Vortech 1996-2004 Ford 4.6L Mustang GT User Manual

P/N: 8N020-030
© 2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured.
23JAN01 V2.1 (2V Maxflow Power Cooler.qxd)

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 [phone]

Fax: [phone] • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM (PST)

ENGINEERING, LLC

VORTECH

®

P/N: 8N020-030
© 2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured.
23JAN01 V2.1 (2V Maxflow Power Cooler.qxd)

ii

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.

© 2001 VORTECH ENGINEERING, INC.

All rights reserved. No parts of this publication may be reproduced, transmitted, transcribed,

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

of Vortech Engineering, Inc.

iii

P/N: 8N020-030

© 2002 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured.

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

P/N: 8N020-030
© 2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured.
23JAN01 V2.1 (2V Maxflow Power Cooler.qxd)

iv

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 [phone] 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.

P/N: 8N020-030

© 2002 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured.

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

v

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!

vi