Vortech Ford SVT Contour Mercury 2.5L V6 Cougar User Manual

Ford SVT Contour/

Mercury 2.5L V-6 Cougar

(5 Speed Manual

Transmission Only)

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-17

1998-2000 Model Years

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • [phone]

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

P/N: 4FS020-010
©2002 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
11JAN02 V2.0

(Cougar (4FS 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
should refer the job to a professional installer/technician. Please call Vortech
Engineering for installers in your area.

prior

to beginning the installation to determine if you

All rights reserved. No parts of this publication may be reproduced, transmitted, transcribed,

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

P/N: 4FS020-010
©2002 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
11JAN02 V2.0

(Cougar (4FS V2.0))

© 2002 VORTECH ENGINEERING, LLC

of Vortech Engineering, LLC.

ii

Table Of Contents

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

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

IMPORTANT NOTES ........................................................................................................................iv

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

PARTS LIST - 1998 FORD SVT CONTOUR/MERCURY 2.5L V-6 COUGAR ..................................vi

PARTS LIST - 1999-2000 FORD SVT CONTOUR/MERCURY 2.5L V-6 COUGAR .........................viii

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

2. FUSE BOX AND BATTERY RELOCATION .........................................................................2

3. OIL DRAIN ...........................................................................................................................3

4. OIL FEED .............................................................................................................................4

5. FUEL MANAGEMENT UNIT INSTALLATION (1998 Only) ..................................................6

6. FUEL PUMP INSTALLATION (1998 Only) ...........................................................................7

7. FUEL INJECTOR REPLACEMENT (1999-2000 Only) ........................................................ 8

8. POWER STEERING COOLER RELOCATION ....................................................................9

9. FAN SHROUD MODIFICATION ...........................................................................................9

10. A/C CANISTER RELOCATION ............................................................................................10

11. MAIN BRACKET ASSEMBLY .............................................................................................. 11

12. WATER PIPE INSTALLATION .............................................................................................14

13. AIR CONDITIONING MODIFICATIONS .............................................................................. 14

14. AIR INLET ............................................................................................................................16

15. SUPERCHARGER DISCHARGE/BYPASS ASSEMBLY .....................................................17

16. FINAL CHECK......................................................................................................................18

©2002 Vortech Engineering, Inc.

iii

All Rights Reserved, Intl. Copr. Secured

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

SVT CONTOUR/COUGAR

IMPORTANT NOTES

SVT Contour Off-Highway Use

When driving the vehicle on non-public roads (off-road applications such as
racing/high rpm) Vortech strongly recommends reducing the spark plug gap
down to .032”.

Electronic Control Module

This kit requires ECM modification and the installation of a Vortech/Superchips ECM
Module. The ECM must be sent directly to Vortech by the installing customer (the charge
for this service with module installation has been included in the purchase price).

• Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1)

Vortech/Superchips ECM Module.

• The modules are made specifically for each individual vehicle with respect to the

factory ECM calibration.

• Simply contact the Vortech Service Department at [phone] to request a

Return Authorization Number (See ECM Module Credit Tag for more details).

- Mail to Vortech the enclosed "ECM Module Credit Tag" (send original tag - no

photocopies will be accepted) and ECM in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Vortech will give an

estimate at the time of your order.

Your Vortech/Superchips ECM Module comes with a twelve (12) month limited
warranty from the original date of purchase of your supercharger system (see
Owner's Manual for details).

Battery Relocation

Battery relocation is required for complete kit installation. Additional parts
must be purchased separately for mandatory battery relocation:

• Option 1: Vortech offers a universal battery relocation kit (Vortech

#8N150-010) which allows the vehicle’s existing battery to be relocated
into the trunk.

• Option 2: Vortech offers a Cougar specific relocation kit (Vortech

#4FS150-010) to mount and connect a Dyna-Batt “mini” dry cell battery to
underneath the left front of the vehicle (underhood). The bracketry/hard­ware sold in this option requires the purchase of a Performance Distribu­tors battery part #5575B (top post). Contact Performance Distributors at:

P/N: 4FS020-010
©2002 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
11JAN02 V2.0

(Cougar (4FS V2.0))

2699 Barris Drive

Memphis, TN 38132

Tel: [phone], Fax: [phone]

iv

1998-2000

FORD SVT CONTOUR/

MERCURY 2.5L V-6 COUGAR

Installation Instructions

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 Automotive Limited Warranties Program
and the Warranty Registration form.

Vortech supercharger systems are performance improving devices. In most cases, increases in torque of
30-35% and horsepower of 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 92 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 every 3,000 miles or less. 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 10,000 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 at least every 20,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 1/2" Socket and Drive Set: SAE & Metric

• 3/8" NPT Tap and Handle

• Adjustable Wrench

• Open End Wrenches: 3/8", 7/16", 1/2", 9/16"

• Center Punch

• Ford Springlock 3/8" Fuel Fitting Disconnect Tool

• 5 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16", 27/64" Drill Bits

• 9/16” Rota Broach Tool (also available from Vortech)

• Molylube

• Wire Strippers and Crimpers

• Utility Knife

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

50 State Smog Legal, as per CARB EO #D-213-17

©2002 Vortech Engineering, Inc.

v

All Rights Reserved, Intl. Copr. Secured

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

1998 FORD SVT CONTOUR/

MERCURY 2.5L V-6 COUGAR

®

ENGINEERING, LLC

Part No. 4FS218-010SQ/018SQ

PARTS LIST

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

Part Number Description Quantity Part Number Description Quantity

2D118-050 V-9 F-TRIM SQ SUPERCHARGER ASSY 1

4FS111-021 SUPERCHARGER MTG. ASSY. 1

4FS110-034 S/C Mtg Plate Assy. Cougar 1

7K312-001 5/16” Flat Washer, AN 11
7A312-175 5/16” X 18 X 1.75” Bolt 6
7C080-045 8mm X 1.25 x 45mm Bolt 5

4FS111-034 SUPERCHARGER DRIVE ASSY. 1

2D160-214 Tube Assy. Ext Drive 1
2D170-224 Assy. Ext Drive, Cougar/GSR 1

4FS110-010 Brg Mtg Plate Assy. 1

7F437-000 7/16” - 14 Hex Nut 1

7J438-081 7/16 SAE Washer Plated 1
2A017-037 Spacer, Threaded Hex, 1.490” 2
2A017-038 Spacer, Threaded Hex, 1.735” 1
2A017-039 Spacer, Idler Plt, 1.926” 1

4FS010-020 Plate, Idler Mounting 1

2A017-044 Spacer, Idler, .509” 1
2A046-923 Belt, K060923-Gates Cougar 1

4FA016-150 Idler Pulley, 6Rib 3.5” Flanged 1

7A312-075 5/16-18 x 3/4 HXCS GR5 Zinc 12
7C060-025 M6 x 1.00” x 25mm Hex 1

7J006-093 6mm Washer, Plated 1
7C080-025 8mm x 1.25 x 25 HXHD 3
7K312-001 5/16” AN Washer 18
7C080-056 8mm x 1.25 x 55 HXHD Zinc Plt. 1
7C080-075 8mm x 1.25 x 75 Stud 2
7C080-100 8mm x 1,25 x 100 HXHD Zinc Plt. 1
2A036-333 S/C Pulley, 3.33” 6 Groove 1
8R101-001 Pulley Retainer Assy. 6 Rib 1
7A437-201 7/16-14 x 2.00 HXHD Zinc Plt 1
7F250-040 1/4-20 Nut Plate 2
7A250-101 1/4-20 x 1 HXHD CPSC 3

7J250-001 1/4 SAE Washer, Pltd. 4
2D070-159 Large Bearing, Extended 2
7U100-084 Snap Ring, V9 1
7X100-025 Wave Washer - Large 1
2D030-041 Brg Hsg, Ext Drive, Mach 1
2A017-093 Spacer, S/C Ply, .093” 1
7A312-079 5/16-18 x .75 Button Hd Plt. 1
7F250-021 1/4-20 Nylock Nut Zinc Pltd. 1

4FS112-010 AIR INTAKE ASSY. 1

4FS112-001 Air Inlet Duct 1

8H040-010 Air Filter 1

4FS110-070 MAF/Filter Mount Brkt 1

7U035-002 3” Flex Hose x 3.5” Long 1
7R002-044 Flex Hose Clamps 2
7S300-002 3” Cast Elbow 1
7U030-056 3/8” Crank Vent Hose x 18” 1
7P375-098 3/8” Crank Vent Hose TEE 1
7U100-052 IAT Sensor Grommet 1

7P750-102 90° Bypass Hose Fitting 1
7P250-047 1/4 NPT x 90° x 3/8” Vent Hose Fitting 1
7R002-056 Inlet Duct Clamp 1
7S300-200 3” Sleeve to MAF 1
7R002-048 Clamps to MAF/Sleeve 2

4FS010-040 Fuse Box Bracket 1

7A250-101 1/4-20 x 1 SHCS 4
7F250-021 1/4-20 Nuts 4

7J250-001 1/4 Washers 8

7E010-046 #8 SHTMTL Screw x .75 3

7J008-001 #8 Washers 3

4FS212-020 AIR DISCHARGE ASSY. 1

4FS112-020 Discharge Duct 1

7P375-106 PCV Valve 1
7S250-200 2.5” Sleeves 2
7R002-040 Sleeve Clamps 4
8D001-001 Bypass 1
7U034-016 1” Hose x 4.25” (Inlet) 1
7U034-016 1” Hose x 4.25” (Outlet) 1
7R002-016 Bypass Clamps 4
7U030-046 Vacuum Hose x 18” 1
7P156-082 TEE 1
7U133-060 .75 x 90° Elbow For IAC 1
7R002-010 #10 Clamps 2
7S275-251 2.75/2.50 Reducer 1
7R002-044 #44 Clamp 4

4FS130-026 OIL FEED ASSY. 1

7U030-026 1/4” Oil Feed Hose x 26” 1
7P525-067 .525 Crimp Ferrules 2
7P250-066 -4 Swivel x 1/4 Hose 2
7P125-026 #4 x 90 x 1/8 NPT 1
7P250-036 #4 x 1/4 NPT Straight 1

4FS130-036 OIL DRAIN ASSY. 1

7R001-008 #8 Stnls Hose Clamp 2
7P375-047 3/8 NPT x 2” Nipple 1
7U030-036 1/2” Oil Drain Hose x 14” 1
7U100-055 Tie Wrap, 6” Nylon 1

4FS100-010 Tube Nut Assy. 1

7P375-004 1/2” Male SAE Flare x 3/8 NPTF 1

4FS238-068 FMU w/LINES 1

7P156-082 TEE 1
7U100-055 Tie Wrap 4

7U030-046 5/32 Vac. Hose x 18” 1
4FH145-030 FMU Line Assy. Female x 22” 1
4FH145-050 FMU Line Assy. Male x 30” 1

6Z110-136 7:1 FMU Assy.

4FS101-001 FUEL PUMP ASSY. 1

7P500-004 1/2” Male Fuel Fitting 1

7P312-003 5/16” Female Fitting 1

8F001-002 Fuel Pump 1
8F101-200? Pump Wiring Harness 1

7U031-018 5/16 Fuel Hose x 24” 1

P/N: 4FS020-010
©2002 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
11JAN02 V2.0

(Cougar (4FS V2.0))

vi

1998 FORD SVT CONTOUR/

®

ENGINEERING, LLC

Part No. 4FS218-010SQ/018SQ

PARTS LIST

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

Part Number Description Quantity

7U030-050 1/2 Fuel Hose x 13” 1

7R004-003 14.5 Stepless Clamps 2
5W001-022 Scotchlock 1
5W001-002 Fuse Tap 1
5W001-011 .25 x 14 GA Ring Term. 1
5W001-014 Fuse Holder 1
5W001-015 Fuse 1

7J010-001 #10 Washer 5

7U100-055 Tie Wrap 5
5W001-019 12 GA Butt Connector 1

7R001-004 #4 Hose Clamp 2
5W001-010 Female Slide 1

7R003-027 Adel Clamp 1

7E010-075 #12 Hex Hd. Shtmtl Screw 2

7C008-032 8-32 X 3/4 HXHD 1

7F008-032 8-32 Lock Nut 1

7J008-001 #8 Flat Washer 1

5W001-001 Wire Tap 1

4FS114-010 WATER TUBE ASSY. 1

4FS017-021 Radiator Spacer, Left 1
4FS017-031 Radiator Spacer, Right 1
4FS017-011 Radiator Spacer, Round 2

7C060-035 M6 x 1.0 x 35 Bolt 2

7C060-045 m6 x 1.0 x 45 Bolt 2

7J006-093 M6 Washer 4

7P625-017 ø5/8 x 3.25 Union (Surge Tank) 1

4FS014-011 Water Crossover Tube (modified) 1

7R001-008 #8 Hose Clamps 2

4FS120-020 ECM Module Coupon Assy. 1

MERCURY 2.5L V-6 COUGAR

vii

©2002 Vortech Engineering, Inc.

All Rights Reserved, Intl. Copr. Secured

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

1999-2000 FORD SVT CONTOUR/

®

ENGINEERING, LLC

Part No. 4FS218-020SQ/028SQ

PARTS LIST

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

Part Number Description Quantity Part Number Description Quantity

MERCURY 2.5L V-6 COUGAR

2D118-050 V-9 F-TRIM SQ SUPERCHARGER ASSY 1

4FS111-021 SUPERCHARGER MTG. ASSY. 1

4FS110-034 S/C Mtg Plate Assy. Cougar 1

7K312-001 5/16” Flat Washer, AN 11
7A312-175 5/16” X 18 X 1.75” Bolt 6

7C080-045 8mm X 1.25 x 45mm Bolt 5

4FS111-034 Supercharger Drive Assy. 1

2D160-214 Tube Assy. Ext Drive 1
2D170-224 Assy. Ext Drive, Cougar/GSR 1

4FS110-010 BRG MTG PLATE ASSY. 1

7F437-000 7/16” - 14 Hex Nut 1

7J438-081 7/16 SAE Washer Plated 1
2A017-037 Spacer, Threaded Hex, 1.490” 2
2A017-038 Spacer, Threaded Hex, 1.735” 1
2A017-039 Spacer, Idler Plt, 1.926” 1

4FS010-020 Plate, Idler Mounting 1

2A017-044 Spacer, Idler, .509” 1
2A046-923 Belt, K060923-Gates Cougar 1

4FA016-150 Idler Pulley, 6Rib 3.5” Flanged 1

7A312-075 5/16-18 x 3/4 HXCS GR5 Zinc 12

7C060-025 M6 x 1.00” x 25mm Hex 1

7J006-093 6mm Washer, Plated 1

7C080-025 8mm x 1.25 x 25 HXHD 3

7K312-001 5/16” AN Washer 18

7C080-056 8mm x 1.25 x 55 HXHD Zinc Plt. 1
7C080-075 8mm x 1.25 x 75 Stud 2
7C080-100 8mm x 1,25 x 100 HXHD Zinc Plt. 1

2A036-333 S/C Pulley, 3.33” 6 Groove 1

8R101-001 Pulley Retainer Assy. 6 Rib 1

7A437-201 7/16-14 x 2.00 HXHD Zinc Plt 1
7F250-040 1/4-20 Nut Plate 2
7A250-101 1/4-20 x 1 HXHD CPSC 3

7J250-001 1/4 SAE Washer, Pltd. 4

2D070-159 Large Bearing, Extended 2
7U100-084 Snap Ring, V9 1

7X100-025 Wave Washer - Large 1

2D030-041 Brg Hsg, Ext Drive, Mach 1

2A017-093 Spacer, S/C Ply, .093” 1
7A312-079 5/16-18 x .75 Button Hd Plt. 1
7F250-021 1/4-20 Nylock Nut Zinc Pltd. 1

4FS112-010 AIR INTAKE ASSY. 1

4FS112-001 Air Inlet Duct 1

8H040-010 Air Filter 1

4FS110-070 MAF/Filter Mount Brkt 1

7U035-002 3” Flex Hose x 3.5” Long 1
7R002-044 Flex Hose Clamps 2

7S300-002 3” Cast Elbow 1

7U030-056 3/8” Crank Vent Hose x 18” 1

7P375-098 3/8” Crank Vent Hose TEE 1

7U100-052 IAT Sensor Grommet 1

7P750-102 90° Bypass Hose Fitting 1
7P250-047 1/4 NPT x 90° x 3/8” Vent Hose Fitting 1

7R002-056 Inlet Duct Clamp 1
7S300-200 3” Sleeve to MAF 1
7R002-048 Clamps to MAF/Sleeve 2

4FS010-040 Fuse Box Bracket 1

7A250-101 1/4-20 x 1 SHCS 4
7F250-021 1/4-20 Nuts 4

7J250-001 1/4 Washers 8

7E010-046 #8 SHTMTL Screw x .75 3

7J008-001 #8 Washers 3

4FS212-020 AIR DISCHARGE ASSY. 1

4FS112-020 Discharge Duct 1

7P375-106 PCV Valve 1
7S250-200 2.5” Sleeves 2
7R002-040 Sleeve Clamps 4
8D001-001 Bypass 1
7U034-016 1” HOSE X 4.25” (Inlet) 1
7U034-016 1” HOSE X 4.25” (Outlet) 1
7R002-016 Bypass Clamps 4
7U030-046 Vacuum Hose x 18” 1
7P156-082 TEE 1
7U133-060 .75 x 90° Elbow For IAC 1
7R002-010 #10 Clamps 2
7S275-251 2.75/2.50 Reducer 1
7R002-044 #44 Clamp 4

4FS130-026 OIL FEED ASSY. 1

7U030-026 1/4” Oil Feed Hose x 26” 1
7P525-067 .525 Crimp Ferrules 2
7P250-066 -4 Swivel x 1/4 Hose 2
7P125-026 #4 x 90 x 1/8 NPT 1
7P250-036 #4 x 1/4 NPT Straight 1

4FS130-036 OIL DRAIN ASSY. 1

7R001-008 #8 Stnls Hose Clamp 2
7P375-047 3/8 NPT x 2” Nipple 1
7U030-036 1/2” Oil Drain Hose x 14” 1
7U100-055 Tie Wrap, 6” Nylon 1

4FS100-010 TUBE NUT ASSY. 1

7P375-004 1/2” Male SAE Flare x 3/8 NPTF 1

4FS114-010 WATER TUBE ASSY. 1

4FS017-021 Radiator Spacer, Left 1
4FS017-031 Radiator Spacer, Right 1
4FS017-011 Radiator Spacer, Round 2

7C060-035 M6 x 1.0 x 35 Bolt 2
7C060-045 m6 x 1.0 x 45 Bolt 2

7J006-093 M6 Washer 4

7P625-017 ø5/8 x 3.25 Union (Surge Tank) 1

4FS014-011 Water Crossover Tube (modified) 1

7R001-008 #8 Hose Clamps 2

4FS120-020 ECM MODULE COUPON ASSY. 1
8F060-038 FUEL INJECTORS 6
SW001-051 JUMPER HARNESS 6
4FS020-010 INSTRUCTION MANUAL 1

P/N: 4FS020-010
©2002 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
11JAN02 V2.0

(Cougar (4FS V2.0))

viii

1. PREPARATION/REMOVAL

A. Disconnect the positive and negative battery

terminals.

B. Detach the electrical connections to the air flow

meter and the air temperature sensor. Remove
the entire air intake assembly. Remove the airbox
and support bracket.

C. Drain the coolant from the radiator and set aside

for reuse.

D. Detach the upper and lower radiator hoses from

the radiator. Remove the three fasteners con­necting the steel water crossover tube to the A/C
line and the engine. Detach the water tube from
the thermostat housing hose (see
recovery tank and remove it from the vehicle.
Leave all three rubber hoses attached to the
water tube for reference when installing the new
supplied tube onto the vehicle. Set the hardware
aside for re-use.

E. Unplug the three electrical connections from the

plastic fan shroud. Disconnect the wiring har­ness attached to the top and bottom of the fan
shroud. Remove and set aside the two bolts
securing the bottom of the A/C condenser to the
radiator.

F. Remove the four bolts securing the two lower

radiator brackets to the crossmember. Lower the
radiator out of the vehicle, leaving the condenser
in place.

G. Temporarily remove the two bolts attaching the

radiator recovery tank to the vehicle. Set aside
the tank for working clearance.

H. Unbolt the power steering cooler from the vehicle

and swing aside temporarily. Do not detach the
hoses.

Fig. 1-a

) and

Water crossover tube (remove)

Fig. 1-a

©2002 Vortech Engineering, Inc.

1

All Rights Reserved, Intl. Copr. Secured

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))