Ford AM/FM Stereo Radio Cassette Car Stereo System User Manual
Contents
1. Q kb SE ect IMPORTANT Before beginning installation verify that all parts are included in the kit Report any shortages or damaged parts immediately Part Number Description 2E228 170 SUPERCHARGER ASSEMBLY 2E128 220 V 2 Supercharger 2A038 333 3 33 8 Rib Pulley 7U100 070 3 16 x 3 16 x 7 8 Key 2A040 011 Pulley Retainer 7B375 125 3 8 24 x 1 1 4 HXHD Bolt 7K375 040 3 8 AN960 Flat Washer 4FM111 054 MAIN MOUNTING BRACKET ASSEMBLY 4FA016 170 Idler Smooth 4FA016 171 Dust Shields 4FM010 140 Bracket Support 4FM010 150 Bracket Support 2 5 4 4FM011 021 Mounting Bracket Mach 4FM016 031 Idlers Grooved 4FM017 010 Spacer Short Bracket Support 2 4FM017 020 Spacer Long Bracket Support 2 7A250 075 1 4 20 x 3 4 S H C S 0 1 4 20 1 Flat Allen 7A375 175 3 8 16 x 1 75 Hex Head 7A375 250 3 8 16 x 2 5 Hex Head 7A437 150 7 16 14 x 1 5 Bolt Hex Head 7C010 080 10mm x 1 5 x 80mm S H C S 7060 016 M6 x 1 00 x 16 HXHD Bolt 7F250 021 1 4 20 Nylock Nut 7J006 093 6mm Washer 7J250 001 1 4 SAE Washer Plated 7J438 091 9 16 SAE Washers Plated 7K375 040 3 8 AN 960 Flat Washer 7010 002 10mm Washer 5W001 012 Solderless Connector 5W001 006 3 8 Heat Shrink Tubing 12 700 14mm x 2 0 30mm HXHD 5W018 070 18 GA Wire Green 12 5W018 030 18 GA Wire Grey 12 7P375 050 3 8 Hose Mender 0 04 4 Hose Clamp 7U032 016 3 8 Hose Hi Pressure 18 4FM010 160 Power Steering Bracket 4FM 112. 9 Heater Hose 7P125 026 1 8 NPT x 4 90 Fitting 1 06 5 32 12 Vacuum Line 1 7100 055 6 Tie Wraps 4 Ld des Ps 7P250 082 1 4 NPT x 4 90 Fitting 1 eer xs 7 250 122 1 4 Pipe Thread 1 7 375 106 CV 7P250 123 1 4 NPT x 1 1 2 Nipple 1 7P250 034 1 4 NPT Strt Tee 1 7U030 026 1 4 x 62 Oil Feed Hose 1 7P125 103 1 8 NPT x 45 4 1 P N 4FM020 010 2003 Vortech Engineering LLC i All Rights Reserved Intl Copr Secured Vil 200CT03 v3 1 4 6 5 4Exped Nav 4FM v3 1 1997 2001 Ford 5 4L 2V F 150 F 250 Expedition Navigator Part No 4FM218 020 028S PARTS LIST ENGINEERING LLC Quantity DO NO OO Es E eh wh E vc Description AIR INLET ASSEMBLY MAF Bracket Assembly 3 3 4 Flanged Air Filter 56 Hose Clamps 3 1 2 x 2 Sleeves 3 1 2 x 15 Flex Hose 7 16 Rubber Grommet 3 4 x 24 Heater Hose 1 2 NPT x 3 4 90 Hose Barb 3 8 NPT x 5 8 90 Hose Barb 90 Intake Elbow 90 Intake Elbow w Boss 1 4 20 x 3 4 SH Cap Screws 1 4 20 Nylock Nuts 1 4 SAE Washers 6 Tie Wraps 5 16 18 x 1 1 2 HXHD Cap Screws 5 16 Fender Washers 5 16 SAE Flat Washers 5 16 18 Nylock Nuts 3 4 x 90 Hose 5 8 Molded Elbow Hose 3 4 NPT x 1 90 Hose Fitting 52 Hose Clamps 5 4 DISCHARGE ASSEM
3. 4 6 5 4Exped Nav 4FM v3 1 P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200CT03 v3 1 4 6 5 4Exped Nav 4FM v3 1 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 nut is visible Place a 14mm deep socket and extension on the flexplate nut and rotate the engine counterclockwise until the socket engages with the top of the access hole This will block the movement of the crankshaft allowing the bolt to be loosened This operation may require the assistance of another person Remove the center balancer bolt B Install the harmonic balancer puller Evenly start three puller bolts not supplied 8mm x 1 25 on the 4 6L and 10mm x 1 50 on the 5 4L Engage the forcing screw against the pivot and check alignment NOTE When using the harmonic balancer puller pay special attention to alignment of the forcing screw and pivot improper alignment can result in damage to the crankshaft C After ensu
4. C Carefully remove approximately 6 of wire wrap from the loom containing the coil cam position sensor and the radio ignition interference capacitor wire Sepa rate the wires and rewrap them individually using black electrical tape and the provided wire wrap D Cut the radio ignition interference wire approximately 4 from the plug and strip approximately 3 4 of in sulation off of the wire Slip the two 2 pieces of shrink tube over the exposed wire ends Solder in the 6 length of red 16 gauge wire E To allow the relocation of the coil it is necessary to remove all spark plug wire retaining clips between the alternator and coil as they will be reinstalled after the coil has been moved to its new location COIL PACK IGNITION CONNECTOR CAPACITOR CAM TRIGGER CONNECTOR REM OVE PLASTIC 90 WIRE SUPPORT EXTEND WITH 6 WIRE SOLDER AND SHRINK TUBE UNWRAP Y BEND APPROXIMATELY 6 Fig 7 a P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 8 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
5. air sensor mounting bracket with the 1 4 20 x 3 4 bolts nuts and washers Mount the air filter to the bracket and secure the 60 clamp C Using the factory air inlet filter can CRUISE ister mounting location secure the CONTROL mass air bracket with the 5 16 18 1 1 2 bolts nuts and washers use the large 5 16 fender washers on the bottom of the factory rub ber grommets D Connect the 90 plastic elbow equipped with the 3 4 barb 90 to the 3 1 2 silicone sleeve Secure with the 56 hose clamps E 5 4 Models only Wire Install the supplied MAF Voltage Limiter As sembly Use the instruction sheet supplied in the MAF Voltage Lim iter Assembly 14 AIR INLET BYPASS ASSEMBLY A Place the 3 1 2 silicone sleeve and the 56 hose clamps onto the supercharger inlet Install the 90 plastic inlet eloow Secure the 56 hose clamps In sert the factory air temperature sensor into the rub ber grommet located on the inlet elbow and attach the connector B Attach the supplied 1 5 hose 1 x 9 hose 4 6L 5 4L and 16 hose clamp to the 1 plastic 90 fitting installed on the inlet elbow Secure clamp SENSOR 4 6L model shown Fig 14 c 4 6L MODELS ONLY see photo above Fig 14 d 5 4L MODELS ONLY Fig 14 e 14 AIR INLET BYPASS ASSEMBLY cont d C Install the bypass valve and 16 hose clamp on the end of the 1
6. belt stretches initially and will require adjustment in 250 to 400 miles Read the STREET SUPERCHARGER SYS TEM OWNER S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty 30 days of purchasing your supercharger system to qualify 4 6L ONLY P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 15 DISCHARGE Install the 3 silicone sleeve and the 48 hose clamps on the throttle body Slide the 2 3 4 silicone sleeve and the 44 hose clamps onto the discharge tube Install the discharge tube on the throttle body side Rotate the supercharger side into position and center the silicone sleeve Secure with 48 and 44 hose clamps Connect the 1 bypass hose to the bung on the back side of the discharge tube and secure using a 16 hose clamp Inspect all ducts and hoses to ensure they are secure and that all hose clamps are properly tightened Remove the factory PCV valve from the right side valve cover and install the supplied PCV in its place WARNING Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check A FINAL CHECK NOTE 99 03 Models Only Once the ECM is re ceived back from Vortech with the ECM mod ule installed reinstall the ECM into the ve hicle In some cases the extra height of the ECM module will not allow th
7. from their bracket unbolt the bracket from the intake manifold and set aside J Unbolt the power steering fluid reservoir from its bracket Separate the throttle cables from the retainer bracket Remove the main bracket from the waterneck and the head and set aside K Remove the plastic wire harness holder mounted on the upper row of valve cover bolts on the driver s side L Remove the accessory drive belt and set aside 1 2WD only 1 4 NPT nipple 1 4 NPT gt tee 1 4 NPT 4 gt Ka flare Factory sending unit VIEW FROM FRONT Fig 2 a AWD Only without oil cooler Remote oil filter hole assembly Factory oil sending unit location remove DRIVER S SIDE VIEW Fig 2 b 1 4 NPT x 4 flare Oil feed to supercharger 1 4 NPT street tee ENGINE BLOCK Relocated sending unit Remote oil filter hose assembly TOP VIEW Fig 0 2 OIL FEED LINE INSTALLATION A Unplug the connector on the oil pressure sending unit 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 B Thread the supplied 1 4 NPT fittings into the block as shown Reinstall the sending unit and connector 4WD applications only without oil cooler e Remove the remote oil filter hose assembly from the two studs on the engine block Disconnect the factory oil
8. 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 supercharger systems are performance improving devices In most cases increases in torque of 30 35 and horsepower of 3595 4576 can be expected with the boost levels specified by Vortech Engineering This product is intended for use on healthy well maintained engines Installation on a worn out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger Vortech Engineering is not responsible for engine damage Installation on new vehicles will not harm or adversely affect the break in period so long as factory break in procedures are followed For best performance and continued durability please take note of the following key points Use only premium grade fuel 91 octane or higher R M 2 The engine must have stock compression ratio If the engine has been modified in any way check with Vortech prior to using this product Always listen for any sign of detonation pinging and discontinue hard use no boost until problem is resolved 5 Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle Thereafter always use a high grade SF rated engine oil or a high quality synthet
9. 01 015 20A Blade Type Fuse 1 ay ashers 5W001 010 16 14 Ga Female Slides 3 8C080 020 8mm x 1 25 x 20mm HXHD Bolt 1 7030 050 19mm x 16 Fuel Hose 1 00 5 16 AN Washer 8F001 002 155 Inline Fuel Pump 1 4FM010 130 Bracket Support Strut 1 7R003 024 4 1 2 Adel Clamp 1 7375 100 3 8 16 x 1 HXHD Bolt 1 7R001 008 8 Hose Clamps 9 EE 7 010 075 12 x 3 4 Sheet Metal HXHD Bolt 1 j Masher 7P500 004 1 2 Fuel Fitting Adapter 1 7R003 008 1 2 Adel Clamp 1 5W018 010 6 18 Ga Std Red Wire 1 AEN 112 010 AIR INLET ASSEMBLY 1 5W001 007 3 16 x 6 Heat shrink Tube 1 4FM010 050 MAF Bracket Assembly 1 7C080 085 8mm Shoulder Bolts 4 8H040 045 3 3 4 Flanged Air Filter 1 7R002 056 56 Hose Clamps 4 4FM 110 040 COIL EGR POWER STEERING ASSEMBLY 1 75350 200 3 1 2 x 2 Ste 2 4FM010 040 Coil Mounting Bracket 1 00 3 1 2 15 Flex Hose 1 ee So Bolts 4 70100 052 7 16 Rubber Grommet 1 101002 8 7038 000 3 4 x 24 Heater Hose 1 a 10 Flat Washers 12 7P500 026 1 2 NPT x 3 4 90 Hose Barb 1 7250 075 1 4 20 x 3 4 SH Cap Screws 4 7P375 052 3 8 NPT x 5 8 90 Hose Barb 1 7F250 021 1 4 20 Nylock Nuts 4 4FA012 012 90 Intake Elbow 1 E 4FA012 013 90 Intake Elbow w Boss 1 010 030 Bracket 7250 075 1 4 20 x 3 4 SH Cap Screws 4 7010 050 10 24 x 1 2 SH Cap Screws 4 7F250 021 1 4 20 Nylock Nuts 4 4FM111 032 SUPERCHARGER DRIVE ASSEMBLY 1 7J250 001 1 4 SAE Washers 4 4FM01 1 032 Belt Tensioner 1 7U100 055 6 Tie Wraps 6 2A04
10. 1 062 SUPERCHARGER DRIVE ASSEMBLY 2A048 802 Belt 8 rib x 80 14 4FA016 170 Idler Smooth 4FA016 171 Dust Shields 4FM011 052 Spring Tensioner Long Ford 4FM016 011 Balancer 4FM016 041 Crank Pulley 8 Rib 7A375 324 3 8 16 x 3 25 HXHD Bolt 7C010 045 10mm x 1 5 x 45mm Hex Head 7C080 026 8mm x 1 25 x 25mm SH Bolts 7C120 065 12mm x 1 5 x 65mm HXHD Bolt 7J438 071 7 16 USS Washer 7K312 001 5 16 AN Washers 7K375 040 3 8 AN 960 Flat Washer 8F203 265 FUEL PUMP ASSEMBLY 5W001 001 Wire Tap 5W001 011 16 14 Ga Eyelets 7E010 050 12 x 1 2 Sheet Metal Screw 7P312 003 5 16 Female Fuel Connector 0 03 14 5 Stepless Clamps 7U100 044 4 Tie Wraps 7U100 055 6 Tie Wraps 7U031 018 5 16 x 11 High Pressure Fuel Hose 8F101 200 T Rex Wiring Assembly 5W001 014 Fuse Holder 5W001 015 20A Blade Type Fuse 5W001 010 16 14 Ga Female Slides 70 12mm 16 Fuel Hose 8F001 002 155 Inline Fuel Pump 7R003 024 1 1 2 Adel Clamp 7R001 008 8 Hose Clamps 7E010 075 12 x 3 4 Sheet Metal HXHD Bolt 7P500 004 1 2 Fuel Fitting Adapter AEN 238 068 FMU with lines 4 8 1 Fuel Management Unit 4FA145 010 Male Fuel Line 4FA145 020 Female Fuel Line 7U030 046 5 32 x 18 Vacuum Line 7P156 082 5 32 TEE 7U100 055 6 Tie Wraps P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 4 6 MODELS ONLY P N 4FM020 010 2003 Vortech Engineering L
11. 6 725 Belt 1 7A312 150 5 16 18 x 1 1 2 HXHD Cap Screws 2 72 12mm Flat Washers 3 1 5 16 Fender Washers 2 7C012 020 12mm x 1 75 X 20mm Bolts 5 7J312 000 5 16 SAE Flat Washers 2 7012 022 12mm x 1 75 X 20mm Thin Head Bolt 1 7F312 017 5 16 18 Nylock Nuts 2 4FA016 150 Smooth Pulley Tensioners 2 7U030 065 3 4 x 90 Hose 1 4GF016 160 Ribbed Idler Pulley 1 7U133 024 5 8 Molded Elbow Hose 1 4FK116 021 Idler Pulley Assembly 1 7P750 102 3 4 NPT x 1 90 Hose Fitting 1 0 55 10mm 1 50 x 85mm HXHD Bolt 1 7R002 052 52 Hose Clamps 2 Ger m es 4FM238 068 FMU with lines 1 017 02 pacer 1 62110 114 8 1 Fuel Management Unit 1 16 011 Balancer 4FA145 010 Male Fuel Line 1 7C080 026 8mm x 125 x 25mm SH Bolts 3 AFA145 020 Female Fuel Line 1 io 5 16 AN Washers 3 70030 046 5 32 x 18 Vacuum Line 1 7120 065 12mm x 1 5 x 65mm HXHD Bolt 1 7P156 082 5 32 Tee 1 7438 071 7 16 USS Washer 1 70100 055 6 Tie Wraps 4 4FM016 012 Crank Pulley 1 4FM130 IL DRAIN ASSEMBLY 1 4FM112 020 DISCHARGE ASSEMBLY 1 S e x 32 Oil Boss 1 Se SR Tube 78001 008 8 Stainless Hose Clamps 2 EH 2 S gt Se 1 2 Male Connector 1 4FH100 01 il Drain Tube Nut Assy 1 7R002 044 144 Hose Clamps 2 07910 O Drain Mee e is Ge 2 4FM130 026 OIL FEED ASSEMBLY 1 Mies DUE 70030 026 1 4 x 36 Oil Feed Hose 1 8000 M ugs 7P525 067 525 Crimp Ferrules 2 ee 5 XT GE SE 7 250 066 4 Swivel x 1 4 Hose Barb Fittings 2 7U034 016
12. BED IDLER P N 4FM020 010 2003 Vortech Engineering LLC 9 All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 8A MAIN MOUNTING PLATE ASSEMBLY AND MOUNTING 4 6L models only cont d 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 Secure the power steering reservoir lines away from the steering shaft with the tie wraps provided Reattach the plug wires to the coil and secure with the previously removed clips 8B MAIN MOUNTING BRACKET ASSEMBLY AND MOUNTING 5 4L models only ing plate remove the three 10mm factory stud bolts located on the driver side engine front cover Reinstall the accessory belt NOTE The use of blue Loctite is recom mended for all idler bolts Cut and extend the cam sensor wires using the sup plied 18GA wires and solderless connectors Using tie wraps secure the cam sensor wire as shown in the photo Install the large support bracket onto the engine block using the 14mm x 2 0 x 35mm bolts washers and spacers NOTE The most forward mounting boss should use the 14mm x 2 0 x 30mm and the smaller of the two spacers Do not tighten the bolts until the upper part of the support bracket has been mounted With the main mounting bracket positioned on the front cover ensure that the cam sensor
13. BLY Discharge Tube 5 4 Only 5 32 TEE 16 Hose Clamps 44 Hose Clamps 48 Hose Clamps 2 3 4 x 2 Sleeve 3 x 2 Sleeve 5 32 x 12 Vacuum Line 1 x 9 Heater Hose 1 x 2 5 Heater Hose Bypass Valve PCV Valve OIL FEED ASSEMBLY 1 4 x 36 Oil Feed Hose 525 Crimp Ferrules 4 Swivel x 1 4 Hose Barb Fittings 1 8 NPT x 4 90 Fitting 6 Tie Wraps 1 4 NPT x 4 90 Fitting 1 4 Pipe Thread TEE 1 4 NPT x 1 1 2 Nipple 1 4 x 62 Oil Feed Hose 1 4 NPT Strt TEE 1 8 NPT x 45 4 Fitting OIL DRAIN ASSEMBLY 1 2 x 32 Oil Drain Hose 8 Stainless Hose Clamps Male Connector Oil Drain Tube Nut Assy MAF CLAMP ASSEMBLY Part Number 4FM112 040 4FM010 050 8H040 045 7R002 056 78350 200 7U035 000 7U100 052 7U038 000 7P500 026 7P375 052 4FA012 012 4FA012 013 7A250 075 7F250 021 7J250 001 7U100 055 7A312 150 2071 000 7F312 017 7U030 065 7U133 024 7P750 102 7R002 052 4FM112 030 4FM012 030 7P156 082 7R002 016 7R002 044 7R002 048 78275 200 78300 200 7U030 046 7U034 016 7U034 016 8D001 001 7P375 106 4FM130 026 7U030 026 7P525 067 7P250 066 7P125 026 7U100 055 7P250 082 7P250 122 7P250 123 7U030 026 7P250 034 7P125 103 4FM130 036 7U030 036 7R001 008 7P375 042 4FH100 010 5A101 016 viii Quantity ee oo ee BSB 09 AN
14. 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 FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience Please browse through each step of this instruction manual priorto 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 another language in any form by any means without written permission of Vortech Engineering LLC P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured oe 200CT03 v3 1 4 6 5 4Exped Nav 4FM v3 1 Il P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured TOOL amp SUPPLY REQUIREMENTS PARTS LIST 1997 2001 FORD 4 6L 2V F 150 F 250 PARTS LIST 1997 2001 FORD 5 4L 2V F 150 F 250 COMPONENT REMOVAL AND PREPARATION OIL FEED EINE INSTALLAT IGON co ctetu dt det nt tuens CRANKSHAFT PULLEY SUPERCHARGER DRIVE ee e MIS ER FUEL BILLARD WIRE PREPARATION 4 6 Mode
15. LC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 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 EE 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 release Remove the ECM from the vehicle 3 Contact the Vortech Service Department for a Return Authorization Number Send both ECM and supplied credit tag to Vortech using the en closed shipping box B Remove the throttle body throttle linkage cover C Detach the crankcase ventilation tube from the driver s side valve cover and the air inlet D Remove the idle air control resonator and air filter cover E Unplug the intake air temperature sensor IAT and the mass air flow MAF sensor F Detach all remaining components of the air inlet as sembly and set aside From the left side coil unplug the radio ignition inter ference capacitor remove the spark plug wires and coil plug H Remove the cam trigger plug unbolt the coil and re move the coil bracket Separate the EGR pressure transducer and the EGR vacuum regulator solenoid
16. cedl B Remove the diaphram and 7 1 disk 2 038 O D and ring from inside of the FMU C Install the replacement 8 1 ring with notched part facing down around the four screws inside the FMU The 8 1 components are larger in diameter that their 7 1 counterparts Place the 8 1 disk 2 22 O D in side the ring on top of the piston D Install the new diaphram and carefully line up the holes to the body E Reinstall the FMU cover with the six allen head screws Do not overtighten the screws The correct torque is 24 in Ib 2 ft Ib 11 IDLE AIR CONTROL RESONATOR AND CRANKCASE VENT HOSE REROUTING 4 6L ONLY 4 6L ONLY Fig 12 a Attach the supplied 3 4 x 90 rubber elbow to the idle control motor near the throttle body See Fig 11 a Insert the factory idle control resonator into the elbow and locate underneath the discharge tube Connect the supplied 3 4 x 28 hose to the idle con trol resonator and route the remaining end to the new air inlet location See step 14 Remove the 90 rubber elbow from the factory valve cover vent on the left side of the engine Attach the short leg of the supplied 5 8 x 90 x 24 hose to the valve cover and route the long straight end over to the brass fitting on the supercharger inlet elbow Trim hose length if necessary See step 14 12 SUPERCHARGER MOUNTING Attach the oil drain hose to the oil drain fitting on the b
17. d hose mender Secure with the two supplied 4 hose clamps Mount the power steering reservoir onto the new power steering reservoir bracket and attach with the provided 1 4 hardware Using tie wraps secure the power steering lines away from the steering shaft H 9 EGR CONTROL MOUNTING AND MAIN MOUNTING PLATE SUPPORT 4 6L models only Fig 9 b Using the 10 24 x 1 2 bolts nuts and washers re mount the EGR controls onto the Vortech mounting bracket Directly beneath the EGR bracket locate the 6mm bolt securing the fuel rail Remove the bolt 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 Make sure that the strap is not sandwiched in between the fuel rail and the manifold The support must be at tached underneath the bolt and on top of the rail tab Improper assembly may cause fuel leakage With the two factory 6mm bolts previously used to mount the EGR controls remount the new EGR as sembly in the original location on the intake manifold and secure Reconnect all factory hoses and connec tors A 10 FUEL MANAGEMENT UNIT FMU Using a spring lock disconnect tool disconnect the fuel return line at the fuel rail Connect the FMU inlet hose to the fuel rail Route the fuel line to the 90 brass fitti
18. e use of the fac tory hold down bracket Reconnect the fac tory Mes and reinstall the factory kick panel Reconnect the battery If your vehicle has gone over 20 000 miles since its last spark plug change you will need to change the spark plugs now before test driving the vehicle Check all fittings nuts bolts and clamps for tight ness Pay particular attention to oil and fuel lines around moving parts sharp edges and exhaust sys tem parts Make sure all wires and lines are properly secured with clamps or tie wraps Check all fluid levels making sure that your tank s is are filled with 92 octane or higher fuel before com mencing test drive Start engine and allow to idle a few minutes then shut off Recheck to be sure that no hoses wires etc are near exhaust headers or moving parts and for signs of any fluid leakage PLEASE TAKE SPECIAL NOTE Operating the vehicle without ALL the subassemblies completely and prop 16 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 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1
19. er pulley H K NOTE The supercharger drive belt should have ap proximately 1 of deflection and will need to be retightened between 250 to 400 miles 5 4L ONLY Using a 1 2 drive breaker bar rotate the tensioner clockwise and align belt Release tensioner to tighten belt Connect the oil drain hose down to the oil pan tube previ ously installed Trim hose length if necessary and secure with a 8 clamp Make sure drain hose runs downhill con tinuously with no kinks or dips Support fitting in oil pan with a wrench while tightening the drain tube fitting Make sure the tube is angled up but maintaining clearance from the drive belt see photo in step 3 ALTERNATOR WATER PUMP HARMONIC BALANCER CRANK PULLEY Fig 12 c 4 6L MODELS ONLY AIR CONDITIONER 12 SUPERCHARGER MOUNTING cont d 5 4L MODELS ONLY SPRING TENSIONER SMOOTH IDLE 7 HARM We BALANCER CRANK PULLEY Fig 12 d P N 4FM020 010 COOLANT RESERVOIR FRONT 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200CT03 v3 1 4 6 5 4Exped Nav 4FM v3 1 13 MASS AIR FLOW SENSOR REMOVAL MOUNTING AND ASSEMBLY INNER FENDERWELL TOP VIEW Fig 13 a A Separate the mass air flow sensor from the air inlet canister B Assemble the mass air sensor and the mass
20. ers the oil hose while routing to the feed fittings A B P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200003 v3 1 4 6 5 4Exped Nav 4FM v3 1 1 4 VORTECH SMOOTH VORTECH RIBBED IDLER PULLEY NOTE SUPERCHARGER BELT IS ON OUTSIDE FORWARD OF ACCESSORY BELT 4 6L ONLY P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 2 25 PULLEY 12 SUPERCHARGER MOUNTING cont d G Secure the oil feed line and oil drain line away from heat and abrasion with the provided tie wraps Mount the belt tensioner plate onto the face of the super charger with the three 12mm x 1 75 x 20mm bolts and washers The thin head bolt must be installed nearest the idler pulley pilot 5 4L ONLY Mount the automatic tensioner to the mount ing bracket using the 3 8 16 x 3 25 bolt and washer Route the supplied supercharger drive belt around the su percharger crank pulley the inner and outer idlers and to the supercharger Install the smooth tensioner pulley to the tensioner plate pilot using the 12mm x 1 75 x 20mm bolt provided With a 1 2 drive breaker bar and a 3 extension rotate the tensioner plate to tighten the belt Tighten the three 12mm fasteners Use thin 18mm wrench to tighten the bolt head nearest to the idl
21. 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 e Reassemble the oil filter base and bracket and secure onto the vehicle Reinstall oil filter WARNING Use engine oil on the pipe threads Teflon tape or sealant is not recommended as it might loosen and cause blockage of the oil Punch feed orifice resulting in supercharger failure Center Punch location x C Temporarily cap off the flare fitting to prevent dirt from Fig 2 d entering the oil feed it will be connected to the supercharger at a later time 3 OIL DRAIN To provide a proper oil drain for the supercharger it is necessary to make a hole the oil pan The best way to provide this hole is to punch the hole rather than drill it B Locate the appropriate area for the through hole as shown in the following illustration remove the paint around the hole area Transmission cooler lines may need slight bending to achieve oil drain tube and fit ting clearance C Usea small center punch to perforate the pan ex pand the hole to approximately 9 16 diameter Most punches are made from a hexagonal material and may be placed in a socket to make this task easier D Tapthehole with a 3 8 NPT pipetap approximately 1 4 deep Pack t
22. he pipe tap flutes with heavy grease to hold the chips and use a small mag net to check for any stray chips OIL PAN FRONT VIEW Fig 3 a P N 4FM020 010 2003 Vortech Engineering LLC 3 All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 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 until after the supercharger drain hose has been con nected G Drain the engine oil and change the oil filter H Temporarily cap off the oil drain fitting to keep out debris until the drain hose is attached to the super charger at a later time FRONT VIEW Refill engine with 5W 30 synthetic or conventional SH Fig 3 b DRAIN HOSE FROM SUPERCHARGER OIL DRAIN TUBE CF rated motor oil CRANK PULLEY L o o OIL PAN VIEW FROM PASSENGER SIDE Fig 3 P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 4 2000103 v3 1
23. ic and change the oil and filter every 3 000 miles or less Never attempt to extend the oil change interval beyond 3 000 miles regardless of oil manufacturer s claims as potential damage to the supercharger may result 6 Before beginning installation replace all spark plugs that are older than 1 year or 20 000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications follow the procedures indicated within the factory repair manual and or as indicated on the factory underhood emissions tag Do not use platinum spark plugs unless they are original equipment Change spark plugs every 40 000 miles and spark plug wires at least every 60 000 miles TOOL amp SUPPLY REQUIREMENTS Factory Repair Manual 3 8 Socket and Drive Set SAE amp Metric 1 2 Socket and Drive Set SAE amp Metric 3 8 Extension 3 1 2 Extension 3 3 8 NPT Tap and Handle Adjustable Wrench Harmonic Balancer Puller Harmonic Balancer Installer Open End Wrenches 5 16 3 8 7 16 1 2 9 16 5 8 11 16 3 4 10mm 13 18mm 18mm tappet thin wrench 3 lb Hammer e 1 1 16 Oil Sending Unit Socket Snap on A119A Center Punch and a 5 8 Tapered Punch Ford Springlock 3 8 Fuel Fitting Disconnect Tool 6 Quarts SH CF Rated Quality Engine Oil Oil Filter and Wrench Hat 2 Screwdriver Phillips 42 Screwdriver Heavy Grease Silicone Sealer Dril
24. istribution box Tap into the green yellow wire with the provided wire tap Double check the wire with a test light to ensure a good con nection has been made From terminal 30 route the heavy red wire to one of the main power lugs at the side of the power distribu tion box With the supplied male and female solderless connectors install the fuse holder and 20 amp fuse in this wire and check with a test light to ensure a good connection has been made Close the bottom and side covers and return the power distribution box to its original position Mark and drill a 1 8 hole above the power distribu tion box on the driver s side inner fenderwell secure with the 12 x 3 4 sheet metal screw and washer provided Connect the short black wire from relay terminal 86 to a secure ground free from paint From terminal 87 route and connect the long red wire to the side of the fuel pump Secure with pro vided tie wraps 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
25. l Motor 1 8 3 16 11 32 Drill Bits 3 16 8mm Allen Wrenchs Wire Strippers and Crimpers Utility Knife 1 8 NPT Tap for 4WD models equipped with oil coolers P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 1997 2001 Ford 4 61 2V F 150 F 250 E xpedition Navigator 4 218 0105 0185 b ENGINEERING LLC 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 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 Eyelets 2 7100 070 3 16 x 3 16 x 7 8 Key 1 7E010 050 12 x 1 2 Sheet Metal Screw 1 2A040 011 Pulley Retainer 1 7P312 003 5 16 Female Fuel Connector 1 7B375 125 3 8 24 x 1 1 4 HXHD Bolt 1 7R004 003 14 5 Stepless Clamps 2 7K375 040 3 8 AN960 Flat Washer 1 7U100 044 4 Tie Wraps 3 7U100 6 Tie W 4 4FM111 034 MAIN MOUNTING BRACKET ASSEMBLY 1 Gate gue High Pressure 1 4FM011 033 Mounting Plate Assembly 1 8F101 200 T Rex Wiring Assembly 1 7A375 251 3 8 16 x 2 1 2 Flat SHCS 5 5W001 014 Fuse Holder 1 7C100 085 10mm x 1 50 x 85mm HXHD Bolts 3 7K437 001 7 16 AN Wash 3 5W0
26. ls only sse Table Of Contents MAIN MOUNTING PLATE ASSEMBLY AND MOUNTING 4 6 Models only MAIN MOUNTING BRACKET ASSEMBLY AND MOUNTING 5 4 Models only EGR CONTROL MOUNTING AND MAIN MOUNTING PLATE SUPPORT 4 6 TEE FUEL MANAGEMENT UNIT EMU IDLER AIR CONTROL RESONATOR AND CRANKCASE VENT HOSE iiri EE EE EE SUPERCHARGING MOUNTING esee emen MASS AIR FLOW SENSOR REMOVAL MOUNTING AND ASSEMBLY AIR INLET BYPASS ASSEMBLY eene emnes Belice eset ties RINAL 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 FOREWORD TABLE OF CONTENTS DISCLAIMER NOTICE 1 SU cR cp 8B 10 11 12 13 14 15 16 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 designed to improve the performance and durability of your vehicle s transmission Several companies make these shift improver products including TransGo Perfo
27. ncer when tightening Torque the 12mm bolt to 80 ft Ibs and the 8mm bolts to 25 ft 108 Reinstall the inspection cover E 5 FUEL PUMP Release any pressure from the fuel tank by momentarily loos ening the filler cap Disconnect the line from the tank to the fuel filter by carefully removing the white retaining clip or by using a 3 8 springlock disconnect tool if equipped Connect the fuel pump inlet adapter fitting to the existing fuel line coming from the fuel tank Attach the supplied 1 2 inlet ADAPTER FITTING 1 2 FUEL LINE I GROUND BLACK WIRE CONNECT TO 4 RELAY TERMINAL 87 Fig 5 a hose to the adapter and pump inlet NOTE Due to the various fuel tank configurations and frame rail lengths it will be necessary to find a good mounting location near the fuel filter Do NOT mount the fuel pump close to exhaust heat or to the bottom of the cab The inside or the outside of the frame rail will work well Prior to securing the fuel pump ensure the fuel lines will not be kinked or pinched and are protected from sharp edges Connect the fuel pump outlet to the filter inlet EXISTING FEED LINE With the fuel pump in a position that FROM TANK allows the lines to be routed loosely secure the fuel pump with the 12 hex screw Secure the pump inlet hose using the supplied 8 clamps Trim hose length if necessary Ensure that NO kinks or shar
28. ng on the FMU Position FMU against the upper firewall directly un der the plastic wire harness cover as shown Mark and drill two 30 holes on the firewall to mount the FMU Secure with the 48 sheet metal screws pro vided Connect the FMU outlet hose to the fuel line that re turns to the tank Route the fuel line to the straight brass fitting on the FMU Secure the fuel lines away from abrasion and exhaust A C P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200003 v3 1 4 6 5 4Exped Nav 4FM v3 1 1 2 FUEL MANAGEMENT UNIT FMU FACTORY QUICK DISCONNECT FITTING FUEL RETURN LINE P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 FILTER VACUUM LINE FACTORY SPRINGLOCK CONNECTOR FUEL FEED LINE FACTORY VACUUM heat with the provided tie wraps CONNECTION Tap into the factory fuel regula F tor vacuum line with the supplied 5 32 hose and TEE Route the new hose to the fitting on top of the FMU see drawing FACTORY REGULATOR Fig 10 b 10 1 FUEL MANAGEMENT UNIT RECALIBRATION 2003 5 4L Only A Remove the six allen head screws on top of the fuel management unit FMU See Fig 7 1 a WARNING Do not remove the four screws holding the valve body Once taken apart the vlave would have to be repla
29. ottom of the supercharger and secure with the pro vided 8 hose clamp Guide the oil drain hose over the driver s side valve cover while placing the supercharger in the appropri ate location See Fig 12 a NOTE The oil drain line must be routed in downward sloping fashion with no kinks or restrictions With the oil drain hose properly routed downward start the five 3 8 16 x 2 1 2 counter sink bolts and tighten evenly 5 4L ONLY Once the oil drain hose has been prop erly routed downward use the five 3 8 16 bolts and washers start and tighten evenly Route the oil drain hose around the side of the power steering pump and to the oil drain fitting on the oil pan NOTE Do NOT use any type of sealant on the oil feed fittings It may become dis lodged and clog the oil feed orifice causing premature failure of the super charger Using a few drops of engine oil on the fitting threads install the 1 8 NPT x 4 x 90 fitting into the super charger oil feed Rotate the fitting toward the front of the vehicle Usea 1 2 wrench to hold the supercharger oil feed while tightening the brass 90 fitting Two oil feed hoses have been supplied The 36 long hose is for use on the 2WD models that are not equipped with an engine oil cooler The 62 hose is for use on 4WD oil cooler equipped models Connect the proper length oil feed line to the vehicle and se cure both ends Make sure that no dirt or debris en t
30. p bends are allowed on pump inlet hose or failure may result Attach the negative pump terminal to aclean ground Scrape the ve hicle undercoat down to bare metal 5 16 HOSE A P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200003 v3 1 4 6 5 4Exped Nav 4FM v3 1 6 Fig 6 a T REX FUEL PUMP LONGEST RED WIRE TO 4 RELAY GREEN WIRE WITH YELLOW STRIPE 12 VOLT RELAY Fig 6 b NOTE Double check that all wires are con nected to their proper relay lug P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 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 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 With the help of an assistant and a test light check the green yellow wire for key on power this wire should show power for approximately two to four sec onds with the key in the accessory on position From relay terminal 85 route the yellow wire into the bottom of the power d
31. 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 to hold the factory coil bracket to the en gine front cover D Remove the front cover bolt located near the lower driver s side of the alternator mounting flange In this location install the supplied 2 25 idler pulley and idler spacer using the 10mm x 1 50 x 85mm bolt and washer Torque to 40 in Ibs NOTE n a limited number of 4 6L engines the main bracket holes and single idler pulley hole are 8mm instead of 10mm Four 8mm shoulder bolts have been supplied for these models E Reinstall the accessory belt Fig 8A a NOTE The use of blue Loctite is recommended 2 25 IDLER PULLEY for all idler bolts F With the main mounting plate positioned on the front cover start the supplied 8mm 1 25 x 25mm bolt and the three 10mm 1 50 x 85mm bolts with washers into the front cover Torque all bolts evenly G Install the large smooth idler on the inner most idler stand and the ribbed idler on the outer stand of the Vortech mounting plate Secure both with the 12mm 1 75 x 20mm bolts and dust shields provided Torque to 45 ft Ibs H Install the cam position sensor plug and secure the wire to the face of the main mounting plate with the provided adel clamp Use the lower coil bracket bolt to secure clamp Fig 8A b SMOOTH IDLER RIB
32. ring the puller is properly aligned on the face of the crank slowly tighten the forcing screw until the harmonic balancer has been removed NOTE The factory uses a small amount of sili cone to seal the crankshaft keyway Thoroughly clean the silicone residue off of the crankshaft prior to installing the Vortech harmonic balancer D With adab of silicone on the keyway of the new har monic balancer guide it on the crankshaft and feel for alignment of the woodruff key and the harmonic bal ancer keyway After the harmonic balancer has been aligned on the crankshaft use your harmonic balancer installation tool to install the new harmonic balancer Slowly tighten until the harmonic balancer is seated on the crankshaft NOTE The use of blue Loctite is recom mended for all harmonic balancer and crank pulley bolts 4 CRANKSHAFT PULLEY SUPERCHARGER DRIVE PULLEY cont d 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 each 8mm bolt head for thru bolt clearance to the engine front cover Inspect behind bala
33. rmance Please contact TransGo Performance or one of the other product companies directly should you wish to obtain more information about their shift improver products TransGo Performance 2621 Merced Avenue El Monte CA 91733 626 443 4953 phone 626 443 1079 fax NOTE This listing is provided solely for informational purposes VORTECH has made no evaluation of the quality or function ality of these products and DOES NOT MAKE ANY RECOM MENDATION ENDORSEMENT NOR PROVIDE ANY WAR RANTY ON ANY OF THESE SHIFT IMPROVER PRODUCTS Only applies to vehicles equipped with automatic transmissions P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured t 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 IV P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 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 e Included in this kit is SE next day air shipping box and a credit tag for one 1 Vortech Superchips ECM Module e The modules are made specifically for each individual vehicle with respect to the factory ECM calibration e Simply contact the Vortech Service Department at 805 247 0226 to reques
34. sending unit connector and remove the sending unit Following the graphic for 4WD applications attach the supplied 1 4 NPT straight TEE and 90 fitting into the hole previously occupied by the oil sending unit Attach the oil sending unit into the remaining 1 4 NPT opening in the TEE e Reconnect the oil filter hose assembly to the original location on the engine block Make sure the gasket is in its proper location Replace gasket if needed e Reattached connector to sending unit 4WD applications only equipped with factory oil cooler Remove the oil filter from the filter base located behind the front bumper of the vehicle Remove the oil filter base mounting bracket from the frame Remove the oil filter mounting base from the bracket e Mark the base in the same location as shown in the photo Center punch the previously marke spot on the base make sure that the spot is marked on the center port of the filter base Drill with an R size drill bit and thread with a 1 8 NPT tap e Thoroughly clean and blow dry the filter base taking care to remove any chips or burrs P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 2 2 OIL FEED LINE INSTALLATION cont d Using alight amount of oil on the threads for lubrication 4WD equipped with factory oil cooler thread the 1 8 NPT x 45 x 4
35. t a Return Authorization Number See ECM Module Credit Tag for more details Mail to Vortech the enclosed ECM Module Credit Tag send original tag no photocopies will be accepted and ECM in the supplied box Turnaround time will be 1 2 days each application varies Vortech will give an estimate at the time of your order Your Vortech Superchips ECM Module comes with a twelve 12 month limited warranty from the original date of purchase of your supercharger system see Owner s Manual for details NOTE Vortech Engineering is not responsible for engine or ECM damage due to an improperly installed mishandled ECM module or ECM 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 property of Vortech Engineering LLC This product may notbe copied or duplicated in whole or part abstractly or fundamentally intentionally or fortuitously nor shall any design dimension or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering LLC V 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 1997 2003 FORD 4 6L 5 4L 2V F 150 F 250 EXPEDITION NAVIGAT OR Installation Instructions CARB EO D 213 20 Congratulations on selecting the best performing and best backed automotive supercharger available today
36. wire is not being pinched by the mounting bracket start the three supplied 10mm x 1 5 x 80mm bolts with washers Torque all bolts evenly Secure the upper portion of the bracket to the previ ously installed support bracket using the supplied 1 4 hardware Using the supplied 7 16 14 x 1 5 bolts and dust shields secure the three 3 idlers to the main mount ing bracket in the configuration shown on page 15 To prepare the mounting location for the main mount P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200003 v3 1 4 6 5 4Exped Nav 4FM v3 1 1 0 8B MAIN MOUNTING BRACKET ASSEMBLY AND MOUNTING 5 4L models only cont d Fig 8B d P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 200CT03 v3 1 4 6 5 4Exped Nav 4FM v3 1 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 Attach the supplied power steering reservoir bracket to the main mounting bracket using the 1 4 20 bolt and washers see photo Trim 4 off of the top end of the stock 5 8 supply hose connecting the reservoir to the pump and reattach Extend the stock power steering return hose using the supplied 3 8 line an
37. x 5 4 6L 1 x 9 hose 5 4L On the 4 6L bypass nipple should be pointing toward the driver s seat On the 5 4L bypass nipple should be pointing downward D Using the supplied 5 32 TEE and hose splice the by pass nipple into the previously installed vacuum hose attached to the FMU lid E Place the 1 x 7 4 6L 1 x 2 5 5 4L piece of hose and 16 hose clamps on the bypass valve The hose will be connected to the discharge in the next step F Connect the two 90 plastic elbows with the 3 1 2 flex hose and secure with 56 hose clamps G Install the idle air and crankcase vent hoses to the air inlet elbow 5 8 90 BARB DRIVER S SIDE VALVE COVER CRANK VENT _ 1 x 5 HOSE 1 x7 HOSE gt TEMP SENSOR FLEX DISCHARGE pisoi SUPERCHARGER HOSE 3 4 90 BARB TO IDLE AIR RESONATOR 3 4 90 BARB TO IDLE AIR RESONATOR 5 8 90 BARB DRIVERS SIDE VALVE COVER CRANK VENT 1 X 90 PLASTIC BYPASS HOSE BARB VALVE WITH 1 x 2 5 HOSE AIR INTAKE TEMP SENSOR SUPERCHARGER BOTTOM VIEW E N TTT P N 4FM020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 2000103 v3 1 4 6 5 4Exped Nav 4FM v3 1 1 8 erly installed may cause FAILURE OF MA JOR COMPONENTS Test drive the vehicle The supercharger
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