Mercury - Cougar - Workshop Manual - 1998 - 2000

F Mercord SVT C ury 2 .5L Vontour/ -6 Co (5 Sp e e ugar d Trans mi Manua l ssion Supe O r c n ha ly) Insta llatio rger Syst n Ins em t 50 St 1998-2 r u ction ate S mog 000 Mo s Lega del l per Y CARB ears EO #D -213- 17 ® ENGINEERING, LLC 1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226 FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area. © 2002 VORTECH ENGINEERING, LLC 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 of Vortech Engineering, LLC. P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) ii Table Of Contents FOREWORD ..................................................................................................................................... ii TABLE OF CONTENTS .................................................................................................................... iii IMPORTANT NOTES ........................................................................................................................ iv TOOL & SUPPLY REQUIREMENTS ................................................................................................ v PARTS LIST - 1998 FORD SVT CONTOUR/MERCURY 2.5L V-6 COUGAR .................................. vi PARTS LIST - 1999-2000 FORD SVT CONTOUR/MERCURY 2.5L V-6 COUGAR ......................... viii 1. PREPARATION/REMOVAL .................................................................................................. 1 2. FUSE BOX AND BATTERY RELOCATION ......................................................................... 2 3. OIL DRAIN ........................................................................................................................... 3 4. OIL FEED ............................................................................................................................. 4 5. FUEL MANAGEMENT UNIT INSTALLATION (1998 Only) .................................................. 6 6. FUEL PUMP INSTALLATION (1998 Only) ........................................................................... 7 7. FUEL INJECTOR REPLACEMENT (1999-2000 Only) ........................................................ 8 8. POWER STEERING COOLER RELOCATION .................................................................... 9 9. FAN SHROUD MODIFICATION ........................................................................................... 9 10. A/C CANISTER RELOCATION ............................................................................................ 10 11. MAIN BRACKET ASSEMBLY .............................................................................................. 11 12. WATER PIPE INSTALLATION ............................................................................................. 14 13. AIR CONDITIONING MODIFICATIONS .............................................................................. 14 14. AIR INLET ............................................................................................................................16 15. SUPERCHARGER DISCHARGE/BYPASS ASSEMBLY ..................................................... 17 16. FINAL CHECK ...................................................................................................................... 18 iii P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) SVT CONTOUR/COUGAR IMPORTANT NOTES SVT Contour Off-Highway Use When driving the vehicle on non-public roads (off-road applications such as racing/high rpm) Vortech strongly recommends reducing the spark plug gap down to .032”. Electronic Control Module This kit requires ECM modification and the installation of a Vortech/Superchips ECM Module. The ECM must be sent directly to Vortech by the installing customer (the charge for this service with module installation has been included in the purchase price). • Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1) Vortech/Superchips ECM Module. • The modules are made specifically for each individual vehicle with respect to the factory ECM calibration. • Simply contact the Vortech Service Department at (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: 2699 Barris Drive Memphis, TN 38132 Tel: 901 396-5782, Fax: 901 396-5783 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) iv 1998-2000 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR Installation Instructions 50 State Smog Legal, as per CARB EO #D-213-17 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 v P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 1998 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR ® Part No. 4FS218-010SQ/018SQ ENGINEERING, LLC PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number 2D118-050 Description Quantity V-9 F-TRIM SQ SUPERCHARGER ASSY 1 4FS111-021 4FS110-034 7K312-001 7A312-175 7C080-045 SUPERCHARGER MTG. ASSY. S/C Mtg Plate Assy. Cougar 5/16” Flat Washer, AN 5/16” X 18 X 1.75” Bolt 8mm X 1.25 x 45mm Bolt 1 1 11 6 5 4FS111-034 2D160-214 2D170-224 4FS110-010 7F437-000 7J438-081 2A017-037 2A017-038 2A017-039 4FS010-020 2A017-044 2A046-923 4FA016-150 7A312-075 7C060-025 7J006-093 7C080-025 7K312-001 7C080-056 7C080-075 7C080-100 2A036-333 8R101-001 7A437-201 7F250-040 7A250-101 7J250-001 2D070-159 7U100-084 7X100-025 2D030-041 2A017-093 7A312-079 7F250-021 SUPERCHARGER DRIVE ASSY. Tube Assy. Ext Drive Assy. Ext Drive, Cougar/GSR Brg Mtg Plate Assy. 7/16” - 14 Hex Nut 7/16 SAE Washer Plated Spacer, Threaded Hex, 1.490” Spacer, Threaded Hex, 1.735” Spacer, Idler Plt, 1.926” Plate, Idler Mounting Spacer, Idler, .509” Belt, K060923-Gates Cougar Idler Pulley, 6Rib 3.5” Flanged 5/16-18 x 3/4 HXCS GR5 Zinc M6 x 1.00” x 25mm Hex 6mm Washer, Plated 8mm x 1.25 x 25 HXHD 5/16” AN Washer 8mm x 1.25 x 55 HXHD Zinc Plt. 8mm x 1.25 x 75 Stud 8mm x 1,25 x 100 HXHD Zinc Plt. S/C Pulley, 3.33” 6 Groove Pulley Retainer Assy. 6 Rib 7/16-14 x 2.00 HXHD Zinc Plt 1/4-20 Nut Plate 1/4-20 x 1 HXHD CPSC 1/4 SAE Washer, Pltd. Large Bearing, Extended Snap Ring, V9 Wave Washer - Large Brg Hsg, Ext Drive, Mach Spacer, S/C Ply, .093” 5/16-18 x .75 Button Hd Plt. 1/4-20 Nylock Nut Zinc Pltd. 1 1 1 1 1 1 2 1 1 1 1 1 1 12 1 1 3 18 1 2 1 1 1 1 2 3 4 2 1 1 1 1 1 1 4FS112-010 4FS112-001 8H040-010 4FS110-070 7U035-002 7R002-044 7S300-002 7U030-056 7P375-098 7U100-052 AIR INTAKE ASSY. Air Inlet Duct Air Filter MAF/Filter Mount Brkt 3” Flex Hose x 3.5” Long Flex Hose Clamps 3” Cast Elbow 3/8” Crank Vent Hose x 18” 3/8” Crank Vent Hose TEE IAT Sensor Grommet 1 1 1 1 1 2 1 1 1 1 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) Part Number 7P750-102 7P250-047 7R002-056 7S300-200 7R002-048 4FS010-040 7A250-101 7F250-021 7J250-001 7E010-046 7J008-001 vi Description Quantity 90° Bypass Hose Fitting 1/4 NPT x 90° x 3/8” Vent Hose Fitting Inlet Duct Clamp 3” Sleeve to MAF Clamps to MAF/Sleeve Fuse Box Bracket 1/4-20 x 1 SHCS 1/4-20 Nuts 1/4 Washers #8 SHTMTL Screw x .75 #8 Washers 1 1 1 1 2 1 4 4 8 3 3 4FS212-020 4FS112-020 7P375-106 7S250-200 7R002-040 8D001-001 7U034-016 7U034-016 7R002-016 7U030-046 7P156-082 7U133-060 7R002-010 7S275-251 7R002-044 AIR DISCHARGE ASSY. Discharge Duct PCV Valve 2.5” Sleeves Sleeve Clamps Bypass 1” Hose x 4.25” (Inlet) 1” Hose x 4.25” (Outlet) Bypass Clamps Vacuum Hose x 18” TEE .75 x 90° Elbow For IAC #10 Clamps 2.75/2.50 Reducer #44 Clamp 1 1 1 2 4 1 1 1 4 1 1 1 2 1 4 4FS130-026 7U030-026 7P525-067 7P250-066 7P125-026 7P250-036 OIL FEED ASSY. 1/4” Oil Feed Hose x 26” .525 Crimp Ferrules -4 Swivel x 1/4 Hose #4 x 90 x 1/8 NPT #4 x 1/4 NPT Straight 1 1 2 2 1 1 4FS130-036 7R001-008 7P375-047 7U030-036 7U100-055 4FS100-010 7P375-004 OIL DRAIN ASSY. #8 Stnls Hose Clamp 3/8 NPT x 2” Nipple 1/2” Oil Drain Hose x 14” Tie Wrap, 6” Nylon Tube Nut Assy. 1/2” Male SAE Flare x 3/8 NPTF 1 2 1 1 1 1 1 4FS238-068 7P156-082 7U100-055 7U030-046 4FH145-030 4FH145-050 6Z110-136 FMU w/LINES TEE Tie Wrap 5/32 Vac. Hose x 18” FMU Line Assy. Female x 22” FMU Line Assy. Male x 30” 7:1 FMU Assy. 1 1 4 1 1 1 4FS101-001 7P500-004 7P312-003 8F001-002 8F101-200? 7U031-018 FUEL PUMP ASSY. 1/2” Male Fuel Fitting 5/16” Female Fitting Fuel Pump Pump Wiring Harness 5/16 Fuel Hose x 24” 1 1 1 1 1 1 1998 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR ® Part No. 4FS218-010SQ/018SQ ENGINEERING, LLC PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number 7U030-050 7R004-003 5W001-022 5W001-002 5W001-011 5W001-014 5W001-015 7J010-001 7U100-055 5W001-019 7R001-004 5W001-010 7R003-027 7E010-075 7C008-032 7F008-032 7J008-001 5W001-001 4FS114-010 4FS017-021 4FS017-031 4FS017-011 7C060-035 7C060-045 7J006-093 7P625-017 4FS014-011 7R001-008 4FS120-020 Description Quantity 1/2 Fuel Hose x 13” 14.5 Stepless Clamps Scotchlock Fuse Tap .25 x 14 GA Ring Term. Fuse Holder Fuse #10 Washer Tie Wrap 12 GA Butt Connector #4 Hose Clamp Female Slide Adel Clamp #12 Hex Hd. Shtmtl Screw 8-32 X 3/4 HXHD 8-32 Lock Nut #8 Flat Washer Wire Tap 1 2 1 1 1 1 1 5 5 1 2 1 1 2 1 1 1 1 WATER TUBE ASSY. Radiator Spacer, Left Radiator Spacer, Right Radiator Spacer, Round M6 x 1.0 x 35 Bolt m6 x 1.0 x 45 Bolt M6 Washer ø5/8 x 3.25 Union (Surge Tank) Water Crossover Tube (modified) #8 Hose Clamps 1 1 1 2 2 2 4 1 1 2 ECM Module Coupon Assy. 1 vii P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 1999-2000 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR ® Part No. 4FS218-020SQ/028SQ ENGINEERING, LLC PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number 2D118-050 Description Quantity Part Number Description 7R002-056 7S300-200 7R002-048 4FS010-040 7A250-101 7F250-021 7J250-001 7E010-046 7J008-001 Inlet Duct Clamp 3” Sleeve to MAF Clamps to MAF/Sleeve Fuse Box Bracket 1/4-20 x 1 SHCS 1/4-20 Nuts 1/4 Washers #8 SHTMTL Screw x .75 #8 Washers 1 1 2 1 4 4 8 3 3 4FS212-020 4FS112-020 7P375-106 7S250-200 7R002-040 8D001-001 7U034-016 7U034-016 7R002-016 7U030-046 7P156-082 7U133-060 7R002-010 7S275-251 7R002-044 AIR DISCHARGE ASSY. Discharge Duct PCV Valve 2.5” Sleeves Sleeve Clamps Bypass 1” HOSE X 4.25” (Inlet) 1” HOSE X 4.25” (Outlet) Bypass Clamps Vacuum Hose x 18” TEE .75 x 90° Elbow For IAC #10 Clamps 2.75/2.50 Reducer #44 Clamp 1 1 1 2 4 1 1 1 4 1 1 1 2 1 4 4FS130-026 7U030-026 7P525-067 7P250-066 7P125-026 7P250-036 OIL FEED ASSY. 1/4” Oil Feed Hose x 26” .525 Crimp Ferrules -4 Swivel x 1/4 Hose #4 x 90 x 1/8 NPT #4 x 1/4 NPT Straight 1 1 2 2 1 1 4FS130-036 7R001-008 7P375-047 7U030-036 7U100-055 4FS100-010 7P375-004 OIL DRAIN ASSY. #8 Stnls Hose Clamp 3/8 NPT x 2” Nipple 1/2” Oil Drain Hose x 14” Tie Wrap, 6” Nylon TUBE NUT ASSY. 1/2” Male SAE Flare x 3/8 NPTF 1 2 1 1 1 1 1 4FS114-010 4FS017-021 4FS017-031 4FS017-011 7C060-035 7C060-045 7J006-093 7P625-017 4FS014-011 7R001-008 WATER TUBE ASSY. Radiator Spacer, Left Radiator Spacer, Right Radiator Spacer, Round M6 x 1.0 x 35 Bolt m6 x 1.0 x 45 Bolt M6 Washer ø5/8 x 3.25 Union (Surge Tank) Water Crossover Tube (modified) #8 Hose Clamps 1 1 1 2 2 2 4 1 1 2 4FS120-020 ECM MODULE COUPON ASSY. 1 FUEL INJECTORS 6 V-9 F-TRIM SQ SUPERCHARGER ASSY 1 4FS111-021 4FS110-034 7K312-001 7A312-175 7C080-045 SUPERCHARGER MTG. ASSY. S/C Mtg Plate Assy. Cougar 5/16” Flat Washer, AN 5/16” X 18 X 1.75” Bolt 8mm X 1.25 x 45mm Bolt 1 1 11 6 5 4FS111-034 2D160-214 2D170-224 4FS110-010 7F437-000 7J438-081 2A017-037 2A017-038 2A017-039 4FS010-020 2A017-044 2A046-923 4FA016-150 7A312-075 7C060-025 7J006-093 7C080-025 7K312-001 7C080-056 7C080-075 7C080-100 2A036-333 8R101-001 7A437-201 7F250-040 7A250-101 7J250-001 2D070-159 7U100-084 7X100-025 2D030-041 2A017-093 7A312-079 7F250-021 Supercharger Drive Assy. Tube Assy. Ext Drive Assy. Ext Drive, Cougar/GSR BRG MTG PLATE ASSY. 7/16” - 14 Hex Nut 7/16 SAE Washer Plated Spacer, Threaded Hex, 1.490” Spacer, Threaded Hex, 1.735” Spacer, Idler Plt, 1.926” Plate, Idler Mounting Spacer, Idler, .509” Belt, K060923-Gates Cougar Idler Pulley, 6Rib 3.5” Flanged 5/16-18 x 3/4 HXCS GR5 Zinc M6 x 1.00” x 25mm Hex 6mm Washer, Plated 8mm x 1.25 x 25 HXHD 5/16” AN Washer 8mm x 1.25 x 55 HXHD Zinc Plt. 8mm x 1.25 x 75 Stud 8mm x 1,25 x 100 HXHD Zinc Plt. S/C Pulley, 3.33” 6 Groove Pulley Retainer Assy. 6 Rib 7/16-14 x 2.00 HXHD Zinc Plt 1/4-20 Nut Plate 1/4-20 x 1 HXHD CPSC 1/4 SAE Washer, Pltd. Large Bearing, Extended Snap Ring, V9 Wave Washer - Large Brg Hsg, Ext Drive, Mach Spacer, S/C Ply, .093” 5/16-18 x .75 Button Hd Plt. 1/4-20 Nylock Nut Zinc Pltd. 1 1 1 1 1 1 2 1 1 1 1 1 1 12 1 1 3 18 1 2 1 1 1 1 2 3 4 2 1 1 1 1 1 1 4FS112-010 4FS112-001 8H040-010 4FS110-070 7U035-002 7R002-044 7S300-002 7U030-056 7P375-098 7U100-052 7P750-102 7P250-047 AIR INTAKE ASSY. Air Inlet Duct Air Filter MAF/Filter Mount Brkt 3” Flex Hose x 3.5” Long Flex Hose Clamps 3” Cast Elbow 3/8” Crank Vent Hose x 18” 3/8” Crank Vent Hose TEE IAT Sensor Grommet 90° Bypass Hose Fitting 1/4 NPT x 90° x 3/8” Vent Hose Fitting 1 1 1 1 1 2 1 1 1 1 1 1 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 8F060-038 viii Quantity SW001-051 JUMPER HARNESS 6 4FS020-010 INSTRUCTION MANUAL 1 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 Fig. 1-a) and 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. 1 Water crossover tube (remove) Fig. 1-a P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 2. FUSE BOX AND BATTERY RELOCATION A. Remove the battery securing strap. Lift the battery 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 Fig. 2-b.) E. Relocate the battery. (See note regarding battery relocation on page iv.) Fig. 2-a Fig. 2-b P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 2 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 Fig. 3-a.) 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 approximately 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 inside 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 Fig. 3-b, 3-d.) 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 Fig. 3-c OIL PAN 7/16” 3/8” NPT NIPPLE 5/8” Fig. 3-a 3/8” NPTF x 1/2” FLARE OIL DRAIN TUBE SUPERCHARGER DRAIN Fig. 3-d / View From Top 3 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 4. OIL FEED A. Remove the 1/4” NPT socket head plug located below the EGR valve on the rear-most cylinderhead. (See Fig. 4-a.) B. Install the supplied 1/4” NPT to #4 straight fitting, using engine oil on the pipe threads. (See Fig. 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. NOTE: Teflon tape, or other sealant is not recommended 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 OIL FEED HOSE CONNECTED P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 4 Fig. 4-b FROM SUPERCHARGER VOLUTE DISCHARGE 5 1/8” NPT HEX NIPPLE (7P125-108) Fig. 4-c FLOW AIR CHECK VALVE (7P125-110) 1/8” NPT TO 1/4” HOSE BARB (7P125-036) 1/8” NPT TO 1/4” HOSE BARB 90° (7P125-037) 1/4” I.D. HOSE 14.5 STEPLESS CLAMP (7R004-003) 2 PLACES AIR ASSIST FITTING (7P125-039) FILTERED ENGINE OIL COUGAR V-9 OIL FEED SCHEMATIC (FACING TOP FRONT OF UNIT) TO SUPERCHARGER GEARCASE OIL FEED 3/8” COPPER WASHER (7J375-024) 2 PLACES 4. OIL FEED, cont’d. P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) FUEL MANAGEMENT UNIT (FMU) INSTALLATION (1998 “Return Style” Vehicles Only) RETURN FUEL LINE A. Using a spring lock disconnect tool, disconnect the fuel return line at the fuel rail. The return line does not have the pressure test fitting on it. B. Connect the FMU inlet hose to the fuel rail. Route the fuel line to the 90° brass fitting on the FMU. (See Figs. 5-a, 5-b.) FUEL C. Connect the FMU outlet hose to the fuel MANAGEMENT line that returns to the tank. Route the UNIT (FMU) 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 Fig. 5-c.) Mark and drill two #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. E. Secure the fuel lines away from abrasion 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. TEE INTO FACTORY FUEL REGULATOR VACUUM HOSE FUEL FEED LINE 5. ENGINE FILTER VORTECH FUEL PUMP FACTORY FUEL PUMP CONNECT TO MANIFOLD PRESSURE/ VACUUM FUEL TANK Fig. 5-b Fig. 5-c INLET (FUEL LINE FROM STOCK REGULATOR OUTLET (FUEL FROM HERE RETURNS TO TANK Fig. 5-a P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 6 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 Figs. 6-a and 6-b. 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 Fig. 6-c.) 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-a Fig. 6-b (+) FUEL PUMP 87 86 GROUND 87a 85 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) 30 Fig. 6-c 7 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 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. P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 8 Fig. 7-a 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 Fig. 8-b 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. 9-a / Passenger’s Side. Fig. 9-b / Driver’s Side. 9 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 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 Fig. 10-a.) 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-b.) REMOVE BOLT TO INSTALL RELOCATION TAB LOOSEN BOLT TO ALLOW CANISTER TO SWIVEL Fig. 10-a BOTTOM VIEW OF INSTALLED RELOCATION TAB Fig. 10-b P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 10 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 Fig. 11-a.) 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 Fig. 11-b.) 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 Fig. 11-c, 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 Fig. 11-d). Attach the two 1.490” 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 (without any washers) through the plate and into the housing. Do not tighten. J. Lower the supercharger/mounting plate assembly 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. Do not force pieces together. Tighten the four 5/16 bolts. 11 INSTALL SUPPLIED STUDS AND TIGHTEN REMOVE FACTORY NUT. INSTALL 1.735 HEX SPACER Fig. 11-a Fig. 11-b P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 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 before the pulley is 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 Fig. 11-e and 11-f using the 7/16-14 bolt, washer, dust shield and locknut. N. Route the supplied supercharger drive belt per the supplied diagram. (See Fig. 11-e.) Lower the 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. NOTE: The belt must be routed around the spacers before the idler plate is installed. SPEED PICKUP TEMPORARILY REMOVED REMOVE FACTORY BOLTS (5) Fig. 11-c M8 x 55 BOLT AND WASHER (2) 1.490” HEX SPACERS BEARING PLATE Fig. 11-d P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 12 11. MAIN BRACKET ASSEMBLY, cont’d. 0.481 SPACER AGAINST ENGINE COVER (REMOVE FACTORY BOLT) 1.490 LONG THREADED HEX SPACER BETWEEN IDLER MOUNTING PLATE AND BEARING PLATE REMOVE FACTORY NUT AND INSTALL 1.735 LONG THREADED HEX SPACER AGAINST POWER STEERING BRACKET (INSTALLED BEFORE IDLER PLATE IS ATTACHED) INSTALL M8 x 55 BOLT w/WASHER POWER STEERING IDLER TENSIONER VORTE ER CH IDL S/C ALT. M8 x 25 BOLTS AND WASHERS THRU TO HEX SPACERS FIRST INSTALL M8 x 75 STUDS INTO BLOCK (REMOVE FACTORY BOLTS) AIR COND. CRANK Ø7/16 NUT AND WASHER (INSTALLED BEFORE PLATE IS ATTACHED TO ENGINE) IDLER PULLEY AND .509 THICK IDLER SPACER BEHIND MOUNTING PLATE 1.926” SPACER AGAINST ENGINE COVER (REMOVE FACTORY BOLT) INSTALL M8 x 100 BOLT AND WASHER Fig. 11-e M8 x 25 BOLT AND WASHER (3 PLACES) .509 IDLER SPACER THREADED HEX SPACER (3 PLACES) 7/16 NUT AND WASHER 7/16 x 2 BOLT DUST SHIELD IDLER PLATE SUPPLIED IDLER PULLEY M8 x 100 BOLT AND WASHER LOWER SPACER (1.926") ENGINE TIMING COVER IDLER PLATE ASSEMBLY (SIDE VIEW) Fig. 11-f 13 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 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 Fig. 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. SUPPLIED HOSE UNION Fig. 12-a 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 Fig. 13-a.) The 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 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 14 13. AIR CONDITIONING MODIFICATIONS, cont’d. * C. Under the vehicle notice the two hard lines coming 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. 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 F. Fig. 13-d Fig. 13-e Fig. 13-b Fig. 13-f * Not required on Contour installation. 15 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 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 Fig. 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. 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. P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 16 Fig. 14-a Fig. 14-b 15. SUPERCHARGER DISCHARGE/BYPASS ASSEMBLY A. Remove the stock PCV valve and install the supplied valve in its place. (See Fig. 4-a on page 4.) B. Slide the 1”x 4-1/4” hose onto the supplied discharge 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 Fig. 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. 15-b INSTALLED IAC HOSE DISCHARGE TUBE INLET DUCT Ø1” x 4-1/4” HOSE COMPRESSOR BYPASS VALVE Fig. 15-c Ø1” x 3-1/2” HOSE VACUUM HOSE Fig. 15-a *SVT Contour models are to install the supplied 2.75 to 2.50 reducer and a #44 clamp. 17 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) 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 before test driving 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 FAILURE OF MAJOR COMPONENTS. H. Test drive the vehicle. I. Read the STREET SUPERCHARGER SYSTEM OWNER’S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify. ® 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 18 P/N: 4FS020-010 ©2002 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 11JAN02 V2.0(Cougar (4FS V2.0)) Ford MercSVT Con ury 2 tour/ . Coug 5L V-6 ar Batte r y SuppRelocatio leme n n 1998 t -2001 Mode l Yea rs NOTE : The b of a Peracketry/ha rd Contac rformance Dware sold in is t Perfo rmanc tributors batthis option re e Distr t ibutors ery part #55quires the pu 75B (to r at: 2699 p postchase arris D ). Tel: 90 MemphB rive is 1 3965782 •, TN 38132 Fax: 9 01 396 -5783 ® 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 P/N: 007056 ©2001 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 31JAN01 V1.0 (Cougar (007056..SU)) COUGAR/COUNTOUR BATTERY RELOCATION A. To make things more accessible you will want to remove the driver’s side headlight. (Not necessary 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 Fig. 1.) Get 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). Slide the heat 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. REAR NUT REMOVED Fig. 1 BOX MOUNTED Fig. 2 BATTERY STRAP HORN MOUNTED TO BATTERY STRAP Fig. 3 © 2001 VORTECH ENGINEERING, INC. 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 of Vortech Engineering, Inc. P/N: 007056 ©2001 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 31JAN01 V1.0 (Cougar (007056..SU)) 2 COUGAR/COUNTOUR BATTERY RELOCATION, cont’d. NOTE: It is important that you use Di-electric 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. (Remove all paint and debris from around 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 Fig. 4.) 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 Fig. 5.) If properly placed, it will mount behind the existing box. Now mount the terminal. BATTERY TERMINALS Fig. 4 NOTE: The terminal will need to be a snug fit. 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 3 P/N: 007056 ©2001 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 31JAN01 V1.0 (Cougar (007056..SU)) 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 headlight. BATTERY MOUNTING PLATE TWO ORIGINAL BOLTS Fig. 7 _ COUGAR BATTERY RELOCATION WIRING SCHEMATIC + Dyna Batt SUPPLIED 1/0 BLACK WIRE GROUND TO CHASSIS DISCONNECT FROM BODY. DISTRIBUTION MANIFOLD ONLY CUT 3 NEGATIVE WIRES STRIP AND CRIMP INTO A LUG END TERMINAL DISCARD DISTRIBUTION MANIFOLD. SUPPLIED 1/4" NUT/BOLT NEGATIVE WIRES (SEE STEP H) GROUND TO BODY POSITIVE WIRES(SEE STEP G) SUPPLIED 1/0 RED WIRE POWER DISTRIBUTION BOX CUT STOCK TERMINAL TO STARTER (DO NOT CUT BLACK WIRE) DISTRIBUTION MANIFOLD FUSABLE LINK CUT 4 RED WIRES. STRIP AND CRIMP INTO A LUG END TERMINAL DISCARD DISTRIBUTION MANIFOLD. TO STARTER Fig. 8 ® 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 4 P/N: 007056 ©2001 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 31JAN01 V1.0 (Cougar (007056..SU))