Vortech Ford SVT Contour Mercury 2.5L V6 Cougar User Manual

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Page 1

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 • (805) 247-0226

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

(Cougar (4FS V2.0))

ENGINEERING, LLC

Page 2

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

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

(Cougar (4FS V2.0))

of Vortech Engineering, LLC.

Page 3

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

iii

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 4

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 (805) 247-0226 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:

(Cougar (4FS V2.0))

2699 Barris Drive

Memphis, TN 38132

Tel: 901 396-5782, Fax: 901 396-5783

Page 5

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

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 6

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

(Cougar (4FS V2.0))

Page 7

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

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 8

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

(Cougar (4FS V2.0))

viii

Page 9

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

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 10

2. FUSE BOX AND BATTERY RELOCATION

A. Remove the battery securing strap. Lift the bat-

tery and the plastic undertray out of the vehicle.

B. Remove the bolt securing the underhood fuse

box to the vehicle.

C. Remove the battery mounting tray and install the

supplied fuse box relocation bracket. (See

Fig. 2-a

D. Mount the factory fuse box to the new bracket

and secure it with the factory bolt. (See

E. Relocate the battery. (See note regarding battery

relocation on

Fig. 2-b

page iv

Fig. 2-a

Fig. 2-b

(Cougar (4FS V2.0))

Page 11

3. OIL DRAIN

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

necessary to make a hole in the front of the oil pan. Locate and mark the hole. (See This hole should be centered 7/16” from the bottom of the oil pan lip and 5/8” from the leftmost edge of the oil pan.

B. Drill an 1/8” pilot hole at the center location. C. Use a 9/16” roto broach to drill a hole in oil pan.

Break through the pan gently, so the cut out piece does not go into the oil pan.

D. Tap the hole with a 3/8” NPT tap to approxi-

mately 1/2” deep or until fitting can be started. Pack the flutes of the tap with heavy grease to hold chips.

E. Thoroughly clean the threaded area. Reach in-

side the oil pan and retrieve any stray chips. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the supplied 3/8” NPT nipple and secure it in the hole. Make sure a seal is formed all around the fitting. Thread the supplied 3/8” NPTF x 1/2 flare fitting onto the nipple. (See

F. Install the supplied oil drain tube assembly onto

the flare fitting. Before tightening the tube nut on the drain tube, angle the tube slightly upward at the open end so the oil will drain “downhill” into the pan.(See

Fig. 3-c

G. Temporarily cover the oil drain tube end to keep

any debris out.

H. Drain the engine oil, install a new filter and refill

the engine with fresh oil.

Fig. 3-b, 3-d

Fig. 3-a

Fig. 3-b

Fig. 3-c

OIL PAN

7/16”

5/8”

Fig. 3-a

3/8” NPT NIPPLE

3/8” NPTF x 1/2” FLARE

OIL DRAIN TUBE

SUPERCHARGER DRAIN

Fig. 3-d / View From Top

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 12

4. OIL FEED

A. Remove the 1/4” NPT socket head plug located

below the EGR valve on the rear-most cylinderhead. (See

B. Install the supplied 1/4” NPT to #4 straight fitting,

using engine oil on the pipe threads. (See

4-b

C. Connect one end of oil feed line to the #4 fitting. D. Temporarily cover the open end of the oil feed

line to protect it from debris until connecting it to the supercharger in a later step.

Fig. 4-a

Fig.

NOTE: Teflon tape, or other sealant is not rec-

ommended at it might loosen and cause blockage of the .032” oil feed orfice, resulting in supercharger failure.

PCV VALVE

FACTORY OIL PLUG

Fig. 4-a

(Cougar (4FS V2.0))

OIL FEED HOSE CONNECTED

Fig. 4-b

Page 13

4. OIL FEED, cont’d.

FLOW

FILTERED ENGINE OIL

COUGAR V-9 OIL FEED SCHEMATIC (FACING TOP FRONT OF UNIT)

14.5 STEPLESS CLAMP

(7R004-003) 2 PLACES

1/4” I.D. HOSE

FROM

SUPERCHARGER

VOLUTE

DISCHARGE

1/8” NPT TO 1/4” HOSE BARB 90° (7P125-037)

1/8” NPT TO 1/4” HOSE BARB (7P125-036)

TO SUPERCHARGER

GEARCASE OIL FEED

3/8” COPPER

WASHER

(7J375-024)

2 PLACES

AIR ASSIST FITTING (7P125-039)

1/8” NPT HEX NIPPLE (7P125-108)

AIR CHECK VAL VE (7P125-110)

Fig. 4-c

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 14

5. FUEL MANAGEMENT UNIT (FMU) INSTALLATION (1998 “Return Style” Vehicles Only)

A. Using a spring lock disconnect tool, disconnect

the fuel return line at the fuel rail. The return line

does not

B. Connect the FMU inlet hose to the fuel rail. Route

the fuel line to the 90° brass fitting on the FMU. (See

C. Connect the FMU outlet hose to the fuel

line that returns to the tank. Route the fuel line to the straight brass fitting on the FMU.

D. Position the FMU against the firewall

directly beneath the plastic panel, between the brake booster and the strut tower. (See #30 holes in the firewall to mount the FMU. Trim firewall insulation as necessary and secure the FMU with the two #8 sheet metal screws provided.

have the pressure test fitting on it.

Figs. 5-a, 5-b

Fig. 5-c

.) Mark and drill two

FUEL

MANAGEMENT

UNIT (FMU)

TEE INTO FACTORY FUEL REGULATOR VACUUM HOSE

ENGINE

E. Secure the fuel lines away from abra-

sion and exhaust heat with the provided tie wraps.

F. Tap into the vacuum line coming from

the stock fuel pressure regulator with the supplied 5/32” hose and TEE. Route the new hose to the fitting on top of the FMU.

CONNECT TO MANIFOLD PRESSURE/ VACUUM

FILTER

RETURN FUEL LINE

VORTECH

FUEL PUMP

FUEL FEED LINE

FACTORY FUEL PUMP

FUEL TANK

Fig. 5-b

OUTLET (FUEL FROM

(Cougar (4FS V2.0))

HERE RETURNS

TO TANK

INLET (FUEL

Fig. 5-c

LINE FROM STOCK REGULATOR

Fig. 5-a

Page 15

6. FUEL PUMP INSTALLATION (1998 “Return Style” Vehicles Only)

A. Jack up the rear of the car and support with jack

stands.

B. Mount the fuel pump to the underbody in front of

the fuel tank on the passenger’s side. Drill a 1/8” hole and secure the pump using the supplied adel clamp and #10 sheet metal screw. (See

Figs. 6-a, 6-b

C. Remove the female hose end connected to the

fuel filter inlet.

D. Insert the pump inlet hose assembly into the

female supply hose fitting by gently pushing the fittings together and making sure they are locked.

E. Plug the female connector located on the pump

discharge line onto the fuel filter inlet, making sure the hose assembly clears all sharp objects.

F. Mark and drill a 1/8” hole locating the relay next

to the fuel pump as shown in Secure the relay with the sheet metal screw provided.

G. Lift the center divider located between the rear

seats and remove the rubber cap beneath it to reveal the fuel pump wiring harness.

H. From relay terminal #85, tap the yellow wire into

the factory fuel pump harness. Tap into the purple wire with pink stripes using the supplied scotch lock. (See

I. Connect the short red wire on relay terminal #87

to the (+) terminal of the fuel pump.

J. Connect the short black wire to a clean ground

from relay terminal #86 (the relay mounting screw works well).

K. Route the remaining long red wire from relay

terminal #30 to the battery. Use the supplied fuse and fuse holder before terminating at the 12V source.

Fig. 6-c

Figs. 6-a and 6-b

Fig. 6-a

Fig. 6-b

(+) FUEL PUMP

GROUND

87a

Fig. 6-c

PURPLE/PINK STRIPE WIRE IN STOCK HARNESS (Check with test light. When key is turned to “ON” position, test light should illuminate for 2-3 seconds & then should turn “OFF” automatically .)

FUSE BOX AT CIGAR LIGHTER TAP (FUSED SIDE)

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 16

7. FUEL INJECTOR REPLACEMENT, (1999-2000 “returnless fuel” vehicles only)

A. Disconnect the EGR tube from the EGR valve at

the rear of the upper intake manifold. Remove all bolts securing the upper manifold to the lower manifold. Unplug the electrical connector from the fuel pressure sensor. The upper manifold should move up enough to access all fuel injectors.

B. Disconnect the six fuel injector wiring clips and

retainers from the fuel injectors. Release any residual fuel pressure from the rail by opening the schrader valve.

C. Remove the plastic from around the injector

wires. Remove the bolts holding down the factory fuel rail. Lift up on the rail evenly and remove all six injectors.

D. Using a small amount of clean motor oil, lightly

lubricate the O-rings on both ends of the Vortech supplied fuel injectors.

E. Install the new injectors into the fuel rail with the

terminals facing outward.

F. Carefully lower the fuel rail/injector assembly

down onto the intake manifold. Check to see that each injector has been seated properly.

G. Tighten down the fuel rail assembly with the

original bolts.

H. Use the supplied jumper harnesses to connect

the factory fuel injector plug to the newly installed fuel injectors. (See

Fig. 7-a

I. Zip tie the jumper harnesses to the fuel rail so the

stay clear of the manifold when reinstalled. (See

Fig. 7-a

J. Reinstall all previously removed components.

Fig. 7-a

(Cougar (4FS V2.0))

Page 17

8. POWER STEERING COOLER RELOCATION

A. Remove the factory installed nut clips from the

cooler.

B. Take the factory nut clips and reinstall them on

the side of the cooler tabs. Attach them so that the bolt can be threaded in from the front of the car.

C. Reinstall the cooler on the front side of the

sheetmetal lip with the supplied 1/4-20 bolts and washers coming in from the front, moving the cooler slightly forward. (See

Figs. 8-a, 8-b

Fig. 8-a

9. FAN SHROUD MODIFICATION

A. Unbolt the fan shroud from the radiator. B. Trim the shroud as shown. Leave approximately

1/8” of material above the outer ring of the fan. (See

Figs. 9-a, 9-b, 9-c

C. Reinstall the fan shroud.

)

Fig. 8-b

Fig. 9-b / Driver’s Side.Fig. 9-a / Passenger’s Side.

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 18

9. FAN SHROUD MODIFICATION, cont’d.

Fig. 9-c / Driver’s Side.

10. A/C CANISTER RELOCATION

A. Remove the bolt closest to the driver’s side of the

A/C canister bracket so that the canister can swivel and have a good amount of play.

B. Follow the hard lines from the canister that runs

to the front of the vehicle. From underneath the vehicle, push the plastic harness while moving the lines down so the canister is able to move forward. (See

C. On the side you removed the bolt, take the

supplied spacer and push the canister froward using the 1/4” hardware to secure it. This spaces the canister forward enough to clear the inlet tube. ( See

Fig. 10-a

Fig. 10-b

(Cougar (4FS V2.0))

REMOVE BOLT TO

INSTALL RELOCATION TAB

LOOSEN BOLT TO ALLOW

CANISTER TO SWIVEL

INSTALLED RELOCATION TAB

BOTTOM VIEW OF

Fig. 10-a

Fig. 10-b

Page 19

11. MAIN BRACKET ASSEMBLY

A. Replace the lowermost nut securing the factory

power steering pump mounting plate with the supplied 1.735” long threaded hex spacer. (See

Fig. 11-a.

B. Remove the four timing cover bolts shown and

install the two supplied studs in the centermost holes. (See

C. Remove the blue plastic cap from the drain fitting

at the supercharger. Attach the supercharger to the mounting plate using the supplied 5/16-18 x

1.75 bolts, and 5/16” washers. (See

D. Slide the supplied 1/2” oil drain hose onto the

supercharger drain fitting and secure with a #8 hose clamp.

E. Remove the five bolts indicated in

which secure the transmission to the bellhousing. Remove the plastic speed pickup to gain access to the rear-most bolt.

F. Remove the stock support bracket connecting

the two aluminum A/C lines together near the A/C compressor. The A/C line may require slight bending for proper bracket fit in the next step.

G. Attach the supplied bearing plate to the engine

front cover (see long threaded hex spacers onto the two studs previously installed and thread the one M8 x 55 bolt with washer through the bearing plate and into the front cover in the top position. Do not tighten the bolt or spacers.

H. Lower the driveshaft and housing assembly into

position. Ensure that the bearing plate previously installed is correctly positioned over it’s mounting studs.

I. Secure the aluminum bearing housing located

on the driveshaft housing assembly to the bearing plate previously mounted to the front cover. Thread four 5/16-18 x 3/4 bolts ( washers) through the plate and into the housing. Do not tighten.

J. Lower the supercharger/mounting plate assem-

bly into position. Join the supercharger and driveshaft housing together using the three 5/1618 x 3/4 hex head bolts and one 5/16”-18 x .75 buttonhead bolt with the 5/16” washers supplied. (Install the buttonhead bolt in the position closest to the fans.) Apply “moly” lube or anti-sieze to the supercharger shaft splines before sliding them together. It may be necessary to turn the pulley on the extended drive assembly by hand to align the splines of the coupling. together. Tighten the four 5/16 bolts.

)

Fig. 11-a.

)

Fig. 11-d

Fig. 11-b

Fig. 11-c

). Attach the two 1.490”

without

Do not

force pieces

any

INSTALL SUPPLIED STUDS AND TIGHTEN

REMOVE FACTORY NUT. INSTALL 1.735 HEX SPACER

Fig. 11-a

Fig. 11-b

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 20

11. MAIN BRACKET ASSEMBLY, cont’d.

K. Install the five supplied M8 x 45mm bolts and

washers securing the supercharger mounting bracket to the bellhousing and transmission. Reinstall the plastic speed pickup. Tighten all bolts previously left loose.

L. Install the drive pulley key onto the pulley shaft.

Make sure that the supplied .093” pulley spacer is installed onto the shaft installed. Slide the pulley onto the shaft carefully. Do not hammer or pry on the pulley if clearance is tight as pulley and driveshaft damage may result. Lightly heat the pulley with a propane torch if required. Secure the pulley with the 3/824 bolt (apply one drop of blue Loctite to the bolt threads prior to installation), AN washer and pulley retainer. The retainer must mate directly to the outside of the pulley. Tighten the bolt.

M. Assemble the supplied idler pulley and spacer to

the idler plate as shown in using the 7/16-14 bolt, washer, dust shield and locknut.

N. Route the supplied supercharger drive belt per

the supplied diagram. (See idler pulley/idler plate assembly, assembled in the previous step, into place and secure with the three 8mm x 25mm bolts and 5/16” washers supplied.

before

the pulley is

Fig. 11-e and 11-f

Fig. 11-e.

) Lower the

TEMPORARILY REMOVED

SPEED PICKUP

NOTE: The belt must be routed around the

spacers before the idler plate is installed.

M8 x 55 BOLT AND WASHER

(2) 1.490” HEX SPACERS

BEARING PLATE

REMOVE FACTORY BOLTS (5)

Fig. 11-c

Fig. 11-d

(Cougar (4FS V2.0))

Page 21

11. MAIN BRACKET ASSEMBLY, cont’d.

0.481 SPACER AGAINST ENGINE COVER (REMOVE FACTOR Y BOLT)

1.490 LONG THREADED HEX SPACER BETWEEN IDLER

REMOVE FACTORY NUT AND INST ALL 1.735 LONG THREADED

HEX SPACER AGAINST POWER STEERING BRACKET

(INSTALLED BEFORE IDLER PLA TE IS A TT ACHED)

MOUNTING PLATE AND BEARING PLATE

POWER

STEERING

IDLER

INSTALL M8 x 55 BOLT w/W ASHER

AL T.

M8 x 25 BOLTS AND W ASHERS

THRU TO HEX SPACERS

Ø7/16 NUT AND WASHER (INST ALLED

BEFORE PLATE IS A TTACHED TO ENGINE)

IDLER PULLEY AND .509 THICK IDLER

SPACER BEHIND MOUNTING PLA TE

1.926” SPACER AGAINST ENGINE COVER (REMOVE

FACTORY BOLT) INSTALL M8 x 100 BOLT AND WASHER

M8 x 25 BOLT AND

WASHER (3 PLACES)

7/16 NUT AND

WASHER

TENSIONER

CRANK

Fig. 11-e

.509 IDLER SPACER

AIR

S/C

FIRST INSTALL M8 x 75 STUDS INTO BLOCK (REMOVE FACTORY BOLTS)

COND.

THREADED HEX SPACER (3 PLACES)

IDLER PLATE

M8 x 100 BOLT AND WASHER

IDLER PLATE ASSEMBLY (SIDE VIEW)

Fig. 11-f

SUPPLIED IDLER PULLEY

LOWER SPACER (1.926")

7/16 x 2 BOLT

DUST SHIELD

ENGINE TIMING

COVER

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 22

11. MAIN BRACKET ASSEMBLY, cont’d.

O. Unload the belt tensioner with a 3/8” drive wrench

and install the belt, power steering pump pulley last.

P. Attach the supplied 90° x 1/8 NPT x #4 fitting into

the feed nozzle on the supercharger. (See

4-a in step 4

.) Connect the oil feed line to the supercharger. Connect the oil drain hose to the drain tube installed in the oil pan.

12. WATER PIPE INSTALLATION

A. Transfer the original three rubber hoses that

were attached to the factory water pipe removed in step 1, to the supplied water pipe.

B. Install the new water crossover pipe assembly

(with rubber hoses attached) onto the front of the engine using the original hardware.

C. Re-install the factory coolant recovery tank and

hardware.

D. Cut the factory recovery tank hose as shown and

install the supplied ø5/8 x 3.25 hose union (see

Fig. 12-a

). Secure with #8 hose clamps.

Fig.

SUPPLIED HOSE UNION

13. AIR CONDITIONING MODIFICATIONS

A. On the air conditioning condenser there is a small

black tab riveted to the driver’s side, which fits a notch in the radiator. Trim 3/16” from the end of this tab and file smooth. (See passenger’s side can remain unaltered.

B. Swing the A/C condenser back into place and

notice how the trimmed tab rests on the plastic air deflector. Cut a notch in the plastic deflector, allowing the condenser to be pushed further forward. (See

Figs. 13-b, 13-c

Fig. 13-a

Fig. 12-a

.) The

Fig. 13-a

(Cougar (4FS V2.0))

Page 23

13. AIR CONDITIONING MODIFICATIONS, cont’d.

C. Under the vehicle notice the two hard lines com-

ing from the passenger’s side of the condenser and where they rest against the edge of the plastic air deflector. Trim the air deflector until the line can be placed flush against the body. (See

Fig. 13-d.

)

D. Install the supplied spacer rings between the

radiator and the factory radiator mounts. (See

Figs. 13-e, 13-f.

)

E. Re-install the radiator and condenser using the

supplied spacer blocks and longer 6mm bolts. The thicker spacer goes on the driver’s side. (See

Fig. 13-g.

)

NOTE: Re-installation will be tight. Be careful

not to damage the radiator and condenser.

F. Cut off 1/2” of the ends of the upper and lower

radiator hoses where they attach to the radiator. Re-attach the power steering cooler.

G. Remove the A/C line support strap at the front of

the engine on the passenger’s side. It connects

the two hard lines coming out of the A/C compressor.

H. Remove the bolt securing the A/C line to the

body, located directly behind the passenger’s

side headlight. Push the A/C line up against the body, mark and drill a new 1/8” hole for the support clamp and secure it with the supplied #10 sheet metal screw. (See

Fig. 13-h.

)

I. Bend the A/C line coming from the compressor,

routed towards the passenger’s side, until it is

nearly parallel with the ground. It will be necessary to put more bend in the 90° section to clear the body.

J. Re-attach all coolant hoses.

Fig. 13-c

Fig. 13-d

Fig. 13-b

Not required on Contour installation.

Fig. 13-e

Fig. 13-f

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 24

13. AIR CONDITIONING MODIFICATIONS, cont’d.

Fig. 13-g Fig. 13-h

14. AIR INLET

A. Install the 1” x 90° and 1/4 NPT x 90° x 3/8” hose

barb fittings into the plastic inlet duct. (See

14-a

B. Attach the supplied flex duct to the inlet duct and

secure it with the supplied clamp.

C. Slide the inlet duct and #56 clamp over the

supercharger inlet. Do not tighten.

Fig.

NOTE: The fit may be very tight. Apply a small

amount of moly paste or antiseize to help with installation.

D. Join the two valve-cover breather vents using the

supplied TEE and 3/8” rubber hose. Connect the remaining leg of the TEE to the 3/8” barb on the plastic inlet duct with the remaining length of 3/8” hose.

E. Drill three holes per template and mount the

mass air flow meter bracket with the three sheet metal screws provided. Secure the mass air meter to the supplied filter adapter through the mass air bracket. Install the air filter on the filter adapter using the clamp provided.

F. Using the sleeve and clamps provided install the

U-shaped duct between the mass air meter and the flex ducting. (See

Fig. 14-b

G. Confirm proper alignment of inlet duct and tighten. H. Install the rubber grommet into the 9/16” hole in

the inlet duct. Insert the stock IAT sensor into the grommet. Cougar models may require a wire extension to reach the sensor. Wires and connectors are supplied in the kit. Some model years may require filing on the plastic IAT sensor to allow complete insertion into the duct.

Fig. 14-a

Fig. 14-b

(Cougar (4FS V2.0))

Page 25

15. SUPERCHARGER DISCHARGE/BYPASS ASSEMBLY

A. Remove the stock PCV valve and install the

supplied valve in its place. (See page 4.)

B. Slide the 1”x 4-1/4” hose onto the supplied dis-

charge tube and secure with the #16 hose clamp provided.

C. Install the supplied compressor bypass valve

onto the 1” hose attached to the discharge duct with the bypass vacuum nipple pointing away from the discharge fitting and secure it with a #16 hose clamp.

D. Using the 5/32” TEE and hose, splice the bypass

nipple into the previously installed vacuum hose attached to the FMU lid.

E. Install the 2-1/2” silicone sleeve and #40 hose

clamp on the throttle body.

F. Install the discharge duct on the supercharger

discharge using the 2-1/2” silicone sleeve and two #44 hose clamps. Slide the other end of the discharge duct into the sleeve on the throttlebody and secure it with a #44 hose clamp. (See

15-b

G. Connect the supplied 3/4” x 90° rubber elbow to

the discharge duct and secure it with a #10 hose clamp. Attach the remaining end to the IAC. (See

Fig. 15-c

Fig. 4-a

Fig.

Fig. 15-b

INSTALLED IAC HOSE

DISCHARGE TUBE

Ø1” x 4-1/4” HOSE

COMPRESSOR BYPASS VALVE

VACUUM HOSE

Ø1” x 3-1/2” HOSE

Fig. 15-a

INLET DUCT

Fig. 15-c

SVT Contour models are to install the supplied 2.75 to 2.50

reducer and a #44 clamp.

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 26

16. FINAL CHECK

A. Reconnect the battery. B. If your vehicle has gone over 20,000 miles since

its last spark plug change, you will need to change the spark plugs now the vehicle.

C. Check all fittings, nuts, bolts and clamps for

tightness. Pay particular attention to oil and fuel lines near moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie wraps.

D. Check all fluid levels, making sure that your

tank(s) is/are filled with 91 octane or higher fuel before commencing test drive.

E. Start engine and allow to idle a few minutes, then

shut off.

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

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

G. PLEASE TAKE SPECIAL NOTE: Operating the

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

URE OF MAJOR COMPONENTS. H. Test drive the vehicle. I. Read the STREET SUPERCHARGER SYSTEM

OWNER’S MANUAL AND RETURN THE WAR-

RANTY REGISTRATION FORM within thirty

(30) days of purchasing your supercharger sys-

tem to qualify.

before

test driving

ENGINEERING, INC.

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

11JAN02 V2.0

P/N: 4FS020-010

(Cougar (4FS V2.0))

Page 27

Ford SVT Contour/

Mercury 2.5L V-6

Cougar

Battery Relocation

Supplement

1998-2001 Model Years

NOTE: The bracketry/hardware sold in this option requires the purchase

of a Performance Distributors battery part #5575B (top post).

Contact Performance Distributors at:

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

(Cougar (007056..SU))

2699 Barris Drive

Tel: 901 396-5782 • Fax: 901 396-5783

Memphis, TN 38132

ENGINEERING, INC.

Page 28

COUGAR/COUNTOUR BATTERY RELOCATION

A. To make things more accessible you will want to

remove the driver’s side headlight.

sary on the Contour.)

B. Remove the plastic skirting from undernearth the

front of the car to gain access to the area where you will mount the battery. Remove the plastic lining from the inner wheel well. The horn is located under the driver’s side front fender. Remove the horn. Remove the nut from the rear bolt holding the transport bracket. (See supplied battery box. There will be three holes in the bottom of the battery box. Place the bottom upward with the back closest to the outside of the fender. Align the largest hole with a bolt located in the fender. With the largest hole aligned mark the smaller holes when you find a suitable position for the box. Use a 13/32” drill bit to make the holes. Mount the box using three provided 3/8-16 bolts and nylock nuts. (See

Fig. 2

C. Attach the piece of supplied foam to the battery

strap. Attach the horn to the strap using the 1/4”20 bolt and nylock nut on the opposite side of the foam so that the hole lines up and the lip hangs over the side to prevent any movement. (See

Fig. 3

D. Place the battery upside down (terminal down) in

the mounted battery box. Install the battery so that the positive terminal is toward the back of the car and the negative terminal is toward the front. (See

Fig. 4

.) Secure it with the battery strap. One end of the strap will go into the battery box with the foam touching the battery, while the other will mount on the rear bolt that holds the transport bracket. If installed properly, the horn will be facing forward and hanging down. Connect the horn wire. Use the stock transport bracket nut to fasten the battery strap.

NOTE: See wiring schematic for steps “G”

and “H” (Fig. 6).

E. Gather all the red positive wires that are attached

to the positive lead on the battery. Cut the wires from the power distribution manifold. Take the four wires and strip and crimp them into a supplied lug end terminal (see

Fig. 6

shrink tube down over the lugs and heat until the tubing is snug over the wires. This will provide protection to the connection. Take the end with the battery lug terminal and route it over to the battery. Use tie wraps to secure wires and to keep them from interfering with themselves.

(Not neces-

Fig. 1

.) Get

). Slide the heat

BATTERY

STRAP

HORN

MOUNTED

TO BATTERY

STRAP

Fig. 1

BOX

MOUNTED

Fig. 2

Fig. 3

REAR NUT REMOVED

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

(Cougar (007056..SU))

of Vortech Engineering, Inc.

Page 29

COUGAR/COUNTOUR BATTERY RELOCATION, cont’d.

NOTE: It is important that you use Di-elec-

tric grease with all the battery connections.

F. Take the negative wires coming off of the original

battery and cut them from the distribution manifold. Combine the wires with a lug end terminal and ground to the engine compartment. With the supplied black wire attach a lug end terminal to one end. Attach the terminal to a place on the chassis.

the hole to ensure a good electrical connection.)

On the opposite end, cut the wire to length and connect a battery terminal.

G. Take the battery terminals from the black and red

wire and connect them to their corresponding terminals on the battery. (See

H. In the engine compartment, on the driver’s side

fender area, use a 1.25” hole saw and make a hole to mount the remote positive power terminal. (See behind the existing box. Now mount the terminal.

(Remove all paint and debris from around

Fig. 4

Fig. 5

.) If properly placed, it will mount

NOTE: The terminal will need to be a snug

fit.

BATTERY TERMINALS

Fig. 4

I. Cut the supplied 1/0 red wire long enough to

reach from the remote terminal to the positive terminal on the battery. On each end crimp a lug end terminal. Attach one lug to the battery and one lug to the remote terminal. (See

Fig. 6

Fig. 5

Fig. 6

31JAN01 V1.0

P/N: 007056

(Cougar (007056..SU))

Page 30

COUGAR/COUNTOUR BATTERY RELOCATION, cont’d.

J. Take the fuse box mounting bracket and mount

it to two of the original battery mounting plate holes using two of the original bolts to secure it. (See

Fig. 7

.) Attach the fuse box to the bracket

and secure it with a 1/4”-20 x 1/2” bolt and nut.

K. Reinstall the plastic skirting to the car and inner

fender.

(Cougar only.)

Reinstall the driver’s side head-

light.

COUGAR BATTERY RELOCATION WIRING SCHEMATIC

Dyna

Batt

BATTERY

MOUNTING

PLATE

TWO ORIGINAL BOLTS

Fig. 7

SUPPLIED 1/0 BLACK WIRE GROUND TO CHASSIS

SUPPLIED 1/0

RED WIRE

DISTRIBUTION

MANIFOLD

DISTRIBUTION

MANIFOLD

SUPPLIED 1/4"

NUT/BOLT

GROUND

TO BODY

CUT STOCK TERMINAL

CUT 4 RED WIRES. STRIP AND CRIMP INTO A LUG END TERMINAL DISCARD DISTRIBUTION MANIFOLD.

POSITIVE WIRES(SEE STEP G)

Fig. 8

DISCONNECT FROM BODY.

ONLY CUT 3 NEGATIVE WIRES STRIP AND CRIMP INTO A LUG END TERMINAL DISCARD DISTRIBUTION MANIFOLD.

NEGATIVE WIRES

(SEE STEP H)

POWER DISTRIBUTION BOX

TO STARTER

(DO NOT CUT BLACK WIRE)

FUSABLE LINK

TO STARTER

ENGINEERING, INC.

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

31JAN01 V1.0

P/N: 007056

(Cougar (007056..SU))