Ford Automobile Parts D 213 20 User Manual

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

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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Table Of Contents

FOREWORD .....................................................................................................................................ii

TABLE OF CONTENTS ....................................................................................................................iii

DISCLAIMER ....................................................................................................................................iv

NOTICE.............................................................................................................................................v

TOOL & SUPPLY REQUIREMENTS ................................................................................................vi

PARTS LIST - 1997-2001 FORD 4.6L 2V F-150/F-250 ....................................................................vii

PARTS LIST - 1997-2001 FORD 5.4L 2V F-150/F-250 ....................................................................viii

COMPONENT REMOVAL AND PREPARATION .................................................................1

OIL FEED LINE INSTALLATION ..........................................................................................2

OIL DRAIN ...........................................................................................................................3

CRANKSHAFT PULLEY/SUPERCHARGER DRIVE PULLEY ............................................5

FUEL PUMP .........................................................................................................................6

FUEL PUMP RELAY ............................................................................................................7

WIRE PREPARATION (4.6 Models only) .............................................................................8

MAIN MOUNTING PLATE ASSEMBLY AND MOUNTING (4.6 Models only) ......................9

MAIN MOUNTING BRACKET ASSEMBLY AND MOUNTING (5.4 Models only) ................10

8A.

8B.

EGR CONTROL MOUNTING AND MAIN MOUNTING PLATE SUPPORT

(4.6 Models only)..................................................................................................................12

10.

11.

FUEL MANAGEMENT UNIT (FMU) .....................................................................................13

IDLER AIR CONTROL RESONATOR AND CRANKCASE VENT HOSE

REROUTING........................................................................................................................14

12.

13.

14.

15.

16.

SUPERCHARGING MOUNTING .........................................................................................14

MASS AIR FLOW SENSOR REMOVAL, MOUNTING AND ASSEMBLY ............................17

AIR INLET/BYPASS ASSEMBLY .........................................................................................17

DISCHARGE ........................................................................................................................19

FINAL CHECK......................................................................................................................19

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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 designed to improve the

performance and durability of your vehicle’s transmission.

Several companies make these shift improver products including TransGo Performance. 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 OFTHESE SHIFT IMPROVER PRODUCTS.

* Only applies to vehicles equipped with automatic transmissions.

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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

factory ECM calibration.

• Simply contact the Vortech Service Department at (805) 247-0226 to request 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.

Thisproductmaynotbecopiedorduplicatedinwholeorpart,abstractlyorfundamentally,

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.

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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 supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and

horsepower of 35%-45% 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:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech prior to using this product.

4. 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 synthetic, 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 & SUPPLY REQUIREMENTS

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 1/2" Socket and Drive Set: SAE & 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

• 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

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• "R", 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

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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

2E128-230

2A036-361

7U100-070

2A040-011

7B375-125

7K375-040

SUPERCHARGER ASSEMBLY

V-2 Supercharger

3.60 Supercharger Drive Pulley

3/16" x 3/16" x 7/8" Key

Pulley Retainer

8F203-265

5W001-001

5W001-011

7E010-050

7P312-003

7R004-003

7U100-044

7U100-055

7U031-018

8F101-200

5W001-014

5W001-015

5W001-010

7U030-050

8F001-002

7R003-024

7R001-008

7E010-075

7P500-004

FUEL PUMP ASSEMBLY

Wire Tap

16-14 Ga. Eyelets

#12 x 1/2” Sheet Metal Screw

5/16” Female Fuel Connector

14.5 Stepless Clamps

4” Tie Wraps

3/8-24 x 1-1/4" HXHD Bolt

3/8" AN960 Flat Washer

6” Tie Wraps

4FM111-034

4FM011-033

7A375-251

7C100-085

7K437-001

8C080-020

7K312-001

4FM010-130

7A375-100

7F375-017

7K375-040

7R003-008

5W018-010

5W001-007

7C080-085

MAIN MOUNTING BRACKET ASSEMBLY

Mounting Plate Assembly

3/8-16 x 2-1/2” Flat SHCS

10mm x 1.50 x 85mm HXHD Bolts

7/16" AN Washers

5/16” x 11” High Pressure Fuel Hose

T-Rex Wiring Assembly

Fuse Holder

20A Blade Type Fuse

16-14 Ga Female Slides

12mm x 16” Fuel Hose

155 Inline Fuel Pump

1-1/2" Adel Clamp

8mm x 1.25 x 20mm HXHD Bolt

5/16" AN Washer

Bracket Support Strut

3/8-16 x 1" HXHD Bolt

3/8-16 Nylock Nut

3/8" AN960 Flat Washer

1/2" Adel Clamp

6" 18 Ga. Std. Red Wire

3/16" x 6" Heat shrink Tube

8mm Shoulder Bolts

#8 Hose Clamps

#12 x 3/4" Sheet Metal HXHD Bolt

1/2" Fuel Fitting Adapter

4FM112-010

4FM010-050

8H040-045

7R002-056

7S350-200

7U035-000

7U100-052

7U038-000

7P500-026

7P375-052

4FA012-012

4FA012-013

7A250-075

7F250-021

7J250-001

7U100-055

7A312-150

7J312-001

7J312-000

7F312-017

7U030-065

7U133-024

7P750-102

7R002-052

AIR INLET ASSEMBLY

MAF Bracket Assembly

3-3/4" Flanged Air Filter

#56 Hose Clamps

4FM110-040

4FM010-040

7C010-150

7F010-024

7J010-001

7A250-075

7F250-021

7J250-001

4FM010-030

7C010-050

COIL/EGR/POWER STEERING ASSEMBLY

Coil Mounting Bracket

10-24 x 1-1/2" SH Bolts

10-24 Nylock Nuts

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

#10 Flat Washers

1/4-20 x 3/4” SH Cap Screws

1/4-20 Nylock Nuts

1/4" SAE Washers

EGR Bracket

10-24 x 1/2” SH Cap Screws

4FM111-032

4FM011-032

2A046-725

7J012-092

7C012-020

7C012-022

4FA016-150

4GF016-160

4FK116-021

7C100-085

7K437-001

2A017-021

4FM016-011

7C080-026

7K312-001

7C120-065

7J438-071

4FM016-012

SUPERCHARGER DRIVE ASSEMBLY

Belt Tensioner

Belt

12mm Flat Washers

12mm x 1.75 X 20mm Bolts

12mm x 1.75 X 20mm Thin Head Bolt

Smooth Pulley Tensioners

Ribbed Idler Pulley

Idler Pulley Assembly

10mm x 1.50 x 85mm HXHD Bolt

7/16" AN Washer

Spacer

Balancer

8mm x 1.25 x 25mm SH Bolts

5/16" AN Washers

12mm x 1.5 x 65mm HXHD Bolt

7/16" USS Washer

3/4" x 90° Hose

5/8" Molded Elbow Hose

3/4" NPT x 1" 90° Hose Fitting

#52 Hose Clamps

4FM238-068

6Z110-114

4FA145-010

4FA145-020

7U030-046

7P156-082

7U100-055

FMU (with lines)

8:1 Fuel Management Unit

Male Fuel Line

Female Fuel Line

5/32” x 18” Vacuum Line

5/32” Tee

6” Tie Wraps

Crank Pulley

4FM130-036

7U030-036

7R001-008

7P375-042

4FH100-010

OIL DRAIN ASSEMBLY

1/2” x 32” Oil Drain Hose

#8 Stainless Hose Clamps

Male Connector

4FM112-020

4FM012-020

7S300-200

7S275-200

7R002-044

7R002-048

7R002-016

8D001-001

7U034-016

7U030-046

7P156-082

7S275-300

7P375-106

DISCHARGE ASSEMBLY

Discharge Tube

3” x 2” Sleeve

2-3/4” x 2” Sleeve

#44 Hose Clamps

#48 Hose Clamps

#16 Hose Clamps

Bypass Valve

1” x 7” Heater Hose

1” x 5” Heater Hose

5/32” x 12” Vacuum Line

5/32” Tee

Oil Drain Tube Nut Assy.

4FM130-026

7U030-026

7P525-067

7P250-066

7P125-026

7U100-055

7P250-082

7P250-122

7P250-123

7P250-034

7U030-026

7P125-103

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 NPT Strt. Tee

1/4" x 62" Oil Feed Hose

1/8" NPT x 45" #4 Ftg.

2-3/4" x 3" Sleeve

PCV Valve

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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

2E128-220

2A038-333

7U100-070

2A040-011

7B375-125

7K375-040

SUPERCHARGER ASSEMBLY

V-2 Supercharger

4FM112-040

4FM010-050

8H040-045

7R002-056

7S350-200

7U035-000

7U100-052

7U038-000

7P500-026

7P375-052

4FA012-012

4FA012-013

7A250-075

7F250-021

7J250-001

7U100-055

7A312-150

7J312-001

7J312-000

7F312-017

7U030-065

7U133-024

7P750-102

7R002-052

AIR INLET ASSEMBLY

MAF Bracket Assembly

3-3/4" Flanged Air Filter

#56 Hose Clamps

3.33 8 Rib Pulley

3/16" x 3/16" x 7/8" Key

Pulley Retainer

3/8-24 x 1-1/4" HXHD Bolt

3/8" AN960 Flat Washer

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

4FM111-054

4FA016-170

4FA016-171

4FM010-140

4FM010-150

4FM011-021

4FM016-031

4FM017-010

4FM017-020

7A250-075

7A250-100

7A375-175

7A375-250

7A437-150

7C010-080

7C060-016

7F250-021

7J006-093

7J250-001

7J438-091

7K375-040

7J010-002

5W001-012

5W001-006

7C140-030

5W018-070

5W018-030

7P375-050

7R001-004

7U032-016

4FM010-160

MAIN MOUNTING BRACKET ASSEMBLY

Idler Smooth

Dust Shields

Bracket Support

Bracket Support #2 5.4

Mounting Bracket Mach.

Idlers Grooved

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

Spacer Short Bracket Support #2

Spacer Long Bracket Support #2

1/4-20 x 3/4" S.H.C.S.

1/4-20 x 1" Flat Allen

3/8-16 x 1.75" Hex Head

3/8-16 x 2.5" Hex Head

7/16-14 x 1.5" Bolt Hex Head

10mm x 1.5 x 80mm S.H.C.S.

M6 x 1.00 x 16 HXHD Bolt

1/4-20 Nylock Nut

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

6mm Washer

4FM112-030

4FM012-030

7P156-082

7R002-016

7R002-044

7R002-048

7S275-200

7S300-200

7U030-046

7U034-016

8D001-001

7P375-106

5.4 DISCHARGE ASSEMBLY

Discharge Tube 5.4 (Only)

5/32” TEE

1/4 SAE Washer Plated

9/16 SAE Washers Plated

3/8" AN 960 Flat Washer

10mm Washer

#16 Hose Clamps

#44 Hose Clamps

#48 Hose Clamps

2-3/4” x 2” Sleeve

3” x 2” Sleeve

Solderless Connector

3/8" Heat Shrink Tubing 12"

14mm x 2.0 x 30mm HXHD

18 GA Wire Green 12"

18 GA Wire Grey 12"

3/8 Hose Mender

#4 Hose Clamp

3/8" Hose Hi-Pressure 18"

Power Steering Bracket

5/32” x 12” Vacuum Line

1" x 9" Heater Hose

1" x 2.5" Heater Hose

Bypass Valve

PCV Valve

4FM130-026

7U030-026

7P525-067

7P250-066

7P125-026

7U100-055

7P250-082

7P250-122

7P250-123

7U030-026

7P250-034

7P125-103

OIL FEED ASSEMBLY

1/4" x 36” Oil Feed Hose

.525 Crimp Ferrules

4FM111-062

2A048-802

4FA016-170

4FA016-171

4FM011-052

4FM016-011

4FM016-041

7A375-324

7C010-045

7C080-026

7C120-065

7J438-071

7K312-001

7K375-040

SUPERCHARGER DRIVE ASSEMBLY

Belt 8 rib x 80.14"

Idler Smooth

-4 Swivel x 1/4” Hose Barb Fittings

1/8" NPT x #4 -90° Fitting

6” Tie Wraps

Dust Shields

Spring Tensioner Long Ford

Balancer

1/4" NPT x -4 -90° Fitting

Crank Pulley, 8 Rib

1/4" Pipe Thread TEE

3/8-16 x 3.25" HXHD Bolt

10mm x 1.5 x 45mm Hex Head

8mm x 1.25 x 25mm SH Bolts

12mm x 1.5 x 65mm HXHD Bolt

7/16" USS Washer

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

5/16" AN Washers

3/8" AN 960 Flat Washer

4FM130-036

7U030-036

7R001-008

7P375-042

4FH100-010

OIL DRAIN ASSEMBLY

1/2” x 32” Oil Drain Hose

#8 Stainless Hose Clamps

Male Connector

8F203-265

5W001-001

5W001-011

7E010-050

7P312-003

7R004-003

7U100-044

7U100-055

7U031-018

8F101-200

5W001-014

5W001-015

5W001-010

7U030-050

8F001-002

7R003-024

7R001-008

7E010-075

7P500-004

FUEL PUMP ASSEMBLY

Wire Tap

16-14 Ga. Eyelets

Oil Drain Tube Nut Assy.

5A101-016

MAF CLAMP ASSEMBLY

#12 x 1/2” Sheet Metal Screw

5/16” Female Fuel Connector

14.5 Stepless Clamps

4” Tie Wraps

6” Tie Wraps

5/16” x 11” High Pressure Fuel Hose

T-Rex Wiring Assembly

Fuse Holder

20A Blade Type Fuse

16-14 Ga Female Slides

12mm x 16” Fuel Hose

155 Inline Fuel Pump

1-1/2" Adel Clamp

#8 Hose Clamps

#12 x 3/4" Sheet Metal HXHD Bolt

1/2" Fuel Fitting Adapter

4FM238-068

6Z110-114

4FA145-010

4FA145-020

7U030-046

7P156-082

7U100-055

FMU (with lines)

8:1 Fuel Management Unit

Male Fuel Line

Female Fuel Line

5/32” x 18” Vacuum Line

5/32” TEE

6” Tie Wraps

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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 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.

G. 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.

I. Separate the EGR pressure transducer and the EGR

vacuum regulator solenoid 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.

*4.6 MODELS ONLY

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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OIL FEED LINE INSTALLATION

2WD only

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.)

ENGINE

BLOCK

1/4” NPT

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

studs on the engine block. Disconnect the factory oil

sending unit connector and remove the sending unit.

Factory

sending unit

• Following the graphic for 4WD applications, attach t h e

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.

VIEW FROM FRONT

Fig. 2-a

• 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.

• Reattached connector to sending unit.

4WD applications only

(equipped with factory oil cooler)

4WD Only (without oil cooler)

• Remove the oil filter from the filter base located behind

the front bumper of the vehicle.

Remote oil filter

• Remove the oil filter base mounting bracket from the

frame. Remove the oil filter mounting base from the

bracket.

hole assembly

Factory oil

sending unit

location (remove)

• 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.

DRIVER’S

SIDE VIEW

• Thoroughly clean and blow dry the filter base taking care

Fig. 2-b

to remove any chips or burrs.

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. 2-c

P/N: 4FM020-010

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2. OIL FEED LINE INSTALLATION, cont'd.

• Using a light amount of oil on the threads for lubrication,

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.

4WD (equipped with factory oil cooler)

• 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

feed orifice resulting in supercharger failure.

Center Punch location (x)

Fig. 2-d

C. Temporarily cap off the flare fitting to prevent dirt from

entering the oil feed, it will be connected to the

supercharger at a later time.

3. OIL DRAIN

A. To provide a proper oil drain for the supercharger it is

necessary to make a hole in 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. Use a 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. Tap the hole with a 3/8” NPT pipe tap

approximately 1/4” deep. Pack the

pipe tap flutes with heavy grease to

hold the chips and use a small mag-

net to check for any stray chips.

5/8"

1-7/8"

OIL PAN

FRONT VIEW

Fig. 3-a

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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

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

I. Refill engine with 5W/30 synthetic or conventional SH/

Fig. 3-b

CF rated motor oil.

DRAIN HOSE

FROM

SUPERCHARGER

CRANK

PULLEY

OIL

DRAIN

TUBE

OIL PAN

VIEW FROM PASSENGER SIDE

Fig. 3-c

P/N: 4FM020-010

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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 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.

Fig. 4-a

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 ensuring 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 a dab 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.

P/N: 4FM020-010

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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 each 8mm bolt head for thru-bolt clearance to the

engine front cover. Inspect behind balancer when tightening).

Torque the 12mm bolt to 80 ft/lbs and the 8mm bolts to 25 ft/

lbs.

F. Reinstall the inspection cover.

5. FUEL PUMP

A. Release any pressure from the fuel tank by momentarily loos-

ening the filler cap.

B. 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.

C. Connect the fuel pump inlet adapter fitting to the existing fuel

line coming from the fuel tank. Attach the supplied 1/2" inlet

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.

D. Connect the fuel pump outlet to the filter inlet.

ADAPTER

FITTING

EXISTING FEED LINE

FROM TANK

1/2” FUEL LINE

E. With the fuel pump in a position that

allows the lines to be routed loosely,

secure the fuel pump with the #12

hex screw.

F. Secure the pump inlet hose using

the supplied #8 clamps. Trim hose

length if necessary. Ensure that NO

kinks or sharp bends are allowed

on pump inlet hose or failure may

result.

5/16” HOSE

STOCK

FUEL

FILTER

G. Attach the negative pump terminal

to a clean ground. Scrape the ve-

hicle undercoat down to bare metal.

(-) GROUND BLACK WIRE

CONNECT TO

(+) RELAY

TERMINAL (87)

Fig. 5-a

P/N: 4FM020-010

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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 show power for approximately two to four sec-

onds with the key in the accessory on position.

D. From relay terminal #85 route the yellow wire into the

bottom of the power distribution 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.

E. 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 _GROUND

covers and return the power distribution box to its

original position.

Fig. 6-a

(+) T-REX FUEL PUMP

(LONGEST RED WIRE)

TO #4 RELAY -

GREEN WIRE WITH

YELLOW STRIPE

87A

12 VOLT (+)

F. 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.

RELAY

Fig. 6-b

G. Connect the short black wire from relay terminal #86

to a secure ground free from paint.

NOTE: Double check that all wires are con-

H. From terminal #87, route and connect the long red

wire to the (+) side of the fuel pump. Secure with pro-

vided tie wraps.

nected to their proper relay lug.

P/N: 4FM020-010

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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

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

CONNECTOR

IGNITION

CAPACITOR

CAM TRIGGER

CONNECTOR

REMOVE PLASTIC

90° WIRE SUPPORT

EXTEND WITH 6”

WIRE, SOLDER

AND SHRINK TUBE

UNWRAP “ Y” BEND

APPROXIMATELY 6”

Fig. 7-a

P/N: 4FM020-010

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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 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/lbs.

NOTE: In 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.

Fig. 8A-a

E. Reinstall the accessory belt.

2.25" IDLER PULLEY

NOTE: The use of blue Loctite is recommended

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/lbs.

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

RIBBED IDLER

Fig. 8A-c

P/N: 4FM020-010

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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 models only)

A. To prepare the mounting location for the main mount-

ing plate, remove the three 10mm factory stud/bolts

located on the driver side engine front cover.

B. Reinstall the accessory belt.

NOTE: The use of blue Loctite is recom-

mended for all idler bolts.

C. 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.

D. Install the large support bracket onto the engine block

Fig. 8B-a

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.)

E. With the main mounting bracket positioned on the

front cover, (ensure that the cam sensor 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.

F. Secure the upper portion of the bracket to the previ-

ously installed support bracket using the supplied 1/4"

hardware.

G. 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.

Fig. 8B-b

P/N: 4FM020-010

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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 stock 5/8" supply hose

connecting the reservoir to the pump and reattach.

K. Extend the stock power steering return hose using

the supplied 3/8" line and hose mender. Secure with

the two supplied #4 hose clamps.

L. 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.

Fig. 8B-c

Fig. 8B-d

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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. 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.

D. 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.

Fig. 9-a

Fig. 9-b

10. FUEL MANAGEMENT UNIT (FMU)

A. Using a spring lock disconnect tool, disconnect the

fuel return line at the fuel rail.

B. Connect the FMU inlet hose to the fuel rail. Route the

fuel line to the 90° brass fitting on the FMU.

C. 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 #8 sheet metal screws pro-

vided.

D. 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.

E. Secure the fuel lines away from abrasion and exhaust

Fig. 10-a

P/N: 4FM020-010

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FACTORY VACUUM

CONNECTION

heat with the provided tie wraps.

FUEL

F. Tap into the factory fuel regula-

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).

MANAGEMENT

UNIT (FMU)

VACUUM LINE

FACTORY

SPRINGLOCK

CONNECTOR

INLET

FACTORY

REGULATOR

OUTLET

FACTORY

QUICK-

DISCONNECT

FITTING

ENGINE

FILTER

T-REX

FUEL TANK

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 replacedl.

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/lb (2 ft/lb.).

Fig. 10-c

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11. IDLE AIR CONTROL RESONATOR AND CRANKCASE VENT HOSE REROUTING

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.

B. 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.

C. 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.

Fig. 11-a

*4.6L ONLY

12. SUPERCHARGER MOUNTING

A. Attach the oil drain hose to the oil drain fitting on the

bottom of the supercharger and secure with the pro-

vided #8 hose clamp.

B. 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 a

downward sloping fashion with no kinks

or restrictions.

C. 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.

D. 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.

Fig. 12-a

E. 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. Use a 1/2” wrench to hold the supercharger

oil feed while tightening the brass 90° fitting.

F. 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-

ters the oil hose while routing to the feed fittings.

*4.6L ONLY

P/N: 4FM020-010

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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.

H. 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.

I. Route the supplied supercharger drive belt around the su-

percharger crank pulley, the inner and outer idlers and to

the supercharger.

J. Install the smooth tensioner pulley to the tensioner plate

pilot using the 12mm x 1.75 x 20mm bolt provided.

K. 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 idler pulley.

*NOTE: The supercharger drive belt should have ap-

proximately 1" of deflection and will need to

be retightened between 250 to 400 miles.

L. 5.4L ONLY - Using a 1/2" drive breaker bar, rotate the

tensioner clockwise and align belt. Release tensioner to

tighten belt.

M. 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).

VORTECH

TENSIONER

ALTERNATOR

VORTECH

SMOOTH

2.25 PULLEY

VORTECH

RIBBED

IDLER PULLEY

IDLER

VORTECH

WATER

PUMP

SMOOTH

IDLER PULLEY

4.6L MODELS ONLY

NOTE: SUPERCHARGER

BELT IS ON OUTSIDE

(FORWARD) OF ACCESSORY

BELT

TENSIONER

POWER

STEERING

PUMP

HARMONIC

BALANCER/

AIR

CRANK PULLEY

CONDITIONER

*4.6L ONLY

Fig. 12-c

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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12. SUPERCHARGER MOUNTING, cont'd.

5.4L MODELS ONLY

SPRING TENSIONER

RIBBED IDLERS

SMOOTH IDLER

HARMONIC

BALANCER/

CRANK PULLEY

Fig. 12-d

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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13. MASS AIR FLOW SENSOR REMOVAL, MOUNTING AND ASSEMBLY

A. Separate the mass air flow sensor

from the air inlet canister.

INNER FENDERWELL

B. Assemble the mass air sensor and

the mass 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.

CRUISE

CONTROL

C. Using the factory air inlet filter can-

ister mounting location, secure the

mass air bracket with the 5/16-18

x 1-1/2” bolts, nuts and washers;

use the large 5/16 fender washers

on the bottom of the factory rub-

ber grommets.

COOLANT

RESERVOIR

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.

MASS AIR

FLOW

SENSOR

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.

FRONT

TOP VIEW

Fig. 13-a

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 elbow. 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” x 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.

AIR TEMPERATURE

SENSOR

Fig. 14-a

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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14. AIR INLET/BYPASS ASSEMBLY, cont'd.

C. Install the bypass valve and #16 hose clamp on the

end of the 1" x 5" hose - 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.

Fig. 14-b

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

VACUUM HOSE

TO FMU

1” x 5” HOSE

3-1/2" x 90°

ELBOW

1” x 7” HOSE

4.6L model shown

Fig. 14-c

AIR INTAKE

TEMP SENSOR

FLEX

HOSE

DISCHARGE

TUBE

SUPERCHARGER

4.6L MODELS ONLY

(see photo above)

3/4” 90° BARB

TO IDLE AIR

RESONATOR

Fig. 14-d

TOP VIEW

3/4” 90° BARB

TO IDLE AIR

RESONATOR

5/8” 90° BARB

DRIVERS SIDE VALVE

COVER CRANK VENT

1” X 90°

PLASTIC

HOSE BARB

BYPASS

FLEX

HOSE

VALVE WITH

1” x 2.5” HOSE

AIR INTAKE

TEMP SENSOR

1” x 9” HOSE

SUPERCHARGER

DISCHARGE

TUBE

5.4L MODELS ONLY

Fig. 14-e

----- = BOTTOM VIEW

TOP VIEW

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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15. DISCHARGE

A. Install the 3” silicone sleeve and the #48 hose clamps

on the throttle body.

B. Slide the 2-3/4” silicone sleeve and the #44 hose

clamps onto the discharge tube.

C. 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.

D. Connect the 1” bypass hose to the bung on the back-

side of the discharge tube and secure using a #16

hose clamp.

E. Inspect all ducts and hoses to ensure they are secure

and that all hose clamps are properly tightened.

F. 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.

16. FINAL CHECK

erly installed may cause FAILURE OF MA-

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 the use of the fac-

tory hold-down bracket. Reconnect the fac-

tory harness and reinstall the factory kick

panel.

JOR COMPONENTS.

H. Test drive the vehicle.

I. The supercharger belt stretches initially and

will require adjustment in 250 to 400 miles.

J. 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.

A. Reconnect the battery.

B. 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.

C. 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.

D. Check all fluid levels, making sure that your tank(s)

is/are filled with 92 octane or higher fuel before com-

mencing test drive.

E. Start engine and allow to idle a few minutes, then shut

off.

Fig. 16-a

F. Recheck to be sure that no hoses, wires, etc. are near

exhaust headers or moving parts and for signs of any

fluid leakage.

G. PLEASE TAKE SPECIAL NOTE: Operating the vehicle

without ALL the subassemblies completely and prop-

*4.6L ONLY

P/N: 4FM020-010

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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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

20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1)

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