Vortech 1994-2000 Ford 3.8 Mustang User Manual

Page 17

P/N: 4FF020-010

09JUN03 V2.1

(94-00 3.8L Mus.(4FF V2.1))

A. Cut off the suction line flush with the junction

block (See

Fig 7-a

). Enlarge the exposed junction

block hole by using a 37/64” drill (preferably
mounted in a milling machine or drill press to
ensure that the hole is round and properly sized).
Thread the hole with a 3/8” NPT tap. Properly
clean all chips and lube out of the hole. It is very
important that no debris be allowed to enter the
A/C compressor.

B. Following the graphic, thread the 3/8” NPT x 90

fitting into the A/C junction block. Tighten the
fitting so that it will point in the proper direction
when finished.

C. Take the cut-off section of A/C line (separated

from the junction block in step 1) and remove the
remaining muffler and tube starting where the
ferrule meets with the rubber portion of the line
(see

Figs. 7-b, 7-c, 7-d

). Discard muffler/steel

tube portion. Clean out the remaining rubber
hose/spring lock connector line. Slightly bend the
remaining muffler tube following the full scale
template on the next page.

D. Assemble the open end of the cut-off rubber hose

assembly onto the 90

junction block fitting. 1994-

95 models require a union and an extra length of
rubber A/C hose (supplied). Connect these pieces
as shown. Temporarily install the assembled A/C
line onto the vehicle. Allow the hoses to rotate so
that proper alignment is achieved. Mark the hose
rotation and remove the line assembly from the
vehicle.

E. Secure hose junction(s) with the supplied #10

hose clamps and permanently install the complete
A/C line onto the vehicle. Make sure that both
O-rings on the A/C line junction block are properly
located and that both of the springlock connectors
snap properly into place.

Extend the wires for the A/C compressor and A/C

line pressure sensor switch with the supplied wire
extensions and heat shrink sleeves.

7. A/C LINE MODIFICATIONS

A/C LINE CUT

MODIFICATIONS

REMOVE

AND

DISCARD

CUT HERE

CUT

HERE

NOTE:

Modified air conditioning (A/C) lines may

be purchased from Vortech or the installer
may perform the modifications by follow-
ing the steps below.

Modify the A/C suction lines as shown. Note that
the 1994-95 models require slightly different
modifications than the 1996-98 models.

Fig. 7-a