Ford Mustang 1986 Page 6 Installation Instructions Manual Download

Page: 6 / 29

P/N: 4FA020-010
© 2008 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
25MAR08 v4.0(86-93 5.0 Mus (4FA v4.0))

PART NUMBER DESCRIPTION QUANTITY
2A228-100 V-1 SUPERCHARGER ASSEMBLY 1
4FA111-032

SUPERCHARGER BELT

TENSIONER ASSEMBLY

7J012-092

12mm FLAT WASHERS

4FA011-032

BELT TENSIONER PLATE

7C012-050

12mm x 1.75" x 50mm BOLT

4FA016-150

SMOOTH PULLEY TENSIONER

2A017-010

IDLER PULLEY SPACER

7C012-020

12mm x 1.75" x 20mm BOLTS

7C012-022 12mm x 1.75" x 22mm THIN HEAD BOLT 1

7G010-175

12mm x 1.75" NUT

4FA112-010

AIR INTAKE ASSEMBLY

7S350-200

3-1/2" x 2" SLEEVE

4FA012-012

90° INTAKE ELBOW

4FA013-010

AIR CLEANER COVER

7J006-093

6mm WASHERS

7P375-097

3/8"NPT x 3/8" BARB

7S300-100

3" x 1" SLEEVE

7E010-046

#8 x 3/4" SHEET METAL SCREWS

8H040-010

AIR FILTER

7R002-056

#56 HOSE CLAMPS

7R002-052

#52 HOSE CLAMPS

7U035-000

3-1/2" x 12" FLEX HOSE

4FA112-020

AIR DISCHARGE ASSEMBLY

4FA012-020

DISCHARGE TUBE

7S275-200

2-3/4" x 2" SLEEVE

7S300-200

3" x 2" SLEEVE

7R002-044

#44 HOSE CLAMPS

7R002-048

#48 HOSE CLAMPS

4FA139-096

PCV BYPASS KIT

8H040-020

3/8" INLINE FILTER

7U375-052

3/8" VACUUM CAP

7U030-056

3/8" x 22" FUEL HOSE

4FA238-068

FMU (WITH LINES)

6Z110-111 12:1 BLACK FUEL MANAGEMENT UNIT 1

4FA145-010

MALE FUEL LINE ASSEMBLY

4FA145-020

FEMALE FUEL LINE ASSEMBLY

7U030-046

5/32" x 54" VACuuM LINE

7E010-046

#8 x 3/4" SHEET METAL SCREWS

7U100-055

6" NYLON TIE WRAPS

4FA130-036

OIL DRAIN ASSEMBLY

7R001-008

#8 STAINLESS HOSE CLAMPS

7P375-017 3/8"NPT x 1/2" STRAIGHT HOSE BARB 1

7U030-036

1/2" x 28" OIL DRAIN HOSE

1986-1993 Mustang

Part No. 4FA218-010

PARTS LIST

PART NUMBER DESCRIPTION QUANTITY
4FA110-011

SPRING TENSIONER

MOUNTING ASSEMBLY

4FA010-011 TENSIONER MOUNTING BRACKET

7A375-100

3/8-16 x 1" BOLTS

7J375-044

3/8"SAE WASHERS

7F375-016

3/8-16 NUT

7A500-350

1/2-13 x 3-1/2" CARRIAGE BOLT

7F500-013

1/2-13 NUT

7J012-092

12mm FLAT WASHER

4FA114-023 RADIATOR HOSE ASSEMBLY

4FA014-011

RADIATOR PIPE

7R002-024

#24 HOSE CLAMPS

4FA111-021 MOUNTING BRACKET ASSEMBLY 1

4FA011-021

MOUNTING BRACKET

4FA010-034

MOUNTING PLATE

4FA015-015

ALTERNATOR STAY

4FA017-021

SMOG PUMP SPACER

7A375-625

3/8-16 x 6-1/4" BOLTS

7A375-700

3/8-16 x 7" BOLT

7A437-175

7/16-14 x 1-3/4" BOLT

7A375-175

3/8-16 x 1-3/4" BOLT

7A375-650

3/8-16 x 6-1/2" BOLT

7A375-200

3/8-16 x 2" BOLT

7A375-075

3/8-16 x 3/4" BOLT

7F375-016

3/8-16 NUTS

7A375-100

3/8-16 x 1" BOLTS

7K375-040

3/8"AN960 FLAT WASHERS

7J375-044

3/8"SAE WASHERS

7J012-092

12mm FLAT WASHER

4FA130-026

OIL FEED ASSEMBLY

7P525-067

.500" CRIMP FERRULES

7P250-066 #4 SWIVEL x 1/4" HOSE BARB FITTING 2

7P125-027

1/8"NPT STRAIGHT FITTING

7P125-103

1/8"NPT -4 x 45° MALE ELBOW

7U030-026

1/4" x 25" OIL FEED HOSE

7P250-121

3" NIPPLE

7P250-122

1/4" TEE

7P250-075

45° ELBOW

7P250-082

90° FLARE

4FA116-011

CRANK PULLEY ASSEMBLY

4FA016-011

6" CRANK PULLEY

7A375-208

3/8-16 x 2" CAP SCREWS

7J375-044

3/8"SAE WASHERS

2A046-527

BELT

IMPORTANT: Before beginning installation, verify that all parts are included in the

kit. Report any shortages or damaged parts immediately.

ENGINEERING, LLC

Summary of Contents for Mustang 1986

Page 1: ...0L Mustang Supercharger System Installation Instructions 1986 1993 MODEL YEARS 50 State Smog Legal per CARB EO D 213 17 CARB E0 not applicable to Renegade Kit P N 4FA218 100 108 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 ...

Page 2: ...onsible for any clutch transmission drive line or engine damage Exclusions from Vortech warranty coverage considerations include but not limited to 1 Neglect abuse lack of maintenance abnormal operation or improper installation 2 Continued operation with an impaired vehicle or sub system 3 The combined use of Vortech components with other modifications such as but not limited to exhaust headers af...

Page 3: ...986 1993 RENEGADE MUSTANG x PARTS LIST 1986 1993 SUPER HIGH OUTPUT MUSTANG xi MSD IGNITION SYSTEM xiii 1 PREPARATION REMOVAL 1 2 CRANKSHAFT PULLEY 1 3 OIL DRAIN 2 4 OIL FEED LINE 2 5 FUEL MANAGEMENT UNIT 3 6 T REX FUEL PUMP High Output and Cobra Systems Only 4 7 MAIN BRACKET ASSEMBLY 7 8 SMOG PUMP HOSES 8 9 RADIATOR HOSE 9 10 ACCESSORY BELT TENSIONER MOUNTING BRACKET 9 11 SUPERCHARGER MOUNTING 10 ...

Page 4: ...without prior written consent of Vortech Engineering LLC NOTICE This Vortech 5 0 supercharger kit was designed for installation and use on Mass Air Flow MAF equipped vehicles The model years include 1988 California and all 1989 1993 models All other years not equipped with MAF systems factory or aftermarket require the installation of a MAP sensor check valve assembly Vortech part number 4FD113 01...

Page 5: ...fications follow the procedures indicated within the factory repair manual and or as indicated on the factory underhood emissions tag Do not use platinum spark plugs unless they are original equipment Change spark plugs every 15 000 miles and spark plug wires at least every 50 000 miles TOOL SUPPLY REQUIREMENT Factory repair manual Timing light 3 8 socket and drive set SAE metric 1 2 socket and dr...

Page 6: ...8 stainless hose clamps 2 7P375 017 3 8 NPT x 1 2 straight hose barb 1 7U030 036 1 2 x 28 oil drain hose 1 1986 1993 Mustang Part No 4FA218 010 PARTS LIST Part Number Description Quantity 4FA110 011 SPRING TENSIONER 1 MOUNTING assembly 4FA010 011 Tensioner mounting bracket 1 7A375 100 3 8 16 x 1 bolts 2 7J375 044 3 8 SAE washers 3 7F375 016 3 8 16 nut 1 7A500 350 1 2 13 x 3 1 2 carriage bolt 1 7F5...

Page 7: ...e 1 7P250 122 1 4 tee 1 7P250 075 45 elbow 1 7P250 082 90 flare 1 Part Number Description Quantity 4FA130 036 Oil drain assembly 1 7R001 008 8 stainless hose clamps 2 7P375 017 3 8 NPT x 1 2 straight hose barb 1 7U030 036 1 2 x 28 oil drain hose 1 4FA139 096 PCV Bypass kit 1 8H040 020 3 8 inline filter 1 7U375 052 3 8 vacuum cap 1 7U030 056 3 8 x 22 fuel hose 1 4FA114 023 Radiator hose assembly 1 ...

Page 8: ...ipple 1 7P250 122 1 4 tee 1 7P250 075 45 elbow 1 7P250 082 90 flare 1 Part Number Description Quantity 4FA130 036 Oil drain assembly 1 7R001 008 8 stainless hose clamps 2 7P375 017 3 8 NPT x 1 2 straight hose barb 1 7U030 036 1 2 x 28 oil drain hose 1 4FA139 096 PCV Bypass kit 1 8H040 020 3 8 inline filter 1 7U375 052 3 8 vacuum cap 1 7U030 056 3 8 x 22 fuel hose 1 4FA114 023 Radiator hose assembl...

Page 9: ...ion Quantity 4FA139 096 PCV Bypass kit 1 8H040 020 3 8 inline filter 1 7U375 052 3 8 vacuum cap 1 7U030 056 3 8 x 22 fuel hose 1 4FA114 023 Radiator hose assembly 1 4FA014 011 Radiator pipe 1 7R002 024 24 hose clamps 2 5A101 001 Stand alone assembly 1 7P156 082 5 32 Tee 1 5A002 002 Ford EFI wiring harness 1 5A001 001 Stand alone ignition retard 1 7U030 046 5 32 x 24 vacuum line 1 4FA112 030 Discha...

Page 10: ...s 2 7P125 027 1 8 straight fitting 1 7P125 103 1 8 NPT 4 x 45 male elbow 1 7U030 026 1 4 x 25 oil feed hose 1 7P250 121 3 nipple 1 7P250 122 1 4 tee 1 7P250 075 45 elbow 1 7P250 082 90 flare 1 4FA130 036 Oil drain assembly 1 7R001 008 8 stainless hose clamps 2 7P375 017 3 8 NPT x 1 2 straight hose barb 1 7U030 036 1 2 x 28 oil drain hose 1 4FA112 070 AIR INLET ASSEMBLY 1 4FA112 060 4 inlet duct wi...

Page 11: ...barb 1 7R001 008 8 stnls hose clamp 2 4FA114 011 RADIATOR HOSE assembly 1 4FA014 011 Radiator pipe polished 1 7R002 024 24 goldseal hose clamp 2 Part Number Description Quantity 4FA112 090DISCH ASSY S H O V 7 KIT SATIN 1 4FA012 041 Discharge tube race 1 7S300 200 3 x 2 sleeve 1 7S325 200 3 25 x 2 sleeve 1 7R002 052 52 goldseal hose clamp 2 7R002 048 48 goldseal hose clamp 2 8D204 001 MaxFlow race ...

Page 12: ...4FA016 170 Idler pulley wide 1 8H140 000 FENDER MOUNT MAF KIT 86 93 1 8H040 030 Air filter 3 1 2 CYL 1 7S350 300 3 1 2 x 3 sleeve 1 7S350 200 3 1 2 x 2 sleeve 1 4FA012 012 Intake elbow 90 2 7R002 056 56 goldseal hose clp 4 7C060 016 M6 x 1 00 x 16 HXHD 3 7J006 093 6mm washer plated 3 5W001 007 3 16 heat shrink tube 666 5W018 020 18GA strd wire blk 1 5W018 010 18GA strd wire red 1 5W018 060 18GA st...

Page 13: ...mitted by law the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied including any implied warranty of merchantability or fitness In no event shall Autotronic Controls Corporation and or Vortech Engineering Inc be liable for labor charges special or consequential damages When returning this unit for service proof of purchase must be supplied ...

Page 14: ...ny paint that would insulate the end of the ground wire from the grounding point on the vehicle F Drain approximately one gallon of coolant Remove upper radiator hose and set aside G Remove the crankcase vent tube from between oil filter and throttle body H Remove belt tensioner assembly I Unplug wire connections and remove alternator assembly make sure the battery is disconnected J Remove brace f...

Page 15: ...he filter 4 OIL FEED LINE Engine oil fed kits only V3 kits skip ahead to section 5 A Remove the oil pressure sender and mounting boss fitting from the engine These are found on the engine s left side just ahead of the oil filter B Threadthesupplied3 x1 4 NPTnippleintothe blockusingengineoilonthethreads Pipetape pasteorothersealantisnotrecommendedasit mightloosenandcauseblockageoftheoilfeed orofice...

Page 16: ...e90 fittingonthe side of the FMU to the return line coming from the fuel rail regulator as shown in Fig 5 b E Connect the unit s return hose that connects to the center fitting to the stock return hose F Secure the fuel lines away from the exhaust header with the tie wraps provided G Connect the top fitting on the FMU to the multi branch fitting located on the driver s side firewall using the supp...

Page 17: ...heoriginalrubberfuellinerunning from the tank to the fuel filter Remove the 90 plastic fitting from the feed hose and set aside F Attach one end of the supplied fuel line with connections to the fuel tank pickup see below Route the hose around to the front of the tank in the factory manner G Place the Vortech supplied fuel adapter fitting located in the T Rex pump inlet hose into the new feed line...

Page 18: ...wn in template N From relay terminal 85 tap the yellow wire into the stock fuel harness in trunk near the right tail light Tie into red purple wire with a scotch lock On some model years wire may be brownish green O Connect the short red wire to the terminal at the fuel pump relay terminal 87 P Connect the longer black wire from the terminal at the fuel pump to a clean ground Q Connect the short b...

Page 19: ...NNECTED AS PER RELAY SCHEMATIC PROVIDE A GOOD GROUND CONNECTION FOR BOTH THE PUMP AND RELAY THAT IS FREE OF RUST OR PAINT T REXª FUEL PUMP GROUND FUSE BOX AT CIGAR LIGHTER TAP FUSED SIDE RED PURPLE 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 RELAY WIRING SCHEMATIC SECURE WIRES WITH ADH...

Page 20: ... idea is to sandwich the alternator and smog pump between the mounting bracket and plate Place washers and nutsonthe6 1 4 boltsandfingertighten For vehicles equipped with alternators having larger 7 16 pivot bolts it will be necessary to enlarge the corresponding hole in the plate D Start the 3 8 16 x 1 fastener with a washer at the top of the bracket and finger tighten Insert the 6 1 2 and 7 bolt...

Page 21: ...e smog pump and alternator with the 3 8 16 x 1 bolts On 1992 and later Mustangs it may be necessary to drill and tap the blanked hole in the smog pump To accomplish this use an R size bit and a 3 8 16 size tap F Tighten all fasteners in the bracket accessory assembly G Lower the entire assembly into position and start all four fasteners that hold it to the engine Tighten all fasteners in a progres...

Page 22: ...he edge of the flange on the A C mounting bracket to provide room for the tensioner mounting bracket D Install the tensioner mounting bracket with tensioner between the supercharger mountingplateandA Cbracketstudusing two standard flat washers as a spacer Secure with two 3 8 16 x 1 bolts and washers and a 3 8 16 nut E Reinstallradiatorshroudandfanassembly Slight shroud trimming may be required on ...

Page 23: ... inner fender just behind the right headlight Use it as a template to mark and drill two 3 32 holes Do not install the cover at this time B Insert the mass air flow MAF sensor into the back of the air filter cover Place the air filter with clamp from the inside over the protruding MAF and the air filter flange Rotate the MAF so that the connector runs parallel to the top as shown Tighten the clamp...

Page 24: ...bowontothesuperchargerinletusing the supplied silicone sleeve and 64 clamps 3 Route the supplied 3 8 blowby hose from the valve cover to the supercharger inlet elbow fitting and trim if necessary Note The engine valve cover vent MUST be properly baffled or else the supercharger may pull in oil from the engine 4 Cut out the Vortech provided template Using the template mark and drill the hole patter...

Page 25: ...raphic at right D Route the Ignition Boost Control wires through the firewall from the interior side Mount the knob in an easily accessible place E Connect the wires to the plastic oval wiring connector on the Ignition Boost Control unit using the snap on connector supplied in the Ignition Boost Control kit NOTE The wiring to the boost control knob can be matched to either of the corresponding wir...

Page 26: ...gear for testing in a safe area or road Adjust the retard according to changes in altitude and fuel quality CAUTION It is extremely important that the boost retard never be turned to 0 It is recom mended that in stock street applications the knob be positioned at 1 per lb to start Fig 15 a 15 Ignition BOOST CONTROL Unit OperAtion high output and Cobra Systems only Fig 14 b BOOST RETARD 0 1 2 3 SUP...

Page 27: ...ve been accidentally moved into harm s way H 1986 93 S H O V 7 AND RENEGADE 5 0L KIT ONLY Fig 16 a 16 VORTECH BYPASS VALVE H O and Cobra Systems Only Skip to step H for S H O V 7 and Renegade applications 1 Mount the supplied bypass valve to the aluminum discharge tube using the gasket and hardware 2 Connect the supplied 1 3 4 or 2 diameter silicone sleeve to the outlet of the bypass valve 3 Mount...

Page 28: ... days of purchasing your supercharger system to qualify Renegade systems are designed for racingandcomewithastandard6month warranty WARNING Do not attempt to operate the vehicle until all components are installed and all operations are completed including the final check 15 For internally lubricated V3 units only This supercharger has been factory pre filled with special Vortech synthetic lubrican...

Page 29: ...neering Inc All Rights Reserved Intl Copr Secured 25MAR08 v4 0 86 93 5 0 Mus 4FA v4 0 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 ...

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Ford Mustang 1986, Installation Instructions Manual

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