Vortech 1999-2001 Ford 6.8L Super Duty User Manual
Maxflow® Power Cooler
Installation Instructions
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226
FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST
P/N: 8N020-100
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
1999-2001 Ford 6.8L Super Duty
Part #8N301-130/138 CARB E.O. #D-213-15
®
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
All rights reserved. No parts of this publication may be reproduced, transmitted, transcribed,
or translated into another language in any form, by any means without written permission
P/N: 8N020-100
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
© 2002 VORTECH ENGINEERING, LLC
of Vortech Engineering, LLC.
ii
Table Of Contents
FOREWORD .....................................................................................................................................ii
TABLE OF CONTENTS ....................................................................................................................iii
TOOL & SUPPLY REQUIREMENTS ................................................................................................ iv
PARTS LIST-1999-2001 FORD SUPER DUTY 6.8L-CHARGE COOLER UPGRADE SYSTEM .....v
1. PREPARATION/REMOVAL ..................................................................................................1
2. SUPERCHARGER RECLOCKING ......................................................................................2
3. IN-TANK FUEL PUMP REPLACEMENT..............................................................................3
4. WATER PUMP AND COOLER INSTALLATION...................................................................4
5. AIR INLET ASSEMBLY ........................................................................................................5
6. CHARGE COOLER INSTALLATION.................................................................................... 6
7. HOSE INSTALLATION & FILLING .......................................................................................7
8. REASSEMBLY AND FINAL CHECK ....................................................................................9
APPENDIX ........................................................................................................................................11
A-1 CHARGE COOLER DIAGRAM ..................................................................................12
A-2 WATER HOSE DIAGRAM ..........................................................................................13
©2002 Vortech Engineering, LLC
iii
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
P/N: 8N020-100
Vortech Maxflow® Power Cooler Installation Instructions
1999-2001 Super Duty V-10
Congratulations on selecting the best performing and most efficient
charge cooler... the VORTECH
®
Maxflow® Power Cooler!
Before beginning this installation, please
read through this entire instruction booklet.
This Vortech Maxflow Power Cooler (referred to in general terms as charge cooler) system was
designed as a street/strip oriented charge cooler, specifically for use on 1999 - 2001 Ford V-10
vehicles equipped with a Vortech supercharger producing up to approximately 580 horsepower.
The Maxflow Power Cooler System will fit and work equally well with other brands of centrifugal
superchargers as well as turbochargers, with minor modifications.
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
• Ratchet - 1/2” drive
• Extension
• 1/2" drive breaker bar
• Ford spring lock 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
• 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
P/N: 8N020-100
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
iv
1999-2001 Ford Super Duty 6.8L
Charge Cooler Upgrade System
®
Part No. 8N301-130/138SQ
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 Qty Part Number Description Qty
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 6MM 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 3'
7A250-050 1/4-20 x .50" SHCS 2
7A250-075 1/4-20 x 3/4 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
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 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
4FT110-030 BRKT ASSY, MAF S.D. GEN II 1
008721 FINISHING PLUGS STEEL 2
2A048-730 BELT 1
2A038-312 8 RIB Ø 3.125 PULLEY 1
8H040-050 AIR FILTER 1
8F101-260 FUEL PMP ASSY, 98+ 4.6,INTANK 1
8F001-260 FUEL PUMP 1
5W001-052 PIGTAIL CONNECTER, FUEL PUMP 1
2A017-048 SPACER, Ø .312 OD / Ø .14 ID 2
5W001-013 14-16AWG, SOLDERLESS CONCTRS 2
7E006-075 #6 x .75 HXHD SHTMTL SCREW 2
4FT011-032 CROWS FOOT, WATER PUMP 1
©2002 Vortech Engineering, LLC
v
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
P/N: 8N020-100
P/N: 8N020-100
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
xii
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