Mercury 2003 Marauder Manuel d'utilisateur

MERCURY MARAUDER SUPERCHARGER SYSTEM INSTALLATION INSTRUCTIONS 2003 & 2004 MODEL-YEAR 3241 South Gulley Road, Dearborn Michigan 48124 W

Page 9 Subsystem Component Name and Description Part Number Qty Picture INTERCOOLER CORE 2R3Z-6K775-BA 1 OUTLET PLATE 4W33-030104-001-E1 1 ACT

Page 99 Intercooler coolant circuit sketch 1: IC Core Reservoir IC Pump Radiator

Page 100 Intercooler coolant circuit sketch 2: a) Install Intercooler (IC) hose #1 and #2 on Water Inlet Ada

Page 101 b) Before installing Crossover tubes, remove 2 front bolts from the Outlet Plate. Remove temperature sensors from old Crossover Tube and pl

Page 102 c) Install hose elbow (P/N 4W33-030304-001-C_PIA1) on crossover tubes and tighten the clamps (size # 20). Make sure to install the clamps p

Page 103 d) Use M14 open wrench to loose the stud that holds the Right Hood support strut just enough to insert the IC Reservoir Bracket. CAUTION: LO

Page 104 f) Install the IC Reservoir on the IC Reservoir Bracket (before tightening the IC reservoir, slide it as indicated on the picture). Tighten

Page 105 j) Remove Horn with bracket. Replace stock horn bracket with the supplied bracket (P/N 4W33-130601-001-A1); k) Install Horn with supplied H

Page 106 n) Slide carefully Front Radiator into Radiator Brackets with hose fittings pointing away from engine.

Page 107 o) Retain front radiator with Top Radiator Brackets. Use 2 M6x16 mm bolts, 2 M6 nuts and use M6 washers on both (nut and bolt) sides.

Page 108 p) Install hoses # 6 and #7 on Front Radiator. Hose #6 connects to radiator inlet port (upper) and hose #7 connects to radiator outlet port

Page 10 Subsystem Component Name and Description Part Number Qty Picture COOLING HOSE (HOSE # 3) SIZE ID 3/4” 4W33-030304-001-A_PIA3 1 COOLING HOSE

Page 109 r) Remove splash shield located below the front bumper on passenger side;

Page 110 s) Cut an opening in the splash shield. Through this opening you will route the hoses # 6 and # 7 from the radiator.

Page 111 t) Slide Convolutes over the hoses # 6 and # 7, and adjust appropriately to prevent rubber hoses from rubbing against edges of the opening

Page 112 u) Insert Intercooler pump in the bracket and place them as shown on the picture (water inlet port facing towards the front of the vehicle)

Page 113 bb) Connect hose #6 to the outlet port of Intercooler (adjust the orientation of the pump if needed to prevent kinking).

Page 114 cc) Install 3/4”-3/4” connector on straight end of hose #5. Install hose #5 on Intercooler pump (inlet port) and route it around bumper supp

Page 115 dd) Connect hose #5 with hose # 4 (Intercooler reservoir outlet). Note : Route hose # 4 through the opening near the battery tray as shown

Page 116 ff) Install front heater hose #8. If necessary, adjust the length of the hose. Where necessary, retain all hoses with straps to prevent

Page 117 6.15. SUPERCHARGER DRIVE INSTALLATION Note: refer to section 7.13 to see the path of the 8-rib belt after installation. Parts:  Bracket

Page 118 b) Install the Bracket Tensioner retaining with 2 bolts M8x140 Socket Hex Head to the cylinder head, and with 1 bolt M8x140 Socket Hex Head

Page 11 Subsystem Component Name and Description Part Number Qty Picture WATER PUMP MOUNT. BRACKET 4W33-8N500-A 1 RADIATOR BRACKET 4W33-030302-001

Page 119 d) Install the Crank Blower Pulley. Tighten with 3 M10x50mm Socket Hexagon head bolts. Use flat M10 and lock washers. Attach crank blower

Page 120 e) Install the Drive Belt – 8 Ribbed.

Page 121 6.16. INTERCOOLER WIRING HARNESS INSTALLATION Parts:  Water Pump Harness  2 self tapping screws # 8  T-TAP Connectors a) Remove

Page 122 b) To install relay and fuse holder drill holes in the sheet metal in the locations as shown on the picture below. To retain relay and fuse

Page 123 d) Remove fuse box so you can access wiring from the bottom of the fuse box. Open the fuse box. Install “T-TAP” connectors on the wires of r

Page 124 6.17. EXTENDING THE ALTERNATOR WIRING HARNESS Parts:  Alternator Extension Wires  Crimp Clamps a) Cut the alternator wires as shown

Page 125 6.18. IAT 2 SENSOR WIRING HARNESS INSTALLATION Parts:  IAT 2 Wiring Harness  Terminals A-345 – 4Pcs.  Shrink Tube – 2Pcs.  Convolut

Page 126 b) Slide one of supplied adhesive Shrink Tubes on one of the grey wires. Then, put one wire from MAS Air Connector (no matter which one) in

Page 127 Harness after modification: IAT2 Wiring ACT Sensor MAF Air Wiring IAT2 Wiring Route of the IAT2 Wiring:

Page 128 6.19. VACUUM LINE INSTALLATION Parts:  PCV Tube (P/N 4W33-6C324-B1)  Fuel Vapor hose extension (P/N 4W33-6C324-C_PIA3)  TEE hose co

Page 12 Subsystem Component Name and Description Part Number Qty Picture WATER INLET ADAPTER O-RINGS N802927S 4 Engine cooling system MARAUDER CR

Page 129 VACUUM DIAGRAM:

Page 130 Install the PCV Hose Assembly on the fitting in the middle of Inlet Duct. a) Installation of the Brake booster vacuum line  Connect Brak

Page 131 b) Installation of Fuel vapor vacuum line.  The rubber hose on the end of the Fuel Vapor Vacuum line that plugs to IAC hose fitting (size

Page 132 c) Installation of IAC vacuum line  Remove PCV hose on the left hand side from ZIP tube. Install the TEE hose connector (P/N 4W33-6C324-C_

Page 133 d) Install the PCV tube

Page 134 e) EGR vacuum line installation (twist the line)  Twist the EGR vacuum lines as shown on pictures below. Connect EGR vacuum lines to EGR v

Page 135 f) Bypass actuator vacuum line installation.  Assemble and connect the following vacuum hoses as shown on the picture:  TEE connector (P

Page 136 6.20. INSTALLATION OF ACCESSORIES Parts:  Coil Covers RH and LH a) Install the LH and the RH coil covers.

Page 137 b) Install Zip tube. c) Connect the wiring harness of the Water Temperature Sensors on Crossover Tube. d) Install Shroud e) Install th

Page 138 m) Fill coolant to engine thru degas bottle until the coolant level is between “COOLANT LEVEL” marks. Then carefully add some more coolant t

Page 13 Subsystem Component Name and Description Part Number Qty Picture FEAD system CRANK BLOWER PULLEY 4W33-030504-005-B1 1 IDLER PULLEY RIBBED

Page 139 6.21. INSTALLATION OF XCalibrator 2 FLASH TUNER (if equiped) 1. Plug the OBD-II connector into the port under the dash of the vehicle you

Page 140 3. Disconnect the fuel pump and electric fan fuses. From the Main Menu, scroll down to the Program Vehicle menu and press “Select”. Here y

Page 141 WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final ch

Page 14 Subsystem Component Name and Description Part Number Qty Picture ALTERNATOR HARNESS EXTENSION 4W33-180101-001-A 1 RED T-TAP CONNECTOR T-250

Page 15 Subsystem Component Name and Description Part Number Qty Picture Other systems BOOST GAGE 4301 1 GAGE FITTING - COUPLING 28-058L 1 GA

Page 16 4.4. LIST OF SUPPLIED FASTENERS Component Bolt Nut Washer Comment Descr. Pc L (mm) Descr. Pc Descr. Pc Water Pump Mount. Brkt Self tapping

Page 17 5. ENGINE DISASSEMBLING INSTRUCTIONS a) Disconnect the battery; b) Drain the engine cooling system; c) Remove the Degas Bottle supply

Page 18 d) Remove the overflow hose; e) Remove the bolt and the Degas Bottle;

Page 1 INDEX 1. NOTICE ... 2

Page 19 f) Unscrew powersteering reservoir (but leave all the hoses connected), and push it to the side to make enough room;

Page 20 g) Remove the pin-type retainers and remove the radiator sight shield; h) Disconnect the connector of the Cooling Fan Mo

Page 21 i) Remove the two bolts and the fan blade, fan motor and the fan shroud assembly; j) Remove the Upper Radiator Hose from the

Page 22 k) Remove Front Facia Grill;

Page 23 l) Remove the crankcase ventilation hose, clamps, and remove the Zip Tube (air cleaner outlet pipe); m) Remove the accelerator con

Page 24 n) Remove the accelerator cable, the speed control cable and the return spring; o) Disconnect the fuel vapor hose;

Page 25 p) Remove the accelerator control cable from the bracket; q) Remove the speed control cable from the bracket;

Page 26 r) Disconnect the vacuum hose; s) Remove the bolt, disconnect the acceleration control cables and position them aside;

Page 27 t) Remove bolt and the bracket;

Page 28 u) Remove the exhaust gas recirculation (EGR) Tube completely from EGR Valve and Exhaust Manifold (use adjustable wrench); EGR Valve and E

Page 2 1. NOTICE This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout,

Page 29 v) Disconnect the throttle position (TP) sensor and the idle air control (AIC) sensor electrical connectors; w) Disconnect

Page 30 x) Remove the EGR system module electrical connector; y) Remove EGR Valve;

Page 31 z) Disconnect the vacuum hoses and the positive crankcase ventilation (PCV) coolant hoses;

Page 32 aa) Remove the Upper Intake Manifold assembly bolts in the sequence shown. Remove the intake manifold assembly;

Page 33 Engine without Upper Intake Manifold

Page 34 bb) Remove Accessory Drive Belt; Accessory belt tensioner

Page 35 cc) Remove Upper Bracket on Alternator; Crossover Tube and Alternator without bracket

Page 36 dd) Disconnect wiring harness from Water Temperature Sensors on Crossover Tube; Connectors from Engine Coolant Temperature Sensors ee) Dis

Page 37 ff) Disconnect the coolant hoses, the electrical connectors, and the wiring harness retainer;

Page 38 gg) Remove the Crossover Tube;

Page 3 2. WARRANTY AND THANK YOU LETTER There is a 1-Year Limited Warranty included with the purchase of your Marauder Supercharger kit; covering t

Page 39 hh) Remove the 2 bolts and the Alternator; Alternator retension bolts

Page 40 ii) Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor; jj) Separate the wiring harness from the fuel

Page 41 kk) Disconnect the eight fuel injector electrical connectors;

Page 42 ll) Remove Fuel Rail and Fuel Injectors (and leave fuel rail on right side of the car) from Lower Intake Manifold. Before removing, release

Page 43 mm) Remove the ten bolts in the sequence shown, and raise the Lower Intake Manifold Slightly (save bolts and gaskets for later use); Lower

Page 44 oo) Remove Knock Sensor(s) from Engine Valley, but leave knock sensor(s) connected to engine wiring harness, and move somewhere close to the

Page 45 pp) Remove the Flat Idler Pulley from the Front Engine Cover;

Page 46 qq) Remove the Water Heat Tube from the Water Pump (unscrew bolt on the back of right cylinder head which is holding the engine ground wire

Page 47 tt) Remove the 3 bolts on the Front Engine Cover (these bolts will be replaced later with bolts for holding the alternator and the Tensione

Page 48 6. SUPERCHARGER ASSEMBLYING INSTRUCTIONS 6.1. SPARK PLUGS a) Re-gap spark plugs to 0.032”. Use of one heat-range colder spark plugs (Motor

Page 4 3. INSTALLATION INSTRUCTIONS Before beginning this installation, please read through this entire instruction booklet. Trilogy Motorsports

Page 49 6.2. FUEL PUMP AMPLIFIER INSTALLATION Parts:  Fuel Pump Amplifier + harness a) Open the trunk and locate, on the left side of the end of

Page 50 g) Locate within the smaller harness the Pink/Black “HOT” (12 Volt Positive +) wire going to the pump. h) To the left of the Pink/Black

Page 51 i) Cut the Pink/Black “HOT” (12 Volt Positive +) wire going to the pump, and connect the wiring harness of the Boost-A-Pump as shown on the

Page 52 j) Mount the controller in the trunk (the initial set for the controller should be put to 10).

Page 53 k) Route the “S” black wire from the Boost-A-Pump to the interior of the car, passing behind the left back seat, then passing under the LH s

Page 54 6.3. BOOST GAGE INSTALLATION Attention: We suggest starting routing of boost gage line from interior to outside. Apply the Teflon tape (or t

Page 55 d) In order to fit boost gage with fittings in floor console, you need to cut out a plastic flange. Make the cut on the floor console accor

Page 56 e) Install coupling (P/N 203200) on boost gage. Then assemble with pipe fitting (P/N 213210), Tee fitting (P/N 227200), vacuum/pressure swit

Page 57 i) Then route hose from Boost Gage through the grommet next to the gas pedal (you may need to punch a hole through the grommet);

Page 58 6.4. KNOCK SENSOR BOSS REMOVAL Parts:  LOWER INTAKE MANIFOLD (P/N 2R3Z-9424-BB) (this part is used here for clearance check and will be in

Page 5 IMPORTANT NOTICE Trilogy Motorsports Mercury Marauder Supercharger Kit Tuning Notes Congratulations on your purchase of the highest-qualit

Page 59 6.5. HEATER WATER TUBE INSTALLATION Parts:  HEATER OUTLET TUBE (P/N F8ZZ-18B402-BA)  HEATER HOSE # 9 – SIZE ID 5/8"  CLAMPS SIZE

Page 60 d) Tighten the heater tube to cylinder head with supplied M6x16mm bolt and reuse stud that retained original heater tube.

Page 61 e) Bolt the right bank knock sensor to the cylinder head at the spot where was previously the stud that retained ground wire and original hea

Page 62 g) To install heater hose extension, use supplied heater hose # 9, 5/8” – 5/8” connector, convolute and 4 clamps of size # 10. h)

Page 63 k) Assemble Outlet Heater Hose with heater hose #9. Slide a convolute over the hoses and hose connector. Cut out the opening in convolute for

Page 64 6.6. LOWER INTAKE MANIFOLD INSTALLATION Parts:  LOWER INTAKE MANIFOLD (P/N 2R3Z-9424-BB)  PCV HOSE ASSEMBLY (P/N: 4W33-6C324-A)  Clamp

Page 65 b) Install Clamp Size # 4 to retain the PCV Hose Assembly (P/N: 4W33-6C324-A) to PCV hose fitting on the Lower Intake Manifold. The screw of

Page 66 d) Tighten intake manifold fasteners in the sequence shown 10 Nm (89 lb-in) 9 1 3 7 5 10 6 2 8 4

Page 67 6.7. FUEL INJECTORS AND FUEL RAIL INSTALLATION Parts:  FUEL INJECTORS (2R3Z-9F593-BA) a) Install new injectors supplied in the kit;

Page 68 b) Install fuel rail with original bolts, however do NOT tight the fuel rail to lower intake manifold yet. You will need a slack in fuel rai

Page 6

Page 69 c) Install back the clips that retained the old fuel injectors on the fuel rail;

Page 70 6.8. SUPERCHARGER INTAKE ASSEMBLY Attention: Supercharger Intake assembly consists of Supercharger unit (P/N 4W33-030407-001-B), Outlet Plate

Page 71 a) Assemble Outlet Plate and IC Core together. Apply silicone sealant on mating faces (approximately 1/8” of height of sealant across the en

Page 72 b) Apply silicone sealant on the face of Blower outlet port (approximately 1/8” of height of sealant across the entire perimeter), as shown

Page 73 c) Bolt the supercharger unit (blower) to Outlet plate with 6 M8x30 mm Socket Hex head bolts and M8 lock washers, using a torque of 20 to 22

Page 74 d) Apply silicone sealant on the face of the blower inlet port (approximately 1/8” of height of sealant across the entire perimeter).

Page 75 e) Bolt the Inlet Duct to the blower with 3 M8x25mm bolts, and 2 M8 nuts with nylon lock. Back view of Inlet Duct assembled with Blower F

Page 76 f) Apply silicone sealant on mating face of Lower intake manifold (approximately 1/8” of height of sealant across the entire perimeter).

Page 77 g) Carefully install Supercharger Intake Assembly in Lower Intake manifold. Note: Bolt # 8 (see picture after 2 pages for correct bolt num

Page 78 h) Install the Compression Fitting of the Boost Gage on Outlet Plate (Apply Teflon tape or thread seal). Then connect the Boost Gage line t

Page 7 4. TOOLS & PARTS LIST The following list details the tools and supplies that are needed to build your kit. The “helpful” items are not cr

Page 79 i) Tighten the Assembly to lower intake manifold with 10 M8x30mm bolts. Note: Bolts # 9 and # 10 will be removed later on, when installing Cr

Page 80 6.9. EGR Parts:  EGR Tube (4W33-9D477-A) a) Install EGR valve on EGR flange of Inlet Duct. Check for any wear or mechanical damage to EGR

Page 81 b) Carefully slide EGR tube, supplied in the kit, between a back of the engine and firewall. Install the EGR tube on exhaust manifold and EGR

Page 82 c) Connect the eight fuel injector electrical connectors. d) Position the fuel charging wiring and connect to the fuel injection supply man

Page 83 6.10. ACCELERATOR CABLE AND CRUISE CONTROL CABLE Parts:  Accelerator/Cruise Cable Bracket (P/N 4W33-031800-002-B1) a) Inspect original

Page 84 c) To check for the clearance between cruise control cable and Inlet Duct (P/N 4W33-030104-003-A), try to install Accelerator/Cruise Cable B

Page 85 6.11. ADAPTER THROTTLE BODY AND SPACER THROTTLE BODY INSTALLATION Parts:  Adapter-Throttle Body (P/N 4W33-030104-004-A1)  Spacer Thrott

Page 86 c) Apply silicone sealant (approximately 1/8” of height of sealant across the entire perimeter) on open face of Spacer Throttle body.

Page 87 d) Install Spacer Throttle body on Inlet Duct. Use 1 Bolt M8x25mm for the RH side at the bottom of the assembly and 3 Bolts M8x30mm for the o

Page 88 e) Install throttle and cruise control cable on throttle body lever. And install the return spring (Attached to Accelerator/Cruise Cable Bra

Page 8 4.3. PARTS LIST Please make sure you have all the parts listed below prior to start with your supercharger installation. If you are missing an

Page 89 f) Install Idle Air Control (AIC) Valve on the Spacer Throttle Body. Check the gasket and replace if necessary. Reuse the original M6 bolts

Page 90 6.12. INTERCOOLER INLET ADAPTOR INSTALLATION Parts:  Water Adapter Tubes (P/N 2R3Z-9L442-AA)  Water Inlet Adapter O-rings (P/N N802927S

Page 91 c) Install Intercooler Water Inlet Adapter with Gasket Water Inlet Adapter and tighten with 4 bolts, using torque of 106 in*lb (use blue Loc

Page 92 6.13. ACCESSORY BELT INSTALLATION Attention: Due to the packaging of the Supercharger, the alternator has to be moved away from its original

Page 93 a) Routing of a new 6-ribbed serpentine belt is shown on the following picture. ALTERNATOR IDLER PULLEY RIBBED TENSIONER ALTERNATOR

Page 94 b) Routing of a new 8-ribbed supercharger belt is shown on the following picture. 8-RIBBED BELT CRANK BLOWER PULLEY BLOWER PULL

Page 95 c) Install Idler Pulley Ribbed. Tighten with M8x20mm bolt and washer (O.D. 23mm). d) Install Alternator Bracket assembly using M8x

Page 96 e) Alternator pulley replacement: The original alternator pulley must be replaced with the new alternator pulley (part number F5OY-10344-F a

Page 97

Page 98 6.14. INTERCOOLER CIRCUIT and ENGINE COOLING Attention: Hoses as installed must not kink and should not rest on any sharp edges of surroundi