Ford - Focus - Parts Catalogue - 2000 - 2003

2.0L F O RD FO Supe C Insta rcharge US r Sys llatio te n m Instru ction s 2000 -2 2002 003 ZX3 M -2003 o SVT M del Years 50 Sta odel te Sm og Leg Years al Per C ARB E .O. #D -213-2 0 ® ENGINEERING, LLC 1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226 Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST) DP/N: 4FJ020-010 - v3.0 04/19/04 FOREWORD This manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for the Ford Focus. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0226, 7:00am-3:30pm PST. An understanding of the information contained herein will help novices, as well as experienced technicians, to correctly install and receive the greatest possible benefit from their Vortech supercharger. When reference is made in this manual to a brand name, number, specific tool or technique, an equivalent product may be used in place of the item mentioned. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. All rights reserved to make changes at any time without notice. © 2004 VORTECH ENGINEERING, LLC All rights reserved. No part of this publication may be reproduced, transmitted, transcrived, or translated into another language in any form, by any means without written permission of Vortech Engineering. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) ii TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii 1. PREPARATION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2. SUPERCHARGER OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3. SUPERCHARGER OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 4. CROSSOVER COOLANT LINE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .3 5. POWER STEERING RELOCATION/SECONDARY PLATE INSTALLATION . . . . . .4 6. POWER STEERING LINE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 7. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . .6 9. AIR INLET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 10. SVT DSI BOX RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 11. STANDARD DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 12. CHARGE COOLED DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .14 13. WATER TANK AND WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .15 14. HEAT EXCHANGER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 15. WATER LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 16. BATTERY RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 17. REFLASH ECM (SVT ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 18. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 iii P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) NOTICE This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry, and engineering features shown in this product are the exclusive property of Vortech Engineering, LLC. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, LLC. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) iv FORD 2.0 FOCUS ZX3 IMPORTANT NOTES This kit requires ECM modification and the installation of a Vortech 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 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” (sending 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 ECM Module comes with a twelve month limited warranty from the original date of purchase of your supercharger system (see Owner’s Manual for details). SVT Owner’s NOTE: The SVT Focus ECM does not use an ECM module as the ZX3 model does. A handheld ECM programmer has been included in the kit box. Vortech Engineering is not responsible for engine or ECM damage due to an improperly installed/mis-handled ECM module or ECM v P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 2000 - 2003 Ford 2.0L Focus ZX3 2002 - 2003 Ford 2.0L Focus SVT Installation Instructions Congratulations on selecting the best performing and best backed automotive supercharger available today... the VORTECH® supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner’s Manual (Race Owner’s Manual for the Focus kit) which includes the Limited Warranty Program, the Warranty Registration form and return envelope. Vortech supercharger systems are performance improving devices. In most cases, increases in horsepower between 35-50% 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 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 oil and filter at least every 3,000 miles. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result. 6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every 15,000 miles and spark plug wires at least every 50,000 miles. TOOL & SUPPLY REQUIREMENT • • • • • • • • • • • • • • • • • • • • • • • Factory repair manual 3/8" socket and drive set: SAE & metric 1/2" socket and drive set: SAE & metric 3/8" Extension 3" 1/2 Extension 3" 3/8" NPT Tap and Handle Adjustable Wrench Open End wrenches: 5/16", 3/8", 7/16", 1/2", 9/16", 5/8", 11/16", 3/4" 10mm, 13-18mm 3 lb hammer 1-1/16" Oil Sending Unit Socket (Snap-On® #A119A) 6 Quarts SH/CF Rated Quality Engine Oil Oil Filter and Wrench Flat #2 Screwdriver Phillips #2 Screwdriver Heavy Grease Silicone Sealer Drill Motor “R”, 1/8", 3/16", 11/32" Drill Bits 3/16", 8mm Allen Wrenches Wire Strippers and Crimpers Utility Knife Blue Loctite Cut-off wheel/hacksaw P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) vi 2002-2003 SVT Ford Focus Part No. 4FJ218-010 ® PARTS LIST ENGINEERING, LLC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. 2E428-010 2A036-262 4FJ111-021 4FJ010-034 4FJ017-021 2A017-878-07 2A017-078-06 7C010-130 7J010-002 7A375-276 7K375-040 7C012-025 7J012-092 7A375-251 4FJ111-041 4FJ010-011 7U250-020 7C080-040 7K312-001 7A312-073 1210517 4FJ017-011 2C017-002 7A437-150 4FJ010-021 7A375-102 7R007-001 7R002-012 7U038-000 7P375-075 7R003-013 7E010-049 7U100-055 4FJ130-036 7P375-008 7U030-036 7S625-000 7R001-006 7P375-041 7P375-017 4FJ130-026 7PP250-034 7P250-031 7U250-090-260 7P125-004 4FJ112-010 4FJ012-010 7P375-106 7S350-200 7R002-056 7P375-039 7P750-100 8D001-001 7R002-016 7R002-048 4FJ010-050 7U133-100 7U034-016 7U030-046 7U035-002 7A250-075 7F250-021 7J250-001 8H040-040 5W014-030 5W001-013 5W001-007 7U033-000 7P625-016 7R001-008 7P156-082 Description Qty. S/C, V5F SQ FOCUS SAT 1 S/C PULLEY 2.62" 6-GROOVE 1 S/C MTG BRKT ASSY, FOCUS 1 MOUNTING PLATE, SUPERCHARGER 1 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 SPACER, .875 OD x 3.560 LONG 2 SPACER, .875 OD x 1.809 LONG 2 M10 x 1.50 x 130 HEXHEAD 3 10mm WASHER, ZINC PLATED 3 3/8"-16 x 2-3/4" HXHD ZINC 1 3/8" AN960 FLAT WASHER PLATED 1 M12 x 1.75 x 25mm HXHD PLTD 1 12mm WASHER, FLAT 1 3/8"-16 x 2-1/2" FLAT SHCS 1 P/S RELOCATION ASSY, FOCUS 1 BRACKET, P/STEERING RELOCATION 1 11mm DOWEL, LONG 2 M8 x 1.25 x 40mm SHCS 4 5/16" AN WASHER, PLATED 4 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 ASY, IDLER PULLEY, SMOOTH 2 SPACER, IDLER PULLEY 2 PILOT, 6203/5 BRG, 7/16 SCREW 2 7/16"-14 x 1-1/2" HXHD GR8 2 MTG PLATE, BEARING HOUSING 1 3/8"-16.x 1" FLT ALLN ZNPLT 3 NYLON RATCHET CLAMP 1-1/8" 2 #12 SAE TYPE F SS HOSE CLAMP 1 3/4" HEATER HOSE 0.54' 3/4" HOSE BARB UNION, BRASS 1 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 TIE WRAP, 7.5" NYLON 6 OIL DRAIN ASSY, FOCUS 1 ELBOW, PLASTIC 3/8" x 90 UNION 1 1/2" OIL DRAIN HOSE 1.41' SHEATH, MYLAR, .625 ID 1 #6 STNLS HOSE CLAMP, NARROW 2 3/8" NPT HEX NIPPLE x 1.5" 1 3/8" NPT x 1/2" BEADED HSE BRB 1 OIL FEED ASSY, FOCUS 1 FITTING, STREET TEE MOD 1 1/4" NPT x -4JIC FLARE FTG STL 1 OIL FEED HOSE, 26" -4 x 90° 1 1/8" NPT 90° x -4 JIC FTG STL 1 AIR INLET ASSY, FOCUS 1 INTAKE ELBOW, FOCUS° 1 PCV VALVE, FORD, 3/8" HOSE 1 3-1/2" x 2" SLEEVE 1 #56 SAE TYPE F SS HOSE CLAMP 2 3/8" NPT x 5/8" BARB CLAMP 90° 1 3/4" NPT x 1" HOSE FITTING 1 STD COMPRESS BYPASS VALVE 1 #16 SAE TYPE F SS HOSE CLAMP 4 #48 SAE TYPE F SS HOSE CLAMP 2 MAF BRKT, FOCUS 1 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 1" GS HEATER HOSE 0.66' 5/32" VACUUM LINE 2.50' 3" FLEX HOSE 1.083' 1/4"-20 x 3/4" SHCS PLTD 2 1/4"-20 NYLOCK NUT ZINC PLTD 2 1/4" WASHER, SAE, PLTD 4 AIR FILTER, 3.5" FLG x 5.5L 1 14GA STRD WIRE BLACK 9' 14-16AWG, SOLDERLESS CONNECTOR 12 3/16" HEAT-SHRINK TUBING 1.5' 5/8" PCV HOSE 3.25' 5/8" HOSE UNION, BARBED ENDS 1 #8 STNLS HOSE CLAMP 1 5/32" TEE 1 Part Number 4FJ212-040 4FJ112-040 9ST100-049 7S275-251 7R002-044 7R002-040 7S275-092 5A102-014 4FJ111-032 2D030-041 2DO70-159 7U100-084 2D070-281 7U250-125 7J375-020 2D070-260 2D160-215 2D030-061 7A312-525 7B375-110 7U100-070 7U312-101 2A040-011 7A312-100 7K375-040 7X100-025 2A046-101 008110 008444 008120 08440 008441 008516 008544 008543 008130 8F060-042 4FJ245-050 4FJ145-050 7P250-130 7P250-132 7P250-011 7P375-120 4FJ210-060 4FJ110-060 2A017-875-08 2A017-879-06 7A375-151 7J375-044 7F375-017 5W001-028 5W008-100 5W001-035 5W001-053 5W008-105 5W001-008 5A003-031 vii Description DISCHARGE ASSY, SVT STD FOCUS DISCH TUBE ASSY, FOCUS SVT STD Ø1" 18GA MILD STEEL TUBE REDUCER, 2.75" TO 2.50" #44 SAE TYPE F SS HOSE CLAMP #40 SAE TYPE F SS HOSE CLAMP ELBOW, 2.75" x 90° SILICONE IAT SENSOR ASSY S/C DRIVE ASSY, FOCUS BRG HSG, EXT DRIVE, MACH GEN2 LARGE BEARING, EXTENDED DRIVE SNAP, RING, EXT DRV HOUSING COUPLING, FLG, 3-PIN DRIVE DOWEL PIN, Ø1.4" x 1.25L WASHER, 1.0 OD, .406 x ID COUPLING, DRIVE, COMPOSITE TUBE HSG ASSY, EXT DRIVE FOCUS HOUSING, COUPLING, EXT DRIVE SH 5/16"-18 x 5.25" HXCS GR8 ZINC 3/8"-24 x 1" GRADE 8 HXHD KEY, 3/16" SQUARE x 7/8" LONG DOWEL BUSHING, .312" x 1.00" PULLEY RETAINER S/C 5/16"-18 x 1" HXCSGR5P 3/8" AN960 FLAT WASHER PLATED WAVE WASHER-LARGE BELT, 4061010 GOODYR FOCUS SMALL SILVER DIE CUT DECAL S/C STRT INFO PKG ASSY VORT SML, BLU DIE CUT DECAL VORT WHITE LG PKGNG ENVELOPE VORT YELLOW WARNTY REG ENVEL VORT STREET S/C OWNERS MAN VORT STRT S/C WARNTY REG FORM VORT WARNTY TERMS/CONDITIONS VORT LICENSE PLATE FRAME, VORTECH FUEL INJECTOR, 42LBS RAIL STYL P/S HOSE INSTALL, ASSY, FOCUS HI-PRESS PWR.STR.HOSE w/ENDS 1/4"NPT MALE TO -6 MALE JIC AL -6 JIC MALE 3/8"NPT x 45° COMPRSSN FTG, 1/4"NPTF x 3/8"T COMPRSSN FTG, 3/8"NPTF x 3/8"T BATT RELOCATION ASSY, FOCUS ASSY, BATT BRKT, FOCUS PLATED SPACER, .875 OD x .290 LONG SPACER, .875 OD x .800 LONG 3/8"-16 x 1.5 HXHD GR8 3/8"SAE WASHER, PLTD 3/8"-16 NYLOCK NUT BATT POST TERMINALS 8GA, RED STRANDED WIRE LUG, 6-2AWG, 3/8" STUD REMOTE BATTERY POST 8GA, BLACK STRANDED WIRE 3/4" HEAT-SHRINK TUBING HANDHELD PROGRAMMER Qty. 1 1 1.37" 1 3 1 1 1 1 1 2 1 2 6 2 1 1 1 4 3 3 2 1 4 1 1 1 2 1 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 8 4 2 6' 4 1 1 1 1 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 2002-2003 SVT H.O. Ford Focus Part No. 4FJ218-020 ® PARTS LIST ENGINEERING, LLC IMPORTANT:: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. 2E428-010 2A036-262 4FJ111-021 4FJ010-034 4FJ017-021 2A017-878-07 2A017-078-06 7C010-130 7J010-002 7A375-276 7K375-040 7C012-025 7J012-092 7A375-251 4FJ111-041 4FJ010-011 7U250-020 7C080-040 7K312-001 7A312-073 1210517 4FJ017-011 2C017-002 7A437-150 4FJ010-021 7A375-102 7R007-001 7R002-012 7U038-000 7P375-075 7R003-013 7E010-049 7U100-055 4FJ130-036 7P375-008 7U030-036 7S625-000 7R001-006 7P375-041 7P375-017 4FJ130-026 7PP250-034 7P250-031 7U250-090-260 7P125-004 4FJ112-010 4FJ012-010 7P375-106 7S350-200 7R002-056 7P375-039 7P750-100 8D001-001 7R002-016 7R002-048 4FJ010-050 7U133-100 7U034-016 7U030-046 7U035-002 7A250-075 7F250-021 7J250-001 8H040-040 5W014-030 5W001-013 5W001-007 7U033-000 7P625-016 7R001-008 7P156-082 Description Qty. S/C, V5F SQ FOCUS SAT 1 S/C PULLEY 2.62" 6-GROOVE 1 S/C MTG BRKT ASSY, FOCUS 1 MOUNTING PLATE, SUPERCHARGER 1 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 SPACER, .875 OD x 3.560 LONG 2 SPACER, .875 OD x 1.809 LONG 2 M10 x 1.50 x 130 HEXHEAD 3 10mm WASHER, ZINC PLATED 3 3/8"-16 x 2-3/4" HXHD ZINC 1 3/8" AN960 FLAT WASHER PLATED 1 M12 x 1.75 x 25mm HXHD PLTD 1 12mm WASHER, FLAT 1 3/8"-16 x 2-1/2" FLAT SHCS 1 P/S RELOCATION ASSY, FOCUS 1 BRACKET, P/STEERING RELOCATION 1 11mm DOWEL, LONG 2 M8 x 1.25 x 40mm SHCS 4 5/16" AN WASHER, PLATED 4 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 ASY, IDLER PULLEY, SMOOTH 2 SPACER, IDLER PULLEY 2 PILOT, 6203/5 BRG, 7/16 SCREW 2 7/16"-14 x 1-1/2" HXHD GR8 2 MTG PLATE, BEARING HOUSING 1 3/8"-16.x 1" FLT ALLN ZNPLT 3 NYLON RATCHET CLAMP 1-1/8" 2 #12 SAE TYPE F SS HOSE CLAMP 1 3/4" HEATER HOSE 0.54' 3/4" HOSE BARB UNION, BRASS 1 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 TIE WRAP, 7.5" NYLON 6 OIL DRAIN ASSY, FOCUS 1 ELBOW, PLASTIC 3/8" x 90 UNION 1 1/2" OIL DRAIN HOSE 1.41' SHEATH, MYLAR, .625 ID 1 #6 STNLS HOSE CLAMP, NARROW 2 3/8" NPT HEX NIPPLE x 1.5" 1 3/8" NPT x 1/2" BEADED HSE BRB 1 OIL FEED ASSY, FOCUS 1 FITTING, STREET TEE MOD 1 1/4" NPT x -4JIC FLARE FTG STL 1 OIL FEED HOSE, 26" -4 x 90° 1 1/8" NPT 90° x -4 JIC FTG STL 1 AIR INLET ASSY, FOCUS 1 INTAKE ELBOW, FOCUS° 1 PCV VALVE, FORD, 3/8" HOSE 1 3-1/2" x 2" SLEEVE 1 #56 SAE TYPE F SS HOSE CLAMP 2 3/8" NPT x 5/8" BARB CLAMP 90° 1 3/4" NPT x 1" HOSE FITTING 1 STD COMPRESS BYPASS VALVE 1 #16 SAE TYPE F SS HOSE CLAMP 4 #48 SAE TYPE F SS HOSE CLAMP 2 MAF BRKT, FOCUS 1 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 1" GS HEATER HOSE 0.66' 5/32" VACUUM LINE 2.50' 3" FLEX HOSE 1.083' 1/4"-20 x 3/4" SHCS PLTD 2 1/4"-20 NYLOCK NUT ZINC PLTD 2 1/4" WASHER, SAE, PLTD 4 AIR FILTER, 3.5" FLG x 5.5L 1 14GA STRD WIRE BLACK 9' 14-16AWG, SOLDERLESS CONNECTOR 12 3/16" HEAT-SHRINK TUBING 1.5' 5/8" PCV HOSE 3.25' 5/8" HOSE UNION, BARBED ENDS 1 #8 STNLS HOSE CLAMP 1 5/32" TEE 1 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) Part Number 4FJ111-032 2D030-041 2DO70-159 7U100-084 2D070-281 7U250-125 7J375-020 2D070-260 2D160-215 2D030-061 7A312-525 7B375-110 7U100-070 7U312-101 2A040-011 7A312-100 7K375-040 7X100-025 2A046-101 008110 008444 008120 08440 008441 008516 008544 008543 008130 8F060-042 4FJ245-050 4FJ145-050 7P250-130 7P250-132 7P250-011 7P375-120 4FJ210-060 4FJ110-060 2A017-875-08 2A017-879-06 7A375-151 7J375-044 7F375-017 5W001-028 5W008-100 5W001-035 5W001-053 5W008-105 5W001-008 5A003-031 8N106-005 viii Description S/C DRIVE ASSY, FOCUS BRG HSG, EXT DRIVE, MACH GEN2 LARGE BEARING, EXTENDED DRIVE SNAP, RING, EXT DRV HOUSING COUPLING, FLG, 3-PIN DRIVE DOWEL PIN, Ø1.4" x 1.25L WASHER, 1.0 OD, .406 x ID COUPLING, DRIVE, COMPOSITE TUBE HSG ASSY, EXT DRIVE FOCUS HOUSING, COUPLING, EXT DRIVE SH 5/16"-18 x 5.25" HXCS GR8 ZINC 3/8"-24 x 1" GRADE 8 HXHD KEY, 3/16" SQUARE x 7/8" LONG DOWEL BUSHING, .312" x 1.00" PULLEY RETAINER S/C 5/16"-18 x 1" HXCSGR5P 3/8" AN960 FLAT WASHER PLATED WAVE WASHER-LARGE BELT, 4061010 GOODYR FOCUS SMALL SILVER DIE CUT DECAL S/C STRT INFO PKG ASSY VORT SML, BLU DIE CUT DECAL VORT WHITE LG PKGNG ENVELOPE VORT YELLOW WARNTY REG ENVEL VORT STREET S/C OWNERS MAN VORT STRT S/C WARNTY REG FORM VORT WARNTY TERMS/CONDITIONS VORT LICENSE PLATE FRAME, VORTECH FUEL INJECTOR, 42LBS RAIL STYL P/S HOSE INSTALL, ASSY, FOCUS HI-PRESS PWR.STR.HOSE w/ENDS 1/4"NPT MALE TO -6 MALE JIC AL -6 JIC MALE 3/8"NPT x 45° COMPRSSN FTG, 1/4"NPTF x 3/8"T COMPRSSN FTG, 3/8"NPTF x 3/8"T BATT RELOCATION ASSY, FOCUS ASSY, BATT BRKT, FOCUS PLATED SPACER, .875 OD x .290 LONG SPACER, .875 OD x .800 LONG 3/8"-16 x 1.5 HXHD GR8 3/8"SAE WASHER, PLTD 3/8"-16 NYLOCK NUT BATT POST TERMINALS 8GA, RED STRANDED WIRE LUG, 6-2AWG, 3/8" STUD REMOTE BATTERY POST 8GA, BLACK STRANDED WIRE 3/4" HEAT-SHRINK TUBING HANDHELD PROGRAMMER ASSY, SETRAB, FOCUS Qty. 1 1 2 1 2 6 2 1 1 1 4 3 3 2 1 4 1 1 1 2 1 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 8 4 2 6' 4 1 1 1 1 1 2002-2003 SVT H.O. Ford Focus Part No. 4FJ218-020 ® PARTS LIST ENGINEERING, LLC IMPORTANT:: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. 8N105-100 7E010-049 7J010-001 7R007-001 7U038-000 7U038-012 7P375-075 7U100-055 8N055-030 4GR010-060 7P500-026 7A250-050 7J250-001 7R003-027 7P100-122 7P125-016 8N107-100 8F001-402 8F101-320 5W001-005 5W001-010 5W001-009 5W001-043 5W001-024 5W001-014 5W001-015 7U100-044 7U100-055 5W001-019 8N401-030 8N055-050 7P500-026 8N301-210 7S275-092 7S275-251 7R002-044 7R002-040 0008341 5A102-014 Description WATER TANK / HOSE ASSY, FOCUS #10X3/4 HEX HD SLF DRL SHT MTL #10 FLAT WASHER NYLON RATCHET CLAMP 1-1/8" 3/4" HEATER HOSE HOSE,3/4"DIA 90°,4X12 LEGS 3/4" HOSE BARB UNION, BRASS TIE WRAP, 7.5" NYLON TANK, WATER, TRIANGLE SHAPE BRKT, WATER RES, C5 CORVETTE 1/2NPT X 3/4 BARB 90° BRASS 1/4-20 X .50 SHCS ZINC PLTD 1/4 WASHER, SAE, PLTD ADEL CLAMP,1-11/16" 1" NPT VENT PLUG 1/8 NPT PLUG WATER PUMP / WIRING ASSY, FOCU PUMP, WATER, PIERBURG FUEL PUMP RELAY ASSY, LS1 TRK 3/8" PLASTIC WIRE LOOM 16-14GA FEMALE SLIDE INSULATED 16-14GA MALE SLIDE INSULATED 12-10GA X 1/4" RING TERMINAL MINI ATC FUSE TAP FUSE HOLDER 10 GA WIRE FUSE, BLADE TYPE 20 AMP TIE WRAP, 4" NYLON TIE WRAP, 7.5" NYLON 10-12 GA BUTT CONN INSULATED FOCUS SVT COOLR CORE/DISCH ASY PLASTIC CAP, SURGE TANK 1/2NPT X 3/4 BARB 90° BRASS WELDED CORE ASSY, SVT FOCUS ELBOW, 2.75 X 90° SILICONE REDUCER, 2.75 TO 2.50 #44 SAE TYPE F SS HOSE CLAMP #40 SAE TYPE F SS HOSE CLAMP VORTECH CHARGE COOLER DECAL IAT SENSOR ASSY Qty. Part Number Description Qty. 1 4 4 9 13 1 1 6 1 1 2 4 4 1 1 1 1 1 1 6' 3 2 2 1 1 1 6 6 1 1 1 2 1 1 1 4 1 1 1 ix P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 2000-2003 ZX3 Ford Focus Part No. 4FJ218-030 ® PARTS LIST ENGINEERING, LLC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. 2E248-010 2A036-287 4FJ111-021 4FJ010-034 4FJ017-021 2A017-878-07 2A017-078-06 7C010-130 7J010-002 7A375-276 7K375-040 7C012-025 7J012-092 7A375-251 4FJ111-041 4FJ010-011 7U250-020 7C080-040 7K312-001 7A312-073 1210517 4FJ017-011 2C017-002 7A437-150 4FJ010-021 7A375-102 7R007-001 7R002-012 7U038-000 7P375-075 7R003-013 7E010-049 7U100-055 4FJ130-036 7P375-008 7U030-036 7S625-000 7R001-006 7P375-041 7P375-017 4FJ130-026 7PP250-034 7P250-031 7U250-090-260 7P125-004 4FJ112-010 4FJ012-010 7P375-106 7S350-200 7R002-056 7P375-039 7P750-100 8D001-001 7R002-016 7R002-048 4FJ010-050 7U133-100 7U034-016 7U030-046 7U035-002 7A250-075 7F250-021 7J250-001 8H040-040 5W014-030 5W001-013 5W001-007 7U033-000 7P625-016 7R001-008 7P156-082 Description Qty. S/C, V5F SQ FOCUS SAT 1 S/C PULLEY 2.87" 6-GROOVE 1 S/C MTG BRKT ASSY, FOCUS 1 MOUNTING PLATE, SUPERCHARGER 1 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 SPACER, .875 OD x 3.560 LONG 2 SPACER, .875 OD x 1.809 LONG 2 M10 x 1.50 x 130 HEXHEAD 3 10mm WASHER, ZINC PLATED 3 3/8"-16 x 2-3/4" HXHD ZINC 1 3/8" AN960 FLAT WASHER PLATED 1 M12 x 1.75 x 25mm HXHD PLTD 1 12mm WASHER, FLAT 1 3/8"-16 x 2-1/2" FLAT SHCS 1 P/S RELOCATION ASSY, FOCUS 1 BRACKET, P/STEERING RELOCATION 1 11mm DOWEL, LONG 2 M8 x 1.25 x 40mm SHCS 4 5/16" AN WASHER, PLATED 4 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 ASY, IDLER PULLEY, SMOOTH 2 SPACER, IDLER PULLEY 2 PILOT, 6203/5 BRG, 7/16 SCREW 2 7/16"-14 x 1-1/2" HXHD GR8 2 MTG PLATE, BEARING HOUSING 1 3/8"-16.x 1" FLT ALLN ZNPLT 3 NYLON RATCHET CLAMP 1-1/8" 2 #12 SAE TYPE F SS HOSE CLAMP 1 3/4" HEATER HOSE 0.54' 3/4" HOSE BARB UNION, BRASS 1 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 TIE WRAP, 7.5" NYLON 6 OIL DRAIN ASSY, FOCUS 1 ELBOW, PLASTIC 3/8" x 90 UNION 1 1/2" OIL DRAIN HOSE 1.41' SHEATH, MYLAR, .625 ID 1 #6 STNLS HOSE CLAMP, NARROW 2 3/8" NPT HEX NIPPLE x 1.5" 1 3/8" NPT x 1/2" BEADED HSE BRB 1 OIL FEED ASSY, FOCUS 1 FITTING, STREET TEE MOD 1 1/4" NPT x -4JIC FLARE FTG STL 1 OIL FEED HOSE, 26" -4 x 90° 1 1/8" NPT 90° x -4 JIC FTG STL 1 AIR INLET ASSY, FOCUS 1 INTAKE ELBOW, FOCUS° 1 PCV VALVE, FORD, 3/8" HOSE 1 3-1/2" x 2" SLEEVE 1 #56 SAE TYPE F SS HOSE CLAMP 2 3/8" NPT x 5/8" BARB CLAMP 90° 1 3/4" NPT x 1" HOSE FITTING 1 STD COMPRESS BYPASS VALVE 1 #16 SAE TYPE F SS HOSE CLAMP 4 #48 SAE TYPE F SS HOSE CLAMP 2 MAF BRKT, FOCUS 1 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 1" GS HEATER HOSE 0.66' 5/32" VACUUM LINE 2.50' 3" FLEX HOSE 1.083' 1/4"-20 x 3/4" SHCS PLTD 2 1/4"-20 NYLOCK NUT ZINC PLTD 2 1/4" WASHER, SAE, PLTD 4 AIR FILTER, 3.5" FLG x 5.5L 1 14GA STRD WIRE BLACK 9' 14-16AWG, SOLDERLESS CONNECTOR 12 3/16" HEAT-SHRINK TUBING 1.5' 5/8" PCV HOSE 3.25' 5/8" HOSE UNION, BARBED ENDS 1 #8 STNLS HOSE CLAMP 1 5/32" TEE 1 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) Part Number 4FJ212-030 4FJ111-032 2D030-041 2DO70-159 7U100-084 2D070-281 7U250-125 7J375-020 2D070-260 2D160-215 2D030-061 7A312-525 7B375-110 7U100-070 7U312-101 2A040-011 7A312-100 7K375-040 7X100-025 2A046-101 008110 008444 008120 08440 008441 008516 008544 008543 008130 8F060-042 4FJ245-050 4FJ145-050 7P250-130 7P250-132 7P250-011 7P375-120 4FJ210-060 4FJ110-060 2A017-875-08 2A017-879-06 7A375-151 7J375-044 7F375-017 5W001-028 5W008-100 5W001-035 5W001-053 5W008-105 5W001-008 4FJ120-020 x Description DISCHARGE ASSY S/C DRIVE ASSY, FOCUS BRG HSG, EXT DRIVE, MACH GEN2 LARGE BEARING, EXTENDED DRIVE SNAP, RING, EXT DRV HOUSING COUPLING, FLG, 3-PIN DRIVE DOWEL PIN, Ø1.4" x 1.25L WASHER, 1.0 OD, .406 x ID COUPLING, DRIVE, COMPOSITE TUBE HSG ASSY, EXT DRIVE FOCUS HOUSING, COUPLING, EXT DRIVE SH 5/16"-18 x 5.25" HXCS GR8 ZINC 3/8"-24 x 1" GRADE 8 HXHD KEY, 3/16" SQUARE x 7/8" LONG DOWEL BUSHING, .312" x 1.00" PULLEY RETAINER S/C 5/16"-18 x 1" HXCSGR5P 3/8" AN960 FLAT WASHER PLATED WAVE WASHER-LARGE BELT, 4061010 GOODYR FOCUS SMALL SILVER DIE CUT DECAL S/C STRT INFO PKG ASSY VORT SML, BLU DIE CUT DECAL VORT WHITE LG PKGNG ENVELOPE VORT YELLOW WARNTY REG ENVEL VORT STREET S/C OWNERS MAN VORT STRT S/C WARNTY REG FORM VORT WARNTY TERMS/CONDITIONS VORT LICENSE PLATE FRAME, VORTECH FUEL INJECTOR, 42LBS RAIL STYL P/S HOSE INSTALL, ASSY, FOCUS HI-PRESS PWR.STR.HOSE w/ENDS 1/4"NPT MALE TO -6 MALE JIC AL -6 JIC MALE 3/8"NPT x 45° COMPRSSN FTG, 1/4"NPTF x 3/8"T COMPRSSN FTG, 3/8"NPTF x 3/8"T BATT RELOCATION ASSY, FOCUS ASSY, BATT BRKT, FOCUS PLATED SPACER, .875 OD x .290 LONG SPACER, .875 OD x .800 LONG 3/8"-16 x 1.5 HXHD GR8 3/8"SAE WASHER, PLTD 3/8"-16 NYLOCK NUT BATT POST TERMINALS 8GA, RED STRANDED WIRE LUG, 6-2AWG, 3/8" STUD REMOTE BATTERY POST 8GA, BLACK STRANDED WIRE 3/4" HEAT-SHRINK TUBING ECM CHIP PKG/SHIP ASSY AUTOL Qty. 1 1 1 2 1 2 6 2 1 1 1 4 3 3 2 1 4 1 1 1 2 1 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 8 4 2 6' 4 1 1 1 1 2000-2003 ZX3 H.O. Ford Focus Part No. 4FA218-040 ® PARTS LIST ENGINEERING, LLC IMPORTANT:: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. 2E428-010 2A036-262 4FJ111-021 4FJ010-034 4FJ017-021 2A017-878-07 2A017-078-06 7C010-130 7J010-002 7A375-276 7K375-040 7C012-025 7J012-092 7A375-251 4FJ111-041 4FJ010-011 7U250-020 7C080-040 7K312-001 7A312-073 1210517 4FJ017-011 2C017-002 7A437-150 4FJ010-021 7A375-102 7R007-001 7R002-012 7U038-000 7P375-075 7R003-013 7E010-049 7U100-055 4FJ130-036 7P375-008 7U030-036 7S625-000 7R001-006 7P375-041 7P375-017 4FJ130-026 7PP250-034 7P250-031 7U250-090-260 7P125-004 4FJ112-010 4FJ012-010 7P375-106 7S350-200 7R002-056 7P375-039 7P750-100 8D001-001 7R002-016 7R002-048 4FJ010-050 7U133-100 7U034-016 7U030-046 7U035-002 7A250-075 7F250-021 7J250-001 8H040-040 5W014-030 5W001-013 5W001-007 7U033-000 7P625-016 7R001-008 7P156-082 Description Qty. S/C, V5F SQ FOCUS SAT 1 S/C PULLEY 2.62" 6-GROOVE 1 S/C MTG BRKT ASSY, FOCUS 1 MOUNTING PLATE, SUPERCHARGER 1 SPACER, FOCUS S/C PLT, Ø.63 x 3 1 SPACER, .875 OD x 3.560 LONG 2 SPACER, .875 OD x 1.809 LONG 2 M10 x 1.50 x 130 HEXHEAD 3 10mm WASHER, ZINC PLATED 3 3/8"-16 x 2-3/4" HXHD ZINC 1 3/8" AN960 FLAT WASHER PLATED 1 M12 x 1.75 x 25mm HXHD PLTD 1 12mm WASHER, FLAT 1 3/8"-16 x 2-1/2" FLAT SHCS 1 P/S RELOCATION ASSY, FOCUS 1 BRACKET, P/STEERING RELOCATION 1 11mm DOWEL, LONG 2 M8 x 1.25 x 40mm SHCS 4 5/16" AN WASHER, PLATED 4 5/16"-18 x 3/4" FLT HD GR8 ZINC 4 ASY, IDLER PULLEY, SMOOTH 2 SPACER, IDLER PULLEY 2 PILOT, 6203/5 BRG, 7/16 SCREW 2 7/16"-14 x 1-1/2" HXHD GR8 2 MTG PLATE, BEARING HOUSING 1 3/8"-16.x 1" FLT ALLN ZNPLT 3 NYLON RATCHET CLAMP 1-1/8" 2 #12 SAE TYPE F SS HOSE CLAMP 1 3/4" HEATER HOSE 0.54' 3/4" HOSE BARB UNION, BRASS 1 ADEL, CLAMP, 3/4" ID, 1/4" EYE 5 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 TIE WRAP, 7.5" NYLON 6 OIL DRAIN ASSY, FOCUS 1 ELBOW, PLASTIC 3/8" x 90 UNION 1 1/2" OIL DRAIN HOSE 1.41' SHEATH, MYLAR, .625 ID 1 #6 STNLS HOSE CLAMP, NARROW 2 3/8" NPT HEX NIPPLE x 1.5" 1 3/8" NPT x 1/2" BEADED HSE BRB 1 OIL FEED ASSY, FOCUS 1 FITTING, STREET TEE MOD 1 1/4" NPT x -4JIC FLARE FTG STL 1 OIL FEED HOSE, 26" -4 x 90° 1 1/8" NPT 90° x -4 JIC FTG STL 1 AIR INLET ASSY, FOCUS 1 INTAKE ELBOW, FOCUS° 1 PCV VALVE, FORD, 3/8" HOSE 1 3-1/2" x 2" SLEEVE 1 #56 SAE TYPE F SS HOSE CLAMP 2 3/8" NPT x 5/8" BARB CLAMP 90° 1 3/4" NPT x 1" HOSE FITTING 1 STD COMPRESS BYPASS VALVE 1 #16 SAE TYPE F SS HOSE CLAMP 4 #48 SAE TYPE F SS HOSE CLAMP 2 MAF BRKT, FOCUS 1 HOSE, ELMOW, 90°, 1" ID, MOLDED 1 1" GS HEATER HOSE 0.66' 5/32" VACUUM LINE 2.50' 3" FLEX HOSE 1.083' 1/4"-20 x 3/4" SHCS PLTD 2 1/4"-20 NYLOCK NUT ZINC PLTD 2 1/4" WASHER, SAE, PLTD 4 AIR FILTER, 3.5" FLG x 5.5L 1 14GA STRD WIRE BLACK 9' 14-16AWG, SOLDERLESS CONNECTOR 12 3/16" HEAT-SHRINK TUBING 1.5' 5/8" PCV HOSE 3.25' 5/8" HOSE UNION, BARBED ENDS 1 #8 STNLS HOSE CLAMP 1 5/32" TEE 1 Part Number 4FJ111-032 2D030-041 2DO70-159 7U100-084 2D070-281 7U250-125 7J375-020 2D070-260 2D160-215 2D030-061 7A312-525 7B375-110 7U100-070 7U312-101 2A040-011 7A312-100 7K375-040 7X100-025 2A046-101 008110 008444 008120 08440 008441 008516 008544 008543 008130 8F060-042 4FJ245-050 4FJ145-050 7P250-130 7P250-132 7P250-011 7P375-120 4FJ210-060 4FJ110-060 2A017-875-08 2A017-879-06 7A375-151 7J375-044 7F375-017 5W001-028 5W008-100 5W001-035 5W001-053 5W008-105 5W001-008 4FJ120-020 8N106-005 xi Description S/C DRIVE ASSY, FOCUS BRG HSG, EXT DRIVE, MACH GEN2 LARGE BEARING, EXTENDED DRIVE SNAP, RING, EXT DRV HOUSING COUPLING, FLG, 3-PIN DRIVE DOWEL PIN, Ø1.4" x 1.25L WASHER, 1.0 OD, .406 x ID COUPLING, DRIVE, COMPOSITE TUBE HSG ASSY, EXT DRIVE FOCUS HOUSING, COUPLING, EXT DRIVE SH 5/16"-18 x 5.25" HXCS GR8 ZINC 3/8"-24 x 1" GRADE 8 HXHD KEY, 3/16" SQUARE x 7/8" LONG DOWEL BUSHING, .312" x 1.00" PULLEY RETAINER S/C 5/16"-18 x 1" HXCSGR5P 3/8" AN960 FLAT WASHER PLATED WAVE WASHER-LARGE BELT, 4061010 GOODYR FOCUS SMALL SILVER DIE CUT DECAL S/C STRT INFO PKG ASSY VORT SML, BLU DIE CUT DECAL VORT WHITE LG PKGNG ENVELOPE VORT YELLOW WARNTY REG ENVEL VORT STREET S/C OWNERS MAN VORT STRT S/C WARNTY REG FORM VORT WARNTY TERMS/CONDITIONS VORT LICENSE PLATE FRAME, VORTECH FUEL INJECTOR, 42LBS RAIL STYL P/S HOSE INSTALL, ASSY, FOCUS HI-PRESS PWR.STR.HOSE w/ENDS 1/4"NPT MALE TO -6 MALE JIC AL -6 JIC MALE 3/8"NPT x 45° COMPRSSN FTG, 1/4"NPTF x 3/8"T COMPRSSN FTG, 3/8"NPTF x 3/8"T BATT RELOCATION ASSY, FOCUS ASSY, BATT BRKT, FOCUS PLATED SPACER, .875 OD x .290 LONG SPACER, .875 OD x .800 LONG 3/8"-16 x 1.5 HXHD GR8 3/8"SAE WASHER, PLTD 3/8"-16 NYLOCK NUT BATT POST TERMINALS 8GA, RED STRANDED WIRE LUG, 6-2AWG, 3/8" STUD REMOTE BATTERY POST 8GA, BLACK STRANDED WIRE 3/4" HEAT-SHRINK TUBING ECM CHIP PKG/SHIP ASSY AUTOL ASSY, SETRAB, FOCUS Qty. 1 1 2 1 2 6 2 1 1 1 4 3 3 2 1 4 1 1 1 2 1 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 8 4 2 6' 4 1 1 1 1 1 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 2000-2003 ZX3 H.O. Ford Focus Part No. 4FA218-040 ® PARTS LIST ENGINEERING, LLC IMPORTANT:: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. 8N105-100 7E010-049 7J010-001 7R007-001 7U038-000 7U038-012 7P375-075 7U100-055 8N055-030 4GR010-060 7P500-026 7A250-050 7J250-001 7R003-027 7P100-122 7P125-016 8N107-100 8F001-402 8F101-320 5W001-005 5W001-010 5W001-009 5W001-043 5W001-024 5W001-014 5W001-015 7U100-044 7U100-055 5W001-019 8N401-020 8N055-050 7P500-026 8N301-200 4FJ012-020 7S275-251 7S275-200 7R002-044 7R002-040 7R002-052 0.008341 7S325-275 Description Qty. Part Number WATER TANK / HOSE ASSY, FOCUS 1 #10X3/4 HEX HD SLF DRL SHT MTL 4 #10 FLAT WASHER 4 NYLON RATCHET CLAMP 1-1/8" 9 3/4" HEATER HOSE 13 HOSE,3/4"DIA 90°,4X12 LEGS 1 3/4" HOSE BARB UNION, BRASS 1 TIE WRAP, 7.5" NYLON 6 TANK, WATER, TRIANGLE SHAPE 1 BRKT, WATER RES, C5 CORVETTE 1 1/2NPT X 3/4 BARB 90° BRASS 2 1/4-20 X .50 SHCS ZINC PLTD 4 1/4 WASHER, SAE, PLTD 4 ADEL CLAMP,1-11/16" 1 1" NPT VENT PLUG 1 1/8 NPT PLUG 1 WATER PUMP / WIRING ASSY, FOCU 1 PUMP, WATER, PIERBURG 1 FUEL PUMP RELAY ASSY, LS1 TRK 1 3/8" PLASTIC WIRE LOOM 6' 16-14GA FEMALE SLIDE INSULATED 3 16-14GA MALE SLIDE INSULATED 2 12-10GA X 1/4" RING TERMINAL 2 MINI ATC FUSE TAP 1 FUSE HOLDER 10 GA WIRE 1 FUSE, BLADE TYPE 20 AMP 1 TIE WRAP, 4" NYLON 6 TIE WRAP, 7.5" NYLON 6 10-12 GA BUTT CONN INSULATED 1 FOCUS ZX3 COOLR CORE/DISCH ASY 1 PLASTIC CAP, SURGE TANK 1 1/2NPT X 3/4 BARB 90^ BRASS 2 WELDED CORE ASSY, ZX3 FOCUS 1 DUCT, DISCH, ZX3 FOCUS H.O 1 REDUCER, 2.75 TO 2.50 1 SLEEVE,BLUE, 2.75"D X 2.00"L 1 #44 SAE TYPE F SS HOSE CLAMP 4 #40 SAE TYPE F SS HOSE CLAMP 1 #52 SAE TYPE F SS HOSE CLAMP 1 VORTECH CHARGE COOLER DECAL 1 ELBOW, 90° SILICONE 3.25/2.75 1 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) xii Description Qty. 1. PREPARATION/REMOVAL NOTE: - ZX3 Models Only 1. Remove the passenger side front kick panel from the interior of the vehicle. Remove the sound deadening material (if any) that is covering the ECM. Remove the plastic ECM hold-down bracket. 2. Using a 10mm socket or wrench, remove the harness and plug from the ECM (as you loosen the bolt, the connector will slowly release). Remove the ECM from the vehicle. 3. Contact the Vortech Service Department for a Return Authorization Number. Send both ECM and supplied credit tag to Vortech using the enclosed shipping box. A. B. C. D. E. F. G. H. I. J. K. Remove the ducting between the air box and the throttle body. Disconnect the MAF from the ducting and set aside. Remove the air box, fresh air tube, battery, battery box and all remaining components running to the inlet of the motor. Remove the Battery/Air Box support bracket: 1. Support the driver’s side of the transmission. 2. Remove four nuts securing the bracket to the driver’s side engine mount. 3. Remove the large central nut securing the transmission to the engine mount. 4. Lift the plate on top of the engine mount and remove the Battery/Air Box support bracket. (See Fig. 1-a.) 5. Reinstall the engine mount plate and resecure all engine mount hardware. Place an oil drain pan beneath the power steering pump. Disconnect the high-pressure (3/8" tube) power steering line from the power steering pump. Disconnect the opposite end of the power steering line from the steering rack. Disconnect all other supports securing the power steering line and remove it from the car. From under the vehicle, remove the plastic cover protecting the belts and pulleys. From under the vehicle, release the tension on the accessory drive belt and remove the drive belt. Disconnect the fill hose from the power steering pump. Remove the four screws securing the power steering pump and remove the power steering pump from the vehicle. Drain sufficient coolant to remove and relocate the plastic upper coolant manifold located near the upper radiator core support. (See Fig. 4-c.) ZX3 Only: Remove the four screws securing the heat shield to the header. Remove the heat shield. Locate the PCV valve located near the driver’s side of the exhaust manifold on the front of the engine. Pull the stock PCV valve and install the supplied PCV valve in its place. Remove the screws and pushpins securing the front bumper cover. Remove the front bumper cover from the car. BATTERY/AIRBOX SUPPORT TO REMOVE Fig. 1-a 1 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 2. SUPERCHARGER OIL DRAIN (SVT Models skip steps A-D and proceed to Step E.) A. B. C. D. E. Disconnect the connectors attached to the oxygen sensors on the catalytic converter assembly. Unsecure all hardware and brackets securing the catalytic converter. Disconnect the EGR tube where it connects to the EGR control valve toward the rear of the engine. Manipulate the catalytic converter to either side to get a clear view of the oil drain location. To provide an oil drain for the supercharger, it is necessary to make a drain hole in the engine block skirt. Locate and center-punch the hole in the exact location as shown per Figs. 2-a, 2-b. Drill a 1/8" pilot hole at the center location. NOTE: F. G. H. I. J. K. L. OIL DRAIN ROUTED BEHIND CAT BRACKET Fig. 2-a / ZX3 Oil Drain SVT Models - It will be necessary to either loosen the exhaust header or shorten the supplied rotabroach .33" to get sufficient room for drilling the oil drain. Use the supplied 9/16" rotobroach to drill the hole. Take care to break through the pan and gently remove the cut out. Pack the flutes of a 3/8" NPT tap with grease. Tap the hole until the fitting can be started. Thoroughly clean the threaded area. Reach inside the oil pan and retrieve any stray chips. Apply a small amount of sealer to the threads of the supplied 3/8" NPT hex nipple and secure in the new hole. Make sure that a seal is formed around the fitting. (See Fig. 2-a.) Apply sealant to the opposite side of the fitting and install the supplied 3/8" x 90° fitting on the end of the hex nipple. Apply sealant to the threaded end of the supplied 3/8" x 1/2" barb fitting. Install this fitting into the 90° fitting. Orient the fittings to point upward towards the driver’s side. (See Fig. 2-a.) (ZX3 Models Only) Resecure the catalytic converter and all brackets back to stock location, reconnect the EGR line back to the EGR control valve. Reconnect the oxygen sensors and reinstall the heat shield. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) Fig. 2-b / Oil Drain Hole Fig. 2-c / SVT Oil Drain 2 3. SUPERCHARGER OIL FEED A. B. C. D. E. F. Locate the oil pressure sender on the back of the engine block near the oil filter. Remove the oil pressure sender. Lightly lubricate the threads of the supplied 1/8" NPT street fitting with engine oil. Install the street fitting into the block. Install the oil pressure sender into the street fitting so that it is pointing upward and parallel with the egine block. Install the 1/8" NPT to -4 fitting into the end of the street fitting so that it is perpendicular to the engine block. (See Fig. 3-a.) Install the 90° end of the feed hose to the -4 fitting and route it close to the block and up to the supercharger mounting location. Install the electronic plug back onto the oil pressure sender. 1/8"NPT TO 4 FITTING STREET FITTING Fig. 3-a 4. CROSSOVER COOLANT LINE MODIFICATION A. B. C. D. E. Locate the coolant manifold running across the top/front of the radiator support. Remove the plastic manifold and disconnect the three coolant lines running to the manifold. (See Fig. 4-c.) Cut 1" off the end of each coolant line running to the manifold. Modify the plastic coolant manifold by grinding both tabs so that they are flush with the manifold. (See Fig. 4-a.) Reattach the lines to their original manifold ports. (Cutting the lines allows for the coolant manifold to sit lower.) Tuck the manifold between the top of the radiator and the upper radiator support. This will allow for clearance between the drive assembly and the coolant manifold. (See Fig. 4-b.) COOLANT MANIFOLD IN RELOCATED POSITION Fig. 4-b 2 AREAS TO GRIND STOCK COOLANT MANIFOLD LOCATION Fig. 4-a Fig. 4-c 3 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 5. POWER STEERING RELOCATION/SECONDARY PLATE INSTALLATION A. B. C. D. E. F. 6. Locate the supplied power steering relocation block. Install the two supplied alignment dowels into the back side of the block. (See Fig. 5-a.) Locate the factory hose clamp securing the lower radiator hose. Orient the clamp to give clearance for the P/S relocation block. Install the supplied power steering relocation block onto the cast power steering mounting bracket that the pump originally mounted to. Make sure the alignment dowels align with their corresponding holes on the stock bracket. Use the four supplied 8mm x 1.0" x 40mm SHCS and 8mm washers to secure the relocation block to the stock bracket. Install the secondary mounting plate to the three hole pattern on the side of the relocation block with the supplied 3/8"-18 x 1" flathead screws. (See Fig. 5-b.) Tighten the 3/8" screws. Place the power steering pump against the installed relocation block. Make sure that the stock alignment dowels are installed into the back of the power steering pump. Secure the pump to the lower set of four holes in the relocation block using the stock hardware. INSTALLED ALIGNMENT DOWELS Fig. 5-a SECONDARY MOUNTING PLATE INSTALLED ON P/S RELOCATION BLOCK P/S PUMP REINSTALLED Fig. 5-b POWER STEERING LINE MODIFICATION NOTE: A. It is necessary when cutting the power steering lines that the cuts are straight and clean. It will be necessary to remove the paint on the lines before installing the compression fittings. Do not “grind” the paint off of the lines as that will reduce the diameter of the line so that the new fitting may not properly function. END ATTACHES TO P/S PUMP LOCATION TO MAKE CUT. LEAVE THE MAXIMUM AMOUNT OF STRAIGHT SECTION POSSIBLE Cut the previously removed high-pressure power steering line in two places. • The first cut is directly after the long rubber section of power steering line. Cut the hard line leaving the maxumum amount of straight section connected to the rubber end. (See Fig 6-a, 6-c.) • The second cut through the hard line will be on the pump side. Cut the line so that the maximum section of straight tube remains with the fitting that connects to the power steering pump. (ZX3 Models refer to Figs. 6-b,6-d.) (SVT Models: refer to Figs. 6-f, 6-g.) NOTE: END ATTACHES TO STEERING RACK KEEP THIS SECTION Fig. 6-a LOCATION TO MAKE CUT. LEAVE THE MAXIMUM AMOUNT OF STRAIGHT SECTION ALLOWABLE POWER STEERING FITTING TO KEEP When installing the compression fitting, initially tighten the fitting finger tight. Using wrenches, continue 1-1/2 turns so that the fitting is secure. Fig. 6-b / ZX3 Models Only P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 4 6. POWER STEERING LINE MODIFICATION, cont’d B. C. D. E. Install the compression fitting with the 3/8"NPT female outlet on the shortest section of power steering line containing the fitting that connects to the power steering pump. (ZX3 Models: see Fig. 6-d, SVT Models: see Fig. 6-g.) Install the compression fitting with the 1/4"NPT female outlet on the longer section of power steering hose. (Both models see Fig. 6-c.) Install the 3/8"NPT x -6 x 45° fitting into the 3/8"NPT female outlet installed on the short section of power steering line. Take this assembly and install it into the bottom of the power steering pump with the 45° fitting pointing toward the front of the car. (ZX3 Models see Fig. 6-e, SVT Models see Fig. 6-h.) Install the 1/4 NPT x -6 fitting into the 1/4 NPT female outlet installed on the long section of the power steering line. Reinstall the stock section of the power steering line back into the steering rack. Route the open end of the hose, in its stock location orienting it toward the front of the car. FITTING ASSEMBLY DIRECTLY OFF THE POWER STEERING PUMP SECURED P/S HOSE Fig. 6-e / ZX3 Models Only 1/4"NPT x -6 FITTING COMPRESSION FITTING CUT COMING FROM P/S RACK SIDE Fig. 6-f / SVT Models Only CUT SECTION w/FITTINGS INSTALLED Fig. 6-c 3/8NPT X -6 x 45° FITTING STOCK, UNCUT P/S HOSE COMPRESSION FITTING STOCK P/S PUMP FITTING REMOVED IN FIG. 6-b Fig. 6-g / SVT Models Only Fig. 6-d / ZX3 Models Only 5 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 6. POWER STEERING LINE MODIFICATION, cont’d F. Connect both ends of the open hose with the supplied high-pressure line. ZX3 Models: Route the hose from the 45° fitting pointing off the P/S pump to the bottom/rear of the radiator, over the air filter, along the drivers side frame rail over to the long section of power steering hose. (See Figs. 6-e, 9-b.) SVT Model: Route the supplied hose from the 45° fitting in front of the radiator over to the driver’s side, over the air filter, along the driver’s side frame rail to the installed stock P/S hose section. (See Figs. 6-h, 6-i.) G. H. I. FITTING POINTING DOWN TOWARD THE FRONT OF CAR Use adel clamps to keep the highpressure line secure. (See Figs. 6e, 9-b.) Using the supplied 5/8" hosemender and length of hose, lengthen the power steering fill hose. Secure it away from the supercharger pulley. Refill the power steering reservoir. SUPPLIED P/S LINE ROUTED OVER THE AIR FILTER TO THE DRIVER’S SIDE FRAME RAIL SUPPLIED P/S HOSE ROUTED IN FRONT OF THE RADIATOR Fig. 6-h / SVT Models 7. Fig. 6-i / SVT Models FUEL INJECTOR REPLACEMENT A. B. C. D. 8. E. Disconnect the four (4) fuel injector wiring clips and retainers from the fuel injectors. Release any residual fuel pressure from the rail by opening the schrader valve on the rail. Have a fire extinguisher nearby and use extreme caution. Remove the bolts holding down the factory fuel rail onto the intake manifold. Lift up on to the rails evenly, removing all four injectors. Using a small amount of clean motor oil, lightly lubricate the O-rings on both ends on the Vortech supplied fuel injectors. Install the new injectors into the fuel rails with the terminals facing outward. F. NOTE: Carefully lower the fuel rail/injector assembly down onto the intake manifold. Check to see that each injector has been seated properly into the manifold. Tighten down the fuel rail assembly with the original bolts and attach the wiring clips to the injector terminals. Make sure injectors are secure and properly installed. Re-check after cycling fuel system. DRIVE SHAFT AND SUPERCHARGER INSTALLATION A. B. C. Remove the three upper, forward most screws from the bell housing. (See Fig. 8-a.) Slide the supplied heat shrouding over the 1/2" fabric braid oil drain hose. Attach the oil drain hose to the supercharger drain fitting and tighten the supplied #8 hose clamp. Install the supplied Ø5/16" x 1.00" dowel into the countersunk holes in the supercharger gear case. (See Fig. 8-b.) P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 6 8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION, Cont’d, D. E. F. Install the supercharger mounting plate on the alignment dowels and tap the plate lightly until it is flush with the supercharger gear case. (See Fig. 8-b.) Align the counter bores in the black coupler housing with the alignment dowels passing through the supercharger mounting plate. Lightly tap the drive housing until it is flush with the mounting plate. (See Fig. 8-c.) Install onto the supercharger input shaft, the supplied key and drive coupling containing three 1/4" diameter dowel pins protruding from it. (Apply a thin film of anti-seize or grease onto the inside diameter of the coupling before installing onto the input shaft.) Secure the coupling with the supplied 3/8"-24 x .75" HXHD and Ø1.0 O.D. washer. NOTE: G. H. I. J. K. 3 LOCATIONS TO REMOVE STOCK HARDWARE 0.630 O.D. SPACER LOCATION Fig. 8-a INSTALLED Ø5/16" DOWELS Heat may also be necessary to install the coupling onto the shaft. (A propane torch will make this easier if needed.) Use a light thread lock compound on the 3/8"-24 x .75" screw threads. Install the two supplied 1.80" spacers between the supercharger and the mounting plate. Secure in one location with a 3/8"-16 x 2.5" flathead and in the other with a 2.75" HXHD. Leave both fasteners loose at this time. (See Fig. 8-c.) In the middle mounting location, secure the supercharger to the mounting plate with the supplied 12mm x 1.75" x 25mm screw and washer. Leave the fastener loose at this time. (See Fig. 8-c.) Locate the preassembled drive shaft assembly. Connect the three-pin coupler from the end of the drive shaft to the three-pin coupler on the supercharger assembly using the supplied composite ring. Align the hole patterns so that one side of pins is alternating with the opposite side of pins. Each pin will have its own hole. Verify that each set of pins is inserted into the raised bosses with holes on their corresponding side of the composite ring. Push together until each coupler is flush with the composite ring. (See Figs. 8d and the boxed section of Fig 8-f.) With the couplers aligned, align the two coupler housings. Using the four 5/16"-18 x 5.25" HXHD screws secure the drive shaft assembly to the supercharger assembly. Lower the supercharger and drive assembly NOTE: Fig. 8-b 12mm x 1.25 x 25mm 1.8" SPACER INSTALLED DRIVE COUPLING COUPLER HOUSING Fig. 8-c LEAVE LOOSE UNTIL STEP O It is necessary to leave the hardware loose to allow for the correct clocking of the housing assembly upon final installation. (See Fig. 8-d.) Fig. 8-d 7 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION, cont’d L. M. N. O. into position locating where the exhaust manifold heat shield and drive shaft will come into contact. (See Fig. 8-e.) ZX3 Models Only: Mark the heat shield, remove the drive assembly and modify the heat shield to clear the drive assembly. (See Fig. 8-e.) Using an oversize tube or dowel to form the heat shield is the easiest method for modification. (See Fig. 8-g.) Place the drive assembly back into position. Loosely install the 10mm x 140mm screws and 3.56" spacers between the supercharger mounting plate and the bell housing locations. The Ø.630 O.D. spacer will be placed in the forward most, bottom position on the bell housing. (See Figs. 8-a., Fig. 8-f.) Loosely install the four 5/16"-18 x .75" flathead screws through the secondary mounting plate into the bearing housing. (See Fig. 8-f.) Tighten all the drive fasteners in the following order: • Four 5/16"-18 x .75" flathead screws connecting the bearing housing to the secondary plate AREA TO MODIFY Fig. 8-e AREA TO MODIFY Fig. 8-g 4 x 5/16"-18 x .75" FLATHEADS DRIVE COUPLING HOUSING Ø.875" x 3.56" SPACER Ø.630" x 3.56" SPACER 4 x 5/16"-18 x 1.00" HXHD 4 x 5/16"-18 x 5.25" HXHD DRIVE COUPLINGS COMPOSITE DISK DRIVE COUPLINGS 10mm x 140mm HARDWARE Fig. 8-f P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 8 8. DRIVE SHAFT AND SUPERCHARGER INSTALLATION, cont’d • P. Four 5/16"-18 x 5.25" HXHD screws connecting the shaft housing and coupler housing to the supercharger and mounting plate • Four 5/16"-18 x 1.00" HXHD screws connecting the bearing housing to the shaft housing • The 3/8"-16 x 2.5" flathead, 3/8"-16 x 2.75" HXHD and 12mm x 1.75 x 25mm HXHD securing the supercharger directly to the mounting plate • Three 10mm x 1.5 x 140mm HXHD screws securing the mounting bracket and 3.56" spacers to the bell housing Lightly grease the extended supercharger input shaft. Install the key and supercharger pulley oriented so that the long snout of the pulley is facing toward the supercharger. Secure the pulley with a 3/8"-24 x 1.0" HXHD, 3/8" washer and pulley retainer. NOTE: Q. S. Fig. 8-g VORTECH SUPPLIED IDLER IDLER RETAINER Blue Loctite is recommended on the 3/8"-24 x 1.00" screws. Install two supplied 2.5" aluminum idlers using 7/16"-18 x 1.5" hardware, pulley retainers and idler spacers. The idler retainers (.220" THK) go between the pulley and the 7/16" screw and spacers (.416" THK) are placed between the idlers and the secondary mounting plate. When the pulleys are installed the snap ring retaining the bearing should be facing away from the mounting plate. (See Fig. 8-h.) NOTE: R. INSTALLED IDLER PULLEY Blue Loctite is recommended on the 7/16" screws. IDLER SPACER SECONDARY MOUNTING PLATE .220 THICK .416 THICK 7/16-18 x 1.5" SCREW Fig. 8-h S/C PULLEY ALT STOCK IDLER Install the drive belt. It may be necessary to loosen one of the idlers to get the belt on due to tight clearances. (See Figs. 8-h, 8-i.) Install the oil feed and oil drain hoses. WATER PUMP SUPPLIED 2.5" IDLERS POWER STEERING TENSIONER CRANK PULLEY A/C Fig. 8-i / Belt Routing 9 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 9. AIR INLET ASSEMBLY A. B. C. D. E. F. G. I. Unplug the electrical connector from the horn. Remove the horn from the car. Install into the 3/4"NPT boss of the 90° rotomold duct the supplied straight 1" barb. (See Fig. 9-a.) Install into the 3/8"NPT boss of the rotomold duct the supplied 5/8" barb x 90°. Connect the Ø3.5" end of the 90° inlet duct to the inlet of the supercharger using the supplied Ø3.5" x 2" sleeve and #56 hose clamps. Orient the duct so that the open end is pointing down. (See Fig. 9-a.) Connect the length of 3" flex-hose to the open end of the 90° duct using a #48 hose clamp. Connect the MAF sensor to the supplied bracket. (See Fig. 9-c.) Attach the supplied air filter to the inlet of the MAF. (See Fig. 9-d.) Set the air filter/MAF assembly on the lower radiator support where the horn was located. Mark two locations and drill using a 9/32" drill. Secure using the supplied 1/4" hardware. (See Fig. 9-b.) ZX3 Models: (See Fig. 9-e) cut all six (6) wires leading to the MAF plug leaving 3"-4" before the plug. Using the supplied wires and butt connectors extend all six wires so that they reach the new MAF location. SVT Models: Cut the middle four wires leaving 3" to 4" after the MAF plug. Cut the outer 2 wires leaving the longest amount of wire attached to the plug. Extend the four middle wires so that the MAF plug can reach the relocated sensor. Connect the white with purple stripe wire to the red wire on the supplied IAT sensor harness. Connect the black with white stripe wire to the brown/black wire on the IAT sensor. (See Fig. 9-e.) Trim the long outer wires left on the MAF plug leaving only a couple of inches of wiring coming out of the plug. NOTE: J. K. 3/4"NPT TO 1" BARB 3/8"NPT TO 5/16" BARB Fig. 9-a P/S HOSE SECURED MAF AND BRACKET MOUNTING LOCATION Fig. 9-b Soldering the wire extension is preferred. Shrink sleeve has been supplied to seal the solder joints. VORTECH SUPPLIED BRACKET Re-attach MAF plug to MAF meter. Reinstall the factory horn as shown in Fig. 9-f using the supplied 6mm screw. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) Fig. 9-c 10 9. AIR INLET ASSEMBLY, cont’d NEW HORN LOCATION Fig. 9-d Fig. 9-f BLACK w/ORANGE STRIPE BROWN w/BLUE STRIPE GREEN w/RED STRIPE (SVT ONLY)-WHITE w/PURPLE STRIPE CONNECT TO THE RED AIR TEMP SENSOR WIRE (ZX3 ONLY)-EXTEND WIRE TO MAF PLUG (ALL 6 WIRES) WHITE w/BLUE STRIPE (SVT ONLY)-BLACK w/WHITE STRIPE CONNECT TO THE BROWN AIR TEMP SENSOR WIRE (ZX3 ONLY)-EXTEND WIRE TO MAF PLUG (ALL 6 WIRES) RED BLACK/BROWN WIRING EXTENSIONS SUPPLIED IAT SENSOR CONNECTOR (SVT MODELS ONLY) EXTEND WIRES TO THE MAF NEW LOCATION (SVT ONLY) WIRING NO LONGER ATTACHED TO MAF PLUG MAF PLUG Fig. 9-e / MAF Plug Modifications 11 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 10. A. B. C. D. E. SVT DSI BOX RELOCATION Locate the DSI Box in the driver’s side fender well. Disconnect the electrical connector from the box. Disconnect the cable from the base of the throttle body. (See Figs. 10-a, 10-b.) Remove the hardware securing the DSI box bracket from the frame rail. Remove the box from the bracket. Using two of the original battery tray hold down screws, secure the supplied DSI box relocation bracket to the top of the driver’s side frame rail (See Fig. 10-c.). Secure the DSI box to the relocation bracket using the supplied 1/4-20 hardware. (See Fig. 10-d.) Reconnect the electrical connector to the DSI box. Route the cable back to the base of the throttle body and reconnect. (Ensure that the cable has no kinks and has free movement.) Fig. 10-a / SVT Model Only UNSNAP LINE Fig. 10-b / SVT Model Only BRACKET INSTALLED Fig. 10-c / SVT Model Only DSI BOX INSTALLED Fig. 10-d / SVT Model Only P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 12 11. STANDARD DISCHARGE INSTALLATION (H.O. Charge-cooled applications skip to Section 12.) A. Install the 2.75" to 2.5" reducer sleeve onto the supercharger discharge. B. Install on the throttle body the supplied 90° silicone sleeve. • ZX3 Models: Use the Ø3.25 x Ø2.75" x 90° sleeve on the throttle body. (See Fig. 11-b.) • SVT Models: Use the Ø2.75" x 90° sleeve on the throttle body. (See Fig. 11-a.) Insert the supplied rubber grommet and IAT sensor into the discharge tube. Lubricate for easier fit if needed. C. Between the two installed sleeves install the Vortech discharge tube: D. ZX3 Models: Secure the sleeve on the throttle body with the supplied #44 and # 48 hose clamps. Secure the sleeve on the supercharger with the supplied #44 and #40 hose clamps. (See Fig. 11-b.) SVT Models: Secure the sleeve on the throttle body with the supplied #44 hose clamps. Secure the sleeve on the supercharger side with the supplied #44 and #40 hose clamps. (See Fig. 11-a.) Connect the recently installed IAT sensor harness to the IAT sensor in the discharge tube. E. Connect the supplied 5" piece of Ø1.0" hose to the barb on the discharge duct. F. Using the supplied #16 hose clamps, connect the inlet of the bypass to the open end of the installed hose. G. Using the supplied #16 hose clamps and 90° molded hose, connect the opposite end of the bypass valve to the Ø1.0" barb installed on the inlet duct. (See Figs. 11-c, 11-d.) Trimming of the rubber 1" elbow may be required. H. Using the supplied 5/32" TEE and vacuum hose connect the bypass valve to an engine vacuum source. (See Fig. 11-d.) NOTE: Fig. 11-a / (SVT Model) Fig. 11-b / (ZX3 Model) 90° MOLDED HOSE Make sure that the vacuum barb on the bypass valve is installed so that it is pointing down, directly away from the discharge tube BYPASS VALVE Fig. 11-c / (ZX3 Model) 13 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 11. STANDARD DISCHARGE INSTALLATION, cont’d (H.O. Charge-cooled applications skip to Section 12.) SUPERCHARGER DISCHARGE TUBE AIR INLET DUCT BYPASS VALVE 5/32” HOSE Fig. 11-d 12. A. B. C. CHARGE COOLED DISCHARGE INSTALLATION Install on the supercharger discharge the Ø2.75" to 2.5" reducer sleeve. Install the supplied 90° sleeve on the throttle body. • ZX3 Models: Ø3.25" to 2.75" reducer x 90° • SVT Models: Ø2.75" x 90° sleeve. Install the welded charge-cooler into the Ø2.75" end of the reducer sleeve on the discharge of the supercharger. ZX3 Models: Install the Ø2.75" x 2.0" sleeve on the discharge side of the charge cooler. Install the supplied discharge tube between the charge cooler and the 90° sleeve on the throttle body. Secure the discharge tube with #44 hose clamps. (See Fig. 12-a.) SVT Models: Connect the discharge of the charge cooler to the throttle body with the installed 90° elbow and #44 hose clamps. (See Fig. 12-b.) Insert the supplied rubber grommet and IAT sensor into the discharge tube. Lubricate for easier fit if needed. Connect the recently installed IAT sensor harness to the IAT sensor in the discharge tube. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 90° ELBOW Fig. 12-a / ZX3 Model 14 12. D. E. F. G. CHARGE COOLED DISCHARGE INSTALLATION Connect the supplied 5" piece of Ø1.0" hose to the barb on the bottom of the charge cooler. Using the supplied #16 hose clamps, connect the inlet of the bypass to the open end of the installed hose. Using the supplied #16 hose clamps and 90° molded hose, connect the open end of the bypass valve to the Ø1.0" barb installed on the inlet duct. (See Fig. 12-a.) Trimming of the 1" rubber elbow may be required. Using the supplied 5/32" TEE and vacuum hose connect the bypass valve to an engine vacuum source. (See Fig. 12-c.) NOTE: Make sure that the vacuum barb on the bypass valve is installed so that it is pointing down and away from the discharge. SUPERCHARGER DISCHARGE TUBE AIR INLET DUCT BYPASS VALVE 90° ELBOW 5/32” HOSE Fig. 12-c Fig. 12-b / SVT Model 13. A. B. C. D. E. F. G. WATER TANK AND WATER PUMP INSTALLATION (H.O. Charged Cooled Kits Only.) Unsnap the A/C line from the driver’s side frame rail bracket, then remove the bracket. Align the supplied bracket with the bottom of the passenger’s side framerail (See Fig. 13-a.) Locate and mark locations to mount the water tank bracket in the passenger’s side fenderwell. (See Fig. 13-a.) Using the supplied sheet metal screws, mount the water tank bracket. (See Fig. 13-a.) Using the #28 adel clamp and 1/4"-20 hardware, secure the water pump to the inside of the water tank as shown. (See Fig. 13-b, 13-d.) Install the 1/2"NPT x 90° brass fittings in the top and bottom of the tank. Install the Ø3/4" x 90° molded hose between the inlet of the water pump and the bottom 90° fitting. (See Fig. 13-d.) Install into the 1"NPT hole in the top of the water tank the supplied aluminum bushing. Leave the 1/8"NPT pipe plug out until you have completely filled the system. 15 Fig. 13-a P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 13. H. I. J. K. L. M. N. O. P. WATER TANK AND WATER PUMP INSTALLATION (H.O. Charged Cooled Kits Only.), cont’d Install the water tank assembly into the mounted bracket securing the tank in three locations with 1/4"-20 x .5" hardware. Point the upper 90° fitting so that it is pointing at the driver’s side. (See Fig. 13-b.) Gently bend the A/C line with the pressure sensor up so the wiring harness will reach. (See Fig. 13-f.) Mount the supplied water pump relay near the firewall just below the fuse box. (See Fig. 13-c.) Connect the red 12-gauge wire from terminal #30 to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt to a positive power supply. Feed the yellow wire from relay terminal #85 to the fuse box on the driver’s side of the engine bay. Route the wire to the D1 engine fuse and using the supplied fuse tap connect the yellow wire to the fuse. Run the black wire from terminal #86 on the relay to a clean ground. With the long red 12-gauge wire connected to the water pump relay terminal #87, route the free end across the firewall, along the fender and down to the water pump. Secure as necessary to avoid heat and sharp edges. Cut the stock electrical plug off the water pump. Connect the blue/green positive wire on the water pump to the positive red wire with the supplied slide connectors. Run the brown negative wire to a clean ground. WATER PUMP RELAY Fig. 13-c Fig. 13-d RELAY (+) WATER PUMP 87 86 87A WATER PUMP 85 D-1 ENGINE FUSE 30 GROUND (+) BATTERY TERMINAL Fig. 13-e 1/2" NPT x 90° FITTINGS LIGHTLY BEND A/C LINE UP TO REACH THE WIRING HARNESS Fig. 13-b MODIFIED A/C LINE Fig. 13-f P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 16 14. A. B. C. D. HEAT EXCHANGER MOUNTING (H.O. Charged Cooled Kits Only.) Un-secure the power steering cooler from the front of the car. Drill 9/32" holes in the rear of the mounting tabs. Remount the power steering cooler using the new holes to position it forward. Mark locations for the supplied water cooler. Mount the supplied cooler using the supplied self tapping screws with the barbs facing to the driver’s side directly behind the remounted power steering cooler. (See Fig. 14-a.) POWER STEERING COOLER MOUNTED FORWARD Fig. 14-a DRILL NEW Ø.28" MOUNTING HOLES IN THIS POSITION 1.25" EXISTING HOLES BOTTOM VIEW POWER STEERING COOLER Fig. 14-b 15. WATER LINE ROUTING (H.O. Charged Cooled Kits Only.) NOTE: A. B. C. When routing hoses, refer to Fig. 15-a. Trim all hoses for best fit. Cut a 60" length of 3/4" hose. Run this from the top 90° fitting on the charge cooler to the 90° fitting located on the top of the triangular water reservoir. Route the hose towards the front of the car between the air conditioning condenser and grill, over to the water tank. Make sure that the hose is smoothly routed without tight bends or kinks. Install the 4" end of the 90° molded rubber elbow to the outlet of the water pump. Cut a 70" length of 3/4" hose. Connect it to the 12" end of the 90° molded hose with the supplied barbed hose mender. Run the hose along the base of the radiator to the supplied rubber 180° hose using the 3/4"-5/8" reducer. Run the open end of the 180° hose to the bottom barb on the water cooler (Running this hose to the bottom barb is important to flush out any air in the water system.) D. E. F. G. 17 Cut a 40" length of 3/4" hose. Run this from the top barb of the water cooler to the bottom 90° fitting on the charge air cooler. Secure all hose ends with the supplied nylon clamps. Start filling the system with a 50/50 water/glycol mix. Check the 1"NPT aluminum fitting in the water tank to see if water is flowing out of the 1/8"NPT hole. Once water is to this point, install the 1/8"NPT plug into the 1” aluminum fitting. With the key on, make sure the charge cooler water pump is operating and that water is flowing through the cooler. Fill the system if necessary. If the water is not flowing, remove the charge cooler supply hose and lower until water flow out of the hose. If necessary, provide light suction to the hose to help prime the pump. Verify water flow. Do not let the pump run for extended periods (30 seconds or more) without water flow. Fill the charge cooler tank until the level stabilizes. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 18 Ø3/4" x 70" HOSE SUPPLIED Ø3/4" HOSEMENDER WATER PUMP MOUNTED UPSIDE DOWN FLOW TOP 1/2" NPT x 3/4" HOSE x 90° BRASS FITTINGS (ONE ON TOP OF TANK, ONE BELOW) 90° MOLDED ELBOW (BELOW) 4" x 12" MOLDED HOSE Fig. 15-a Ø3/4" x 60" HOSE Ø3/4"-5/8" HOSE REDUCER CHARGE AIR COOLER CHARGE COOLER PLUMBING SCHEMATIC (H.O. KITS ONLY) 180° MOLDED HOSE Ø3/4" x 40" HOSE Ø90° BRASS FITTINGS FLOW 16. BATTERY RELOCATION NOTE: A. B. C. D. E. Clearance between the battery and front bumper will be tight. Position the battery box not to interfere with the side marker lights or front fog lights Remove the battery strap from the stock battery support bracket. Install the battery strap into the supplied battery box using the supplied 1/4" hardware. With the front bumper cover removed, align the battery box along the driver’s side frame rail. Mark tentative locations for the box to mount. Place the bumper back into stock location and check for clearance issues between the side marker lights, fog lights, battery box and the plastic inner fender liner. Take into account clearance when the battery will be installed into the battery box. (See Fig. 16-f.) When a position has been found, drill four 13/32" holes in the marked locations. Mount the battery box in the driver’s side fender using the supplied spacers and 3/8" hardware. The .290" spacers will go between the two forwardmost holes and the upper rear hole. The lower rear hole will need a .80" spacer. (See Fig. 16-a.) Install the battery into the battery box. Have the battery orientated so that the terminals will be away from the frame rail. Remove the stock 6mm screw from the factory battery strap. Install into its location the supplied 1/4"20 screw and washer. Secure the battery with the screw and battery strap. NOTE: F. G. H. I. J. K. NEW BATTERY GROUND 1/4"-20 x 1" SCREW POSSIBLE LIGHT CONTACT HERE Fig. 16-b REAR LOCATION OF THE REMOTE BATTERY TERMINAL Fig. 16-c Secure the positive wires with tie wraps and shrink sleeves to prevent contact with other objects. Use the supplied battery terminal, lug end and wire to ground the battery to the frame. Reinstall the front bumper cover. Check for clearance issues. Readjust if necessary. NOTE: Fig. 16-a When wiring the battery, see Fig. 16-e. Cut any extra ground wires away from the engine ground strap. Install a ring terminal on the ground strap and ground to a clean, paint free section on the frame. Using a hole saw, make a 1.25" hole inside the driver’s side fender. Check the location from the engine compartment before drillling. (See Figs. 16-c, 16-d.) Mount the remote battery terminal as shown. Using the supplied wire, shrink sleeve and lug terminals, extend the positive wires to the new remote terminal location. Extend a wire from the remote battery terminal to the positive terminal on the battery. NOTE: .80" SPACER ENGINE COMPARTMENT VIEW OF REMOTE BATTERY POST There might be light contact with the thin plastic splash guard. Fig. 16-d 19 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 16. BATTERY RELOCATION, cont’d. TO ENGINE BLOCK DISCARD THE FACTORY BATTERY TERMINAL AND GROUND WIRE TO BODY CUT ENGINE GROUND FROM TERMINAL. INSTALL SUPPLIED RING TERMINAL AND GROUND TO BODY RUN LEAD TO THE POSITIVE BATTERY TERMINAL ON THE RELOCATED BATTERY USE THE SUPPLIED HARDWARE, RING TERMINALS, SHRINK SLEEVE AND WIRE TO LENGTHEN THE POSITIVE LEAD TO THE REMOTE BATTERY TERMINAL 5/16" -18 .75" HXHD FACTORY POSITIVE TERMINAL MODIFIED GROUND TO FRAME RAIL WITH VORTECH SUPPLIED WIRE, LUG TERMINALS AND BATTERY TERMINAL BATTERY + - Fig. 16-e MOUNT TOP OF BATTERY BOX FLUSH WITH TOP OF FRAME RAIL MEASURE FROM BACK SIDE OF FRONT BUMPER KEEP THE BATTERY BOX LEVEL AS THE FRAME RAIL RISES. THIS WILL MAKE A GAP BETWEEN THIS CORNER OF THE BATTERY BOX AND TOP OF THE FRAME RAIL 3.60" THIS LOCATION WILL MOUNT AT THE VERY BOTTOM OF THE FRAME RAIL THERE SHOULD BE LIGHT CONTACT BETWEEN THIS CORNER AND THE INSIDE OF THE SPLASH GUARD. (THE BOX IS PLACED THIS FAR BACK IN ORDER TO LEAVE CLEARANCE BETWEEN THE FOG LIGHTS MARKER LIGHTS AND THE BATTERY) FRONT OF CAR Fig. 16-f P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 20 17. REFLASH COMPUTER, SVT Models Only IMPORTANT! To ensure trouble-free programming of your vehicle's computer: • Make sure the vehicle's battery is sufficiently charged. • Turn off all accessories and close doors to prevent unnecessary drain on the battery. • Do not attempt to program your vehicle while a battery charger is connected. • Improper battery voltage will result in failure of the programming process. • Do not disconnect the cable or turn off the ignition during programming. A. B. C. D. E. F. G. H. I. J. Reconnect the battery. Locate the vehicles OBD2 connector located in the lower left hand corner of the dash on the drivers side of the vehicle. (See Fig 17-a.) Attach the OBD2 connector from the Flash tool that is provided in the kit to the vehicle’s OBD2 port. (See Fig 17-b.) Make sure this connector is seated all the way in the vehicles OBD2 port. You do not want this connector coming out during programming or damage may occur to the vehicle’s ECM. The Reflash tool should power up and display three parameters. 1. Performance Tune 2. Diagnostics 3. Options Select “Performance Tune” and press the enter button in the middle of the arrow keys. (See Fig 17-c.) Read the disclaimer entirely, then select agree and press ENTER. At this point please read the screen displayed on the reflash tool. If you have any questions, either refer to the manual that is provided with the reflash tool or contact our service department for further assistance. Turn the ignition on (do not start the vehicle). Set the parking brake and press the ENTER button to continue. SELECT TUNE will be displayed at the top of the screen. Use the arrow keys to select the appropriate tune for your vehicle and press the ENTER button. You will have a choice of three to choose from: 1. SVT STD 2. SVT HO 3. Original Backup Continue to follow the screen and when finished unplug the reflash tool from the vehicles OBD2 port. NOTE: Fig. 17-a Fig. 17-b ESCAPE ARROW KEYS ENTER OR SELECT Do not disturb the cable, or turn the ignition off during this time. If the programming is disrupted, the computer will not start or run your vehicle! Fig. 17-c 21 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 18. FINAL CHECK WARNING: Do not attempt to operate the vehicle until all components are installed and all operations are completed including the final check. A. B. C. D. E. F. G. H. I. ZX3 MODELS ONLY - Once the ECM is received back from Vortech with the ECM module installed, reinstall the ECM into the vehicle. In some cases, the extra height of the ECM module will not allow the use of the factory hold-down bracket. Reconnect the factory harness and reinstall the factory kick panel. Make sure that the oil drain to oil pan fitting is secure and that the engine is filled with factory specified oil. Fill the factory radiator and the factory coolant surge tank with a 50/50 coolant/water mix. 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. Check all fittings, nuts, bolts and clamps for tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and line are properly secured with clamps or tie-wraps. Make a visual inspection of the engine and engine compartment Check all fluid levels, making sure that your tank is filled with 91 octane or higher fuel before commencing test-drive. (H.O. Kits Only.) With the key on, make sure the water pump is operating and that water is flowing through the charge cooler. Fill as necessary. If water is not flowing, remove the supply hose (attached to the water cooler) and lower until water flows out of the hose. This should prime the pump. Reconnect the hose and verify water flow. Do not run the water pump for extended periods (30 seconds or more) without water flow. At this point, it is ok to start the vehicle. With the engine running, check power steering hose connections for leakage. Let the engine run for two minutes. Turn the steering wheel in both directions. Verify: • Smooth power assist • Noiseless operation • Proper fluid level • No system leaks • No bubbles, foam or discoleration in fluid. P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) J. K. L. M. 22 Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts and for signs of any fluid leakage. Test-drive the vehicle. Recheck the coolant and aftercooler fluid levels. 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 for the 3 year limited warranty. This Page Left Intentionally Blank 23 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) ® 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 P/N: 4FJ020-010 ©2004 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 19APR04 v3.0 Focus(4FJ v3.0) 24