Vortech 2007-2009 FORD GT500 OEM POWER PACK UPGRADE User Manual

2007-2009 FORD GT500 OEM POWER PACK UPGRADE

®

Installation Instructions

2007-2009 FORD GT500

P/N: 8E023-265

ENGINEERING, LLC

1650 Pacific Avenue, Channel Islands, CA 93033-9901 • Phone [phone]

Fax: [phone] • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM (PST)

FOREWORD

STOP

This manual provides information on the installation, maintenance and service of the
Vortech supercharger kit expressly designed for this vehicle. All information, illustrations
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 [phone] 8:00am-4:30pm PST.

Take note of the following before proceeding:

1. Proper installation of this supercharger kit requires general automo-

tive 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 (unmodified, OEM)
vehicles. The PCM (computer), engine, transmission, drive axle
ratios and tire O.D. must be stock. If the vehicle or engine has been modi-

fied 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 detonatlion (knocking/pinging) and discontinue hard

use (no boost) until the 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 limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party
PCM programming or other such changes.

DP/N: 007125v1.0
© 2010 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured.
27AUG2010 GT500 OEM POWER PACK

©2010 VORTECH ENGINEERING, LLC

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

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

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TABLE OF CONTENTS

FOREWORD ..............................................................i

TABLE OF CONTENTS ....................................................ii

TOOL & SUPPLY REQUIREMENTS ....................................... iii

PARTS LIST OEM POWER PACK (8E023-265) ............................. iv

1. OEM SUPERCHARGER PULLEY REMOVAL .................................1

2. NEW SUPERCHARGER PULLEY INSTALLATION ............................5

3. AUXILIARY IDLER PULLEY INSTALLATION .................................7

4. OEM AIR BOX/AFTERMARKET CAI REMOVAL ..............................9

5. POWER PACK CAI INSTALLATION .......................................12

6. REFLASH COMPUTER .................................................15

7. FINAL CHECK ........................................................20

© 2010 Vortech Engineering, LLC

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All Rights Reserved, Intl. Copr. Secured.

27AUG2010 GT500 OEM POWER PACK

DP/N: 007125v1.0

VORTECH OEM POWER PACK UPGRADE

Installation Instructions

2007-2009 FORD GT500

Before beginning this installation,

please read through this entire instruction booklet

The Vortech 2007-2009 FORD GT500 OEM Power Pack upgrade was designed specifi­cally for use on 2007-2009 Ford Mustang Shelby GT500 vehicles equipped with the
OEM supercharger to support applications with increased horsepower over the OEM
design. As with any power enhancing product, this unit is intended for use on healthy,
well-maintained engines. 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 a note of the following key
points:

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

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

TOOL & SUPPLY REQUIREMENTS:

• 15/16” wench

• 9/16” wrench

• 8mm socket, 1/4” drive

• 10mm socket, 1/4” drive

• 13mm socket, 1/4” drive

• 15/16” socket, 1/2” drive

• 19mm socket, 1/2” drive

• 1/4” drive ratchet

• 1/4” drive, 3” extension

• 3/8” drive breaker bar

• 1/2” drive breaker bar

• 5/32” Allen

• 2.5mm Allen

• 5mm Allen

• 5/16 Nut Driver

• Flat screw driver or upholstery tool

• Moly-based grease

• Utility Knife

DP/N: 007125v1.0
© 2010 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured.
27AUG2010 GT500 OEM POWER PACK

iiiiii

2007-2009 FORD GT500

OEM POWER PACK UPGRADE

Part No. 8E023-265

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit.

Report any shortages or damaged parts immediately.

PART NO. DESCRIPTION QTY

007125 POWER PACK INSTRUCTION MAN 1

2L031-265-02 PULLEY, GT500 2.65" OEM REPL 1
4LFR110-031 AUX IDLER ASSY, 07-09 GT500 1

2A017-753-03 SPACER, PILOT, .750 OD X 1.650 3
4FD017-011 PILOT, 6203/5 BRG, 1/2 SCREW 1
4LFR010-031 PLATE, AUX IDLER, GT500VTS 1
4LFR017-011 SPACER, ADJ IDLER, 07-09 GT500 1
4LFR116-011 IDLER ASSY, SMOOTH, 10-RIB, 3.50 1
7C012-065 M12 X 1.75 X 65MM HX 1
7C060-091 M6 X 1.0 X 90MM SHCS PLT GR12. 3
7G012-175 MACH NUT, COG DRV, SPECIAL 1
7J006-093 6MM WASHER, PLATED 3

4LFR212-020 CAI ACCESSORY KIT, GT500 1

4LFR010-020 HEAT SHIELD, AIR FILTER, GT500 1
4LFR112-020 INTAKE AIR TUBE ASSY, GT500 1
7PS500-300 SLEEVE, Ø5.0 X 3.0, 3-PLY, MAT 2
7R002-080 #80 SAE TYPE F SS HOSE CLAMP 4
7U030-046 5/32" VACUUM LINE 2
8A003-111 MAF HSG, 07-10 GT500, 123MM 1
8H040-600 AIR FILTER, 6" FLANGE X 9" LONG 1

5A003-062 SCT TUNER, GT500 UPGRADE KIT 1
TL0336 TOOL SET, GT500 OEM PULLEY 1

7A375-651 3/8-16 X 6-1/2 HX GR8 2
7C080-031 M8 X 1.25 X 30MM SET SCREW 1
7F625-001 5/8"-18, NYLOC-NUT 1
7J375-044 3/8 SAE WASHER, PLTD 2
7J625-001 5/8", SAE, FLAT WASHER 1
7T001-001 1/2" STEEL PULLER 1
7T001-002 1.250" SOLID SQUARE SUPPORT BL 1
7T625-001 5/8" THRUST BEARING 1
7T625-002 MODIFIED 5/8-18 SCREW EXT THD, 1

© 2010 Vortech Engineering, LLC

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27AUG2010 GT500 OEM POWER PACK

DP/N: 007125v1.0

1. OEM SUPERCHARGER PULLEY REMOVAL

NOTE: It is best to attempt to remove the pulley only

after the vehicle has been allowed to cool down,
preferably overnight. It is also much easier to
remove the pulley in the morning when all the
metals are still cold.

A. Disconnect the negative battery cable.

B. Remove the two screws securing the de-gas bot-

tle to the vehicle with a 10mm socket (See Figure
1-a)

C. Temporarily relocate the de-gas bottle as shown

to gain access to the serpentine belt tensioner
and supercharger pulley. (See Figure 1-b)

Fig. 1-a

Fig. 1-b

DP/N: 007125v1.0
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27AUG2010 GT500 OEM POWER PACK

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1. OEM SUPERCHARGER PULLEY REMOVAL, CONT’D

D. Using a 3/8” drive breaker bar on the tensioner,

remove the serpentine belt from the supercharger
pulley. (See Figure 1-c & 1-d)

E. The center plug on the supercharger will need to

be removed so as not to damage it when remov­ing or installing the pulley. Using a flat screw driver
or upholstery tool, pry the plug off the supercharg­er snout. (See Figure 1-e)

Fig. 1-c

Fig. 1-d

Fig. 1-e

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27AUG2010 GT500 OEM POWER PACK

DP/N: 007125v1.0

1. OEM SUPERCHARGER PULLEY REMOVAL, CONT’D

F. Pre-assemble the supplied tool as shown. Insert

the two 3/8”x6-1/2" screws with washers through
the outer holes of the pulley removal bar and
thread them evenly into the pulley removal plate.
Be sure the two 3/8” bolts are exactly flush to the
back of the pulley removal plate. It is very impor­tant that the pulley removal plate and the pulley
removal bar are evenly spaced. (See Figure 1-f)

G. At this time you will need to lightly apply anti-sieze

or moly grease to the threads of the 5/8” screw
and light oil into the thrust bearing. Then insert the
screw through the center hole of the pulley remov­al bar.

H. Assemble the thrust bearing with the free rolling

face towards the pulley removal bar, and install
the supplied 5/8” nut with the flange surface
towards the back of the thrust bearing. (See
Figure 1-g)

I. Apply loctite onto the supplied M8 set screw and

thread it into the center of the 5/8” screw. Tighten
the set screw. This will aid in keeping the tool cen­tered on the supercharger pulley shaft. (See
Figure 1-h)

Step in plate must

face as shown

Fig. 1-f

Fig. 1-g

Fig. 1-h

DP/N: 007125v1.0
© 2010 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured.
27AUG2010 GT500 OEM POWER PACK

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