Vortech 1999-2001 Ford 5.4L 6.8L Super Duty SUV User Manual

1999-2001 FORD 5.4L/

1999-2003 6.8L

SUPER DUTY TRUCK

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-20

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

®

ENGINEERING, LLC

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of

prior

this instruction manual should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

to beginning the installation to determine if you

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

P/N: 4FT020-010

of Vortech Engineering, LLC.

ii

Table Of Contents

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

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

IMPORTANT NOTES ........................................................................................................................iv

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

PARTS LIST-1999-2001 FORD SUPER DUTY 5.4L-STANDARD SYSTEM.....................................vi

PARTS LIST-1999-2003 FORD SUPER DUTY 6.8L-STANDARD SYSTEM.....................................viii

PARTS LIST-1999-2003 FORD SUPER DUTY 6.8L-H.O. w/CHARGE COOLER SYSTEM.............xi

1. PREPARATION/REMOVAL ..................................................................................................1

2. HARMONIC BALANCER & CRANK PULLEY INSTALLATION............................................2

3. OIL FEED LINE INSTALLATION ..........................................................................................4

4. OIL DRAIN LINE ..................................................................................................................4

5. FUEL PUMP INSTALLATION ...............................................................................................5

6. PUMP RELAY INSTALLATION.............................................................................................7

7. IN-TANK FUEL PUMP REPLACEMENT ( H.O. Systems Only) ...........................................7

8. FUEL MANAGEMENT UNIT................................................................................................8

9. WA TER PUMP AND COOLER INSTALLATION (H.O. Systems Only) .................................9

10. MOUNTING BRACKET & SUPERCHARGER INSTALLATION ...........................................11

11. AIR INLET ASSEMBLY ........................................................................................................11

12. DISCHARGE DUCTING ......................................................................................................12

13. CHARGE COOLER INSTALLATION (H.O. Systems Only) ..................................................13

14. HOSE INSTALLATION & FILLING (H.O. Systems Only)......................................................14

15. REASSEMBLY AND FINAL CHECK ....................................................................................15

APPENDIX ........................................................................................................................................17

A-1 V-10 FMU DIAGRAM..................................................................................................18

A-2 V-8 FMU DIAGRAM....................................................................................................19

A-3 MOUNTING PLATE AND SUPPORT PLATE ASSEMBLIES .....................................20

A-4 V-8 INLET AND DISCHARGE DIAGRAM-STANDARD SYSTEM ..............................21

A-5 V-10 INLET AND DISCHARGE DIAGRAM-STANDARD SYSTEM ............................22

A-6 BELT ROUTING DIAGRAM........................................................................................23

A-7 CHARGE COOLER DIAGRAM ..................................................................................24

A-8 WATER HOSE DIAGRAM ..........................................................................................25

P/N: 4FT020-010

iii

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

Ford 5.4L/6.8L Super Duty

IMPORTANT NOTES

1999-2003 Models

This kit requires ECM modification and the installation of a Vortech 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 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 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).

P/N: 4FT020-010

iv

1999-2003

FORD SUPER DUTY

Installation Instructions

1999-2001 50 State Smog Legal, as per CARB EO #D-213-17

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form.

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 at least every 3,000 miles. 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 2 years or 30,000 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 at least every 30,000 miles.

®

V-2® Supercharger!

TOOL & SUPPLY REQUIREMENTS:

• Metric and standard - socket set, wrench set

• Ratchet - 1/2” drive

• Extension

• 1/2" drive breaker bar

• Ford springlock tool 3/8" & 1/2”

• Pliers

• Drill motor

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

• Test light

• Rubber mallet or dead blow hammer

• Harmonic balancer puller and installer

• Wire cutters and crimping tool

• Standard hex key set (Allen wrenches)

• Alcohol (denatured or rubbing)

• Silicone sealer/RTV

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

v

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

P/N: 4FT020-010

1999-2001 Ford Super Duty 5.4L

Part No. 4FT218-010/018SQ

®

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

4FT120-020 ECM CHIP PKG/SHIPPING ASSY 1 2E228-340 V2 SQ SUPER DUTY 5.4L 1

2E128-340 S/C S.D. 5.4 V-2SQ SATIN 1 2A038-333 S/C PULLEY Ø3.33" 8 GROOVE 1 8R101-002 8-RIB PULLEY RET.ASSY 1

4FT111-062 CRANK PULLEY ASSY 5.4 1

4FT016-031 5.4 CRANK PULLEY 1 4FT016-021 DAMPER 5.4 MACHINED 1 4FT017-010 SPCR, CRNK PULLEY 1

2A048-730 BELT, K080730 GATES 1 7C120-065 M12 x 1.5 x 65mm HHCS 1 7C100-040 M10 x 1.5 x 40mm SHCS 3 7K437-001 7/16" AN WASHER 3

4FT111-054 MNTG. BRKT. ASSY 1

4FM016-031 IDLER 8-RIB GROOVED 1

4FA016-171 DUST COVER 3 4FT017-070 SPACER, IDLER S.D. 1

7A437-250 7/16-14 x 2.5" HXHD 1 7F437-000 7/16-14 NUT NYLOCK 1

7J438-081 7/16 WASHER SAE 1 4FT110-044 MAIN BRKT ASSY, WELDED 1 4FT010-034 SUPPORT PLATE 1

7C100-085 M10 x 1.5 x 85mm HXHD 1 7C100-110 M10 x 1.5 x 110mm HXHD 2

7J010-002 M10 WASHER 3

7A375-178 3/8-16 x 1.75" HXHD GR8 5 7K375-030 3/8 WASHER AN 5

4FM011-052 5.4 SPRING TENSIONER 1

7C010-045 M10 x 1.5 x 45mm HXHD 1 4FA016-170 IDLER 8-RIB SMOOTH 1 4FA016-171 DUST COVER 1 4FT017-060 SPACER, SPRING TENSIONER 1

7A375-400 3/8-16 x 4" HXHD PLTD 1

7F375-017 3/8-16 NUT NYLOCK 1

7K375-030 3/8 WASHER AN 2

7A250-075 1/4-20 x .75" SHCS 2

7J250-001 1/4 WASHER PLTD 2

4FT010-020 DAMPER BRKT. S.D. 1

4FM017-020 5.4 SPCR LONG 1

7C140-035 M14 x 2.0 x 35mm, HXHD PLTD 1

7J438-091 9/16" WASHER SAE PLTD 1

4FT010-050 BRKT, WIRNG HRNS S.D. 1

7A250-075 1/4-20 x .75" SHCS PLTD 2

7J250-001 1/4 WASHER PLTD 4

7F250-021 1/4-20 NUT NYLOCK 2

5W018-070 WIRE 22-18GA GREEN 6" 5W018-030 WIRE 22-18GA GRAY 6" 5W001-012 SOLDERLESS CONNECTORS 22-18GA 4

7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 3

7K375-030 3/8 WASHER AN 6

7F375-017 3/8-16 NUT NYLOCK 3

7C012-035 M12 x 1.75 x 35mm HXHD 3

7J012-092 M12 WASHER 3

Part Number Description Quantity

4FT130-026 OIL FEED ASSY. SUPER DUTY 1

7U030-026 1/4" x 25" OIL FEED HOSE 25" 7P250-034 STREET TEE 1 7P250-082 1/4"NPT x -4 x 90° FITTING 1 7P525-067 CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4 HOSE BARB 2 7U100-055 6" TIE WRAPS 4 7P125-026 1/8 NPT x #4 X 90° FITTING 1

4FT238-068 FMU ASSY SUPER DUTY 1

4FT145-020 FUEL LINE, FEMALE 7" 1

4FD145-010 FUEL LINE, MALE 17" 1

7U030-046 5/32" X 18" VACUUM LINE 18" 7P156-082 5/32" TEE 1 7U100-055 6" TIE WRAPS 2 6Z110-136 7:1 FMU 1

8F203-265 FUEL PUMP ASSY. 1

5W001-001 WIRE TAP 1 5W001-011 16-14 GA EYELET .25” HOLE 2

7E010-050 #12 x 1/2 SHEET METAL SCREW 1 7P312-003 5/16 FEMALE FUEL 1 7R004-003 14.5 STEPLESS CLAMP 2 7U100-044 TIE WRAP, 4” NYLON 3 7U100-055 TIE WRAP, 6” NYLON 4 7U031-018 5/16 FUEL HOSE HI-PRESSURE 11"

8F101-200 T-REX WIRING ASSY MUSTANG 1 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-010 16-14 GA FEMALE SLIDE 1

8F001-002 155 INLINE FUEL PUMP 1

7R003-027 ADEL CLAMP 1

7R001-008 #8 STNLS HOSE CLAMP 2

7E010-075 #12 x 3/4” SHEET METAL SCREW 1

7P500-004 FITTING, FUL.ADAPT.1/2 1 5W001-017 LARGE RING TERMINAL 1 5W001-019 SOLDERLESS CONNECTOR 10-12 2

7U030-050 12mm FUEL HOSE 16" 5W001-042 12-10 GA 3/16” RING TERMINAL 2

7A250-100 1/4-20 x 1” FLAT ALLEN 1

7J250-001 1/4 SAE WASHER, PLATED 2

7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1 5W001-040 12-10 GA FEMALE SLIDE 2

4FT130-036 OIL DRAIN ASSY. SUPER DUTY 1

7P100-121 SEALING NUT 1

7P375-045 45° STREET ELBOW 1

7P375-017 3/8 NPT HOSE BEAD x 1/2 BEADED 1

7U030-036 1/2" OIL DRAIN HOSE x 1' 1

7R001-008 #8 HOSE CLAMPS 2

7R003-027 ADEL CLAMP 1

7R001-008 #8 HOSE CLAMPS 2

4FT011-032 CROWS FOOT, WATER PUMP 1 4FT011-022 CROWS FOOT, FORD V-8 1

P/N: 4FT020-010

vi

1999-2001 Ford Super Duty 5.4L

Part No. 4FT218-010/018SQ

®

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

4FT112-010 AIR INLET ASSY 1

4FT012-030 DUCT, INLET Ø3.5” S.D. 1 7R002-056 #56 GOLDSEAL HOSE CLAMP 2 7R002-052 #52 GOLDSEAL HOSE CLAMP 2 8H040-045 AIR FILTER F-150 1 4FT110-010 BRKT ASSY, MAF SUPERDUTY 1 7P375-106 PCV VALVE, F150, 3/8” INLET 1 7P625-016 5/8” UNION 1 7U133-024 5/8” MOLDED ELBOW HOSE 1 7A250-075 1/4-20 x 3/4 SHCS PLATED 4 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 4 7J250-001 1/4 SAE WASHER, PLATED 8 7S350-200 3-1/2 x 2 SLEEVE 1 7U035-001 3-1/2” FLEX HOSE 15"

4FT112-020 AIR DISCHARGE ASSY 1

4FT012-020 DISCH. DUCT 5.4 SUPER DUTY 1 8D001-001 BYPASS VALVE 1 7U034-016 1” GS HOSE 3" 7R002-016 #16 GOLDSEAL HOSE CLAMP 5 7U133-090 RUBBER ELBOW, Ø1.0” x 90° 1 7U030-046 5/32” VACUUM LINE 25" 7S275-200 2-3/4 x 2 SLEEVE 2 7R002-044 #44 GOLDSEAL HOSE CLAMP 3 7R002-048 #48 GOLDSEAL HOSE CLAMP 1 7P750-102 3/4NPT x 1” x 90° HOSE FITTING 1 7U034-016 1” GS HOSE 3"

vii

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

1999-2003 Ford Super Duty 6.8L

Part No. 4FT218-020/028SQ

®

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

4FT120-020 ECM CHIP PKG/SHIPPING ASSY 1 4FT130-036 OIL DRAIN ASSY. SUPER DUTY 1

7P100-121 SEALING NUT 1 7P375-045 45° STREET ELBOW 1 7P375-017 3/8 NPT HOSE BEAD x 1/2 BEADED 1 7U030-036 1/2" OIL DRAIN HOSE x 1' 1 7R001-008 #8 HOSE CLAMPS 2

4FT112-030 DISCHARGE ASSY 6.8 SUPER DUTY 1

7R002-072 #72 HOSE CLAMPS 2 7S450-200 4 1/2 x 2 SLEEVE 1

4FT012-010 DISCHARGE DUCT 1

7S300-275 REDUCER Ø3.00 x Ø2.75 1 7R002-048 #48 HOSE CLAMP 1 7R002-044 #44 HOSE CLAMP 1 8D001-001 BYPASS VALVE 1 7R002-016 HOSE CLAMPS #16 4 7U030-046 5/32" VAC LINE x 25" 25" 7U133-090 HOSE, RUBBER ELBOW Ø1" x 90° 1 7U034-016 1" HEATER HOSE X 3" 3"

4FT111-052 CRANK PULLEY ASSY 6.8 V-10 1

7K437-001 7/16 AN WASHER 3 4FT016-011 DAMPER V-10 MACH 1 4FT016-031 CRNK PULLEY 8 - RIB MACH 1 4FT017-010 SPACER, CRNK PLLY V-10 1

7C120-065 M12 x 1.5 x 65mm HHCS 1

7C100-040 M10 x 1.5 x 40mm SHCS 3

2A048-733 BELT, K080733 GATES 1 4FT017-011 SPACER, FAN V-10 1

2E228-330 V2SQ S.D. 6.8L 1

2E128-330 S/C S.D. 6.8 V-2SQ SATIN 1

2A038-347 S/C PULLEY Ø3.47" 8 GROOVE 1

8R101-002 8-RIB PULLEY RET. ASSY 1

4FT112-010 AIR INLET ASSY. 1

4FT012-030 CAST AIR INLET 1

7S350-200 3.5"X2" SLEEVE 1 7R002-056 HOSE CLAMPS #56 2 7R002-052 HOSE CLAMPS #52 2 7U035-001 3.5" FLEX HOSE x 15" 15" 8H040-045 AIR FILTER 1

4FT110-010 MAF BRKT ASSY 1

7P375-106 PCV VALVE 1 7P625-016 5/8" UNION 1 7U133-024 5/8" MOLDED ELBOW HOSE 1 7A250-075 1/4-20 x 3/4" SHCS 4 7F250-021 1/4-20 NYLOCK NUTS 4

7J250-001 1/4" WASHERS 8

Part Number Description Quantity

4FT111-054 MNTG. BRKT. ASSY 1

4FM016-031 IDLER 8-RIB GROOVED 1

4FA016-171 DUST COVER 3 4FT017-070 SPACER, IDLER SUPER DUTY 1

7A437-250 7/16-14 x 2.5" HXHD PLTD 1 7F437-000 7/16-14 NUT NYLOCK 1

7J438-081 7/16 WASHER SAE PLTD 1 4FT110-044 MAIN BRKT ASSY, WELDED 1 4FT010-034 SUPPORT PLATE 1

7C100-085 M10 x 1.5 x 85mm HXHD PLTD 1

7C100-110 M10 x 1.5 x 110mm HXHD PLTD 2

7J010-002 M10 WASHER 3

7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 5

7K375-030 3/8 WASHER AN 5

4FM011-052 5.4 SPRING TENSIONER 1

7C010-045 M10 x 1.5 x 45mm HXHD PLTD 1 4FA016-170 IDLER 8-RIB SMOOTH 1 4FA016-171 DUST COVER 1 4FT017-060 SPACER, SPRING TENSIONER 1

7A375-400 3/8-16 x 4" HXHD PLTD 1

7F375-017 3/8-16 NUT NYLOCK 1

7K375-030 3/8 WASHER AN 2

7A250-075 1/4-20 x .75" SHCS PLTD 2

7J250-001 1/4 WASHER PLTD 2 4FT010-020 DAMPER BRKT. SUPER DUTY 1

4FM017-020 5.4 SPCR LONG 1

7C140-035 M14 x 2.0 x 35mm, HXHD PLTD 1

7J438-091 9/16" WASHER SAE PLTD 1 4FT010-050 BRKT, WIRNG HRNS S.D. 1

7A250-075 1/4-20 x .75" SHCS PLTD 2

7J250-001 1/4 WASHER PLTD 4

7F250-021 1/4-20 NUT NYLOCK 2

5W018-070 WIRE 22-18GA GREEN 6" 5W018-030 WIRE 22-18GA GRAY 6" 5W001-012 SOLDERLESS CONNECTORS 22-18GA 4

7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 3

7K375-030 3/8 WASHER AN 6

7F375-017 3/8-16 NUT NYLOCK 3

7C012-035 M12 x 1.75 x 35mm HXHD 3

7J012-092 M12 WASHER 3

4FT130-026 OIL FEED ASSY. SUPER DUTY 1

7U030-026 1/4" x 25" OIL FEED HOSE 25"

7P250-034 STREET TEE 1

7P250-082 1/4"NPT x -4 x 90° FITTING 1

7P525-067 CRIMP FERRULES 2

7P250-066 #4 SWIVEL x 1/4 HOSE BARB 2

7U100-055 6" TIE WRAPS 4

7P125-026 1/8 NPT x #4 x 90° FITTING 1

4FT011-032 CROWS FOOT, WATER PUMP 1 4FT011-012 CROWS FOOT, FORD V-10 1

P/N: 4FT020-010

viii

1999-2003 Ford Super Duty 6.8L

Part No. 4FT218-020/028SQ

®

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

4FT238-068 FMU ASSY SUPER DUTY 1

4FT145-020 FUEL LINE, FEMALE 7" 1 4FD145-010 FUEL LINE, MALE 17" 1

7U030-046 5/32" x 18" VACUUM LINE 1.5’ 7P156-082 5/32" TEE 1 7U100-055 6" TIE WRAPS 2

6Z110-136 7:1 FMU 1

8F203-265 FUEL PUMP ASSY. 1

5W001-001 WIRE TAP 1 5W001-011 16-14 GA EYELET .25” HOLE 2

7E010-050 #12 x 1/2 SHEET METAL SCREW 1 7P312-003 5/16 FEMALE FUEL 1 7R004-003 14.5 STEPLESS CLAMP 2 7U100-044 TIE WRAP, 4” NYLON 3 7U100-055 TIE WRAP, 6” NYLON 4 7U031-018 5/16 FUEL HOSE HI-PRESSURE 11"

8F101-200 T-REX WIRING ASSY MUSTANG 1 5W001-014 FUSE HOLDER 10 GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20 AMP 1 5W001-010 16-14 GA FEMALE SLIDE 1

8F001-002 155 INLINE FUEL PUMP 1

7R003-027 ADEL CLAMP 1 7R001-008 #8 STNLS HOSE CLAMP 2 7E010-075 #12 x 3/4” SHEET METAL SCREW 1

7P500-004 FITTING, FUL.ADAPT.1/2 1 5W001-017 LARGE RING TERMINAL 1 5W001-019 SOLDERLESS CONNECTOR 10-12 2

7U030-050 M12 FUEL HOSE 16" 5W001-042 12-10 GA 3/16” RING TERMINAL 2

7A250-100 1/4-20 x 1” FLAT ALLEN 1

7J250-001 1/4 SAE WASHER, PLATED 2 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1

5W001-040 12-10 GA FEMALE SLICE 2

P/N: 4FT020-010

ix

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

1999-2003 Ford Super Duty 6.8L

w/Charge Cooler System

®

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

008110 SMALL SILVER DIE CUT 2 008130 LICENSE PLATE FRAME 1 8N101-110 WELDED CORE ASSY. V-10 S.D. 1 4FT112-040 DISCH ASSY PWR COOLR V-10 SD 1

4FT010-060 BRKT, COOLER SUPPORT V-10 S.D. 1 4FT012-040 DUCT, V-10 A.C. TUBE A 1 4FT012-050 DUCT, V-10 A.C. TUBE B 1 4FT012-060 DUCT, V-10 A.C. TUBE C 1 4FT017-080 SPACER, COOLER SUPRT BRKT 1 7C060-025 M6 x 1.0 x 25MM HHCS 1 7F008-020 NUT, M8 x 1.5 1 7J006-094 M6 WASHER S.S. 1 7L312-000 WASHER LOCK 5/16" 1 7R002-044 #44 HOSE CLAMPS 6 7S275-200 2 3/4" x 2" SLEEVE 3 7U034-016 Ø 1.00" G.S. HOSE 6"

8N106-100 WATER COOLER ASSY. V-10 S.D. 1

4FT006-001 WATER COOLER, SUPERDUTY 1 5W018-020 18GA STRD WIRE BLK, UL1015 3' 7A250-050 1/4-20 x .50" SHCS 2 7A250-075 1/4-20X3/4 SHCS PLTD 1 7A250-100 1/4-20 x 1" SHCS 1 7A250-275 1/4-20 X 2.75" SOC HD, ZINC 2 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD. 2 7F250-040 1/4-20 NUT PLATE 2 7J250-001 1/4 SAE WASHER, PLTD 6 7J250-022 1/4" WASHER 2 7P250-020 1/4NPT DRAIN COCK 1 7P500-026 1/2NPT-3/4 BARB 90^ 2 7P500-078 1/2NPT x 3/4 HOSE FIT 4 7R002-052 HOSE CLAMP #52 4 7R007-001 NYLON CLAMP 1-1/8" 8 7S325-200 3.25" x 2.00" SLEEVE 2 7U038-000 3/4" HEATER HOSE 13' 7U100-066 TIE WRAP 11" NYLON 10 8N010-090 MNTG TAB, PLASTIC SURGE TANK 1 8N017-020 ADAPTER, WATER COOLER S.D. 2 8N055-050 CAP, SURGE TANK PLASTIC 1 8N056-060 SURGE TANK 1

8N107-020 WATER PUMP ASSY. 4.6 1

5W001-011 16-14 GA EYELET 1 5W001-012 SOLDERLESS CONNECTOR 1 5W018-010 18GA STRD WIRE RED 8.25' 5W001-019 SOLDERLESS CONNECTOR 2 5W001-014 FUSE HOLDER 10 GA 1 5W001-015 FUSE, BLADE TYPE 20A 1 5W001-040 12-10GA FEMALE SLIDE 1 5W001-002 FUSE TAP 1 7R003-027 ADEL CLAMP 1-11/16" 1 8F001-402 PUMP, WATER, PIERBURG 1 7E010-075 #12 x 3/4" SHEET METAL SCREW 1 7J010-001 #10 FLAT WASHER 1 7U133-060 3/4" x 90° HOSE ELBOW 1 5W001-024 MINI ATC FUSE TAP 1 5W001-025 FEMALE SLIDE, INSULATED, MINI 1

4FT120-020 ECM CHIP PKG ASSY 1 4FT111-052 CRANK PULLEY ASSY 6.8 V-10 1

7K437-001 7/16 AN WASHER 3

4FT016-011 DAMPER V-10 MACH 1 4FT016-031 CRNK PULLEY 8 - RIB MACH 1 4FT017-010 SPACER, CRNK PLLY V-10 1 7C120-065 M12 x 1.5 x 65MM HXHD PLTD 1 7C100-040 M10 x 1.5 x 40MM SHCS PLTD 3 4FT017-011 SPACER, FAN V-10 1

2E228-370 V2SQ SUPERCHARGER S.D. 6.8L H.O. 1 4FT111-054 MNTG. BRKT. ASSY 1

4FM016-031 IDLER 8-RIB GROOVED 1 4FA016-171 DUST COVER 1 4FT017-070 SPACER, IDLER S.D. 1 7A437-250 7/16-14 x 2.5" HXHD PLTD 1 7F437-000 7/16-14 NUT NYLOCK 1 7J438-081 7/16 WASHER SAE PLTD 1 4FT110-044 MAIN BRKT ASSY, WELDED 1 4FT010-034 SUPPORT PLATE 1 7C100-085 M10 x 1.5 x 85MM HXHD PLTD 1 7C100-110 M10 x 1.5 x 110MM HXHD PLTD 2 7J010-002 M10 WASHER 3 7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 5 7K375-030 3/8 WASHER AN 5 4FM011-052 5.4 SPRING TENSIONER 1 7C010-045 M10 x 1.5 x 45MM HXHD PLTD 1 4FA016-170 IDLER 8-RIB SMOOTH 1 4FA016-171 DUST COVER 1 4FT017-060 SPACER, SPRING TENSIONER 1 7A375-400 3/8-16 x 4" HXHD PLTD 1 7F375-017 3/8-16 NUT NYLOCK 1 7K375-030 3/8 WASHER AN 2 7A250-075 1/4-20 x .75" SHCS PLTD 2 7J250-001 1/4 WASHER PLTD 2 4FT010-020 DAMPER BRKT. S.D. 1 4FM017-020 5.4 SPCR LONG 1 7C140-035 M14 x 2.0 x 35MM, HXHD PLTD 1 7J438-091 9/16" WASHER SAE PLTD 1 4FT010-050 BRKT, WIRNG HRNS S.D. 1 7A250-075 1/4-20 x .75" SHCS PLTD 2 7J250-001 1/4 WASHER PLTD 4 7F250-021 1/4-20 NUT NYLOCK 2 5W018-070 WIRE 22-18GA GREEN 6" 5W018-030 WIRE 22-18GA GRAY 6" 5W001-012 SOLDERLESS CONECTORS 22-18GA 4 7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 3 7K375-030 3/8 WASHER AN 6 7F375-017 3/8-16 NUT NYLOCK 3 7C012-035 12MM x 1.75 x 35MM HXHD 3 7J012-092 12MM WASHER 3

4FT130-026 OIL FEED ASSY. S.D. 1

7U030-026 1/4" x 25" OIL FEED HOSE 25" 7P250-034 STREET TEE 1 7P250-082 1/4"NPT x -4 x 90° FITTING 1 7P525-067 CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4 HOSE BARB 2 7U100-055 6" TIE WRAPS 4 7P125-026 1/8 NPT x #4 x 90° FITTING 1

4FT011-032 CROWS FOOT, WATER PUMP 1 4FT011-012 CROWS FOOT, FORD V-10 1

Part No. 4FT218-030/038SQ

PARTS LIST

P/N: 4FT020-010

x

1999-2003 Ford Super Duty 6.8L

w/Charge Cooler System

®

Part No. 4FT218-030/038SQ

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

4FT238-068 FMU ASSY S.D. 1

4FT145-020 FUEL LINE, FEMALE 7" 1 4FD145-010 FUEL LINE, MALE 17" 1 7U030-046 5/32" x 18" VACUUM LINE 18" 7P156-082 5/32" TEE 1 7U100-055 6" TIE WRAPS 2 6Z110-136 7:1 FMU 1

8F203-265 FUEL PUMP ASSY. 1

5W001-001 WIRE TAP 1 5W001-010 16-14GA FEMALE SLIDE 1 5W001-011 16-14 GA EYELETS 2 5W001-014 FUSE HOLDER 1 5W001-015 20A BLADE TYPE FUSE 1 5W001-017 12 GA LARGE RING TERMINAL 1 5W001-019 12 GA SOLDERLESS CONCTR 1 5W001-040 12 GA FEMALE SLIDE 2 5W001-042 12 GA 3/16" RING TERMINAL 2 7A250-100 1/4-20 x 1" CAP SCREW 1 7E010-050 #12 X 1/2" SHET METAL SCREW 1 7E010-075 #12 X 3/4" SHEET METAL SCREW 1 7F250-021 1/4-20 NUT NYLOCK 1 7J250-001 1/4 WASHER PLTD 2 7P312-003 5/16" FEMALE FUEL CONNECT 1 7P500-004 FTNG FUEL ADAPTER 1/2" 1 7R001-008 #8 HOSE CLAMPS 2 7R003-027 ADEL CLAMP 1 7R004-003 14.5 STEPLESS CLAMPS 2 7U030-050 12MM x 16" FUEL HOSE 1 7U031-018 5/16" X 11" HIGH PSI FUEL LINE 11" 7U100-044 4" TIE WRAPS 3 7U100-055 6" TIE WRAPS 4 8F001-002 155 INLINE FUEL PUMP 1 8F101-200 T-REX WIRING ASSY 1

4FT130-036 OIL DRAIN ASSY. S.D. 1

7P100-121 SEALING NUT 1 7P375-045 45° STREET ELBOW 1

7P375-017 3/8 NPT HOSE BEAD x 1/2 BEADED 1 7U030-036 1/2" OIL DRAIN HOSE x 1' 1 7R001-008 #8 HOSE CLAMPS 2

4FT112-050 AIR INLET ASSY. GEN II 1

4FT012-030 CAST AIR INLET TUBE 1 7S350-200 3.5" x 2" SLEEVE 1 7R002-056 HOSE CLAMPS #56 2 7R002-052 HOSE CLAMPS #52 2 7U035-001 3.5" FLEX HOSE x 15" 15" 8H040-050 AIR FILTER 1 4FT110-030 MAF BRKT ASSY GEN II 1 7P375-106 PCV VALVE 1 7P625-016 5/8" UNION 1 7U133-024 5/8" MOLDED ELBOW HOSE 1 7A250-075 1/4-20 x 3/4" SHCS 4 7F250-021 1/4-20 NYLOCK NUTS 4 7J250-001 1/4" WASHERS 8 008721 FINISHING PLUGS STEEL 2

4FT104-010 H.O. SUPPORT PARTS 1

7R002-016 HOSE CLAMPS #16 5 7R002-044 #44 HOSE CLAMP 1 7R002-048 #48 HOSE CLAMP 1 7R002-072 #72 HOSE CLAMPS 2 7S300-275 REDUCER Ø3.00 X Ø2.75 1 7S450-200 4 1/2 x 2 SLEEVE 1 7U030-046 5/32" VAC LINE X 25" 25" 8D001-001 BYPASS VAL VE 1

8F001-265 FUEL PMP ASSY,98+ 4.6,INTANK 1

P/N: 4FT020-010

xi

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

P/N: 4FT020-010

xii

1. PREPARATION/REMOVAL

A. Disconnect the negative battery terminal from

the battery.

B. The Electronic Control Module (ECM) is the

vehicles computer. The ECM should be located above the emergency brake pedal. The wiring harness and plug to the ECM is located on the opposite side of the firewall, in the engine compartment.

C. Using a 10mm socket remove the harness and

plug from the ECM located below the brake booster in the engine compartment (as the screw is loosened, the connector will slowly release).

D. Remove the plastic bracket securing the ECM to

the vehicle. Note the mounting orientation of the computer. Remove the ECM from the vehicle.

E. Contact the Vortech Service Department for a

Return Authorization Number. Send both ECM and supplied credit tag to Vortech using the enclosed shipping box.

F. Detach the crankcase ventilation hose from the

drivers side valve cover.

G. Remove the stock air inlet ducting and mounting

bracket.

H. Disconnect the Mass Air Flow (MAF) sensor

wiring from MAF and pull the wiring out from the air inlet. Remove the MAF from the stock air inlet.

P/N: 4FT020-010

1

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

2. HARMONIC BALANCER AND CRANK PULLEY INSTALLATION

NOTE:

V-8 ONL Y - This process can be done with the fan and fan shroud

in place providing your balancer puller is equipped with a 5" or shorter forcing screw. Removing the fan and fan shroud will allow eaiser access to the crank pulley and the front of the engine.

A. Drain approximately one gallon of coolant from

the radiator (into a clean container for reuse later) using the drain valve located at the bottom of the radiator, driver’s side.

B. Remove the upper radiator hose (note hose

orientation), tire iron, upper 1/4" hose and the three screws securing the surge tank. Rotate the surge tank out of the way.

C. Disconnect the radiator hose support clamp,

located on the underside of the fan shroud. Remove the two top fasteners securing the fan shroud. Do not remove the fan shroud at this time.

D. Attach the supplied crows foot tool to a 1/2"

breaker bar and slide onto the hex of the fan. Attach the crows foot with the larger opening to a 1/2” drive ratchet. Slide onto the four screws retaining the water pump pulley. Remove the fan and shroud together. Do not allow the fan to fall against the radiator.

E. V-10 only - Install the fan spacer onto the water

pump and tighten.

NOTE:

With the fan properly installed, the fan, fan spacer and

water pump assembly will keep itself “tightened” on a running engine due to its right handed threads.

F. Using a 1/2" breaker bar on the vehicles spring

tensioner remove the accessory drive belt.

G. Remove the center balancer screw.

NOTE:

If the center balancer screw rotates the engine and will not unscrew. Remove the rubber inspection plug on the left rear of the block to make the flexplate accessible. Using an 18mm socket and ratchet, rotate the engine 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.

P/N: 4FT020-010

2

2. HARMONIC BALANCER AND CRANK PULLEY INSTALLATION, cont’d.

H. Install the harmonic balancer puller. Evenly start

the three puller screws (M10 x 1.5). Engage the forcing screw against the pivot and check alignment.

NOTE:

When using the harmonic balancer puller , pay special atten-

tion to alignment of the forcing screw and pivot. Improper alignment can result in crankshaft damage.

I. 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 silicone to seal the crank-

shaft keyway. Thoroughly clean the silicone and any oil residue off of the crankshaft prior to installing the Vortech harmonic balancer.

J. With a small amount of silicone on the keyway of

the new harmonic balancer, guide it on the crankshaft and feel for alignment of the woodruff key and the harmonic balancer 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 Loctite blue is recommended for all harmonic

balancer and crank pulley screws.

SPACER

Fig. 2-a

K. Remove the installation tool and place the su-

percharger drive pulley and spacer on the front of the harmonic balancer. (See

Fig. 2-a

.) Feeling for alignment, start the supplied M12 x 1.5 x 65mm center screw and rotate the supercharger drive pulley until the three screw holes are aligned. Start the three M10 x 1.5 x 40mm cap screws with washers, evenly tighten all beginning with the center screw. Torque the M12 screw to 80 ft/lbs and the M10 screws to 25 ft/ lbs.

L. Reinstall the rubber inspection plug (if previ-

ously removed) and the accessory drive belt.

Do not reinstall the fan and fan shroud at this time.

P/N: 4FT020-010

3

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

3. OIL FEED LINE INSTALLATION

A. Unplug the connector on the oil pressure send-

ing unit (sending unit should be located on the driver’s side of the block, behind the lower cast radiator inlet) and remove sending unit from engine block. Note a “catch can” may be required if engine oil constantly pours from block.

B. Thread the supplied 1/4" NPT fitting into the

engine block as shown and tighten. Reinstall the sending unit and connector.

ENGINE

BLOCK

OIL PRESSURE SENSOR

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 and voiding your warranty.

C. Connect the supplied oil feed line to the -4 flare

fitting previously installed and tighten.

D. Temporarily cap off the swivel on the oil feed

line to prevent dirt or debris from entering the line.

4. OIL DRAIN INSTALLATION

A. Completely loosen the screws securing the valve

cover to driver’s side of the head. (Note, the valve cover screws are captivated.) Remove valve cover, using care not to damage the sealing gasket. V-8 models may require the disconnection of the fuel return line (as described in the FMU mounting section) allowing clearance to remove the valve cover.

B. Cover the exposed valve train with a clean cloth/

rag to help prevent debris from contaminating the engine.

C. Using the

Fig. 4-a

where the oil drain is to be located. V-10 models, 5" back from the front edge of the valve cover and 2" up from the edge of the valve cover. V-8 models, five and a quarter inches (5 1/4") back from the front edge of the valve cover and 2-1/2" up from the edge of the valve cover. Using a drill motor and Ø11/16" bit, drill through the valve cover at the previously marked location.

D. Thoroughly clean the valve cover and install the

oil drain fittings as shown in 1/2" hose bead fitting into the 45° elbow first and tighten, then install the drain assembly into the valve cover. Use a small amount of silicone sealer on the male threads of the 45° elbow.

as a guide, mark the location

Fig 4-b

. Thread the

1/4” NPT

STREET TEE

VIEW FROM FRONT

Fig. 3-a

Fig. 4-a

CROSS SECTION OF

VALVE COVER

SEALING NUT

1/4” NPT x

-4 FLARE (POINT TO WHERE THE SUPERCHARGER WILL BE MOUNTED)

OIL DRAIN HOLE

3/8 NPT

HOSE BEAD

45° STREET

ELBOW

P/N: 4FT020-010

Fig. 4-b

4

4. OIL DRAIN INSTALLATION, cont’d.

E. Check for proper oil drain orientation (position of

the oil drain assembly). Install the sealing nut onto the 45° elbow and tighten. (See

Fig. 10-b

F. Reinstall the valve cover and tighten all mount-

ing screws. Replace the sealing gasket if it has been damaged in any way.

5. FUEL PUMP INSTALLATION

A.

V-10 only

the inner frame rail with plastic snaps on the driver’s side, above the fuel filter. Undo the three plastic snaps above the fuel filter, securing the wiring looms to the chassis, and pull the wiring looms up.

V-10 only

B.

fuel pump to the chassis using one of the 1/4" sized holes that was securing the wiring looms above the fuel filter. The fuel filter bracket may temporarily have to be removed to accommodate mounting of the fuel pump.

V-8 only

C.

pump to the fuel filter clamping bolt using the supplied adel clamp.

D. Release any pressure from the fuel tank by

momentarily loosening the filler cap.

E. Disconnect the line from the tank to the fuel filter

using a 3/8" springlock disconnect tool.

F. 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 as shown in

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

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 the pump inlet hose or pump failure may result.

H. Attach the negative terminal on the pump to a

clean ground. (Scrape the vehicles undercoating down to bare metal.)

- Locate the wiring looms secured to

- Following the

Fig. 5-a,

Fig. 5-b

Fig. 5-c

attach the

, attach the fuel

.

.)

Fig. 5-a

Fig. 5-b

P/N: 4FT020-010

5

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

5. FUEL PUMP INSTALLATION, cont’d.

DENOTES FUEL FLOW DIRECTION

VORTECH SUPPLIED FUEL PUMP

STOCK

FUEL

FILTER

STOCK FUEL LINE FROM TANK

V-10

VORTECH SUPPLIED FUEL PUMP

V-8

STOCK FUEL FILTER

TO FUEL RAILS/

INJECTORS

P/N: 4FT020-010

Fig. 5-c

6

6. FUEL PUMP RELAY INSTALLATION

A. (See

Fig. 6-a

for the following instructions.) With the two wiring looms above the fuel pump, locate the red wire with black stripe in the wiring loom that runs to the fuel tank. Check the red/ black wire (with a test light) for key-on power, this wire should show power for approximately two to four seconds with the key in the on position.

B. From relay terminal #85 tap the yellow wire into

the red wire with black stripe using the provided wiretap. Using the test light double check the wire to ensure a good electrical connection has been made.

C. From terminal #30 route the heavy red wire

along the chassis up to one of the main power lugs at the front of the power distribution box. With the supplied solderless connectors, install the fuse holder and 20 amp fuse in the red wire and check with a test light.

D. Connect the short black wire from relay terminal

#86 to a secure ground, free from paint or use the same ground as the fuel pump.

E. From terminal #87 route and connect the long

red wire to the positive (+) side of the fuel pump. Secure all wires with the provided tie wraps.

GROUND

NOTE:

86

30

87

87A

85

(+) FUEL PUMP

TO RED WIRE w/ BLACK STRIPE

(+)12 VOLT MAIN POWER LUG

RELAY

Fig. 6-a

Double check that all wires are connected to their

proper relay lug.

7. IN-TANK FUEL PUMP REPLACEMENT (6.8L H.O. Systems Only)

NOTE:

A. Support the gas tank with a jack and remove the B. Slightly lower the gas tank and disconnect the fill C. Disconnect the fuel pump/sender wiring har-

D. Disconnect the fuel feed and return lines using E. Completely lower the gas tank to the ground.

F. Unscrew the outer ring securing the fuel lines G. Depress the two clips securing the plastic fuel

H. Remove the two screws securing the plastic fuel

The following steps are best performed with the gas

tank with the least amount of fuel in it as possible.

screws securing the two gas tank straps. & vent tubes from the gas tank, front and rear. ness located in the frame rail and the fuel fill and

overflow lines. a springlock tool.

and remove the cover. pump enclosure and slide it out of the tank, the

fuel sender float is attached to the fuel pump enclosure and must be handled with care. Be careful not to damage the filter.

pump outlet manifold to the enclosure cap. Pull the manifold up and away from the fuel pump.

P/N: 4FT020-010

7

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

7. IN-TANK FUEL PUMP REPLACEMENT (6.8L H.O. Systems Only), cont’d.

I. Remove the three screws securing the fuel

pump enclosure’s cover using a 3/16 nut-driver and remove the cover.

J. Remove the stock fuel pump from its enclosure.

Separate the rubber pump support from beneath the filter and install it on the supplied pump. Secure the support with the new filter provided.

K. Using the supplied fuel pump, reassemble the

fuel pump assembly and canister with cap.

L. Reinstall the canister assembly into the fuel tank

and reattach the electrical connections.

M. Reinstall the fuel tank, reconnect the fuel filter

inlet line, reattach the fuel filler neck and reinstall the fuel cap.

N. Turn the ignition key on and check the fuel pump

for leaks.

8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION

A. Using a 3/8" springlock disconnect tool, discon-

nect the fuel return line at the back of the engine on V-10 models (See

Fig. 8-a

valve cover on V-8 models (See

) or drivers side

Fig. 8-b

).

B. Following the diagram connect the 17" male

FMU inlet line to the fuel rail. Route the fuel line to the -4 x 90° brass fitting on the FMU and tighten.

See Appendix A-1

for detail view.

V-10

NOTE:

Refer to the Appendix for complete diagrams.

C. Connect the 7" female FMU outlet line to the

vehicles stock return line. Route the opposite end to the -4 straight fitting on the FMU and tighten.

D. Position the FMU against the upper firewall

(driver’s side) directly under the plastic wire harness cover. Mark and drill two #30 holes on the firewall to mount the FMU. Secure with the #8 sheet metal screws and washers provided. (See

Fig. 8-c

.)

E. Secure the fuel lines away from abrasion and

exhaust heat with the provided tie wraps.

F. Tap into the factory fuel regulator vacuum line

with the supplied 5/32" hose and TEE. Route the new hose to the fitting on top of the FMU.

V-8

Fig. 8-a

Fig. 8-b

Fig. 8-c

See Appendix

A-2 for detail

view.

P/N: 4FT020-010

8

9. WATER PUMP AND COOLER INSTALLATION (6.8L H.O. Systems Only)

A. Remove the upper shroud, located between the

core support and the grille.

B. Remove the three screws securing the radiator

reservoir and rotate out of the way.

C. Remove jack tools and tray holding brackets. D. Remove the upper two supports securing the

condenser.

E. Remove the hood latch from the core support

(leaving it attached to the cable) and set out of the way.

F. Remove the upper core support - secured with

(8-10) screws. (See

G. Following

Fig 14-b

Fig. 9-a

.)

on page 14, install the supplied water fitting adapters onto the heat exchanger securing with the provided Ø3.25" x 2" sleeves and clamps.

H. Using the diagram as a guide (see Fig. 14-b),

install the supplied 3/4" NPT brass fittings into the charge cooler as shown. A small amount of thread sealant may be used on these threads.

I. Lower the heat exchanger into place between

the vehicle’s condenser and radiator. Rest the heat exchanger on the pads of the lower core support. (See

Fig. 9-b

.)

J. Remove the factory nut clips if any, from the

engine side of the core support and replace with the ones provided. Secure the heat exchanger to the vehicle using the supplied 1/4-20 x 2" cap screws and washers.

K. Reinstall the upper core support, hood latch and

condenser supports.

L. Using the

Fig. 9-c

as a guide, measure down 20" from the top of the fan shroud and over 5" and drill a hole through the fan shroud using a Ø9/32" drill bit.

M. Using the supplied adel clamp and 1/4" screw,

washers and nylock nut secure the pump to the fan shroud.

N. Cut the stock connector off of the pump wiring

and install the provided solderless connectors. Connect the supplied red wire to the green wire and the supplied black wire to the brown wire using the previously installed connectors.

O. Reinstall the vehicle’s stock fan, spacer, shroud

and tighten.

P. Connect the black wire to a suitable ground, free

from paint and vehicle undercoating.

Q. Route the red wire to the vehicle’s fuse box

located near the master cylinder. Using the supplied fuse tap, fuse holder and slide connectors, tap into the #7 mini-fuse. Check that the fuse only receives power when the key is in the ON position using a test light.

Fig. 9-a

Fig. 9-b

Fig. 9-c

P/N: 4FT020-010

9

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

10. MOUNTING BRACKET & SUPERCHARGER INSTALLATION

A. Remove the wiring harness bracket and the

three mounting screws from the driver’s side front cover of the engine.

B. Cut and extend the cam sensor wires using the

supplied wire and solderless connectors. Following

Fig. 10-a

wires to the sensor.

C. Loosely screw the 1" wide damper bracket to the

driver’s side head using the spacer, M14 screw and washer. Do not tighten. (See

, use a tie wrap to secure the

Fig. 10-b

.)

NOTE: There are two threaded holes. Attach the bracket to the

D. Following

one closest to the firewall.

Fig A-3

in the Appendix, attach the wiring harness bracket to the backside of the mounting plate with the supplied 1/4-20 x 3/4" socket heads, and 1/4" nylock nuts and washers. Secure the support plate to the mounting plate using only two (2) 3/8-16 x 1.75" screws, 3/8" nylock nuts and washers.

E. Attach the mounting bracket assembly to the

front cover of the engine using the M10 screws and washers. Attach the damper bracket to the mounting plate and secure using the 3/8" hardware. Finally, secure the damper bracket by tightening the M14 screw.

F. Bolt the grooved idler with dust cover and idler

spacer to the support plate using the 7/16-14 x

2.5" hex head screw, 7/16" nylock nut and washer. Do not over tighten. (See

Fig. A-3 in the Appendix

.)

Fig. 10-c or

G. Mount the spring tensioner spacer to the mount-

ing bracket using the 1/4" hardware. Note the orientation or position of the mounting holes of the spacer (screws thread through the bracket and into the spacer from the rear). Secure the spring tensioner to the spacer/mounting plate using the 3/8-16 x 4" bolt, 3/8" nylock nut and washers. (See

Fig. A-3 in the appendix

.)

H. Attach the oil drain line to the supercharger and

secure with one #8 hose clamp. Hold the supercharger into position on the mounting plate and determine the correct oil drain line length and trim. Ensure that there are no kinks, sharp bends or upward travel in the drain line.

I. Mount the supercharger to the mounting bracket

and support plate using five 3/8-16 x 1.75" screws, 3/8" washers and three M12 screws and M12 washers. Connect the oil drain line coming from the supercharger to the fitting on the valve cover and secure with the other #8 hose clamp.

Fig. 10-a

Fig. 10-b

7/16” NYLOCK NUT

IDLER

SPACER

7/16” WASHER

Grooved Idler Assembly (Side View)

7/16-14 x 2.5”

SUPPORT PLATE

Fig. 10-c

HEX HEAD

SCREW

DUST COVER

GROOVED IDLER

P/N: 4FT020-010

10

10. MOUNTING BRACKET BRACKET & SUPERCHARGER INSTALLATION, cont’d.

J. Thread the 1/8" NPT x #4 x 90° fitting into the oil

feed fitting on the supercharger. Rotate the fitting down. Connect the oil feed line to the #4 fitting and tighten. Use only clean engine oil on the oil feed fittings threads.

NOTE:

Do not use any type of sealant on the oil feed fittings. It

may become dislodged and clog the oil feed orifice, causing premaature failure of the supercharger and voiding your warranty.

K. Secure the oil feed line away from heat and

abrasion with the provided tie wraps.

L. Route the supplied supercharger drive belt

around the crank pulley, supercharger drive pulley and grooved idler. Using a 1/2" drive breaker bar, rotate the spring tensioner clockwise and align the belt. (See

Fig 10-d

.)

M. Relocate the capacitor (previously attached to

the upper front cover mounting stud) to one of the screws securing the water neck or upper manifold. (See

Fig 10-e

.)

CAPACITOR

SUPERCHARGER

See Appendix A-6

for detail view.

TENSIONER PULLEY

CRANK PULLEY

Fig. 10-d

IDLER PULLEY

11. AIR INLET ASSEMBLY

A. Attach the MAF meter to the MAF bracket using

the supplied 1/4” hardware. Slide the air filter onto the tube of the MAF bracket. Using a 5/16” nut driver or socket, reach in through one of the Ø5/8” holes and tighten the hose clamp. Cover the holes with the provided finishing plugs.

B. Install the MAF assembly onto the driver’s side

of the core support using the factory hardware.

Fig. 11-a

(See

NOTE:

C. Reconnect the MAF wiring connector to the

MAF meter.

D. Install the Ø3.5” x 2” silicone sleeve and #56

hose clamps onto the supercharger inlet. Install the cast aluminum inlet duct into the silicone sleeve and tighten the hose clamps.

.)

The thick rubber mat may need to be unsnapped and

folded over toward the radiator to allow proper mounting of the MAF assembly.

Fig. 10-e

?

Fig. 11-a

11

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

11. AIR INLET ASSEMBLY, cont’d.

E. Connect the cast aluminum duct to the MAF

meter using the supplied Ø3.5" x 15" flex hose and secure with #52 hose clamps.

F. Install the short end of the Ø5/8" molded elbow

hose onto the Ø5/8" bung on the air inlet.

NOTE:

Refer to Figs. A-4, A-5 and A-7 in the Appendix.

G. Cut a 90° section from the stock crank case

breather hose and attach to the Ø5/8" molded elbow hose with the Ø5/8" union. Reconnect the other end to the crank case breather on the valve cover. Trim hose length for a proper fit.

12. DISCHARGE DUCTING (Standard Output Systems Only)

A.

V-10 ONLY

hose clamps onto one end of the discharge duct and the Ø3.00" to Ø2.75" reducer with hose clamps onto the other end. Install the discharge duct in between the supercharger and the throttle body and secure with the hose clamps.

NOTE:

B.

V-8 ONLY

hose clamps onto both ends of the discharge duct.

- Slide the 4-1/2" sleeve and #72

If the discharge duct is difficult to install, the supercharger

may require slight re-clocking. Call Vortech for the proper procedure.

- Slide the Ø2.75" sleeves and #44

Fig. 12-a

See Appendix A-5

for detail view.

NOTE:

C.

V-8 ONLY

The #48 hose clamp is to be used on the throttle body end of the discharge duct.

- Thread the 3/4" NPT x 1" hose barb x 90° into the discharge duct. Following the diagram, install the discharge duct in between the supercharger and the throttle body and secure with the hose clamps. The previously mentioned 3/4" NPT fitting should be pointing toward the firewall.

D. Following the diagram, install the bypass as

shown. Use the provided hose clamps to secure the bypass valve to the discharge duct and the inlet duct as shown. Attach the Ø5/32" vacuum line to the bypass valve and connect to the vacuum line on the FMU/ fuel regulator. Ensure the vacuum line has no kinks.

E. Connect the idle air tube to the bung on the

discharge tube and secure with the provided hose clamp.

F. Locate and remove the PCV valve on the

passenger’s side valve cover and replace with the one provided.

See Appendix A-4

for detail view.

Fig. 12-b

P/N: 4FT020-010

12

13. CHARGE COOLER INSTALLATION (6.8L H.O. Systems Only)

A. Remove the coolant line attached to the intake

manifold (see

Fig. 13-a

2” from the bottom of the coolant line (to allow for clearance of the cooler support bracket) and reinstall.

B. Cut 4-1/2” off of the supplied piece of foam tape

and the remaining 7-1/2” in half. Thoroughly clean the top portion of the cooler support bracket with alcohol and allow it to dry. Following the diagram (see

Fig. 13-b

the top of the cooler support bracket. Trim the excess from any over hanging edge.

C. Following the photo (see

supplied cooler support bracket onto the front passenger’s side of the intake manifold and secure it using the provided spacer and 6mm hardware.

NOTE:

The spacer is located between the cooler support bracket and the top of the manifold.

Secure the lower part of the bracket to the front cover’s M8 stud using the M8 nut and lock washer provided.

D. Install the provided Ø2-3/4” x 2” sleeves onto

each one of the cooler ducts along with four #44 hose clamps (2 per sleeve).

E. Install the plastic discharge duct onto the throttle

body and secure with the supplied Ø4-1/2” sleeve and two #72 hose clamps. (See

.)

13-d

F. Connect the idle air line and the bypass valve to

the duct as shown (see using the #16 hose clamps.

G. Connect the bypass valve to the cast air inlet

duct using the supplied Ø1” x 6” hose and secure using two #16 hose clamps.

H. Slide the Ø3” x Ø2-3/4” reducer sleeve onto the

plastic discharge duct and secure with one #48 hose clamp.

I. Slide one Ø2-3/4" x 2" sleeve and two #44 hose

clamps onto the discharge of the supercharger.

J. Following

Fig 13-d

the supercharger and discharge duct “B” to the previously installed plastic duct leading to the throttle body.

K. Set the charge cooler on top of the cooler

support bracket and connect the discharge ducts to the charge cooler securing it with the previously installed hose clamps.

). Remove approximately

) attach the foam tape to

Fig. 13-c

) install the

Fig.

Fig. 13-d

) and secure

, attach discharge duct “A” to

Fig. 13-a

Fig. 13-b

NOTE:

Discharge duct “A” must be rotated over enough so that

the vehicle’s hood does not come in contact with the duct.

13

Fig. 13-c

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

13. CHARGE COOLER INSTALLATION (6.8L H.O. Systems Only), cont’d.

CONNECT TO VALVE COVER

TO IDLE AIR CONTROL

DUCT, TUBE C

DUCT, TUBE A

Ø5/8" HOSE UNION

ALUMINUM INLET DUCT

BYPASS VALVE

CHARGE AIR COOLER

DUCT, TUBE B

MAF BRACKET ASSEMBLY

FLEX HOSE

Fig. 13-d / See Appendix A-7 for detail

14. HOSE INSTALLATION & SYSTEM FILLING (6.8L H.O. Systems Only)

A. Attach the surge tank mounting bracket to the

surge tank using the supplied 1/4” hardware. Using

Fig. 14-a

a template, drill a Ø9/32” hole in the vehicle’s evaporator bracket and secure the surge tank assembly with the 1/4” hardware.

B. Cut an 8” section of the Ø3/4” hose and attach

one end to the driver’s side fitting on the water cooler and the other end to the water pump inlet.

C. Secure both ends with the provided nylon clamps.

Fig. 14-b

(See

D. Cut an 8” section of the Ø3/4” hose and attach

one end to the inlet of the water pump and the fitting on the water cooler. Secure with nylon clamps.

E. Route the hose toward the firewall and back of

the engine. Connect the hose to the straight fitting on the charge cooler and secure with a nylon clamp. Make sure the hose is away from sharp edges and the exhaust system. Ensure that NO kinks or sharp bends are allowed on any of the hoses.

F. Cut a 23” section of the Ø3/4” hose and connect

between the bottom of the surge tank and the water cooler. Secure both ends with nylon clamps.

G. Temporarily plug the hose fitting on the surge

tank that is to connect to the 90° fitting on the charge cooler.

H. When filling the system, ensure that the pump is

OFF and the drain valve on the water cooler is OPEN.

and the surge tank assembly as

.)

Fig. 14-a

98

"

SURGE TANK TOP VIEW

23"

CONNECTS

TO

BOTTOM

OF

SURGE

TANK

3/4" NPT BRASS FITTING

8"

CHARGE AIR

ADAPTER Ø3.25" X 2"

COOLER

FRONT OF VEHICLE

SURGE TANK SIDE VIEW

AIR FROM SUPERCHARGER

AIR TO THROTTLE BODY

WATER PUMP

WATER COOLER

Fig. 14-b / See Appendix A-7 for detail

DENOTES FLOW DIRECTION

8"

P/N: 4FT020-010

14

14. HOSE INSTALLATION & SYSTEM FILLING (6.8L H.O. Systems Only), cont’d.

I. Pour 3/4 of a gallon of antifreeze into the surge

tank. Fill the system with water until water comes out of the drain fitting, then close the drain valve being careful

not to over tighten

.

J. Continue to fill the system with water until it pours

out of the OPEN fitting on the charge cooler.

K. Connect the water line from the surge tank to the

charge cooler and secure with the provided clamps. Top off the system with water and install the surge tank cap.

15. REASSEMBLY AND FINAL CHECK

NOTE:

Once the ECM is received back from Vortech with the ECM mod-

ule installed, reinstall the ECM into the vehicle. In some cases, the extra length of the ECM module will not allow the use of the factory hold-down bracket unless it is modified. Reconnect the factory harness.

A. Reinstall the stock surge tank and tire iron.

Reinstall the upper radiator hose opposite of the factory installation (the short leg of the hose should connect to the radiator). (See Refill the radiator.

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

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

D. Check all fluid levels, making sure that your fuel

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

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

then shut off.

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

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

Fig. 15-a

.)

Fig. 15-a

WARNING:

Operating the vehicle without ALL the subassem-

blies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS.

G. Test drive the vehicle. Listen for any sign of

detonation (pinging) and discontinue hard use (no boost) until problem is resolved.

H. 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 for the 3 year limited warranty.

15

Fig. 15-b

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

This page left intentionally blank

P/N: 4FT020-010

16

APPENDIX

17

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

FMU

VEHICLE’S RETURN

LINE TO TANK

FUEL LINE

(FEMALE 7”)

FUEL LINE

(MALE 17”)

FUEL PRESSURE

REGULATOR

FUEL SUPPLY LINE

(FROM PUMP)

BACK OF ENGINE

APPENDIX A-1

P/N: 4FT020-010

18

Fig. A-1

V-10 Diagram

APPENDIX A-2

FMU

FUEL SUPPLY LINE

(FROM PUMP)

FUEL PRESSURE

REGULATOR

V-8 DIAGRAM

FUEL LINE

(FEMALE 7”)

RETURN LINE

(TO TANK)

FUEL LINE (MALE 7”)

Fig.A-2

V-8 Diagram

19

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

SPACER, SPRING

TENSIONER (NOTE

ORIENTATION)

BRACKET WIRING HARNESS

(NOTE: BRACKET IS MOUNTED

BEHIND PLATE)

8-RIB IDLER

GROOVED

MOUNTING

PLATE

SUPPORT

PLATE

(MOUNT ON

TOP OF

MOUNTING

PLATE)

APPENDIX A-3

Fig. A-3

P/N: 4FT020-010

20

APPENDIX A-4

V-8 INLET AND DISCHARGE DIAGRAM

Standard System

CONNECT TO VALVE COVER

TO IDLE AIR CONTROL

#48 HOSE CLAMP

DISCHARGE DUCT

Ø5/8” UNION

BYPASS VALVE

ALUMINUM INLET DUCT

FLEX HOSE

MAF BRACKET

ASSEMBLY

(TOP VIEW)

Fig. A-4

21

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

APPENDIX A-5

V-10 INLET AND DISCHARGE DIAGRAM

Standard System

CONNECT TO VALVE COVER

TO IDLE AIR

CONTROL

DISCHARGE DUCT

BYPASS VALVE

Ø5/8” UNION

ALUMINUM

®

INLET DUCT

FLEX HOSE

P/N: 4FT020-010

BRACKET MAF

ASSEMBLY

(TOP VIEW)

Fig. A-5

22

APPENDIX A-6

Belt Routing Diagram

TENSIONER PULLEY

SUPERCHARGER

CRANK PULLEY

Fig. A-6

IDLER PULLEY

23

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

APPENDIX A-7

V-10 Inlet And Discharge Diagram

(H.O. System)

DUCT, TUBE A

CHARGE AIR

COOLER

CONNECT TO VALVE COVER

DUCT, TUBE C

TO IDLE AIR CONTROL

DUCT, TUBE B

Ø5/8" HOSE UNION

ALUMINUM

INLET DUCT

BYPASS VALVE

FLEX HOSE

P/N: 4FT020-010

MAF BRACKET ASSEMBLY

Fig. A-7

24

DENOTES FLOW

DIRECTION

WATER PUMP

AIR TO THROTTLE

BODY

AIR FROM

SUPERCHARGER

ADAPTER

3/4" NPT BRASS FITTING

23"

SURGE TANK

SIDE VIEW

SURGE TANK

TOP VIEW

8"

CHARGE AIR COOLER

98"

Ø3.25" x 2" SLEEVE

CONNECTS TO

BOTTOM OF

SURGE TANK

WATER COOLER

FRONT OF VEHICLE

8"

APPENDIX A-8

Water Hose Diagram

Fig. A-8

25

P/N: 4FT020-010

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

®

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

02AUG04 v2.1(99-03SuperDuty(4FT v2.1))

P/N: 4FT020-010