far as possible, leaving the two #44 hose clamps loose.

D. Slide the 3” silicone sleeves (1 supplied, 1 original)

onto the throttle body and aftercooler outlet. Leave the four #48 hose clamps loose.

E. With cooler into position, slide the silicone sleeve

and clamps from the supercharger outlet onto the aftercooler inlet and secure.

F. Install the discharge tube between aftercooler and

throttle body and secure sleeves and clamps. (See Figure 3-a.)

G. Reconnect the bypass valve outlet to the 90° plas-

tic elbow on the air inlet and secure with the original hose clamps. A small amount of trimming to the 1” hose may be necessary to ensure proper fit.

Figure 3-a

* Ignore these steps and refer to the supercharger kit

instruction manual if the Power Cooler is being installed at the same time as the supercharger kit.

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A. Using the 3/4” 90° elbow slide the shortest end

onto the 3 1/2” x 45° inlet elbow and insert the 3/4” hose union into the opposite end.

B. Cut a piece of 3/4” hose 34” in length and attach

to the 3/4” hose union and to the idle air control motor.

C. Attach the short end of the 5/8” x 24” 90° hose to

the 3 1/2” x 45° inlet elbow and install the 5/8” hose union into the free end (see Figure 4-a).

D. Connect the valve cover vent line to the 5/8” hose

union and trim the excess line as needed (see Figure 4-b).

4. Idle Air Control and Valve Cover Vent Lines

Figure 4-a

1996-1998 Models

Figure 4-b

Figure 4-c

1999-2001 Models

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

5. Water Tank Mounting (Plumbing Schematic)

A. Remove battery tray and notch to allow tank

to sit flush with bottom of tray and reinstall

(see Figure 5-a).

B. Place the water tank in the tray previously occu-

pied by the battery and secure using the original battery hold down (see Figure 5-b).

C. Cut a piece of the 3/4” hose 50” in length and

attach to the 3/4” 90° fitting (located at the lower rear of the water tank). Route downward and toward the front of the car (see Figure 5-e on the next page).

D. Cut a piece of the 3/4” hose 98” in length and

attach it to the water return fitting on the tank. Route the hose downward and secure with the supplied adel clamps and #12 hardware to the bottom of the radiator core support (see Figure 5–c). Connect the hose to the outlet fitting on the aftercooler routing it up and through the headlight well (see Figure 5-d).

Figure 5-a

Figure 5-b

Figure 5-c

Figure 5-d

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5. Water Tank Mounting, cont’d (Plumbing Schematic)

Figure 5-e

FROM

SUPERCHARGER

FRONT VIEW OF COOLER

TO THROTTLE BODY

WATER

INLET

WATER

OUTLET

Water Out

Flow

Water In

Flow

42"

FROM

SUPERCHARGER

TOP VIEW

BLUE/GREEN

(-)

BROWN/BLACK

WATER

COOLER

(+)

DRAINCOCK

WATER

PUMP

3/4” 90°

HOSE BEND

RETURN WATER FROM

AFTERCOOLER CORE

WATER

TANK

WATER

FLOW

50"

FEEDHOSE

FROM TANK

98"

FRONT OF VEHICLE

SECURE TO THE BOTTOM OF THE RADIATOR CORE

SUPPORT

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

A. Remove the air dam from the lower radiator

core support.

B. Loosely attach the supplied water cooler brackets

to the cooler using the supplied 1/4” hardware (see Fig. 6-b). Following the photo, position the cooler on the core support as far towards the passenger side as possible. Using the mounted cooler brackets as a guide, mark the position on the lower radiator core support where the bracket mounting holes must be drilled (see Fig. 6-a). Drill the four mounting holes and attach the cooler assembly to the core support with #12 hardware.

C. Notch the air dam to allow clearance for the cooler

mounting brackets and reinstall.

D. Route the previously attached 50” section of hose

extending downward from the lower 90° fitting on the water tank to the inlet of the water pump. Secure hose with nylon ratchet clamps.

E. Secure the hoses to the chassis with provided tie

wraps.

F. Cut a piece of the 3/4” hose 42” in length and

attach to the outlet fitting of the water cooler. Connect hose to the inlet fitting on the aftercooler. The line should run parallel with the return line. Trim the ends appropriately and secure both with nylon ratchet clamps.

G. Following Figs. 6-b and 6-c, attach the supplied

rubber 90° hose bend to the water cooler inlet. Slide the water pump bracket onto the water pump and position the outlet of the pump in line with the 90° hose bend. Using the bracket as a guide, mark and drill holes in core support and attach with the supplied hardware. Trim the 90° hose if necessary, and secure with nylon ratchet clamps.

NOTE: Hoses must not be kinked or restricted.

Route away from moving parts and direct engine heat.

6. Water Cooler and Pump Installation

Figure 6-a

Water Pump Outlet

Figure 6-c

Water Pump Inlet

Figure 6-b

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7. Water Pump Wiring

A. Cut the supplied wiring harness plug from the end

at the water pump harness. Attach a 16 GA eyelet to the brown/black wire (negative) and route to a clean ground free from paint and vehicle undercoating. A cooler mounting tab works well for this.

B. Route the red wire from the water pump through

the firewall to the fuse panel. Connect to fuse #18 using the supplied fuse tap, fuse and fuse holder (make sure that the supplied secondary fuse is spliced into the power wire). Secure the red wire to the chassis using the provided tie wraps. Connect the red wire using a solderless connector to the black wire with a yellow stripe or blue/green wire (positive) on the wiring harness of the water pump.

C. Fill the water tank with 25% antifreeze and 75%

water to approximately 3” from the top. Do not fill past the water return fitting (doing so will not allow system to purge itself of air).

D. Turn the ignition key to the “ON” position and

check that the water is flowing through the system. Once water is flowing, allow to run for approximately one minute. This will allow any trapped air to be purged from the system. Once all the air is removed, fill the tank to one inch below the filler ring.

NOTE: Do not attach the red wire to the power

until the water tank is full of water, running the water pump without water will lead to premature failure and void your warranty.

NOTE: In some cases, the water pump must be

primed on initial start-up. This may be accomplished by turning on the pump, removing the RETURN line from the tank and providing light suction on the hose to remove the air in the system.

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

8. FMU Recalibration (1996-1998 MODELS ONLY)

A. Remove the six (6) allen head screws on top of

the fuel management unit (FMU).

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

if equipped) from inside of the FMU.

C. Remove the four screws holding the valve body.

Once taken apart, remove the piston, small diaphragm, disk and O-ring.

D. Remove and exchange fittings on the valve body.

A small amount of Teflon sealant (not silicone or RTV) may be used on the fittings. Excessive sealant may damage the FMU.

E. Install the new O-ring, disk and small diaphragm

as shown. The disk must be centered on the valve body. The disk should not be allowed to make contact with the screws as this can damage it, resulting in FMU leakage and/or malfunction.

F. Before tightening the valve bodyscrews, install the

piston with the radius side down. Apply a small amount of pressure on the piston to eliminate any possibility of an air bubble being trapped between the disk and diaphragm.

G. Tighten the four screws to 24in/lbs (2ft/lbs) in a

crisscross pattern to ensure a proper seal.

H. Install the replacement ring (with the notched part

facing down) around the four screws inside the FMU.

I. Place the new washer inside the ring on top of the

piston.

J. Install the new diaphragm and carefully line up

holes to the body.

K. Reinstall the FMU cover with the six (6) allen head

screws. DO NOT OVERTIGHTEN THE SCREWS. The correct torque is 24in/lbs (2ft/lbs).

NOTE: If you are unsure of your ability to correctly

complete these steps, please contact Vortech Engineering at (805)247-0226 and ask for the Service Department.

NOTE: Ignore this section if the Power Cooler is

being installed at the same time as the supercharger kit.

Page 18

8. FMU Recalibration, cont’d (FMU Assembly)

Figure 8-a

1996-1998 Models Only

COVER W/FITTING

DIAPHRAGM (LARGE)

RING SPACER

(NOTCH DOWN)

WASHER

FLARE FITTING

PISTON

TEFLON SEALANT

ON THESE

THREADS ONLY

O-RING

VALVE BODY

90° FLARE FITTING

HOUSING

VALVE DISK

DIAPHRAGM (SMALL)

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P/N: 8N020-030

23JAN00 V2.1 (2V Maxflow Power Cooler.qxd)

9. FMU Mounting (1996-1998 Models Only)

A. Install the new 30” long male FMU line to the fuel

rail and to the FMU.

B. Remount the FMU next to the air inlet (see Figure

9-a).

C. Connect the supplied length of 5/32” vacuum hose

to the FMU and the original manifold vacuum source.

D. Route the 5/32” vacuum line from the bypass valve

and TEE into the FMU vacuum line with the original 5/32” TEE. Make sure vacuum line to bypass valve is not kinked.

Figure 9-a

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10. Final Check

A. Check all fittings, hose and clamps for tightness

and leaks. Make sure all wires and lines are properly secure with clamps or tie wraps.

B. Make sure all wires and hoses are routed away

from hot, moving or sharp objects.

C. Double check to ensure water is flowing through

the system.

ENGINEERING, INC.

WARNING: Do not attempt to operate the vehicle until

ALL components are installed and ALL operations are completed including the final check.

1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone 805 247-0226

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

VORTECH