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:[phone]

Fax:[phone] • 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

®

P/N: 4FJ020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr.Secured
19APR04 v3.0 Focus(4FJ v3.0)

ii

© 2004 VOR TECH ENGINEERING, LLC

All rights reserved. No part of this publication may be reproduced, transmitted, transcrived, or translated

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 [phone],
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

©2004 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr.Secured

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

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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

P/N: 4FJ020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr.Secured
19APR04 v3.0 Focus(4FJ v3.0)

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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

©2004 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr.Secured

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

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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

P/N: 4FJ020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr.Secured
19APR04 v3.0 Focus(4FJ v3.0)

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

©2004 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr.Secured

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

®

P/N: 4FJ020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr.Secured
19APR04 v3.0 Focus(4FJ v3.0)

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

©2004 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr.Secured

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

®

P/N: 4FJ020-010
©2004 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr.Secured
19APR04 v3.0 Focus(4FJ v3.0)

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

©2004 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr.Secured

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

®