Vortech Charge Air Cooler

Transcription

1 NOT ALL BOOST I S C R E AT E D E Q U A L Vortech Charge Air Cooler Installation Instructions Ford Focus ST* P/N: 8N * Legal in California only for racing vehicles which may never be used or registered or licensed for use upon a highway. ENGINEERING, INC Pacific Avenue, Channel Islands, CA Phone Fax: M-F 7:00 AM - 3:30 PM (PST) DP/N: 8N v1.1, 09/16/2016

2 FOREWORD This manual provides information on the installation, maintenance and service of the Vortech Intercooler kit expressly designed for this vehicle. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) :00am-3:30pm PST. Take note of the following before proceeding: 1. Proper installation of this intercooler kit requires general automotive mechanic knowledge and experience. Please browse through each step STOP of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please contact your dealer or Vortech Engineering for possible installers in your area. 2. This product was designed for use on stock (un-modified, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product. 3. Use only premium grade fuel with a minimum of 91 octane (R+M/2). 4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost) until problem is resolved. 5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage. Exclusions from Vortech warranty coverage considerations include, but not limited to: 1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation. 2. Continued operation with an impaired vehicle or sub-system. 3. The combined use of Vortech components with other modifications such as, but not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes VORTECH ENGINEERING, INC All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into another language in any form, by any means without written permission of Vortech Engineering, INC. ii

3 TABLE OF CONTENTS FOREWORD...ii TABLE OF CONTENTS.... TOOLS & SUPPLY REQUIREMENTS...v PARTS LIST ( FORD FOCUS ST CHARGE AIR COOLER UPGRADE)...vi 1. PREPARATION & REMOVAL INSTALLATION FINAL CHECK...7 iii

4 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, INC. 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, INC. iv

5 ford focus st Charge air cooler Installation Instructions Congratulations on selecting the best performing and most effective charge air cooler today... the Vortech Charge Air Cooler! Before beginning this installation, please read through this entire instruction booklet The Vortech Charge Air Cooler upgrade was designed as a street/strip oriented charge air cooler, specifically for use on the Ford Focus ST. As with any power enhancing product, this system is intended for use on healthy, well-maintained engines. 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 a note of the following key points: 1. Use only premium grade fuel 91 octane or higher (R+M/2). 2. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is resolved. TOOL & SUPPLY REQUIREMENTS: Torx 25 Screwdriver Torx 30 Screwdriver Flat #2 Screwdriver 8mm Wrench 10mm Wrench 3/16" Allen Wrench v

6 '13-'14 Ford Focus ST Charge Air Cooler Upgrade PARTS LIST ENGINEERING, INC IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part No. Description Qty. 8N cooler upgrade, focus st 1 8pn cac core, focus st, coated 1 7c m6 x 1.0 x 20mm hhcs zn 2 7f nut, m6 x 1.0 nylock, plated 2 7j mm washer, plated 4 vi

7 1. PREPARATION & REMOVAL A. Secure the vehicle on a lift, raise the hood & disconnect battery. If you do not have access to a lift, raise the front of the vehicle & secure with jack stands. Refer to your vehicle owner s manual if you are unsure of your vehicles lift points. (See Fig. 1-A) B. Using a T30 screw driver, remove all of the OEM screws securing both splash guards. (See Fig. 1-B & 1-C) C. Remove the (6) plastic push pins securing the forward-most splash guard to the bumper. (See Fig. 1-D) D. Remove both splash guards & set aside for reinstallation in a later step. Fig. 1-A NOTE: Some of the T30 screws are longer than others. Make note of all screw locations for future reassembly. Splash Guards Fig. 1-B Fig. 1-D Fig. 1-C 1

8 1. PREPARATION & REMOVAL, cont d E. Located behind the bumper cover on the driver s side is the connector for the fog lights. Unplug this connector. (See Fig. 1-E) F. Remove the T30 screws (5 per fender liner) from both fender liners & set aside. Carefully pull back on the fender liners, giving you enough space to work. The fender liners do not have to be completely removed. (See Fig. 1-F) G. On the top corners of the bumper cover, you'll notice a plastic push pin securing the bumper to each front fender. Remove this plastic push pin & set aside. (See Fig. 1-G) H. Remove the hood latch cable from the yellow hood latch lever. (See Fig. 1-H) Fog Light Connector Fig. 1-E NOTE: Some of the T30 screws are longer than others. Make note of all screw locations for future reassembly. T30 Screws 3x T30 screws towards front of fender liner. (Not shown) Fig. 1-F. (Drivers side shown) Plastic Push Pin Fig. 1-H Fig. 1-G 2

9 1. PREPARATION & REMOVAL, cont'd I. Remove the (4) plastic push pins & (2) T30 screws securing the top of the bumper cover to the upper radiator support. (See Fig. 1-I) J. Remove the T30 screws (2 per headlight) that secure each headlight. (See Fig. 1-I & 1-J) Once removed, unplug the headlight connector & set both headlight assemblies aside. This is done to gain access to a bumper cover tab. K. Lightly pull on the corners of the bumper cover to release the bumper cover from its holster. (See Fig. 1-K) L. One of the bumper cover supports is held in place by a white tab on the body. Lightly lift up on the white tab & slide the bumper cover support out. (See Fig. 1-L) T30 Inner Headlight Screws Plastic Push Pins T30 Screws Fig. 1-I T30 Screw Fig. 1-J Lift this tab up. Fig. 1-L Fig. 1-K 3

10 1. PREPARATION & REMOVAL, cont d M. Remove the bumper cover from the vehicle & set aside. (See Fig. 1-M) N. Unplug the connector for the louvers. The plug & harness for the louvers is secured by plastic push pins to the lower radiator support. Free the wiring harness & connector from the lower radiator support. (See Fig. 1-N) O. Unclip the louvers from below, then remove the (2) T30 screws up top & set the louvers aside. (See Fig. 1-O) P. Remove the plastic bumper support by pushing down on the lock tabs & pulling the plastic towards you. (See Fig. 1-P) Q. Remove the top shroud by pulling back on the metal tabs & pulling the shroud towards you. (See Fig. 1-Q) Fig. 1-M Pull back metal tab Louver Connector Fig. 1-N Fig. 1-Q T30 Screw Push down on lock tab Fig. 1-O Fig. 1-P 4

11 1. PREPARATION & REMOVAL, cont d R. Unplug the TMAP sensor from the passenger side of the OEM charge air cooler. (See Fig. 1-R) S. Using a flat head screw driver or appropriate nut driver, loosen each hose clamp on both silicone couplers for the OEM charge air cooler. Pull the couplers off & push aside. (See Fig. 1-S) T. Using an 8mm wrench, remove the (2) screws at the bottom of the OEM charge air cooler securing it to the radiator support. These screws will not be reused. (See Fig. 1-T) U. Carefully pull the bottom of the OEM charge air cooler towards you, then slide it down. The top of the OEM charge air cooler is held in place by (2) plastic guide tabs. Be sure not to break these tabs during removal & installation. TMAP Sensor Fig. 1-R Fig. 1-S 8mm Screw Fig. 1-T 5

12 2. CHARGE AIR COOLER INSTALLATION A. Using a T25 screw driver, remove the screw securing the TMAP sensor to the OEM charge air cooler. Remove the sensor & transfer it over to the new Vortech charge air cooler. Use the supplied M6x20 bolt to secure the TMAP sensor to the Vortech charge air cooler (See Fig. 2-A) B. Since the Vortech charge air cooler is considerably larger, you will need to trim the bottom curve of the louvers to keep them from pressing against the charge air cooler. The louvers are held in place to the radiator by 4 plastic holding tabs. Carefully lift up on the louvers & release the louvers from the radiator. Once the louvers are free, carefully slide them out from underneath the vehicle & trim off the curve from the bottom of the louvers. (See Fig. 2-B) C. Once trimmed, loosely reinstall the louvers to the radiator. Slide the upper charge air cooler tabs into place using the plastic guide tabs on the radiator. Be sure not to break off the tabs from the radiator. (See Fig. 2-C) D. The lower charge air cooler tabs should sit above the lower radiator support. Using a 3/16" allen wrench, 10mm wrench & the supplied nuts & bolts, secure the charge air cooler to the lower radiator support on both ends of the cooler. Make sure that the M6 bolt slides in from underneath, then secured with the supplied nut from up top. (See Fig. 2-D) E. Resecure the louves to their 4 plastic holding tabs on the radiator, then reinstall the previously removed silicone couplers & secure with the factory hose clamps. Also plug in the connector for the TMAP sensor Fig. 2-A Trim this section all the way across to the other end. Fig. 2-B Upper Charge Air Cooler Tab Supplied Nut M6 Bolt Lower Charge Air Cooler Tabs Plastic guide tabs Fig. 2-D Fig. 2-C 6

13 3. 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. Check all fittings, hose and clamps for tightness and leaks. Make sure all wires and lines are properly secured with clamps or tie-wraps. B. Make sure all wires and hoses are routed away from hot, moving or sharp objects. C. Test drive the vehicle. D. Always listen carefully for engine detonation. Discontinue heavy throttle usage if detonation is heard. 7

14 1650 Pacific Avenue, Channel Islands CA Phone: Fax: M-F 7:00AM - 3:30PM (PST) DP/N: 8N v1.1, 09/16/2016 ENGINEERING, INC