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Ford 4.6/5.4 2V
F-150/F-250
Expedition/Navigator
Supercharger System
Installation Instructions
1997-2003 Model Years
50 State Smog Legal per CARB EO #D-213-20
®
ENGINEERING, LLC
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226
FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST
P/N: 4FM020-010
© 2003 Vortech Engineering, LLC
All Rights Reserved. Intl. Copr. Secured
20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)
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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 installers in your area. © 2003 VORTECH ENGINEERING, LLC All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into a
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Table Of Contents FOREWORD .....................................................................................................................................ii TABLE OF CONTENTS ....................................................................................................................iii DISCLAIMER ....................................................................................................................................iv NOTICE...............................................
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SUPERCHARGED F-150/F-250/EXPEDITION/NAVIGATOR DISCLAIMER Towing, racing performance driving, hard accelerations, and other heavy/severe duty driving activities place extra demands on a vehicle’s transmission. If you use or plan to use your supercharged ‘97 or later Ford F-150, F-250, Expedition under any of these special driving circumstances, Vortech suggests that you evaluate the purchase of a transmission shift improver product.* In simple terms, a transmission shift improver product is de
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IMPORTANT NOTES 1999-2003 Models This kit requires ECM modification and the installation of a Vortech/Superchips ECM Module. The ECM must be sent directly to Vortech by the installing customer (the charge for this service with module installation has been included in the purchase price). • Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1) Vortech/Superchips ECM Module. • The modules are made specifically for each individual vehicle with respect to the facto
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1997-2003 FORD 4.6L, 5.4L 2V F-150/F-250/EXPEDITION/NAVIGATOR Installation Instructions CARB EO #D-213-20 Congratulations on selecting the best performing and best backed automotive supercharger available today... ® ® the VORTECH V-2 Supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty Registration form and return envelope. Vortech super
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1997-2001 Ford 4.6L 2V F-150/F-250/Expedition/Navigator Part No. 4FM218-010S/018S ® PARTS LIST ENGINEERING, LLC 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 2E228-160 SUPERCHARGER ASSEMBLY 1 8F203-265 FUEL PUMP ASSEMBLY 1 2E128-230 V-2 Supercharger 1 5W001-001 Wire Tap 1 2A036-361 3.60 Supercharger Drive Pulley 1 5W001-011 16-14 Ga. Eye
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1997-2001 Ford 5.4L 2V F-150/F-250/Expedition/Navigator Part No. 4FM218-020/028S ® PARTS LIST ENGINEERING, LLC 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 2E228-170 SUPERCHARGER ASSEMBLY 1 4FM112-040 AIR INLET ASSEMBLY 1 2E128-220 V-2 Supercharger 1 4FM010-050 MAF Bracket Assembly 1 2A038-333 3.33 8 Rib Pulley 1 8H040-045 3-3/4" Flanged
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1. COMPONENT REMOVAL AND PREPARATION A. Disconnect the negative battery cable. NOTE: 1999-2003 Models Only 1. Remove the passenger side front kick panel from the interior of the vehicle. Remove the sound deadening material (if any) that is covering the ECM. Remove the plastic ECM hold-down bracket. 2. From the engine side of the firewall (in the en- gine compartment), use a 10mm socket or wrench and remove the harness and plug from the ECM (as you loosen the bolt, the connector will slowly rele
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2. OIL FEED LINE INSTALLATION A. Unplug the connector on the oil pressure sending unit. 2WD only Remove the sending unit from the engine block. (The unit is located on the left front side of the engine, just above the oil pan.) ENGINE 1/4” NPT BLOCK nipple B. Thread the supplied 1/4" NPT fittings into the block as shown. Reinstall the sending unit and connector. 1/4” NPT tee 4WD applications only (without oil cooler) 1/4” NPT x -4 flare • Remove the remote oil filter hose assembly from the two s
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2. OIL FEED LINE INSTALLATION, cont'd. • Using a light amount of oil on the threads for lubrication, 4WD (equipped with factory oil cooler) thread the 1/8" NPT x 45° x #4 fitting into the threaded hole. Teflon tape, paste or other sealant is not recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure. Rotate the fitting so that when it is tight, it will face the front of the vehicle. • Reassemble the oil filter base and bracket and secure ont
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3. OIL DRAIN, cont'd. NOTE: This method of rolling over the lip of the hole and tapping works very well if care- fully done and should cause no problem. E. Thoroughly clean the threaded area. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8" NPT x 1/2" inverted flare fitting and secure in hole. Make sure a seal is formed all around the fitting. F. Thread the tube nut and 1/2" x 90° aluminum tube into the inverted flare fitting by hand. Do not tighten un
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4. CRANKSHAFT PULLEY/SUPERCHARGER DRIVE PULLEY NOTE: This process can be done with the fan shroud and radiator in place providing your balancer puller is equipped with a 5” or shorter forcing screw. Removing the fan shroud and the radiator will allow easier access to the crank pulley and the front of the engine. A. Remove the rubber inspection plug on the left rear of the block to make the flexplate accessible. Using an 18mm socket and a 1/2” drive ratchet, rotate the en- gine until a flexplate
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4. CRANKSHAFT PULLEY/SUPERCHARGER DRIVE PULLEY, cont'd. E. Remove the installation tool and place the supercharger drive pulley on the front of the harmonic balancer. Feeling for align- ment, start the 12mm x 1.50 x 65mm center bolt with thick factory washer and rotate the supercharger drive pulley until the three bolt holes are aligned. Start the three 8mm x 1.25 x 25mm cap screws with washers, tighten all evenly beginning with the center bolt (some applications may need two wash- ers under eac
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6. FUEL PUMP RELAY A. Remove the power distribution box from its mount- ing bracket. Remove the bottom cover and the side panel exposing the main power lugs, the bottom of the fuses and relays. B. Looking at the underside of the power distribution box, locate the fuel pump relay (should be labeled #4). Directly beneath the fuel pump relay, locate the green wire with yellow stripe. C. With the help of an assistant and a test light, check the green/yellow wire for key-on power, this wire should s
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7. WIRE PREPARATION (4.6 models only) A. To accommodate the installation of the supercharger and the relocation of the coil, it will be necessary to modify the coil and cam trigger loom, extend the ra- dio ignition interference wire and relocate the spark plug wire clips. B. Remove the 90° plastic wire support from the cam sensor plug, this will allow the wire to be routed tightly against the face of the main mounting plate at a later time. C. Carefully remove approximately 6” of wire wrap from
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8A. MAIN MOUNTING PLATE ASSEMBLY AND MOUNTING (4.6L models only) A. Attach the supplied power steering reservoir/coil bracket to the main mounting plate using the 1/4-20 x 3/4” bolts, nuts and washers (see photo). B. Using the supplied 10-24 x 2” bolts and washers, se- cure the coil and the radio ignition interference ca- pacitor to the power steering reservoir/coil bracket. C. To prepare the mounting location for the main mount- ing plate, remove the three factory stud/bolts previ- ously used
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8A. MAIN MOUNTING PLATE ASSEMBLY AND MOUNTING (4.6L models only) cont'd. I. Move the power steering reservoir into the appropri- ate location on the new power steering reservoir/coil mounting bracket and secure with the provided 1/4" hardware. J. Secure the power steering reservoir lines away from the steering shaft with the tie wraps provided. K. Reattach the plug wires to the coil and secure with the previously removed clips. Fig. 8A-d 8B. MAIN MOUNTING BRACKET ASSEMBLY AND MOUNTING (5.4L mode
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8B. MAIN MOUNTING BRACKET ASSEMBLY AND MOUNTING (5.4L models only), cont'd. H. Install the supplied support strap between the back of the main mounting bracket and the boss on top of the thermostat housing. Secure both ends using the sup- plied 6mm bolt and washer and the 1/4-20 x 1" flat allen bolt, washer and lock nut. I. Attach the supplied power steering reservoir bracket to the main mounting bracket using the 1/4-20 bolt and washers (see photo). J. Trim 4" off of the top end of the stoc
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9. EGR CONTROL MOUNTING AND MAIN MOUNTING PLATE SUPPORT (4.6L models only) A. Using the #10-24 x 1/2” bolts, nuts and washers, re- mount the EGR controls onto the Vortech mounting bracket. B. Directly beneath the EGR bracket, locate the 6mm bolt securing the fuel rail. Remove the bolt. C. Install the supplied support strap between the intake manifold and the main mounting plate. Secure both ends using the factory 6mm fuel rail bolt and the sup- plied 3/8-16 x 1" hexhead bolt, nut and washer. Ma
