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

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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

Page 2

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.

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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

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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.

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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

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1997-2003 Ford F-150/Expedition 5.4L

Charge Cooler Upgrade System

Part No. 8N301-300/308

ENGINEERING, LLC

PARTS LIST

2A038-295 S/C PULLEY 2.95" 8-GRV 1 4FM212-010 DISCHARGE ASY, '99-'03 5.4 F-150 1

4FM112-015 DISCHARGE TUBE “A”, F-150 H.O. 1 4FM012-016 DISCHARGE TUBE “B”, F-150 H.O. 1 7S275-200 SLEEVE, Ø2.75" x 2.00"L, BLUE 2 7S300-200 SLEEVE, 3" x 2", BLUE 2 7U034-016 1" GS HEATER HOSE .5' 7U034-016 1" GS HEATER HOSE 1.0' 7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 4 7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 4 8N055-050 PLASTIC CAP, SURGE TANK 1 7R002-016 #16 SS HOSE CLAMP 4 7U030-046 5/32" VACUUM LINE 2' 7P156-082 5/32" TEE 1 8D001-001 STD COMPRESS BYPASS VALVE 1

8N105-180 WATER TANK/COOLER ASY, '99-'03 1

8N055-030 TANK, WATER TRIANGLE SHAPE 1 7R007-001 NYLON RATCHET CLAMP, 1-1/8" 10 4FM010-180 BRKT, TRIANGLE RES, F-150 H.O. 1 7P500-026 1/2"NPT x 3/4" BARB, 90° BRASS 6 8N006-010 WATER COOLER, SETRAB SINGLE PAS 1 4FM010-190 BRKT, SETRAB UPPER, F-150 H.O. 2 4FM010-170 BRKT, SETRAB LOSER, F-150 H.O. 1 7E010-049 #10 x 3/4" HEX HD SLF DRL SHT MTL 5 7A250-049 1/4-20 x .75" SHCS PLTD 8 7F250-021 1/4-20 NYLOCK NUT, ZINC PLATED 5 7J250-022 1/4" WASHER SAE STAINLESS 15 7U038-000 3/4" HEATER HOSE 15' 7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 2 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7J010-001 #10 FLAT WASHER 5 7U100-055 TIE-WRAP, 7.5" NYLON 10

8N107-180 WATER PUMP ASY, 5.4 H.O. 1

5W014-010 14GA STRD WIRE, RED UL1015 8' 5W001-009 16-14GA MAKE SLIDE, INSULATED 2 5W001-010 16-14GA, FEMALE SLIDE, INSULATED 2 5W001-011 16-14GA RING TERM, .26" HOLE 1 5W014-030 14GA STRD WIRE, BLACK 5' 5W001-032 1/4" PLASTIC WIRE LOOM 5" 5W001-041 12-10GA, MALE SLIDE, INSULATED 1 5W001-022 T-TAP CONN, 14-16 AWG 1 5W001-054 16GA FUSE HOLDER WITH WIRE 1 5W001-013 14-16GA BUTT CONN, BLUE, INSULATED 2 5W001-015 FUSE, BLADE TYPE, 20AMP 1 7U100-055 TIE-WRAP, 7.5" NYLON 8 8F001-402 PUMP, WATER, PIERBURG 1 7R003-027 ADEL CLAMP, 1-11/16" 1

8N201-310 WELDED CORE ASY, 5.4 H.O. 1

8N003-030 COOLER DUCT, LT1, GROUND 1 8N030-070 DUCT, COOLER OUTLET, LS1 FBODY 1 8N201-001 WELDED CORE ASSY w/ENDS, S2K 1

8R101-002 PULLEY RETAINER ASSY, 8-RIB 1

2A040-011 PULLEY RETAINER, S/C 1 7B375-125 3/8-24 x 1-1/4" HXHD GR8 7K375-040 3/8"AN960 FLAT WASHER, PLATED 1 7U100-070 KEY, 3/16"SQUARE x 7/8"LONG 1 6Z170-020 8:1 RING SPACER ASSY 1 6Z050-191 FMU WASHER, 8:1 PLATED 1 6Z070-030 FMU 8:1 RING SPACER 1 6Z020-140 LRG DIAPHRAGM, FLOURO 1 007032 FMU RECALIBRATION INSTRUCTIONS 1 6Z170-020 RING AND SPACER, 8:1 FMU 1 2A048-795 8-RIB BELT 1

PART NUMBER DESCRIPTION QTY

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P/N: 8N020-130

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

1. Preparation and Removal

A. Disconnect and remove the negative bat-

tery terminal.

B. Remove the supercharger discharge tube

and bypass valve assembly.

C. Remove and set aside the supercharger

inlet elbow and flex tube.

D. Remove the supercharger drive belt and

supercharger.Set aside.

NOTE: Temporarily cap oil feed and oil drain to

protect your engine from foreign particles.

E. Remove the FMU, disconnect the lines not-

ing their position for re-assembly.

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2. Supercharger Reclocking

A. Loosen and remove the six 1/4-20 cap

screws and retaining plates that hold the compressor housing to the gearcase.

B. Carefully rotate the compressor housing to

the specified location as shown. (See Fig. 2-a.)

C. Evenly retighten the six cap screws, torque

to 60 in/lbs (5ft/lbs).

D. Remove original Ø3.33" supercharger pul-

ley from the supercharger and install the supplied Ø2.95" pulley. Use heat on the pulley if necessary.

Fig. 2-a

F-150 5.4L H.O.Supercharger Clocking

NOTE: If the compressor housing does not

rotate freely relative to the gearcase, DO NOT FORCE IT. SERIOUS SUPERCHARGER DAMAGE MAY OCCUR. The machined mating surfaces are designed to prevent pressurized air from escaping and have minimal tolerances. If the housing will not move or is very tight, contact Vortech Engineering immediately at (805) 247-0226 and ask for our service department for further assistance.

NOTE: Included in this kit is a smaller than orig-

inally supplied supercharger pulley. This new pulley is recommended to achieve 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 Vortech for removal, installation and re-sealing. If 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. Be aware that hammering/prying etc. on the supercharger may damage precision parts.

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P/N: 8N020-130

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

3. Discharge Installation

A. Locate the supplied Ø2.75" straight dis-

charge duct. Using a Ø2.75" x 2.0" silicone sleeve connect the end closest to the bypass bung to the discharge of the supercharger.Secure this end with #44 hose clamps. At this time, snug the hose clamps to leave the ability to fine tune the discharge assembly. (See Fig. 3-a.)

B. Locate the Ø2.75 x 90° discharge tube.

Using a Ø3.0" to 2.75" reducer and silicone sleeve, connect the lightly curved end to the throttle body. Point the 90° end of the duct to the passenger’s side of the vehicle.

C. Install two 3/4" x 90° brass fittings into the

two threaded ports in the supplied charge cooler.

D. Using the Ø2.75" x 2.0" silicone sleeves

connect the corresponding ends of the cooler to the open ends of the discharge ducts. Secure the Ø2.75" end with #44 hose clamps.

E. Align the discharge assembly and tighten

all hose clamps.

F. Lightly bend down the radiator hose sup-

port so that the charge cooler does not rub against the radiator hose.

Fig. 3-a

Fig. 3-b

Ø2.75" SILICONE SLEEVES

& #44 HOSE CLAMPS

90° BRASS

FITTINGS

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A. Locate the front bumper/fender support

brace from underneath the front passenger’s side fender well. (See Fig. 4-a.)

B. Remove the two screws securing the

brace, then remove the brace.

C. Using an adel clamp mount the supplied

water pump to the triangle water tank. (See Fig. 4-b.)

D. Dr ill through the two 1/2"NPT ports in the

water reservoir if necessary.Be careful not to contact the threads. Blow out any debris from inside the tank. Install a supplied Ø3/4" x 90° brass fitting in each threaded hole. Use thread sealant on the threads to help prevent leakage.

E. Connect the pump inlet to the bottom 90°

brass fitting with the supplied 4" x 12" rubber hose. Fit the hose, then cut it to length. (See Fig. 4-b.)

F. Mount the pump/tank assembly to the sup-

plied mounting bracket with the supplied 1/4-20 x .50" SHCS. (See Fig. 4-c.)

G. Using the factory hardware mount the

entire pump/tank assembly into the fender well in place of the factory support. (See Fig. 4-d.) It may be necessary to bend the horn out of the way to gain clearance.

4. Water Reservoir/Pump Installation

Fig. 4-a

Fig. 4-b

Fig. 4-c

Fig. 4-d

PASSENGER SIDE SUPPORT BRACE

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P/N: 8N020-130

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

5. Water Cooler Installation

A. If not already removed, take off the

plastic cover over the radiator.This will allow access to the area behind the grill and in front of the radiator.

B. Locate the supplied Setrab cooler and L-

shaped brackets. Attach the brackets to the top of the tabs on the Setrab cooler.(See Fig. 5-a.)

C. Position the cooler behind the grill with the

L-shaped tabs pointing upward. Align the tabs along the side of the cross-member and mark locations of the four Ø3/32" pilot holes to be drilled. (See Fig. 5-b.)

D. Dr ill the holes and temporarily mount the

water cooler.

E. Locate the supplied lower mounting brack-

et. Using the supplied 1/4" hardware secure one end of the bracket to the forward-most hole on the lower driver’s side flange of the cooler.Point the bracket toward the grill. (See Fig. 5-c.) Mark where the hole sits over the rear grill support rib. Use a sheet metal screw to secure the bracket to the grill.

For the following steps, see Fig. 5-d: F. Locate the 4" x 12" x 90° molded hose.

Connect the short end of the supplied 90° hose to the top fitting on the installed water reservoir.Using a hose mender and supplied length of hose connect the open end of the 90° hose to the lower fitting on the charge cooler.Route the hose along side the passenger’s side of the radiator snaking down to the upper brass fitting.

G. Using a section of Ø3/4" hose connect the

discharge of the water pump to the passenger’s side 90° fitting in the setrab water cooler.Route the hose near the frame rail in front of the radiator and up to the installed cooler.

H. Using the supplied Ø3/4" hose, connect the

driver’s side fitting in the Setrab cooler to the upper 90° fitting in the setrab water cooler.Route the hose to the passenger’s side of the radiator passing by the core support, up to the charge cooler.

I. Secure all ends with the supplied nylon

ratchet clamps.

Fig. 5-a

Fig. 5-b

Fig. 5-c

CONNECT TO LOWER

D-SIDE TAB ON

SETRAB COOLER

SECURE TO THE

REAR OF THE

FACTORY GRILL

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Fig. 5-d

4" x 12" x 90° HOSE

TRIMMED TO FIT

1/2"NPT x 3/4" BARB x 90°

WATER RESERVOIR

WATER PUMP

3/4" HOSE MENDER

1/2"NPT x 3/4" BARB x 90°

VORTECH

CHARGE COOLER

WATER

FILL PORT

WATER DIRECTION FLOW

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P/N: 8N020-130

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

A. Locate the supplied 14GA red wire and

wire loom. Route the wire from the water pump over to the power distribution box on the driver’s side. Use the supplied loom and tie-wraps to secure the wire.

B. Use the supplied slide connectors to attach

the red wire to the (blue/green) positive wire on the water pump.

C. Connect the brown wire to a good ground

with the supplied black wire, ring terminal and slide connectors.

D. Locate the positive wire running to the fuel

pump at the power distribution box.Use the supplied T-tap terminal and male slide connector to connect the water pump positive wire to the fuel pump positive wire.

6. Water Pump Wiring

NOTE: In some cases, the water pump must be

primed on initial start-up. This may be accomplished by turning on the pump, removing the RETURN line from the charge cooler and providing light suction on the hose to remove air in the system.

E. Fill the system with 25% anti-freeze and

75% water. Cycle the key a few times to verify water is flowing. Let the pump run for a few minutes to allow for any trapped air to be released.The combination of running for shor t periods of time and stopping the pump helps in purging the system.Top the system off when all air is purged.

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7. Fuel Management Unit Recalibration

Fig. 7-a

WARNING: Do not remove the four screws hold-

ing the valve body. Once taken apart, the valve would have to be replaced.

A. Remove the six allen-head screws on top of

the fuel management unit (FMU).

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 counterpar ts.) Place the 8:1 disk (2.22" O.D.) inside the r ing 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.).

8:1

RING &

DISC

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8. Reassembly and Final Check

A. Reconnect the battery. B. Check all fittings, nuts, bolts and clamps for

tightness. Pay particular attention to the oil and fuel lines, especially around moving parts, sharp edges and exhaust headers. Make sure all wires and lines are properly secured with clamps or tie-wraps.

C. Check all fluid levels, making sure that your

fuel tank is filled with 91 octane or higher fuel before test driving.

D. Start the engine and allow to idle for a few

minutes, then shut the engine off.

E. Recheck to be sure that no hoses, wires,

etc are near exhaust headers or moving parts and for signs of fluid leakage.

F. Test drive the vehicle.Listen for any signs

of detonation (pinging). If detected, discontinue hard use (no boost) until the problem is resolved.

WARNING: Operating the vehicle without all the

sub-assemblies completed and properly installed, may cause FAILURE OF MAJOR COMPONENTS.

WARNING: Custon ECM calibration by a competent

tuner is suggested before operation at wide open throttle.

Page 16

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

VORTECH

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 1997-2003 Ford 5.4 F-150 Expedition User Manual

FOREWORD

TABLE OF CONTENTS

NOTICES

1. Preparation and Removal

2. Supercharger Reclocking

3. Discharge Installation

5. Water Cooler Installation

6. Water Pump Wiring

P/N: 8N020-130 © 2005 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured. 19SEP05 v1.0 97-03F150PwrClr(8N020-130v1.0) 9

8. Reassembly and Final Check

P/N: 8N020-130

© 2005 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured.

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

9