Vortech Engineering 4FC020-010 User Manual

Ford 5.0 and 5.8

Bronco/F-Series/Lightning

Supercharger System

Installation Instructions

’87-’96 5.8L F-Series Truck - 50 State Smog Legal per CARB EO #D-213-16

’93-’95 5.8L Lightning Truck - 50 State Smog Legal per CARB EO #D-213-16

’87-’96 5.0L F-Series Truck - 50 State Smog Legal per CARB EO #D-213-16

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901

(86-93 5.0 Lt Truck(4FC))

ENGINEERING, INC.

FOREWORD

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

prior

manual to a professional installer/technician. Please call Vortech Engineering for possible installers in your area.

to beginning the installation to determine if you should refer the job

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

(86-93 5.0 Lt Truck(4FC))

Vortech Engineering, Inc.

Table Of Contents

FOREWORD ...........................................................................................................................

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

IMPORTANT NOTICES ..........................................................................................................

CRANE IGNITION SYSTEMS ................................................................................................

MSD IGNITION SYSTEMS .....................................................................................................

INSTALLATION INSTRUCTIONS FOR SPECIFIC TRUCKS.................................................

PARTS LIST - 1987-1996 FORD 5.8 TRUCK ........................................................................

PARTS LIST - 1993-1995 FORD 5.8 LIGHTNING TRUCK ....................................................

PARTS LIST - 1987-1996 FORD 5.0 TRUCK ........................................................................

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

2. OIL FEED LINE INSTALLATION ................................................................................. 1

3. OIL DRAIN FITTING .................................................................................................... 2

4. CRANKSHAFT PULLEY.............................................................................................. 2

5. MAIN BRACKET INSTALLATION ............................................................................... 2

6. SUPERCHARGER INSTALLATION ............................................................................ 3

i ii iii iv v vi vii viii ix

7. OUTLET PLENUM DISCHARGE TUBE...................................................................... 4

8. WATER PUMP PULLEY AND FAN ASSEMBLY ........................................................ 5

9. SUPERCHARGER DRIVE BELT AND TENSIONER .................................................. 5

10. FUEL PUMP ................................................................................................................ 6

11. FUEL MANAGEMENT UNIT INSTALLATION ............................................................. 7

12. AIR FILTER COVER AND INLET DUCT ..................................................................... 8

13. 5.8 LIGHTNING SUPPLEMENTAL INSTALLATION INSTRUCTIONS

FOR THE BYPASS VALVE ......................................................................................... 9

14.1 IGNITION/BOOST CONTROL UNIT INSTALLATION (NON-

LIGHTNING TRUCKS ONLY) ..................................................................................... 9

14.2 IGNITION/BOOST CONTROL UNIT INSTALLATION (LIGHTNING

TRUCKS ONLY) .......................................................................................................... 11

15. IGNITION/BOOST CONTROL UNIT OPERATION ..................................................... 12

16. FINAL CHECK ............................................................................................................. 13

13SEP00 V1.3

P/N: 4FC020-010

(86-93 5.0 Lt Truck(4FC))

IMPORTANT NOTICES!

BEFORE BEGINNING INSTALLATION

On 1993 and later model years, it will be necessary to replace the fan blade assembly (not the entire fan clutch assembly) with an earlier model unit. The Ford part number is E7TZ-8600B.

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, Inc. This product 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, Inc.

Refer to page 5, item 8 of this manual.

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iii

SPECIAL NOTICE CONCERNING THE

CRANE IGNITION SYSTEM

The ignition system, manufactured by Crane Electronics, included in this kit is serviced exclusively by the manufacturer. Crane Electronics warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warranty. If found to be defective as mentioned above, it will be repaired or replaced if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Crane Electronics and/or Vortech Engineering, Inc. To the extent permitted by law, the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall Crane Electronics and/or Vortech Engineering, Inc. be liable for labor charges, special or consequential damages.

When returning this unit for service, proof of purchase must be supplied for warranty verification. After the warranty period has expired, repair service is charged between a minimum and maximum charge. In either case, please send the unit prepaid with proof of purchase to the attention of:

Crane Electronics Customer Service Department 530 Fentress Boulevard Daytona Beach, Florida, 32114 Phone: (904) 258-6167 Fax: (904) 258-6174 www.cranecams.com

The repaired unit will be returned as soon as possible after receipt, COD for any charges. Be sure you include a detailed account of any problems experienced, the type of vehicle and any modifications.

Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Inc. directly at (805) 247-0226 M-F 8:00AM - 4:30PM (PST).

ENGINEERING, INC.

13SEP00 V1.3

P/N: 4FC020-010

(86-93 5.0 Lt Truck(4FC))

SPECIAL NOTICE CONCERNING THE

ENGINEERING, INC.

MSD IGNITION SYSTEM

The MSD Boost Timing Master, manufactured by Autotronic Controls Corporation, included in this kit is serviced exclusively by the manufacturer. Autotronic Controls Corporation warrants this product to be free from defects in material and workmanship under normal use and if properly installed for a period of one (1) year from the date of purchase. In case of malfunction, this unit will be repaired free of charge according to the terms of the warranty. If found to be defective as mentioned above, it will be repaired or replaced if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Autotronic Controls Corporation and/or Vortech Engineering, Inc. To the extent permitted by law, the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall Autotronic Controls Corporation and/or Vortech Engineering, Inc. be liable for labor charges, special or consequential damages.

Autotronic Controls Corporation Customer Service Department 12120 Esther Lama Suite #114 El Paso, Texas, 79936 (915) 855-7123 Technical

Should you have any technical or installation questions regarding this unit, contact Vortech Engineering, Inc. directly at (805) 247-0226 M-F 8:00AM - 4:30PM (PST).

(86-93 5.0 Lt Truck(4FC))

Installation Instructions for

’87-’96 5.8L F-Series Truck ’93-’95 5.8L Lightning Truck ’87-’96 5.0L F-Series Truck

- 50 State Smog Legal per CARB EO #D-213-16

Congratulations on selecting the most technically innovative, best performing and best

backed automotive supercharger available today... the VORTECH V-2® supercharger!

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 wornout 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 breakin procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 92 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 every at least 3,000 miles. Never attempt to extend the oil change

interval beyond 3,000 miles, regardless of oil manufacturer's claims; potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 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 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factory repair manual

• Timing light

• 3/8" socket and drive set: SAE & metric

• 1/2" breaker bar and 4" extension

• Flat #2 screwdriver

• Phillips #2 screwdriver

• Large screwdriver or pry bar

• Adjustable wrench

• Open end wrenches: 3/8", 7/16", 9/16", 3/4", 7/8"

• Drill motor

• 9/16" and 3/32" drill bits

• Power steering pump pulley puller and installer (rent if you do not own)

• 3/8" NPT tap & handle

• Ford Snaplock fuel fitting disconnect tool

• Silicone sealer

• Heavy grease

• 1993 and later models: Ford Fan Blade Assembly part # E7TZ-8600B

If your vehicle has in excess of 10,000 miles since its last spark plug change you will also need:

• Spark Plug Socket

• NEW Spark Plugs

13SEP00 V1.3

P/N: 4FC020-010

(86-93 5.0 Lt Truck(4FC))

1987-1996 FORD 5.8 TRUCK

Part No. 4FC218-030SQ

ENGINEERING, INC.

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

2E228-030 SUPERCHARGER ASSEMBL Y 1

2E128-030 V-2 SQ Supercharger 1 2A036-287 2.87” supercharger drive pulley 1 8R101-001 6 rib pulley retainer assembly 1

4FC111-021 MOUNTING BRACKET ASSEMBLY 1

4FC011-021 Mounting bracket 1 4FC010-034 Mounting plate 1

7A375-100 3/8-16 x 1" bolts 9 7K375-040 3/8" AN washers 7

4FC116-081 WATER PUMP PULLEY ASSEMBLY 1

4FC016-081 Water pump pulley 1

7U313-124 5/16-24 x 2.5” studs 4

7J312-000 5/16" washers 4 7L312-000 5/16" lock washers 4 7F312-021 5/16-24 nuts 4

4FC040-160 Water pump pilot 1

4FC112-010 AIR INTAKE ASSEMBLY 1

4FC013-021 Air filter cover 1

7S350-200 3-1/2” x 2” sleeve 1

4FA012-012 90° intake elbow 1 4FC012-010 3-1/2” x 20" flex hose 1

7R002-056 #56 hose clamps 2 7R002-052 #52 hose clamps 2

4FC112-020 AIR DISCHARGE ASSEMBLY 1

4FC012-030 Discharge duct 1

7S225-125 2-1/4” x 1-1/4” sleeves 2 7S275-200 2-3/4” x 2” sleeve 1 7R002-044 #44 hose clamps 2 7R002-036 #36 hose clamps 4

4FC116-011 CRANK PULLEY ASSEMBLY 1

4FC016-011 Crank pulley 1 4FC017-041 Crank pulley spacer 1

7A375-325 3/8-16 x 3-1/4” bolts 4

7J375-044 3/8" SAE washers 4 7L375-075 3/8" lock washers 4 2A046-580 4060580 Goodyear belt 1

4FC130-026 OIL FEED LINE ASSEMBLY 1

4FC047-176 1/4” x 22" oil feed line 1

7P125-103 -4 x 45° 1/8” NPT male elbow 1 7P250-066 #4 swivel x 1/4” hose barb fittings 2 7P525-067 .500 crimp ferrules 2 7P250-122 AN917 1/4" pipe thread tee 1 7P250-123 1/4" NPT x 1-1/2” nipple 1 7P250-036 #4 flare to 1/4” NPT fitting 1

4FC130-036 OIL DRAIN ASSEMBLY 1

4FC048-186 1/2" x 16” oil drain line 1

7P375-033 3/8” NPT x 3/8” NPT street elbow 1 7P375-017 3/8” NPT x 1/2” straight hose barb 1 7R001-008 #8 hose clamps 2 7P100-121 Sealing nut 1

Part Number Description Quantity

4FC238-068 FMU (WITH LINES) 1

6Z110-111 12:1 black fuel management unit 1 4FC145-156 Male fuel line assembly 1 4FC146-166 Female fuel line assembly 1 4FC049-196 5/32” x 48” vacuum line 1

7U100-055 6” nylon tie wraps 2 7E010-046 #8 x 3/4” sheet metal screws 2

4FB101-002 FUEL PUMP ASSEMBLY 1

8F001-002 155 Inline fuel pump 1 7R003-008 1/2" adel clamp 1 7R003-024 1-1/2" adel clamp 1 7R001-004 #4 hose clamps 5

7U100-055 6” nylon tie wraps 6 5W001-011 16-14GA eyelets 3 5W001-010 16-14GA female slides 3 5W118-021 10" 18GA black wire 1 5W118-034 156" 18GA red wire 1 5W001-002 Fuse tap 1

7P312-003 5/16” female fuel connector 1

7P156-082 5/32” tee 1

7U129-012 5/32" x 12” vacuum hose 1

7U100-066 11” nylon tie wrap 1 5W001-012 22GA red solderless connector 1

8D002-001 Fuel pressure switch 1 5W001-015 20A blade type fuse 1 5W001-014 Fuse holder 1

7P125-105 1/8” NPT to 5/32” barb 1

7J010-001 #10 washers 6 7F010-032 10-32 nuts 3 7C011-075 10/32” x 3/4” bolts 3 7U131-024 5/16” x 24” fuel hose 1 7U132-050 12mm x 30” fuel hose 1 7P500-004 Fuel fitting adaptor 1

5A101-001 STAND ALONE ASSEMBLY 1

7P156-082 5/32” tee 1 5A002-002 EFI Ford wiring harness 1 5A001-001 Stand alone ignition retard 1 7U129-024 5/32” x 24” vacuum line 1

4FE111-032 BELT TENSIONER ASSEMBLY 1

7J012-092 12mm washers 3

4FA011-032 Tensioner plate 1

4GF116-160 Idler ribbed pulley assembly 1

2A017-010 Idler pulley spacer 1 7C012-020 12mm 1.75 x 20mm bolts 2 7C012-022 12mm 1.75 x 22mm thin head bolt 1

7G010-175 12mm x 1.75 nut 1

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+ 16 hidden pages

Vortech Engineering 4FC020-010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual