Proper installation of this supercharger kit requires general automotive
mechanic knowledge and experience. Please browse through each step
of this instruction manual
if you 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
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
Also applicable for the 1990-94 Mazda Navajo and 1994 Mazda B4000
50 State Smog Legal, as per CARB EO #D-213-17
Congratulations on selecting the best performing and best backed automotive
NOTE: This supercharger kit is designed to fit on Ford Explorer/Mazda Navajo vehicles. This kit, with the
addition of the Ranger Supplement assembly part number 4FD248-050, may be installed on 1990-1994 Ford
Ranger and 1994 Mazda B4000 vehicles.
Before beginning this installation, please read through this entire instruction booklet and the Street
Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty
Registration form and return envelope.
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.
supercharger available today... the VORTECH® V-2® Supercharger!
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 every 15,000 miles and spark plug wires every 50,000 miles or earlier.
TOOL & SUPPLY REQUIREMENTS
• Factory Repair Manual
• 3/8" socket and drive set: SAE & metric
• Flat #2 screwdriver
• Phillips #2 screwdriver
• Large screwdriver or pry bar
• Adjustable wrench
• Ford style Snap Lock fuel disconnect tool
• 3/32" drill bit
• Drill motor
• Center punch
• 11/16" Greenlee™ Punch
• Silicone sealer
• Open end wrenches:
3/8", 7/16", 9/16", 5/8", 3/4", 7/8
Note: If your vehicle has in excess of 10,000 miles since its last spark plug change, then you may need:
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. 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, LLC.
A. Disconnect the battery.
B. Remove the air intake duct and valve cover
breather hose.
C. Remove the accessory drive belt.
D. Rotate the vacuum reservoir located on top of
the air conditioning condenser 180° (see
1-a
), rerouting the vacuum line attached to the
Fig.
mounting tab.
E. Remove the air conditioning compressor, but do
not break open any lines. Disconnect the air
conditioning line bracket located in front of the
water pump. Remove the air conditioning clutch
electrical connector. Temporarily secure the
compressor on top of the radiator shroud to
provide work area.
2. OIL FEED LINE INSTALLATION
Fig. 1-a
A. Remove the oil pressure sender (located near
the power steering pump).
B. Thread the 1/4" NPT street TEE into the oil
pressure sender extension in the block. Position
the tee so that the branch portion faces forward.
C. Thread the 1/4" NPT x #4 flare 90° fitting into the
upper branch so that the flare end points up
toward the brake master cylinder.
D. Thread the original pressure sender into the
center branch and reconnect sender wire.
NOTE: Keep all oil fittings and hoses abso-
lutely clean. Use Teflon paste SPARINGLY ON THE MALE PIPE
THREADS ONL Y. NEVER use Teflon
tape. Apply ONLY MOTOR OIL TO
FLARE FITTINGS. NEVER OVERTIGHTEN FITTINGS.
E. Install the Vortech supplied oil line onto the flare
fitting. Cover the loose end with a plastic bag for
later assembly.
THREAD INTO OIL
SENDING UNIT
FITTING LOCATED
IN BLOCK NEAR
POWER STEERING
PUMP
reference module and mark their position for
reinstallation. Remove module and bracket.
B. Remove EGR reference module from mount.
Bend the mount down lengthwise so that the
module will run perpendicular to the ground to
accommodate the discharge tube. (See
.)
3-a
C. Remove the EGR tube coming from the ex-
haust. Disconnect the EGR guard, vacuum line
and electrical connector. Remove the EGR valve
and assembly and set aside for reinstallation
later. Remove the guard/bracket. Cut off and
discard the upper portion of the bracket in the
area shown in
Fig 3-b
D. Remove the breather line connecting the intake
to the vapor canister (located on the left fender
apron) for clearance. Remove three left side
spark plug wires from the spark plugs and the
PCV valve and line for access to the left valve
cover.
E. Remove the EGR tube from the exhaust mani-
fold.
F. Remove the left valve cover using care to save
the gasket.
G. An 11/16" hole must be punched or drilled.
Measure and mark the hole location following
the graphic on the next page.
H. Make an 11/16" diameter hole at the mark using
a drill or chassis punch. Deburr the hole completely. Thoroughly clean the valve cover. (See
Fig. 3-c
.)
I.Install the 1/2" hose fitting into the 3/8" NPT x 45°
elbow and tighten.
J. Insert the elbow fitting through the hole in the
valve cover so the barb points forward and
slightly up from horizontal. Secure with the
sealing nut provided in the kit. Make sure to
place the sealing side of the nut against the
valve cover surface.
K. Reinstall the valve cover. (See
L. Install the 1/2" oil drain hose piece and #8
clamps to drain fitting on valve cover.
M. Reinstall the PCV valve and spark plug wires.
Check and reposition any existing lines around
the area.
rarily moved off to one side, install the two
Vortech supplied 11mm dowel sleeves into the
air conditioning compressor mount. (See
4-a
.)
B. Position the spacer and bracket on the air con-
ditioning compressor mount as shown. (See
Fig. 4-b
C. Remove the factory dowel sleeves from the
bottom of the air conditioning compressor and
set aside. Install the compressor on top of the air
conditioning mount and brackets.
D. Install the factory dowel sleeves into the Vortech
aluminum adapter bracket and install the bracket
on top of the air conditioning compressor. Insert
the four supplied 8mm x 150mm bolts and AN
washers. Start all bolts before tightening in a
crisscross sequence. Make sure all dowels and
brackets are aligned properly. (See
E. Using the supplied tie wraps, resecure the left
side air conditioning line to prevent contact with
the power steering pump or brake lines.
F. Install the supercharger mounting plate using
four 3/8-16 x 1" bolts, four AN washers, two 3/8"16 nuts and two 3/8" lock washers.
G. Reroute and install air conditioning clutch wiring
connector. (See
.)
Fig. 4-c
Fig. 4-d
NOTE: If your vehicle has gone over 10,000
miles since its last spark plug change,
you will need to change the spark plugs
now before test driving the vehicle.
A. Locate the return fuel line spring lock connector
(left side frame below master cylinder). Separate the return line with a spring lock disconnect
tool. Snap the Vortech fuel line with the male
spring lock connector into the fuel rail outlet.
Attach the other end to the Vortech fuel management unit inlet.
B. Snap the second line with the female spring lock
connector onto the fuel return line that returns to
the tank (see
Fig. 5-a
.) Connect the other end to
the FMU outlet at the center fitting. (See
5-b
.)
EXPLORER/MAZDA NAVAJO FMU:
1. Remove windshield washer fluid/cool-
ant overflow reservoir by removing the
two mounting bolts on the left side fender
apron, disconnecting the fluid lines and
wiring connection.
2. Mount the FMU behind the gas vapor
canister bracket on the driver's side
(FMU lines should be attached to the
unit before it is mounted) using the
sheet metal screws supplied in the kit.
3. Connect the 5/32" vacuum line from the
FMU to the intake manifold vacuum
tree (located at the top rear of the upper
intake manifold) and secure. (See
5-c
.)
Fig.
Fig.
OUTLET
(FUEL FROM
HERE
RETURNS
TO TANK)
CONNECT TO MANIFOLD
VACUUM/PRESSURE
INLET
(FUEL LINE
FROM
STOCK
REGULATOR)
Fig. 5-a
RANGER/MAZDA B4000 FMU:
1. Mount the FMU on the left side fender
apron, forward of the starter relay (FMU
lines should be attached to the unit
before it is mounted), using the sheet
metal screws supplied in the kit.
2. Connect the 5/32" vacuum line from the
FMU to the intake manifold vacuum
tree (located at the top rear of the upper
intake manifold) and secure. (See
5-c
.)
NOTE: Make sure you have routed all fuel
lines away from all moving parts,
sharp edges, exhaust pipes and
manifolds. Secure the fuel lines
with the tie wraps provided.
haust manifold tube first, then the valve. Tighten
all the fittings, EGR bolts and connect all the
vacuum lines.
B. Reinstall the modified EGR guard. Reconnect
all wires and vacuum lines.
C. Mount the modified EGR reference module.
Reconnect all wires and hoses.
D. Mount the supercharger mounting brace from
the back of the mounting plate to the cylinder
head using the supplied 10mm x 1.5 bolt, 3/8-16
x 3-1/4" bolt, 3/8 x 16 nut and 3/8" lock washers.
Fig. 7-a
(See
E. Align the drain tube according to
F. Mount the supercharger by guiding the drain
tube into the 1/2" drain hose on the valve cover.
Secure the drain hose with the hose clamp.
Fasten the supercharger to the mounting plate
with the five 3/8-16 x 3/4" bolts and AN type
washers provided.
G. Install the 45° flare to the 1/8" pipe fitting into the
oil feed on the supercharger and "clock" it to the
4 or 5 o'clock position.
H. Attach the oil feed line and secure away from all
moving parts and the exhaust manifold with tie
wraps.
I.On Explorer/Navajo applications, reinstall the
washer/coolant tank and the necessary plumbing and wiring connections.
.)
Fig. 7-b
.)
Fig. 7-a
8. SUPERCHARGER DRIVE BELT
A. The new longer accessory drive belt is routed
the same as the original belt except for accommodation of the supercharger and idler pulleys.
B. Route the belt around the outside of the super-
charger drive pulley then around the inside of
the idler pulleys as shown in
A. Rotate the vacuum tree located on the rear left
side of the intake manifold approximately 180°
to gain clearance for the intake/discharge plenum. (See
Fig. 9-c
B. On automatic transmission equipped applica-
tions, the transmission vacuum line must be
removed from the manifold, rerouted and formed
to run along the firewall for plenum clearance.
The rubber portion of the transmission vacuum
line must be cut and the Vortech supplied
restrictor and check valve assembly spliced into
the two cut ends. (See
C. Remove the plastic throttle cable retaining clip
from the top of the intake manifold.
D. Attach the two 1/4-20 nut plates to each of the
supplied steel plenum mounting tabs. Mount the
plenum mounting tab assemblies to the upper
intake manifold. The thin, non-slotted tab is
mounted to the upper manifold boss that is
located near the idle-air motor using the supplied 6mm flat head screw. At the top rear of the
upper intake manifold, install the thick, slotted
tab with the 8mm flat head screw. (See
E. Position the plenum bosses over the adjustable
tabs and secure with 1/4-20 bolts.
F. Mount the plastic intake duct to the super-
charger inlet with the 3-1/2" T-bolt clamp, leaving the clamp loose.
G. Secure intake tube 'B' to the plenum and plastic
intake duct using 3" x 2" and 3" x 3" blue silicone
sleeves and #48 clamps as shown in
on the page 10.
H. Position intake tube 'A', 3" x 2" silicone sleeve
and #48 clamps onto the plenum. Mount the 3"
90° rubber elbow and #52 clamps into the mass
air flow housing and connect to the intake tube.
Connect the crankcase breather hose to the
barb on intake tube 'A'.
onto the supercharger discharge. Use a 2-1/2"
x 2" sleeve with #40 clamps on the discharge
plenum. Install discharge tube A. Refer to
on page 10.
10-a
B. Mount discharge tubes B and C together using
a 2-1/2" x 2" sleeve and #40 clamps. Slide a 23/4" sleeve onto the throttle body and a 2-1/2"
sleeve onto the discharge plenum. Attach the
discharge tube assembly to the plenum and
throttle body using #40 and #44 clamps.
C. Underhood lamp must be removed or relocated
to provide adequate clearance for the supercharger.
NOTE: Position the intake and discharge tubes
as low as possible for hood clearance.
Due to factory variations, on some models modification to hood insulation may
be necessary.
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, making sure that your
tank(s) is filled with 92 octane or higher fuel
before commencing test drive.
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. Check ignition timing
to make sure it is set to stock specifications
before commencing test drive.
F. PLEASE TAKE SPECIAL NOTE: Operating
the vehicle without all of the subassemblies
completely and properly installed may cause
FAILURE OF MAJOR ENGINE COMPO-
NENTS.
G. Test drive the vehicle.
H. Read the STREET SUPERCHARGER SYS-
TEM OWNER'S MANUAL AND WARRANTY
REGISTRATION FORM within thirty (30) days
of purchasing your supercharger system to
qualify.
Fig. 11-a
WARNING: Do not attempt to operate the
vehicle until ALL components
are installed and ALL operations
are completed including the final check.