Vortech 2004-2006 Ford 5.4L 3V F-150 User Manual

DP/N: 4FN020-010 - v2.0 03/02/07

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone:[phone]

Fax:[phone] • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

For d 5.4 3V F-150

Supercharger System

Installation Instructions

2004-2007 Model Year

50 State Smog Legal per CARB EO #D-213-25

®

ii

P/N: 4FN020-010
©2007 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
02MAR07 v2.0 Ford F-150(4FNv2.0)

FOREWORD

Take note of the following before proceeding:

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 you
should refer the job to a professional installer/technician.Please contact

your dealer or Vortech Engineering for possible installers in your area.

2. This product was designed for use on stock (un-modified, OEM) vehicles. The
PCM (computer), engine, transmission, drive axle ratios and tire O.D.must be stock. If
the vehicle or engine has been modified in any way, check with Vortech prior to installa­tion and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

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

boost) until problem is resolved.

5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech warranty coverage considerations include, but
not limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Vortech components with other modifications such as, but not limit-

ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM program­ming or other such changes.

©2007 VORTECH ENGINEERING, LLC

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated
into another language in any form, by any means without written permission of Vortech Engineering, LLC.

T

his manual provides information on the installation, maintenance and service of the
Vortech supercharger kit expressly designed for this vehicle.All information, illustra-

tions and specifications contained herein are based on the latest product information
available at the time of this publication.Changes to the manual may be made at any time
without notice. Contact Vortech Engineer ing for any additional information regarding this kit
and any of these modifications at [phone] 8:00am-4:30pm PST.

STOP

iii

P/N: 4FN020-010

©2007 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

02MAR07 v2.0 Ford F-150(4FNv2.0)

TABLE OF CONTENTS

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

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

NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

PARTS LIST (2004-2007 Ford 5.4L F-150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

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

2. OIL DRAIN LINE INSTALLATLION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

5. SUPERCHARGER MOUNTING PLATE INSTALLATION . . . . . . . . . . . . . . . . 5

6. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7. CHARGE AIR COOLER SYSTEM INSTALLATION. . . . . . . . . . . . . . . . . . . . 8

9. RE-FLASH COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

10. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

iv

P/N: 4FN020-010
©2007 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
02MAR07 v2.0 Ford F-150(4FNv2.0)

This Page Left Intentionally Blank

v

P/N: 4FN020-010

©2007 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

02MAR07 v2.0 Ford F-150(4FNv2.0)

NOTICE

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 fea-

tures shown in this product are the exclusive property of

Vortech Engineering, LLC.This products may 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.

vi

P/N: 4FN020-010
©2007 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
02MAR07 v2.0 Ford F-150(4FNv2.0)

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 Vor tech 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 prob-

lem 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 every 3,000 miles or less. 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 1 year or 20,000 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 every 40,000 miles and spark plug wires at least every 60,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

• 3/8" Socket and Drive Set: SAE & Metric

• 1/2" Socket and Drive Set: SAE & Metric

• 3/8" NPT Tap and Handle

• Open End Wrenches: 5/16", 3/8", 7/16", 1/2", 9/16", 5/8",

11/16", 3/4", 10mm, 13-18mm, 18mm tappet (thin) wrench

• 1-1/16" Oil Sending Unit Socket (Snap-on #A119A)

• 6 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• "R", 1/8", 5/16", 11/32" Drill Bits

• 3/16", 8mm Allen Wrenches

• Wire Strippers and Crimpers

• Utility Knife

• 3/8" profile drill

• T15 Torx Wrench

• 9/16" Crows Foot

2004-2007

Ford 5.4L F-150

Installation Instructions

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 form and return envelope.

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® V-2® Supercharger!

®

ENGINEERING, LLC

vii

P/N: 4FN020-010

©2007 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

02MAR07 v2.0 Ford F-150(4FNv2.0)

2E229-110(8) V2SQ S-TRIM ASY, '04 F150, w/CLR 1

2A036-131 S/C PULLEY 3.125" 6-RIB w/FLG 1
2A046-120 BELT, GATES K061203 1
4FN012-011(8) DUCT, S/C INTAKE, '04 F150 1

4FN110-033 MTG PLATE ASY, '04 F150 1

2A017-462 SPACER, IDLER SMOOTH 6-RIB 2
2A017-102-740 SPACER, .74"L x 1"OD ?
2A017-102-205 SPACER, 1"OD x 2.055" LONG 2
2A017-087-077 SPACER, .875"OD x .770" LONG 6
4FA016-171 DUST COVER (IDLER PULLEY) 1
4FH016-150 IDLER PULLEY, 6-RIB SMOOTH 3" FLANGD 1
4FN010-010 BRKT, PWR STR RES, '04 F150 1
4FN010-033 PLATE, MTG, PRIMARY 1
4HS017-021 SPACER, S/C BOSS S2000 2
7A312-075 5/16-18 x 3/4" HXCS GR5 ZINC 2
7A375-175 3/8-16 x 1-3/4" HXHD GR5 PLT 5
7A375-225 3/8-16 x 2-1/4" HXHD G8 1
7A375-275 3/8-16 x 2-3/4" HXCS G8 P 1
7C010-055 M10-1.5 x 50 HXHD GR10.9 1
7C080-120 M8-1.25 x 120 HXHD ZN PLT 2
7F006-093 6mm NYLOCK NUT 2
7F375-017 3/8-16 NYLOCK NUT 1
7J250-001 1/4" SAE WASHER, PLTD 5
7J312-000 5/16" FLAT WASHER-SAE 4
7J375-044 3/8" SAE WASHER, PLTD 12
4FN110-040 MNT BRKT SPT, '04 F150 1
7A250-074 1/4-20 x .75" HHCS 2
2A017-750-03 SPACER, .13" 2

4FN130-026 OIL FEED LINE ASY, '04 F150 1

7P125-004 1/8"NPT x 90° x -4 JIC FTG 1
7P250-122 1/4" PIPE THRD AN917 TEE 1
7P250-123 1/4"NPT x 1-1/2" NIPPLE 1
7P250-250 1/4"NPT STR x -4 JIC FTG 1
7U100-055 TIE-WRAP, 7.5" NYLON 5
7U250-000-465 OIL FEED HOSE, 46.5" -4 STRT 1

4FN130-036 OIL DRAIN LINE ASY, '04 F150 1

7P375-055 3/8"NPT x 1/2" HOSE BARB 1
7R001-008 #8 STNLS HOSE CLAMP 2
7T560-001 CUTTER, 9/16" ROTABROACH 1
7T560-002 ARBOR, ROTABROACH 1
7U030-036 1/2" OIL DRAIN HOSE 0.67'

4FN112-040 AIR INTAKE ASY, '04 F150 1

4FA012-012 INTAKE ELBOW, 90° w/o BOSSES 1
4FN012-040 COVER, AIR FILTER, '04 F150 1
7A250-075 1/4-20 x .75" HHCS 3
7F250-021 1/4-20 x NYLOCK NUT 3
7J250-001 1/4" WASHER SAE 4
7J250-150 1/4" FENDER WASHER 2
7P250-033 1/4" x 5/32" RED.UNION 1
7P250-125 1/4" BARBED MALE TEE 1
7P375-008 ELBOW, 3/8" x 90° UNION 1
7P375-050 3/8" HOSEMENDER 1
7R002-016 #16 GOLDSEAL HOSE CLAMP 2
7R002-056 #56 GOLDSEAL HOSE CLAMP 4
7R005-001 208-91 T-BOLT CLAMP 1
7S350-200 3-1/2" x 2" SLEEVE 1
7S350-300 3-1/2" x 3" SLEEVE 1
7U030-030 1/4" VACUUM HOSE 0.167'
7U030-046 5/32" VACUUM LINE 2.5'
7U030-056 3/8" PCV HOSE 3.25'

2004-2007 Ford 5.4L F-150

Part No. 4FN218-020(8)SQ

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages

or damaged parts immediately.

7U100-061 GROMMET, 3/8"ID x 5/8" FLANGE 1
7U100-100 GROMMET, 1"ID x 1.38"OD, .12-GRV 1
7U133-100 HOSE, ELBOW, 90° x 1"ID, MOLDED 1
5W001-012 18-22GA BUTT CONNECTOR 13
5W018-010 18GA STD RED WIRE 1'
5W018-020 18GA WIRE, BLK 1'
5W018-090 18GA WIRE, BROWN 1'
5W018-080 18GA WIRE, BLUE 1'
5W018-240 18GA WIRE, WHITE/YELLOW 1'
5W018-030 18GA WIRE, GREY 1'
8A002-021 MAF, 3.8", '04 F150 1
8D001-001 STD COMP BYPASS VALVE 1
8H040-095 AIR FILTER, MOSSELMAN 4" FLG 1

4FN139-096 ASY, PCV INSTALL, '04 F150 1

7P375-106 PCV VALVE, FORD, 3/8" HOSE 1
7P625-375 REDUCER, 5/8" BARB TO 3/8" BARB 1
7R001-006 #6 STNLS HOSE CLAMP 2
7R001-008 #8 STNLS HOSE CLAMP 4
7U030-056 3/8" PCV/VAC RUBBER HOSE 1.6'
7U033-000 5/8" PCV HOSE .5'

8N301-260(8) POWER COOLER ASY, '04 F150 1
8N201-260(8) DISCHARGE ASY, '04 F150 1

8N101-260(8) CAC ASY, '04 F150, AIR/WATER 1
008341 POWERCOOLER DECAL 1
7P100-100 1"NPT x 1" BARB FITTING 1
7S350-303 ELBOW, 3.5" x 3.0" 90° w/LEG, SILICONE 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 2
7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 1
7R002-056 #56 GOLDSEAL HOSE CLAMP 1
8N055-050 PLASTIC CAP, SURGE TANK 1
7S275-200 2-3/4" x 2" SLEEVE 1

8N105-260 WATER TANK MTG ASY, '04 F150 1

4FN010-060 BRKT, WATER RES, 2004 F150 1
7A250-051 1/4-20 x .50" HXHD ZN PLT 3
7E010-075 #12 x 3/4" SHT METL SCRW, HEX 3
7J250-001 1/4"SAE WASHER, PLTD 3
7P500-026 1/2"NPT x 3/4" BARB 90° 1
7P500-034 1/2"NPT x 3/4" BARB 90° NICKEL PLATE 2
7P500-078 1/2"NPT x 3/4" HOSE FIT 3
7R007-001 NYLON CLAMP 1-1/8" 8
7U030-065 3/4" x 90° HOSE SHORT 1
7U038-000 3/4" HEATER HOSE 6'
8N055-030 TANK, LT1 AFTERCOOLER 1

8N006-010 WATER COOLER 1
8N107-260 WATER PUMP ASY, '04 F150 1

5W001-005 3/8" PLASTIC WIRE LOOM 3.5'
5W001-009 16-14GA MALE SLIDE INSULATED 1
5W001-046 16-14GA EYELET .33" HOLE 1
5W001-013 14-16AWG, SOLDERLESS CONNECTOR 2
5W001-022 T-TAP CONN, 14-16AWG 1
5W014-010 14GA STRD WIRE, RED, UL1015 3'
5W014-030 14GA STRD WIRE, BLACK 3'
7U100-044 TIE-WRAP, 4" NYLON 8
8F001-402 PUMP, WATER, PIERBURG 1
8N100-001 NYLON MOUNTING KIT 1

8F060-048 FUEL INJ, 48LB PENCIL, FACT. '03 COBRA 8
5A003-033 ECU TUNER, F150, 3V 1

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

PARTS LIST

®

ENGINEERING, LLC