Vortech 2003-2004 Mustang Mach 1 User Manual

Ford 4.6L 1999-2001 DOHC

®

Mustang Cobra/2003-2004 Mach 1

Supercharger System

1999 MODEL YEAR -

2001-2003 MODEL YEAR -

Installation Instructions

50 State Smog Legal per CARB EO #D-213-17

50 State Smog Legal per CARB EO #D-213-20

* 2004 Model Year

* 2004 Models legal in California only for racing vehicles which may never be used upon a highway

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

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for possible installers in your area.

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

Vortech Engineering, LLC.

ii

TABLE OF CONTENTS

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

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

IMPORTANT NOTES ..........................................................................................................iv

TOOLS AND SUPPLY REQUIREMENTS...........................................................................v

PARTS LIST - 1999 4.6L DOHC MUSTANG.......................................................................vi

PARTS LIST - 1999 4.6L DOHC MUSTANG w/AFTERCOOLER .......................................vii

PARTS LIST - 2001 4.6L DOHC MUSTANG.......................................................................viii

PARTS LIST - 2001 4.6L DOHC MUSTANG w/AFTERCOOLER .......................................ix

PARTS LIST - 2003-2004 4.6L DOHC MACH 1..................................................................x

PARTS LIST - 2003-2004 4.6L DOHC MACH 1 w/AFTERCOOLER ..................................xi

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

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

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

4. FUEL PUMP INSTALLATION...................................................................................3

5. FUEL INJECTOR REPLACEMENT .........................................................................4

6. AIR CONDITIONING LINE MODIFICATION............................................................5

7. FAN RESISTOR RELOCATION (2001 Cobra and 2003-2004 Mach 1 Only) ..........5

8. MAIN BRACKET ASSEMBLY/DRIVE BELT.............................................................6

8.1 MAIN BRACKET ASSEMBLY/DRIVE BELT (1999 0nly)..........................................7

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT (2001 Cobra and 2003-2004

Mach 1 0nly) ............................................................................................................11

9. RADIATOR HOSE/WATER TUBE............................................................................18

10. AIR INLET................................................................................................................20

11. SUPERCHARGER DISCHARGE ............................................................................27

12. ECM MODULE INSTALLATION...............................................................................28

13. FINAL CHECK .........................................................................................................29

iii

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

1999-2004 4.6L DOHC Cobra/Mach

1 Mustang

IMPORTANT NOTES

This kit requires ECM modication and the installation of a Vortech ECM Module. The modules are made specically for each individual vehicle with respect to the factory ECM calibration. The ECM must be sent directly to Vortech by the installing customer (the charge for this service with module installation has been included in the purchase price).

•Included in this kit is a prepaid next-day air shipping box and a credit tag for

one Vortech ECM Module.

• Simply contact the Vortech Service Department at (805) 247-0226 to request a

Return Authorization Number (See ECM Module Credit Tag for more details).

- Mail the enclosed "ECM Module Credit Tag" (send original tag - no photocopies will be accepted) and ECM to Vortech in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Vortech will give an estimate at the time of your order.

Your Vortech ECM Module comes with a twelve month limited warranty from the original date of purchase of your supercharger system (see owner's manual for details).

OFF-HIGHWAY USE:

When driving vehicle on non-public roads (off-road applications such as racing/high rpm) Vortech strongly recommends replacing the factory platinum plugs with NGK #4177 or Denso IT20 and reducing the factory spark plug gap down to .032".

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

iv

1999-2004

FORD 4.6L DOHC COBRA/MACH 1 MUSTANG

Installation Instructions

CARB E0 #D-213-17 / CARB E0 #D-213-20 (Except 2004 Models)

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® V-2® supercharger!

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30 - 35% and horsepower between 35 - 45% can be expected with the boost levels specied by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech Engineering is

not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modied in any way, check with Vortech prior to using this product.

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

is resolved. Any knocking (detonation) that occurs will cause engine damage. Sustained knocking will lead to engine failure. Vortech Engineering is not responsible for engine damage or failure.

5. Perform an oil and lter 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 oil, and change the oil and lter at least every 3,000 miles. Never attempt to extend the oil change inter-

val 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 20,000 miles with original heat range plugs as specied by the manufacturer. Do not use platinum spark plugs unless they are original equipment. Change spark plugs at least every 40,000 miles and

spark plug wires at least every 60,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 1/2" Socket and Drive Set: SAE & Metric

• 3/8" NPT Tap and Handle

• Adjustable Wrench

• Open End Wrenches: 3/8", 7/16", 1/2", 9/16", 15/16"

• Center Punch and a 5/8" Tapered Punch

• Ford Springlock 3/8" Fuel Fitting Disconnect Tool

• 6 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16", 11/32" Drill Bits

• 1/2" Tube Bender

• 3/16" Allen Wrench

• Wire Strippers and Crimpers

• Utility Knife

• Hacksaw/Cut-Off/Bandsaw

v

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

1999 4.6L DOHC Mustang

®

Part No. 4FR218-010SQ

ENGINEERING, LLC

PARTS LIST

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

aged parts immediately.

Part Number Description Quantity

2E229-160 V-2 E-TRIM SUPERCHARGER ASSEMBLY 1 4FR111-021 '99 MOUNTING BRACKET ASSEMBLY 1

7A375-178 3/8-16 x 1-3/4” HXHD G8 3 7K375-040 3/8” AN960 Flat Washers 5 7K312-001 5/16" AN Washers 9 2A046-113 Belt, K061130-Gates 4.6 4V 1 4FK011-031 Mounting Bracket 1 7J312-875 5/16" Custom Washer 1 7C080-065 8mm x 1.25 x 65 SOC 1 4FK116-021 Idler Pulley Assembly 1 2A017-025 Spacer, Idler 4V 1 7C080-016 8mm x 1.25 x 16 HXHD Bolt 1 7C080-140 8mm x 1.25 x 140 HXHD Bolts 2 7C080-070 8mm x 1.25 x 70 HXHD Bolts 2 7U313-133 M8 x 1.25" 4V Alternator Stud 1 7F008-020 M8 x 1.25 Nut 1 7A375-225 3/8-16 x 2-1/4" HXHD G8 2 7J010-001 #10 Flat Washers 4 7C080-025 8mm x 1.25 x 25 HXHD 2 7C010-050 10-24 x 1/2" SOC HD CAP, ZINC PLT 4 4FK016-081 Water Pump Pulley, Stock 1 4FR010-011 Plaque, '99 4V Mtng Brkt. 1

4FR112-015 AIR INTAKE ASSY, '01 4V 1

4FR012-010 Inlet Elbow, Mod Cast 4V 1 4FR110-050 90mm MAF Brkt Assy 1 7R002-056 #56 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 1 7U035-001 3-1/2" Flex Hose 1 7R002-052 #52 Goldseal Hose Clamp 2 8H040-097 Air lter, 4" Flg 7" Long 1 7A250-075 1/4-20 x 3/4 SHCS Plated 4 7F250-021 1/4-20 Nylock Nut Zinc Plated 4 7U100-052 7/16 Rubber Grommet 1 7U100-056 Vent Tube 90° 1 7R001-008 #8 Stnls Hose Clamp 1 7U100-055 Tie Wrap, 6" Nylon 10 7J250-001 1/4 SAE Washer, Plated 4 7U038-000 3/4" Heater Hose 1 4FK012-040 Air Inlet Elbow 4.6 GEN2 1 7P750-100 3/4 NPT x 1" Hose Fitting 1 7R002-064 #64 Goldseal Hose Clamp 2 7S400-200 4 x 2 Sleeve 1 8A003-040 MAF, 90mm 1 7U375-055 Vacuum Cap, 5/8" Nipple 1 7E010-049 #10 x 3/4 Hex Head Sheet 2 4PFL010-041 Brkt, Tan Resistor Reloc 1 7C010-075 10-24 x 3/4 SHCS GR5 Zinc 2 7F010-024 10-24 Nylock Nut 2

4FR114-010 COOLANT PIPE ASSEMBLY '99+ 1

7U100-046 O-Rings 2 4FE014-010 Radiator Pipe Stnlss 1 7U133-050 1-1/2" x 90° Hose 1 7R002-020 #20 Goldseal Hose Clamps 3 7R002-024 #24 Goldseal Hose Clamps 3 7P375-016 3/8" Pipe Plug 1 70000 Inspector Number 0 4FR014-010 '99 U-Bend Assembly-Coated 1 4FR014-020 '99 L-Bend Assembly-Coated 1 7F006-093 6mm Nylock Nuts 2

4FH130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 14” Oil Drain Hose 1 7R001-008 #8 Stainless Hose Clamps 2 7P500-003 90° 1/2" Alum. Tube 1 7P500-020 Tube Nut 1 7P375-042 Male Connector 1

Part Number Description Quantity

4FH130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 26” Oil Feed Hose 1 7P525-067 .525 Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fitting 2 7P125-103 1/8” NPT -4 x 45° Male Elbow 1 7P250-082 1/4" NPT x -4 90° Fitting 1 7P250-034 1/4 NPT Street TEE 1 7P250-036 -4 Flare to 1/4 NPT 1

4FR112-015 DISCHARGE ASSEMBLY 1

7S275-300 2-3/4" x 3" Sleeve 1 7R002-044 #44 Goldseal Hose Clamps 2 7R002-016 #16 Hose Goldseal Clamps 4 8D001-001 Bypass Valve 1 7U034-016 1" GS Hose 1 7U034-016 1" GS Hose 1 7U030-046 5/32" Vacuum Line 1 7P156-082 5/32" TEE 1 7S450-200 4-1/2" x 2" Sleeve 1 7R002-072 #72 Goldseal Hose Clamps 2 7P750-100 3/4" NPT x 1" Hose Fitting 1 4FR012-030 Duct Discharge B '99 Cobra 1 7S350-200 3-1/2" x 2" Sleeve 1 7R002-056 #56 Goldseal Hose Clamps 2 4FR012-020 Duct Discharge A - Casting 1

4FR020-020 ECM CHIP PKG/SHPNG ASSY 99 1 8F060-042 FUEL INJECTOR 42LB 8 5W001-051 JUMPER HARNESS 8 8F101-260 FUEL PUMP 1

vi

1999 4.6L DOHC Mustang w/aftercooler

®

Part No. 4FR218-020SQ

ENGINEERING, LLC

PARTS LIST

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

aged parts immediately.

Part Number Description Quantity

2E229-170 V-2 SC-TRIM SUPERCHARGER ASSEMBLY 1 4FR111-021 '99 MOUNTING BRACKET ASSEMBLY 1

7A375-178 3/8-16 x 1-3/4” HXHD G8 3 7K375-040 3/8” AN960 Flat Washers 5 7K312-001 5/16" AN Washers 9 2A046-113 Belt, K061130-Gates 4.6 4V 1 4FK011-031 Mounting Bracket 1 7J312-875 5/16" Custom Washer 1 7C080-065 8mm x 1.25 x 65 SOC 1 4FK116-021 Idler Pulley Assembly 1 2A017-025 Spacer, Idler 4V 1 7C080-016 8mm x 1.25 x 16 HXHD Bolt 1 7C080-140 8mm x 1.25 x 140 HXHD Bolts 2 7C080-070 8mm x 1.25 x 70 HXHD Bolts 2 7U313-133 M8 x 1.25" 4V Alternator Stud 1 7F008-020 M8 x 1.25 Nut 1 7A375-225 3/8-16 x 2-1/4" HXHD G8 2 7J010-001 #10 Flat Washers 4 7C080-025 8mm x 1.25 x 25 HXHD 2 7C010-050 10-24 x 1/2" SOC HD CAP, ZINC PLT 4 4FK016-081 Water Pump Pulley, Stock 1 4FR010-011 Plaque, '99 4V Mtng Brkt. 1

4FR112-015 AIR INTAKE ASSY, '01 4V 1

4FR012-010 Inlet Elbow, Mod Cast 4V 1 4FR110-050 90mm MAF Brkt Assy 1 7R002-056 #56 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 1 7U035-001 3-1/2" Flex Hose 1 7R002-052 #52 Goldseal Hose Clamp 2 8H040-097 Air Filter, 4" Flg 7" Long 1 7A250-075 1/4-20 x 3/4 SHCS Plated 4 7F250-021 1/4-20 Nylock Nut zinc Plated 4 7U100-052 7/16 Rubber Grommet 1 7U100-056 Vent Tube 90° 1 7R001-008 #8 Stnls Hose Clamp 1 7U100-055 Tie Wrap, 6" Nylon 10 7J250-001 1/4 SAE Washer, Plated 4 7U038-000 3/4" Heater Hose 1 4FK012-040 Air Inlet Elbow 4.6 GEN2 1 7P750-100 3/4 NPT x 1" Hose Fitting 1 7R002-064 #64 Goldseal Hose Clamp 2 7S400-200 4 x 2 Sleeve 1 8A003-040 MAF, 90mm 1 7U375-055 Vacuum Cap, 5/8" Nipple 1 7E010-049 #10 x 3/4 Hex Head Sheet 2 4PFL010-041 Brkt, Fan Resistor Reloc 1 7C010-075 10-24 x 3/4 SHCS GR5 Zinc 2 7F010-024 10-24 Nylock Nut 2

4FR114-010 COOLANT PIPE ASSEMBLY '99+ 1

7U100-046 O-Rings 2 4FE014-010 Radiator Pipe Stnlss 1 7U133-050 1-1/2" x 90° Hose 1 7R002-020 #20 Goldseal Hose Clamps 3 7R002-024 #24 Goldseal Hose Clamps 3 7P375-016 3/8" Pipe Plug 1 70000 Inspector Number 0 4FR014-010 '99 U-Bend Assembly-Coated 1 4FR014-020 '99 L-Bend Assembly-Coated 1 7F006-093 6mm Nylock Nuts 2

4FH130-036 OIL DRAIN ASSEMBLY 1

(See Parts List For 4FR218-010SQ)

4FH130-026 OIL FEED ASSEMBLY 1

(See Parts List For 4FR218-010SQ)

Part Number Description Quantity

4FR112-030 DISCHARGE ASSEMBLY '99 4V COOLER 1

7R002-044 #44 Goldseal Hose Clamps 2 7R002-016 #16 Goldseal Hose Clamps 4 8D001-001 Bypass Valve 1 7U034-016 1" GS Hose 0.229' 7U034-016 1" GS Hose 0.312' 7U030-046 5/32" Vacuum Line 4' 7P156-082 5/32" TEE 1 7S450-200 4-1/2" x 2" Sleeve 1 7R002-072 #72 Goldseal Hose Clamps 2 7S275-300 2-3/4" x 3" Sleeve 1 4FR012-030 Duct Discharge B 1 7R002-056 #56 Goldseal Hose Clamp 1 7P500-078 1/2" NPT x 3/4" HOSE Fits 2 7R002-048 #48 Goldseal Hose Clamps 2 7S350-301 Reducer, 3-1/2" to 3" 1 8N101-060 Welded Core Assembly 1 008341 Powercooler Decal 1

8N106-030 WATER COOLER ASSEMBLY, 4.6 1

7A250-075 1/4-20 X 3/4 SHCS PLTD 4 7F250-021 1/4-20 Nylock Nuts 4 7J250-001 1/4 SAE Washers 8 7P500-026 1/2 NPT-3/4 Barbs 90° 2 8N006-010 Water Cooler 1 7E010-075 #12 x 3/4" Sheet Metal Screw 4 7J010-001 #10 Flat Washers 4 8N010-050 Mount Tabs, Cooler 2

8N107-020 WATER PUMP ASSEMBLY, 4.6 1

5W001-011 16-14 GA Eyelet .25" Hole 1 5W001-012 Solderless Connector 1 5W018-010 18GA Strd Wire Red 8-1/4' 5W001-019 Solderless Connectors 10-12 2 5W001-014 Fuse Holder 10 GA Wire 1 5W001-015 Fuse, Blade Type 20 amp 1 5W001-015 12-10 GA Female Slide 1 5W001-002 Fuse Tap 1 8N010-060 Bracket, Bosch Water Pump 1 8F001-403 Pump, Water Bosch 1 5W001-050 Connector, Fuel Injector 1 7E010-075 #12 x 3/4" Sheet Metal Screws 2 7J010-001 #10 Flat Washers 2 7U133-060 3/4" x 90° Hose Elbow 1 5W001-024 Mini ATC Fuse Tap 1 5w001-025 Female Slide, Insulated Mini 1

8N105-030 WATER TANK ASSEMBLY, 4.6 1

7U038-000 3/4" Heater Hose 20 7R007-001 Nylon Clamps 1-1/8" 8 7R003-016 Adel Clamps, 7/8" 3 7E010-075 #12 x 3/4" Sheet Metal Screws 3 7J010-001 #10 Flat Washers 3 7U100-044 Tie Wraps, 4" Nylon 16 7U100-066 Tie Wraps, 11" Nylon 6 8N105-010 Water Tank w/Fitting 1

8N201-060 PWR COOLR ASSY '99 4.6 4V 1

8N101-060 Welded Core Assy '99 4.6 4V 1 7R002-048 #48 Goldseal Hose Clamp 1 7P500-078 1/2NPT x 3/4 Hose Fit 2 7S350-301 Reducer, 3.50-3.00 1 008341 PowerCooler Decal 1

4FL120-025 ECM PCK/SHPNG ASSEMBLY '99 4V 1 8F060-042 FUEL INJECTOR 42LB 8 5W001-051 JUMPER HARNESS 8 8F101-260 FUEL PUMP 1

vii

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

2001 4.6L DOHC Mustang

®

Part No. 4FR218-030SQ

ENGINEERING, LLC

PARTS LIST

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

aged parts immediately.

Part Number Description Quantity

2E229-160 V-2 E-TRIM SUPERCHARGER ASSEMBLY 1 4FR111-031 '01 4V MOUNTING BRACKET ASSEMBLY 1

7A375-178 3/8-16 x 1-3/4 HXHD G8 3 7K375-040 3/8 AN960 Flat Washer Plated 6 7K312-001 5/16 AN-Washer 14 4FR011-021 Mach. Mtg Bkt, '01 4V 1 7J312-875 5/16" Washer, Custom 1 7C080-065 8mm x 1.25 x 65 SOC 1 7C080-016 8mm x 1.25 x 16 HXHD 2 7C080-140 8mm x 1.25 x 140 HXHD 2 7C080-070 8mm x 1.25 x 70mm HXHD Zinc 1 7U313-133 M8 x 1.25 Stud, 4V Alternator 1 7F008-020 M8 x 1.25 Nut 1 7A375-225 3/8-16 x 2-1/4 HXHD G8 2 7J010-001 #10 Flat Washer 4 7C080-025 8mm x 1.25 x 25 HXHD 2 7C010-052 10-24 x 1/2 Button Hd. Cap 4 4FR010-011 Plaque, '99 4V Mtng Brkt 1 7C060-075 M6 x 1.0 x 75 HXHD Zink Plated 2 7A375-100 3/8-16 x 1 G5 HXHD Plated 1 7A312-175 5/16-18 x 1-3/4 HXHD G5 Zinc Plated 2 7A312-100 5/16-18 X 1 HXHD GR5P 1 7C080-130 m8 x 1.25 x 130 HXHD Zinc Plated 1 2A017-016 Shrt. Assy. Idler, V-3 1 4FR017-021 Spacer. Alternator '01 4V 2 4FR017-041 Alt Brkt, D-Side '01 4V 1 4FR017-051 Alt Brkt, P-Side, '01 4V 1 4FR111-032 Assy, Idler Plate, '01 4V 1 7J006-093 6mm Washer, Plated 2 2A046-115 Belt, K061115-Gates Vortec 1 4FH016-150 Idler Pulley, 6Rib 3" Flanged 1 4FR017-031 Spacer, Alt/Mtg Brkt, '01 4V 1

4FR112-015 AIR INTAKE ASSY, '01 4V 1

4FR012-010 Inlet Elbow, Mod Cast 4V 1 4FR110-050 90mm MAF Brkt Assy 1 7R002-056 #56 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 1 7U035-001 3-1/2" Flex Hose 1 7R002-052 #52 Goldseal Hose Clamp 2 8H040-097 Air Filter, 4" Flg 7" Long 1 7A250-075 1/4-20 x 3/4 SHCS Plated 4 7F250-021 1/4-20 Nylock Nut Zinc Plated 4 7U100-052 7/16 Rubber Grommet 1 7U100-056 Vent Tube 90° 1 7R001-008 #8 Stnls Hose Clamp 1 7U100-055 Tie Wrap, 6" Nylon 10 7J250-001 1/4 SAE Washer, Plated 4 7U038-000 3/4" Heater Hose 1 4FK012-040 Air Inlet Elbow 4.6 GEN2 1 7P750-100 3/4 NPT x 1" Hose Fitting 1 7R002-064 #64 Goldseal Hose Clamp 2 7S400-200 4 x 2 Sleeve 1 8A003-040 MAF, 90mm 1 7U375-055 Vacuum Cap, 5/8" Nipple 1 7E010-049 #10 x 3/4 Hex Head Sheet 2 4PFL010-041 Brkt, Fan Resistor Reloc 1 7C010-075 10-24 x 3/4 SHCS GR5 Zinc 2 7F010-024 10-24 Nylock Nut 2

Part Number Description Quantity

4FR114-010 COOLANT PIPE ASSY '99+ 1

7U100-046 O-Rings 2 4FE014-010 Radiator Pipe Stnlss 1 7U133-050 1-1/2" x 90° Hose 1 7R002-020 #20 Goldseal Hose Clamps 3 7R002-024 #24 Goldseal Hose Clamps 3 7P375-016 3/8" Pipe Plug 1 70000 Inspector Number 0 4FR014-010 '99 U-Bend Assembly-Coated 1 4FR014-020 '99 L-Bend Assembly-Coated 1 7F006-093 6mm Nylock Nuts 2 7P500-020 Tube Nut 1 7P375-042 Male Connector 1

4FH130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 14” Oil Drain Hose 1 7R001-008 #8 Stainless Hose Clamps 2 7P500-003 90° 1/2" Alum. Tube 1

4FH130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 26” Oil Feed Hose 1 7P525-067 .525 Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fitting 2 7P125-103 1/8” NPT -4 x 45° Male Elbow 1 7P250-082 1/4" NPT x -4 90° Fitting 1 7P250-034 1/4 NPT Street TEE 1 7P250-036 -4 Flare to 1/4 NPT 1

4FR112-020 DISCHARGE ASSEMBLY 1

7S275-300 2-3/4" x 3" Sleeve 1 7R002-044 #44 Goldseal Hose Clamps 2 7R002-016 #16 Hose Goldseal Clamps 4 8D001-001 Bypass Valve 1 7U034-016 1" GS Hose 1 7U034-016 1" GS Hose 1 7U030-046 5/32" Vacuum Line 1 7P156-082 5/32" TEE 1 7S450-200 4-1/2" x 2" Sleeve 1 7R002-072 #72 Goldseal Hose Clamps 2 7P750-100 3/4" NPT x 1" Hose Fitting 1 4FR012-030 Duct Discharge B '99 Cobra 1 7S350-200 3-1/2" x 2" Sleeve 1 7R002-056 #56 Goldseal Hose Clamps 2 4FR012-020 Duct Discharge A - Casting 1

4FR020-025 ECM CHIP PKG/SHPNG ASSY '01 1 5W001-051 JUMPER HARNESS 8 8F101-260 FUEL PUMP 1 8F060-042 FUEL INJECTOR 42 lb. 8

viii

2001 4.6L DOHC Mustang w/aftercooler

®

Part No. 4FR218-040SQ

ENGINEERING, LLC

PARTS LIST

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

aged parts immediately.

Part Number Description Quantity

2E229-170 V-2 SC-TRIM SUPERCHARGER ASSEMBLY 1 4FR111-031 '01 4V MOUNTING BRACKET ASSEMBLY 1

7A375-178 3/8-16 x 1-3/4 HXHD G8 3 7K375-040 3/8 AN960 Flat Washer Plated 6 7K312-001 5/16 AN-Washer 14 4FR011-021 Mach. Mtg bkt, '01 4V 1 7J312-875 5/16" Washer, Custom 1 7C080-065 8mm x 1.25 x 65 SOC 1 7C080-016 8mm x 1.25 x 16 HXHD 2 7C080-140 8mm x 1.25 x 140 HXHD 2 7C080-070 8mm x 1.25 x 70mm HXHD zinc 1 7U313-133 M8 x 1.25 Stud, 4V Alternator 1 7F008-020 M8 x 1.25 Nut 1 7A375-225 3/8-16 x 2-1/4 HXHD G8 2 7J010-001 #10 Flat Washer 4 7C080-025 8mm x 1.25 x 25 HXHD 2 7C010-052 10-24 x 1/2 Button Hd. Cap 4 4fr010-011 Plaque, '99 4V Mtng Brkt 1 7C060-075 M6 x 1.0 x 75 HXHD Zing Plated 2 7A375-100 3/8-16 x 1 G5 HXHD Plated 1 7A312-175 5/16-18 x 1-3/4 HXHD G5 Zinc Plated 2 7A312-100 5/16-18 X 1 HXHD GR5P 1 7C080-130 m8 x 1.25 x 130 HXHD zinc Plated 1 2A017-016 Shrt. Assy. Idler, V-3 1 4FR017-021 Spacer. Alternator '01 4V 2 4FR017-041 Alt Brkt, D-Side '01 4V 1 4FR017-051 Alt Brkt, P-Side, '01 4V 1 4FR111-032 Assy, Idler Plate, '01 4V 1 7J006-093 6mm Washer, Plated 2 2A046-115 Belt, k061115-gates Vortec 1 4FH016-150 Idler Pulley, 6Rib 3" Flanged 1 4FR017-031 Spacer, Alt/Mtg Brkt, '01 4V 1

4FR112-015 AIR INTAKE ASSY, '01 4V 1

4FR012-010 Inlet Elbow, Mod Cast 4V 1 4FR110-050 90mm MAF Brkt Assy 1 7R002-056 #56 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 1 7U035-001 3-1/2" Flex Hose 1 7R002-052 #52 Goldseal Hose Clamp 2 8H040-097 Air Filter, 4" Flg 7" Long 1 7A250-075 1/4-20 x 3/4 SHCS Plated 4 7F250-021 1/4-20 nylock nut zinc Plated 4 7U100-052 7/16 Rubber Grommet 1 7U100-056 Vent Tube 90° 1 7R001-008 #8 stnls Hose Clamp 1 7U100-055 Tie Wrap, 6" Nylon 10 7J250-001 1/4 SAE Washer, Plated 4 7U038-000 3/4" Heater Hose 1 4FK012-040 Air Inlet Elbow 4.6 GEN2 1 7P750-100 3/4 NPT x 1" Hose Fitting 1 7R002-064 #64 Goldseal Hose Clamp 2 7S400-200 4 x 2 Sleeve 1 8A003-040 MAF, 90mm 1 7U375-055 Vacuum Cap, 5/8" Nipple 1 7E010-049 #10 x 3/4 Hex Head Sheet 2 4PFL010-041 Brkt, Fan Resistor Reloc 1 7C010-075 10-24 x 3/4 SHCS GR5 Zinc 2 7F010-024 10-24 Nylock Nut 2

4FR114-012 COOLANT PIPE ASSEMBLY '99+ 1

7U100-046 O-Rings 2 4FE014-010 Radiator Pipe Stnlss 1 7U133-050 1-1/2" x 90° Hose 1 7R002-020 #20 Goldseal Hose Clamps 3 7R002-024 #24 Goldseal Hose Clamps 3 7P375-002 3/8" Pipe Plug 1 70000 Inspector Number 0 4FR014-012 U-Bend Assembly-Coated 1 7J250-001 1/4" Washer 2 4FR017-061 Spacer, Rad Pipe, '03 Mach 1 2

Part Number Description Quantity

4FR014-020 '99 L-Bend Assembly-Coated 1 7F006-093 6mm Nylock Nuts 2

4FH130-036 OIL DRAIN ASSEMBLY 1

(See Parts List For 4FR218-010SQ)

4FH130-026 OIL FEED ASSEMBLY 1

(See Parts List For 4FR218-010SQ)

4FR112-030 DISCHARGE ASSEMBLY '99 4V COOLER 1

7R002-044 #44 Goldseal Hose Clamps 2 7R002-016 #16 Goldseal Hose Clamps 4 8D001-001 Bypass Valve 1 7U034-016 1" GS Hose 0.229' 7U034-016 1" GS Hose 0.312' 7U030-046 5/32" Vacuum Line 4' 7P156-082 5/32" TEE 1 7S450-200 4-1/2" x 2" Sleeve 1 7R002-072 #72 Goldseal Hose Clamps 2 7S275-300 2-3/4" x 3" Sleeve 1 4FR012-030 Duct Discharge B 1 7R002-056 #56 Goldseal Hose Clamp 1 7P500-078 1/2" NPT x 3/4" HOSE Fits 2 7R002-048 #48 Goldseal Hose Clamps 2 7S350-301 Reducer, 3-1/2" to 3" 1 8N101-060 Welded Core Assembly 1 008341 Powercooler Decal 1

8N106-030 WATER COOLER ASSEMBLY, 4.6 1

7A250-075 1/4-20 x 3/4 SHCS PLTD 4 7F250-021 1/4-20 Nylock Nuts 4 7J250-001 1/4 SAE Washers 8 7P500-026 1/2 NPT-3/4 Barbs 90° 2 8N006-010 Water Cooler 1 7E010-075 #12 x 3/4" Sheet Metal Screw 4 7J010-001 #10 Flat Washers 4 8N010-050 Mount Tabs, Cooler 2

8N107-020 WATER PUMP ASSEMBLY, 4.6 1

5W001-011 16-14 GA Eyelet .25" Hole 1 5W001-012 Solderless Connector 1 5W018-010 18GA Strd Wire Red 8-1/4' 5W001-019 Solderless Connectors 10-12 2 5W001-014 Fuse Holder 10 GA Wire 1 5W001-015 Fuse, Blade Type 20 amp 1 5W001-015 12-10 GA Female Slide 1 5W001-002 Fuse Tap 1 8N010-060 Bracket, Bosch Water Pump 1 8F001-403 Pump, Water Bosch 1 5W001-050 Connector, Fuel Injector 1 7E010-075 #12 x 3/4" Sheet Metal Screws 2 7J010-001 #10 Flat Washers 2 7U133-060 3/4" x 90° Hose Elbow 1 5W001-024 Mini ATC Fuse Tap 1 5w001-025 Female Slide, Insulated Mini 1

8N105-030 WATER TANK ASSEMBLY, 4.6 1

7U038-000 3/4" Heater Hose 20 7R007-001 Nylon Clamps 1-1/8" 8 7R003-016 Adel Clamps, 7/8" 3 7E010-075 #12 x 3/4" Sheet Metal Screws 3 7J010-001 #10 Flat Washers 3 7U100-044 Tie Wraps, 4" Nylon 16 7U100-066 Tie Wraps, 11" Nylon 6 8N105-010 Water Tank w/Fitting 1

8N201-060 PWR COOLR ASSY '99 4.6 4V 1

8N101-060 Welded Core Assy '99 4.6 4V 1 7R002-048 #48 Goldseal Hose Clamp 1 7P500-078 1/2NPT x 3/4 Hose Fit 2 7S350-301 Reducer, 3.50-3.00 1 008341 PowerCooler Decal 1

4FR020-025 ECM PCK/SHPNG ASSEMBLY '01 1 8F060-042 FUEL INJECTOR 42 lb. 8 5W001-051 JUMPER HARNESS 8 8F101-260 FUEL PUMP 1

ix

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

2003-2004 4.6L DOHC Mach 1 Mustang

®

Part No. 4FR218-080SQ

ENGINEERING, LLC

PARTS LIST

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

aged parts immediately.

Part Number Description Quantity

4FR111-041 '03 MACH 1 MNTG BRACKET ASSEMBLY 1

7A375-178 3/8-16 x 1-3/4 HXHD G8 3 7K375-040 3/8 AN960 Flat Washer Plated 6 7K312-001 5/16 AN-Washer 14 4FR011-021 Mach. Mtg Bkt, '01 4V 1 7J312-875 5/16" Washer, Custom 1 7C080-065 8mm x 1.25 x 65 SOC 1 7C080-016 8mm x 1.25 x 16 HXHD 2 7C080-140 8mm x 1.25 x 140 HXHD 2 7C080-070 8mm x 1.25 x 70mm HXHD Zinc 1 7U313-133 M8 x 1.25 Stud, 4V Alternator 1 7F008-020 M8 x 1.25 Nut 1 7A375-225 3/8-16 x 2-1/4 HXHD G8 2 7J010-001 #10 Flat Washer 4 7C080-025 8mm x 1.25 x 25 HXHD 2 7C010-052 10-24 x 1/2 Button Hd. Cap 4 4FR010-011 Plaque, '99 4V Mtng Brkt 1 7C060-075 M6 x 1.0 x 75 HXHD Zink Plated 2 7A375-100 3/8-16 x 1 G5 HXHD Plated 1 7A312-175 5/16-18 x 1-3/4 HXHD G5 Zinc Plated 2 7A312-100 5/16-18 X 1 HXHD GR5P 1 7C080-130 M8 x 1.25 x 130 HXHD Zinc Plated 1 2A017-016 Shrt. Assy. Idler, V-3 1 4FR017-021 Spacer. Alternator '01 4V 2 4FR017-041 Alt Brkt, D-Side '01 4V 1 4FR017-051 Alt Brkt, P-Side, '01 4V 1 4FR111-032 Assy, Idler Plate, '01 4V 1 7J006-093 6mm Washer, Plated 2 2A046-115 Belt, K061115-Gates Vortec 1 4FH016-150 Idler Pulley, 6Rib 3" Flanged 1 4FR017-031 Spacer, Alt/Mtg Brkt, '01 4V 1

4FR112- 017 AIR INTAKE ASSY, '03 MACH 1 1

4FR012-010 Inlet Elbow, Mod Cast 4V 1 4FR110-050 90mm MAF Brkt Assy 1 7R002-056 #56 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 1 7U035-001 3-1/2" Flex Hose 1 7R002-052 #52 Goldseal Hose Clamp 2 8H040-097 Air Filter, 4" Flg 7" Long 1 7A250-075 1/4-20 x 3/4 SHCS Plated 4 7F250-021 1/4-20 Nylock Nut Zinc Plated 4 7U100-052 7/16 Rubber Grommet 1 7U100-056 Vent Tube 90° 1 7R001-008 #8 Stnls Hose Clamp 1 7U100-055 Tie Wrap, 6" Nylon 10 7J250-001 1/4 SAE Washer, Plated 4 7U038-000 3/4" Heater Hose 1 4FK012-040 Air Inlet Elbow 4.6 GEN2 1 7P750-100 3/4 NPT x 1" Hose Fitting 1 7R002-064 #64 Goldseal Hose Clamp 2 7S400-200 4 x 2 Sleeve 1 8A003-040 MAF, 90mm 1 7U375-055 Vacuum Cap, 5/8" Nipple 1 7E010-049 #10 x 3/4 Hex Head Sheet 2 4PFL010-041 Brkt, Fan Resistor Reloc 1 7C010-075 10-24 x 3/4 SHCS GR5 Zinc 2 7F010-024 10-24 Nylock Nut 2 5A002-014 Sensor, Ford Intake Air Temp 1 5W001-063 Harness, Ford IAT Sensor 1 4FR014-050 PCV Tube, 03 Mach 1 1 7P375-106 PCV Valve, Ford, 3/8" Hose 1 7P625-375 Reducer, 5/8" Barb to 3/8" Barb 1 7U032-016 3/8" EFI Fuel Hose Hi-Pressure .1666' 7U033-010R Hose, 5/8" ID Fuel, P/Str Ret 2" 7U033-010R Hose, 5/8" ID Fuel, P/Str Ret 2" 7R001-006 #6 Stnls Hose Clamp, Carrow 2 7J250-001 1/4" Washer, SAE, Pltd 6 7A250-074 1/4"-20 x .75" HHCS Pltd 3 7F250-021 1/4"-20 Nylock Nut Zinc Pltd 3 4FR010-030 Shaker Bracket, P.Side 03 Mach 1 1 4FR010-040 Shaker Bracket, D.Side 03 Mach 1 1 4FR010-040R Shaker Bracket, D.Side 03 Mach 1,L 1

Part Number Description Quantity

4FR114-012 COOLANT PIPE ASSY '99+ 1

7U100-046 O-Rings 2 4FE014-010 Radiator Pipe Stnlss 1 7U133-050 1-1/2" x 90° Hose 1 7R002-020 #20 Goldseal Hose Clamps 3 7R002-024 #24 Goldseal Hose Clamps 3 7P375-016 3/8" Pipe Plug 1 70000 Inspector Number 0 4FR014-010 '99 U-Bend Assembly-Coated 1 4FR014-020 '99 L-Bend Assembly-Coated 1 7F006-093 6mm Nylock Nuts 2 7P500-020 Tube Nut 1 7P375-042 Male Connector 1

4FH130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 14” Oil Drain Hose 1 7R001-008 #8 Stainless Hose Clamps 2 7P500-003 90° 1/2" Alum. Tube 1

4FH130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 26” Oil Feed Hose 1 7P525-067 .525 Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fitting 2 7P125-103 1/8” NPT -4 x 45° Male Elbow 1 7P250-082 1/4" NPT x -4 90° Fitting 1 7P250-034 1/4 NPT Street TEE 1 7P250-036 -4 Flare to 1/4 NPT 1

4FR112-020 DISCHARGE ASSEMBLY 1

7S275-300 2-3/4" x 3" Sleeve 1 7R002-044 #44 Goldseal Hose Clamps 2 7R002-016 #16 Hose Goldseal Clamps 4 8D001-001 Bypass Valve 1 7U034-016 1" GS Hose 1 7U034-016 1" GS Hose 1 7U030-046 5/32" Vacuum Line 1 7P156-082 5/32" TEE 1 7S450-200 4-1/2" x 2" Sleeve 1 7R002-072 #72 Goldseal Hose Clamps 2 7P750-100 3/4" NPT x 1" Hose Fitting 1 4FR012-030 Duct Discharge B '99 Cobra 1 7S350-200 3-1/2" x 2" Sleeve 1 7R002-056 #56 Goldseal Hose Clamps 2 4FR012-020 Duct Discharge A - Casting 1

2E229-190 V2SQ SC-TRIM ASY, 03 MACH 1 STD 1

2A036-361 S/C Pulley 3.60" 6-Grv 1

4FL120-025 ECM CHIP PKG/SHPNG ASSY '01 1 5W001-051 JUMPER HARNESS 8 8F101-265 FUEL PUMP 1 8F060-042 FUEL INJECTOR 42 lb. 8 2A046-112 BELT, 6-RIB GATES K061120 1

x

2003-2004 4.6L DOHC Mach 1

®

ENGINEERING, LLC

PARTS LIST

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

aged parts immediately.

Part Number Description Quantity Part Number Description Quantity

2E229-200 V-2 SC - TRIM 1 4FR111-041 '03 MACH 1MNTNG BRACKET ASSEMBLY 1

7A375-178 3/8-16 x 1-3/4 HXHD G8 3 7K375-040 3/8 AN960 Flat Washer Plated 6 7K312-001 5/16 AN-Washer 14 4FR011-021 Mach. Mtg Bkt, '01 4V 1 7J312-875 5/16" Washer, Custom 1 7C080-065 8mm x 1.25 x 65 SOC 1 7C080-016 8mm x 1.25 x 16 HXHD 2 7C080-140 8mm x 1.25 x 140 HXHD 2 7C080-070 8mm x 1.25 x 70mm HXHD Zinc 1 7U313-133 M8 x 1.25 Stud, 4V Alternator 1 7F008-020 M8 x 1.25 Nut 1 7A375-225 3/8-16 x 2-1/4 HXHD G8 2 7J010-001 #10 Flat Washer 4 7C080-025 8mm x 1.25 x 25 HXHD 2 7C010-052 10-24 x 1/2 Button Hd. Cap 4 4fr010-011 Plaque, '99 4V Mtng Brkt 1 7C060-075 M6 x 1.0 x 75 HXHD Zink Plated 2 7A375-100 3/8-16 x 1 G5 HXHD Plated 1 7A312-175 5/16-18 x 1-3/4 HXHD G5 Zinc Plated 2 7A312-100 5/16-18 X 1 HXHD GR5P 1 7C080-130 m8 x 1.25 x 130 HXHD Zinc Plated 1 2A017-016 Shrt. Assy. Idler, V-3 1 4FR017-021 Spacer. Alternator '01 4V 2 4FR017-041 Alt Brkt, D-Side '01 4V 1 4FR017-051 Alt Brkt, P-Side, '01 4V 1 4FR111-032 Assy, Idler Plate, '01 4V 1 7J006-093 6mm Washer, Plated 2 2A046-112 Belt, K061112-Gates 1 4FH016-150 Idler Pulley, 6Rib 3" Flanged 1 4FR017-031 Spacer, Alt/Mtg Brkt, '01 4V 1

4FR016-011 Pulley, 03 Mach 1, Water Pump 1

4FR112-017 AIR INTAKE ASSY, '03 Mach 1 1

4FR012-010 Inlet Elbow, Mod Cast 4V 1 4FR110-050 90mm MAF Brkt Assy 1 7R002-056 #56 Goldseal Hose Clamp 2 7S350-200 3-1/2 x 2 Sleeve 1 7U035-001 3-1/2" Flex Hose 1 7R002-052 #52 Goldseal Hose Clamp 2 8H040-097 Air Filter, 4" Flg 7" Long 1 7A250-075 1/4-20 x 3/4 SHCS Plated 4 7F250-021 1/4-20 Nylock Nut Zinc Plated 4 7U100-052 7/16 Rubber Grommet 1 7U100-056 Vent Tube 90° 1 7R001-008 #8 Stnls Hose Clamp 1 7U100-055 Tie Wrap, 6" Nylon 10 7J250-001 1/4 SAE Washer, Plated 4 7U038-000 3/4" Heater Hose 1 4FK012-040 Air Inlet Elbow 4.6 GEN2 1 7P750-100 3/4 NPT x 1" Hose Fitting 1 7R002-064 #64 Goldseal Hose Clamp 2 7S400-200 4 x 2 Sleeve 1 8A003-040 MAF, 90mm 1 7U375-055 Vacuum Cap, 5/8" Nipple 1 7E010-049 #10 x 3/4 Hex Head Sheet 2 4PFL010-041 Brkt, Fan Resistor Reloc 1 7C010-075 10-24 x 3/4 SHCS GR5 Zinc 2 7F010-024 10-24 Nylock Nut 2 5A002-014 Sensor, Ford Intake Air Temp 1 5W001-063 Harness, Ford IAT Sensor 1 4FR014-050 PCV Tube, 03 Mach 1 1 7P375-106 PCV Valve, Ford, 3/8" Hose 1 7P625-375 Reducer, 5/8" Barb to 3/8" Barb 1 7U032-016 3/8"EFI Fuel Hse Hi-Psr .1666' 7U033-101R Hose, 5/8" 5/8" ID Fuel, P/Str Ret 2 7U033-010R Hose, 5/8" ID Fuel, P/Str Ret 2 7R001-006 #6 Stnls Hose Clamp, Narrow 2

7J250-001 1/4" Washer, SAE, Pltd 6 7A250-074 1/4"-20 x .75" HHCS Pltd 3 7f250-021 1/4"-20 Nylock Nut Zinc Pltd 3 4FR010-030 Shaker Brkt, P.Side 03 Mach 1 1 4FR010-040 Shaker Brkt, D.Side 03 Mach 1 1

4FR114-012 COOLANT PIPE ASSY '99-'03 1

7U100-046 O-Rings 2 4FE014-010 Radiator Pipe Stnlss 1 7U133-050 1-1/2" x 90° Hose 1 7R002-020 #20 Goldseal Hose Clamps 3 7R002-024 #24 Goldseal Hose Clamps 3 7P375-002 3/8" Pipe Plug 1 70000 Inspector Number 0 4FR014-012 U-Bend Assembly-Coated 1 4FR014-020 '99 L-Bend Assembly-Coated 1

xi

7F006-093 6mm Nylock Nuts 2 7P500-020 Tube Nut 1 7P375-042 Male Connector 1 4FR017-061 Spacer, Rad Pipe, 03 Mach 1 2 7J250-001 1/4" Washer 2

4FH130-036 OIL DRAIN ASSEMBLY 1

7U030-036 1/2” x 14” Oil Drain Hose 1 7R001-008 #8 Stainless Hose Clamps 2 7P500-003 90° 1/2" Alum. Tube 1

4FH130-026 OIL FEED ASSEMBLY 1

7U030-026 1/4” x 26” Oil Feed Hose 1 7P525-067 .525 Crimp Ferrules 2 7P250-066 #4 Swivel x 1/4” Hose Barb Fitting 2 7P125-103 1/8” NPT -4 x 45° Male Elbow 1 7P250-082 1/4" NPT x -4 90° Fitting 1 7P250-034 1/4 NPT Street TEE 1 7P250-036 -4 Flare to 1/4 NPT 1

4FL120-025 ECM CHIP PKG/SHPNG ASSY '01 1 5W001-051 JUMPER HARNESS 8 8F101-265 FUEL PUMP 1 8F060-042 FUEL INJECTOR 42 lb. 8 4FR112-030 DISCHARGE ASSEMBLY '99 4V COOLER 1

7R002-044 #44 Goldseal Hose Clamps 2 7R002-016 #16 Goldseal Hose Clamps 4 8D001-001 Bypass Valve 1 7U034-016 1" GS Hose 0.229' 7U034-016 1" GS Hose 0.312' 7U030-046 5/32" Vacuum Line 4' 7P156-082 5/32" TEE 1 7S450-200 4-1/2" x 2" Sleeve 1 7R002-072 #72 Goldseal Hose Clamps 2 7S275-300 2-3/4" x 3" Sleeve 1 4FR012-030 Duct Discharge B 1 7R002-056 #56 Goldseal Hose Clamp 1 7P500-078 1/2" NPT x 3/4" HOSE Fits 2 7R002-048 #48 Goldseal Hose Clamps 2 7S350-301 Reducer, 3-1/2" to 3" 1 8N101-060 Welded Core Assembly 1 008341 Powercooler Decal 1

8N106-030 WATER COOLER ASSEMBLY, 4.6 1

7A250-075 1/4-20 X 3/4 SHCS PLTD 4 7F250-021 1/4-20 Nylock Nuts 4 7J250-001 1/4 SAE Washers 8 7P500-026 1/2 NPT-3/4 Barbs 90° 2 8N006-010 Water Cooler 1 7E010-075 #12 x 3/4" Sheet Metal Screw 4 7J010-001 #10 Flat Washers 4 8N010-050 Mount Tabs, Cooler 2

8N107-020 WATER PUMP ASSEMBLY, 4.6 1

5W001-011 16-14 GA Eyelet .25" Hole 1 5W001-012 Solderless Connector 1 5W018-010 18GA Strd Wire Red 8-1/4' 5W001-019 Solderless Connectors 10-12 2 5W001-014 Fuse Holder 10 GA Wire 1 5W001-015 Fuse, Blade Type 20 amp 1 5W001-015 12-10 GA Female Slide 1 5W001-002 Fuse Tap 1 8N010-060 Bracket, Bosch Water Pump 1 8F001-403 Pump, Water Bosch 1 5W001-050 Connector, Fuel Injector 1 7E010-075 #12 x 3/4" Sheet Metal Screws 2 7J010-001 #10 Flat Washers 2 7U133-060 3/4" x 90° Hose Elbow 1 5W001-024 Mini ATC Fuse Tap 1 5w001-025 Female Slide, Insulated Mini 1

8N105-030 WATER TANK ASSEMBLY, 4.6 1

7U038-000 3/4" Heater Hose 20 7R007-001 Nylon Clamps 1-1/8" 8 7R003-016 Adel Clamps, 7/8" 3 7E010-075 #12 x 3/4" Sheet Metal Screws 3 7J010-001 #10 Flat Washers 3 7U100-044 Tie Wraps, 4" Nylon 16 7U100-066 Tie Wraps, 11" Nylon 6 8N105-010 Water Tank w/Fitting 1

8N201-060 PWR COOLR ASSY '99 4.6 4V 1

8N101-060 Welded Core Assy '99 4.6 4V 1 7R002-048 #48 Goldseal Hose Clamp 1 7P500-078 1/2NPT x 3/4 Hose Fit 2 7S350-301 Reducer, 3.50-3.00 1 008341 PowerCooler Decal 1

2A046-115 111.5" belt 1

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

This Page Left Intentionally Blank

xii

1. PREPARATION/REMOVAL

A. Disconnect the negative battery cable. B. Loosen the water pump pulley bolts. C. Remove the accessory drive belt.

NOTE: The supplied 8mm x 16 bolt can be

threaded into the spring tensioner idler hole to remove the accessory drive belt.

D. Remove the "question mark" shaped crankcase

vent hose with attached ttings from between the passenger side valve cover and the air inlet.

E. Remove all components that lead to the throttle

body including the rubber air inlet duct, mass air ow (MAF) sensor, air lter assembly and intake air temperature (IAT) sensor. Separate the MAF and IAT sensors from the intake assembly and set aside.

F. Mach 1 Only: Remove the shaker scoop (upper

and lower pieces), steel support bracket attached to the top of the intake manifold and the aluminum support bracket attached to the front cover of the engine. (See Fig. 1-a, 1-b.)

G. Drain approximately one gallon of coolant from

the radiator. Remove the upper and lower radiator hoses from the steel water tube junction located around the alternator. Disconnect the water temperature sensor connector located on the water tube.

H. Remove the steel water tube assembly from

the engine by removing the 2 nuts. Pull the tube directly upwards.

I. Remove the coolant temperature sensor from

the factory water tube and set aside.

J. Remove the rear attachment screws that secure

the steel alternator support to the intake manifold. Remove the two screws that attach the alternator base to the engine block. This will allow for the alternator to be raised. Leave the factory steel bracket attached to the top of the alternator intact (the two front screws will remain).

Fig. 1-a / Mach 1 Models Only

Fig. 1-b / Aluminum Bracket Removed

From Front Cover / Mach 1 Models Only

* 1999 Models and Mach 1 only

** 2001-2004 Models only

1

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

1-7/8"

5/8"

2. OIL DRAIN

OIL PAN

DRAIN HOSE FROM SUPERCHARGER

OIL DRAIN TUBE

CRANK PULLEY

VIEW FROM PASSENGER SIDE

A. To provide an oil drain for the supercharger,

it is necessary to make a hole in the oil pan. Locate and mark the hole per Fig. 2-a. The drain hole must be punched rather than drilled.

B. Remove the paint around the hole area. C. Use a small center punch to perforate the

pan and expand hole. Switch to a larger diameter punch and expand the hole further to approximately 9/16" diameter. Most punches are made from hexagon material and may be placed in a socket with an extension to make this procedure easier.

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

1/4" deep. Pack the utes of the tap with heavy grease to hold chips. Use a small magnet to check for any stray chips.

NOTE: This method of rolling over the lip of

the hole and tapping it works very well if carefully done and should cause no problems.

E. Thoroughly clean the threaded area. Apply a small

amount of silicone sealer to the new threads. Apply more sealer to the male portion of the 3/8" NPT x 1/2" inverted are tting and secure in hole. Make sure a seal is formed all around the tting.

F. Thread the tube nut and 1/2" x 90° aluminum

tube into the inverted are tting by hand. Do not tighten until after the supercharger drain hose has been connected. (See Figs. 2 b, 2 c.)

G. Drain the engine oil and change the lter. H. Temporarily cap off the oil drain tting to keep

out debris until drain hose is attached at a later time.

I. Rell engine with 5W/30 synthetic or conventional

SH/CF rated motor oil.

Fig. 2-a - Front of Oil Pan

Fig. 2-b

2

Fig. 2-c

3. OIL FEED

A. Remove the 1/4" NPT socket head plug located

perpendicular to and directly beneath the factory oil pressure sending unit. This is found on the engine's driver's side below the oil lter.

B. Thread the supplied 1/4" NPT #4 are x 90° tting

into the pressure sending unit mount using engine oil on the pipe threads (see Fig. 3-a). The use of Teon tape or other sealants is not recommended as a small piece of either may break loose and cause blockage of the oil feed orice, resulting in supercharger failure. Rotate the tting so that the are points toward the front of the vehicle.

C. Temporarily cap off the are tting to prevent dirt

from entering. The oil feed will be connected at a later time.

4. FUEL PUMP INSTALLATION

NOTE: It is recommended when performing this

step that the fuel level in the tank be below 1/4 tank.

1/4" NPT x 90° FITTING

Fig. 3-a

A. Raise the rear of the car and support it with jack-

stands.

B. Open the fuel door and remove the fuel-cap

and the three ller neck screws using a 10mm socket.

C. Remove the fuel lter inlet line with a 3/8 sprin-

glock tool.

D. With the weight of the fuel tank supported with a

jack, remove the bolts securing the two fuel tank straps.

E. Slowly lower the fuel tank, allowing it to lean over

with the ller side up, until the electrical connections leading to the center mounted fuel pump are revealed. Disconnect these two electrical connections.

F. Remove the six bolts securing the fuel pump

access cover (on top of the fuel tank) with an 8mm wrench. Depress the two clips securing the plastic fuel pump enclosure and slide it out of the tank. The fuel sender oat is attached to the fuel pump enclosure and must be handled with care. Ensure that the tank has been lowered enough to remove the fuel pump enclosure.

G. Remove the two screws securing the plastic fuel

pump outlet manifold to the enclosure cap. Pull the manifold up and away from the fuel pump.

H. Remove the three screws securing the fuel pump

enclosure’s cover using a 3/16 nut-driver and remove the cover.

I. Remove the stock fuel pump from its enclosure.

Separate the rubber pump support from beneath the lter and install it on the supplied pump. Secure the support with the new lter provided.

3

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

4. FUEL PUMP INSTALLATION, cont'd.

J. Using the supplied fuel pump, reassemble the

fuel pump assembly and canister with cap.

K. Reinstall the canister assembly into the fuel tank

and reattach the electrical connections.

L. Reinstall the fuel tank, reconnect the fuel l-

ter inlet line, reattach the fuel ller neck and reinstall the fuel cap.

M. Turn the ignition key on and check the fuel

pump for leaks.

5. FUEL INJECTOR REPLACEMENT

A. Disconnect the EGR tube from the EGR valve at

the back of the intake manifold. Remove all bolts securing the upper manifold to the lower manifold. Unplug the electrical connector from the throttle body. The upper manifold should now move up enough to access all fuel injectors.

B. Disconnect the eight (8) 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 re extinguisher nearby and use extreme caution.

C. Remove the bolts holding down the factory fuel

rail onto the intake manifold. Lift up on to the rails evenly, removing all eight (8) injectors.

D. Using a small amount of clean motor oil, lightly

lubricate the O-rings on both ends of the Vortech supplied fuel injectors.

E. Install the new injectors into the fuel rails with the

terminals facing outward.

F. 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.

G. Tighten down the fuel rail assembly with the

original bolts.

H. Use supplied jumper harnesses to connect the

factory fuel injector plug to the newly installed fuel injectors (see Fig. 5-a).

I. Reinstall all components removed in step A.

Fig. 5-a

Vortech supplied

fuel injector

4

Vortech supplied jumper har-

ness (5W001-051)

Factory fuel

injector plug

6. AIR CONDITIONING LINE MODIFICATION

NOTE: Air conditioning lines are under high pres-

sure and the uid is highly toxic. Therefore, use extreme caution when bending the line to avoid kinking or breaking the line. Support the assembly as much as possible while bending for clearance.

A. Carefully bend the high pressure air conditioning

line (the line with the pressure port and cap) so that the pressure port rotates down (for supercharger inlet clearance). (See Fig. 6-a.)

Fig. 6-a

7. FAN RESISTOR RELOCATION (2001 and 2003-2004 Mach 1 models only)

A. 2003-2004 Mach 1: In order to remove the fan

resistor, you must unbolt the fan shroud from the radiator. Pull the fans forward and remove the resistor for the rear of the fans.

B. Cobra: Unsnap the resistor from the fanshroud

bracket. (See Fig. 7-b.) Pull the wire clips securing the wires to the fan away from the shroud so that the resistor can reach down. With the supplied relocation bracket and sheet metal screws mount the resistor (see Fig. 7-a).

C. SHROUD MODS: Trim the plastic which holds

the fan high/low resistor as shown in Fig. 7-b to give clearance for the inlet duct.

Fig. 7-a

FACTORY FAN

RESISTOR LOCATION

MODIFY SHROUD

AS SHOWN

5

Fig. 7-b

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

8. MAIN BRACKET ASSEMBLY/DRIVE BELT

A. Attach the supplied 1/8" NPT x 45° are tting

and oil feed hose to the oil feed tting on the supercharger. Rotate the tting so that it points forward, toward the volute side of the supercharger, perpendicular to the front cover. When tightening tting, use a 1/2" wrench on the oil feed base for support.

WARNING: When threading the 1/8" NPT x 45° are

tting into the supercharger, use engine oil on the pipe threads for lubrication. Teon tape, paste or other sealant is not recommended as it might loosen and cause blockage of the oil feed orice, resulting in supercharger failure.

B. Slide the supplied 1/2" oil drain hose onto the

supercharger drain and secure with a #8 hose clamp.

C. Using the supplied 3/8-16 x 1.75, 2.25 bolts and

3/8" AN washers, secure the supercharger to the Vortech aluminum mounting bracket. (See Figs. 8-a, 8-b.) Do not overtighten bolts.

Fig. 8-a

Fig. 8-b

6

8.1 MAIN BRACKET ASSEMBLY/DRIVE BELT - 1999 Models

A. Remove the three timing cover bolts, xed idler

pulley bolt (replace the factory idler pulley bolt with the supplied 8mm x 16 bolt and heavy duty washer) and passenger's side alternator mounting bolt from the front of the engine. Remove the upper bolt/stud located on the factory belt tensioner and replace with the supplied 8mm x 25mm bolt and washer. Remove the middle bolt also located on the belt tensioner. (See Fig. 8.1-a.)

B. Remove the air conditioning line silencer bracket

and mounting hardware from the silencer and engine front cover. Trim the corner of the bracket per Fig. 8.1-b on the following page. Enlarge the smaller of the two holes on the bracket with an 11/32" drill, remove any sharp edges around enlarged hole and reinstall onto the silencer. (See Fig. 8.1-c.)

NOTE: When mounting the supercharger bracket

assembly to the front cover, make sure that the air conditioning line silencer bracket is sandwiched in between the Vortech aluminum bracket and the front cover in positions #1 and #2. See Fig. 8.1-c.

C. Install the supplied M8 x 1.25 threaded stud into

the passenger side alternator mount. (Make sure the end with the least number of threads goes into the block.)

NOTE: On 1999 models, a tensioner stop has

been added to the tensioner. This must be removed before bracket installation.

REMOVE FACTORY BOLT/STUD AND REPLACE WITH SUPPLIED 8mm x 65mm ALLEN HEAD BOLT AND WASHER

REMOVE FACTORY BOLT/STUD AND REPLACE WITH SUPPLIED 8mm X 25 BOLT AND WASHER

REMOVE FACTORY HARDWARE (NEW SUPERCHARGER BRACKET MOUNTING HOLES)

FACTORY A/C SUCTION LINE SILENCER BRACKET MOUNTING HOLES

REMOVE FACTORY BOLT AND WASHER AND REINSTALL FACTORY IDLER WITH SUPPLIED 8mm x 16 BOLT AND HEAVYDUTY WASHER

1999 models

Fig. 8.1-a

7

INSTALL 8mm BOLT HERE IF 1/2" SQUARE DRIVE IN TENSIONER IS NOT PROVIDED.

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

A/C LINE

SILENCER

BRACKET

VIEW FROM FRONT

VORTECH

IDLER PULLEY

VORTECH

MOUNTING

BRACKET

ALTERNATO

R

OIL DRAIN HOSE

#1

#2

VORTECH

#3

8mm X 140 BOLT AND WASHER

8mm X 140 BOLT

AND WASHER

8mm X 70 BOL

T

AND WASHER

8mm X 70 BOLT

AND WASHER

8mm

THREADED STUD

,

WASHER AND NUT

SANDWICH TABS BETWEEN

ENGINE FRONT COVER AND

SUPERCHARGER BRACKET

ENLARGE

TO

11/32"

VIEW A

1/2”

REMOVE THE SHADED

AREA

FOR SUPER-

CHARGER MOUNTING

BRACKET CLEARANCE

8.1 MAIN BRACKET ASSEMBLY/DRIVE BELT - 1999 Models, cont'd.

Fig. 8.1-c

Fig. 8.1-b

8

8.1 MAIN BRACKET ASSEMBLY/DRIVE BELT - 1999 Models, cont'd.

VIEW FROM DRIVER'S SIDE

VORTECH IDLER PULLEY

VO

RTECH SUPERCHARGER MOUNTING BRACKET

STEEL IDLER SPACER

ALTERNATOR BOSS

HOLE POSITION #3 (SEE GRAPHIC ON NEXT PAGE)

SUPPLIED 8mm STUD (THREAD COMPLETELY INTO BLOCK UNTIL THREADS STOP)

ENGINE BLOCK

E. Loosen and remove the three nuts securing the

factory coolant reservoir to the car. Temporarily move aside to provide room to mount the supercharger. (Do not remove any hoses or connectors from reservoir.)

F. Remove the factory anged water pump pulley

and replace with the supplied non-anged pulley.

G. Following Figs. 8.1-c & 8.1-d, attach the

supercharger/aluminum bracket assembly with the Vortech idler pulley and idler spacer to the alternator stud and front cover using the supplied 8mm hardware. Route the new, longer belt around the outside of the supercharger drive pulley, then around the inside of the Vortech idler. Finish routing the belt around all of the pulleys, except for the water pump. Make sure that the Vortech idler pulley and spacer (located against the alternator base), are seated and located in their proper positions before tightening down the bolts (see Fig. 8.1-e for belt routing).

NOTE: When installing the Vortech idler pulley,

make sure that the bearing shim located between the bearings in the pulley allows for complete insertion of the idler spacer and bracket pilot. Install the steel idler spacer into the idler pulley and verify that the shim is not interfering with the idler spacer pilot.

Fig. 8.1-d

9

1999 Models Only

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

8.1 MAIN BRACKET ASSEMBLY/DRIVE BELT - 1999 Models, cont'd.

S/C

FACTORY

IDLER

VORTECH

IDLER

WA

TER

PUMP

CRANK

A/C

TENSIONER

POWER

STEERING

ALT.

PUSH BELT OVER THE TOP OF THE WATER PUMP PULLEY LAST

* PUSH BELT IN BETWEEN THE IDLER AND TENSIONER TO OBTAIN WRAP AROUND ACCESSORY AND SUPERCHARGER PULLEYS

*

H. After the bracket has been fully secured (the belt

should be properly routed around/under all pulleys except for the water pump), use a 1/2" breaker bar or ratchet to release the belt tension. Push the belt over the top radius of the water pump pulley, underneath the crank pulley, over the top of the tensioner pulley and release the tensioner (see Fig. 8.1-e).

I. Route the oil drain hose down to the oil pan tube

previously installed. The hose must be routed downhill, free from dips and kinks. Trim hose end if necessary, slide onto the drain tube and secure with #8 hose clamp. Support tting in oil pan with a wrench while tightening the drain tube tting.

IMPORTANT: It is imperative that the tensioner does

not get overloaded when being pulled down during belt installation. Bending of the tensioner may cause belt throwing/shredding problems when vehicle is driven at high speeds.

J. Route the oil feed hose next to the drain hose,

down to the feed tting and secure. Use tie wraps to fasten the lines together.

K. Reinstall the factory coolant reservoir and se-

cure.

Fig. 8-h

1999 only

BELT ROUTING

Fig. 8.1-e

10

REMOVE FACTORY BOLT/STUD AND

REPLACE WITH SUPPLIED 8mm x 65mm

ALLEN HEAD BOLT & WASHER

REMOVE FACTORY

BOLT, WASHER & IDLER & INSTALL

THE VORTECH

SUPPLIED

COMPOSITE IDLER

USING FACTORY

HARDWARE

REMOVE FACTORY

HARDWARE (NEW

SUPERCHARGER

BRACKET

MOUNTING BOLTS)

INSTALL M8 x 1.25 STUD (SHORT THREADED END GOES INTO THE BLOCK)

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models, cont'd.

A. Remove the three timing cover bolts,

xed idler pulley bolt (replace the factory idler with the supplied Vortech composite idler) and passenger's side alternator mounting bolt from the front of the engine. (See Fig. 8.2-a.)

B. Remove the air conditioning line silencer

and mounting hardware from the engine front cover.

C. Install the supplied M8 x 1.25 threaded

stud into the passenger's side alternator mount. (Make sure the end with the least number of threads goes into the block.)

D. Loosen and remove the three nuts se-

curing the factory coolant reservoir to the car. Temporarily move aside to provide room to mount the supercharger. (Do not remove any hoses or connectors from the reservoir.)

E. Mach 1 Models Only: Remove the fac-

tory water pump pulley and replace with the supplied aluminum pulley. Use the factory bolts.

F. Mach 1 Models Only: Remove the belt

tensioner from the front cover. Grind the top belt shield section off as seen in Fig.

8.2-b.

G. Following Figs. 8.2-c through 8.2-m

(Mach 1 Models Ignore Fig. 8.2-l), rst route the Vortech supplied supercharger belt and then attach the idler relocation assembly and mounting bracket/supercharger assembly to the front cover using the supplied 8mm

hardware. Finish by routing around all of the pulleys along with the supercharger pulley, except for the water pump.

H. After the bracket has been

fully secured (the belt should be properly routed around/ under all pulleys except the water pump). Use a large pair of channel locks to release the belt tension. Push the belt over the top radius of the water pump pulley, then release the tension. (See Fig.

8.2-n.)

I. Secure the air conditioner

canister to the Vortech mounting bracket as shown in Fig. 8.2-m.

IMPORTANT: It is imperative that the ten-

sioner does not get overloaded when being pulled down during belt installation. Bending of the tensioner may cause belt throwing/shredding problems when vehicle is driven at high speeds.

J. Route the oil feed hose next to the

drain hose down to the feed tting and secure. Use tie wraps to fasten the lines together.

K. Reinstall the factory coolant reservoir

and secure.

GROUND SECTION TO

CLEAR MOUNTING BRACKET

Fig. 8.2-b / Mach 1 Only

Fig. 8.2-a

11

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models

SECTION VIEW OF VORTECH

MOUNTING BRACKET

SPACER

ALTERNATOR

BRACKET 1

8mm STUD (THREAD THE END WITH THE LEAST NUMBER OF THREADS INTO THE BLOCK UNTIL THE THREADS STOP)

5/16-18 x 1.75 SCREWS w/WASHERS

ALTERNATOR BRACKET 2

RELOCATED FACTORY IDLER (open side must face toward the alternator)

IDLER ASSEMBLY

8mm NUT

WASHER

2001 ONLY

3/8-16 x 1.00 SCREW

2A017-016 BEARING PILOT

5/16-18 x 1.00 SCREW w/WASHER

8mm x 1.25 x 130mm

SCREW w/WASHER

2001-2004 ONLY

Fig. 8.2-c

12

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models, cont'd.

INSTALL SUPPLIED COMPOSITE

IDLER USING FACTORY HARDWARE

ROUTE BELT BEFORE

INSTALLING BRACKETRY

Fig 8.2-d / Step 1

ALTERNATOR BRACKET AND SPACER

(THREADED TIGHTLY INTO BLOCK

SUPPLIED STUD

W/SHORT THREADED END)

Fig 8.2-e / Step 2

13

Fig 8.2-f / Step 3 - Install supercharger/bracket

assembly as shown

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models, cont'd.

Fig. 8.2-g / Step 4 - Install alternator bracket 2

with idler plate assembly

5/16-18 x 1.75 BOLTS/WASHERS

LOOSELY INSTALLED

INSTALL w/"OPEN" SIDE

TOWARD ENGINE

BEARING PILOT WASHER

(STEP FITS INTO BEARING BORE)

Fig. 8.2-h / Step 5

14

Fig. 8.2-i / Step 6

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models, cont'd.

M8 NUT w/ WASHER

ROUTE BELT AS SHOWN

Fig. 8.2-j / Step 7

PLACE ALTERNATOR DOWN ONTO

THE 5/16-18 SCREWS AND SECURE

(MAKE SURE THE WASHERS ARE

PROPERLY LOCATED UNDER SCREW

HEADS)

SECURE BRACKETRY USING SUPPLIED

M6 x 1.00 x 75 SCREWS W/WASHERS

SUPPLIED SPACER (ONE EACH SIDE)

Fig. 8.2-k / Step 8 - Complete tightening hardware

15

Fig. 8.2-l / Step 9 (Cobra Models Only)

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models, cont'd.

ALTERNATOR

VORTECH

MOUNTING

BRACKET

8MM X 70 BOLT

AND

WASHER

A/C CANISTER

BRACKET

OIL DRAIN

HOSE

8MM x 140 BOLT

AND WASHER

RELOCATED

STOCK IDLER

IDLER RELOCATION

ASSEMBL

Y

8MM THREADED STUD,

WASHER AND NUT

MOUNTING LOCATION

FOR A/C CANISTER

2001-2004 Only

Fig. 8.2-m

16

RELOCATED

FACTORY

IDLER

RELOCATED

ALTERNATOR

PULLEY

SUPERCHARGER

PULLEY

TENSIONER

VORTECH SUPPLIED

IDLER

A/C

FACTORY

IDLER

WATER

PUMP

CRANK

POWER

STEERING

8.2 MAIN BRACKET ASSEMBLY/DRIVE BELT - 2001-2004 Models, cont'd.

BELT ROUTING

2001-2004 Only

Fig. 8.2-n

17

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

9. RADIATOR HOSE/WATER TUBE

A. Remove the upper radiator hose from the

radiator and modify (cut) as shown in Fig. 9-b on page 19.

B. With the lower radiator hose still connected

to the radiator, remove 2" from the end previously connected to the factory water tube. Set the 2" section aside.

C. Following Fig. 9-c on page 19, pre-assemble

the Vortech supplied "L" and "U" bent water tubes using the 2" hose (section removed in the previous step) and the supplied #20 clamps. Do not tighten clamps until assembly is mounted on the engine.

D. Thread the factory coolant temperature

sensor into the Vortech water tube using pipe thread sealant on the sensor threads. Make sure that the sensor is installed into the underside of the "U" bend (see Fig. 9-a).

E. 99-01 Cobra: Install the two supplied

O-rings into the O-ring grooves located on each end of the Vortech water tube assembly. Apply a small amount of anti-freeze around each O-ring to act as a lubricant for easier installation. With the "U" and "L" bends put together as one assembly, install the unit into the engine block in the factory water tube location making sure that both pipe tabs are aligned onto the intake manifold holes. Push both pipes down until the tabs and/or pipes hit bottom. Secure the assembly with the two factory nuts, or supplied 6mm nuts and washers if the factory water tube was originally attached to the alternator.

(2003-2004) Mach 1 Models: Install the

two supplied O-rings into the O-ring grooves located on each end of the Vortech water tube assembly. Apply a small amount of anti-freeze around each O-ring to act as a lubricant for easier installation. Place the two supplied aluminum spacers (.28" thick) between the bottom of each of the water pipe mounting tabs and the intake manifold ange where the factory water pipes were originally attached. With the "U" and "L" bends put together as one assembly, install the unit into the engine block in the factory water tube location making sure that both pipe tabs are aligned onto the intake manifold holes. Push both pipes down until the tabs and/or pipes hit bottom. Make sure that the tabs are on the top of the supplied .28" spacers. Secure the assembly with the two factory screws.

COOLANT TEMPERATURE SENSOR

Fig. 9-a

F. Reattach the factory coolant sensor con-

nector.

G. Reinstall the modied upper radiator hose

to the radiator with the factory clamp.

H. As shown in Fig. 9-d on the next page, re-

move 2-1/2" from the long leg of the Vortech supplied 1-1/2" diameter x 90° hose. Attach the hose, along with the factory radiator hose, to the supplied 1-1/2" splice using #24 clamps. Connect the entire assembly to the new Vortech water tube.

I. Attach the open end of the lower radiator

hose to the remaining barb on the Vortech water tube and secure with a #20 hose clamp.

J. Rell radiator. Completely ll engine block

through the 3/8" NPT water ll port on the Vortech water tube. Plug ll port with supplied 3/8" NPT plug.

18

CUT

DISCARD

4-3/4"

RADIATOR

ENGINE

RADIATOR

VORTECH

WA

TER TUBE

1-1/2" DIAMETER SUPPLIED HOSE

2-1/2"

CUT

SUPPLIED (3X) #24 CLAMPS

FACTORY CLAMP

SUPPLIED 1-1/2" DIA. SPLICE

CUT FROM LONG END AND DISCARD

9. RADIATOR HOSE/COOLANT TUBE, cont'd.

"U" BEND ASSEMBLY

COOLANT TEMPERATURE SENSOR (UNDERSIDE OF TUBE)

"L" BEND ASSEMBLY

LOWER RADIATOR HOSE CONNECTION

UPPER RADIATOR HOSE CONNECTION

SUPPLIED #20 CLAMPS (3X)

WA

TER FILL/AIR PURGE (3/8" NPT PLUG)

TOP VIEW

2" WIDE HOSE REMOVED FROM THE TOP END OF THE LOWER FACTOR

Y

RADIATOR HOSE

Fig. 9-b

Mach 1 Models Only: Place .28" spacers under tabs

UPPER

RADIATOR HOSE (STOCK)

VORTECH

WATER TUBE ASSEMBLY

19

Fig. 9-c

Fig. 9-d

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

10. AIR INLET

FRONT

INSIDE FRONT PASSENGER FENDERWELL

#64 CLAMPS

SLEEVE

ALUMINUM REDUCER ELBOW

FACTORY STUDS & NUTS

INT

AKE AIR TEMPERATURE SENSOR

MAF BRA

CKET

MAF METER

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

supplied MAF meter to the Vortech MAF bracket and secure (see Fig. 10-a for orientation). Remove the factory MAF screen before attaching the meter to the new MAF bracket.

B. Attach the supplied K & N air lter, 4" sleeve, 90°

x 3-1/2" x 4" elbow and #64 hose clamps to the MAF and secure.

C. Mach 1 Models Only: Cut the outer two wires

attached to the MAF harness plug approximately 2" from the MAF connector. (See Fig. 10-h.) Connect the gray with red stripe wire coming from the main harness to the red wire in the supplied IAT sensor harness using solder and the supplied shrink sleeve.Connect the gray wire coming from the main harness to the black/brown wire on the supplied IAT sensor harness using solder and the supplied shrink sleeve.

D. Insert the factory air temperature sensor into the

rubber grommet located on the side of the 90° elbow. Lubricate it for easier t.

E. Working from beneath the vehicle, remove the

two factory nuts and washers from the passenger side lower fender valence. Mount the MAF/bracket assembly onto the existing studs using the same washers and nuts originally removed. (See Fig. 10-a).

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

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

G. Route the factory temperature sensor and MAF

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

H. Connect the supplied molded inlet duct onto the

supercharger inlet (see Fig. 10-b) using the 3-1/2" sleeve and #56 hose clamps provided.

I. Attach the supplied 1" x 90° rubber hose and #16

hose clamp to the 3/4" x 1" straight hose tting located on the inlet duct. (See Fig. 10-c.)

J. Connect the previously installed 3-1/2" ex hose

to the inlet duct and secure with the #52 clamp.

K. Install the supplied length of 3/4" hose from the

inlet duct to the crankcase breather tting (see Fig. 10-d). Trim hose length as necessary.

L. Take the supplied 5/8" rubber end cap and install

it on the 5/8" boss on the molded inlet duct.

VIEW FROM INSIDE ENGINE COMPARTMENT

(Steel inner fender not shown for ease of description)

Fig. 10-a

Fig. 10-b

20

10. AIR INLET, cont'd.

3” x Ø1” HOSE

(TRIM TO FIT)

TO DISCHARGE

TUBE

1” UNION

1999-2004 4V FORD MUSTANG AFTERCOOLED AND

NON-AFTERCOOLED AIR INLET/BYPASS ASSEMBLY

8” x Ø1” HOSE

(TRIM TO FIT)

Ø1” x 90° ELBOW TO 1” FITTING

ON INLET DUCT

INLET DUCT

STRAIGHT FITTING

VIEW FROM FRONT

OF VEHICLE

TO MANIFOLD PRESSURE/VACUUM

#16 HOSE CLAMPS

BYPASS

VALV

E

Fig. 10-c

21

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

10. AIR INLET, cont'd.

VORTECH SUPPLIED 3/4" PLASTIC ELBOW

INSERTED INTO VALVE COVER

HOSE CONNECTS TO INLET DUCT

3/4" HOSE TRIM TO FIT

FRONT OF VEHICLE

Fig. 10-d

RIGHT SIDE VALVE COVER BREATHER

22

10. AIR INLET, cont'd.

M. (Mach 1 Models Only):

1. Remove the factory plastic PCV tube from the

driver side of the engine and discard. Insert the large end of the supplied PCV valve into the factory rubber PCV elbow attached to the rear of the driver's side valve cover. Attach the supplied 5/8" bent tube to the intake manifold port previously connected to the plastic PCV tube using the supplied short length of 5/8" hose, 3/8" hose piece and the brass 3/8" to 5/8" reducer as shown. (See Figs. 10-e, 10-f.) Secure the hoses with the supplied #6 hose clamps.

2. Mark and modify the aluminum air scoop base as shown. (See Fig. 10-g ). If you have access to a machine shop with a milling machine, this is the ideal method. If not, drill the marked location with a hole saw at each corner and then cut the remaining portion out with an abrasive cut-off wheel, grinder or jigsaw. This is an alternative way to provide a clean hole.

3/8" HOSE

5/8' HOSE

SUPPLIED PCV VALVE

FACTORY RUBBER ELBOW

5/8' - 3/8'

UNION

Fig. 10-e / (Mach 1 Models Only)

SUPPLIED PCV TUBE

Fig. 10-f / (Mach 1 Models Only)

2-1/2"

2-1/8"

Fig. 10-g / Modify Air Scoop Base as Shown

(Mach 1 Models Only)

2-1/4"

3-3/4"

23

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

GRAY WIRE CONNECT TO THE BLACK/BROWN AIR TEMP SENSOR WIRE

GRAY w/RED STRIPE WIRE

CONNECT TO RED

AIR TEMP SENSOR WIRE

RED

BLACK/BROWN

SUPPLIED IAT SENSOR CONNECTOR

MAF PLUG

LEAVE APPROX. 2" OF WIRE ATTACHED TO PLUG

CUT TWO OUTER

WIRES HERE

10. AIR INLET, cont'd.

Fig. 10-h / MAF Modications

(Mach 1 Models Only)

24

10. AIR INLET, cont'd

FRONT VIEW AFTER

MODIFICATION

USE THE BRACKET PROVIDED

AS A TEMPLATE AND

DRILL 2 Ø5/16" HOLES

DRIVER SIDE VIEW

AFTER MODIFICATION

THIS PORTION REMOVED AND DISCARDED

.50

2.25

1.75

3. Modify the steel air scoop base mount as shown. (See Figs. 10-i, 10-j.) A bandsaw is the best tool to use. An abrasive cut-off wheel or hacksaw may also be used.

4. Temporarily place the modied steel air scoop base into its factory location on top of the intake manifold. Loosely install the two factory screws that secure the rear of the bracket to the intake manifold (do not tighten at this time). The two supplied relocation brackets must be attached to the modied steel scoop base.

Fig. 10-i / Modied Shaker Bracket

(Mach 1 Models Only)

Fig. 10-j / Bracket mods (Mach 1 Only)

25

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

10. AIR INLET, cont'd

Referring to Figs. 10-k, 10-l, attach the driver's

side relocation bracket to the alternator and the underside of the modied steel air scoop base and align. Mark and drill two 5/16" holes in the modified scoop base. Permanently attach the relocation bracket to the modied steel air scoop base using the 1/4-20 x .75 screws, nuts and washers.

5. Remove the front passenger's side intake manifold cover bolt. (See Fig. 10-m.) Locate the driver's side relocation bracket in between the bottom of the modied steel air scoop base and the front passenger's side intake manifold cover bolt. Re-install the intake manifold cover bolt through the new bracket. Mark and drill a 5/16" hole in the modied steel air scoop base. Permanently attach the relocation bracket to the modied steel air scoop base using the 1/4-20 x .75" screw, nut and washer. Tighten the two factory screws securing the steel air scoop base at the rear of the intake manifold.

6. Re-install the modied aluminum shaker scoop assembly onto the modied steel air scoop base using the factory hardware and rubber grommets. Ensure the assembly alignment by carefully closing the hood. Adjust the scoop base if necessary.

SUPPLIED 1/4-20 SCREWS, NUTS, WASHERS

SUPPLIED

BRACKET

SUPPLIED BRACKET

Fig. 10-k / (Mach 1 Models Only)

Fig. 10-l / Modied Shaker Bracket w/Vortech

Brackets Attached (Mach 1 Models Only)

26

SUPPLIED

BRACKET

FACTORY

MANIFOLD

COVER BOLT

Fig. 10-m / (Mach 1 Models Only)

AFTERCOOLER KITS ONLY: If an aftercooler kit is

being installed, please substitute the supplied "Maxow Power Cooler" instructions in place of step 11. Resume at step 12 after the completion of the Aftercooler installation.

11. SUPERCHARGER DISCHARGE

A. Slide the 4-1/2" diameter sleeve and #72 hose

clamps onto the throttle body. Slide the 2-3/4" sleeve and #44 hose clamps onto the supercharger discharge.

B. Install the 1" x 3" hose, #16 hose clamps and

bypass valve onto the discharge tube with the 5/32" nipple on the valve pointing down.

C. Install the aluminum discharge tube onto the

throttle body. Slide the 3-1/2" sleeve and #56 clamps onto the round end of the tube. Next, connect the supercharger to the aluminum tube using the long discharge tube/bypass valve assembly. Align the bypass valve, all hoses and, tighten all clamps. If necessary, trim the 1" bypass hose lengths for best t. (See Fig. 11-a.)

D. Attach the supplied 5/32" vacuum line to the

bypass valve. Using the supplied 5/32" TEE, connect the hose to the fuel pressure sensor (located on the fuel rail) vacuum port.

E. Install supplied laser-etched plaque on top

of mounting bracket using the supplied #10 screws.

Fig. 11-a

27

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

12. ECM MODULE INSTALLATION

NOTE: When the ECM is sent, the following step will be

performed by Vortech to ensure proper cleaning and module installation. (Step 12 is for reference only.)

A. Double check that the battery cable is disconnected

from the vehicle.

B. Remove the passenger side front kickpanel 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.

C. 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.

D. Gently remove the plastic service port cover on the

opposite end from the main harness connection. The main circuit board with a double sided electrical edge connector will now be exposed (see Fig. 12-a).

E. Using alcohol and a cotton swab, carefully clean

the grease off of both sides of the main circuit board service contacts.

F. Using a sharp knife, small at screwdriver or

scraper, gently scrape the remaining thin layer of silicone off of the contacts. This can easily be done by removing the corner screws on the ECM and opening the cover to better expose the connector to be cleaned. DO NOT remove or damage the electrical contacts. If the silver contacts start to give off ne metal shavings, you are done. STOP. It is extremely important that all of the silicone be removed from the contacts. If the surface is not completely clean, the vehicle may not start or run properly. If the ECM cover was removed, reinstall it at this time.

Fig. 12-a / ECM & Module Alignment

Fig. 12-b / Proper Module Installation

Fig. 12-c / Improper Module Installation

NOTE: Improper contact cleaning is the largest rea-

G. With the ECM service port contacts now clean,

you are ready to install the ECM module. Align the module with the ECM (see Figs. 12-b, 12-c). Slide the module onto the ECM by applying gentle pressure evenly. Apply the supplied section of adhesive tape to the top of the ECM and module to resist movement from vibration.

H. Reinstall the ECM into the vehicle. In some cases,

the extra height of the ECM module will not allow the use of the factory ECM bracket. Reconnect the factory harness and reinstall the factory kick panel.

son ECM modules fail or work improperly.

28

WARNING: Do not attempt to operate the vehicle

until ALL components are installed and ALL operations are completed including the nal check.

13. FINAL CHECK

NOTE: Once the ECM is recieved 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.

A. Reconnect the battery. B. 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.

C. Check all fittings, nuts, bolts and clamps for

tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie wraps.

D. Double check water pump pulley bolts for

tightness.

E. Check all uid levels, making sure that your tank(s)

is/are lled with 91 octane or higher fuel before commencing test drive.

F. Start the engine and allow to idle a few minutes,

then shut off.

G. Recheck to be sure that no hoses, wires, etc. are

near exhaust headers or moving parts and for signs of any uid leakage. (See Fig. 13-a.)

H. PLEASE TAKE SPECIAL NOTE: Operating the

vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF

MAJOR COMPONENTS. I. Test drive the vehicle. J. Read the STREET SUPERCHARGER SYSTEM

OWNER'S MANUA L AND RET U R N THE

COMPLETED WARRANTY REGISTRATION

FORM within thirty (30) days of purchasing your

supercharger system .

Fig. 13-a

29

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

®

ENGINEERING, LLC

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

23AUG04 86-93 4V Mus. Cobra(4FR v3.1)

P/N: 4FR020-010

Vortech 2003-2004 Mustang Mach 1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual