engineering, llc - summit racing equipment · supercharger system owner's manual which...

P/N: 4FL020-010© 2002 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1))

Ford 4.6L SOHCMustang GT & BULLITT

(2 Valve)Supercharger System

Installation Instructions

1996-2002 MODEL YEARS

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

®

ENGINEERING, LLC1650 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

*2002 Models - Legal in California only for racing vehicles which may never be used upon a highway.


Proper installation of this supercharger kit requires general automotivemechanic knowledge and experience. Please browse through each stepof this instruction manual prior to beginning the installation to determineif you should refer the job to a professional installer/technician. Pleasecall Vortech Engineering for installers in your area.

FOREWORD

ii

© 2003 VORTECH ENGINEERING, LLCAll 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 permissionof Vortech Engineering, LLC

P/N: 4FL020-010© 2002 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1))

Table Of ContentsFOREWORD ..................................................................................................................................... ii

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

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

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

PARTS LIST - 1996-1997 4.6L SOHC MUSTANG GT .....................................................................vi

PARTS LIST - 1998 4.6L SOHC MUSTANG GT ..............................................................................vii

PARTS LIST - 1999 4.6L SOHC MUSTANG GT ..............................................................................viii

PARTS LIST - 2000-2002 4.6L SOHC MUSTANG GT ..................................................................... ix

PARTS LIST - 2001 4.6L SOHC MUSTANG BULLITT .....................................................................x

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

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

3. OIL FEED .............................................................................................................................3

4. FUEL MANAGEMENT UNIT (1996-1998 MODELS) ...........................................................3

5.1 FUEL PUMP INSTALLATION1996-1997 MODELS ............................................................................................................5

5.2 FUEL PUMP INSTALLATION1998 MODELS .....................................................................................................................8

5.3 FUEL PUMP INSTALLATION1999-2002 MODELS ............................................................................................................9

6. FUEL INJECTOR REPLACEMENT (1999-2002 MODELS) ................................................10

7. AIR CONDITIONING LINE MODIFICATION ........................................................................11

8.1 MAIN BRACKET ASSEMBLY1996-1999 MODELS ............................................................................................................12

8.2 MAIN BRACKET ASSEMBLY2000-2002 MODELS ............................................................................................................15

9. COOLANT HOSE MODIFICATION ......................................................................................19

10. AIR INLET ............................................................................................................................20

11.1 SUPERCHARGER DISCHARGE ........................................................................................23

11.2 BULLITT DISCHARGE ........................................................................................................23

12. IGNITION RELOCATION .....................................................................................................24

13. FINAL CHECK .....................................................................................................................25

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1997-1999 ModelsMost Mustangs produced after 11/1/96 may utilize a water pump pulley that employs alarge lip on both the front and rear edges (earlier units used a lip only on the rear). Thefront lip on the pulley may cause belt installation problems. For proper clearance, the"1996 style" pulley (Ford P/N F3LY-8509-A) may be installed. This pulley is availablefrom your Ford dealer or Vortech Distributor (Vortech P/N 4FK016-081).

This kit requires ECM modification and the installation of a Vortech/Superchips ECMModule. The ECM must be sent directly to Vortech by the installing customer (the chargefor 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 thefactory ECM calibration.

• Simply contact the Vortech Service Department at (805) 247-0226 to request aReturn Authorization Number (See ECM Module Credit Tag for more details).

- Mail to Vortech the enclosed "ECM Module Credit Tag" (send original tag - nophotocopies will be accepted) and ECM in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Vortech will give anestimate at the time of your order.

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

IMPORTANT NOTES

1999-2002 Models

NOTE: Vortech Engineering is not responsible for engine or ECM damage dueto an improperly installed/mishandled ECM module or ECM.

This product is protected by state common law, copyright and/or patent. All legal rightstherein are reserved. The design, layout, dimensions, geometry, and engineeringfeatures 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 beincorporated into any product or apparatus without prior written consent of VortechEngineering, LLC.

iv

FORD 4.6L SOHC MUSTANG



Before beginning this installation, please read through this entire instruction booklet and the StreetSupercharger System Owner's Manual which includes the Automotive Limited Warranties Programand the Warranty Registration form.Vortech supercharger systems are performance improving devices. In most cases, increases in torque of30-35% 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 damagedengine is not recommended and may result in failure of the engine as well as the supercharger. VortechEngineering 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-inprocedures are followed.For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 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 oiland filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000miles, regardless of oil manufacturer's claims as potential damage to the supercharger mayresult.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles withoriginal 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 factoryunderhood emissions tag). Do not use platinum spark plugs unless they are original equipment.Change spark plugs every at least 15,000 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 and a 5/8" Tapered 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• 1/2" Tube Bender (1996-1998 Models only)• 3/16" Allen Wrench• 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

1996-2002FORD 4.6L SOHC MUSTANG

Installation Instructions50 State Smog Legal, as per CARB EO #D-213-17 (Except 2002 Models)

Congratulations on selecting the best performing and best backed automotivesupercharger available today... the VORTECH® V-2® Supercharger!

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P/N: 4FL020-010© 2002 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1)) vi

Part Number Description Quantity

2E229-130 SUPERCHARGER ASSEMBLY 12E129-030 V-2 SQ Supercharger 12A036-360 3.60" Supercharger Pulley 18R101-001 6 Rib Pulley Retainer Assembly 1

4FH111-041 MOUNTING BRACKET ASSY GEN 3 17A375-178 3/8-16 X 1-3/4 HXHD G8 57K375-040 3/8 AN960 Flat Washr 62A046-113 Belt, K061130-Gates 17C080-065 8mm x 1.25 x 65 SOC 27C080-140 8mm x 1.25 x 140 HXH 37K312-001 5/16 AN-Washer 97C080-051 8mm x 1.25 x 50 HXHD 10.9 17C080-025 8mm x 1.25 x 25 HXHD 1

4FE014-010 Radiator Pipe-Stnlss 17R002-024 #24 Goldseal Hose Clamps 27R003-013 Adel Clamp, 3/4" ID 17C010-050 10-24 x 1/2 SOC HD Cap, Zinc PLT 17J010-001 #10 Flat Washer 17J312-000 5/16 Flat Washer-SAE 27A375-208 3/8-16 x 2 G8HXHD 1

4FH016-150 Idler Pulley, 6-rib 3"v Flanged 14FA016-171 Dust Cover (Idler Pulley) 17C012-020 12mm x 1.75 x 20mm PLD 12A017-045 Spacer, Idler Plate 2V G3 14FH111-032 Idler PLT Assy, 2V Gen3 14FH011-041 Mounting Bracket-Mach 1

4FH112-010 AIR INTAKE ASSEMBLY 14FA012-012 90° Intake Elbow 14FH110-050 MAF Meter Bracket Assembly 17R002-056 #56 Hose Clamps 47S350-200 3-1/2" x 2" Sleeve 27U035-000 3-1/2" x 9" Flex Hose 17R002-052 #52 Hose Clamps 28H040-090 Air Filter 17A250-075 1/4-20 x 3/4" SHCS 47F250-021 1/4-20 Nylock Nuts 47J250-001 1/4" SAE Washers 4

4FK012-040 Inlet Elbow 17P750-100 3/4" NPT x 1" Hose Fitting 17U033-000 5/8" x 48" Hose 17U038-000 3/4" x 27" Hose 17U100-052 7/16" Rubber Grommet 1

4FH112-020 DISCHARGE ASSEMBLY 14FH012-020 Discharge Tube 17S300-200 3" x 2" Sleeve 17S275-200 2-3/4" x 2" Sleeve 17R002-044 #44 Hose Clamps 27R002-048 #48 Hose Clamps 27R002-016 #16 Hose Clamps 68D001-001 Bypass Valve 17U034-016 1" x 3.5" Heater Hose 17U034-016 1" x 13.5" Heater Hose 17U030-046 5/32" x 24" Vacuum Line 17P156-082 5/32" TEE 17P100-010 1" Hose Union 17U133-090 1" x 90° Rubber Elbow 1

1996-1997 4.6L SOHC Mustang GTPart No. 4FH218-010SQ/018SQ

PARTS LIST


4FH130-026 OIL FEED ASSEMBLY 17U030-026 1/4" x 26" Oil Feed Hose 17P525-067 .525 Crimp Ferrules 27P250-066 #4 Swivel x 1/4" Hose Barb Fitting 27P125-103 1/8" NPT -4 x 45° Male Elbow 17P250-082 1/4" NPT x -4 90° Fitting 17P250-034 1/4 NPT Street TEE 17P250-036 -4 Flare to 1/4 NPT 1

4FH130-036 OIL DRAIN ASSEMBLY 17U030-036 1/2" x 14" Oil Drain Hose 17R001-008 #8 Stainless Hose Clamps 27P500-003 90° 1/2" Alum. Tube 17P500-020 Tube Nut 17P375-042 Male Connector 1

4FH238-068 FMU (with lines) 16Z110-123 10:1 Blue Fuel Management Unit 1

4FH145-010 Male Fuel Line 14FH145-020 Female Fuel Line 17U030-046 5/32" x 46" Vacuum Line 17P156-082 5/32" TEE 1

4FH110-040 COIL BRACKET ASSEMBLY 14FH010-040 Coil Bracket 17C010-150 10-24 x 1-1/2 SH Bolts 47F010-024 10-24 Nylock Nuts 47J010-001 #10 Flat Washers 4

8F202-265 T-REX ASSEMBLY 14FA020-030 T-Rex Template 15W001-001 Wire Tap 15W001-011 16-14GA Eyelets 37E010-050 #12 x 1/2 Sheet Metal Screw 17F008-032 8-32 Hex Lock Nuts 87J008-001 #8 Flat Washers 87P312-001 Fuel Fitting Adapter 17P312-003 5/16 Female Fuel Connector 17R004-003 14.5 Stepless Clamps 27R004-002 17.0 Stepless Clamps 27U100-044 4" Tie Wraps 67U100-055 6" Tie Wraps 67U031-018 5/16 x 17-1/2" High Pressure Fuel Hose 17U032-016 3/8" x 23" Fuel Hose 17U314-001 #8 Lord Mounts 47U375-135 Adhesive Mounting Pads 48F002-265 T-Rex Fuel Pump 18F101-200 T-Rex Wiring Assembly 1

008340 T-Rex Fuel Pump Decal 15W001-014 Fuse Holder 15W001-015 20A Blade Type Fuse 15W001-019 12-10 GA. Solderless Connector 15W001-005 3/8" x 8" Plastic Wire Loom 17S625-000 Fire Sleeve 15W001-010 16-14 Ga. Female Slide 15W001-002 Fuse Tap 1

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ENGINEERING, LLC

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


All Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1))vii



4FH111-041 MOUNTING BRACKET ASSY GEN 3 17A375-178 3/8-16 X 1-3/4 HXHD G8 57K375-040 3/8 AN960 Flat Washr 62A046-113 Belt, K061130-Gates 17C080-065 8mm x 1.25 x 65 SOC 27C080-140 8mm x 1.25 x 140 HXH 37K312-001 5/16 AN-Washer 97C080-051 8mm x 1.25 x 50 HXHD 10.9 17C080-025 8mm x 1.25 x 25 HXHD 1

4FE014-010 Radiator Pipe-Stnlss 17R002-024 #24 Goldseal Hose Clamp 27R003-013 Adel Clamp, 3/4" ID 17C010-050 10-24 x 1/2 SOC HD cap, Zinc PLT 17J010-001 #10 Flat Washer 17J312-000 5/16 Flat Washer-SAE 27A375-208 3/8-16 x 2 G8HXHD 1

4FH016-150 Idler Pulley, 6-rib 3" Flanged 14FA016-171 Dust Cover (Idler Pulley) 17C012-020 12mm x 1.75 x 20mm PLD 12A017-045 Spacer, Idler Plate 2V G3 14FH111-032 Idler PLT Assy, 2V Gen3 14FH011-041 Mounting Bracket-Mach 1


4FK012-040 Inlet Elbow 17P750-100 3/4" NPT x 1" Hose Fitting 17U033-000 5/8" x 48" Hose 17U038-000 3/4" x 27" Hose 17U100-052 7/16" Rubber Grommet 1

4FH112-020 DISCHARGE ASSEMBLY 14FH012-020 Discharge Tube 17S300-200 3" x 2" Sleeve 17S275-200 2-3/4" x 2" Sleeve 17R002-044 #44 Hose Clamps 27R002-048 #48 Hose Clamps 27R002-016 #16 Hose Clamps 68D001-001 Bypass Valve 17U034-016 1" x 3.5" Heater Hose 1

1998 4.6L SOHC Mustang GTPart No. 4FH218-070SQ/078SQ

PARTS LIST


7U034-016 1" x 13.5" Heater Hose 17U030-046 5/32" x 24" Vacuum Line 17P156-082 5/32" TEE 17P100-010 1" Hose Union 17U133-090 1" x 90° Rubber Elbow 1



4FH238-068 FMU (with lines) 16Z110-123 10:1 Blue Fuel Management Unit 1

4FH145-010 Male Fuel Line 14FH145-020 Female Fuel Line 17U030-046 5/32" x 46" Vacuum Line 17P156-082 5/32" TEE 1

4FH110-040 COIL BRACKET ASSEMBLY 14FH010-040 Coil Bracket 17C010-150 10-24 x 1-1/2 SH Bolts 47F010-024 10-24 Nylock Nuts 47J010-001 #10 Flat Washers 4

4FF101-002 FUEL PUMP ASSEMBLY 18F001-002 155 Inline Fuel Pump 18F101-200 T-Rex Wiring Assy. 15W001-010 16-14 Gauge Female Slide, Insulated 37R004-003 14.5 Stepless Clamps 27R001-004 #4 Hose Clamps 27U030-050 12mm Fuel Hose (2.41 ft.) 17U031-018 5/16 Fuel Hose (2 ft.) 17R003-024 Adel Clamp, 1-1/2 ID 17E010-075 #12 x 3/4" Sheet Metal, Hex only 27P312-003 5/16" Female Fuel Connector 17P500-004 1/2" Fuel Adapter Fitting 17C008-032 #8-32 Hex Lock Nut 17J008-001 #8 Flat Washer 15W001-001 Wire Tap 17U100-055 Tie Wrap, 6" Nylon 55W001-002 Fuse Tap 15W001-015 Blade Type Fuse, 20 Amp 15W001-014 #10 Fuse Holder 15W001-019 Solderless Connector, 12-10 Gauge 15W001-011 16-14 Gauge Eyelet, .25" Bolt 17U375-135 Mounting Pad 57U100-044 Tie Wrap 57S625-000 Fire Sleeve 1 ft.

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ENGINEERING, LLC


P/N: 4FL020-010© 2002 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1)) viii


2E229-130 SUPERCHARGER ASSEMBLY 12E128-030 V-2 SQ Supercharger 12A036-360 3.60” Supercharger Pulley 18R101-001 6 Rib Pulley Retainer Assembly 1

4FL111-041 MOUNTING BRACKET ASSY, 99 2V 17A375-178 3/8-16 x 1-3/4 HXHD G8 57K375-040 3/8 AN960 Flat Washer 62A046-113 Belt, K061130-Gates 17C080-065 8mm x 1.25 x 65 SOC 27C080-140 8mm x 1.25 x 140 HXH 17K312-001 5/16 AN-Washer 77C080-051 8mm x 1.25 x 50 HXHD 10.9 17C080-025 8mm x 1.25 x 25 HXHD 14FE014-010 Radiator Pipe-Stnlss 17R002-024 #24 Goldseal Hose Clamp 27R003-013 Adel Clamp, 3/4" ID 17C010-050 10-24 x 1/2 SOC HD Cap, Zinc PLT 17J010-001 #10 Flat washer 17C010-140 10mm x 1.50 x 140 HXHD 27J010-002 10mm Washer, Zinc Plated 37C010-066 10mm x 1.5 x 65 Bolt, SHCS 17E010-046 #8 x 3/4 Sheet Metal 17A375-208 3/8-16 x 2 G8 HXHD 1

4FH016-150 Idler Pulley,6-RIB 3" Flanged 14FA016-171 Dust Cover (Idler Pulley) 17C012-020 12mm x 1.75 x 20mm PLD 12A017-045 Spacer, Idler Plate 2V G3 14FH111-032 Idler Plt Assy, 2V GEN3 14FH011-041 Mounting Bracket-Mach 1


4FK012-040 Inlet Elbow 17P750-100 3/4" NPT x 1" Hose Fitting 17U033-000 5/8" x 48" Hose 17U038-000 3/4" x 27" Hose 17U100-052 7/16" Rubber Grommet 17P625-002 5/8" Barb 1


1999 4.6L SOHC Mustang GTPart No. 4FL218-010SQ/018SQ

PARTS LIST



4FH112-020 DISCHARGE ASSEMBLY 14FH012-020 Discharge Tube 17S300-200 3" x 2" Sleeve 17S275-200 2-3/4" x 2" Sleeve 17R002-044 #44 Hose Clamps 27R002-048 #48 Hose Clamps 27R002-016 #16 Hose Clamps 68D001-001 Bypass Valve 17U034-016 1" x 3.5" Heater Hose 17U034-016 1" x 13.5" Heater Hose 17U030-046 5/32" x 52" Vacuum Line 17P156-082 5/32" TEE 17P100-010 1" Hose Union 17U133-090 1" x 90° Rubber Elbow 1

4FL020-020 ECM CHIP PACKAGE 1

4F060-030 30lb. Injectors 8

8F101-260 FUEL PUMP ASSY, 99 4.6, INTANK 18F001-260 Fuel Pump, 99+ Ford 4.6 15W001-052 Pump, Fuel, Pigtail-Connection 12A017-048 Spacers 2

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All Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1))ix



4FL111-031 MTNG BRKT ASSY, '00-'02 2V GT 17A375-178 3/8-16 x 1-3/4" HXHD G8 57K375-040 3/8" AN960 Flat Washers 52A046-080 Belt, K061080-Gates Saleen 14fl011-031 Mach, 2000 GT Mtg Brkt 17C080-065 8mm X 1.25 X 65 Soc 17C080-140 8mm X 1.25 X 140 HXH 17K312-001 5/16 AN-Washer 47C060-050 6mm X 1.0 X 50mm HXHD Zinc 17C080-025 8mm X 1.25 X 25 HXHD 1

4FE014-010 Radiator Pipe-Stnlss 17R002-024 #24 Gold Seal Hose C 27R003-013 Adel Clamp, 3/4" ID 17C010-050 10-24 x 1/2 Soc HD Cap, Zinc Plt 17J010-001 #10 Flat Washer 17C010-140 10mm x 1.50 x 140 Hex Head 27J010-002 10mm Washer, Zinc Plated 47C010-066 10mm X 1.5 x 65 Bolt, SHCS 17E010-046 #8 X 3/4 Sheet Metal 14FL116-150 2000 2V Idler Ply Assy 14FH111-032 Idler Plt Assy, 2V GEN3 14FH016-150 Idler Pulley, 6Rib 3" Flangd 14FA016-171 Dust Cover (Idler Pulley) 17C012-020 12mm x 1.75 x 20mm Pld 12A017-045 Spacer, Idler Plate 2V G3 17A375-208 3/8-16 X G8 HXHD 17J250-001 1/4 SAE Washer, Pltd 17C080-140 M8 x 1.25 x 140 Bolt 2


4FK012-040 Inlet Elbow 17P750-100 3/4" NPT x 1" Hose Fitting 17U033-000 5/8" x 48" Hose 17U038-000 3/4" x 27" Hose 17U100-052 7/16" Rubber Grommet 17P625-002 5/8” Barb 1

2000 4.6L SOHC Mustang GTPart No. 4FL218-020SQ/028SQ

PARTS LIST




4FH112-020 DISCHARGE ASSEMBLY 1 4FH012-020 Discharge Tube 1

7S300-200 3" x 2" Sleeve 17S275-200 2-3/4" x 2" Sleeve 17R002-044 #44 Hose Clamps 27R002-048 #48 Hose Clamps 27R002-016 #16 Hose Clamps 68D001-001 Bypass Valve 17U034-016 1" x 3.5" Heater Hose 17U034-016 1" x 13.5" Heater Hose 17U030-046 5/32" x 52" Vacuum Line 17P156-082 5/32" TEE 17P100-010 1" Hose Union 17U133-090 1" x 90° Rubber Elbow 1




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4FL111-031 MTNG BRKT ASSY, '00-'02 2V GT 17A375-178 3/8-16 x 1-3/4" HXHD G8 57K375-040 3/8" AN960 Flat Washers 52A046-080 Belt, K061080-Gates Saleen 14fl011-031 Mach, 2000 GT Mtg Brkt 17C080-065 8mm X 1.25 X 65 Soc 17C080-140 8mm X 1.25 X 140 HXH 17K312-001 5/16 AN-Washer 47C060-050 6mm X 1.0 X 50mm HXHD Zinc 17C080-025 8mm X 1.25 X 25 HXHD 1

4FE014-010 Radiator Pipe-Stnlss 17R002-024 #24 Gold Seal Hose C 27R003-013 Adel Clamp, 3/4" ID 17C010-050 10-24 X 1/2 Soc HD Cap, Zinc Plt 17J010-001 #10 Flat Washer 17C010-140 10mm X 1.50 X 140 Hex Head 27J010-002 10mm Washer, Zinc Plated 47C010-066 10mm X 1.5 X 65 Bolt, SHCS 17E010-046 #8 X 3/4 Sheet Metal 14FL116-150 2000 2V Idler Ply Assy. 14FH111-032 Idler Plt Assy, 2V GEN3 14FH016-150 Idler Pulley, 6Rib 3" Flangd 14FA016-171 Dust Cover (Idler Pulley) 17C012-020 12mm X 1.75 X 20mm Pld 12A017-045 Spacer, Idler Plate 2V G3 17A375-208 3/8-16 X G8 HXHD 17J250-001 1/4 SAE Washer, Pltd 17C080-140 M8 x 1.25 x 140 Bolt 2



4FH012-012 90° Inlet Elbow w/Hole 1

2001-2002 4.6L SOHC Mustang GTPart No. 4FL218-050SQ/058SQ

PARTS LIST




4FH112-020 DISCHARGE ASSEMBLY 1 4FH012-020 Discharge Tube 1

7S300-200 3" x 2" Sleeve 17S275-200 2-3/4" x 2" Sleeve 17R002-044 #44 Hose Clamps 27R002-048 #48 Hose Clamps 27R002-016 #16 Hose Clamps 68D001-001 Bypass Valve 17U034-016 1" x 3.5" Heater Hose 17U034-016 1" x 13.5" Heater Hose 17U030-046 5/32" x 52" Vacuum Line 17P156-082 5/32" TEE 17P100-010 1" Hose Union 17U133-090 1" x 90° Rubber Elbow 1


4F060-038 38lb. INJECTORS 8


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ENGINEERING, LLC

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

x


All Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1))xi



4FL111-051 MTNG BRKT ASSY BULLITT 17A375-178 3/8-16 x 1-3/4" HXHD G8 57K375-040 3/8" AN960 Flat Washers 52A046-109 Belt, 109" Dayco4FL011-031 Mach, 2000 GT Mtg Brkt 17C080-065 8mm x 1.25 x 65 Soc 17C080-140 8mm x 1.25 x 140 HXHD 17K312-001 5/16 AN-Washer 47C060-050 6mm x 1.0 x 50mm HXHD Zinc 17C080-025 8mm x 1.25 x 25 HXHD 1

4FE014-010 Radiator Pipe-Stnlss 17R002-024 #24 Gold Seal Hose C 27R003-013 Adel Clamp, 3/4" ID 17C010-050 10-24 x 1/2 Soc HD Cap, Zinc Plt 17J010-001 #10 Flat Washer 17C010-140 10mm x 1.50 x 140 Hex Head 27J010-002 10mm Washer, Zinc Plated 47C010-066 10mm x 1.5 x 65 Bolt, SHCS 17E010-046 #8 x 3/4 Sheet Metal 14FL116-150 2000 2V Idler Ply Assy 14FH111-032 Idler Plt Assy, 2V GEN3 14FH016-150 Idler Pulley, 6Rib 3" Flangd 14FA016-171 Dust Cover (Idler Pulley) 17C012-020 12mm x 1.75 x 20mm Pld 12A017-055 Spacer, Idler Bullitt 1

4FK016-081 Water Pump Pulley, Stock 17A375-208 3/8-16 x G8 HXHD 17J250-001 1/4 SAE Washer, Pltd 17C080-140 M8 x 1.25 x 140 Bolt 2



2001 4.6L SOHC Mustang BULLITTPart No. 4FL218-070SQ/078SQ

PARTS LIST




4FL112-020 DISCHARGE ASSEMBLY 17S300-200 3" x 2" Sleeve 17R002-044 #44 Hose Clamps 17R002-048 #48 Hose Clamps 37R002-016 #16 Hose Clamps 68D001-001 Bypass Valve 17U034-016 1" x 10" Heater Hose 17U030-046 5/32" x 52" Vacuum Line 17P156-082 5/32" TEE 17P100-010 1” Hose Union 17U133-090 1" x 90° Rubber Elbow 24FL012-021 Discharge Tube A 14FK012-050 Discharge Tube B 17S300-275 Reducer, 3.00-2.75 17R002-072 #72 Goldseal Clamp 27S450-250 Sleeve, Ø4.50 x 2.5 Wide 1




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P/N: 4FL020-010© 2002 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1)) xii

This Page Left Intentionally Blank



2. OIL DRAIN

A. To provide an oil drain for the supercharger, it isnecessary to make a hole in the oil pan. Locateand mark hole per diagram (see Fig. 2-a). Thedrain hole must be punched rather than drilled.

1. PREPARATION/REMOVAL

A. Disconnect the negative battery cable.

B. Remove the accessory drive belt.C. Remove the plastic radiator cover and fasteners

located above the core support.D. Remove the crankcase vent tube located be-

tween the driver’s side valve cover and the airinlet and discard. Remove the hose from the airinlet tube to the idle air motor resonator inlet anddiscard.

E. Remove all components that lead to the throttlebody including the rubber bellows, mass air flow(MAF) sensor, air filter assembly and intake airtemperature (IAT) sensor. Separate the MAFand IAT sensors from the intake assembly andset aside.

1

NOTE: 1999-2002 MODELS ONLY1. Remove the passenger side front kick panel from the interior of the

vehicle. Remove the sound deadening material (if any) that iscovering the ECM. Remove the plastic ECM hold-down bracket.

2. Using a 10mm socket or wrench, remove the harness and plugfrom the ECM (as you loosen the bolt, the connector will slowlyrelease). Remove the ECM from the vehicle.

3. Contact the Vortech Service Department for a Return Authoriza-tion Number. Send both ECM and supplied credit tag to Vortechusing the enclosed shipping box.

Fig: 2-a / Front of Oil Pan

1-7/8"

5/8"

NOTE: 2002 models do not have a separate IATsensor. (The IAT sensor is integrated withthe factory MAF.)

F. Drain approximately one gallon of cool-ant from the radiator. Remove theupper radiator hose and set aside.

G. (2001 Bullitt only) - Loosen the fourwater pump pulley bolts.


2. OIL DRAIN, cont'd.

B. Remove the paint around the hole area.C. Use a small center punch to perforate the pan

and expand hole. Switch to a larger diameterpunch and expand the hole further to approxi-mately 9/16" diameter. Most punches are madefrom hexagon material and may be placed in asocket with an extension to make this procedureeasier.

D. Tap the hole with a 3/8" NPT tap approximately1/4" deep. Pack the flutes of the tap with heavygrease to hold chips. Use a small magnet tocheck for any stray chips.

E. Thoroughly clean the threaded area. Apply asmall amount of silicone sealer to the new threads.Apply more sealer to the 3/8" NPT x 1/2" invertedflare fitting and secure in hole. Make sure a sealis formed all around the fitting.

F. Thread the tube nut and 1/2" x 90° aluminum tubeinto the inverted flare fitting by hand. (See Figs.2-b, 2-c.) Do not tighten until after the super-charger drain hose has been connected.

G. Drain the engine oil and change the filter.H. Temporarily cap off the oil drain fitting to keep out

debris until drain hose is attached at a later time.I. Refill engine with 5W/30 synthetic or conven-

tional SH/CF rated motor oil.

2

Fig. 2-b

NOTE: This method of rolling over the lip ofthe hole and tapping it works very wellif carefully done and should cause noproblems.

Fig. 2-c / View From Passenger’s Side

OIL PAN

DRAIN HOSE FROMSUPERCHARGER

OIL DRAIN TUBE

CRANK PULLEY



4. FUEL MANAGEMENT UNIT (1996-1998 models only)A. Position the fuel management unit (FMU) against the inner fender

ahead of the right side shock tower about an inch from the top. Mark anddrill two holes in the inner fender to mount the FMU. Secure with thesheet metal screws provided. (See Figs. 4-a, 4-b, 4-c.)

B. Disconnect and discard the factory rubber fuel return line running fromthe fuel rail (the return line DOES NOT have a pressure test fitting on it)to the steel return line (the smaller of the two) located behind the rightside shock tower using a spring lock disconnect tool.

C. Connect the FMU inlet hose (the hose that goes to the 90° fitting on theside of the FMU) to the return side of the factory fuel regulator on the fuelrail.

D. Connect the FMU outlet hose (attaches to the center fitting on the bottomof the unit) to the steel return line running to the tank. Make sure hoseend is securely “snapped” onto factory fuel return line.

E. Secure the fuel lines away from abrasion and exhaust heat with the tiewraps provided.

F. Attach the supplied length of 5/32" vacuum hose to the fitting on top ofthe FMU. Connect the opposite end of the hose to the factory fuelregulator vacuum connection using the 5/32" TEE provided.

3. OIL FEED

*A. Remove the 1/4" NPT socket head plug locatedperpendicular to and directly beneath the factoryoil pressure sending unit. This is found on thedriver’s side below the oil filter.

*B. Thread the supplied 1/4" NPT #4 flare x 90° fittinginto the pressure sending unit mount using en-gine oil on the pipe threads. Rotate the fitting sothat the flare points toward the front of the vehicle.(See Fig. 3-a.)

**C. Remove the oil pressure sender. This is locatedthe driver’s side of the engine below the oil filter.

**D. Thread the supplied 1/4" street TEE into thepressure sending unit mount using engine oil onthe pipe threads.

**E. Install the sending unit and the 1/4" NPT #4 flarefitting into the street TEE as shown and tighten.(See Fig. 3-b.)

F. Temporarily cap off the flare fitting to prevent dirtfrom entering. The oil feed will be connected at alater time.

1/4" NPT x 90° FITTING (96-98, 01 Models)

* '96-'98, 01Models Only ** '99-'00 Models Only

3

Fig. 3-a

NOTE: Teflon tape, or other sealant is not rec-ommended as it might loosen and causeblockage of the oil feed orifice, result-ing in supercharger failure.

Fig. 3-b / View From Driver’sSide ('99-'00 Models Only)

SENDINGUNIT

1/4” NPT x -4 FLARE

1/4” NPTSTREET TEE

OILFEED HOSE

VIEW FROM DRIVER’S SIDE

OIL FILTERMOUNTING

BOSS

ENGINE BLOCK


4. FUEL MANAGEMENT UNIT (1996-1998 models only), cont'd.

4

Fig. 4-a

Fig. 4-b Fig. 4-c

FUEL

FEE

D LI

NE

FUEL

RET

URN

LINE

FUELMANAGEMENT

UNIT (FMU)

T-REX

FILTER

FACTORYSPRINGLOCKCONNECTOR

VACUUM LINE

FACTORYREGULATOR

INLETOUTLET

FACTORYQUICK-

DISCONNECTFITTING

FUEL TANK

ENGINE

FMU

STRUT SHOCKTOWER

PASSENGER SIDEENGINE COMPARTMENT

TOP VIEW



A. Remove the spare tire, etc. from the trunk.B. Trim “cut-out” from the template provided in the kit

and place over spare tire hold-down. Centerpunchand drill the four 3/16" holes in the trunk floor.

C. Jack up the rear of the car and support with jackstands.

D. Mount the T-Rex fuel pump to the underside of thetire well with the rubber mounts, adel clamps andfasteners provided. Refer to the graphic on thefollowing page.

E. Remove the female hose end connected to the fuelfilter inlet.

F. Insert the T-Rex inlet hose assembly into the femalesupply hose fitting by gently pushing the fittingstogether and making sure they are locked.

G. Fasten the extended feed line clear of the filter bylooping the two 11" cable ties through the front slot onthe fuel filter mount, being careful not to kink the line.

H. Plug the female connector located on the T-Rexdischarge line onto the fuel filter inlet making sure thehose assembly clears all exhaust tubing and sharpobjects.

I. Position the reflective sleeve on the pump dischargeline so that it receives maximum protection from thetailpipe.

J. Mark and drill a 1/8" hole and mount the relay insidethe trunk in position as shown in the template. Usethe sheet metal screw provided.

K. From relay terminal #85, tap the yellow wire into thestock fuel pump harness in the trunk near the right taillight. Tap into the purple wire with the suppliedscotch lock. (On some model years, the wire may bebrownish-green.)

L. Connect the short red wire on relay terminal #8 to the(+) terminal on the fuel pump.

M. Connect the longer black wire from the (-) terminal onthe fuel pump to a clean ground.

N. Connect the short black wire to a clean ground fromrelay terminal #86 (relay screw mount works well).

O. Route the remaining long red wire from relay terminal#30 up to the fuse panel located under the dash.Using a solderless connector, connect the suppliedfuse holder and fuse to the end of the wire. Crimp thefuse wire to the supplied female slide and fuse tap.Attach fuse tap and wire to fuse #17.

5.1 FUEL PUMP INSTALLATION (1996-1997 models only)

5

NOTE: Use extreme caution when routing fuellines. Make sure fuel lines are located awayfrom hot exhaust pipes and sharp edgeson vehicle underbody.


5.1 FUEL PUMP INSTALLATION, 1996-1997 models only, cont'd.

6

Fig. 5.1-a

NOTE: Make sure everything is secure and away from all moving partsor exhaust pipes. Make sure no wires will rub on sharp edges.After you have activated the pump, check for any leaks andcorrect if necessary.

T-REX®

MAGNIFICATION - UNDERSIDE VIEWFUEL TANK STRAP

T-REX FUEL PUMP

5/16" x 17-1/2" HOSE

3/8" x 23" HOSE

11" CABLE TIES

CABLE TIEFLEX LOOM

FROMFUELTANK

STOCK HOSEASSEMBLYFROM TANK

FLOW

STOCK FUEL FILTERAND BRACKET

FLOWFRONTOF CAR

SPARETIRE WELL

UNDERDASHFUSE BOX

20 AMPINLINEFUSE

MAGNIFICATION OF RELAY WIRING

86

GROUND

RELAY

30

87A85

87

(+)T-REX FUEL PUMP

PURPLE WIREIN STOCK HARNESS

HEATER-A/C FUSE ATINTERIOR FUSE BOX

FRONT OF CAR

Pump is mounted below the tire well, under the car.

Secure wires with adhesive anchors and tie wraps.

Mount relay in the right rear corner of the spare tire well. Make sure wires areconnected as per the relay schematic below. Provide a good ground connectionfree of rust and paint, for both the pump and relay. Connect the red power leadfrom the relay position #30 to fuse #17 in the under-dash fuse panel. Route thewire underneath the rear seat and carpet. Take care to avoid sharp edges and notdamage the wire insulation.



A. Remove the spare tire, etc. from the trunk.B. Jack up the rear of the car and support with jack

stands.C. Mount the fuel pump to the underside of the

spare tire well with the adel clamp and #8 fasten-ers provided. (See Figs. 5.2-a, 5.2-b.)

D. Remove the factory female hose end connectedto the fuel filter inlet.

E. Insert the supplied 1/2" fuel pump inlet hoseadapter fitting into the factory female supply hosefitting by gently pushing the fittings together andmaking sure they are locked.

F. Attach the supplied 1/2" fuel hose to the pumpinlet and the inlet hose adapter fitting. Use thesupplied #4 clamps to secure both ends. Cuthose length, if necessary.

G. Fasten the extended pump inlet line clear of thefilter by looping the two 11" cable ties through thefront slot on the fuel filter mount, being careful notto kink the line.

H. Plug the female connector located on the pumpdischarge line onto the fuel filter inlet makingsure the hose assembly clears all exhaust tubingand sharp objects.

I. Mark and drill a 1/8" hole and mount the relayinside the trunk in position as shown in thetemplate. Use the sheet metal screw provided.

J. From relay terminal #85, tap the yellow wire intothe stock fuel pump harness in the trunk near theright tail light. Tap into the purple wire with thesupplied scotch lock. (On some model years, thewire may be brownish-green.)

K. Connect the short red wire on relay terminal #8 tothe (+) terminal on the fuel pump.

L. Connect the longer black wire from the (-) termi-nal on the fuel pump to a clean ground.

M. Connect the short black wire to a clean groundfrom relay terminal #86 (relay screw mount workswell).

N. Route the remaining long red wire from relayterminal #30 up to the fuse panel located underthe dash. Using a solderless connector, connectthe supplied fuse holder and fuse to the end ofthe wire. Crimp the fuse wire to the suppliedfemale slide and fuse tap. Attach fuse tap andwire to fuse # 17.

5.2 FUEL PUMP INSTALLATION (1998 models only)

7

Fig. 5.2-aNOTE: Use extreme caution when routing fuel

lines. Make sure fuel lines are locatedaway from hot exhaust pipes and sharpedges on the vehicle underbody.


5.2 FUEL PUMP INSTALLATION (1998 models only), cont'd.

8

Fig. 5.2-b

FRONTOF CAR

UNDERDASHFUSE BOX

MAGNIFICATION - UNDERSIDE VIEW

FUEL TANKSTRAP

FUEL PUMP

1/2” x 29" HOSE

11" CABLE TIES

FLEXLOOM

FUEL LINEFROM TANK

FRONT OF CARSTOCK HOSEASSEMBLYFROM TANK

STOCK FUEL FILTERAND BRACKET20 AMP

INLINEFUSE

FLOW

CABLETIE

5/16" x 24" HOSE

FLOW

Pump is mounted below the tire well, under the car.

Secure wires with adhesive anchors and tie wraps.

MAGNIFICATION OF RELAY WIRING

86

GROUND

RELAY

30

87A85

87

(+) FUEL PUMP

RED/PURPLE WIREIN STOCK HARNESS(Check with test light. Whenkey is turned to “ON” position,test light should illuminatefor 2-3 seconds & then shouldturn “OFF” automatically.)

HEATER/A/C FUSE ATINTERIOR FUSE BOX

SPARETIRE WELL

Mount relay in the right rear corner of the spare tire well. Make sure wiresare connected as per the relay schematic below. Provide a good groundconnection free of rust and paint, for both the pump and relay. Connect thered power lead from the relay position #30 to fuse #17 in the underdashfuse panel. Route the wire underneath the rear seat and carpet. Take careto avoid sharp edges and not damage the wire insulation.


All Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1))9

5.3 FUEL PUMP INSTALLATION (1999-2002 models only)

A. Raise the rear of the car and support it with jack-stands.

B. Open the fuel door and remove the fuel-cap and thethree filler neck screws using a 10mm socket.

C. Remove the fuel filter inlet line with a 3/8 springlocktool.

D. With the weight of the fuel tank supported with a jack,remove the bolts securing the two fuel tank straps.

E. Slowly lower the fuel tank, allowing it to lean over withthe filler side up, until the electrical connectionsleading to the center mounted fuel pump are re-vealed. Disconnect these two electrical connections.

F. Remove the six bolts securing the fuel pump accesscover (on top of the fuel tank) with an 8mm wrench.Depress the two clips securing the plastic fuel pumpenclosure and slide it out of the tank. The fuel senderfloat is attached to the fuel pump enclosure and mustbe handled with care. Ensure that the tank has beenlowered enough to remove the fuel pump enclosure.

G. Cut the two fuel pump power wires about 1" from thefuel pump electrical connector. Noting the corre-sponding (+) and (-) connections, splice the suppliedwiring harness into place usng two butt connectors.

H. Remove the two screws securing the plastic fuelpump outlet manifold to the enclosure cap. Pull themanifold up and away from the fuel pump.

I. Remove the three screws securing the fuel pumpenclosure’s cover using a 3/16 nut-driver and re-move the cover. Cut three equally spaced 1/2" longslits in the perimeter of the cover’s fuel pump locatingcylinder (see Fig. 5.3-a). This allows the larger O.D.pump to fit in the cover. Some material may need tobe removed from the I.D. of the pump locatingcylinder for proper pump fit.

J. Remove the stock fuel pump from its enclosure.Separate the rubber pump support from beneath thefilter and install it on the supplied pump. Secure thesupport with the new filter provided.

K. Using the supplied fuel pump, reassemble the fuelpump assembly and canister with cap. Install thesupplied 1/8" spacers beneath the pump outlet mani-fold and the canister cap. (See Fig. 5.3-b.) Using theoutlet manifold mounting holes as a template, drilltwo 1/16" pilot holes into the enclosure cover. Securethe outlet manifold to the cap using the two supplied#6 screws. Thread the two screws into the 1/16" pilotholes. Reinstall the fuel tank assembly and reattachthe electrical connections.

L. Reinstall the canister assembly into the fuel tank andreattach the electrical connections.

M. Reinstall the fuel tank, reconnect the fuel filter inletline, reattach the fuel filler neck and reinstall the fuelcap.

N. Turn the ignition key on and check the fuel pump forleaks.


6. FUEL INJECTOR REPLACEMENT1999-2002 models only

A. Disconnect the eight (8) fuel injector wiring clipsand retainers from the fuel injectors. Releaseany residual fuel pressure from the rail by open-ing the schrader valve on the rail. Have a fireextinguisher nearby and use extreme caution.

B. Remove the bolts holding down the factory fuelrail onto the intake manifold. Lift up on to the railsevenly, removing all eight injectors.

C. Using a small amount of clean motor oil, lightlylubricate the O-rings on both ends on the Vortechsupplied fuel injectors.

D. Install the new injectors into the fuel rails with theterminals facing outward.

E. Carefully lower the fuel rail/injector assemblydown onto the intake manifold. Check to see thateach injector has been seated properly into themanifold.

F. Tighten down the fuel rail assembly with theoriginal bolts and attach the wiring clips to theinjector terminals.

5.3 FUEL PUMP REPLACEMENT, cont’d.1999-2002 models only

CUT THREE 1/2”LONG SLITS HERE

Fig. 5.3-aFuel Pump Locating Cylinder

10

NOTE: Make sure injector retainers are se-cure and properly installed. Re-check after cycling fuel system.

(BOTTOM SIDEOF CAP SHOWN)

Fig. 5.3-bFuel Pump Diagram

PUMP CANISTER

BYPASSTUBE

VORTECH SUPPLIED#6 x .75” SCREWSPLASTIC

FUEL PUMPOUTLET

MANIFOLD

FUELOUTLETHOSE

FUEL PUMP OUTLET

SUPPLIED 1/8"SPACERS



A. Remove the factory ignition coil, coil bracketand all coil mounting hardware from the pas-senger side of the engine.

B. Remove the 8mm fastener attaching the airconditioning pressure line silencer to the lowerradiator support to allow line movement duringline modification. (See Fig. 7-b.)

C. Using a hand-held 1/2" tubing bender, bend thehigh pressure air conditioning line (the line withthe pressure port and cap) so that the pressureport rotates down for supercharger inlet clear-ance. (See Figs. 7-a, 7-c.)

D. Reattach the air conditioning silencer bracketto the radiator support.

E. Bend the high pressure air conditioning line(the line with the pressure port and cap) so thatthe pressure port rotates down (for super-charger inlet clearance). (See Fig. 7-d.)

7. AIR CONDITIONING LINE MODIFICATION

REMOVE FASTENER TO ALLOWLINE MOVEMENT

* '96-'98 models only** '99-'01 models only

Fig. 7-a / 96-98 Models Only

NOTE: Air conditioning lines are under highpressure and the fluid is highly toxic;therefore, use extreme caution whenbending the line to avoid kinking orbreaking the line. Support the assem-bly as much as possible while bend-ing for clearance.

Fig. 7-b / 96-98 models only

Fig. 7-c / 96-98 models only

Fig. 7-d / 99-01 models only

**

*

*

*

*

FRONT VIEW

VORTECHVORTECH

PRESSUREPORT

BENT A/C LINEPOSITION

SUPERCHARGER(SHOWN FOR REFERENCE,

NOT YET INSTALLED)

AIR INLET

ORIGINALA/C LINEPOSITION

BEND UNTILPORT ANGLE IS

APPROX. 45°


A. Attach the supplied 1/8" NPT x 45° flare fittingand oil feed hose to the oil feed fitting on thesupercharger. Rotate the fitting so that it pointsforward, toward the volute (intake) side of thesupercharger, perpendicular to the front cover.When tightening the fitting, use a 1/2" wrench onthe oil feed base for support.

B. Slide the supplied 1/2" oil drain hose onto thesupercharger drain and secure with a #8 hoseclamp.

C. Install the 8mm x 65mm bolt and washer throughthe supercharger bracket in the location shown(see Fig. 8.1-e).

D. Using the supplied 3/8-16 x 1.75 bolts and 3/8"AN washers, secure the supercharger to theVortech aluminum mounting bracket. (See Figs.8.1-a, 8.1-b.)

12

Fig: 8.1-a

Fig. 8.1-b

WARNING: When threading the 1/8" NPT x 45°flare fitting into the supercharger,use engine oil on the pipe threadsfor lubrication. Teflon tape, pasteor other sealant is not recom-mended as it might loosen andcause blockage of the oil feed ori-fice, resulting in supercharger fail-ure.

8.1 MAIN BRACKET ASSEMBLY (1996-1999 models only)

12mm x 25mm Bolt

Dust Shield

Suppliedcomposite Idler

(smooth)

3/8"-16 x 2" Bolt(no washer)

(5) 3/8-16 x 1.75"Bolt and Washer

Temporarily insert an8mm bolt tightly into

this hole to ensureproper alignment



8.1 MAIN BRACKET ASSEMBLY (1996-1999 models only), cont’d.

E. Using the supplied 3/8-16 x 2" bolt, fasten theVortech idler mounting plate to the superchargerand mounting bracket. Do not use a washer.Align the second hole while torquing the bolt.Secure the supplied composite idler to the idlermounting plate with the supplied 12mm x 25mmbolt and dust shield. Use thread locking com-pound. (See Fig. 8.1-b.)

F. Remove the four timing cover bolts, fixed idlerpulley bolt and right side alternator mounting boltfrom the front of the engine. Remove the upperbolt/stud located on the factory belt tensionerand replace with the supplied 8mm x 25mm boltand washer. (See Fig. 8.1-c.)

G. Remove the air conditioning line silencer bracketand mounting hardware from the silencer andfront cover. Enlarge both of the holes on thebracket with a 27/64" drill bit, remove any sharpedges around the enlarged hole and reinstallonto the silencer. (See Fig. 8.1-e.)

REMOVE FACTORY BOLT/STUD AND REPLACEWITH SUPPLIED 8mm x 65 (10mm on '99 only)SOCKET HEAD BOLT AND WASHER

REMOVE FACTORY HARDWARE (NEWSUPERCHARGER BRACKET MOUNTINGHOLES). See A, B, C, D and E.

FACTORY A/CSUCTION LINESILENCERBRACKETMOUNTING HOLES

REMOVE FACTORYBOLT/STUD ANDREPLACE WITHSUPPLIED 8mm x25mm BOLT ANDWASHER

CCBB

DD

EE

AA

REMOVE BOLT/STUD ANDREPLACE WITHSUPPLIED 8mm X25mm BOLT ANDWASHER ('98-'99MODELS)

Fig. 8.1-c

NOTE: On some 1997-1999 models, atensioner stop has been added to thetensioner. This must be removed be-fore bracket installation. Remove themounting studs and thread the two sup-plied 8mm x 25mm bolts and washersin their place.

NOTE: When mounting the superchargerbracket assembly to the front cover,make sure that the air conditioning linesilencer bracket is sandwiched in be-tween the Vortech aluminum bracketand the front cover in positions #1 and#2. (See Fig. 8.1-e.) On vehicles notequipped with A/C, two .060" washersmust be installed in positions #1 and#2 in place of the factory A/C silencerbracket. These have been includedwith the kit.


H. Route the Vortech supplied accessory drive beltaround all engine pulleys except for the waterpump pulley. Lower the supercharger/bracketassembly into place and route the belt around thesupercharger pulley and the relocated factoryidler. (See Fig. 8.1-d.) Insert the alternator spacerand secure the supercharger/bracket assemblywith the supplied fasteners per Figs. 8.1-e, 8.1-f.Use a 1/2" breaker bar or ratchet to release thebelt tension. Push the belt over the top radius ofthe water pump pulley and release the tensioner.

I. Secure the oil drain hose to the mounting bracketusing the supplied adel clamp, #10 bolt andwasher. (See Figs. 8.1-a, 8.1-e .)

J. Route the oil drain hose down to the oil pan tubepreviously installed. The hose must be routeddownhill, free of dips and kinks. Trim hose end ifnecessary, slide it onto the drain tube and securewith a #8 hose clamp. Support the fitting in the oilpan with a wrench while tightening the drain tubefitting.

K. Route the oil feed hose next to the drain hose,down to the feed fitting and secure. Use tie wrapsto fasten the lines together.


14

NOTE: The new longer accessory drive belt is routedthe same as the original belt except for the ac-commodation of the supercharger and idler pul-ley. Should an emergency arise, the factory beltmay be reinstalled in it’s original configuration.

Fig. 8.1-d

Fig. 8.1-f

NOTE: It is imperative that the tensioner does not be-come overloaded when being pulled down dur-ing belt installation. Bending of the tensionermay cause belt throwing/shredding problemswhen vehicle is driven at high engine speeds.

Fig. 8.1-e / View From Front

8mm x 140mm (96-98 models) or 10mmx 140mm (99 models)

BOLT & WASHER

A/C LINESILENCERBRACKET

ENLARGETO 27/64"

ADEL CLAMP

STOCK IDLERPULLEY

VORTECHIDLERPULLEY

8mm x 140mmBOLT (2.249”SPACER MUST BESANDWICHEDBETWEEN THEALTERNATOR ANDTHE PREVIOUSLYMOUNTED IDLERMOUNTING PLATEASSEMBLY

VORTECHMOUNTING

BRACKET

ALTERNATOR

8mm x 65mm BOLT & WASHER

8mm x 50mmBOLT & WASHER

OIL DRAIN HOSE

10-24 x 1/2"BOLT & WASHER

SANDWICH TABS BETWEENENGINE FRONT COVER ANDSUPERCHARGER BRACKET

8mm x 140mm (96-98 models)or 10mm x 140mm (99 models)

BOLT & WASHER

1

2

3

VVORORTECHTECH

5

4

VIEW FROM FRONT

*

FACTORYIDLER

VORTECHIDLER

WATERPUMP

CRANKA/C

TENSIONER

POWERSTEERING

ALT.

* Push belt in between idlersand tensioner to obtainwrap around A/C and S/Cpulleys.

S/C



8.2 MAIN BRACKET ASSEMBLY (2000-2002 models only)

A. Attach the supplied 1/8” NPT x 45° flare fittingand oil feed hose to the oil feed fitting on thesupercharger. Rotate the fitting so that it pointsforward, toward the volute (intake) side of thesupercharger, perpendicular to the front cover.When tightening the fitting, use a 1/2” wrench onthe oil feed base for support.

B. Slide the supplied 1/2” oil drain hose onto thesupercharger drain and secure with a #8 hoseclamp.

C. Remove the A/C silencer and wiring harnesssupport bracket from the timing cover stud.Remove the 3 timing cover bolts/studs and thepassenger side alternator mounting bolt. (SeeFig. 8.2-a.) Install the supplied 10mm x 65mmsocket head bolt and washer in place of theupper-most bolt/stud.

D. Replace the factory ribbed idler pulley with thesupplied Vortech idler. Use thread lock on thebolt.

E. Unscrew the previously loosened water pumppulley bolts and install the Vortech suppliedwater pump pulley.

WARNING: When threading the 1/8” NPT x 45°flare fitting into the supercharger,use engine oil on the pipe threadsfor lubrication. Teflon tape, pasteor other sealant is not recom-mended as it might loosen andcause blockage of the oil feed ori-fice, resulting in supercharger fail-ure.

Fig. 8.2-a / Timing Cover

REMOVE FACTORY HARDWARE (NEW SUPERCHARGERBRACKET MOUNTING HOLES SEE CALLOUTS A, B, C and D)

REMOVE FACTORY BOLT/STUD AND REPLACEWITH SUPPLIED 10MM X 65MM SOCKET HEADBOLT AND WASHER

FACTORY SMOOTH IDLER LOCATION

INSTALL VORTECH RIBBEDIDLER (ALUMINUM)

FACTORY WIRING HARNESS SUPPORTBRACKET MOUNTING HOLE

D

CB

A

*

* 2001 Bullitt Only

FILE EDGES OF BOSS DOWN (CHECK S/CBRACKET CLEARANCE)

P/N: 4FL020-010© 2002 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1)) 16

F. Using the supplied 3/8-16 x 1.75" bolts and 3/8"AN washers, secure the supercharger to theVortech aluminum mounting bracket, exceptwhere indicated in Fig. 8.2-b.

G. Using the supplied 3/8-16 x 2" bolt, fasten theVortech idler mounting plate to the superchargerand mounting bracket. Do not use a washer.Align the second hole while torquing the bolt.Secure the supplied smooth idler to the idlermounting plate with the supplied 12mm x 25mmbolt and dust shield. Use thread locking com-pound. Make sure the “open” side of the pulley isinstalled toward the alternator.

H. Detach the wiring harness support bracket fromthe harness. Enlarge the hole on the bracketusing a 27/64" drill bit. (See Fig. 8.2-c.) Removeany sharp edges around the enlarged hole andreinstall it onto the harness. (Failure to re-installthis bracket between the Vortech bracket andfront cover will result in bracket misalignmentand possible parts failure.)

Fig. 8.2-b / Upper Idler


12mm x 25mm Bolt

Dust Shield

Supplied Idler(smooth)

3/8"-16 x 2" Bolt (nowasher)

(5) 3/8-16 x 1.75" Boltand Washer

Temporarily insert an8mm bolt tightly into

this hole to ensureproper alignment

*

* 2000 Models Only



10-24 x 1/2" BOLT and WASHER

ADEL CLAMP

SUPPLIED SPACER(2.249"-GT models/2.049"Bullitt models) MUST BESANDWICHED BETWEENTHE ALTERNATOR ANDSUPERCHARGERMOUNTING BRACKET

Fig. 8.2-c / Supercharger-Front View

OIL DRAINHOSE

NOTE: When mounting the supercharger bracket assembly to the frontcover, make sure the wiring harness support bracket is sand-wiched in-between the timing cover and the Vortech aluminumbracket in position #1 (See Figure 8.2-c.)

VORTECH MOUNTINGBRACKET


AIR CONDITIONINGSILENCER BRACKET

(SANDWICH TABS BETWEENENGINE COVER AND TIMINGSUPERCHARGER BRACKET)

2001-2002 MODELS - USE THESUPPLIED 10mm x .06 THICK

WASHER IN THIS POSITION

ENLARGE TO 27/64"

1999-2000 MODELS - 10mm x140mm BOLTS and WASHERS

2001 MODELS - 8mm x 140BOLTS & WASHERS

#1



P/N: 4FL020-010© 2002 Vortech Engineering, LLCAll Rights Reserved, Intl. Copr. Secured07NOV02 V2.1(96 2V Mus.GT(4FL V2.1)) 18

I. Route the Vortech supplied accessory drive beltaround all engine pulleys except for the waterpump pulley. Lower the supercharger/bracketassembly into place and route the belt around thesupercharger pulley and the Vortech idler. (SeeFigs. 8.2-d, 8.2-e.) Insert the alternator spacerand secure the supercharger/bracket assemblywith the supplied fasteners per diagram. Uselocking pliers to release the belt tension. Pushthe belt over the top radius of the water pumppulley and release the tensioner.


Fig. 8.2-d / Belt Diagram

NOTE: The new, longer accessory drive belt isrouted the same as the original belt ex-cept for the accommodation of the su-percharger and idler pulley. Should anemergency arise, the factory belt maybe reinstalled in it's original configura-tion.

Fig. 8.2-e

“OPEN” SIDE OF PULLEY MUST BEINSTALLED TOWARD THE ALTERNATOR

FACTORYIDLER

SMOOTH

SUPPLIEDIDLER

(SMOOTH)

VORTECHIDLER

(RIBBED)

S/C

ALT.

WATERPUMP

POWERSTEERING

A/C CRANK

TENSIONER



J. Secure the air conditioning silencer and the oildrain hose to the mounting bracket using the adelclamp, #10 bolt and washer. (See Fig. 8.2-f.)

K. Route the oil drain hose down to the oil pan tubepreviously installed. The hose must be routeddownhill, free of dips and kinks. Trim the hoseend if necessary, slide the hose onto the draintube and secure it with a #8 hose clamp. Supportthe fitting in the oil pan with a wrench whiletightening the drain tube fitting.

L. Route the oil feed hose next to the drain hose,down to the feed fitting and secure. Fig. 8.2-f / Air Conditioning Silencer

NOTE: Minor bending of the air conditioninglines may be necessary.


A. Trim 1” of hose from the radiator end of the upperradiator hose (straight portion). (See Fig. 9-b.)Cut the radiator hose, into 2 pieces in the middleof the upper straight section.

B. Install the supplied stainless steel radiator tubeinto the separated radiator hose and secure withthe supplied clamps. Reinstall radiator hose, andrefill radiator (see Fig. 9-a).

Fig. 9-a Fig. 9-b

9. COOLANT HOSE MODIFICATION

RADIATOR

TRIM 1”

SUPPLIED TUBE


10. AIR INLET

VIEW FROM INSIDE ENGINECOMPARTMENT

(Steel inner fender not shown forease of description)

Fig. 10-a

20

A. Using the supplied 1/4-20 hardware, mountthe MAF meter to the Vortech MAF bracketand secure. (See Fig. 10-a). Remove thefactory MAF screen before attaching themeter to the new bracket.

B. Attach the supplied K & N air filter, 3-1/2"sleeve, 90° 3-1/2" elbow and #56 hose clampsto the MAF and secure. (1996-2001 modelsonly.)

C. (1996-2001 Models only) Insert the factoryair temperature sensor into the rubber grom-met located on the side of the 90° elbow.Lubricate for easier fit.

D. Working from beneath the vehicle, removethe two factory nuts and washers from thepassenger’s side lower fender valence. Mountthe MAF/bracket assembly onto the existingstuds using the same washers and nutsoriginally removed. (see Fig. 10-a).

E. Using a #52 hose clamp, connect the piece of3-1/2" flex hose to the elbow attached to theMAF meter and route it through the openingin the right side inner fender toward thesupercharger. Make sure the 3-1/2" flex hosedoes not contact or rub on the edge of theinner fender opening. (Eventual hose failurewill result if hose is not properly routed.)

F. Route the factory temperature sensor andMAF sensor connectors out through the in-ner fender opening. Reattach the connec-tors to the relocated sensors.

FRONT

INSIDERIGHT FRONTPASSENGERFENDERWELL

#56 CLAMPS

FACTORYSTUDS & NUTS

FACTORY AIRTEMPERATURE SENSOR

(NOT ON 2002+ MODELS)

3-1/2" ELBOW

SLEEVE

NOTE: 1996-2001 models use the 90° x 3-1/2" plastic inlet elbow with the holeand grommet in the side. 2002 mod-els use the 90° x 3-1/2" plastic el-bow without any hole in the side.Both elbows have been supplied.

NOTE: 2002 models do not have a sepa-rate IAT sensor.



10. AIR INLET, cont’d.

G. Attach the supplied 1" x 3.5" rubber hose to thewhite 1" plastic barb fitting located on the moldedplastic supercharger inlet duct (see Fig. 10-d).Attach the supplied compressor bypass valveoutlet to the 1" x 3.5" rubber hose (make sure thevacuum nipple is oriented as shown).

H. Attach the 1" x 90° rubber elbow to the white 1"plastic barb fitting located on the molded plasticsupercharger inlet duct. (See Fig. 10-e.) Attachthe supplied compressor bypass valve outlet tothe 1" x 90° elbow (make sure the vacuum nippleis oriented as shown).

I. Attach the 1" x 13.5" rubber hose to the inlet of thecompressor bypass valve. Secure both hoseswith supplied #16 hose clamps.

J. Insert the 1" x 10" rubber hose to the inlet of thecompressor bypass valve. Secure both hoseswith the supplied #16 hose clamps.

K. Connect the plastic inlet duct (with bypass valveand hoses attached) to the supercharger inletusing the supplied 3-1/2" sleeve and #56 clamps(see Fig. 10-b). The 13.5" bypass hose will needto be routed in between the brake line coming outof the ABS unit and the ABS unit itself.

L. Join the supercharger inlet duct to the previouslyinstalled MAF hose with the supplied #52 hoseclamp.

M. Install the supplied lenghts of 5/8" and 3/4" hosesto the barbs located on the plastic superchargerinlet duct. Connect the opposite ends of eachhose to the crankcase breather fitting on thedriver’s side valve cover (5/8" hose) and the idleair control resonator (3/4" hose). Trim hose lengthif required.

N. Install the 5/8" hose union into the crankcasebreather line. It may be necessary to trim this lineto ensure a proper fit. (See Fig. 10-c.)

O. The plastic radiator cover removed in step 1Cmust be modified to clear the air inlet duct (1996-1997 only). Install the cover in its original positionand mark it as to where material needs to beremoved for duct clearance. Using a razor bladeor utility knife, cut out the radiator cover to fit theinlet ducting. Reinstall the cover and re-secure.

* '99-'02 GT Models Only** '01 Bullitt Model Only*** '96-'02 GT Models Only

5/8” BREATHER HOSE 5/8” HOSE UNION

*

Fig. 10-b

Fig. 10-c / 99-01 Models Only

21

***

**

**

***


Fig.10-d

Fig.10-e

10. AIR INLET, cont’d.

22

’01 2V MUSTANG BULLITT INLET/BYPASS ASSY

PLASTIC UNION

INLET DUCT

VIEW FROM FRONTOF VEHICLE

TO 90° RUBBER HOSEØ1” x 10" HOSETRIM TO FIT

Ø1” x 90° RUBBER HOSE

STRAIGHT FITTING

TO BUNG ONDISCHARGE DUCT

TO STRAIGHT FITTINGON INLET DUCT

BYPASS VALVE

TO FLEX HOSEAND MAF METER

7R002-016 HOSE CLAMPS

TO 1" FITTING ON INLET DUCT3.5" x Ø1" TRIM TO FIT

1" UNION

STRAIGHT FITTING

TO DISCHARGE DUCT

PART #7U133-090

'96-'02 FORD 2V MUSTANGINLET/BYPASS ASSY

TO FLEX HOSE AND MAF METER

TO MANIFOLDPRESSURE/VACUUM

13.5" x Ø1": TRIM TO FIT FOR NON-AFTERCOOLED KIT4.5" x Ø1": TRIM TO FIT FOR AFTERCOOLED KIT

INLET DUCT

VIEW FROM FRONTOF VEHICLE

BYPASS VALVE



A. Slide the 3" sleeve and #48 hose clamps onto thethrottle body. Slide the 2-3/4" sleeve and #44hose clamps onto the supercharger discharge.

B. Install the supplied 1" x 90° rubber elbow to the1" bung on the supercharger discharge tubeusing a #16 hose clamp. Insert the plastic 1" hoseunion fitting into the remaining end of the rubberelbow. (See Fig. 10-d.)

C. Install the discharge tube assembly. Align thebypass valve, all hoses and tighten all clamps.(See Fig. 11-a.)

D. Join the end of the plastic hose union to the 1"bypass inlet hose installed in Step 10. Secure allhoses with the supplied #16 hose clamps.

E. Route the 5/32" vacuum line to the bypass valveand TEE into the FMU vacuum line with thesupplied 5/32" TEE.

F. Route the 5/32" vacuum line from the bypassvalve over to the fuel pressure sensor and TEEinto the vacuum line. Refer to Figures on previ-ous page.

* '96-'98 models only ** '99-'02 models only

Fig. 11-a*

**

11.2 SUPERCHARGER DISCHARGE (Bullitt models only)

A. Slide the 4-1/2" sleeve and #72 hose clamps ontothe throttle body.

B. Install the supplied 1" x 90° rubber elbow to the1” bung on the supercharger discharge tube-Ausing a #16 hose clamp. Insert the 1" hose unioninto the remaining end of the rubber elbow.

C. Install discharge tube-A onto the superchargerdischarge using the 2-3/4" - 3" adapter sleevewith #44 and #48 hose clamps.

D. With discharge tube-A in position, install dis-charge tube-B between discharge tube-A andthe throttle body. Secure with the 3" x 2" sleeveand #48 hose clamps.

E. Join the end of the plastic hose union to the 1"bypass inlet hose installed in Step 10. Secure allhoses with the supplied #16 hose clamps.

F. Route the 5/32" vacuum line from the bypassvalve over to the fuel pressure sensor and TEEonto the vacuum line.

23

Fig. 11.1-a

11.1 SUPERCHARGER DISCHARGE (GT models only)


12. IGNITION RELOCATION

A. Separate the passenger side ignition coil fromthe factory bracket previously removed from thefront engine cover.

B. Remove the two bolts located at the front/topcorner of the passenger side valve cover.

C. Install the Vortech supplied coil bracket onto thevalve cover reusing the factory bolts to secure.

D. Attach the coil to the new bracket using thesupplied #10 hardware. Orient the assemblyfollowing the graphic (see Figures 12-b, 12-c),reattach all plug wires and reconnect the factoryharness.

E. Relocate the ignition capacitor to the passengerside alternator mounting bolt. The paint mayneed to be scraped away to ensure proper ground-ing. (See Fig. 12-a).

* '96-'98 models only ** '99-'01 GT/01 Bullitt models

1999-2002 models only

Fig. 12-a

Fig. 12-b Fig. 12-c

24

*

*

*

*

**

1996-1998models only

FRONT

COIL BRACKET MOUNTING LOCATION

FRONT

RELOCATED CAPACITOR



A. Reconnect the battery.B. If your vehicle has gone over 10,000 miles since

its last spark plug change, you will need tochange the spark plugs now before test drivingthe vehicle.

C. Check all fittings, nuts, bolts and clamps fortightness. Pay particular attention to oil and fuellines around moving parts, sharp edges andexhaust system parts. Make sure all wires andlines are properly secured with clamps or tiewraps. (See Fig. 13-a.)

D. Check all fluid levels, making sure that yourtank(s) is/are filled with 92 octane or higher fuelbefore commencing test drive.

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

F. Recheck to be sure that no hoses, wires, etc. arenear exhaust headers or moving parts and forsigns of any fluid leakage.

G. PLEASE TAKE SPECIAL NOTE: Operating thevehicle without ALL the subassemblies com-pletely 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.

Fig. 13-a / Final Check

WARNING: Do not attempt to operate the vehicleuntil ALL components are installedand ALL operations are completedincluding the final check.

NOTE: 99-02 MODELS ONLY - Once the ECM isreceived back from Vortech with the ECMmodule installed, reinstall the ECM into thevehicle. In some cases, the extra heightof the ECM module will not allow the useof the factory hold-down bracket. Recon-nect the factory harness and reinstall thefactory kick panel.

25

13. FINAL CHECK



®

ENGINEERING, LLC1650 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

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