VORTECH ENGINE BELT DRIVE INTERCOOLER KIT … · 2020. 2. 17. · Fit intercooler from underneath...

BA8RR-INT-MANUAL – V1.0 Printed 13 February 2020 - 0 -

FORD FALCON BA-BF V8 5.4L 4V (2002-2008)

VORTECH ENGINE BELT DRIVE

INTERCOOLER KIT INSTALLATION MANUAL

For any further technical information contact:

Centrifugal Air Pumps Australia Pty Ltd 20 Verrall Cres, Berri SA 5343, Australia

Email [email protected] Phone 08 8582 3499 (Intl. +61 8 8582 3499)


INTRODUCTION Congratulations on selecting the best performing and best backed automotive Intercooler available today. Before beginning this installation please read this instruction booklet thoroughly. CAPA Supercharger Systems are a performance improving device. This product is intended for use on healthy and well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine and or the supercharger. CAPA IS NOT RESPONSIBLE FOR ANY DAMAGES RESULTING FROM THE USE OF THIS KIT. For best performance and durability please take note of the following key points: 1. Use only Premium unleaded or OPTIMAX fuel. 2. The engine must have stock compression ratio. 3. If the motor has been modified in any way, check with CAPA prior to installation. 4. Cold Starts - never race your engine when your engine is cold. Allow water temperature to

rise up to operating range before driving above 2500 r.p.m. Engine damage may result in high r.p.m. and boost conditions when cold.

5. Always listen for signs of deterioration (pinging) and discontinue hard use (no boost) until the problem is resolved.

6. Change oil and oil filter every 5,000km. Over fill sump by 0.5 Litre. (Std Sump only) 7. Always use an air-filter. 8. Never strike the supercharger pulley with a hammer or other tools. (Evidence of such force

will void warranty).


KITS PARTS LIST Part no. Description and Size Quantity Checked

1. Intercooler 1

2. Rubber Button Mounts 4

3. 5/16 UNF Nuts 8

4. 5/16 Flat Washers 8

5. 5/16 Spring Washers 8

6. Intercooler Mount Bracket, RHT 1

7. Intercooler Mount Bracket, RHB 1

8. Intercooler Mount Bracket, LHT 1

9. Intercooler Mount Bracket, LHB 1

10. 16mm x 6mm Bolts 10

11. 6mm Flat Washers 13

12. 6mm Spring Washers 13

13. 700mm Small Pinch Weld 1

14. 100mm x 13mm Conduit 1

15. Steel Tube A – Supercharger to Intercooler 1

16. Steel Tube B – Intercooler Outlet 1

17. Steel Tube C – Intermediate, Intercooler to Throttle Body 1

18. Steel Tube D – Throttle (50mm Longer than Tube B) 1

19. 80mm x 3” Rubber Hose (Supercharger outlet – Tube A) 1

20. 160mm x 3” Rubber Hose (Bottom Outlet – Tube C) 1

21. 76mm x 90° Rubber Bend, Short End (Tube B - Top Outlet) 1

22. 100mm x 3” Rubber Hose (Tube B - Tube C) 1

23. 76mm x 45° Rubber Joiner (Tube C - Tube D) 1

24. HS45 Hose Clamps 10

25. HS60 Hose Clamps 1

26. 1m x 4mm Electrical Wire 1

27. 1m Conduit 1

28. Blue Male Terminal 1

29. Blue Female Terminal 1

30. Drivers Side Power Steering Cooler Bracket 1

31. Passengers Side Power Steering Cooler Bracket 1

32. 10mm Brass Hose Joiner (Power Steering Cooler) 1

33. 100mm x 10mm Hose (Power Steering Cooler) 1

34. 10mm Hose Clamps 3

35. 25mm x 6mm Bolts 3

36. 10mm Nut 1

37. HS16 Hose Clamp 1

38. 1000mm x 4mm Vacuum Hose 1

39. Washer Bottle Kit and Pump Assembly 1

40. Windscreen Washer Bracket 1

41. 16mm x M6 Bolt, Nut, Flat & Spring Washer 2

42. Black 4.5mm Self Tapping Screw 1

43. 4mm x 1200mm Clear Plastic Tube 1

44. Windscreen washer wires with plug connected 1

Parts List continued on Next Page…


KITS PARTS LIST, CONTINUED Part no. Description and Size Quantity Checked

Optional - High Boost Applications 2nd By-Pass Valve

45. Blowoff Valve 1

46. Blowoff Valve Grommet 1

47. BOV Sock 1

NOTE: Parts listed below are required. Already Supplied in Supercharger Kit.

3” 90° Rubber Bend (Pipe D to Throttle Body) __

1000mm Supercharger Intake Duct __

Blowoff Valve __

Blowoff Valve Grommet __

BOV Sock __

Zip Tie __

Important before beginning installation, verify that all parts are included in the kit - report any shortages or damaged parts immediately.

NOTE: For Supercharger / Intercooler Kit running more than 5psi of Boost, Two Blowoff Valves must be used. A 32mm Hole will need to be drilled into the steel tube beside or near the existing hole.

Above: Parts Overview

D

B

C

A

Optional: 3” 90° Bend to Throttle Body


PREPARATION & PART REMOVAL 1. Remove Bumper Bar 2. Remove RH & LH Headlight 3. Remove Radiator Cooling Fan 4. Remove Horns 5. Remove Washer Bottle 6. Remove Power Steering Cooler 7. Remove Blower and Mount Bracket if fitted

SPECIAL TOOLS

dyno or use of accurate fuel ratio meter boost gauge fuel pressure gauge fuel return gauge


Engine Bay Hole Template. You can use the template on the vehicle using the chassis rail and earth bolt for reference.


INSTALLATION NOTE: Remove Vortech Supercharger unit and send back to CAPA for Outlet modification. If non-inter cooled kit has already been fitted. Ask about cost. Intercooler Fitment

Diagram 1. Measurements for Intercooler Mounting. Fit Mounts as shown in Images below. Additional information provided on next page.

Images 1a and 1b: Driver and Passenger Side Top Intercooler Mounts

Images 1c and 1d: Driver and Passenger Side Bottom Intercooler Mounts

Bumper Front Beam

Top Lip 200mm 345mm

190mm 320mm


Intercooler Fitment 1. Measurements on top lip of front bumper beam for top mounts: Drivers Side – measure in 200mm from outer edge of beam and drill 8.5mm hole Passengers Side – measure in 345mm from outer edge of beam and drill 8.5mm hole 2. Measurements on bottom lip of front beam for lower intercooler mounts: Drivers Side – measure in 190mm from end of beam and drill 8.5mm hole Passengers Side – measure in 320mm from end of beam and drill 8.5mm hole 3. Fit button rubber mounts to top mount bracket and secure with 2 x 5/16 UNF nuts, flat and

spring washers. Fit brackets to top mounting holes on each end of intercooler with 4 x 16mm x 6mm bolts, flat and spring washers.

4. Fit intercooler from underneath car up between front beam and radiator. Locate rubber

mounts in top holes and secure with 2 x 5/16 UNF nuts, flat and spring washers. 5. Fit rubber mounts to lower mount brackets, secure with 2 x 5/16 UNF nuts, flat and spring

washers. Fit mount and bracket to lower mount holes in front beam. Secure with 2 5/16 UNF nuts, spring and flat washers (do not tighten yet). Secure bracket to intercooler with 16mm x 6mm bolts, flat and spring washers (now tighten all bolts and nuts).


Pipework Fitment

1. Passengers side chassis rail has to be cut at front of radiator to allow clearance for lower tube and also top lip on passenger side rail under headlight has to be cut to allow clearance for top tube.

Also see photo 5c for cutting under headlight.

NOTE: This can also be done before

intercooler core is fitted into place.

At this point you can also fit an oil cooler assembly if supplied.

Image 2a and 2b: Passenger Side Rail Modification

Image 2c: Passenger Side Top Lip Modification

2b

2a

2c


2. Cut hole in engine bay floor on passenger side wheel arch above where washer bottle fits (use template in fitting instructions). Fit small pinch weld to hole when cut out. Bend air conditioning aluminium pipe to clear hole.

With supercharger in place, connect pipe A from supercharger to intercooler using provided joining sleeves and clamps. Ensure fitment is correct. Fit 170mm Joiner Sleeve from Pipe A to Intercooler, see photo 5a. Photo of supercharger fitted to vehicle in photo 6a

3. Fit BOV grommet and blow off valve to tube. Secure sock to one inch blow off valve hose and secure with zip tie. Fit tube up through hole cut in floor for intercooler piping and secure to BOV with clamp.

With BOV in place, route new vacuum

tube up to inlet manifold connect to existing T-Piece at fuel regulator.

Image 4: Blowoff Valve Fitment

Image 3: Engine Bay Hole, Looking from Drivers Side

3

4

Connect to Supercharger


4. Pipework from Intercooler to Throttle Body - Fit 90 Degree rubber bend to top intercooler outlet and secure with clamp. Ensure air conditioning pipe does not rub against intercooler tube.

Fit Steel Tube B to 90 Degree Rubber Bend

and Secure.

Fit 100mm long rubber hose joiner to opposite end of tube B. Ensure there is enough clearance on body panel to fit tube C through inner guard. See Photos 5b, 5c and 6a. Fit Air Filter as per photo 5b and 5c.

Image 4a and 4b: Pipework Installation

Image 5a, 5b & 5c: Front Pipework Fitment

B

A

C

5a

5b

5c


5. Fit Steel Tube which routes through inner guard and secure loose with clamp, fit rubber angle to tube from inner guard to throttle body pipe. Align all tubes to clear body work and fit clamps to tube and throttle body. Tighten all clamps (throttle body takes large clamp). See Photos 6a & 6b

6. If blower was previously fitted, it can now

be refitted. If blower not previously fitted, follow fitting instructions. Reattach air filter conduit and secure air filter to hose using two clamps and 50mm steel sleeve.

Image 6a, 6b: Engine Bay Pipework Fitment

6a

6b


Power Steering Cooler Fitment

1. Bend passenger side pipe to clear front beam as per photo.

2. Drill holes in bottom lip of front beam to

fit new mount brackets.

a. Drivers side 300mm in from end of beam

b. Passengers side 385mm in from end of beam c. Drill 5mm hole in both and tap to 6 x 1.0 metric thread. Secure brackets to beam using 16mm x 6mm bolts, flat and spring washers (longer bracket to driver’s side).

3. Mount cooler to bracket using 25mm x

6mm bolts, flat and spring washers. Connect passenger’s side hose to pipe with 10mm hose clamp. Driver’s side will need to be extended using brass joiner and 100mm of rubber hose and hose clamps.

Horn Relocation 1. Relocate horn to drivers side wheel arch

under RH indicator light. Drill hole in arch as per photo and mount horns using 1 x 25mm x 6mm bolt, nut flat and spring washer.

2. Extend existing wiring using 4mm wire, 1

x male blue terminal and 1 x blue female terminal. Cover wire with conduit.

Image 7: Power Steering Cooler Fitment

Image 8: Horn Relocation

7

8


Washer Bottle Fitment 1. Windscreen washer position being taken

up by the pipework. A replacement windscreen washer bottle and bracket are provided. You have an option to fit this assembly on the driver’s side or on the passenger’s side.

Use tube and wires supplied to join to

original wiring and hose.


GENERAL NOTES It is the installer’s responsibility to dyno the car to check that all systems are working correctly, especially maximum fuel delivery and to check for any presence of detonation. Check boost on dyno and that advertised boost is not exceeded and rpm occurs at designated rpm. Have injectors cleaned and flowed. A must on used injectors, peace of mind on new injectors. Make sure that all fuel hoses are in excellent condition, or replace. Check that all clamps are tight and that there are no fuel leaks.

FINAL CHECKLIST 1. Carefully review the entire installation. Check oil and fuel lines near moving parts and the

exhaust system to ensure that these lines are safe, secure and not twisted or kinked. All wires and hoses should be firmly secured with clamps or wire ties.

2. Check all fluid levels. Your vehicle should be filled with premium fuel before any driving. It is important that you performed an oil and filter change. If you did not do so before, it should be performed now before proceeding further.

3. Start engine and idle for a few minutes. Check your timing. You want to run as much timing as possible while avoiding detonation. It is better to lean on the side of less timing and no detonation!

4. Shut off your engine and check for fluid leakage, signs of rubbing parts, and other potential problems. Pay particular attention to fuel leaks, check by using CRC spray any vacuum leaks at base of injector.

5. Check nothing is near any hot spots. 6. Your vehicle should display a significant increase in performance when you step into the

throttle, with no detonation, yet should maintain its previous driveability during daily driving. If this is not so, review your installation, then contact CAPA assistance.

7. For best performance and reliability, always use premium grade fuel and listen for signs of detonation. Back off throttle should detonation occur. With a properly installed supercharger and appropriate timing, detonation should not be an issue.

8. Never race your engine when your engine is cold. Allow the water temperature to climb into operating range for several minutes before driving above 2,500r.p.m. to ensure adequate oil lubrication.

9. Please review the maintenance and warranty sections within this owner's manual. 10. Please take special note, operation of vehicle without all sub assemblies completed and

properly installed may cause failure of major components.


WARNING

DO NOT ATTEMPT TO OPERATE VEHICLE UNTIL ALL COMPONENTS ARE INSTALLED AND COMPLETE. SUPERCHARGER KITS EXTRUDE A HUGE AMOUNT OF HORSEPOWER FROM A STOCK ENGINE THEY ARE NOT INTENDED FOR CONTINUOUS PERIODS OF MAXIMUM POWER OUTPUT. IT IS NOT OUR INTENTION TO CREATE RACE PROVEN HORSEPOWER BUT LEISURE ENDURING SYSTEMS.

GET OUT THERE & ENJOY...

VORTECH ENGINE BELT DRIVE INTERCOOLER KIT … · 2020. 2. 17. · Fit intercooler from underneath...

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Transcript of VORTECH ENGINE BELT DRIVE INTERCOOLER KIT … · 2020. 2. 17. · Fit intercooler from underneath...