Vortech 8-Rib Drive Upgrade for 2000-2004 Mustang GT User Manual

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8-Rib

SUPERCHARGERS

Drive Upgrade

Installation Instructions

2000-2004 Ford 4.6 Mustang GT

ENGINEERING, INC

1650 Pacific Avenue, Channel Islands, CA 93033-9901

Phone: 805 247-0226 • Fax: 805 247-0669

www.vortechsuperchargers.com

P/N: 4FL116-001

1300 Beacon Place, Oxnard, CA 93033-9901

Phone: 805 487-3796 • Fax: 805 247-0669

www.paxtonautomotive.com

P/N: 007043

(007043v1.1)00-04MusGT

FOREWORD

Proper installation of this upgrade 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 installers in your area.

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

of Vortech Engineering, INC.

TABLE OF CONTENTS

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

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

NOTICES ............................................................................... iv

TOOL & SUPPLY REQUIREMENTS .........................................................v

PARTS LIST (2000-2004 4.6L 2V Mustang GT)............................................ vi

1. PREPARATION AND REMOVAL....................................................1

2. PULLEY AND SPACER INSTALLATION..............................................2

3. SUPERCHARGER RE-INSTALLATION ...............................................4

4. FINAL CHECK ....................................................................5

iii

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NOTICES

(Read before installation is started)

Included in this kit is an 8-rib supercharger pulley that may be smaller than the one originally supplied. This new pulley is recommended to achieve the best performance results. Removal of the factory sealed pulley will reduce the supercharger warranty from three years to one year unless the supercharger unit (with the original pulley still attached) and new pulley are sent into Vortech for removal, installation and re-sealing. If the supercharger warranty is not a concern or if the supercharger warranty has expired, the pulley may simply be removed and replaced with the new part supplied. Hammering/prying etc. on the supercharger and/or pulley will cause damage to the parts. Light heating of the supercharger pulley with a propane torch (if the pulley is tight on the shaft) will aid removal. A return authorization number is required before the supercharger and pulley are sent into Vortech. Call the Vortech service department at (805) 2470226 for a return authorization number. Return freight (ground) will be paid by Vortech.

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/Paxton Automotive. 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, INC / Paxton Automotive.

This product may not be legal for use on public roads in all 50 states.

IMPORTANT

• Custom ECM programming and fuel / ignition system upgrades will be required when changing the supercharger drive pulley to any size other than what was originally supplied in the complete supercharger kit.

• Supercharger pulley removal may reduce or void the supercharger unit warranty.

• Pulley Diameter Changes: Careful size selection is mandatory for proper engine and super-

charger longevity. Contact the applicable Vortech and Paxton tech line for assistance with impeller speed calculations if necessary.

• A Vortech Maxflow Race or Mondo compressor bypass valve is required for applications producing more than 11-12 psig.

VORTECH 8RIB DRIVE UPGRADE

2000-2004 Ford Mustang GT Installation Instructions

TOOL & SUPPLY REQUIREMENTS:

• Open End Wrench Set: SAE/Metric

• Allen Wrenches: SAE

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Utility Knife

• Torque Wrench (in/lbs)

• Tape Measure

• Adjustable Wrench

• Ford Power Steering Puller/Installer

• Crank Pulley Puller/Installer

• 1/2" Drive Ratchet

• Pliers

• Blue Loc-Tite

(007043v1.1)00-04MusGT

P/N: 007043

8-Rib Upgrade, 2000-2004 4.6L 2V

Mustang GT

Part No. 4FL116-001

ENGINEERING, INC

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.

007043 INSTR., 8RIB UPGRD '04 MUS GT 1 2A01787808 SPACER, .875"OD x .406"ID x .280" 4 2A038333 S/C PULLEY, 3.33" 8GRV 1 2A048108 BELT, K081079GATES, 8RIB 107. 1 8R101002 PULLEY RETAINER ASY, 8RIB 1

2A040011 PULLEY RETAINER, S/C 1 7B375125 3/824 x 11/4" HXHD GR8 1 7K375040 3/8"AN960 FLAT WASHER, PLATED 1

7U100070 KEY, 3/16" SQUARE x 7/8"LONG 1 7C080150 M8 x 1.25" x 150mm HXHD CL10.9 3 7C060060 M6 x 1.0 x 60 HXHD CL8.8 1 2A01788201 SPACER, .875"OD x .140"LONG 4 4FU116031 IDLER ASY, 3" 8RIB SMOOTH 2 4FL017011 SPACER, SPNG TENS. ASY, .140" 1 4FL017021 PILOT, TENS., '04 GT 8RIB 1 4FL016170 IDLER PULLEY, 8RIB SMOOTH, Ø3.0 1 4FU016011 PULLEY, FORD, ALT. 8RIB, 2.5"OD 1 4FR016051 PULLEY, 8RIB W/P SMOOTH, '03 COBRA 1 4FK016081 WATER, PUMP PULLEY  STOCK 1 4FR016021 PULLEY, 8RIB A/C PLY '03 COBRA 1 4FR016031 PULLEY, 8RIB P/S '03 COBRA 1 4FR016041 DAMPER, CRANK, 8RIB '03 COBRA 1 4FL116160 IDLER PULLEY, ASY 8RIB Ø2.6" 1

1. PREPARATION AND REMOVAL

A. Disconnect the battery. B. 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.

C. Remove the bolts securing the coolant overflow

reservoir to the plastic fan shroud. (See Fig. 1-a.)

D. Loosen the hose clamps securing the super-

charger discharge tube/cooler from the supercharger. Disconnect the by-pass valve hose(s) where they connect to the inlet and discharge tubes. Disconnect the by-pass valve vacuum lines where it connects at the fuel rail. Set the by-pass valve(s) aside to be reinstalled in a later step. Remove the discharge tube or tubes/airwater cooler (if equipped), and set aside, to be reinstalled in a later step.

E. Loosen the hose clamps securing the inlet duct

to the supercharger. Remove the inlet duct assembly and set it aside to be reinstalled in a later step

F. Disconnect the oil feed and oil drain lines.

COOLANT RESERVOIR

RETAINING HARDWARE

Fig. 1-a

NOTE: Temporarily cap the oil lines to protect

your engine from foreign particles.

G. Loosen the alternator and water pump pulley

retaining hardware.

H. Using a 1/2" ratchet loosen the accessory belt

tensioner and remove the belt from the supercharger pulley.

I. Remove the four screws that secure the super-

charger mounting bracket to the front of the engine. Set the supercharger/bracket assembly on a clean flat work surface with the drive pulley facing up.

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2. PULLEY AND SPACER INSTALLATION

NOTE: Refer to Fig. 2-c on Page 3, for the next few

steps.

A. Remove the original 6-rib supercharger pulley

from the supercharger and install the supplied 8-rib pulley (2A038-333) and secure using the provided retainer assembly (8R101-002).

NOTE: This kit may include a smaller than originally sup-

plied supercharger pulley. Removal of the factory sealed pulley will reduce the supercharger warranty from three years to one year unless the supercharger unit (with the original pulley still attached) and new pulley are sent into Vortech for removal, installation and re-sealing. If supercharger warranty is not a concern or if the supercharger warranty has expired, the pulley may simply be removed and replaced with the new part supplied. Hammering/ prying etc. on the supercharger and/or pulley will cause damage to the parts. Light heating of the supercharger pulley with a propane torch (if the pulley is tight on the shaft) will aid removal. A return authorization number is required before the supercharger and pulley are sent into Vortech. Call the Vortech service department at (805) 247-0226 for return authorization number. Return freight (ground) will be paid by Vortech.

B. Remove the smooth (steel) idler pulley located

on the supercharger mounting bracket and retain the hardware. Install one of the supplied .875"OD x .663"ID x .140" thick spacers (2A017882-01) and Ø3.0" smooth aluminum idler (4FU116-031) provided. Secure using the hardware previously removed. (See Fig. 2-b.)

NOTE: The snap-ring that retains the bearing

in the idler should be facing the engine.

F. Using a 10mm socket, remove the

retaining screw securing the A/C pulley outer clutch. Remove the snap ring that retains the factory A/C pulley. Remove and replace the factory pulley with the 8-rib A/C pulley (4FR016-021) provided. Secure using the factory snap-ring. Reinstall the outer clutch using the factory 10mm headed screw previously removed.

G. Remove the spring tensioner retain-

ing screw and tensioner. Replace the spring tensioner pulley using one of the supplied .875"OD x .663"ID x .140" thick spacers and Ø3.0" smooth steel idler (4FL116-170) provided. Locate the .280" thick spring tensioner spacer and Pilot (4FL017-011 & 4FL017-021). Reinstall the spring tensioner assembly using the factory retainer and the tensioner spacer and pilot provided. (See Fig. 2-g for pulley orientation).

8-RIB S/C PULLEY

INSTALLED

NOTE: The snap-ring that retains the bearing in

the idler should be facing the supercharger mounting bracket.

C. Remove the factory alternator pulley. Install the

supplied Ø2.5" 8-rib alternator pulley and secure using the factory retaining nut.

D. Remove the smooth idler located just above the

spring tensioner and retain the hardware to be reinstalled. Replace with one of the supplied .875"OD x .663"ID x .140" thick spacers (2A017882-01 and Ø3.0" smooth alumiinum idler (4FU116-031) provided. Secure using the hardware previously removed.

NOTE: The snap-ring that retains the bearing in

the idler should be facing the engine.

E. Replace the 2.6" 6-rib idler located above the

A/C compressor, using a .875"OD x .663"ID x .140" thick spacers (2A017-882-01) and Ø2.6" 8-rib idler pulley (4FL116-160) supplied.

.875"OD x .663"ID

x .140" THICK SPACER

Fig. 2-b

3.0" STEEL IDLER

SPACER &

SPACER PILOT

Fig. 2-g

2.5" 8-RIB ALTERNATOR PULLEY - 4FUO16-011

3" SMOOTH IDLER (ALUM.) 4FU116-031 WITH 2A017-882-01 Ø.140" THICK SPACER BETWEEN IT AND IDLER BRACKET

3.33" 8-RIB SUPERCHARGER PULLEY - 2A038-333

3" SMOOTH IDLER (ALUM.)

2A017-882-01 Ø.140" THICK

SPACER BETWEEN IT AND COVER

3" SMOOTH IDLER (STEEL) 4FL016-170

2A017-882-01 Ø.140" THICK SPACER

BETWEEN IT AND TENSIONER (OPEN

SIDE OF PULLEY TO GO AGAINST COVER)

2.6" RIBBED IDLER PULLEY 4FL116-160 WITH 2A017-882-01 Ø.140" THICK SPACER BETWEEN IT AND COVER

SPRING TENSIONER SPACER .280" THICK

4FL017-011 WITH 4FL017-021 PILOT

BUSHING BETWEEN COVER AND TENSIONER

CRANK PULLEY

4FR016-041

WATER PUMP

PULLEY

4FK016-081 FOR

'00-'02 EARLY/

4FR016-051 FOR

'02 LATE-'04

POWER STEERING

PULLEY

4FR016-031

A/C PULLEY 4FR016-021

2. PULLEY AND SPACER INSTALLATION, cont ’d

H. Remove the crank pulley retaining

screw. Using the appropriate crank pulley/puller, remove the factory crank pulley. Locate and install the 8-rib crank pulley (4FR016-041) provided. Secure using the factory retaining screw.

NOTE: A small amount of grease on the

sealing surface of the pulley is recommended. Also a small amount of silicone sealant should be used on the bore of the pulley and threads of the retaining screw.

I. Remove the previously loosened

water pump pulley retaining hardware.

Replace the water pump pulley with the

appropriate pulley provided and secure using the factory hardware.

NOTE: Two water pump pulleys are provided in

this up-grade. 2000-2002 1/2 will use the 4FK016-081 steel pulley, while 2002 1/2 + 2004 will use the 4FR016-051 aluminum pulley.

J. Using the appropriate power steering pul-

ley puller, remove the factory P/S pulley. Locate the 8-rib P/S pulley (4FR016-031) provided and install using the appropriate pulley installer. (See Fig. 2-d.)

NOTE: The end of the P/S pump shaft should be

Fig. 2-d

flush with the end of the pulley when properly installed. (See Fig. 2-d.)

Fig. 2-c

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3. SUPERCHARGER REINSTALLATION

A. Loosely install install the 8-rib drive belt

provided using Fig. 2-c for belt route reference.

NOTE: Not all pulleys are installed at this

time

B. Refer to Fig. 3-a for hardware and spacer

placement and loosely install the supercharger/bracket assembly. Take care to route the drive belt properly. Make sure the bracket and spacers mount flush against their mounting surfaces.

C. Tighten the supercharger mounting

assembly at this time.

D. Using a 1/2" ratchet, release tension from

the factory belt tensioner and install the 8-rib drive belt. Release the tensioner and confirm that the belt is in place and the tensioner is within operating range.

VORTECH MOUNTING

BRACKET

E. Connect the oil feed and drain lines previ-

ously remove.

F. Reinstall the supercharger discharge tube

or tubes/air-water cooler if equipped.

G. Reinstall the air-inlet duct assembly and

secure. Reconnect the by-pass valve(s) hoses where they connect to the supercharger inlet and discharge tubes/airwater cooler. Reconnect the by-pass valve vacuum line.

H. Reinstall the factory coolant reservoir and

secure using the factory hardware. Reconnect all hoses previously removed and secure using the factory hose clamps. Refill the coolant system using the coolant previously removed (if in good condition).

SUPPLIED SPACER

(2.249"-GT MODELS/2.049"

BULLITT MODELS) MUST

BE SANDWICHED BETWEEN

THE ALTERNATOR AND

SUPERCHARGER

MOUNTING BRACKET

AND +.280 SPACER

6mm x 60mm

BOLT & WASHER

AIR CONDITIONING SILENCER BRACKET

(SANDWICH TABS BETWEEN

ENGINE COVER & TIMING

SUPERCHARGER BRACKET)

2001-2004 MODELS - USE THE

SUPPLIED 10mm x .06 THICK

WASHER IN THIS POSITION

ENLARGE TO 27/64"

1999-2000 MODELS - 10mm x

140mm BOLTS & WASHERS

2001 MODELS - 8mm x 150

BOLTS & WASHERS

.280 SPACER BETWEEN

ENGINE COVER &

VORTECH BRACKET

NOTE: When mounting the supercharger bracket assembly to the front cover, make

8mm x 150mm BOLT & WASHER

ADEL CLAMP

OIL DRAIN HOSE

.280 + SPACER AND

WASHER BETWEEN ENGINE

COVER &VORTECH BRACKET

10-24 x 1/2" BOLT & WASHER

Fig. 3-a / Supercharger-Front View

sure the wiring harness support bracket is sandwiched in-between the timing cover and the Vortech aluminum bracket in position. (See Fig. 3-a.)

4. FINAL CHECK

WARNING: Do not attempt to operate the vehi-

cle until ALL components are installed and ALL operations are completed including the final check.

• A Vortech Maxflow Race or Mondo compressor bypass valve is requires for applicaitons producing more than 11-12 psig.

A. Check all fittings, hose and clamps for tightness

and leaks. Make sure all wires and lines are properly secure with clamps or tie-wraps.

B. Make sure all wires and hoses are routed away

from hot, moving or sharp objects.

C. Double check to ensure water is flowing through

the CAC system. (If equipped.) D. Test drive the vehicle. E. Always listen carefully for engine detonation.

Discontinue heavy throttle usage if detonation is

heard.

(007043v1.1)00-04MusGT

P/N: 007043

ENGINEERING, INC

SUPERCHARGERS

1650 Pacific Avenue, Channel Islands, CA 93033-9901

Phone: 805 247-0226 • Fax: 805 247-0669

www.vortechsuperchargers.com

1300 Beacon Place, Oxnard, CA 93033-9901

Phone: 805 487-3796 • Fax: 805 247-0669

www.paxtonautomotive.com

Vortech 8-Rib Drive Upgrade for 2000-2004 Mustang GT User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual