Vortech 1997-2003 Ford 5.4 F-150 Expedition User Manual

PN: 8N020-130 v1.0 — F-150 PwrClr 09/19/05

Maxflow®Power Cooler

Installation Instructions

1997-2003 Ford 5.4 F-150/Expedition

P/N: 8N301-300/308

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

VORTECH

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please read through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

or translated into another language in any form, by any means without written permission

of Vortech Engineering, LLC.

P/N: 8N020-130

19SEP05 v1.0 97-03F150PwrClr(8N020-130v1.0)

iii

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

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

NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

PARTS LIST - 1997-2003 5.4L Ford F-150/Expedition . . . . . . . . . . . . . . . . . . . . vi

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

2. SUPERCHARGER RECLOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3. DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4. WA TER RESERVOIR/PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . .4

5. WA TER COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

6. WA TER PUMP WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

7. FUEL MANAGEMENT UNIT RECALIBRATION . . . . . . . . . . . . . . . . . . . .8

8. REASSEMBLY AND FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

This product may not be legal for use on public roads in all 50 states.

NOTICES

(Read before installation is started)

Included in this kit is a smaller than originally supplied supercharger pulley. This new pulley is recommended to achieve the best performance results. Removal of the factory sealed pulley will reduce the supercharger warranty from three years to one year unless the supercharger unit (with the original pulley still attached) and new pulley are sent into Vor tech for removal, installation and re-sealing. If the supercharger warranty is not a concern or if the supercharger warranty has expired, the pulley may simply be removed and replaced with the new part supplied.Hammering/prying etc. on the supercharger and/or pulley will cause damage to the parts. Light heating of the supercharger pulley with a propane torch (if the pulley is tight on the shaft) will aid remov al.A return authorization number is required before the supercharger and pulley are sent into Vortech.Call the Vor tech service depar tment at (805) 247-0226 for a return authorization number.Return freight (ground) will be paid by Vor tech.

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 ma y not be 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.

Custon ECM calibration by a competent tuner is suggested before operation at wide open throttle.

P/N: 8N020-130

19SEP05 v1.0 97-03F150PwrClr(8N020-130v1.0)

Vortech Maxflow Power Cooler

Installation Instructions

1997-2003 5.4L F-150/Expedition

Before beginning this installation,

please read through this entire instruction booklet

The Vor tech Maxflow Power Cooler system was designed as a street/strip oriented aftercooler, specifically for use on 1997-2003 5.4L F-150/Expedition vehicles equipped with a Vortech supercharger.

As with any power enhancing product, this system is intended for use on healthy, well-maintained engines. 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 a note of the following key points:

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

2. Always listen for any sign of detonation (pinging) and discontinue hard use (no

boost) until problem is resolved.

TOOL & SUPPLY REQUIREMENTS:

• Metric and standard - socket set, wrench set

• Ratchets - 1/2", 3/8", 1/4" drive

• Extensions: 3" & 6"

• 1/2" drive breaker bar

• Pliers

• Drill motor

• Ø1/16" and #30, Ø9/32", and Ø11/16" drill bits

• Test light

• Wire cutters and crimping tool

• Standard hex key set (Allen wrenches)

• Silicone sealer/RTV

Congratulations on selecting the best performing and most

efficient aftercooler today... the Vortech Maxflow Power Cooler!

If your vehicle has in excess of 30,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

+ 11 hidden pages

Vortech 1997-2003 Ford 5.4 F-150 Expedition User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

NOTICES