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.
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.
TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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. AIR INLET ASSEMBLY, cont’d NEW HORN LOCATION Fig. 9-d Fig.
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.).
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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® 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.
