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Ford Ford 4.6/5.4 2V manual

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Table of contents for the manual

  • Page 1

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) For d 4.6/5.4 2V F-150/F-250 Expedition/Navigator 1997-200 3 Model Y ears 50 State Smog Legal per CARB EO #D-213- 20 Super char ger System Installation Instructions ENGINEERING, LLC 1650 P A CIFIC A VENUE • CHANNEL I[...]

  • Page 2

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if[...]

  • Page 3

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) iii T able Of Contents FOREWORD ....................................................................................................................... .............. ii T ABLE OF CONTENTS ............................[...]

  • Page 4

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) iv SUPERCHARGED F-150/F-250/EXPEDITION/NA VIGA TOR DISCLAIMER T owing, racing per formance driving, hard accelerations, and other heavy/severe duty driving activities place extra demands on a vehicle’ s transmission.[...]

  • Page 5

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) v 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 h[...]

  • Page 6

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 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 f[...]

  • Page 7

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) vii Part No. 4FM218-010S/018S PA R TS LIST Part Number Description Quantity 8F203-265 FUEL PUMP ASSEMBL Y 1 5W001-001 Wire T ap 1 5W001-011 16-14 Ga. Eyelets 2 7E010-050 #12 x 1/2” Sheet Metal Screw 1 7P312-003 5/16[...]

  • Page 8

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) Part No. 4FM218-020/028S PA R TS LIST Part Number Description Quantity 4FM112-040 AIR INLET ASSEMBL Y 1 4FM010-050 MAF Bracket Assembly 1 8H040-045 3-3/4" Flanged Air Filter 1 7R002-056 #56 Hose Clamps 4 7S350-200[...]

  • Page 9

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 1 *4.6 MODELS ONL Y A. Disconnect the negative battery cable. 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.[...]

  • Page 10

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 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&qu[...]

  • Page 11

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 3 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 appropriat[...]

  • Page 12

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 4 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 for[...]

  • Page 13

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 5 4. CRANKSHAFT PULLEY/SUPERCHARGER DRIVE PULLEY 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- gin[...]

  • Page 14

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 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/[...]

  • Page 15

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 6. FUEL PUMP RELA Y 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 unde[...]

  • Page 16

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 7. WIRE PREP ARA TION (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 i[...]

  • Page 17

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 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[...]

  • Page 18

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 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. C . Cut and extend the cam se[...]

  • Page 19

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 11 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" [...]

  • Page 20

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 10. FUEL MANA GEMENT 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 o[...]

  • Page 21

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 13 ENGINE FUEL FEED LINE FUEL RETURN LINE FUEL T ANK FUEL MANAGEMENT UNIT (FMU) T- REX FIL TER F ACTORY SPRINGLOCK CONNECTOR V ACUUM LINE F ACTORY REGULA TOR INLET OUTLET F ACTORY QUICK- DISCONNECT FITTING F ACTORY V [...]

  • Page 22

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 11. IDLE AIR CONTROL RESONA T OR AND CRANKCASE VENT HOSE REROUTING 14 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 cont[...]

  • Page 23

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 15 4.6L MODELS ONL Y VORTECH TENSIONER IDLER TENSIONER AIR CONDITIONER HARMONIC BALANCER/ CRANK PULLEY POWER STEERING PUMP VORTECH SMOOTH IDLER PULLEY VORTECH RIBBED IDLER PULLEY WA TER PUMP AL TERNA TOR VORTECH SMOOT[...]

  • Page 24

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 12. SUPERCHARGER MOUNTING, cont'd. 16 5.4L MODELS ONL Y RIBBED IDLERS SPRING TENSIONER HARMONIC BALANCER/ CRANK PULLEY SMOOTH IDLER Fig. 12-d[...]

  • Page 25

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 13. MASS AIR FLO W SENSOR REMO V AL, MOUNTING AND ASSEMBL Y 17 A. Separate the mass air flow sensor from the air inlet canister . B. Assemble the mass air sensor and the mass air sensor mounting bracket with the 1/4-2[...]

  • Page 26

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 18 14. AIR INLET/BYP ASS ASSEMBL Y , 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 poin[...]

  • Page 27

    P/N: 4FM020-010 © 2003 V ortech Engineer ing, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 16. FINAL CHECK 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 fitt[...]

  • Page 28

    P/N: 4FM020-010 © 2003 V ortech Engineering, LLC All Rights Reserved. Intl. Copr . Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) ENGINEERING, LLC 1650 P A CIFIC A VENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226 F AX (805) 247-0669 • www .vor techsuperchargers.com • M-F 8:00 AM - 4:30 PM PST ®[...]