Vortech Engineering 4FC020-010 User Manual

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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.

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

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

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

vii

1993-1995 FORD 5.8

LIGHTNING TRUCK

Part No. 4FC218-040SQ

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

2E228-130 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

4FC112-015 AIR INTAKE ASSEMBLY 1

4FA012-013 90° intake elbow with boss 1 4FC012-010 3-1/2” x 20" flex hose 1 4FC013-021 Air filter cover 1

7P375-097 3/8" NPT x 3/8" barb 1 7R002-052 #52 hose clamps 2 7R002-056 #56 hose clamps 2 7S350-200 3-1/2” x 2” sleeve 1

4FC112-040 AIR DISCHARGE ASSEMBLY 1

4FC012-040 Discharge tube A 1 4FC012-050 Discharge tube B 1

7P156-082 5/32 tee 1 7P750-102 3/4 NPT x 1" 90° hose fitting 1 7R002-016 #16 hose clamps 4 7R002-044 #44 hose clamps 4 7R002-048 #48 hose clamps 2 7S275-200 2-3/4” x 2” sleeve 1 7S275-300 2-3/4” x 3” sleeve 1 7S300-200 3” x 2” sleeve 1 7U030-046 5/32" x 24" vacuum line 1 7U034-016 1" x 3" heater hose 1 7U034-016 1" x 4-1/2" heater hose 1 8D001-001 Bypass valve 1

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 7U132-030 12mm x 30” fuel hose 1 7P500-004 Fuel fitting adaptor 1

Part Number Description Quantity

4FC139-096 PCV BYPASS KIT 1

7U100-055 6" nylon tie wraps 6 7U030-056 3/8" x 40" PCV hose 1 7U375-052 3/8" vacuum cap 1 8H040-020 3/8" inline filter 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

4FC130-026 OIL FEED LINE ASSEMBLY 1

4FC047-176 1/4” x 22" oil feed line 1

5A101-006 HI-6TR ASSEMBLY 1

5A001-009 Crane HI-6TR ignition system 1

5A002-002 EFI Ford wiring harness 1 5W001-001 Wire taps 2 5W001-009 16-14GA male slides 16 5W001-010 16-14GA female slides 20 5W001-011 16-14GA eyelets 2 5W001-017 Large ring terminals 2 5W001-019 12-10GA solderless connector 1

7E010-048 #10 x 3/4" sheet metal bolts 8

7P250-125 1/4" tee 1

7U030-030 1/4" x 24" vacuum hose 1

7U375-001 36" velcro-hook 1

7U375-002 36" velcro-latch 1 5W018-010 18GA x 30" red wire 1 5W018-240 18GA x 30" white/yellow wire 1 5W018-060 18GA x 30" orange wire 1 5W018-020 18GA x 30" black wire 1 5W012-000 18GA x 24" red wire 1

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

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

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

viii

13SEP00 V1.3

P/N: 4FC020-010

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

1987-1996 FORD 5.0 TRUCK

Part No. 4FE218-070SQ

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 2A036-312 3.125” 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

4FE112-010 AIR INTAKE ASSEMBLY 1

4FA012-012 90° intake elbow 1

4FC012-010 3-1/2” x 20" flex hose 1 4FC013-021 Air filter cover 1

7P625-002 5/8" hose barb 1 7R001-008 #8 Stainless hose clamps 2 7R002-052 #52 hose clamps 2 7R002-056 #56 hose clamps 2

7S300-075 3" x 3/4" orange sleeve 1

7S350-200 3-1/2” x 2” sleeve 1 7U100-050 5/8" grommet 1 7U033-000 5/8" x 40" PVC hose 1

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

4FC114-033 RADIATOR HOSE ASSEMBLY 1

4FC014-010 Stainless radiator pipe 1

7R002-024 #24 hose clamps 2

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 7P500-004 Fuel fitting adaptor 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

5A101-001 ST AND 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

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

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

1. COMPONENT REMOVAL

FRONT

A. Remove the following:

1. intake air duct

2. air filter box cover & inlet hoses

3. accessory drive belt

4. cooling fan & fan shroud

5. water pump pulley

6. crank pulley

7. power steering pulley (using a pulley)

B. Remove the A/C compressor from the mount-

ing bracket and secure to one side.

NOTE: When removing the power

steering pump and A/C compressor, do not break any lines; just set the unit aside.

C. Remove the power steering pump from the

bracket.

D. Remove the cast bracket from the engine

and save the fastening hardware.

2. OIL FEED LINE INSTALLATION A. Remove the oil pressure sender from the

engine block (located just ahead of the oil filter).

B. Screw the 1-1/2" long 1/4" pipe nipple into

the block, then the 1/4" pipe TEE onto the nipple.

C. Position the TEE so the branch faces for-

ward. Screw the original pressure sender into the branch.

NOTE: Keep all oil fittings and hoses

absolutely clean. Use Teflon paste sparingly only on the male pipe threads only. NEVER use Teflon tape. Apply only motor oil to flare fittings. Never overtighten fittings.

D. Screw the 1/4" pipe/flare fitting into the end

of the TEE as shown. (See

Figure 2-a

E. Install the Vortech supplied oil line onto the

flare fitting. Cover the loose end with a plastic bag for later.

Figure: 2-a

13SEP00 V1.3

P/N: 4FC020-010

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

3. OIL DRAIN FITTING

FACTORY PULLEY

SPACER

NEW ADDITIONAL PULLEY

3 BOLTS: 3/8-16 x 2-3/4”

A. Remove the driver's side valve cover. B. Measure 4-3/4" forward from the middle of

the center bolt hole and up 3/4" from the flange as shown on the inboard side of the valve cover and mark. (See

Figure 3-a

C. Make an 11/16" diameter hole at the mark

using a drill or chassis punch. Debur the hole completely. Thoroughly clean the valve cover.

D. Install the 1/2" hose fitting into the elbow and

tighten.

E. Insert the elbow fitting through the hole in the

valve cover so the hose fitting points forward. Secure with the special sealing nut provided in the kit. Make sure to place the sealing side of the nut against the valve cover surface.

F. Reinstall the valve cover.

4. CRANKSHAFT PULLEY A. Remove the crankshaft pulley from the

engine.

B. Place the Vortech provided crank pul-

ley spacer and crank pulley into the stock pulley just removed. (See

4-a

Figure

C. Make sure the pulleys are properly

centered. Reinstall as a unit using the 3/8-16 x 2 3/4" bolts and washers provided.

LEFT

VALVE

FORWARD FROM

HOLE 4-1/2"

HOLE 4-3/4"

UP 3/4"

FROM FLANGE

FRONT OF ENGINE

Figure: 3-a

Figure: 4-a

COVER

OIL

FILLER

5. MAIN BRACKET INSTALLATION

A. Mount the Vortech main mounting bracket B. Remount the power steering pump to the C. Reinstall the air conditioner compressor to

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

NOTE: For 5.0 applications, the water pump

bolt/stud must be modified. Remove the bolt that is one bolt clockwise from the top center water pump bolt. Cut off the stud portion and reinstall the water pump bolt for mounting bracket clearance.

to engine using the original fasteners.

new bracket using the original fasteners.

the new bracket using the original fasteners. (See

Figure 5-a

NOTE: On certain models, the Vortech mounting bracket may need

to be redrilled and tapped to accommodate the M10 x 1.25 threads for the air conditioning mount.

Figure: 5-a

5. MAIN BRACKET INSTALLATION, CONT'D.

5.0 and 5.8

Configuration

5.8 Lightning

Configuration

D. Reinstall the power steering pump pulley.

Make sure that the pulley is properly placed on the pump shaft so that the end of the shaft and the front face of the pulley hub are flush.

NOTE: For proper accessory drive belt alignment, it is imperative that

the power steering pump pulley be reinstalled properly. There should be no recess nor should there be any protrusion of the shaft. It must be FLUSH.

6. SUPERCHARGER INSTALLATION A. Mount the supercharger mounting plate to

the main mounting bracket with four 3/8 - 6 x 1" bolts. DO NOT use any washers on these bolts.

B. Install the 1/2" drain hose onto the fitting on

the supercharger and secure with the hose clamp provided.

NOTE: Before tightening the clamp,

rotate the clamp housing as necessary so that it DOES NOT interfere with the mounting plate when installed.

NOTE: On Lightning applications, it will

be necessary to remove the coil and bracket. Modify the bracket as shown (see Figure 6-b) and mount the coil onto the thermostat housing bolt.

C. Lower the supercharger into the bracket and

secure with five 3/8-16 x 1" bolts and AN type washers provided in the kit.

NOTE: The supercharger discharge has

a different position for either the standard or Lightning applications (see Figure 6-a).

D. Route the 1/2" drain hose from the super-

charger to the fitting on the valve cover and secure. It may be necesary to trim the length of the hose. The drain hose should be routed so that it gradually flows downward with minimal dips and no kinks.

E. Install the 45° flare to 1/8" pipe fitting into the

oil feed fitting on the supercharger and "clock" it so that it points to the 4:00-5:00 position (lower right). Use Teflon paste.

F. Attach the oil feed line and secure away from

all moving parts and the exhaust manifold with tie wraps.

Figure: 6-a

LIGHTNING COIL BRACKET

Figure: 6-b

CUT OUT NOTCH

13SEP00 V1.3

P/N: 4FC020-010

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

7. OUTLET PLENUM DISCHARGE TUBE A. Temporarily place the 2 3/4" diameter blue

sleeve on the supercharger outlet as far as it will go.

NOTE: If installing the kit on a 5.8

Lightning, disregard points B, C and D. Install the discharge tube to the throttle body using the 3" x 2" sleeve and the clamps provided. (See Figures 7-a, 7-b.)

B. Slide the two 2" diameter blue sleeves onto

the throttle body inlets, temporarily, as far as they will go. It is easier to unscrew and open the clamps and place them after sleeves are in place.

C. Fit the smaller ends of the plenum into the 2"

sleeves and check the alignment with the supercharger outlet. It may be necessary to loosen the bolts on the mounting plate to achieve proper alignment. In some cases the socket head screws on the perimeter of the supercharger must be loosened and the volute housing rotated slightly. Do not overtighten these screws, torque to 6-8 ft/lbs.

D. Once proper alignment has been achieved,

slide the sleeves onto the plenum and secure with the hose clamps.

Figure: 7-a - 5.0, 5.8 F-Series/Bronco

Figure: 5-b - 5.8 Lightning

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

8. WATER PUMP PULLEY AND FAN ASSEMBLY

NOTE: 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.

A. Screw the four 5/16" studs into the water

pump flange.

B. Place the Vortech supplied water pump pul-

ley onto the studs.

C. Lower the fan assembly and fan shroud into

place together.

D. Secure the fan assembly onto the water

pump with the nuts and the washers provided.

E. Secure the fan shroud. F. Reinstall the stock accessory belt according

to the original diagram.

G. For 5.0 applications, it may be necessary to

shorten the upper radiator hose.

1. Drain enough coolant to empty the up-

per hose.

2. In the middle of the straight hose section

over the radiator fan, remove a 3" section.

3. Place the supplied tube section into the

two hose ends as a splice, and secure with the clamps provided.

9. SUPERCHARGER DRIVE BELT AND TENSIONER

A. Install the supercharger drive belt on the

new crank pulley and supercharger drive pulley as shown. (See

Figure 9-a

B. Install the tensioner assembly onto the su-

percharger. Make sure the bolt with the narrow head is placed in the slot nearest the idler pulley.

C. Using a 1/2" drive breaker bar and exten-

sion, set the tension on the belt by moving the plate and securing the fasteners.

NOTE: DO NOT overtighten the fasten-

ers. Torque to 28-32 ft/lbs.

D. The supercharger drive belt tension should

be about as tight as the accessory drive belt. It will be necessary to reset the tension between 250 and 500 miles after the original installation.

Figure: 9-a

13SEP00 V1.3

P/N: 4FC020-010

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

10. FUEL PUMP A. Release any pressure from the fuel tank by

momentarily loosening the filler cap.

B. Disconnect the line to the fuel filter by care-

fully removing the white retaining tab. Attach the line to the adapter fitting, as shown. (See

Figure 10-a

C. Connect the fuel pump inlet to the adapter

with the 3/8" hose provided.

D. Connect the fuel pump outlet to the filter inlet

with the 5/16" hose. Use the supplied Ford fuel connector and hose clamp.

E. Attach the negative pump terminal to a clean

ground fastener with the wire provided.

F. Mount the Hobbs switch with the 11" tie wrap

to the wiring harness located on the driver's side plastic inner fender (or any convenient place free from metal contact).

G. Connect positive terminal on fuel pump to

switch. Attach inline fuse to opposite switch terminal. Connect a length of wire from fuse to fuse box for power supply (30 amp A/C works well).

H. Connect switch to vacuum source with the

provided 5/32" TEE, 1/8" NPT to nipple, and 12" long vacuum line.

I. Secure the fuel pump and hose with the

clamps provided.

J. After installation is complete, start engine

and check system for leakage.

EXISTING FEED LINE

FROM TANK

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

ADAPTER

FITTING

5/16”

HOSE

STOCK

FUEL FILTER

VORTECH FUEL PUMP

FUEL PUMP

GROUND (-)

HOBBS SWITCH

EXISTING

LINE TO

RAIL

3/8” FUEL LINE

Figure: 10-a

11. FUEL MANAGEMENT UNIT INSTALLATION A. Mount the fuel management unit (FMU) to

the firewall on the driver's side. Placement should be on the flat area near the top of the firewall just below the hood hinge base and outward from the swinging portion of the hood hinge. Use the sheet metal screws in the kit to secure.

B. Using a special tool for springlock connec-

tors, disconnect the stock fuel return line where it exits the stock fuel pressure regulator near the fuel rail.

C. Snap the Vortech fuel line with the male

springlock connector into the regulator outlet. Attach the other end to the Vortech fuel management unit inlet. Route the line over the brake booster and through the existing clamps.

D. Snap the second line with the female

springlock connector onto the fuel return line that was connected to the regulator outlet. Connect the other end to the FMU outlet at the center fitting. Route this line along with the first line.

NOTE: Make sure you have routed all

fuel lines away from all moving parts, sharp edges, exhaust pipes and manifolds. Secure the fuel lines with the tie wraps and hose clamps provided.

OUTLET

(FUEL FROM

HERE

RETURNS

TO TANK)

CONNECT TO MANIFOLD VACUUM/PRESSURE

INLET (FUEL LINE FROM STOCK REGULATOR)

Figure: 11-a

BYPASS VALVE (LIGHTNING ONLY)

MANIFOLD VACUUM TREE

FMU

TOP VIEW

E. Connect the 5/32" vacuum line from FMU to

intake manifold fitting and secure (see

ures 11-a, 11-b, 11-c

Fig-

F. Install the 3-1/2" flex hose between the air

filter and elbow and secure with hose clamps.

ENGINE

FUEL TANK

Figure: 11-b

FUEL FEED LINE

VORTECH FUEL PUMP

FUEL PUMP

Figure: 11-c

FUEL

MANAGEMENT

UNIT (FMU)

FUEL RETURN LINE

13SEP00 V1.3

P/N: 4FC020-010

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

12. AIR FILTER COVER AND INLET DUCT A. Secure the Vortech air filter cover in place of

the stock air filter cover with the original screws. Replace or clean the air filter element, if necessary.

IMPORTANT: For the 94-96 5.0 and

95-96 5.8, disregard step A and complete the following steps before proceeding to step B.

1. Remove the air filter cover/MAF assem-

bly. Drill a 7/8" hole into the rear portion of the cover (the side facing the brake master cylinder). Reinstall the air filter cover/MAF assembly onto the air box.

2. Install the supplied 5/8" grommet and

barb fitting into the hole previously drilled into the air filter cover.

3. Route the supplied length of 5/8" hose

from the valve cover to the air filter cover. Trim the hose to length and secure with #8 hose clamps.

4. Slide the orange sleeve onto the MAF

housing outlet.

B. Place the 3-1/2" diameter blue sleeve on the

inlet of the supercharger. Insert the 3-1/2" 90° plastic elbow into the sleeve and face the opening towards the air filter outlet. Secure with the hose clamps provided.

C. Install the 3-1/2" flex hose between the air

filter and elbow and secure with hose clamps.

IMPORTANT: On Lightning appli-

1. Plug the breather tube at the throttle

2. Connect the vent tube on the oil filler cap

3. If necessary, trim the hose and secure

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

cations, it is necessary to remove the tube from the valve cover to the throttle body.

body with the rubber cap provided.

to the fitting on the air box with the filter, hose, and clamps provided.

with the tie wraps.

13. 5.8 LIGHTNING SUPPLEMENTAL INSTALLATION INSTRUCTIONS

MSD

FMU

MANIFOLD VACUUM

FOR THE BYPASS VALVE A. Screw the fitting into the new inlet elbow as

shown in the graphic.

B. Install the inlet elbow onto the supercharger

with the fitting on top and pointing towards the small tube branched off of the discharge tube.

C. Place the hoses, as shown, on the valve and

secure with the clamps provided.

D. Install the valve with the hoses connected,

between the inlet elbow and discharge tube. Secure hoses with the clamps.

E. Attach one end of the small sensor hose

onto the valve.

F. Connect the 5/32" vacuum hose from the

bypass valve to the intake manifold vacuum fitting. See

Figure 11-b

on page 7.

G. Make sure everything is secure and that no

fuel lines or wires have been accidentally moved into harm's way.

14.1 IGNITION/BOOST CONTROL UNIT INSTALLATION (NON-LIGHTNING TRUCKS ONLY)

DISCHARGE TUBE

BYPASS VALVE

CONNECT TO MANIFOLD PRESSURE

INLET ELBOW

Figure: 13-a

A. The Ignition/Boost Control unit has been

prewired for installation convenience. Installation is a simple matter of disconnecting the stock connector at the ignition coil and plugging in the new adapter. Then plug the stock connector into the adapter.

B. The next step is to provide a good ground for

the black wire and mounting the box in as cool a place as possible under the hood. The box should be mounted with the aluminum cover on the bottom.

C. Splice the supplied 5/32" hose and TEE into

the FMU vacuum line and connect to the Ignition/Boost Control Unit (see

Figure 14-a

D. Route the Ignition/Boost Control wires

through the firewall from the interior side. Mount the knob in an easily accessible place.

E. Connect the wires to the plastic oval wiring

connector on the Ignition/Boost Control unit using the snap-on connector supplied in the Ignition/Boost Control kit.

NOTE: The wiring to the Boost/Control

knob can be matched to either of the corresponding wires in the boost retard connector.

Figure: 14-a

13SEP00 V1.3

P/N: 4FC020-010

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

14.1 IGNITION/BOOST CONTROL UNIT INSTALLATION (NON-LIGHTNING TRUCKS ONLY), CONT'D.

BOOST

TO MANIFOLD

VACUUM

BOOST RETARD

RETARD

GROUND

CONNECTOR

SUPERCHARGERS

Ignition/Boost

Control

MANUFACTURED FOR

VORTECH SUPERCHARGERS

MSD

IGNITION COIL

FROM FACTORY COIL HARNESS

MAGNETIC PICKUP CONNECTOR (NOT USED)

WHITE

RED

ORANGE

BLACK

WHITE

RED

ORANGE

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

Figure: 14-b

14.2 IGNITION/BOOST CONTROL UNIT INSTALLATION (LIGHTNING TRUCKS ONLY)

A. Mount the main ignition box under the hood

in a location that will keep the unit as cool and dry as possible. Use the supplied sheet metal screws to secure.

B. Route the heavy black cable to a clean

ground. Route the heavy red cable to the (+) positive battery terminal.

C. Install the ignition/boost retard wiring har-

ness following

Figure 14A-a

D. Mount the retard adjustment knob in an

easily accessible position from the driver's seat. Attach the black wire to a clean ground and the red wire to a keyed on 12V power source or to the red wire from the Vortech Ignition box. Tape up the end of the yellow wire to prevent contact with a metal surface. Route the three-wire harness out into the engine compartment and connect to the supplied GM-style map sensor.

E. Route the supplied vacuum line and TEE

from the map sensor to a boost source on the intake manifold.

FACTORY FORD

HARNESS

(UNPLUGGED

FROM COIL)

SUPPLIED

FORD ADAPTER

HARNESS

TO BATTERY +

TO GROUND –

RANE

HI-6R

cams

*GREY MAGNETIC TRIGGER HARNESS (TAPE UP)

MANIFOLD

VACUUM

*NOTE: CABLE CONTAINS RED AND BLACK LEADS. MAKE SURE LEADS DO NOT CONTACT EACH OTHER AND SHORT UNIT WHEN TAPING UP

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

GREEN (TAPE UP)

HEAVY RED

HEAVY BLACK

SUPPLIED MAP SENSOR

3 WIRE HARNESS

WIRE TAP

RED

WHITE

BLACK

ORANGE

BROWN WITH WHITE STRIPE

RED (12V SWITCHED)

RANE

ELECTRONICS

HI-6R

TIMING RETARD CONTROL

YELLOW (TAPE UP) BLACK (GROUND)

Figure: 14A-a

CONNECT TO

COIL

13SEP00 V1.3

P/N: 4FC020-010

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

15. IGNITION/BOOST CONTROL UNIT OPERATION A. The Ignition/Boost Control unit is designed

to retard ignition in relation to boost.

B. The unit is adjustable from 0° to 4°of ignition

retard for each pound of boost, up to a maximum of 20°. (See

Figure 15-a

C. Using the 1° per pound position as a starting

place, adjust the ignition retard knob until just beyond the point of detonation. Use third gear for testing in a safe area or road. Adjust the retard according to changes in altitude and fuel quality.

Caution: It is extremely important

that the boost retard never be turned to 0° using pump fuel. It is recommended that in stock street applications, the knob be at no less than 1° per lb.

Example of Boost

5 psi at 3° per lb. 7 psi at 2° per lb.

DEGREES OF RETARD

PSI BOOST

MAX. RETARD = 15°

10 psi at

1/2° per lb.

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

Figure: 15-a

16. FINAL CHECK

WARNING: Do not attempt to operate

the vehicle until ALL components are installed and ALL operations are completed including the final check.

A. Reconnect the battery. B. If your vehicle has gone over 10,000 miles

since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

C. Check all fittings, nuts, bolts and clamps for

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

D. Check all fluid levels, making sure that your

tank(s) is/are filled with 92 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 any fluid leakage. Check ignition timing to make sure it is set to stock specifications before commencing test drive.

G. PLEASE TAKE SPECIAL NOTE: Operat-

ing the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPO-

NENTS. H. Test drive the vehicle. I. The supercharger drive belt stretches ini-

tially and will require adjustment between

250 and 400 miles.

J. 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.

13SEP00 V1.3

P/N: 4FC020-010

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

1650 Pacific Avenue, Channel Islands, CA 93033-9901 • (805) 247-0226

FAX (805) 247-0669 • vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

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

ENGINEERING, INC.

Vortech Engineering 4FC020-010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual