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Ford 5.0 and 5.8
Bronco/F-Series/Lightning
Supercharger System
Installation Instructions
’87-’96 5.8L F-Series Truck - 50 State Smog Legal per CARB EO #D-213-16
’93-’95 5.8L Lightning Truck - 50 State Smog Legal per CARB EO #D-213-16
’87-’96 5.0L F-Series Truck - 50 State Smog Legal per CARB EO #D-213-16
®
ENGINEERING, INC.
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901
P/N: 4FC020-010
©2000 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
13SEP00 V1.3 (86-93 5.0 Lt Truck
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FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for possible installers in your area. © 2000 VORTECH ENGINEERING, INCORPORATED All rights reserved. No parts of this publication may be reproduced, transmitted, transcribed, o
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Table Of Contents FOREWORD ........................................................................................................................... i TABLE OF CONTENTS .......................................................................................................... ii IMPORTANT NOTICES .......................................................................................................... iii CRANE IGNITION SYSTEMS ...................................................................
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IMPORTANT NOTICES! BEFORE BEGINNING INSTALLATION On 1993 and later model years, it will be necessary to replace the fan blade assembly (not the entire fan clutch assembly) with an earlier model unit. The Ford part number is E7TZ-8600B. Refer to page 5, item 8 of this manual. 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 proper
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SPECIAL NOTICE CONCERNING THE CRANE IGNITION SYSTEM The ignition system, manufactured by Crane Electronics, included in this kit is serviced exclusively by the manufacturer. Crane Electronics warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warranty. If found to be defective as m
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SPECIAL NOTICE CONCERNING THE MSD IGNITION SYSTEM The MSD Boost Timing Master, manufactured by Autotronic Controls Corporation, included in this kit is serviced exclusively by the manufacturer. Autotronic Controls Corporation warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warra
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Installation Instructions for ’87-’96 5.8L F-Series Truck - 50 State Smog Legal per CARB EO #D-213-16 ’93-’95 5.8L Lightning Truck - 50 State Smog Legal per CARB EO #D-213-16 ’87-’96 5.0L F-Series Truck - 50 State Smog Legal per CARB EO #D-213-16 Congratulations on selecting the most technically innovative, best performing and best ® backed automotive supercharger available today... the VORTECH V-2 supercharger! Before beginning this installation, please read through this entire instruction book
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1987-1996 FORD 5.8 TRUCK Part No. 4FC218-030SQ ® ENGINEERING, INC. PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-030 SUPERCHARGER ASSEMBLY 1 4FC238-068 FMU (WITH LINES) 1 2E128-030 V-2 SQ Supercharger 1 6Z110-111 12:1 black fuel management unit 1 2A036-287 2.87” supercharger drive pulley 1 4FC145-156 Male fuel line assemb
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1993-1995 FORD 5.8 LIGHTNING TRUCK Part No. 4FC218-040SQ ® ENGINEERING, INC. PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 4FC139-096 PCV BYPASS KIT 1 2E228-130 SUPERCHARGER ASSEMBLY 1 7U100-055 6" nylon tie wraps 6 2E128-030 V-2 SQ Supercharger 1 2A036-287 2.87” supercharger drive pulley 1 7U030-056 3/8" x 40" PCV hose 1 8R101
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1987-1996 FORD 5.0 TRUCK Part No. 4FE218-070SQ ® ENGINEERING, INC. PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. Part Number Description Quantity Part Number Description Quantity 2E228-030 SUPERCHARGER ASSEMBLY 1 4FC238-068 FMU (WITH LINES) 1 2E128-030 V-2 SQ Supercharger 1 6Z110-111 12:1 black fuel management unit 1 2A036-312 3.125” supercharger drive pulley 1 4FC145-156 Male fuel line assem
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1. COMPONENT REMOVAL A. Remove the following: 1. intake air duct 2. air filter box cover & inlet hoses 3. accessory drive belt 4. cooling fan & fan shroud 5. water pump pulley 6. crank pulley 7. power steering pulley (using a pulley) B. Remove the A/C compressor from the mount- ing bracket and secure to one side. NOTE: When removing the power steering pump and A/C compressor, do not break any lines; just set the unit aside. C. Remove the power steering pump from the bracket. D. Remove the cast
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3. OIL DRAIN FITTING A. Remove the driver's side valve cover. B. Measure 4-3/4" forward from the middle of LEFT VALVE the center bolt hole and up 3/4" from the COVER flange as shown on the inboard side of the FORWARD FROM FORWARD FROM valve cover and mark. (See Figure 3-a.) HOLE 4-1/2" HOLE 4-3/4" C. Make an 11/16" diameter hole at the mark using a drill or chassis punch. Debur the hole completely. Thoroughly clean the valve OIL cover. FILLER D. Install the 1/2" hose fitting into the elbow and U
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5. MAIN BRACKET INSTALLATION, CONT'D. D. Reinstall the power steering pump pulley. Make sure that the pulley is properly placed on the pump shaft so that the end of the shaft and the front face of the pulley hub are flush. NOTE: For proper accessory drive belt alignment, it is imperative that the power steering pump pulley be reinstalled properly. There should be no recess nor should there be any protrusion of the shaft. It must be FLUSH. 6. SUPERCHARGER INSTALLATION A. Mount the supercharger m
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7. OUTLET PLENUM DISCHARGE TUBE A. Temporarily place the 2 3/4" diameter blue sleeve on the supercharger outlet as far as it will go. NOTE: If installing the kit on a 5.8 Lightning, disregard points B, C and D. Install the discharge tube to the throttle body using the 3" x 2" sleeve and the clamps provided. (See Figures 7-a, 7-b.) Figure: 7-a - 5.0, 5.8 F-Series/Bronco B. Slide the two 2" diameter blue sleeves onto the throttle body inlets, temporarily, as far as they will go. It is easier to un
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8. WATER PUMP PULLEY AND FAN ASSEMBLY NOTE: On 1993 and later model years, it will be necessary to replace the fan blade assembly (not the entire fan clutch assembly) with an earlier model unit. The Ford part number is E7TZ-8600B. A. Screw the four 5/16" studs into the water pump flange. B. Place the Vortech supplied water pump pul- ley onto the studs. C. Lower the fan assembly and fan shroud into place together. D. Secure the fan assembly onto the water pump with the nuts and the washers pro- v
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10. FUEL PUMP A. Release any pressure from the fuel tank by momentarily loosening the filler cap. B. Disconnect the line to the fuel filter by care- fully removing the white retaining tab. Attach the line to the adapter fitting, as shown. (See Figure 10-a.) C. Connect the fuel pump inlet to the adapter with the 3/8" hose provided. D. Connect the fuel pump outlet to the filter inlet with the 5/16" hose. Use the supplied Ford fuel connector and hose clamp. E. Attach the negative pump terminal to a
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11. FUEL MANAGEMENT UNIT INSTALLATION A. Mount the fuel management unit (FMU) to CONNECT TO MANIFOLD the firewall on the driver's side. Placement VACUUM/PRESSURE should be on the flat area near the top of the firewall just below the hood hinge base and outward from the swinging portion of the hood hinge. Use the sheet metal screws in the kit to secure. INLET B. Using a special tool for springlock connec- (FUEL LINE tors, disconnect the stock fuel return line FROM where it exits the stock fuel pr
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12. AIR FILTER COVER AND INLET DUCT A. Secure the Vortech air filter cover in place of the stock air filter cover with the original screws. Replace or clean the air filter ele- ment, if necessary. IMPORTANT: For the 94-96 5.0 and 95-96 5.8, disregard step A and complete the following steps before proceeding to step B. 1. Remove the air filter cover/MAF assem- bly. Drill a 7/8" hole into the rear portion of the cover (the side facing the brake master cylinder). Reinstall the air filter cover/MAF
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13. 5.8 LIGHTNING SUPPLEMENTAL INSTALLATION INSTRUCTIONS FOR THE BYPASS VALVE DISCHARGE TUBE A. Screw the fitting into the new inlet elbow as shown in the graphic. B. Install the inlet elbow onto the supercharger with the fitting on top and pointing towards the small tube branched off of the discharge tube. C. Place the hoses, as shown, on the valve and secure with the clamps provided. D. Install the valve with the hoses connected, BYPASS VALVE between the inlet elbow and discharge tube. Secure
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14.1 IGNITION/BOOST CONTROL UNIT INSTALLATION (NON-LIGHTNING TRUCKS ONLY), CONT'D. BOOST RETARD TO MANIFOLD 1 2 VACUUM BOOST RETARD 0 3 GROUND CONNECTOR BLACK ® SUPERCHARGERS Ignition/Boost Control MANUFACTURED FOR VORTECH SUPERCHARGERS BY MSD MAGNETIC PICKUP CONNECTOR IGNITION (NOT USED) COIL WHITE WHITE RED RED ORANGE ORANGE BLACK FROM FACTORY COIL HARNESS Figure: 14-b P/N: 4FC020-010 ©2000 Vortech Engineering, Inc. All Rights Reserved, Intl. Copr. Secured 10 13SEP00 V1.3 (86-93 5.0 Lt Truck(4
