Vortech 2000-2003 Ford Focus Zetec SVT User Manual

DP/N: 4FJ020-010 - v3.0 04/19/04

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

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

ENGINEERING, LLC

2.0L FORD FOCUS

Supercharger System

Installation Instructions

2000-2003 ZX3 Model Years

2002-2003 SVT Model Years

50 State Smog Legal Per CARB E.O. #D-213-20

®

ii

into another language in any form, by any means without written permission of Vortech Engineering.

This manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for the Ford Focus.Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0226, 7:00am-3:30pm PST. An understanding of the information contained herein will help novices, as well as experienced technicians, to correctly install and receive the greatest possible benefit from their Vortech supercharger.When reference is made in this manual to a brand name, number, specific tool or technique, an equivalent product may be used in place of the item mentioned. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. All rights reserved to make changes at any time without notice.

FOREWORD

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

iii

TABLE OF CONTENTS

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

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

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

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

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

2. SUPERCHARGER OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3. SUPERCHARGER OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4. CROSSOVER COOLANT LINE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .3

5. POWER STEERING RELOCATION/SECONDARY PLATE INSTALLATION . . . . . .4

6. POWER STEERING LINE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

7. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . .6

9. AIR INLET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

10. SVT DSI BOX RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

11. STANDARD DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

12. CHARGE COOLED DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .14

13. WATER TANK AND WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .15

14. HEAT EXCHANGER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

15. WATER LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

16. BATTERY RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

17. REFLASH ECM (SVT ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

18. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

iv

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 Engineer ing, LLC.This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or for tuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, LLC.

NOTICE

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

v

FORD 2.0 FOCUS ZX3

IMPORTANT NOTES

This kit requires ECM modification and the installation of a Vor tech ECM Module.The ECM must be sent directly to Vor tech 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 (1) Vortech ECM Module.

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

• Simply contact the Vor tech Ser vice Depar tment at 805.247.0226 to request a Return Authorization Number (see ECM Module Credit Tag for more details). — Mail to Vor tech the enclosed “ECM Module Credit Tag” (sending original

tag - no photocopies will 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 Vor tech 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).

SVT Owner’s NOTE: The SVT Focus ECM does not use an ECM module as the ZX3 model does. A handheld ECM programmer has been included in the kit box.

Vortech Engineering is not responsible for engine or ECM damage due to an improperly installed/mis-handled ECM module or ECM

vi

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner’s Manual (Race Owner’s Manual for the Focus kit) 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 horsepower between 35-50% can be expected with the boost levels specified by Vortech Engineer ing. This product is intended for use on healthy, well maintained engines. Installation on a wor n-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 91 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 Vor tech pr ior 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 1 year or 10,000 miles with origi-

nal 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 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENT

•Factory repair manual

• 3/8" socket and drive set:SAE & metric

• 1/2" socket and drive set:SAE & metric

• 3/8" Extension 3"

• 1/2 Extension 3"

• 3/8" NPT Tap and Handle

• Adjustable Wrench

• Open End wrenches: 5/16", 3/8", 7/16", 1/2", 9/16", 5/8", 11/16", 3/4" 10mm, 13-18mm

•3 lb hammer

• 1-1/16" Oil Sending Unit Socket (Snap-On® #A119A)

•6 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

•Drill Motor

• “R”, 1/8", 3/16", 11/32" Drill Bits

• 3/16", 8mm Allen Wrenches

•Wire Strippers and Cr impers

• Utility Knife

• Blue Loctite

• Cut-off wheel/hacksaw

2000 - 2003 Ford 2.0L Focus ZX3 2002 - 2003 Ford 2.0L Focus SVT

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® supercharger!

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

vii

2E428-010 S/C, V5F SQ FOCUS SAT 1 2A036-262 S/C PULLEY 2.62" 6-GROOVE 1 4FJ111-021 S/C MTG BRKT ASSY, FOCUS 1

4FJ010-034 MOUNTING PLATE, SUPERCHARGER 1 4FJ017-021 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 2A017-878-07 SPACER, .875 OD x 3.560 LONG 2 2A017-078-06 SPACER, .875 OD x 1.809 LONG 2 7C010-130 M10 x 1.50 x 130 HEXHEAD 3 7J010-002 10mm WASHER, ZINC PLATED 3 7A375-276 3/8"-16 x 2-3/4" HXHD ZINC 1 7K375-040 3/8" AN960 FLAT WASHER PLATED 1 7C012-025 M12 x 1.75 x 25mm HXHD PLTD 1 7J012-092 12mm WASHER, FLAT 1 7A375-251 3/8"-16 x 2-1/2" FLAT SHCS 1

4FJ111-041 P/S RELOCATION ASSY, FOCUS 1

4FJ010-011 BRACKET, P/STEERING RELOCATION 1 7U250-020 11mm DOWEL, LONG 2 7C080-040 M8 x 1.25 x 40mm SHCS 4 7K312-001 5/16" AN WASHER, PLATED 4 7A312-073 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 1210517 ASY, IDLER PULLEY, SMOOTH 2 4FJ017-011 SPACER, IDLER PULLEY 2 2C017-002 PILOT, 6203/5 BRG, 7/16 SCREW 2 7A437-150 7/16"-14 x 1-1/2" HXHD GR8 2 4FJ010-021 MTG PLATE, BEARING HOUSING 1 7A375-102 3/8"-16.x 1" FLT ALLN ZNPLT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8" 2 7R002-012 #12 SAE TYPE F SS HOSE CLAMP 1 7U038-000 3/4" HEATER HOSE 0.54' 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7R003-013 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 7E010-049 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 7U100-055 TIE WRAP, 7.5" NYLON 6

4FJ130-036 OIL DRAIN ASSY, FOCUS 1

7P375-008 ELBOW, PLASTIC 3/8" x 90 UNION 1 7U030-036 1/2" OIL DRAIN HOSE 1.41' 7S625-000 SHEATH, MYLAR, .625 ID 1 7R001-006 #6 STNLS HOSE CLAMP, NARROW 2 7P375-041 3/8" NPT HEX NIPPLE x 1.5" 1 7P375-017 3/8" NPT x 1/2" BEADED HSE BRB 1

4FJ130-026 OIL FEED ASSY, FOCUS 1

7PP250-034 FITTING, STREET TEE MOD 1 7P250-031 1/4" NPT x -4JIC FLARE FTG STL 1 7U250-090-260 OIL FEED HOSE, 26" -4 x 90° 1 7P125-004 1/8" NPT 90° x -4 JIC FTG STL 1

4FJ112-010 AIR INLET ASSY, FOCUS 1

4FJ012-010 INTAKE ELBOW, FOCUS° 1 7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7S350-200 3-1/2" x 2" SLEEVE 1 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 2 7P375-039 3/8" NPT x 5/8" BARB CLAMP 90° 1 7P750-100 3/4" NPT x 1" HOSE FITTING 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-048 #48 SAE TYPE F SS HOSE CLAMP 2 4FJ010-050 MAF BRKT, FOCUS 1 7U133-100 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 7U034-016 1" GS HEATER HOSE 0.66' 7U030-046 5/32" VACUUM LINE 2.50' 7U035-002 3" FLEX HOSE 1.083' 7A250-075 1/4"-20 x 3/4" SHCS PLTD 2 7F250-021 1/4"-20 NYLOCK NUT ZINC PLTD 2 7J250-001 1/4" WASHER, SAE, PLTD 4 8H040-040 AIR FILTER, 3.5" FLG x 5.5L 1 5W014-030 14GA STRD WIRE BLACK 9' 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 12 5W001-007 3/16" HEAT-SHRINK TUBING 1.5' 7U033-000 5/8" PCV HOSE 3.25' 7P625-016 5/8" HOSE UNION, BARBED ENDS 1 7R001-008 #8 STNLS HOSE CLAMP 1 7P156-082 5/32" TEE 1

Part No. Description Qty. Part Number Description Qty.

4FJ212-040 DISCHARGE ASSY, SVT STD FOCUS 1

4FJ112-040 DISCH TUBE ASSY, FOCUS SVT STD 1

9ST100-049 Ø1" 18GA MILD STEEL TUBE 1.37" 7S275-251 REDUCER, 2.75" TO 2.50" 1 7R002-044 #44 SAE TYPE F SS HOSE CLAMP 3 7R002-040 #40 SAE TYPE F SS HOSE CLAMP 1 7S275-092 ELBOW, 2.75" x 90° SILICONE 1 5A102-014 IAT SENSOR ASSY 1

4FJ111-032 S/C DRIVE ASSY, FOCUS 1

2D030-041 BRG HSG, EXT DRIVE, MACH GEN2 1 2DO70-159 LARGE BEARING, EXTENDED DRIVE 2 7U100-084 SNAP, RING, EXT DRV HOUSING 1 2D070-281 COUPLING, FLG, 3-PIN DRIVE 2 7U250-125 DOWEL PIN, Ø1.4" x 1.25L 6 7J375-020 WASHER, 1.0 OD, .406 x ID 2 2D070-260 COUPLING, DRIVE, COMPOSITE 1 2D160-215 TUBE HSG ASSY, EXT DRIVE FOCUS 1 2D030-061 HOUSING, COUPLING, EXT DRIVE SH 1 7A312-525 5/16"-18 x 5.25" HXCS GR8 ZINC 4 7B375-110 3/8"-24 x 1" GRADE 8 HXHD 3 7U100-070 KEY, 3/16" SQUARE x 7/8" LONG 3 7U312-101 DOWEL BUSHING, .312" x 1.00" 2 2A040-011 PULLEY RETAINER S/C 1 7A312-100 5/16"-18 x 1" HXCSGR5P 4 7K375-040 3/8" AN960 FLAT WASHER PLATED 1 7X100-025 WAVE WASHER-LARGE 1

2A046-101 BELT, 4061010 GOODYR FOCUS 1 008110 SMALL SILVER DIE CUT DECAL 2 008444 S/C STRT INFO PKG ASSY VORT 1

008120 SML, BLU DIE CUT DECAL VORT 2 08440 WHITE LG PKGNG ENVELOPE VORT 1 008441 YELLOW WARNTY REG ENVEL VORT 1 008516 STREET S/C OWNERS MAN VORT 1 008544 STRT S/C WARNTY REG FORM VORT 1 008543 WARNTY TERMS/CONDITIONS VORT 1

008130 LICENSE PLATE FRAME, VORTECH 1 8F060-042 FUEL INJECTOR, 42LBS RAIL STYL 4 4FJ245-050 P/S HOSE INSTALL, ASSY, FOCUS 1

4FJ145-050 HI-PRESS PWR.STR.HOSE w/ENDS 1 7P250-130 1/4"NPT MALE TO -6 MALE JIC AL 1 7P250-132 -6 JIC MALE 3/8"NPT x 45° 1 7P250-011 COMPRSSN FTG, 1/4"NPTF x 3/8"T 1 7P375-120 COMPRSSN FTG, 3/8"NPTF x 3/8"T 1

4FJ210-060 BATT RELOCATION ASSY, FOCUS 1

4FJ110-060 ASSY, BATT BRKT, FOCUS PLATED 1 2A017-875-08 SPACER, .875 OD x .290 LONG 1 2A017-879-06 SPACER, .875 OD x .800 LONG 1 7A375-151 3/8"-16 x 1.5 HXHD GR8 4 7J375-044 3/8"SAE WASHER, PLTD 8 7F375-017 3/8"-16 NYLOCK NUT 4 5W001-028 BATT POST TERMINALS 2 5W008-100 8GA, RED STRANDED WIRE 6' 5W001-035 LUG, 6-2AWG, 3/8" STUD 4 5W001-053 REMOTE BATTERY POST 1 5W008-105 8GA, BLACK STRANDED WIRE 1 5W001-008 3/4" HEAT-SHRINK TUBING 1

5A003-031 HANDHELD PROGRAMMER 1

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

immediately.

2002-2003 SVT Ford Focus

Part No. 4FJ218-010

ENGINEERING, LLC

PARTS LIST

®

viii

Part No. Description Qty. Part Number Description Qty.

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

immediately.

2002-2003 SVT H.O. Ford Focus

Part No. 4FJ218-020

ENGINEERING, LLC

PARTS LIST

2E428-010 S/C, V5F SQ FOCUS SAT 1 2A036-262 S/C PULLEY 2.62" 6-GROOVE 1 4FJ111-021 S/C MTG BRKT ASSY, FOCUS 1

4FJ010-034 MOUNTING PLATE, SUPERCHARGER 1 4FJ017-021 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 2A017-878-07 SPACER, .875 OD x 3.560 LONG 2 2A017-078-06 SPACER, .875 OD x 1.809 LONG 2 7C010-130 M10 x 1.50 x 130 HEXHEAD 3 7J010-002 10mm WASHER, ZINC PLATED 3 7A375-276 3/8"-16 x 2-3/4" HXHD ZINC 1 7K375-040 3/8" AN960 FLAT WASHER PLATED 1 7C012-025 M12 x 1.75 x 25mm HXHD PLTD 1 7J012-092 12mm WASHER, FLAT 1 7A375-251 3/8"-16 x 2-1/2" FLAT SHCS 1

4FJ111-041 P/S RELOCATION ASSY, FOCUS 1

4FJ010-011 BRACKET, P/STEERING RELOCATION 1 7U250-020 11mm DOWEL, LONG 2 7C080-040 M8 x 1.25 x 40mm SHCS 4 7K312-001 5/16" AN WASHER, PLATED 4 7A312-073 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 1210517 ASY, IDLER PULLEY, SMOOTH 2 4FJ017-011 SPACER, IDLER PULLEY 2 2C017-002 PILOT, 6203/5 BRG, 7/16 SCREW 2 7A437-150 7/16"-14 x 1-1/2" HXHD GR8 2 4FJ010-021 MTG PLATE, BEARING HOUSING 1 7A375-102 3/8"-16.x 1" FLT ALLN ZNPLT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8" 2 7R002-012 #12 SAE TYPE F SS HOSE CLAMP 1 7U038-000 3/4" HEATER HOSE 0.54' 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7R003-013 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 7E010-049 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 7U100-055 TIE WRAP, 7.5" NYLON 6

4FJ130-036 OIL DRAIN ASSY, FOCUS 1

7P375-008 ELBOW, PLASTIC 3/8" x 90 UNION 1 7U030-036 1/2" OIL DRAIN HOSE 1.41' 7S625-000 SHEATH, MYLAR, .625 ID 1 7R001-006 #6 STNLS HOSE CLAMP, NARROW 2 7P375-041 3/8" NPT HEX NIPPLE x 1.5" 1 7P375-017 3/8" NPT x 1/2" BEADED HSE BRB 1

4FJ130-026 OIL FEED ASSY, FOCUS 1

7PP250-034 FITTING, STREET TEE MOD 1 7P250-031 1/4" NPT x -4JIC FLARE FTG STL 1 7U250-090-260 OIL FEED HOSE, 26" -4 x 90° 1 7P125-004 1/8" NPT 90° x -4 JIC FTG STL 1

4FJ112-010 AIR INLET ASSY, FOCUS 1

4FJ012-010 INTAKE ELBOW, FOCUS° 1 7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7S350-200 3-1/2" x 2" SLEEVE 1 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 2 7P375-039 3/8" NPT x 5/8" BARB CLAMP 90° 1 7P750-100 3/4" NPT x 1" HOSE FITTING 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-048 #48 SAE TYPE F SS HOSE CLAMP 2 4FJ010-050 MAF BRKT, FOCUS 1 7U133-100 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 7U034-016 1" GS HEATER HOSE 0.66' 7U030-046 5/32" VACUUM LINE 2.50' 7U035-002 3" FLEX HOSE 1.083' 7A250-075 1/4"-20 x 3/4" SHCS PLTD 2 7F250-021 1/4"-20 NYLOCK NUT ZINC PLTD 2 7J250-001 1/4" WASHER, SAE, PLTD 4 8H040-040 AIR FILTER, 3.5" FLG x 5.5L 1 5W014-030 14GA STRD WIRE BLACK 9' 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 12 5W001-007 3/16" HEAT-SHRINK TUBING 1.5' 7U033-000 5/8" PCV HOSE 3.25' 7P625-016 5/8" HOSE UNION, BARBED ENDS 1 7R001-008 #8 STNLS HOSE CLAMP 1 7P156-082 5/32" TEE 1

4FJ111-032 S/C DRIVE ASSY, FOCUS 1

2D030-041 BRG HSG, EXT DRIVE, MACH GEN2 1

2DO70-159 LARGE BEARING, EXTENDED DRIVE 2

7U100-084 SNAP, RING, EXT DRV HOUSING 1

2D070-281 COUPLING, FLG, 3-PIN DRIVE 2

7U250-125 DOWEL PIN, Ø1.4" x 1.25L 6

7J375-020 WASHER, 1.0 OD, .406 x ID 2

2D070-260 COUPLING, DRIVE, COMPOSITE 1

2D160-215 TUBE HSG ASSY, EXT DRIVE FOCUS 1

2D030-061 HOUSING, COUPLING, EXT DRIVE SH 1

7A312-525 5/16"-18 x 5.25" HXCS GR8 ZINC 4

7B375-110 3/8"-24 x 1" GRADE 8 HXHD 3

7U100-070 KEY, 3/16" SQUARE x 7/8" LONG 3

7U312-101 DOWEL BUSHING, .312" x 1.00" 2

2A040-011 PULLEY RETAINER S/C 1

7A312-100 5/16"-18 x 1" HXCSGR5P 4

7K375-040 3/8" AN960 FLAT WASHER PLATED 1

7X100-025 WAVE WASHER-LARGE 1

2A046-101 BELT, 4061010 GOODYR FOCUS 1 008110 SMALL SILVER DIE CUT DECAL 2 008444 S/C STRT INFO PKG ASSY VORT 1

008120 SML, BLU DIE CUT DECAL VORT 2

08440 WHITE LG PKGNG ENVELOPE VORT 1

008441 YELLOW WARNTY REG ENVEL VORT 1

008516 STREET S/C OWNERS MAN VORT 1

008544 STRT S/C WARNTY REG FORM VORT 1

008543 WARNTY TERMS/CONDITIONS VORT 1

008130 LICENSE PLATE FRAME, VORTECH 1 8F060-042 FUEL INJECTOR, 42LBS RAIL STYL 4 4FJ245-050 P/S HOSE INSTALL, ASSY, FOCUS 1

4FJ145-050 HI-PRESS PWR.STR.HOSE w/ENDS 1

7P250-130 1/4"NPT MALE TO -6 MALE JIC AL 1

7P250-132 -6 JIC MALE 3/8"NPT x 45° 1

7P250-011 COMPRSSN FTG, 1/4"NPTF x 3/8"T 1

7P375-120 COMPRSSN FTG, 3/8"NPTF x 3/8"T 1

4FJ210-060 BATT RELOCATION ASSY, FOCUS 1

4FJ110-060 ASSY, BATT BRKT, FOCUS PLATED 1

2A017-875-08 SPACER, .875 OD x .290 LONG 1

2A017-879-06 SPACER, .875 OD x .800 LONG 1

7A375-151 3/8"-16 x 1.5 HXHD GR8 4

7J375-044 3/8"SAE WASHER, PLTD 8

7F375-017 3/8"-16 NYLOCK NUT 4

5W001-028 BATT POST TERMINALS 2

5W008-100 8GA, RED STRANDED WIRE 6'

5W001-035 LUG, 6-2AWG, 3/8" STUD 4

5W001-053 REMOTE BATTERY POST 1

5W008-105 8GA, BLACK STRANDED WIRE 1

5W001-008 3/4" HEAT-SHRINK TUBING 1

5A003-031 HANDHELD PROGRAMMER 1 8N106-005 ASSY, SETRAB, FOCUS 1

®

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

ix

Part No. Description Qty. Part Number Description Qty.

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

immediately.

2002-2003 SVT H.O. Ford Focus

Part No. 4FJ218-020

ENGINEERING, LLC

PARTS LIST

8N105-100 WATER TANK / HOSE ASSY, FOCUS 1

7E010-049 #10X3/4 HEX HD SLF DRL SHT MTL 4 7J010-001 #10 FLAT WASHER 4 7R007-001 NYLON RATCHET CLAMP 1-1/8" 9 7U038-000 3/4" HEATER HOSE 13 7U038-012 HOSE,3/4"DIA 90°,4X12 LEGS 1 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7U100-055 TIE WRAP, 7.5" NYLON 6 8N055-030 TANK, WATER, TRIANGLE SHAPE 1 4GR010-060 BRKT, WATER RES, C5 CORVETTE 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 2 7A250-050 1/4-20 X .50 SHCS ZINC PLTD 4 7J250-001 1/4 WASHER, SAE, PLTD 4 7R003-027 ADEL CLAMP,1-11/16" 1 7P100-122 1" NPT VENT PLUG 1 7P125-016 1/8 NPT PLUG 1

8N107-100 WATER PUMP / WIRING ASSY, FOCU 1

8F001-402 PUMP, WATER, PIERBURG 1 8F101-320 FUEL PUMP RELAY ASSY, LS1 TRK 1 5W001-005 3/8" PLASTIC WIRE LOOM 6' 5W001-010 16-14GA FEMALE SLIDE INSULATED 3 5W001-009 16-14GA MALE SLIDE INSULATED 2 5W001-043 12-10GA X 1/4" RING TERMINAL 2 5W001-024 MINI ATC FUSE TAP 1 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 7U100-044 TIE WRAP, 4" NYLON 6 7U100-055 TIE WRAP, 7.5" NYLON 6 5W001-019 10-12 GA BUTT CONN INSULATED 1

8N401-030 FOCUS SVT COOLR CORE/DISCH ASY 1

8N055-050 PLASTIC CAP, SURGE TANK 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 2 8N301-210 WELDED CORE ASSY, SVT FOCUS 1 7S275-092 ELBOW, 2.75 X 90° SILICONE 1 7S275-251 REDUCER, 2.75 TO 2.50 1 7R002-044 #44 SAE TYPE F SS HOSE CLAMP 4 7R002-040 #40 SAE TYPE F SS HOSE CLAMP 1 0008341 VORTECH CHARGE COOLER DECAL 1 5A102-014 IAT SENSOR ASSY 1

®

x

2E248-010 S/C, V5F SQ FOCUS SAT 1 2A036-287 S/C PULLEY 2.87" 6-GROOVE 1 4FJ111-021 S/C MTG BRKT ASSY, FOCUS 1

4FJ010-034 MOUNTING PLATE, SUPERCHARGER 1 4FJ017-021 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 2A017-878-07 SPACER, .875 OD x 3.560 LONG 2 2A017-078-06 SPACER, .875 OD x 1.809 LONG 2 7C010-130 M10 x 1.50 x 130 HEXHEAD 3 7J010-002 10mm WASHER, ZINC PLATED 3 7A375-276 3/8"-16 x 2-3/4" HXHD ZINC 1 7K375-040 3/8" AN960 FLAT WASHER PLATED 1 7C012-025 M12 x 1.75 x 25mm HXHD PLTD 1 7J012-092 12mm WASHER, FLAT 1 7A375-251 3/8"-16 x 2-1/2" FLAT SHCS 1

4FJ111-041 P/S RELOCATION ASSY, FOCUS 1

4FJ010-011 BRACKET, P/STEERING RELOCATION 1 7U250-020 11mm DOWEL, LONG 2 7C080-040 M8 x 1.25 x 40mm SHCS 4 7K312-001 5/16" AN WASHER, PLATED 4 7A312-073 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 1210517 ASY, IDLER PULLEY, SMOOTH 2 4FJ017-011 SPACER, IDLER PULLEY 2 2C017-002 PILOT, 6203/5 BRG, 7/16 SCREW 2 7A437-150 7/16"-14 x 1-1/2" HXHD GR8 2 4FJ010-021 MTG PLATE, BEARING HOUSING 1 7A375-102 3/8"-16.x 1" FLT ALLN ZNPLT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8" 2 7R002-012 #12 SAE TYPE F SS HOSE CLAMP 1 7U038-000 3/4" HEATER HOSE 0.54' 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7R003-013 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 7E010-049 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 7U100-055 TIE WRAP, 7.5" NYLON 6

4FJ130-036 OIL DRAIN ASSY, FOCUS 1

7P375-008 ELBOW, PLASTIC 3/8" x 90 UNION 1 7U030-036 1/2" OIL DRAIN HOSE 1.41' 7S625-000 SHEATH, MYLAR, .625 ID 1 7R001-006 #6 STNLS HOSE CLAMP, NARROW 2 7P375-041 3/8" NPT HEX NIPPLE x 1.5" 1 7P375-017 3/8" NPT x 1/2" BEADED HSE BRB 1

4FJ130-026 OIL FEED ASSY, FOCUS 1

7PP250-034 FITTING, STREET TEE MOD 1 7P250-031 1/4" NPT x -4JIC FLARE FTG STL 1 7U250-090-260 OIL FEED HOSE, 26" -4 x 90° 1 7P125-004 1/8" NPT 90° x -4 JIC FTG STL 1

4FJ112-010 AIR INLET ASSY, FOCUS 1

4FJ012-010 INTAKE ELBOW, FOCUS° 1 7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7S350-200 3-1/2" x 2" SLEEVE 1 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 2 7P375-039 3/8" NPT x 5/8" BARB CLAMP 90° 1 7P750-100 3/4" NPT x 1" HOSE FITTING 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-048 #48 SAE TYPE F SS HOSE CLAMP 2 4FJ010-050 MAF BRKT, FOCUS 1 7U133-100 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 7U034-016 1" GS HEATER HOSE 0.66' 7U030-046 5/32" VACUUM LINE 2.50' 7U035-002 3" FLEX HOSE 1.083' 7A250-075 1/4"-20 x 3/4" SHCS PLTD 2 7F250-021 1/4"-20 NYLOCK NUT ZINC PLTD 2 7J250-001 1/4" WASHER, SAE, PLTD 4 8H040-040 AIR FILTER, 3.5" FLG x 5.5L 1 5W014-030 14GA STRD WIRE BLACK 9' 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 12 5W001-007 3/16" HEAT-SHRINK TUBING 1.5' 7U033-000 5/8" PCV HOSE 3.25' 7P625-016 5/8" HOSE UNION, BARBED ENDS 1 7R001-008 #8 STNLS HOSE CLAMP 1 7P156-082 5/32" TEE 1

Part No. Description Qty. Part Number Description Qty.

4FJ212-030 DISCHARGE ASSY 1 4FJ111-032 S/C DRIVE ASSY, FOCUS 1

2D030-041 BRG HSG, EXT DRIVE, MACH GEN2 1

2DO70-159 LARGE BEARING, EXTENDED DRIVE 2

7U100-084 SNAP, RING, EXT DRV HOUSING 1

2D070-281 COUPLING, FLG, 3-PIN DRIVE 2

7U250-125 DOWEL PIN, Ø1.4" x 1.25L 6

7J375-020 WASHER, 1.0 OD, .406 x ID 2

2D070-260 COUPLING, DRIVE, COMPOSITE 1

2D160-215 TUBE HSG ASSY, EXT DRIVE FOCUS 1

2D030-061 HOUSING, COUPLING, EXT DRIVE SH 1

7A312-525 5/16"-18 x 5.25" HXCS GR8 ZINC 4

7B375-110 3/8"-24 x 1" GRADE 8 HXHD 3

7U100-070 KEY, 3/16" SQUARE x 7/8" LONG 3

7U312-101 DOWEL BUSHING, .312" x 1.00" 2

2A040-011 PULLEY RETAINER S/C 1

7A312-100 5/16"-18 x 1" HXCSGR5P 4

7K375-040 3/8" AN960 FLAT WASHER PLATED 1

7X100-025 WAVE WASHER-LARGE 1

2A046-101 BELT, 4061010 GOODYR FOCUS 1 008110 SMALL SILVER DIE CUT DECAL 2 008444 S/C STRT INFO PKG ASSY VORT 1

008120 SML, BLU DIE CUT DECAL VORT 2

08440 WHITE LG PKGNG ENVELOPE VORT 1

008441 YELLOW WARNTY REG ENVEL VORT 1

008516 STREET S/C OWNERS MAN VORT 1

008544 STRT S/C WARNTY REG FORM VORT 1

008543 WARNTY TERMS/CONDITIONS VORT 1

008130 LICENSE PLATE FRAME, VORTECH 1 8F060-042 FUEL INJECTOR, 42LBS RAIL STYL 4 4FJ245-050 P/S HOSE INSTALL, ASSY, FOCUS 1

4FJ145-050 HI-PRESS PWR.STR.HOSE w/ENDS 1

7P250-130 1/4"NPT MALE TO -6 MALE JIC AL 1

7P250-132 -6 JIC MALE 3/8"NPT x 45° 1

7P250-011 COMPRSSN FTG, 1/4"NPTF x 3/8"T 1

7P375-120 COMPRSSN FTG, 3/8"NPTF x 3/8"T 1

4FJ210-060 BATT RELOCATION ASSY, FOCUS 1

4FJ110-060 ASSY, BATT BRKT, FOCUS PLATED 1

2A017-875-08 SPACER, .875 OD x .290 LONG 1

2A017-879-06 SPACER, .875 OD x .800 LONG 1

7A375-151 3/8"-16 x 1.5 HXHD GR8 4

7J375-044 3/8"SAE WASHER, PLTD 8

7F375-017 3/8"-16 NYLOCK NUT 4

5W001-028 BATT POST TERMINALS 2

5W008-100 8GA, RED STRANDED WIRE 6'

5W001-035 LUG, 6-2AWG, 3/8" STUD 4

5W001-053 REMOTE BATTERY POST 1

5W008-105 8GA, BLACK STRANDED WIRE 1

5W001-008 3/4" HEAT-SHRINK TUBING 1

4FJ120-020 ECM CHIP PKG/SHIP ASSY AUTOL 1

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

immediately.

2000-2003 ZX3 Ford Focus

Part No. 4FJ218-030

ENGINEERING, LLC

PARTS LIST

®

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

xi

Part No. Description Qty. Part Number Description Qty.

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

immediately.

2000-2003 ZX3 H.O. Ford Focus

Part No. 4FA218-040

ENGINEERING, LLC

PARTS LIST

2E428-010 S/C, V5F SQ FOCUS SAT 1 2A036-262 S/C PULLEY 2.62" 6-GROOVE 1 4FJ111-021 S/C MTG BRKT ASSY, FOCUS 1

4FJ010-034 MOUNTING PLATE, SUPERCHARGER 1 4FJ017-021 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 2A017-878-07 SPACER, .875 OD x 3.560 LONG 2 2A017-078-06 SPACER, .875 OD x 1.809 LONG 2 7C010-130 M10 x 1.50 x 130 HEXHEAD 3 7J010-002 10mm WASHER, ZINC PLATED 3 7A375-276 3/8"-16 x 2-3/4" HXHD ZINC 1 7K375-040 3/8" AN960 FLAT WASHER PLATED 1 7C012-025 M12 x 1.75 x 25mm HXHD PLTD 1 7J012-092 12mm WASHER, FLAT 1 7A375-251 3/8"-16 x 2-1/2" FLAT SHCS 1

4FJ111-041 P/S RELOCATION ASSY, FOCUS 1

4FJ010-011 BRACKET, P/STEERING RELOCATION 1 7U250-020 11mm DOWEL, LONG 2 7C080-040 M8 x 1.25 x 40mm SHCS 4 7K312-001 5/16" AN WASHER, PLATED 4 7A312-073 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 1210517 ASY, IDLER PULLEY, SMOOTH 2 4FJ017-011 SPACER, IDLER PULLEY 2 2C017-002 PILOT, 6203/5 BRG, 7/16 SCREW 2 7A437-150 7/16"-14 x 1-1/2" HXHD GR8 2 4FJ010-021 MTG PLATE, BEARING HOUSING 1 7A375-102 3/8"-16.x 1" FLT ALLN ZNPLT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8" 2 7R002-012 #12 SAE TYPE F SS HOSE CLAMP 1 7U038-000 3/4" HEATER HOSE 0.54' 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7R003-013 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 7E010-049 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 7U100-055 TIE WRAP, 7.5" NYLON 6

4FJ130-036 OIL DRAIN ASSY, FOCUS 1

7P375-008 ELBOW, PLASTIC 3/8" x 90 UNION 1 7U030-036 1/2" OIL DRAIN HOSE 1.41' 7S625-000 SHEATH, MYLAR, .625 ID 1 7R001-006 #6 STNLS HOSE CLAMP, NARROW 2 7P375-041 3/8" NPT HEX NIPPLE x 1.5" 1 7P375-017 3/8" NPT x 1/2" BEADED HSE BRB 1

4FJ130-026 OIL FEED ASSY, FOCUS 1

7PP250-034 FITTING, STREET TEE MOD 1 7P250-031 1/4" NPT x -4JIC FLARE FTG STL 1 7U250-090-260 OIL FEED HOSE, 26" -4 x 90° 1 7P125-004 1/8" NPT 90° x -4 JIC FTG STL 1

4FJ112-010 AIR INLET ASSY, FOCUS 1

4FJ012-010 INTAKE ELBOW, FOCUS° 1 7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7S350-200 3-1/2" x 2" SLEEVE 1 7R002-056 #56 SAE TYPE F SS HOSE CLAMP 2 7P375-039 3/8" NPT x 5/8" BARB CLAMP 90° 1 7P750-100 3/4" NPT x 1" HOSE FITTING 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7R002-016 #16 SAE TYPE F SS HOSE CLAMP 4 7R002-048 #48 SAE TYPE F SS HOSE CLAMP 2 4FJ010-050 MAF BRKT, FOCUS 1 7U133-100 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 7U034-016 1" GS HEATER HOSE 0.66' 7U030-046 5/32" VACUUM LINE 2.50' 7U035-002 3" FLEX HOSE 1.083' 7A250-075 1/4"-20 x 3/4" SHCS PLTD 2 7F250-021 1/4"-20 NYLOCK NUT ZINC PLTD 2 7J250-001 1/4" WASHER, SAE, PLTD 4 8H040-040 AIR FILTER, 3.5" FLG x 5.5L 1 5W014-030 14GA STRD WIRE BLACK 9' 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 12 5W001-007 3/16" HEAT-SHRINK TUBING 1.5' 7U033-000 5/8" PCV HOSE 3.25' 7P625-016 5/8" HOSE UNION, BARBED ENDS 1 7R001-008 #8 STNLS HOSE CLAMP 1 7P156-082 5/32" TEE 1

4FJ111-032 S/C DRIVE ASSY, FOCUS 1

2D030-041 BRG HSG, EXT DRIVE, MACH GEN2 1 2DO70-159 LARGE BEARING, EXTENDED DRIVE 2 7U100-084 SNAP, RING, EXT DRV HOUSING 1 2D070-281 COUPLING, FLG, 3-PIN DRIVE 2 7U250-125 DOWEL PIN, Ø1.4" x 1.25L 6 7J375-020 WASHER, 1.0 OD, .406 x ID 2 2D070-260 COUPLING, DRIVE, COMPOSITE 1 2D160-215 TUBE HSG ASSY, EXT DRIVE FOCUS 1 2D030-061 HOUSING, COUPLING, EXT DRIVE SH 1 7A312-525 5/16"-18 x 5.25" HXCS GR8 ZINC 4 7B375-110 3/8"-24 x 1" GRADE 8 HXHD 3 7U100-070 KEY, 3/16" SQUARE x 7/8" LONG 3 7U312-101 DOWEL BUSHING, .312" x 1.00" 2 2A040-011 PULLEY RETAINER S/C 1 7A312-100 5/16"-18 x 1" HXCSGR5P 4 7K375-040 3/8" AN960 FLAT WASHER PLATED 1 7X100-025 WAVE WASHER-LARGE 1

2A046-101 BELT, 4061010 GOODYR FOCUS 1 008110 SMALL SILVER DIE CUT DECAL 2 008444 S/C STRT INFO PKG ASSY VORT 1

008120 SML, BLU DIE CUT DECAL VORT 2 08440 WHITE LG PKGNG ENVELOPE VORT 1 008441 YELLOW WARNTY REG ENVEL VORT 1 008516 STREET S/C OWNERS MAN VORT 1 008544 STRT S/C WARNTY REG FORM VORT 1 008543 WARNTY TERMS/CONDITIONS VORT 1

008130 LICENSE PLATE FRAME, VORTECH 1 8F060-042 FUEL INJECTOR, 42LBS RAIL STYL 4 4FJ245-050 P/S HOSE INSTALL, ASSY, FOCUS 1

4FJ145-050 HI-PRESS PWR.STR.HOSE w/ENDS 1 7P250-130 1/4"NPT MALE TO -6 MALE JIC AL 1 7P250-132 -6 JIC MALE 3/8"NPT x 45° 1 7P250-011 COMPRSSN FTG, 1/4"NPTF x 3/8"T 1 7P375-120 COMPRSSN FTG, 3/8"NPTF x 3/8"T 1

4FJ210-060 BATT RELOCATION ASSY, FOCUS 1

4FJ110-060 ASSY, BATT BRKT, FOCUS PLATED 1 2A017-875-08 SPACER, .875 OD x .290 LONG 1 2A017-879-06 SPACER, .875 OD x .800 LONG 1 7A375-151 3/8"-16 x 1.5 HXHD GR8 4 7J375-044 3/8"SAE WASHER, PLTD 8 7F375-017 3/8"-16 NYLOCK NUT 4 5W001-028 BATT POST TERMINALS 2 5W008-100 8GA, RED STRANDED WIRE 6' 5W001-035 LUG, 6-2AWG, 3/8" STUD 4 5W001-053 REMOTE BATTERY POST 1 5W008-105 8GA, BLACK STRANDED WIRE 1 5W001-008 3/4" HEAT-SHRINK TUBING 1

4FJ120-020 ECM CHIP PKG/SHIP ASSY AUTOL 1 8N106-005 ASSY, SETRAB, FOCUS 1

®

xii

Part No. Description Qty. Part Number Description Qty.

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

immediately.

2000-2003 ZX3 H.O. Ford Focus

Part No. 4FA218-040

ENGINEERING, LLC

PARTS LIST

8N105-100 WATER TANK / HOSE ASSY, FOCUS 1

7E010-049 #10X3/4 HEX HD SLF DRL SHT MTL 4 7J010-001 #10 FLAT WASHER 4 7R007-001 NYLON RATCHET CLAMP 1-1/8" 9 7U038-000 3/4" HEATER HOSE 13 7U038-012 HOSE,3/4"DIA 90°,4X12 LEGS 1 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7U100-055 TIE WRAP, 7.5" NYLON 6 8N055-030 TANK, WATER, TRIANGLE SHAPE 1 4GR010-060 BRKT, WATER RES, C5 CORVETTE 1 7P500-026 1/2NPT X 3/4 BARB 90° BRASS 2 7A250-050 1/4-20 X .50 SHCS ZINC PLTD 4 7J250-001 1/4 WASHER, SAE, PLTD 4 7R003-027 ADEL CLAMP,1-11/16" 1 7P100-122 1" NPT VENT PLUG 1 7P125-016 1/8 NPT PLUG 1

8N107-100 WATER PUMP / WIRING ASSY, FOCU 1

8F001-402 PUMP, WATER, PIERBURG 1 8F101-320 FUEL PUMP RELAY ASSY, LS1 TRK 1 5W001-005 3/8" PLASTIC WIRE LOOM 6' 5W001-010 16-14GA FEMALE SLIDE INSULATED 3 5W001-009 16-14GA MALE SLIDE INSULATED 2 5W001-043 12-10GA X 1/4" RING TERMINAL 2 5W001-024 MINI ATC FUSE TAP 1 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 7U100-044 TIE WRAP, 4" NYLON 6 7U100-055 TIE WRAP, 7.5" NYLON 6 5W001-019 10-12 GA BUTT CONN INSULATED 1

8N401-020 FOCUS ZX3 COOLR CORE/DISCH ASY 1

8N055-050 PLASTIC CAP, SURGE TANK 1 7P500-026 1/2NPT X 3/4 BARB 90^ BRASS 2 8N301-200 WELDED CORE ASSY, ZX3 FOCUS 1 4FJ012-020 DUCT, DISCH, ZX3 FOCUS H.O 1 7S275-251 REDUCER, 2.75 TO 2.50 1 7S275-200 SLEEVE,BLUE, 2.75"D X 2.00"L 1 7R002-044 #44 SAE TYPE F SS HOSE CLAMP 4 7R002-040 #40 SAE TYPE F SS HOSE CLAMP 1 7R002-052 #52 SAE TYPE F SS HOSE CLAMP 1

0.008341 VORTECH CHARGE COOLER DECAL 1 7S325-275 ELBOW, 90°SILICONE 3.25/2.75 1

®

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

1

A. Remove the ducting between the air box and

the throttle body. Disconnect the MAF from the ducting and set aside.

B. Remove the air box, fresh air tube, battery,

battery box and all remaining components running to the inlet of the motor.

C. Remove the Battery/Air Box support bracket:

1. Support the driver’s side of the transmis-

sion.

2. Remove four nuts securing the bracket to the driver’s side engine mount.

3. Remove the large central nut securing the transmission to the engine mount.

4. Lift the plate on top of the engine mount and remove the Battery/Air Box support bracket.(See Fig. 1-a.)

5. Reinstall the engine mount plate and resecure all engine mount hardware.

D. Place an oil drain pan beneath the power

steering pump. Disconnect the high-pressure (3/8" tube) power steering line from the power steering pump. Disconnect the opposite end of the power steering line from the steering rack. Disconnect all other suppor ts securing the power steering line and remove it from the car.

E. From under the vehicle, remove the plastic

cover protecting the belts and pulleys.

F. From under the vehicle, release the tension

on the accessory drive belt and remove the drive belt.

G. Disconnect the fill hose from the power steer-

ing pump.Remove the four screws securing the power steering pump and remove the power steering pump from the vehicle.

H. Drain sufficient coolant to remove and relo-

cate the plastic upper coolant manifold located near the upper radiator core support. (See Fig. 4-c.)

I. ZX3 Only: Remove the four screws securing

the heat shield to the header.Remove the heat shield.

J. Locate the PCV valve located near the dri-

ver’s side of the exhaust manifold on the front of the engine. Pull the stock PCV valve and install the supplied PCV valve in its place.

K. Remove the screws and pushpins securing

the front bumper cover. Remove the front bumper cover from the car.

1. PREPARATION/REMOVAL

Fig. 1-a

BATTERY/AIRBOX SUPPORT

TO REMOVE

NOTE: - ZX3 Models Only

1. 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-down bracket.

2. Using a 10mm socket or wrench, remove the harness and plug from the ECM (as you loosen the bolt, the connector will slowly release). Remove the ECM from the vehicle.

3. Contact the Vortech Service Department for a Return Authorization Number. Send both ECM and supplied credit tag to Vortech using the enclosed shipping box.

2

A. Disconnect the connectors attached to the

oxygen sensors on the catalytic converter assembly.

B. Unsecure all hardware and brackets securing

the catalytic converter.

C. Disconnect the EGR tube where it connects

to the EGR control valve toward the rear of the engine.

D. Manipulate the catalytic converter to either

side to get a clear view of the oil drain location.

E. To provide an oil drain for the supercharger, it

is necessary to make a drain hole in the engine block skirt. Locate and center-punch the hole in the exact location as shown per Figs. 2-a, 2-b.Drill a 1/8" pilot hole at the center location.

F. Use the supplied 9/16" rotobroach to drill the

hole.Take care to break through the pan and gently remove the cut out.

G. Pack the flutes of a 3/8" NPT tap with grease.

Tap the hole until the fitting can be star ted.

H. Thoroughly clean the threaded area. Reach

inside the oil pan and retrieve any stray chips.

I. Apply a small amount of sealer to the threads

of the supplied 3/8" NPT hex nipple and secure in the new hole.Make sure that a seal is formed around the fitting. (See Fig. 2-a.)

J. Apply sealant to the opposite side of the fit-

ting and install the supplied 3/8" x 90° fitting on the end of the hex nipple.

K. Apply sealant to the threaded end of the sup-

plied 3/8" x 1/2" barb fitting. Install this fitting into the 90° fitting. Orient the fittings to point upward towards the driver’s side. (See Fig. 2-a.)

L. (ZX3 Models Only) Resecure the catalytic

converter and all brackets back to stock location, reconnect the EGR line back to the EGR control valve. Reconnect the oxygen sensors and reinstall the heat shield.

2. SUPERCHARGER OIL DRAIN (SVT Models skip steps A-D and proceed to Step E.)

Fig. 2-a / ZX3 Oil Drain

OIL DRAIN ROUTED

BEHIND CAT BRACKET

Fig. 2-b / Oil Drain Hole

Fig. 2-c / SVT Oil Drain

NOTE: SVT Models - It will be necessary to

either loosen the exhaust header or shorten the supplied rotabroach .33" to get sufficient room for drilling the oil drain.

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

3

A. Locate the oil pressure sender on the back of

the engine block near the oil filter. Remove the oil pressure sender.

B. Lightly lubr icate the threads of the supplied

1/8" NPT street fitting with engine oil. Install the street fitting into the block.

C. Install the oil pressure sender into the street

fitting so that it is pointing upward and parallel with the egine block.

D. Install the 1/8" NPT to -4 fitting into the end of

the street fitting so that it is perpendicular to the engine block.(See Fig. 3-a.)

E. Install the 90° end of the feed hose to the -4

fitting and route it close to the block and up to the supercharger mounting location.

F. Install the electronic plug back onto the oil

pressure sender.

3. SUPERCHARGER OIL FEED

Fig. 3-a

A. Locate the coolant manifold running across

the top/front of the radiator support. Remove the plastic manifold and disconnect the three coolant lines running to the manifold. (See Fig. 4-c.)

B. Cut 1" off the end of each coolant line r un-

ning to the manifold.

C. Modify the plastic coolant manifold by grind-

ing both tabs so that they are flush with the manifold. (See Fig. 4-a.)

D. Reattach the lines to their original manifold

ports. (Cutting the lines allows for the coolant manifold to sit lower.)

E. Tuck the manifold between the top of the radi-

ator and the upper radiator support. This will allow for clearance between the drive assembly and the coolant manifold.(See Fig. 4-b.)

4. CROSSOVER COOLANT LINE MODIFICATION

Fig. 4-a

Fig. 4-b

Fig. 4-c

1/8"NPT TO -

4 FITTING

STREET FITTING

2 AREAS TO GRIND

COOLANT MANIFOLD

IN RELOCATED

POSITION

STOCK COOLANT

MANIFOLD LOCATION

4

A. Locate the supplied power steering relocation

block.Install the two supplied alignment dowels into the back side of the block.(See Fig. 5-a.)

B. Locate the factory hose clamp secur ing the

lower radiator hose.Orient the clamp to give clearance for the P/S relocation block.

C. Install the supplied power steering relocation

block onto the cast power steering mounting bracket that the pump originally mounted to. Make sure the alignment dowels align with their corresponding holes on the stock bracket.

D. Use the four supplied 8mm x 1.0" x 40mm

SHCS and 8mm washers to secure the relocation block to the stock bracket.

E. Install the secondar y mounting plate to the

three hole pattern on the side of the relocation block with the supplied 3/8"-18 x 1" flathead screws.(See Fig. 5-b.) Tighten the 3/8" screws.

F. Place the power steering pump against the

installed relocation block.Make sure that the stock alignment dowels are installed into the back of the power steering pump. Secure the pump to the lower set of four holes in the relocation block using the stock hardware.

5. POWER STEERING RELOCATION/SECONDARY PLATE INSTALLATION

Fig. 5-a

Fig. 5-b

A. Cut the previously removed high-pressure

power steering line in two places.

• The first cut is directly after the long rubber section of power steering line. Cut the hard line leaving the maxumum amount of straight section connected to the rubber end. (See Fig 6-a, 6-c.)

• The second cut through the hard line will be on the pump side. Cut the line so that the maximum section of straight tube remains with the fitting that connects to the power steering pump.(ZX3 Models refer to Figs.6-b,6-d.) (SVT Models: refer to Figs.6-f, 6-g.)

6. POWER STEERING LINE MODIFICATION

Fig. 6-a

Fig. 6-b / ZX3 Models Only

NOTE: It is necessar y when cutting the power

steering lines that the cuts are straight and clean. It will be necessary to remove the paint on the lines before installing the compression fittings. Do not “grind” the paint off of the lines as that will reduce the diameter of the line so that the new fitting may not properly function.

INSTALLED ALIGNMENT DOWELS

P/S PUMP

REINSTALLED

SECONDARY MOUNTING

PLATE INSTALLED ON P/S

RELOCATION BLOCK

LOCATION TO MAKE CUT.

LEAVE THE MAXIMUM

AMOUNT OF STRAIGHT

SECTION POSSIBLE

END ATTACHES

TO P/S PUMP

LOCATION TO MAKE

CUT. LEAVE THE MAX-

IMUM AMOUNT OF

STRAIGHT SECTION

ALLOWABLE

POWER STEERING

FITTING TO KEEP

END ATTACHES

TO STEERING

RACK

KEEP THIS

SECTION

NOTE: When installing the compression fitting,

initially tighten the fitting finger tight. Using wrenches, continue 1-1/2 turns so that the fitting is secure.

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

5

B. Install the compression fitting with the

3/8"NPT female outlet on the shortest section of power steering line containing the fitting that connects to the power steering pump. (ZX3 Models: see Fig. 6-d, SVT Models: see Fig. 6-g.)

C. Install the compression fitting with the

1/4"NPT female outlet on the longer section of power steering hose. (Both models see Fig. 6-c.)

D. Install the 3/8"NPT x -6 x 45° fitting into the

3/8"NPT female outlet installed on the short section of power steering line.Take this assembly and install it into the bottom of the power steering pump with the 45° fitting pointing toward the front of the car. (ZX3

Models see Fig. 6-e, SVT Models see Fig. 6-h.)

E. Install the 1/4 NPT x -6 fitting into the 1/4

NPT female outlet installed on the long section of the power steering line. Reinstall the stock section of the power steering line back into the steering rack. Route the open end of the hose, in its stock location orienting it toward the front of the car.

6. POWER STEERING LINE MODIFICATION, cont’d

Fig. 6-d / ZX3 Models Only

Fig. 6-e / ZX3 Models Only

Fig. 6-c

COMPRESSION FITTING

COMPRESSION

FITTING

STOCK P/S PUMP

FITTING REMOVED

IN FIG. 6-b

3/8NPT X -6

x 45° FITTING

1/4"NPT x -6 FITTING

COMING FROM P/S RACK SIDE

FITTING ASSEMBLY DIRECTLY OFF THE

POWER STEERING PUMP

SECURED P/S HOSE

Fig. 6-f / SVT Models Only

CUT

Fig. 6-g / SVT Models Only

CUT SECTION w/FITTINGS

INSTALLED

STOCK, UNCUT P/S HOSE

6

A. Remove the three upper, forward most

screws from the bell housing. (See Fig.8-a.)

B. Slide the supplied heat shrouding over the

1/2" fabric braid oil drain hose.Attach the oil drain hose to the supercharger drain fitting and tighten the supplied #8 hose clamp.

C. Install the supplied Ø5/16" x 1.00" dowel into

the countersunk holes in the supercharger gear case. (See Fig.8-b.)

8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION

A. Disconnect the four (4) fuel injector wiring

clips and retainers from the fuel injectors. Release any residual fuel pressure from the rail by opening the schrader valve on the rail. Have a fire extinguisher nearby and use extreme caution.

B. Remove the bolts holding down the factory

fuel rail onto the intake manifold.Lift up on to the rails evenly, removing all four injectors.

C. Using a small amount of clean motor oil,

lightly lubricate the O-rings on both ends on the Vor tech supplied fuel injectors.

D. Install the new injectors into the fuel rails with

the terminals facing outward.

7. FUEL INJECTOR REPLACEMENT

NOTE: Make sure injectors are secure and

properly installed. Re-check after cycling fuel system.

E. Carefully lower the fuel rail/injector

assembly down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

F. Tighten down the fuel rail assem-

bly with the original bolts and attach the wiring clips to the injector terminals.

F. Connect both ends of the open hose with the

supplied high-pressure line. ZX3 Models: Route the hose from the 45° fitting pointing off the P/S pump to the bottom/rear of the radiator, over the air filter, along the drivers side frame rail over to the long section of power steering hose. (See Figs. 6-e, 9-b.) SVT Model: Route the supplied hose from the 45° fitting in front of the radiator over to the driver’s side, over the air filter, along the driver’s side frame rail to the installed stock P/S hose section. (See Figs.6-h, 6-i.)

Fig. 6-h / SVT Models Fig. 6-i / SVT Models

G. Use adel clamps to keep the high-

pressure line secure. (See Figs. 6- e, 9-b.)

H. Using the supplied 5/8" hose-

mender and length of hose, lengthen the power steering fill hose. Secure it away from the supercharger pulley.

I. Refill the power steering reservoir.

FITTING POINTING DOWN

TOWARD THE FRONT OF CAR

SUPPLIED P/S HOSE ROUTED

IN FRONT OF THE RADIATOR

SUPPLIED P/S LINE

ROUTED OVER THE AIR

FILTER TO THE DRIVER’S

SIDE FRAME RAIL

6. POWER STEERING LINE MODIFICATION, cont’d

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

7

D. Install the supercharger mounting plate on

the alignment dowels and tap the plate lightly until it is flush with the supercharger gear case. (See Fig. 8-b.)

E. Align the counter bores in the black coupler

housing with the alignment dowels passing through the supercharger mounting plate. Lightly tap the drive housing until it is flush with the mounting plate. (See Fig.8-c.)

F. Install onto the supercharger input shaft, the

supplied key and drive coupling containing three 1/4" diameter dowel pins protruding from it. (Apply a thin film of anti-seize or grease onto the inside diameter of the coupling before installing onto the input shaft.) Secure the coupling with the supplied 3/8"-24 x .75" HXHD and Ø1.0 O.D. washer.

8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION, Cont’d,

Fig. 8-a

Fig. 8-b

Fig. 8-c

Fig. 8-d

NOTE: Heat may also be necessary to install the

coupling onto the shaft. (A propane torch will make this easier if needed.) Use a light thread lock compound on the 3/8"-24 x .75" screw threads.

NOTE: It is necessary to leave the hardware

loose to allow for the correct clocking of the housing assembly upon final installation. (See Fig. 8-d.)

G. Install the two supplied 1.80" spacers

between the supercharger and the mounting plate. Secure in one location with a 3/8"-16 x

2.5" flathead and in the other with a 2.75" HXHD. Leave both fasteners loose at this time. (See Fig. 8-c.)

H. In the middle mounting location, secure the

supercharger to the mounting plate with the supplied 12mm x 1.75" x 25mm screw and washer. Leave the fastener loose at this time. (See Fig. 8-c.)

I. Locate the preassembled drive shaft assem-

bly. Connect the three-pin coupler from the end of the drive shaft to the three-pin coupler on the supercharger assembly using the supplied composite ring. Align the hole patterns so that one side of pins is alternating with the opposite side of pins. Each pin will have its own hole.Verify that each set of pins is

inserted into the raised bosses with holes on their corresponding side of the composite ring. Push together until each coupler

is flush with the composite ring. (See Figs. 8d and the boxed section of Fig 8-f.)

J. With the couplers aligned, align the two cou-

pler housings. Using the four 5/16"-18 x 5.25" HXHD screws secure the drive shaft assembly to the supercharger assembly.

K. Lower the supercharger and drive assembly

12mm x 1.25 x 25mm

1.8" SPACER

0.630 O.D.

SPACER LOCATION

INSTALLED

Ø5/16" DOWELS

INSTALLED DRIVE

COUPLING

COUPLER HOUSING

LEAVE LOOSE UNTIL STEP O

3 LOCATIONS TO REMOVE STOCK

HARDWARE

8

into position locating where the exhaust manifold heat shield and drive shaft will come into contact. (See Fig. 8-e.)

L. ZX3 Models Only: Mark the heat shield,

remove the drive assembly and modify the heat shield to clear the drive assembly. (See Fig. 8-e.) Using an oversize tube or dowel to form the heat shield is the easiest method for modification. (See Fig. 8-g.)

M. Place the drive assembly back into position.

Loosely install the 10mm x 140mm screws and 3.56" spacers between the supercharger mounting plate and the bell housing locations. The Ø.630 O.D. spacer will be placed in the forward most, bottom position on the bell housing. (See Figs. 8-a., Fig. 8-f.)

N. Loosely install the four 5/16"-18 x .75" flat-

head screws through the secondary mounting plate into the bearing housing. (See Fig. 8-f.)

O. Tighten all the drive fasteners in the following

order:

•Four 5/16"-18 x .75" flathead screws connecting the bearing housing to the secondary plate

8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION, cont’d

Fig. 8-e

Fig. 8-f

AREA TO MODIFY

Fig. 8-g

AREA TO MODIFY

4 x 5/16"-18 x .75" FLATHEADS

4 x 5/16"-18 x 1.00" HXHD

4 x 5/16"-18 x 5.25" HXHD

DRIVE COUPLING HOUSING

DRIVE COUPLINGS

COMPOSITE DISK

DRIVE COUPLINGS

Ø.875" x 3.56" SPACER

Ø.630" x 3.56"

SPACER

10mm x 140mm HARDWARE

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

9

8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION, cont’d

Fig. 8-g

Fig. 8-h

R. Install the dr ive belt. It may be

necessary to loosen one of the idlers to get the belt on due to tight clearances. (See Figs. 8-h, 8-i.)

S. Install the oil feed and oil drain

hoses.

NOTE: Blue Loctite is recom-

mended on the 7/16" screws.

•Four 5/16"-18 x 5.25" HXHD screws connecting the shaft housing and coupler housing to the supercharger and mounting plate

•Four 5/16"-18 x 1.00" HXHD screws connecting the bearing housing to the shaft housing

• The 3/8"-16 x 2.5" flathead, 3/8"-16 x

2.75" HXHD and 12mm x 1.75 x 25mm HXHD securing the supercharger directly to the mounting plate

• Three 10mm x 1.5 x 140mm HXHD screws securing the mounting bracket and 3.56" spacers to the bell housing

P. Lightly grease the extended supercharger

input shaft. Install the key and supercharger pulley oriented so that the long snout of the pulley is facing toward the supercharger. Secure the pulley with a 3/8"-24 x 1.0" HXHD, 3/8" washer and pulley retainer.

Q. Install two supplied 2.5" aluminum idlers

using 7/16"-18 x 1.5" hardware, pulley retainers and idler spacers.The idler retainers (.220" THK) go between the pulley and the 7/16" screw and spacers (.416" THK) are placed between the idlers and the secondary mounting plate. When the pulleys are

installed the snap ring retaining the bearing should be facing away from the mounting plate. (See Fig. 8-h.)

NOTE: Blue Loctite is recommended on the

3/8"-24 x 1.00" screws.

INSTALLED IDLER PULLEY

Fig. 8-i / Belt Routing

STOCK

IDLER

SUPPLIED

2.5"

IDLERS

VORTECH SUPPLIED IDLER

IDLER RETAINER

IDLER SPACER

SECONDARY MOUNTING PLATE

ALT

TENSIONER

.220 THICK

7/16-18 x 1.5" SCREW

WATER

PUMP

CRANK

PULLEY

.416 THICK

A/C

S/C

PULLEY

POWER

STEERING

10

9. AIR INLET ASSEMBLY

Fig. 9-a

Fig. 9-b

A. Unplug the electr ical connector from the hor n.

Remove the horn from the car.

B. Install into the 3/4"NPT boss of the 90° roto-

mold duct the supplied straight 1" barb.(See Fig. 9-a.)

C. Install into the 3/8"NPT boss of the rotomold

duct the supplied 5/8" barb x 90°.

D. Connect the Ø3.5" end of the 90° inlet duct to

the inlet of the supercharger using the supplied Ø3.5" x 2" sleeve and #56 hose clamps. Orient the duct so that the open end is pointing down. (See Fig.9-a.)

E. Connect the length of 3" flex-hose to the

open end of the 90° duct using a #48 hose clamp.

F. Connect the MAF sensor to the supplied

bracket.(See Fig. 9-c.) Attach the supplied air filter to the inlet of the MAF. (See Fig. 9-d.)

G. Set the air filter/MAF assembly on the lower

radiator support where the horn was located. Mark two locations and drill using a 9/32" drill. Secure using the supplied 1/4" hardware. (See Fig. 9-b.)

I. ZX3 Models: (See Fig. 9-e) cut all six (6)

wires leading to the MAF plug leaving 3"-4" before the plug. Using the supplied wires and butt connectors extend all six wires so that they reach the new MAF location.

SVT Models: Cut the middle four wires leaving 3" to 4" after the MAF plug. Cut the outer 2 wires leaving the longest amount of wire attached to the plug. Extend the four middle wires so that the MAF plug can reach the relocated sensor.Connect the white with purple stripe wire to the red wire on the supplied IAT sensor har ness. Connect the black with white stripe wire to the brown/black wire on the IAT sensor. (See Fig. 9-e.) Trim the long outer wires left on the MAF plug leaving only a couple of inches of wiring coming out of the plug.

3/4"NPT TO 1" BARB

3/8"NPT TO 5/16" BARB

MAF AND BRACKET MOUNTING LOCATION

P/S HOSE SECURED

Fig. 9-c

VORTECH SUPPLIED BRACKET

NOTE: Soldering the wire extension is pre-

ferred. Shrink sleeve has been supplied to seal the solder joints.

J. Re-attach MAF plug to MAF meter. K. Reinstall the factory hor n as shown in Fig. 9-f

using the supplied 6mm screw.

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

11

Fig. 9-d

Fig. 9-f

Fig. 9-e / MAF Plug Modifications

9. AIR INLET ASSEMBLY, cont’d

NEW HORN LOCATION

BLACK w/ORANGE STRIPE

GREEN w/RED STRIPE

(SVT ONLY)-WHITE w/PURPLE

STRIPE CONNECT TO THE RED

AIR TEMP SENSOR WIRE

(ZX3 ONLY)-EXTEND WIRE TO

MAF PLUG (ALL 6 WIRES)

RED

BLACK/BROWN

SUPPLIED IAT SENSOR CONNECTOR

(SVT MODELS ONLY)

BROWN w/BLUE STRIPE

WHITE w/BLUE STRIPE

(SVT ONLY)-BLACK w/WHITE STRIPE CONNECT TO THE BROWN AIR TEMP SENSOR WIRE (ZX3 ONLY)-EXTEND WIRE TO MAF PLUG (ALL 6 WIRES)

WIRING EXTENSIONS

EXTEND WIRES TO THE MAF NEW LOCATION

(SVT ONLY)

WIRING NO LONGER ATTACHED TO MAF PLUG

MAF PLUG

12

10. SVT DSI BOX RELOCATION

A. Locate the DSI Box in the driver’s side fender

well. Disconnect the electrical connector from the box. Disconnect the cable from the base of the throttle body. (See Figs.10-a, 10-b.)

B. Remove the hardware securing the DSI box

bracket from the frame rail. Remove the box from the bracket.

C. Using two of the original batter y tray hold

down screws, secure the supplied DSI box relocation bracket to the top of the driver’s side frame rail (See Fig. 10-c.).

D. Secure the DSI box to the relocation bracket

using the supplied 1/4-20 hardware. (See Fig. 10-d.)

E. Reconnect the electrical connector to the DSI

box. Route the cable back to the base of the throttle body and reconnect. (Ensure that the cable has no kinks and has free movement.)

Fig. 10-a / SVT Model Only

Fig. 10-b / SVT Model Only

Fig. 10-c / SVT Model Only

Fig. 10-d / SVT Model Only

UNSNAP LINE

BRACKET INSTALLED

DSI BOX INSTALLED

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

13

11. STANDARD DISCHARGE INSTALLATION (H.O. Charge-cooled applications skip to

Section 12.)

Fig. 11-a / (SVT Model)

A. Install the 2.75" to 2.5" reducer sleeve onto

the supercharger discharge.

B. Install on the throttle body the supplied 90°

silicone sleeve.

• ZX3 Models: Use the Ø3.25 x Ø2.75" x 90° sleeve on the throttle body. (See Fig. 11-b.)

• SVT Models: Use the Ø2.75" x 90° sleeve on the throttle body. (See Fig.11-a.) Inser t the supplied rubber grommet and IAT sensor into the discharge tube. Lubricate for easier fit if needed.

C. Between the two installed sleeves install the

Vortech discharge tube:

D. ZX3 Models: Secure the sleeve on the throt-

tle body with the supplied #44 and # 48 hose clamps. Secure the sleeve on the supercharger with the supplied #44 and #40 hose clamps. (See Fig. 11-b.)

SVT Models: Secure the sleeve on the throttle body with the supplied #44 hose clamps. Secure the sleeve on the supercharger side with the supplied #44 and #40 hose clamps. (See Fig. 11-a.) Connect the recently installed IAT sensor har ness to the IAT sensor in the discharge tube.

E. Connect the supplied 5" piece of Ø1.0" hose

to the barb on the discharge duct.

F. Using the supplied #16 hose clamps, connect

the inlet of the bypass to the open end of the installed hose.

G. Using the supplied #16 hose clamps and 90°

molded hose, connect the opposite end of the bypass valve to the Ø1.0" barb installed on the inlet duct. (See Figs.11-c, 11-d.) Trimming of the rubber 1" elbow may be required.

H. Using the supplied 5/32" TEE and vacuum

hose connect the bypass valve to an engine vacuum source.(See Fig. 11-d.)

NOTE: Make sure that the vacuum barb on the

bypass valve is installed so that it is pointing down, directly away from the discharge tube

Fig. 11-b / (ZX3 Model)

Fig. 11-c / (ZX3 Model)

90° MOLDED HOSE

BYPASS VALVE

14

11. STANDARD DISCHARGE INSTALLATION, cont’d (H.O. Charge-cooled applications skip

to Section 12.)

Fig. 11-d

12. CHARGE COOLED DISCHARGE INSTALLATION

Fig. 12-a / ZX3 Model

90° ELBOW

A. Install on the supercharger discharge the

Ø2.75" to 2.5" reducer sleeve.

B. Install the supplied 90° sleeve on the throttle

body.

• ZX3 Models: Ø3.25" to 2.75" reducer x 90°

• SVT Models: Ø2.75" x 90° sleeve.

C. Install the welded charge-cooler into the

Ø2.75" end of the reducer sleeve on the discharge of the supercharger.

ZX3 Models: Install the Ø2.75" x 2.0" sleeve

on the discharge side of the charge cooler.Install the supplied discharge tube between the charge cooler and the 90° sleeve on the throttle body. Secure the discharge tube with #44 hose clamps. (See Fig. 12-a.)

SVT Models: Connect the discharge of the

charge cooler to the throttle body with the installed 90° elbow and #44 hose clamps. (See Fig. 12-b.) Insert the supplied rubber grommet and IAT sensor into the discharge tube. Lubricate for easier fit if needed. Connect the recently installed IAT sensor har ness to the IAT sensor in the discharge tube.

SUPERCHARGER

DISCHARGE TUBE

AIR INLET

DUCT

BYPASS VALVE

5/32” HOSE

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

15

12. CHARGE COOLED DISCHARGE INSTALLATION

Fig. 12-b / SVT Model

Fig. 12-c

D. Connect the supplied 5" piece of Ø1.0" hose

to the barb on the bottom of the charge cooler.

E. Using the supplied #16 hose clamps, connect

the inlet of the bypass to the open end of the installed hose.

F. Using the supplied #16 hose clamps and 90°

molded hose, connect the open end of the bypass valve to the Ø1.0" barb installed on the inlet duct. (See Fig. 12-a.) Tr imming of the 1" rubber elbow may be required.

G. Using the supplied 5/32" TEE and vacuum

hose connect the bypass valve to an engine vacuum source.(See Fig. 12-c.)

NOTE: Make sure that the vacuum barb on the

bypass valve is installed so that it is pointing down and away from the discharge.

13. WATER TANK AND WATER PUMP INSTALLATION (H.O. Charged Cooled Kits Only.)

A. Unsnap the A/C line from the driver’s side

frame rail bracket, then remove the bracket.

B. Align the supplied bracket with the bottom of

the passenger’s side framerail (See Fig. 13-a.)

C. Locate and mark locations to mount the water

tank bracket in the passenger’s side fenderwell. (See Fig. 13-a.)

D. Using the supplied sheet metal screws, mount

the water tank bracket. (See Fig. 13-a.)

E. Using the #28 adel clamp and 1/4"-20 hard-

ware, secure the water pump to the inside of the water tank as shown.(See Fig. 13-b, 13-d.)

F. Install the 1/2"NPT x 90° brass fittings in the

top and bottom of the tank. Install the Ø3/4" x 90° molded hose between the inlet of the water pump and the bottom 90° fitting. (See Fig. 13-d.)

G. Install into the 1"NPT hole in the top of the

water tank the supplied aluminum bushing. Leave the 1/8"NPT pipe plug out until you have completely filled the system.

90° ELBOW

Fig. 13-a

SUPERCHARGER

DISCHARGE TUBE

AIR INLET

DUCT

BYPASS VALVE

5/32” HOSE

16

13. WATER TANK AND WATER PUMP INSTALLATION (H.O. Charged Cooled Kits Only.), cont’d

Fig. 13-b

Fig. 13-c

Fig. 13-e

Fig. 13-d

H. Install the water tank assembly into the

mounted bracket securing the tank in three locations with 1/4"-20 x .5" hardware.Point the upper 90° fitting so that it is pointing at the driver’s side. (See Fig. 13-b.)

I. Gently bend the A/C line with the pressure

sensor up so the wiring harness will reach. (See Fig. 13-f.)

J. Mount the supplied water pump relay near the

firewall just below the fuse box. (See Fig. 13-c.)

K. Connect the red 12-gauge wire from terminal

#30 to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt to a positive power supply.

L. Feed the yellow wire from relay terminal #85

to the fuse box on the driver’s side of the engine bay. Route the wire to the D1 engine fuse and using the supplied fuse tap connect the yellow wire to the fuse.

M. Run the black wire from terminal #86 on the

relay to a clean ground.

N. With the long red 12-gauge wire connected to

the water pump relay terminal #87, route the free end across the firewall, along the fender and down to the water pump. Secure as necessary to avoid heat and sharp edges.

O. Cut the stock electrical plug off the water

pump.Connect the blue/green positive wire on the water pump to the positive red wire with the supplied slide connectors.

P. Run the brown negative wire to a clean

ground.

WATER PUMP RELAY

WATER PUMP

1/2" NPT x 90°

FITTINGS

LIGHTLY BEND A/C LINE UP TO

REACH THE WIRING HARNESS

Fig. 13-f

MODIFIED A/C LINE

GROUND

RELAY

87

86

87A

30

(+) WATER PUMP

85

D-1 ENGINE FUSE

(+) BATTERY

TERMINAL

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

17

14. HEAT EXCHANGER MOUNTING (H.O.Charged Cooled Kits Only.)

Fig. 14-a

Fig. 14-b

A. Un-secure the power steering cooler from the

front of the car.Drill 9/32" holes in the rear of the mounting tabs.

B. Remount the power steering cooler using the

new holes to position it forward.

C. Mar k locations for the supplied water cooler. D. Mount the supplied cooler using the supplied

self tapping screws with the barbs facing to the driver’s side directly behind the remounted power steering cooler.(See Fig. 14-a.)

15. WATER LINE ROUTING (H.O.Charged Cooled Kits Only.)

A. Cut a 60" length of 3/4" hose. Run this

from the top 90° fitting on the charge cooler to the 90° fitting located on the top of the triangular water reservoir. Route the hose towards the front of the car between the air conditioning condenser and grill, over to the water tank. Make sure that the hose is smoothly routed without tight bends or kinks.

B. Install the 4" end of the 90° molded

rubber elbow to the outlet of the water pump.

C. Cut a 70" length of 3/4" hose. Connect

it to the 12" end of the 90° molded hose with the supplied barbed hose mender.Run the hose along the base of the radiator to the supplied rubber 180° hose using the 3/4"-5/8" reducer. Run the open end of the 180° hose to the bottom barb on the water cooler (Running this hose to the bottom barb is important to flush out any air in the water system.)

NOTE: When routing hoses, refer to Fig. 15-a.

Trim all hoses for best fit.

D. Cut a 40" length of 3/4" hose. Run this

from the top barb of the water cooler to the bottom 90° fitting on the charge air cooler.

E. Secure all hose ends with the supplied

nylon clamps.

F. Start filling the system with a 50/50

water/glycol mix. Check the 1"NPT aluminum fitting in the water tank to see if water is flowing out of the 1/8"NPT hole. Once water is to this point, install the 1/8"NPT plug into the 1” aluminum fitting.

G. With the key on, make sure the charge

cooler water pump is operating and that water is flowing through the cooler. Fill the system if necessary. If the water is not flowing, remove the charge cooler supply hose and lower until water flow out of the hose. If necessary, provide light suction to the hose to help prime the pump.Verify water flow. Do not let the pump run for extended periods (30 seconds or more) without water flow. Fill the charge cooler tank until the level stabilizes.

POWER STEERING COOLER

MOUNTED FORWARD

DRILL NEW Ø.28" MOUNTING HOLES IN THIS POSITION

1.25" EXISTING HOLES

BOTTOM VIEW

POWER STEERING COOLER

18

FLOW

Fig. 15-a

Ø90° BRASS FITTINGS

Ø3/4" x 40" HOSE

CHARGE AIR COOLER

180° MOLDED HOSE

Ø3/4"-5/8" HOSE REDUCER

CHARGE COOLER PLUMBING SCHEMATIC (H.O. KITS ONLY)

HOSE

Ø3/4" x 60"

UPSIDE DOWN

WATER PUMP MOUNTED

(BELOW)

90° MOLDED ELBOW

4" x 12" MOLDED HOSE

TOP

HOSEMENDER

SUPPLIED Ø3/4"

(ONE ON TOP OF

TANK, ONE BELOW)

90° BRASS FITTINGS

1/2" NPT x 3/4" HOSE x

Ø3/4" x

70" HOSE

FLOW

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

19

16. BATTERY RELOCATION

Fig. 16-a

Fig. 16-b

Fig. 16-c

Fig. 16-d

NOTE: Clearance between the battery and front

bumper will be tight. Position the battery box not to interfere with the side marker lights or front fog lights

NOTE: There might be light contact with the thin

plastic splash guard.

J. Use the supplied batter y ter minal, lug end

and wire to ground the battery to the frame.

K. Reinstall the front bumper cover.Check for

clearance issues. Readjust if necessar y.

REAR LOCATION OF THE

REMOTE BATTERY TERMINAL

.80" SPACER

NEW BATTERY

GROUND

1/4"-20 x 1" SCREW

POSSIBLE LIGHT

CONTACT HERE

A. Remove the battery strap from the stock bat-

tery suppor t bracket. Install the battery strap into the supplied battery box using the supplied 1/4" hardware.

B. With the front bumper cover removed, align

the battery box along the driver’s side frame rail. Mark tentative locations for the box to mount. Place the bumper back into stock location and check for clearance issues between the side marker lights, fog lights, battery box and the plastic inner fender liner. Take into account clearance when the batter y will be installed into the battery box. (See Fig. 16-f.)

C. When a position has been found, drill four

13/32" holes in the marked locations.

D. Mount the batter y box in the driver’s side

fender using the supplied spacers and 3/8" hardware.The .290" spacers will go between the two forwardmost holes and the upper rear hole.The lower rear hole will need a .80" spacer.(See Fig. 16-a.)

E. Install the batter y into the batter y box. Have

the battery orientated so that the ter minals will be away from the frame rail. Remove the stock 6mm screw from the factory batter y strap.Install into its location the supplied 1/4"20 screw and washer. Secure the battery with the screw and battery strap.

F. Cut any extra ground wires away from the

engine ground strap.Install a ring ter minal on the ground strap and ground to a clean, paint free section on the frame.

G. Using a hole saw, make a 1.25" hole inside

the driver’s side fender.Check the location from the engine compartment before drillling. (See Figs. 16-c, 16-d.)

H. Mount the remote batter y ter minal as shown. I. Using the supplied wire, shrink sleeve and lug

terminals, extend the positive wires to the new remote terminal location. Extend a wire from the remote battery terminal to the positive terminal on the battery.

NOTE: When wiring the battery, see Fig. 16-e.

NOTE: Secure the positive wires with tie wraps

and shrink sleeves to prevent contact with other objects.

ENGINE COMPARTMENT VIEW

OF REMOTE BATTERY POST

20

Fig. 16-e

16. BATTERY RELOCATION, cont’d.

KEEP THE BATTERY BOX LEVEL

AS THE FRAME RAIL RISES. THIS

WILL MAKE A GAP BETWEEN THIS

CORNER OF THE BATTERY BOX AND

TOP OF THE FRAME RAIL

THERE SHOULD BE LIGHT CONTACT

BETWEEN THIS CORNER AND THE

INSIDE OF THE SPLASH GUARD.

(THE BOX IS PLACED THIS FAR BACK

IN ORDER TO LEAVE CLEARANCE

BETWEEN THE FOG LIGHTS MARKER

LIGHTS AND THE BATTERY)

THIS LOCATION WILL MOUNT AT THE VERY

BOTTOM OF THE

FRAME RAIL

FRONT OF CAR

MEASURE FROM

BACK SIDE OF

FRONT BUMPER

MOUNT TOP OF

BATTERY BOX

FLUSH WITH TOP

OF FRAME RAIL

3.60"

Fig. 16-f

CUT ENGINE

GROUND FROM

TERMINAL. INSTALL

SUPPLIED RING TERMINAL AND

GROUND TO

BODY

GROUND TO FRAME RAIL WITH VORTECH SUPPLIED WIRE, LUG TERMINALS AND BATTERY TERMINAL

TO ENGINE BLOCK

DISCARD THE FACTORY BATTERY TERMINAL AND GROUND WIRE TO BODY

TERMINAL MODIFIED

-

USE THE SUPPLIED HARDWARE,

RING TERMINALS, SHRINK SLEEVE

AND WIRE TO LENGTHEN THE

POSITIVE LEAD TO THE REMOTE

BATTERY TERMINAL

FACTORY POSITIVE

BATTERY

RUN LEAD TO THE POSITIVE

BATTERY TERMINAL ON

THE RELOCATED BATTERY

5/16" -18

.75" HXHD

+

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

21

Fig. 17-a

17. REFLASH COMPUTER, SVT Models Only

A. Reconnect the batter y. B. Locate the vehicles OBD2 connector located

in the lower left hand corner of the dash on the drivers side of the vehicle.(See Fig 17-a.)

C. Attach the OBD2 connector from the Flash

tool that is provided in the kit to the vehicle’s OBD2 port. (See Fig 17-b.) Make sure this connector is seated all the way in the vehicles OBD2 port.You do not want this connector coming out during programming or damage may occur to the vehicle’s ECM.

D. The Reflash tool should power up and display

three parameters.

1. Perf ormance Tune

2. Diagnostics

3. Options

E. Select “Performance Tune” and press the

enter button in the middle of the arrow keys. (See Fig 17-c.)

F. Read the disclaimer entirely, then select

agree and press ENTER.

G. At this point please read the screen displayed

on the reflash tool. If you have any questions, either refer to the manual that is provided with the reflash tool or contact our service department for further assistance.

H. Turn the ignition on (do not start the vehicle).

Set the parking brake and press the ENTER button to continue.

I. SELECT TUNE will be displayed at the top of

the screen. Use the arrow keys to select the appropriate tune for your vehicle and press the ENTER button.You will have a choice of three to choose from:

1. SVT STD

2. SVT HO

3. Original Backup

J. Continue to follow the screen and when fin-

ished unplug the reflash tool from the vehicles OBD2 port.

IMPORTANT! To ensure trouble-free programming of your vehicle's computer:

• Make sure the vehicle's battery is sufficiently charged.

• Turn off all accessories and close doors to prevent unnecessary drain on the battery.

• Do not attempt to program your vehicle while a battery charger is connected.

• Improper battery voltage will result in failure of the programming process.

• Do not disconnect the cable or turn off the ignition during programming.

NOTE: Do not disturb the cable, or turn the

ignition off during this time. If the programming is disrupted, the computer will not start or run your vehicle!

Fig. 17-b

Fig. 17-c

ESCAPE

ENTER

OR

SELECT

ARROW KEYS

22

18. FINAL CHECK

A. ZX3 MODELS ONLY - Once the ECM is

received back from Vortech with the ECM module installed, reinstall the ECM into the vehicle.In some cases, the extra height of the ECM module will not allow the use of the factory hold-down bracket.Reconnect the factory harness and reinstall the factory kick panel.

B. Make sure that the oil drain to oil pan fit-

ting is secure and that the engine is filled with factory specified oil.

C. Fill the factory radiator and the factory

coolant surge tank with a 50/50 coolant/water mix.

D. If your vehicle has gone over 20,000

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

E. 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 line are properly secured with clamps or tie-wraps. Make a visual inspection of the engine and engine compartment

F. Check all fluid levels, making sure that

your tank is filled with 91 octane or higher fuel before commencing test-drive.

G. (H.O. Kits Only.) With the key on, make

sure the water pump is operating and that water is flowing through the charge cooler.Fill as necessar y. If water is not flowing, remove the supply hose (attached to the water cooler) and lower until water flows out of the hose.This should prime the pump. Reconnect the hose and verify water flow. Do not run the water pump for extended periods (30 seconds or more) without water flow.

H. At this point, it is ok to start the vehicle. I. With the engine running, check power

steering hose connections for leakage. Let the engine run for two minutes.Turn the steering wheel in both directions. Verify:

• Smooth power assist

• Noiseless operation

• Proper fluid level

• No system leaks

• No bubbles, foam or discoleration in

fluid.

WARNING: Do not attempt to operate the

vehicle until all components are installed and all operations are completed including the final check.

J. Recheck to be sure that no hoses,

wires, etc. are near exhaust headers or moving parts and for signs of any fluid leakage.

K. Test-drive the vehicle. L. Recheck the coolant and aftercooler

fluid levels.

M. 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.

P/N: 4FJ020-010

19APR04 v3.0 Focus(4FJ v3.0)

23

This Page Left Intentionally Blank

24

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

®

Vortech 2000-2003 Ford Focus Zetec SVT User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual