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.

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.

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

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

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

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

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

4FR114-010 COOLANT PIPE ASSEMBLY '99+ 1

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

Part Number Description Quantity

4FR114-010 COOLANT PIPE ASSY '99+ 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

4FR112-020 DISCHARGE ASSEMBLY 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

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

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

8N105-030 WATER TANK ASSEMBLY, 4.6 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

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

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

4FR112-020 DISCHARGE ASSEMBLY 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

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

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

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

8N106-030 WATER COOLER ASSEMBLY, 4.6 1

8N107-020 WATER PUMP ASSEMBLY, 4.6 1

8N105-030 WATER TANK ASSEMBLY, 4.6 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

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

P/N: 4FR020-010

+ 29 hidden pages

Vortech 2003-2004 Mustang Mach 1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual