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FORD FALCON BA-BF 6CYL (INC. SX-SY TERRITORY) 4.0L BARRA (2002-2010)

VORTECH ENGINE BELT DRIVE INTERCOOLER & PIPE KIT INSTALLATION MANUAL

For any further technical information contact:

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

Email sales@capadrift.com.au Phone 08 8582 3499 (Intl. +61 8 8582 3499)

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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). 9. Retention belt after 500-600km, if not sooner, because the belt will stretch during initial

break in period. Tighten belt only enough to stop slippage (the belt must still have some flex), over-tension of the belt is the cause of input bearing failure.

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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. 90 Degree Rubber Bend (Top Outlet) 1

14. HS45 Hose Clamps 10

15. HS60 Hose Clamps 1

16. 700mm Small Pinch Weld 1

17. 100mm x 13mm Conduit 1

18. 100mm x 3” Rubber Hose 1

19. Steel Tube ‘A’ 1

20. Steel Tube ‘B’ 1

21. Steel Tube ‘C’ 1

22. Steel Tube ‘D’ 1

23. 80mm x 3” Tube 1

24. Rubber Tube Inlet Assembly ‘E’ 1

25. 1m x 4mm Electrical Wire 1

26. 1m Conduit 1

27. Blue Male Terminal 1

28. Blue Female Terminal 1

29. Drivers Side Power Steering Cooler Bracket 1

30. Passengers Side Power Steering Cooler Bracket 1

31. 10mm Brass Hose Joiner 1

32. 100mm x 10mm Fuel Hose 1

33. 10mm Hose Clamps 3

34. 25mm x 6mm Bolts 3

35. 10mm Nut 1

36. 70mm x 3” Rubber Hose 1

37. 160mm x 3” Rubber Hose 1

38. Washer Bottle Kit 1

39. BOV Grommet Plug (Low Boost, mounts in Pipe A) 1

Parts List continued on Next Page…

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KITS PARTS LIST, CONTINUED Part no. Description and Size Quantity Checked NOTE: Parts listed below are required. Already Supplied in Supercharger Kit. Blowoff Valve __

Blowoff Valve Grommet __

BOV Sock __

Zip Tie __

NOTE: Second Blowoff Valve kit for over 5psi of boost. Mounts in pipe A Blowoff Valve & T Piece __

Blowoff Valve Grommet __

HS16 Hose Clamp __

450mm x 1” BOV Hose __

BOV Sock __

Zip Tie __

NOTE: Intercooler supplementary parts are supplied as a separate kit, to convert non-intercooled into intercooled systems.

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

E

C

D

B

A

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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

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

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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.

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

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Intercooler Fitment (Cont.) 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).

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Pipe Work 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 (check pictures).

Image 2a and 2b: Passenger Side Rail Modification

Image 2c: Passenger Side Top Lip Modification

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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.

Image 3: Engine Bay Hole, Looking from Drivers Side

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3 Fit 90 Degree rubber bend to top intercooler outlet and secure with clamp. Fit 100mm of conduit to air conditioning pipe to prevent intercooler tube rubbing through pipe. Fit 100mm long hose to bent end of steel tube marked ‘C’. and secure loose with clamp. Fit tube to 90 degree bend and secure loose with clamp. Fit steel tube marked ‘D’. to 100mm rubber hose and loose secure with clamp. Fit rubber pre-made tube ‘E’ to bend and throttle body, align all tubes to clear body work and fit clamps to tube and throttle body. Tighten all clamps (throttle body takes large clamp).

Image 4a and 4b: Pipework Installation

Image 4c: Pre-Made Tube Fitment 4 Fit 170mm long rubber hose to lower intercooler outlet and secure with clamp. Fit steel

tube marked ‘B’. to rubber hose and loose secure with clamp. Fit blowoff valve to Pipe ‘B” (Use blowoff valve assembly already supplied in supercharger kit).

5 If blower was previously fitted, it can now be refitted (nb. connect and tighten air filter

conduit to blower before fitting bracket to head). If blower not previously fitted, follow fitting instructions. Route air filter conduit out side hole in wheel arch and secure air filter to hose using two clamps and 50mm rubber sleeve fitted with aluminium sleeve inside.

A

B

C

E

D

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6 Fit 70mm rubber hose to blower outlet, fit steel tube ‘A’ to blower and middle tube. Loose fit two clamps. Align tubes to clear bodywork etc. Tighten all clamps.

For low boost applications, fit plug to blowoff valve grommet in Pipe A. For applications

over 5psi, a second blowoff valve should be fitted to Pipe ‘A’. See fitting instructions on next page.

Fit BOV grommet and blow off valve to tube A (shorten original hose to 450mm, see image

4b for BOV hose location). 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.

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Power Steering Cooler Fitment

Image 5: 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 6: Horn Relocation

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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.

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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...