Vortech Ford Driver's Side Renegade System User Manual

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Ford 5.0 Mustang

Driver's Side Renegade

Supercharger System

Installation Instructions

1986-1993 Model Years

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

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

(DS Rngde S/C Sys(7062 v2.0))

ENGINEERING, LLC

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual

prior

to beginning the installation to determine if you should refer the job to a professional

installer/technician. Please call Vortech Engineering for installers in your area.

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

(DS Rngde S/C Sys(7062 v2.0))

of Vortech Engineering, LLC.

TABLE OF CONTENTS

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

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

NOTICE.............................................................................................................................. iv

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

PARTS LIST ....................................................................................................................... vi

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

2. OIL DRAIN ............................................................................................................. 1

3. OIL FEED LINE...................................................................................................... 2

4. CRANK/WATER PUMP PULLEY MOUNTING...................................................... 2

5. MAIN BRACKET ASSEMBLY ............................................................................... 3

6. SUPERCHARGER MOUNTING ............................................................................ 4

7. ALTERNATOR MOUNTING ................................................................................... 4

8. SUPERCHARGER/ACCESSORY DRIVE BELTS ................................................. 5

9. RADIATOR HOSE & THERMOSTAT HOUSING.................................................... 6

10. DISCHARGE DUCTING......................................................................................... 7

11 FINAL CHECK ....................................................................................................... 8

iii

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NOTICE

This product is protected by state common law, copyright and/or patent. All legal r ights therein are reserved. The design, layout, dimensions, geometry, and engineering features shown in this product are the exclusive proper ty of Vortech Engineer ing, Inc. 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.

(DS Rngde S/C Sys(7062 v2.0))

1986 - 1993

Ford 5.0 Mustang

Driver's Side Renegade Supercharger System

4FA218-110/118

THIS PRODUCT IS NOT FOR A FIRST TIME VORTECH USER. These products are intended for racing use ONLY by professional racers/installers. These packages were designed for "off-road" racing use only and are not legal for "public highway" use. Installation of this package requires a trunk mounted battery and removal of all factory front engine accessories with their related bracketry.

This product is intended for use on healthy, well maintained racing engines. It is recommended by Vortech that an aftermarket (SVO) high strength engine block and cylinder heads (TFS, Edelbrock, World Products, etc.) be used. An "O-ringed" cylinder head-to-block seal is also suggested. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger.

Before beginning this installation, please read through this entire instruction booklet and the Vortech Race Supercharger System Owner's Manual. Other available pieces designed for use:

2A038-285 Renegade Profile, ø2.85 2A038-300 Renegade Profile, ø3.00 2A038-315 Renegade Profile, ø3.15

To determine the proper supercharger pulley(s), use this formula:*

crank pulley diameter

(

supercharger pulley diameter

Vortech Crank/Supercharger Support Strut:** 4FA110-020

• Reduces crank snout side-loading. (Places the super-

charger load onto the crankshaft main bearing centerline and cancels out the load generated by the drive belt between the crank and supercharger pulleys.)

• Reduces supercharger input bearing load and wear.

• Eliminates the possibility of supercharger plate flex. * Refer to the Vortech racing supercharger system owner's

manual for each individual supercharger's specifications.

** Not required for kit function although strongly

recommended by Vortech.

x 3.45 x max. engine rpm = impeller speed

)

TOOL & SUPPLY REQUIREMENTS

• 3/8" socket and drive set: SAE & metric

• 1/2" socket and drive set: SAE & metric

• 1/2" breaker bar and 4" extension

• 3/8" NPT tap, 3/8-16 tap & handle

• Adjustable wrench

• Open end wrenches: 3/8", 7/16", 1/2", 9/16"

18mm, 19mm

• Center punch and a 5/8" tapered punch

• 5 quarts SF rated quality engine oil

• Oil filter and wrench

• Large screwdriver or pry bar

• Flat #2 screwdriver

• Phillips #2 screwdriver

• Heavy grease

• Silicone sealer

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P/N: 007062

Driver's Side Renegade

Supercharger System

ENGINEERING, INC.

IMPORTANT: Before beginning installation, verify that all parts are included in the package. Report any shortages or damaged parts immediately.

Part Number Description Quantity Part Number Description Quantity

2A158-040 S/C V-7 YS 1

4FP130-011 OIL FEED/DRAIN ASSY 1

4FP130-026 Oil Feed Line Assy 1

7P250-121 1/4 NPT Steel Nipple 1 7P250-122 1/4 Pipe Thrd AN 917 1 7P250-120 1/4 NPT Pipe Plug 1 7P125-103 -4 x 45° Male Elbow 1

7P250--36 -4 Flare To 1/4 NPT 1

4FP114-023 RADIA TOR HOSE ASSY 1

4FP020-011 45° Thermostat 1 4FP040-050 Thermostat Gasket 1 4FP014-011 Radiator Pipe 1

7R002-020 #20 Goldseal Hose Clamp 3 7A312-100 5/16-18 x 1 HXCSGR5P 2 7K213-001 5/16 AN Washer 2 7R002-024 #24 Goldseal Hose Clamp 1

8E018-300 PULLEY PACKAGE, RENEGADE 1

2A038-300 S/C Pulley 3.00" 8 Groove 1 7A375-158 3/8-16 x 1/5" SOC HD GR8 Pltd 4 7K375-040 3/8 AN 960 Flat Washer 4 7L375-075 3/8 Lock Washer 4

4FA018-027 4.75" 8.0" 8Gv Crank Pulley 1

7U100-070 Key, 3/16 x 3/16 x 7/8 1

4FA111-042 S/C Belt Tensioner Assy, H.O. 1

2A048-565 Belt, 5080565-DAYCO "94 2.95" 1 2A040-011 Pulley Retainer S/C 1 7B375-125 3/8 24 x 1-1/4 HX CLS 1 7K375-040 3/8 AN 960 Flat Washer Plated 1

4FA111-071 MTG BRKT. ASSY DSIDE 1

4FP011-021 Mounting Brkt. Mach 1

7A375-100 3/8-16 x 1 G5 HXHD Plt 9 7K375-040 3/8 AN960 Flat Washer, Plated 17 7K437-001 7/16" AN Washer 2 7A437-750 7/16-14 x 7.25 HXHD GR8 2

4GF016-160 Pulley, Idler-Ribbed 1

2A017-017 Spacer, ACC Idler 5.0 Rngd 1 2A017-016 Shrt. ACC. Idler, V-3 1 7A375-250 3/8-16 x 2.5" GR5 HX 1

4FA017-061 Brkt Spacer, Renegade S/C 1

7A437-300 7/16-14 x 3.00 SHCS GR8 1 4FA010-051 Mntg Plt, S/C, Renegade Dual 1 4FA010-061 Suprt Plt, S/C, Renegade Dual 1 4FA017-081 Spacer, Idler, Dual Renegade 1

7B500-240 Arbor, S/C Tens Ply, Renegade 1 4FA116-021 Idler Assy, 8-Rib x Ø4.0 Alum 1

2A017-049 Spacer A, SBChev Carb Brkt 5 7PA375-500 Screw, Idler Adjust, 5.00" 1 4PF010-031 Brackt, Idler Adjust Screw 1

7F500-020 1/2-20 Hex Jam Nut GR5 Zinc 1 4FD017-011 Bearing Pilot, 1/2" Bore 1

7A250-077 1/4-20 x .75 Flat Allen GR5 2

7A375-275 3/8-16 x 2-3/4 HXCS G8P Zinc 5

7C012-020 M12 x 1.75 x 20mm Pltd 3

7J012-092 12mm Washer, Flat 3

4FA111-051 ALT. BRKT ASSY. DSIDE RENEGADE 1

4FP010-011 Bracket, Alternator 1 4FP015-020 Alter.Stay, Lower 1 4FP015-010 Alter.Stay, Upper 1

7A375-100 3/8-16 x 1 G5 HXHD Plt 2 7A312-100 5/16-18 x 1 HXCS GR5P 2 7K375-040 3/8 AN 960 Flat Washr 7 7K312-001 5/16 AN Washer 6 7K437-001 7/16" AN Washer 1 7F375-016 3/8-16 HX Nut 1

7J375-044 3/8 SAE Washer, Pltd 1 7A437-550 7/16 x 5-1/2" Bolt 1 7A375-525 3/8 x 5-1/4 Bolt 2 7A375-325 3/8 x 3-1/4" Bolt 1

4FA017-071 Renegade Brkt Spacer 1

Part No. 4FA218-110/118

PARTS LIST

(DS Rngde S/C Sys(7062 v2.0))

1. PREPARATION/REMOVAL

ENGINE BLOCK

FRONT

PAN

1-1/2” BACK FROM FIRST BOLT ON SIDE OF BLOCK

1-3/4” DOWN

FROM FLANGE

A. Disconnect the battery negative cable. (The battery must be

relocated to the trunk in order for the system to fit properly.)

B. Remove all drive belts (accessory/supercharger). C. Remove the radiator shroud, fan, upper radiator hose and

thermostat housing.

D. Remove all components that lead to the throttle body

(tubing, air filter, etc.).

E. Remove all accessories, brackets and related items from

the front of the engine block and heads. Remove the crankshaft pulley. Set aside the alternator for reinstallation.

2. OIL DRAIN

A. To provide an oil drain for the supercharger, it is

necessary to make a hole in the oil pan. Locate and mark hole per diagram. It is best to punch the hole rather than drill.

B. Remove the oil filter. C. Remove paint around the hole area. 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 9/16" diameter. Most punches are made from hexagon material and may be placed in a socket with an extension to make this procedure easier.

Fig. 2-a

NOTE

: When punching the hole, make sure that

no contact is made with the crankshaft or rods. Rotate the crank for clearance, if needed.

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.

F. Thoroughly clean the threaded area. Apply a

small amount of silicone sealer to the new threads. Apply more sealer to the 3/8" NPT hose fitting and secure in hole. Make sure a seal is formed all around the fitting.

G. Drain the engine oil.

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3. OIL FEED LINE

A. Remove the oil pressure sender and mounting

boss fitting from the engine.

B. Assemble the supplied 1/4" NPT fittings as

shown. Teflon tape, paste or other sealant is not recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure.Thread the assembly into the block.

C. Connect the red oil

1/4” NPT x 3” NIPPLE 1/4” NPT TEE 1/4” NPT x -4 FLARE

feed line to the #4 flare fitting. Cover the end of the hose from dirt and debris until hose can be attached to the su-

ENGINE

BLOCK

percharger.

D. Install a new oil filter

and refill the engine

1/4” NPT PLUG

(IF NEEDED)

with oil. DO NOT OVERFILL.

4. CRANK/WATER PUMP PULLEY MOUNTING

Fig. 3-a

IMPORTANT

: Check the crank pulley and super-

charger alignment after installaltion. If a Ford Motorsport balancer and spacer are used, the Motorsport spacer MUST be machined down to .615" thick (in most cases).

A. Make sure the harmonic balancer mounting

surface is clean.

NOTE

: It is HIGHL Y recommended that an NHRA

approved aftermarket balancer be used.

B. Place the crank pulley onto the balancer (with-

out using bolts) to check balancer-to-pulley fit. If any slop exists (up and down/side to side), use feeler gauges or shim stock to temporarily center the pulley onto the hub. (Due to tolerance variations of different aftermarket balancer manufacturers, Vortech has found that this important exercise may be necessary on some, but not all applications to achieve minimal pulley runout.) If the pulley is not centered on the hub correctly, it may create an out-of-balance condition which will directly affect the engine and supercharger bearing life. Proceed with the next step and remove the feeler gauge/shim stock after the bolts have been torqued.

C. Using the supplied 3/8-16 bolts and 3/8" AN

washers, (a small drop of blue Loctite on the threads of each bolt should be used) attach the Vortech crank pulley to the balancer. Torque to 35 ft/lbs.

(DS Rngde S/C Sys(7062 v2.0))

NOTE

: Tighten bolts progressively and evenly

in a crisscross pattern so that the pulley will seat properly.

5. MAIN BRACKET ASSEMBLY

ACCESSORY IDLER ASSEMBLY

SIDE VIEW

3/8” AN

WASHER

PILOT

IDLER

SPACER

3/8-16 x 2-1/2” BOLT

SUPERCHARGER MOUNTING PLATE

SUPERCHARGER

MOUNTING BRACKET

A. Attach the cast aluminum bracket and billet

aluminum "3-hole" spacer (the spacer must be between the bracket and cylinder head) to the front of the driver side (left) cylinder head using the supplied 7/16-14 socket-head bolt without washer. Install the bolt finger tight only (see

5-a

Fig.

NOTE

: The largest hole (5/8-11) in the end of the

cylinder head MUST have the factory Ford adapter plug to allow proper hardware fit.

B. Match the mounting plate up to the mounting

bracket and finish attaching the assembly to the head using the supplied hardware as shown in

Fig. 5-a

(make sure that all bolts use the proper

AN washer except the socket-head bolt).

C. Following

Fig. 5-b

, attach the idler pulley to the plate and bracket using the 3/8 x 2-1/2" bolt, bearing pilot and spacer. Tighten all fasteners in a progressive manner.

GROOVED IDLER PULLEY WITH SPACER & PILOT (ON TOP OF MOUNTING PLATE)

3/8-16 x 2 1/2 HX HD

GROOVED

ACCESSORY

7/16-14 x 7-1/2 HEX HD w/WASHER

7/16-14 X 7 1/2 HEX HD w/WASHER

S/C MOUNTING PLATE

(ON TOP OF MOUNTING

BRACKET)

LEFT SIDE CYLINDER HEAD

7/16-14 X 3 SOC. HD. (THROUGH BRACKET CASTING ONLY)

Fig. 5-a

Fig. 5-b

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6. SUPERCHARGER MOUNTING

A. Place the oil drain hose onto the supercharger

drain fitting and secure with a hose clamp. Arrange the clamp screw housing so it will not interfere with the mounting plate when installed.

B. Secure the supercharger to the mounting plate

with eight 3/8-16 x 1" bolts and AN washers. (See

Fig. 6-a

C. Attach the supplied belt tensioner hardware to

the plate as shown in

Figs. 6-b, 6-d

D. Attach the supplied front mount plate and 1.309"

spacers to the supercharger mounting plate and supercharger as shown in

E. Attach the supplied 4" idler as shown in

6-d

Fig. 6-b

Fig.

F. Connect the lower end of the oil drain hose to

the fitting on the pan and secure with a hose clamp. Trim hose length if necessary. (It is VERY important that the hose has NO dips or kinks.)

G. Attach the supplied 1/8" NPT x 45° flare fitting

and oil feed hose to the oil feed fitting on the supercharger. When tightening the fitting, use a 1/2" wrench on the oil feed base for support.

WARNING:

When threading the 1/8" NPT x 45 flare fitting into the supercharger, use engine oil on the pipe threads for lubrication. Teflon tape, paste or other sealant is NOT recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure.

1/4-20 x .75 SCREW

IDLER ADJUST SCREW

3/8-16 x 2.75 HEX HD w/WASHER (5 PLACES)

1.309" SPACERS LOCATED BETWEEN S/C MOUNTING PLATE AND FRONT PLATE

FRONT

PLATE

M12 X 1.75 x 20 w/WASHERS (3 PLACES)

BELT TENSIONER ARBOR

SUPERCHARGER MOUNTING PLATE

Fig. 6-b

Ø.750 x 1.309" SPACERS (5 PLACES) TO BE SANDWICHED BETWEEN S/C MOUNTING PLATE AND FRONT PLATE

3/8-16 x 1" HEX HD

w/WASHER (8 PLACES)

(DS Rngde S/C Sys(7062 v2.0))

Fig. 6-a

S/C BELT

IDLER/TENSIONER

Fig. 6-c

6. SUPERCHARGER MOUNTING, Cont'd.

1/4-20 x .75

IDLER

PULLEY

Ø4.0

.218

PLATE SPACER (5 TOTAL)

SCREW

IDLER

SPACER

Ø.515

IDLER

ADJUST

SCREW

IDLER

ADJUST

SCREW

BRACKET

VIEW FROM DRIVER'S SIDE

7. ALTERNATOR MOUNTING

A. Attach the Vortech aluminum

bracket and billet aluminum "3hole" spacer (the spacer must go between the bracket and cylinder head) to the right side cylinder head using the supplied hardware. Make sure that each fastener uses the proper AN washer, unless noted otherwise (see graphic).

B. Attach the lower and upper alternator

tabs to the bracket and mount the alternator. Thread the supplied 3/8-16 x 1" bolt and SAE washer through the back of the upper alternator tab to the alternator. (This is used to secure the unit after tensioning the belt.)

C. Tighten all brackets to the head bolts

and reattach electrical connection to the alternator.

Fig. 6-d

3/8-16 x 1” BOLT

& SAE WASHER

UPPER

ALTERNATOR

STAY

ALTERNATOR STAY

.320

BEARING PILOT, Ø.515 I.D.

1/2-20 JAM NUT (DO NOT TIGHTEN UNTIL LAST STEP)

7/16-14 x 5-1/2” BOLT 3/8-16 x 1” BOLT

BELT TENSIONER

ARBOR

SUPERCHARGER

MOUNTING

FRONT PLATE

1.309

3/8-16 x 3-1/4” BOLT

VORTECH

4FP010-010

ALTERNATOR

LOWER

3/8-16 x 5-1/4” BOLT & NUT

Fig. 7-a

BRACKET

3/8-16 x 5-1/4” BOLT

ALTERNATOR BRACKET

5/16-18 x 1” BOLTS

8. SUPERCHARGER/ACCESSORY DRIVE BELTS

A. Route the accessory belt as shown. Tension

the belt by rotating the alternator and tightening the upper bolt and pivot.

B. Before installing the supercharger pulley

onto the supercharger, make sure that the input shaft is lightly lubricated with a very small amount of grease or oil. Insert the supplied key into the keyway and slide onto the supercharger shaft. Secure the pulley onto the supercharger using the supplied retainer, 3/8-24 bolt and AN washer. (A

small drop of blue Loctite is recommended on the bolt threads.)

NOTE: The supercharger pulley should be a

slip fit at 70° F. If pulley-to-shaft fit is tight, slightly heat the pulley until it slips easily onto the shaft. At NO point should the pulley be hammered or pried off or onto the shaft.

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8. SUPERCHARGER/ACCESSORY DRIVE BELTS, Cont'd.

C. Fit the supercharger drive belt over the new

crank pulley and supercharger pulley.

D. Make sure the 1/2-20 jam nut previously

threaded onto the tensioner arbor is threaded down almost all of the way, but not tight. The belt is tightened/loosened by rotating the belt tensioner adjustment screw. Tighten the belt until light resistance is felt in the belt tensioner adjustment screw. Proper belt tension is achieved when the belt can be twisted approximately 1/4 of a turn by hand. Adjust belt tension as needed. Do not over tension the belt.

E. Tighten the 1/2-20 jam nut on the belt

tensioner arbor.

STANDARD BELT

ROUTING (USING THE

SUPPLIED BELT TO DRIVE

WATER PUMP)

OPTIONAL IDLER

BYPASSED WATER

PUMP BELT ROUTING

Fig. 8-a

(DS Rngde S/C Sys(7062 v2.0))

9. RADIATOR HOSE & THERMOSTAT HOUSING

3”

THERMOSTAT

HOUSING

A. From the stock radiator hose, make a 90° elbow

by trimming as shown. Also, cut a 2-1/2" long straight piece from the stock hose and attach to the upper radiator tank.

B. Remove the factory thermostat housing and

replace with the supplied 45° unit, gasket and hardware.

C. Place the stainless steel water pipe between the

two hoses placing the shorter leg nearer the radiator.

D. Position the hoses and tube so there is ample

overlap for sealing, and secure with provided clamps.

E. Refill radiator and coolant bottle.

Fig. 9-a

WARNING:

Do not attempt to operate the vehicle

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

10. FINAL CHECK

A. Reconnect the battery. 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. D. Start engine and allow to idle a few minutes,

then shut off.

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

near exhaust headers or moving parts and for signs of any fluid leakage.

F. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without ALL the subassemblies completely and properly installed may cause FAIL-

URE OF MAJOR COMPONENTS.

G. Test drive the vehicle.

28JAN03 v2.0

(DS Rngde S/C Sys(7062 v2.0))

P/N: 007062

ENGINEERING, LLC

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

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

28JAN03 v2.0

(DS Rngde S/C Sys(7062 v2.0))

P/N: 007062

Vortech Ford Driver's Side Renegade System User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual