his manual provides information on the installation, maintenance and service of the
Vortech supercharger kit expressly designed for this vehicle. All information, illustra-
T
tions and specifications contained herein are based on the latest product information
available at the time of this publication. Changes to the manual may be made at any time
without notice. Contact Vortech Engineering for any additional information regarding this kit
and any of these modifications at (805) 247-0226 8:00am-4:30pm PST.
Take note of the following before proceeding:
1. 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 contact your dealer or Vortech Engineering for possible installers in your
area.
2. This product was designed for use on stock (un-modified, OEM) vehicles. The PCM
(computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the
vehicle or engine has been modified in any way, check with Vortech prior to installation
and use of this product.
3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).
4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use
(no boost) until problem is resolved.
5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.
Exclusions from Vortech warranty coverage considerations include, but not limited to:
1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.
2. Continued operation with an impaired vehicle or sub-system.
3. The combined use of Vortech components with other modifications such as, but not limit-
ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.
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.
Congratulations on selecting the best performing and best backed automotive
supercharger available today... the VORTECH® 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, the Warranty
Registration form and return envelope.
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 specified
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 modified 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.
5. Perform an oil and filter change upon completion of this installation and prior to test driving
your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles. Never attempt to extend the
oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential
damage to the supercharger may result.
6. Before beginning installation, replace all spark plugs that are older than 1-year or 15,000
miles with original heat range plugs as specified by the manufacturer and reset timing to
factory specifications (follow the procedures indicated within the factory repair manual and/
or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs
unless they are original equipment. Change spark plugs every 20,000 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, 3/8-18 tap & handle
• Adjustable wrench
• Open end wrenches: 3/8", 7/16", 1/2", 9/16"
• Center punch and a 5/8" tapered punch
• 6 quarts (or what is specified in your owner’s manual)
SF rated quality engine oil, oil filter and wrench
If it has been 15,000 miles or more since your vehicle’s last spark plug change, then you will
also need:
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU111-044 S/C MOUNTING BRKT ASY 1
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU114-030 WATER PIPE ASSY, 07-08 MUST GT 1
4FU014-051 HOUSING, THRMST RELC 07 MUST G 1
4FU014-060 WATER PIPE, Ø1.5 X 90°,07 MUST 1
5W001-085 SLEEVE, FLEX BRD Ø1.5" NOM. 0.83
7C060-015 M6 X 1.0 X 16MM SHCS CL10.9+ Z 2
7C060-020 M6 X 1.0 X 20MM HX 2
7J006-094 6MM WASHER S.S. 2
7R002-024 #24 HOSE CLAMP 3
7U012-018 O-RING, 07 MUST GT THERM HSG 1
4FU130-026 OIL FEED ASY 1
7U250-090-260 OIL FEED HOSE, 26" -4X90° 1
7P125-005 1/8 NPT STR. X -4 JIC FTG STL 1
7P250-091 1/4 NPT 90° X -4JIC FTG STL 1
7P250-034 1/4 NPT X 1/4 NPT STRT T 1
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU114-030 WATER PIPE ASSY, 07-08 MUST GT 1
4FU014-051 HOUSING, THRMST RELC 07 MUST G 1
4FU014-060 WATER PIPE, Ø1.5 X 90°,07 MUST 1
5W001-085 SLEEVE, FLEX BRD Ø1.5" NOM. 0.83
7C060-015 M6 X 1.0 X 16MM SHCS CL10.9+ Z 2
7C060-020 M6 X 1.0 X 20MM HX 2
7J006-094 6MM WASHER S.S. 2
7R002-024 #24 HOSE CLAMP 3
7U012-018 O-RING, 07 MUST GT THERM HSG 1
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU010-044 S/C MOUNT PLT, MUST GT 1
4FU010-034 IDLER MOUNT PLATE, MUST 1
4FU017-011 SPACER, STUDDED MUST GT 2
2A017-750-05 SPACER, .750 OD X 2.691 LONG 2
2A017-750-06 SPACER, .750 OD X 2.712 LONG 1
2A017-879-08 SPACER, .875 OD X 1.776 LONG 1
2A017-750-07 SPACER, .750 OD X .097 LONG 1
4FU017-021 SPACER, IDLER, MUST GT 1
4PCS016-160 PULLEY, IDLER 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 X 3-3/4 HX HD 1
7C080-150 M8 X 1.25 X 150MM HXHD CL10.9 1
7C080-140 M8 X 1.25 X 140 HXHD CL8.8 2
7A375-100 3/8-16 X 1 G5 HHCS, PLT 7
7K312-030 5/16 AN WASHER, S.S. 2
7K375-040 3/8 AN960 FLAT WASHR PLATED 10
4FU112-010 AIR INTAKE ASY 1
4FU012-010 INLET DUCT,"A" 1
4FU012-015 INLET DUCT,"B" 1
7R002-056 #56 HOSE CLAMP 1
7S400-200 SLEEVE, 4 X 2, BLUE 2
7S400-351 REDUCER SLV 4.00 X 3.5 X 2.35L 1
7R002-064 #64 HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0FLG X 7.0L 1
8A003-071 MAF, 3.8 I.D. MUSTANG GT 1
7P750-102 3/4NPT X 1" X 90° HSE FIT 1
7P250-047 1/4NPT TO 3/8"BARB 90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PSR 4
4FU013-010 COVER, AIR FILTER, MUST GT 1
7C040-008 M4-.7X8MM SCHD SS 2
4FU114-030 WATER PIPE ASSY, 07-08 MUST GT 1
4FU014-051 HOUSING, THRMST RELC 07 MUST G 1
4FU014-060 WATER PIPE, Ø1.5 X 90°,07 MUST 1
5W001-085 SLEEVE, FLEX BRD Ø1.5" NOM. 0.83
7C060-015 M6 X 1.0 X 16MM SHCS CL10.9+ Z 2
7C060-020 M6 X 1.0 X 20MM HX 2
7J006-094 6MM WASHER S.S. 2
7R002-024 #24 HOSE CLAMP 3
7U012-018 O-RING, 07 MUST GT THERM HSG 1
Disconnect the plastic 3/8" tube assembly
attached to the passenger’s side valve cover.
Remove the plastic 3/8" x 90° connector from the
plastic tube that was connected at the passenger’s side valve cover. Set this connector aside to
be re-used in a later step. Discard the remainder
of the hose assembly, as it will not be re-used.
(See Fig. 1-c.)
NOTE: The preferred method of removing
the 90° connector from its original
plastic tube is to apply a small
amount of heat to the tube and slide
the connector free.
C. Disconnect the mass air flow (MAF) sensor plug
and remove the inlet duct and upper air filter
cover from the car if applicable. (See Figs. 1-a,
1-b, 1-c.)
D1. Remove the 10mm headed bolt (located next to
the inner fender) which secures the lower portion
of the air filter enclosure. Remove the lower portion from the car - it will not be reused. (See Fig.
1-d.)
F. Locate the coolant drain plug on the passenger’s
side of the radiator. Next drain the coolant into a
clean container. This coolant will be reused in a
later step.
NOTE: Loosening the coolant reservoir cap will allow for
coolant to drain more freely.
G.Remove the two 8mm headed bolts securing the
coolant overflow reservoir to the plastic fan
shroud. (See Fig. 1-f.)
H. Disconnect the small overflow hose (running
across the top of the radiator) from the overflow
reservoir. (See Fig. 1-f.)
I.1(2007-2010 Models and Bullitt Only) Remove the
large hose connected to the bottom of the coolant
overflow reservoir. (See Fig. 1-g.)
I.2(2005-2006 Only) Remove the large hose con-
necting the thermostat housing to the bottom of
the overflow reservoir. Set the hose and reservoir
aside to be reinstalled in a later step. (See Fig.
1-g.)
NYLON
CLIPS
Fig. 1-e
COOLANT
OVERFLOW
HOSE
NOTE: If you are installing H.O. (charge cooled) kit,
the coolant reservoir will not be reused. Retain
only the fill cap for reuse.
J.1. (2005-2006 Only) Remove the two upper radiator
hoses from the engine coolant crossover tube and
set aside. The radiator hose located on the driver’s
side will not be reused. (See Fig. 1-g.)
J.2. (2007-2010 Only) Remove single upper radiator
hose. This host will be reused in a later step.
K.(2005-2006 Only) Remove the thermostat housing
from the large formed hose leading to the engine
block and the lower outlet of the radiator. (See
Fig. 1-h.) Set the thermostat housing aside to be
reinstalled in a later step.
L.(2005-2006 Only) Remove the lower hose on the
radiator and set the hose aside, as it will not be
reused.
M. Drain and remove the power steering reservoir.
This reservoir will be relocated in a later step.
N.1Disconnect and remove the factory 5/8" plastic
breather hose assembly attached to the driver’s
side valve cover and intake manifold. Remove the
two fittings from the ends of the plastic tube for reuse. Discard the striped plastic tube. (See Fig.
1-i.)
N.2(Bullitt Only) Remove strut tower brace two nuts
requires the removal, in part or whole, of the
intake manifold so that modifications can be made
to the coolant crossover tube or thermostat housing depending on year of application:
1.(2005-2006 Only) Unplug the wire connectors from each of the eight injectors. Remove
all of the vacuum hoses and connectors located at the front and rear of the intake manifold.
Remove the connector attached to the intake
manifold runner control (IMRC) unit located at
the rear of the manifold on the passeger’s
side.
2.(2007-2010 Only): Unplug the wire connectors from each of the eight injectors.
3.Remove the four 8mm headed bolts securing
the injector rails to the intake manifold. Do not
remove the small clips that retain the injectors
to the fuel rails. Using a 5/8" spring lock tool,
disconnect the fuel feed line from the fuel rail.
Remove the vacuum line from the fuel regulator. Remove the rails and injectors as a complete unit and set aside. New injectors will be
installed in a later step. (See Figs. 1-i, 1-j.)
4.Locate and remove the remaining 10mm
headed bolts retaining the intake manifold to
the cylinder heads. There are five on each
side.
5.(2005-2006 Only): Remove the intake manifold and set aside so it can be reinstalled after
modifications to the coolant crossover tube
are made.
REMOVED IN STEP
“G”
THERMOSTAT
HOUSING
LARGE
FORMED
HOSE TO
ENGINE
BLOCK
Fig. 1-h
8mm HEADED
SCREWS
RETAIN
FACTORY
HOSE ENDS
Fig. 1-i
NOTE: Modification to the crossover
tube will be completed in a later
step
6.(2007-2010 Only): It is not necessary to
remove the intake manifold from the vehicle
completely. Raise the front of the manifold
3-4" and support between the throttle-body
and alternator.
P. Using a 1/2" ratchet, release the tension from the
accessory drive belt and remove it from the car.
This drive belt will be replaced with a longer one
later in the installation.
Q.Locate and remove the stud bolt that secures the
alternator in place as well as the bolt located to
the right of the alternator. (See Fig. 1-o.) Using a
15mm socket or wrench, remove the nut that
secures the capacitor, resistor and coolant hose
support bracket to the stud bolt. Using an 18mm
socket or wrench, remove the stud bolt, it will be
modified and replaced in a later step.
On 2010 Models, no coolant hose support bracket is used.
R.There is a small tab that secures the wiring har-
ness in place on the valve cover that will need to
be removed to gain clearance for the supercharger belt. This tab is best removed with a small air
saw but a grinder will work. After removal, smooth
the area to prevent damage to the belt. (See
Figs. 1-r, 1-r1.)
S.As seen in Fig. 1-o, the upper bolt is removed
from the timing chain cover. This bolt will have to
be modified by cutting off the threaded end where
the resistor attaches. Modify and reinstall the bolt.
(See Fig. 1-s.)
T. Disconnect the plug to the cam position sensor.
Remove the wiring harness from the retaining
clips that hold it to the valve cover. Move the harness out of the way. This harness will have to be
relocated to gain clearance for the supercharger.
3. OIL DRAIN ASSEMBLY INSTALLATION (Engine oil-fed kits only.
Applications with V-3 superchargers skip ahead to step 4.)
A.To provide an oil drain for the supercharger, it is nec-
essary to make a hole in the oil pan. It is best to
punch the hole rather than to drill it.
B. Remove paint from the area around the hole.
C. Mark the oil pan 5/8" down from the oil pan
mounting rail on the driver’s side of the engine.
Measure forward 3/4" from the first bolt on the
side of the oil pan. (See Fig. 3-a.)
D.Use a small center punch to perforate the pan and
expand the hole. Switch to a larger diameter
punch and expand the hole further to approximately Ø9/16". Most punches are made from
hexagon material and may be placed in a socket
with an extension to make this procedure easier.
E.Tap the hole with a 3/8"NPT tap approximately 1/4"
deep. Pack the flutes 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.
5/8"
Fig. 3-a
3/4"
F. Thoroughly clean the threaded area. Apply a small
amount of silicone sealer or teflon paste to the
new threads. Apply more sealer to the 3/8"NPT
hose fitting and secure in the hole. Make sure a
seal is formed all around the fitting. (See Fig. 3-b.)
5.1 COOLANT TUBE RELOCATION (2005-2006 Models Years Only), cont’d
F. Remove the factory O-ring type gaskets to pre-
vent damage from heat. Clamp the steel hose
barb end of the coolant crossover tube in a vise
as shown. Using a small amount of heat, heat the
aluminum crossover tube. Using a twisting motion,
remove the steel insert. (See Fig. 5.1-d.)
Penetrating oil will also aid in this step.
G.Locate the supplied 1-1/4" expansion plug
(7P125-002).
H.Coat the expansion plug with sealant. Using a tube
or socket that matches the recessed diameter of
the plug, install the plug flush with the machined
surface sealing the outlet of the crossover tube.
(See Figs. 5.1-e, 5.1-f.)
I.Locate the supplied coolant relocation fitting, sealing
nut and O-ring washer. (See Fig. 5.1-g.)
J.Install the fitting in the location of the factory cool-
ant bleed plug. (See Fig. 5.1-h.) Screw the jam
nut all the way onto the fitting. Tighten the fitting in
the position shown. (See Fig. 5.1-h.) Secure with
the jam nut.
Fig. 5.1-d
NOTE: It is recommended that sealant be
used to seal the thread of the fitting.
K. Reinstall the factory O-ring gaskets to the cross-
over tube.
L.Set the coolant crossover tube back in its original
location.
M.Reinstall the two 10mm headed bolts through the
crossover tube into the cylinder heads.
Temporarily install two intake manifold retaining
bolts through the crossover tube into the cylinder
heads, where the manifold will be secured. Leave
these loose as they are there only as a pilot for
the crossover tube.
5.1 COOLANT TUBE RELOCATION (2005-2006 Models Years Only), cont’d
O.Reconnect the coolant crossover tube hose at the
lower rear portion of the coolant crossover tube.
Remove any coolant that may have spilled into
the engine valley.
P. Reinstall the alternator support bracket and the
four 10mm headed retaining bolts removed earlier. Attach the capacitor resistor removed from the
stud bolt on the front cover to one of the 10mm
bracket retainers. Route the resistor and its wire
away from moving parts.
NOTE: Leave two 10mm headed bolts that
attach the bracket to the crossover
tube loose.
Q.Reinstall the Intake Manifold removed in a previ-
ous step. Check to see that the rubber intake runner gaskets are in place and undamaged. Make
sure the cylinder head surface is clean.
R. Lower the intake manifold onto the cylinder heads.
S. Install the ten factory 10mm headed manifold
retainers and tighten to factory specifications.
Tighten the two 10mm headed bracket bolts that
were previously left loose.
T. Reconnect the IMRC control unit at the rear of the
manifold along with the vacuum hose.
U.Remove the small clips that retain the factory fuel
injectors to the fuel rail. Remove the factory fuel
injectors and set aside - they will not be reused.
V.Locate the supplied fuel injectors. Lubricate the
injector O-rings with clean motor oil and install
into the fuel rail. Reinstall the small retaining clips
onto the injectors.
W.Lower the fuel rail/injector assembly onto the
manifold, making sure that the injectors seat properly into the manifold. Secure with the four factory
8mm headed bolts.
X.Reconnect the fuel injector plugs and all other
connections and vacuum lines previously removed
from the manifold assembly.
screws that retain the thermostat housing. Set the
housing aside to be reused later. Leave the factory thermostat and O-ring seal in place as they will
be reused (provided they are in good condition).
(See Fig. 5.2-a.)
B.Locate the supplied thermostat housing adaptor
and hardware. Using the two 6mm socket-head
screws, install the housing adaptor as shown.
(See Fig. 5.2-b.)
C.Using the 6mm hardware, washers and
O-ring provided, reinstall the thermostat housing.
Attach the previously removed resistor to the
housing as shown. (See Fig. 5.2-c.)
D.Reinstall the intake manifold removed in a previ-
ous step. Check to see that the rubber intake runner gaskets are in place and undamaged. Make
sure the cylinder head surface is clean.
E. Lower the intake manifold onto the cylinder heads.
F. Install the ten factory 10mm headed manifold
retainers, and tighten to factory specifications.
G.Remove the small clips that retain the factory fuel
injectors to the fuel rail. Remove the factory fuel
injectors and set aside. These will not be reused.
H.Locate the supplied fuel injectors. Lubricate the
injector O-rings with clean motor oil and install
into the fuel rail. Reinstall the small retaining clips
onto the injectors.
I.Lower the fuel rail/injector assembly onto the
manifold, making sure that the injectors seat properly into the manifold. Secure with the four factory
8mm headed bolts.
J.Reconnect the fuel injector plugs, all other con-
nections and vacuum lines previously removed
from the manifold assembly.
6.1 PULLEY AND SPACER REPLACEMENT (Bullitt/V-Power/8-Rib Kits Only - All
others skip to step 6.2)
A. Unplug the cam sensor connector.
B. Tensioner modification (skip to step c. if installing
belt tensioner assist):
1.Remove the three screws retaining the factory
spring tensioner to the front of the engine.
Remove the factory steel idler from the tensioner and replace with the supplied 3" idler
(4FU116-031) using the factory hardware.
(See Fig. 6.1-a.)
2.Install the three M8 x 40mm bolts w/washers
through the tensioner mounting holes.
3.Slide the three .75"OD x .328"ID x .140" spacers onto the three bolts protruding through the
tensioner. (See Fig. 6.1-a.)
4.Secure the tensioner assembly to the front of
the engine. Use Fig. 6.1-a as guide for spacer
placement.
6.1 PULLEY AND SPACER REPLACEMENT (Bullitt/V-Power/8-Rib Kits Only - All
4FU010-081
3/8-16 x 2.5"
SCREW, WITH JAM
NUT INSTALLED
3 x 2A017-752-03
.75"OD x .328”ID
x.927" LONG
3 x 2A017-750-014
.75"OD x .328”ID
x .140” THICK
BETWEEN
TENSIONER AND
TENSIONER ASSIST
PLATE
BETWEEN
TENSIONER AND
FRONTCONVER
3.0" 8-RIB WIDE
SMOOTH IDLER
others skip to step 6.2)
C. OPTIONAL Belt tensioner assist up-grade:
1. Remove the three screws retaining the factory
spring tensioner to the front of the engine.
Remove the factory steel idler from the tensioner and replace with the supplied 3" idler
(4FU116-031) using the factory hardware.
(See Fig. 6.1-C1.)
2.Locate the supplied tensioner assist plate.
Install the supplied 3/8-16 x 2.5" screw and
3/8-16 jam nut into the plate. Install the three
M8 x 55mm bolts w/washers through the plate.
Slide the three .75"OD x .328"ID x .927" long
spacers onto the previously installed hardware. (See Fig. 6.1-C2.)
3.Install the plate, hardware and spacers onto
the factory spring tensioner. Slide the three
.75"OD x .328"ID x .140" spacers onto the
three bolts protruding through the tensioner.
(See Fig. 6.1-C2.)
4.Secure the tensioner assembly to the front of
the engine. Use Figs. 6.1-C1, 6.1-C2 as
guides for spacer placement.
NOTE: Leave the 3/8" screw and jam nut
loose at this time.
D.Remove the factory idler pulley located just above
the spring tensioner location. Replace with the
supplied 3.5" idler (4FU016-021) and .875"OD x
.663"ID x .101" thick spacer (2A017-882-02) using
the factory hardware. (See Fig. 6.1-a.)
E. Replace the alternator pulley:
1. First remove the plastic cap from the end of
the alternator pulley to reveal the splined hub.
2.Rotate the pulley so that a round punch can
be inserted through the front of the alternator
into the alternator-cooling fan. This will hold
the alternator assembly from turning. Using
the appropriate splined hub tool (see notes on page iv), loosen and remove the alternator
pulley. The threads are standard.
3.Install the supplied 8-rib alternator pulley
(4FU016-011) and secure using the M16 x
6.1 PULLEY AND SPACER REPLACEMENT (Bullitt/V-Power/8-Rib Kits Only - All
others skip to step 6.2), cont'd
F. Remove the two bolts that retain the factory
idlers to the front cover. Discard the idlers and
bolts. Replace the top idler with the 3.5"
smooth idler (4FU016-021) .875"OD x .663"ID
x .101" spacer and stud bolt provided. Replace
the lower idler with the 3.5" ribbed idler
(4FU016-041) .875"OD x .663"ID x .101" spacer and stud bolt provided. (See Fig. 6.1-c.)
G.Using the appropriate pulley puller, remove the
factory power steering pulley and discard.
Replace with the supplied 8-rib power steering
pulley with the appropriate installer tool.
H.Remove the A/C clutch retaining screws.
Carefully remove the clutch and set aside with
the hardware and small spacer located
between tip of A/C compressor drive shaft and
A/C clutch spline. Replace with the supplied
8-rib A/C pulley (4FR016-021), and secure
using the factory hardware and spacer.
I.Remove the crank pulley retaining bolt.
Using the appropriate pulley puller,
remove the crank pulley and discard.
Install the supplied 8-rib crank pulley
using the factory retaining bolt. (Thread
locking compound must be applied to the
screw threads.)
J.Loosely install the 8-rib drive belt provid-
ed using Fig. 6.1-c for belt route reference. Not all pulleys are installed at this
time.
6.1 PULLEY AND SPACER REPLACEMENT (Bullitt/V-Power/8-Rib kits Only - All
others skip to step 6.2), cont'd
NOTE: See Fig. 6.1-d for the next few steps.
K. S/C mounting plate installation:
1. Install the two 140mm bolts into their mounting plate
hole locations and slide the two 2.691" long spacers
onto them. (See Figs. 6.1-d,
6.2-a.)
2.Install the idler plate onto the previously installed hardware and spacers.
3.Install the .097" long spacer onto the bolt that will be
secured through the alternator. (See Figs. 6.1-d, 6.2-a.)
4.Loosely install the S/C mounting plate assembly using
the original S/C mounting plate hardware, taking care to
route the drive belt on the correct side of the spacers.
(See Figs. 6.2-b, 6.2-c.)
5.Locate the remaining 3.5" smooth idler (4FU017-031),
.544" long pilot spacer, and 1.597" long spacer as
depicted in Fig. 6.1-d.
6.Install the idler pulley assembly referencing Figs. 6.1-d,
A.The mounting plate is provided with the spacers and
bolts as they would be installed on the vehicle. Keep
these bolts and spacers marked as to their locations. They are all different in size and mismatching
them will result is misalignment of the mounting
plate.
B. (Non V-Power/Bullitt Kits only) Locate the two sup-
plied stud-bolt spacers (see Figs. 6.2-b, 6.2-c) in the
S/C mounting plate assembly. Remove the factory
screws retaining the idler pulleys on the driver’s side of
the engine and replace with the stud spacers.
C.It is necessary to install the supercharger acces-
sory drive belt and loosely route it following Fig.
6.2-c, as not all pulleys are currently in place.
D.Locate the supercharger mounting plate 4FU010-
044 from the supercharger mounting plate assembly. (See Fig. 6.2-a.)
E.(Non V-Power/Bullitt Kits only) Locate the two 8mm
x 140mm long bolts and washers from the mounting bracket assembly and install in the locations
noted. (See Fig. 6.2-a.)
F. Slide the two long spacers onto the bolts previ-
ously installed. (See Fig. 6-f.) Install the small triangle-shaped idler pulley mounting bracket to the
spacers. Install the .093" spacer onto the bolt that
will be attached in the alternator location.
G.Lower the mounting plate assembly into position on
the front of the engine. Be sure to route the drive
belt on the correct side of the idler bracket and spacers. (See Fig. 6.2-g.)
H.Loosely attach the plate using the previously
installed 140mm hardware. Locate the two 3/8-16
x 1.0" bolts and washers and install through the
plate into the two stud bolt spacers retaining the
factory idlers. (See Figs. 6.2-a, 6.2-c.)
I.Locate the 8mm x 150mm bolt and washer.
Loosely install the bolt through the mounting plate
and remaining long spacer into the engine cover
using Fig. 6.2-a for location reference.
J.(Non V-Power/Bullitt Kits only) Locate the supplied
idler, 1.776" idler spacer, idler pilot spacer, 3/8-16
x 3.75" long bolt and washer. Install the bolt/washer through the mounting plate, 1.776" spacer, supplied idler, idler pilot spacer and into the triangleshaped bracket. (See Figs. 6.2-f to 6.2-h for
assistance.)
2 x 8mm x
140mm
SCREWS
2 x 3/8-16 x 1.0"
SCREWS
2005-2008 NON-COOLED & 2010
H.O. MODEL IDLER LOCATION
3/8-16 x 3.75"
SCREW
H.O. KIT SCREW
LOCATION
(NOT FOR 2010)
5 x 3/8-16
x 1.0"
SCREWS
8mm x 150mm
SCREW
Fig. 6.2-a 2005-2008 NON-COOLED & 2010
H.O. MODEL IDLER LOCATION
STUD
BOLT
SPACERS
Fig. 6.2-b
NOTE: This figure is just for reference.
The small idler pulley mounting
bracket will need to be installed at
the same time as the supercharger
(S/C) Mounting Plate. (See Fig. 7-d.)
STUD
BOLT
SPACERS
INSTALLED
NOTE: If installing a standard output kit (non-
cooled), the 3/8" x 3.75" bolt will be
installed in the upper hole location. H.O.
kits install in the lower hole.
K. Tighten all mounting plate hardware, making sure
the drive belt is properly routed and no wiring or
hoses are caught between the mounting surfaces.
(See Fig. 6.2-g.)
L1. (Non V-Power/Bullitt Kits only) Install the five 3/8-16
x 1.0" bolts and washers through the back side of
the mounting plate. (See Fig. 6.2-h.)
L2. (V-Power/Bullitt Kits only) Install the five 3/8-16 x
1.5" supplied bolts and washers through the back
side of the mounting plate. Install the five .280"
long spacers (2A017-878-08) onto the previously
installed hardware. (See Fig 6.1-d)
*M. Attach the supplied length of 1/2" oil drain line
hose, and one #8 hose clamp from the previously
installed oil drain assembly, to the 1/2" barbed fitting in the supercharger.
*N. Install the supplied 1/8"NPT x -4 straight fitting
from assembly 4FU130-026 to the oil feed fitting
on the supercharger.
NOTE: Use only clean engine oil on the pipe threads.
Teflon tape or pipe sealant is not recommended as it might loosen and cause blockage of
the small oil feed orifice resulting in possible
supercharger failure.
Fig. 6.2-f
.093"
SPACER
O. Attach the supercharger assembly to the mount-
ing plate using the previously installed hardware.
A 9/16" ratcheting end wrench will greatly aid in
this step.
* P. Secure the oil drain hose to the prevously
installed brass fitting in the oil pan, making sure to
route in a smooth downward manner and away
from moving or hot objects.
NOTE: Any dips, “uphill” sections, kinks or restrictions
may cause drainage problems and possible
supercharger failure.
*Q. Attach the -4 oil feed hose to the straight -4 fitting
previously installed in the supercharger. Secure
away from moving or hot objects.
R. Using a 1/2" ratchet, rotate the factory spring ten-
sioner clockwise and install the accessory drive
belt. (Refer to Fig. 6.2-e for proper belt routing.)
S. Optional belt tensioner assist upgrade only:
Once the drive belt has been installed, snug the
tensioner assist bolt. Lock in place with the previously installed jam nut.
NOTE: Do not overtension the tensioner assist bolt, as
damage may occur to the OEM tensioner..
Fig. 6.2-g
SUPERCHARGER
HARDWARE
Fig. 6.2-h
* Applies to "engine oil-fed" units only. V-3
applications skip these steps
T. Reconnect the cam sensor plug.
**U. Secure the remote drain hose away from the belt
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY)
NOTE: For non-cooled kits skip this section
and proceed to Section 9.
A. BUMPER COVER AND SPLASH PAN
1. Raise the vehicle with a floor jack and set on
jack stands.
2.Remove the seven 5.5mm headed screws
retaining the lower splash panel. (See Fig. 8A-a.)
3.Remove the six Phillips-head screws (three
on each side) from the lower portions of the
plastic innner fender liners. (See Fig. 8A-b.).
On 2010 Models, remove the four 7mm headed screws (2 per side) from the lower portions
of the plastic inner fender liner.
4.Remove the five plastic clips retaining the
front portion of the fender liner. Both sides
need to be removed. (See Fig. 8A-c.)
5.Remove the four 10mm nuts (two on each
side) retaining the bumper cover to the fenders. (See Fig. 8A-d.)
2010 models do not use the bracket depicted
in Fig.8A-d. Pull outward from rear most portion of the bumper where it attaches to the
inner fender to unsnap from retainers. The
bumper detaches along the bumper to fender
body line and underneath the headlights.
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
B. WATER COOLER ASSEMBLY
INSTALLATION, cont’d
7. Attach the previously assembled water cooler
to the bolts and spacers and secure with the
8mm nuts and washers provided. Tighten all
cooler hardware at this time. (See Fig. 8B-e.)
NOTE: When installing the cooler, make
sure that the water ports are
configured as shown in Figs.
8B-a, 8B-q. The “top cooler port”
must be the highest point on the
cooler for proper air purging.
8.Attach the supplied short 90° hose (7U030-
065) to the top port on the CAC cooler as
shown. (See Fig. 8B-f.)
9.Install one of the supplied 3/4" hose unions
into the open end of the previously installed
90° hose and secure. (See Figs. 8B-f, 8B-q.)
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
B. WATER COOLER ASSEMBLY
INSTALLATION, cont’d
10. 2005-2009 models: Locate assembly 8N104-
125. Confirm that the assembly is complete.
2010 Models: use assembly 8N104-127.
11. Attach the provided ring terminal to the ground
wire on the suplied water pump plug harness.
Connect the supplied length of 16GA wire to
the positive wire using the supplied butt connector. Connect the water pump harness to
the water pump.
12. Locate the supplied water pump (8F001-403),
two 2-3/8" adel clamps, and water pump
mounting bracket. Place the adel clamps on
the water pump. Using the supplied 1/4-20
hardware, secure the water pump and clamps
to the mounting bracket. When installing,
attach the water pump ground wire to one of
the water pump mounting clamps using the
previously installed ring terminal. (See Fig. 8B-g.)
2010 Models: use water pump bracket depicted in Fig. 8B-g2.
13. Attach the pump assembly to the two 8mm x
35mm long bolts previously installed and
secure using the 8mm nuts and washers provided. (See Fig. 8B-h.)
2010 Models: see Fig. 8B-h2
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
B. WATER COOLER ASSEMBLY
INSTALLATION, cont’d
BALLAST
RESISTOR
14. Route the positive wire up towards the driver’s
side valve cover.
15. Locate the ballast resistor plug. Install the supplied T-tap connector, cut the water pump positive wire (from the water pump) for best fit,
attach the supplied male spayed connector
and attach to the wire T-tap connnector. (See
Fig., 8B-i.)
16. Cut the water pump positive wire and install
the inline fuse holder and fuse. Install the wire
loom provided and secure away from heat and
moving parts. (See Fig. 8B-i.)
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
B. WATER COOLER ASSEMBLY INSTALLATION, cont’d
17. Locate the 3/4" x 150° molded rubber hose
(7U038-150). Connect the short end of the
3/4" x 150° hose to the lower port on the previously installed water cooler. Install one of
the provided 3/4" hose unions into the open
end of the 150° hose. Attach a length of 3/4"
hose approximately 24" between tthe hose
union and the previously installed water pump
discharge. Secure all hose connections using
the nylon ratchet clamps provided. (See Fig.
8B-j.)
2010 models will require the passenger side
air diverter to be trimmed where the power
steering cooler line passes through. Enlarge
the bottom of this notch 1-1/2˝ for 3/4˝ hose to
pass through
18. Attach a length of 3/4" hose approximatelly
48" long to the previously installed water
pump feed port and secure. Route the open
end of the installed hose toward the passenger’s side shock tower. This hose will be
connnected in later step. (See Fig. 8B-h.)
HOSE TO
FRONT OF VEHICLE
WATER COOLER
WATER
PUMP
Fig. 8B-j | Viewed From Below
3/4" HOSE
UNION
3/4" x 150°
HOSE (7U038-
150)
NOTE: The installation of this hose sec-
tion should maintain an “uphill”
routing wthout dips or kinks.
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
B. WATER COOLER ASSEMBLY INSTALLATION, cont’d
19. Assemble the surge tank reservoir 8N056-060
install a 1/2"NPT x 3/4" straight barbed fitting
in the bottom of the surge tank and one
1/2"NPT x 3/4" x 90° in the side. (See Fig. 8B-k.)
20. Locate and attach the surge tank mounting
bracket 8N010-160. Attach the bracket with
two 1/4-20 x 1/2" socket head cap screws and
washers. (See Fig. 8B-l.)
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
B. WATER COOLER ASSEMBLY INSTALLATION, cont’d
21. On the passenger’s side of the engine,
attached to the valve cover, is a large wire
harness. The harness will have to be relocated to gain clearance for the surge tank and
the radiator overflow reservoir. (See Figs. 8B-n, 8B-m.)
22. Detach the wiring harness from the retaining
clips and move the harness to the shock
tower. Secure the harness to the A/C line with
wire ties. (See Fig. 8B-n.)
23. Remove the small clip retaining the small wiring harness to the shock tower. (See Fig. 8B-n.)
24. Attach the small harness to the large harness
with wire ties.
25. To gain clearance for the coolant reservoir,
the A/C line will need to be bent slightly
towards the passenger’s side fender. (See
Fig. 8B-n.)
SECURE
HARNESS
WITH WIRE-TIES
Fig. 8B-m
NOTE: A/C line is under high pres-
sure. Use caution not to kink
or damage the line.
(2005-2006 Only)
26. Remove the 10mm headed screw retaining
the ground strap to the bracket on the strut
tower. (See Fig. 8B-o.)
4FU010-051 to the reservoir with the 1/4-20 x
1/2" long bolts and washers provided. (See
Fig. 8C-a.)
3.Attach bracket 4FU010-061 to the front of the
reservoir with the hardware provided. (See
Fig. 8C-b.)
4.Locate and install 1/4"NPT x 3/8" barbed fitting in the tapped hole just above the previously installed mounting bracket. This hole
may have to be opened using the appropriate
drill bit. (See Fig. 8C-c.)
the back of the ECU and the power distribution box. (See Fig. 8C-d.)
6.Install the coolant reservoir. Secure the front
of the reservoir with the factory fastener
removed previously. (See Fig. 8C-e.)
NOTE: Leave this bolt loose for final
adjustment in a later step.
7.Attach the rear mounting bracket with the
surge tank mounting bracket to the strut tower
with the 6mm x 20mm long screws and washer provided. (See Fig. 8C-f.)
NOTE: Reinstall the factory ground wire
with one of the 6mm screws and
washers.
10mm
HEADED
BOLT
Fig. 8C-d
RESERVOIR
BRACKET
8.Attach a length of 3/4" hose (approximately 3'
long) to the 3/4" bung on the front of the cool-
ant reservoir. Route the hose to the 3/4" outlet
on the thermostat housing secure the hose
with the clamps provided. (See Fig. 8C-g.)
NOTE: A/C line on the passenger side
must be bent away from block
for reservoir clearance. This can
be done with a large screwdriver
as depicted in figure 8C-g2.
tory coolant overflow reservoir. By cutting the
"S” bend off the hose end. (See Fig. 8C-h.)
10. Install a 3/8" union and a #17 stepless clamp.
Secure the clamp. Using a length of 3/8"
(approximately 40" long) hose that is provided, secure the hose to the union with a #17
stepless clamp. (See Fig. 8C-i.)
11. Route the overflow hose across the radiator
and under the radiator retaining bracket to the
1/4"NPT x 3/8" hose barb fitting in the coolant
reservoir securing with a clamp. (See Fig. 8C-j.)
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
D.
RADIATOR HOSE MODIFICATIONS ('05-'06
Models Only)
1.Remove the passenger’s side upper radiator
hose. (See Fig. 8D-a.)
2.Modify the upper hose by cutting the hose just
after the bend. (See Fig. 8D-b.)
3.Attach the hose to the formed stainless tube
4FU014-010 with a #24 hose clamp.
4.A section of 1-1/2"ID hose left from the coolant tube relocation will be cut to approximately
2-3/4" long and attached to the outlet of the
radiator reusing the factory spring clamp to
secure the hose to the outlet.
5.Install the formed coolant tube to the inlet on
the engine and to the radiator. Secure with
hose clamps. (See Fig. 8D-c.)
4FU010-091 to the reservoir with the 1/4-20 x
1/2" long bolts and washers provided. (See
Fig. 8E-a.)
3.Attach bracket 4FU010-061 to the front of the
reservoir with the hardware provided. (See
Fig. 8E-b.)
4.Locate and install 1/4"NPT x 3/8" barbed fitting in the tapped hole just above the previously installed mounting bracket. This hole
may have to be opened using the approppriate drill bit. (See Fig. 8E-c.)
the back of the ECU and the power distribution box. (See Fig. 8E-d.)
6.Install the coolant reservoir. Secure the front
of the reservoir with the factory fastener
removed previously. (See Fig. 8E-e.)
NOTE: Leave this bolt loose for final adjustment in a
later step.
10mm HEADED
BOLT
Fig. 8E-d
7.1 Attach the rear mounting bracket with the
surge tank mounting bracket to the strut tower
using the factory strut mounting hardware.
(See Fig. 8E-f.)
7.2 (Bullitt Only) Attach bracket 4FU010-061 on
the underside of the 4FU010-091 reservoir
bracket to ensure clearance from strut tower
brace.
8.Attach a length of 3/4" hose (approximately
22" long) to the 3/4" bung on the front of the
coolant reservoir. Secure using one of the #10
hose clamps provided. Route the open end of
the hose to the 1" hose previously connected
to the factory coolant reservoir. Connect and
secure the two hoses using the 3/4" x 1" hose
union, the factory 1" spring clamp and the #10
hose clamp provided.
tory coolant overflow reservoir. By cutting the
"S” bend off the hose end. (See Fig. 8E-h.)
10. Install a 3/8" union and a #17 stepless clamp.
Secure the clamp. Using a length of 3/8"
(approximately 40" long) hose that is provided, secure the hose to the union with a #17
stepless clamp. (See Fig. 8E-i.)
11. Route the overflow hose across the radiator
and under the radiator retaining bracket to the
1/4"NPT x 3/8" hose barb fitting in the coolant
reservoir securing with a clamp. (See Fig. 8E-j.)
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
F. COOLER CORE INSTALLATION
1. Locate the charge air cooler assembly.
2. Attach the 4.5" x 2" sleeve to the throttle body
and secure with a #72 hose clamp.
3.a(Non-V-Power/Bullitt Kits only) Install the
1/2"NPT x 3/4" barb 90° and straight fittings into
the charge cooler as shown. (See Fig. 8F-a.)
3.b(V-Power/Bullitt Kits only) Install the two 1/2"
NPT x 3/4" barb 90º fittings into the charge cooler as shown (See Fig. 8F-b)
4.Attach the long end of the 2.75" (3" if V-Power)
silicone elbow to the cooler inlet and loosely
install a #44 (#48 on V-Power cars) hose clamp.
The open end of the elbow should be facing up
as it will be attached to the supercharger discharge.
5.Lower the cooler assembly into position. Attach the
open end of the previously installed 2.75" elbow to the
supercharger discharge and loosely install a #44 hose
clamp.
6.Attach the cooler discharge to the previously
installed sleeve on the throttle body. Secure with
a #72 hose clamp.
7. Tighten all cooler clamps at this time.
8. Locate one of the remaining 3/4" molded 90°.
Trim approximately 5" from the long end and
attach the short end to the forward most 3/4" x
90° fitting previously installed in the cooler.
Secure with the nylon ratchet clamp provided.
9.Install a 3/4" hose union into the open end of the
previously installed hose. Attach a section of
3/4" hose approximately 32" long to the union.
Route the open end of the hose to the surge
tank. Using the remaining adel clamp and factory hardware, secure the hose to the factory coolant reservoir mounting location. (See Figs. 8B-q, 8F-c for assistance.) Secure all hose connections with the supplied nylon ratchet clamps.
10a. (Non-V-Power/Bullitt Kits only) Locate the supplied
“S” shaped hose. Trim approximately 1" from the short
end and attach it to the straight fitting previously
installed in the cooler. Install a 3/4" hose union into the
open end of the “S” hose. Attach a section of 3/4"
hose approximately 24" long to the union and route to
the driver’s side and down to the water cooler. Trim for
best fit and connect to the 3/4" hose union previously
installed in the 90° short rubber hose attached to the
top water port on the CAC cooler.
DISCHARGE
Fig. 8F-a
Fig. 8F-b
ADEL
CLAMP
3/4"
STRAIGHT
FITTING
3/4" x 90°
FITTING
INLET
HOSE
“S”
NOTE: The installation of this hose section
should maintain an “uphill” routing
without dips or kinks.
10b (V-Power/Bullitt Kits only) Locate the remaining
3/4" molded 90° hose and install on the rear
most 3/4" x 90° fitting previously installed in the
CAC. Secure with the nylon ratchet clamp provided. Trim as required. Using the supplied 3/4"
barb union connect the other end of the molded
90° hose to a section of 3/4" hose approximately
24" long routed to the driver side and down to
the top of the water cooler. trim for best fit and
connect to the 3/4" hose union previously
installed in the 90° short rubber hose attached to
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
the top port on the CAC water cooler.
11.At this time, verify that all hose connections are
secure using the nylon ratchet clamps provided.
12.(2007-2010 Models Only) To provide additional
clearance for the CAC, you will need to cut the
factory radiator hose approximately 4" from its
connection at the radiator. Install the supplied
Ø1.5" x 4" hose union and two #24 hose
clamps. Adjust to allow CAC clearance and
secure. (See Fig. 8F-c.)
CAC
#24 HOSE
CLAMPS
G. COOLANT RESERVOIR FILL
1. Check to make sure all previously installed
hose connections are secure.
2.Fill the engine cooling system through the
Vortech supplied coolant reservoir using the
factory coolant previously drained.
3.Locate the factory coolant reservoir cap
removed in section 1 and install it on the
Vortech supplied reservoir.
4.(2005-2006 Only) Once the coolant system is
filled and all trapped air expelled, install the
1/8"NPT plug provided in the previoisly
installed cross-over tube. Thread sealant
should be used.
5. CAC cooling system.
a. Temporarily remove the 3/4" hose
attached to the 3/4" x 90° fitting on the
CAC surge tank.
b. Cap the open end of the 3/4" x 90° fitting
using the provided vinyl cap.
c.Fill the CAC system using a 25%/75%
antifreeze/water mix. Using a funnel, fill
through the 3/4" hose removed from the
surge tank fitting.
d. Fill the system until the coolant level
reaches the surge tank.
e.Remove the vinyl cap from the surge
tank fitting and reinstall the 3/4" hose
previously removed and secure with the
nylon ratchet clamp.
6.Reinstall the front bumper assembly including
the foam inner bumper, all plastic splash panels and light connections in the reverse order
removed.
2010 Models skip this step and see section
8H.
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
H. BUMPER COVER MODIFICATION (2010
MODELS ONLY)
1. 2010 Models will require the removal of the
lower grill uprights and certain surronding
areas to clear the water cooler. (See Fig.
8H-a)
2. Cut out vertical supports in lower grill opening.
the upper lip of the grill should be trimmed
back to approximately 4-1/4” when measured
from the back side of the grill. (See Fig. 8H-b)
3. The lower lip should be trimmed back approxi
mately 4-1/4” measured from the front of the
grill. (See Fig. 8H-c)
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
H. BUMPER COVER MODIFICATION (2010
MODELS ONLY) con'td
4.. Trial fit bumper and check for interference
against intercooler. Additional removal of mate
rial may be required to clear the intercooler
end tanks and brackets (See Fig 8H-d,e).
5. Remove bumper and mark on upper lip supports 1” from edge. Drill a 1/4 “ hole from the
top of the support through the lip of the grill.
From the bottom drill a 5/16” hole through the
lip only, being careful not to drill through the
support. An angle drill using the shortest bit
possible is recommended.
5. Install the supplied 1/4-20 Nylon shouldered
bolts from the lip side so that the threads pro
trude through the supports and attach with the
supplied 1-4/20 Nylock nut (See Fig. 8H-f). Do
not over tighten nuts.
6. Reinstall the front bumper assembly including
the foam inner bumper, all plastic splash panels and light connections in the reverse order
removed. See Fig. 8H-g for final installation
reference.
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
I. COMPRESSOR BYPASS VALVE
INSTALLATION (V-POWER/BULLIT KITS SKIP TO
8J)
1. Assemble the bypass using a piece of 1"
hose cut to 11" long and a piece cut to
13" long and four #16 hose clamps.
2.Attach the 11" piece of hose to the inlet
of the bypass and secure with a clamp.
3.Secure the 13" piece to the outlet of the
valve, securing it with a clamp. (See Fig. 8I.)
4.Attach the bypass assembly to the
charge cooler. The 11" long piece will be
attached to the charge cooler. Secure
with clamps. Leave the 13" long section
open for future attachement to the air
inlet.
5.Attach a length of 5/32" vacuum hose to
the bypass valve and route to the vacuum port of the fuel rail sensor.
6.Cut a section of the factory hose and
install the vacuum TEE that is provided.
(See Fig. 10-b)
7.Attach the vacuum hose from the
bypass valve to the TEE.
8. CHARGE AIR COOLER INSTALLATION (CHARGE COOLED KITS ONLY), cont’d
J. V-POWER/BULLIT COMPRESSOR BYPASS VALVE
INSTALLATION
1. Assemble the bypass using the sup-
plied Maxflow Race Bypass valve, Ø 1.75" silicone coupler with two #28 hose clamps,
Bypass "Y", and two lengths of 1" hose cut to
lengths of 16" and 17.5" with four #16 hose
clamps. (See Fig. 8J)
2.Attach the Maxflow Race Bypass Valve to the
flange located on the lower duct of the CAC
using the supplied hardware and gasket.
3.Attach one end of the Ø 1.75" silicone coupler
to the outlet of the bypass valve and secure
with #28 hose clamp.
4.Insert the Ø 1.75" side of the bypass "Y" into
the open end of the Ø 1.75" silicone coupler
and secure with #28 hose clamp.
5.Secure the two lengths of 1" hose cut to 16"
and 17.5" to the two outlets on the bypass "Y"
with #16 hose clamps (See Figure 8I-a for orientation).
6.Leave the opposite ends of the 1" hose open
for future attachment to the air inlet box.
7.Attach a length of 5/32" vacuum hose to the
bypass valve and route to the vacuum port of
the fuel rail sensor.
8.Cut a section of the factory hose and install
the vacuum TEE that is provided (See Fig.
10-b).
9.Attach the vacuum hose from the bypass
valve to the TEE
a piece of 1" hose cut 15" long and a piece cut to
4.25" long, and four #16 hose clamps.
B.Attach the 4.25" piece of hose to the inlet of the
bypass and secure with a #16 clamp.
C.Secure the 15" piece to the by-pass valve outlet
using a #16 hose clamp. (See Fig. 10-a.)
D.Attach the open end of the 4.25" hose to the boss
on the air discharge duct. Secure with a #16 hose
clamp. The open end of the 15" long hose will be
connected to the air inlet in a future step.
E. Secure all hoses with the clamps provided.
F. Connect the supplied length of 5/32" vacuum to
the port on the bypass valve. Route the line to the
fuel regulator vacuum hose. Using the supplied
vacuum TEE, connect the bypass vacuum line.
(See Figs. 10-a, 10-b, for assistance.)
side valve cover and the intake manifold. Secure
hose connections as necessary using the supplied
stepless clamps.
(See Figs. 12-a, 12-b for assistance.)
C.Locate the factory 3/8" x 90° fitting removed from
the passenger’s side valve cover in a previous
step.
D.Connect the remainder of the supplied 3/8"ID
hose to the 90° fitting and connect to the passenger’s side valve cover. (See Fig. 12-c.)
E.Route the open end of the 3/8" hose behind the
alternator and across to where the air inlet duct
will be located.
B. Remove two of the 3/8-16 x 1" bolts securing the
supercharger in place. Install the air inlet support
bracket and secure with the 3/8" bolts removed
from the supercharger mounting plate. (See Fig. 13-a.)
C.Install the 3/4"NPT x 1" x 90° plastic fitting to the
air inlet duct. (See Fig. 13-b.)
D.Install the 1/4"NPT x 3/8" hose barb fitting in the
location noted. (See Fig. 13-c.)
D.2(V-Power/Bullitt Kits Only) Drill out the second
3/4" NPT location on the air inlet duct using caution not to damage the threads and install the second 3/4" NPT x 1 x 90° plastic fitting to the air
inlet duct. Orient both fittings as shown in Fig
13-d2.
E.Attach the 4.0" x 3.5" reducer sleeve to the inlet
duct. Secure the sleeves with the clamps provided. (See Fig. 13-d.)
wires be soldered. Temporary solderless connectors have been provided in case you are unable to solder.
2.Remove the split loom from the factory wires
on the MAF sensor.
3.Cut the wires to the connector approximately
2" from the plug.
4.Using the supplied connectors and wire,
extend the connector to the MAF.
5.Install the supplied 3/8" split-loom to the
extended sensor plug harness. Secure the
split-loom with wire-ties or tape.
6.Route the lengthened wires and connector to
the MAF, keeping the wires away from hot or
moving parts.
P. MAF Interface Adapter Installation (Charge
Cooled kits only)
1. Locate the MAFia (Interface Adapter) box.
2. Plug the MAFia in between the factory MAF
connector and the MAF sensor.
3.Remove the small red cover in the middle of
the supplied MAFia box.
4.Verify that the MAFia box is set on number
“2”.
5.If you find that the MAFia box is not set, use
the tool that is provided with the MAF
Interface Adapter box and set to the number
“2”.
6.Replace the cover and secure the MAFia box
and set to the number “2”.
Fig. 13-h
NOTE: It is critical that the MAF Interface
Adapter box be set on number “2”,
The calibration that is provided
with this kit has been created to
work at this setting. Any change to
the MAF Interface Adapter box by
setting it to a higher or lower number could cause damage to the
engine.
Q. On 2010 models it will be neccesary to bend
the hood latch cable bracket 90° for air filter
clearence.(See Fig 13-j)
2.75" length of Ø3/8" rubber hose, connect the
supplied “Y” fitting to the distribution rail. (See
Fig. 14-e.)
I.Locate the supplied fuel pump and pump inlet
screen. Attach the pump inlet screen to the pump
and orient exactly as shown. (See Fig. 14-f.)
J.Secure the supplied fuel pump to the side of the
factory pump assembly using the #44 hose clamp
supplied. Verify that the hose clamp is routed
inside of the metal posts so that they can be
pushed down without restriction. (See Fig. 14-f.)
K. Slide the two supplied .75" long teflon sleeves
over the discharge of each fuel pump. (See Fig. 14-g.)
L.Slide the supplied 11.3 stepless clamps onto the
two open legs of the Y-fitting. Connect the discharge of both pumps to the previously installed
“Y” fitting using the two supplied Ø3/8" corrugated
teflon hoses. Secure the remaining hose ends
using the supplied 11.3 stepless clamps. (See
Fig. 14-h.)
M. Secure all hoses to the fuel pump assembly using
the supplied ties. Make sure the lid is able to
spring up and down without restriction and that
the hoses do not kink. (See Fig. 14-h.)
N.Use the supplied T-splice and slide connectors to
connect the black and red wires from the supplied
pump to the corresponding power and ground on
the factory pump. (See Fig. 14-h.)
O.Reinstall the fuel pump assembly into the fuel
tank in the reverse order of removal. Ensure that
the fuel hoses do not rub on the sharp edges of
the fuel tank. Take care not to damage the assembly. INSTALLATION WILL BE TIGHT. Connect all
fuel and electrical connections. Verify that the fuel
gauge float is able to move freely. Make sure the
O-ring seal is in place and not damaged. There is
an alignment arrow on the pump assembly top
that will need to be aligned with the dot on the fuel
tank. (See Fig. 14-b.)
SUPPLIED
.75" LONG
TEFLON
SLEEVES
Fig. 14-g
POWER AND
GROUND
CONNECTIONS
NOTE: Retaining ring indents must engage
their receivers for proper seal. (See
Fig. 14-b.)
P. Locate the power distribution box located on the
passenger’s side of the engine compartment.
Verify the #41 fuse is for the fuel pump.(2010
Model year uses #13) Replace the factory
15AMP fuse with the supplied 20AMP fuse.
IMPORTANT! To ensure trouble-free programming of your vehicle's computer:
• Make sure the vehicle's battery is sufficiently charged.
• Turn off all accessories and close doors to prevent unnecessary drain on the battery.
• Do not attempt to program your vehicle while a battery charger is connected.
• Improper battery voltage will result in failure of the programming process.
• Do not disconnect the cable or turn off the ignition during programming.
A. Reconnect the battery.
B. Locate the vehicle’s OBD2 connector located in the
lower left hand corner of the dash on the driver’s
side of the vehicle. (See Fig 15-a.)
C.Attach the OBD2 connector from the Flash tool
(provided in the kit) to the vehicle’s OBD2 port.
(See Fig 15-b.) Make sure this connector is seated all the way into the vehicle’s OBD2 port. You
do not want this connector coming out during programming or damage may occur to the vehicle’s
ECM.
D.The Reflash tool should power up and display
three parameters:
1. Performance Tune
2. Diagnostics
3. Options
E. Select “Performance Tune” and press the enter
button in the middle of the arrow keys. (See Fig
15-c.)
F. Read the disclaimer entirely, then select agree
and press ENTER.
G.At this point please read the screen displayed on
the reflash tool. If you have any questions, either
refer to the manual provided with the reflash tool
or contact our service department for further
assistance.
H.Turn the ignition on (do not start the vehicle). Set
the parking brake and press the “ENTER” button
to continue.
I.“SELECT TUNE” will be displayed at the top of
the screen. Use the arrow keys to select the
appropriate tune for your vehicle and press the
ENTER button. You will have four choices to
select from:
1. STD OUTPUT (non charge-cooled)
2. Charge-cooled, air/water
3. Charge-cooled, air/air (this option is NOT
used in this application)
4. Original Backup
J. Continue to follow the screen and when finished
unplug the reflash tool from the vehicles OBD2
port.
Fig. 15-a
Fig. 15-b
ESCAPE
ARROWKEYS
ENTER
OR
SELECT
NOTE: Do not disturb the cable, or turn the
ignition off during this time. If the
programming is disrupted, the computer will not start or run your vehicle!
vehicle until all components are
installed and all operations are
completed including the final
check.
A.If your vehicle has gone over 15,000 miles
since its last spark plug change, you will need
to change the spark plugs now before test
driving the vehicle.
B.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.
C.Check all fluid levels, making sure that your
tank(s) is/are filled with 91 octane or higher
fuel before commencing test drive.
D.Start the engine and allow to idle a few min-
utes, then shut off.
H.O Charge Cooled Kits Only
NOTE: Check to see that CAC coolant is
flowing through the surge tank. If
coolant is not flowing, remove the
3/4" rubber hose from the side of the
surge tank and apply light suction in
an attempt to pass any trapped air in
the system. Reconnect the hose and
recheck coolant flow.
E. Recheck to be sure that no hoses, wires, etc.
are near exhaust headers or moving parts.
Look also for any signs of fluid leakage.
F. PLEASE TAKE SPECIAL NOTE: Operating
the vehicle without ALL the subassemblies
completely and properly installed may cause
FAILURE OF MAJOR COMPONENTS.
G. Test drive the vehicle.
H. Always listen carefully for engine detonation.
Discontinue heavy throttle usage if detonation
is heard.
I. Read the STREET SUPERCHARGER
SYSTEM OWNER'S MANUAL AND RETURN
THE WARRANTY REGISTRATION FORM
within thirty (30) days of purchasing your
supercharger system to qualify.
For internally lubricated V3 units only
This supercharger has been factory pre-lled with
special Vortech synthetic lubricant. Oil does not
need to be added to a brand new unit; however a
uid level check should be performed.
Prior to operating the supercharger on the vehicle
and after installation onto the vehicle:
Remove the factory installed at-head brass shipping plug (not the dipstick) from the top of the
supercharger case. Replace the sealed shipping
plug with the supplied “vented” plug. Do not operate
the supercharger without it. Check the supercharger
uid level.
Fluid level checking procedure:
1. Ensure that the .06” copper sealing washer
is located on the dipstick base.
2. Thread the clean dipstick into the unit until
it seats.
3. Once the dipstick has seated, remove the
dipstick from the unit. Fluid should register
in the crosshatched area on the dipstick.
4. DO NOT OVERFILL!!! Drain excess uid from
the unit if it is above the maximum level on
the dipstick.
Check the uid level using the dipstick at least every
2,500 miles.
Initial supercharger uid change must be performed
at 2,500 miles. The supercharger uid must be
changed at least every 7,500 miles.
Drain the uid, rell the unit with 4 oz. of Vortech V3
lubricating uid and then conrm proper oil level using the dipstick. DO NOT OVERFILL!!!
WARNING: Use of any other uid other
than the special Vortech lubricant will void the warranty and
may cause component failure.