Vortech Engineering 4FD020-010 User Manual

Ford 4.0L

Explorer/Ranger

Supercharger System

Installation Instructions

FORD EXPLORER 1991-1994 MODEL YEARS

50 STATE SMOG LEGAL AS PER CARB EO #D-213-17

FORD RANGER 1990-1994 MODEL YEARS

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

(Explorer/Ranger(4FD V1.1))

ENGINEERING, LLC

FOREWORD

Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual if you should refer the job to a professional installer/technician. Please call Vortech Engineering for installers in your area.

prior

to beginning the installation to determine

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

(Explorer/Ranger(4FD V1.1))

of Vortech Engineering, LLC

Table Of Contents

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

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

TOOL & SUPPLY REQUIREMENTS.................................................................................. iv

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

PARTS LIST ....................................................................................................................... vi

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

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

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

4. MOUNTING BRACKET INSTALLATION ................................................................ 4

5. FMU INSTALLATION .............................................................................................. 5

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

7. SUPERCHARGER INSTALLATION ....................................................................... 7

8. SUPERCHARGER DRIVE BELT ........................................................................... 7

9. AIR INLET DUCT ................................................................................................... 8

10. SUPERCHARGER DISCHARGE DUCT ................................................................ 9

11. FINAL REASSEMBLY & CHECK ........................................................................... 11

iii

31JUL01 V1.1

P/N: 4FD020-010

(Explorer/Ranger(4FD V1.1))

FORD 1991-1994

4.0L EXPLORER/RANGER

Installation Instructions

Also applicable for the 1990-94 Mazda Navajo and 1994 Mazda B4000

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

Congratulations on selecting the best performing and best backed automotive

NOTE: This supercharger kit is designed to fit on Ford Explorer/Mazda Navajo vehicles. This kit, with the addition of the Ranger Supplement assembly part number 4FD248-050, may be installed on 1990-1994 Ford Ranger and 1994 Mazda B4000 vehicles.

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.

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.

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

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 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 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 every 15,000 miles and spark plug wires every 50,000 miles or earlier.

TOOL & SUPPLY REQUIREMENTS

• Factory Repair Manual

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

• Flat #2 screwdriver

• Phillips #2 screwdriver

• Large screwdriver or pry bar

• Adjustable wrench

• Ford style Snap Lock fuel disconnect tool

• 3/32" drill bit

• Drill motor

• Center punch

• 11/16" Greenlee™ Punch

• Silicone sealer

• Open end wrenches:

3/8", 7/16", 9/16", 5/8", 3/4", 7/8

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

• Spark plug socket

• 6 new OE heat range spark plugs

(Explorer/Ranger(4FD V1.1))

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 features shown in this product are the exclusive property of Vortech Engineering, LLC. 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, LLC.

31JUL01 V1.1

P/N: 4FD020-010

(Explorer/Ranger(4FD V1.1))

1991-1994 EXPLORER/RANGER

ENGINEERING, LLC

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

Part No. 4FD218-050SQ

PARTS LIST

Part Number Description Quantity

2E228-020 V-2 SUPERCHARGER ASSEMBLY 1

4FD111-021 MOUNTING BRACKET ASSEMBLY 1

4FD011-021 Mounting bracket 1 4FD110-043 Welded bracket assembly 1 4FD010-063 Bracket C 1 4FD015-136 Support brace 1

7U250-020 11mm dowels 2 7A375-124 3/8-16 x 1-1/4" bolts 4 7A375-100 3/8-16 x 1" bolts 5 7A375-075 3/8-16 x 3/4" bolts 9 7F375-016 3/8-16 nuts 3

7L312-000 5/16 - split (lock) washers 4 7A375-325 3/8-16 x 3-1/4" bolts 1 7C080-050 8mm x 1.5 x 150 bolts 4 7C010-035 M10-1.5 x 35mm bolt 1

7L375-075 3/8" lock washers 3 7K375-040 3/8" AN flat washers 13

4FD010-034 Mounting plate 1

4FD112-010 AIR PASSAGE ASSEMBLY 1

4FD012-010 Inlet duct A 1 4FD012-020 Intake tube A 1 4FD012-030 Intake tube B 1

7R005-001 208-91 3.75" T-bone clamp 1 7S300-000 3" 90° rubber elbow 1 7R002-052 #52 hose clamps 2 7S300-300 3" x 3" sleeve 1 7S300-200 3" x 2" sleeves 2

4FD050-010 Air plenum 1 4FD015-020 Dual pipe bracket, adjustable 1 4FD015-010 Dual pipe bracket, fixed 1

7F250-040 1/4-20 nut plates, clip on 2 7A250-175 1/4-20 x 1-3/4" bolts 2 7R002-048 #48 hose clamps 6 7C060-010 6mm x 1.0 x 16 flat allen 1 7F006-093 6mm nylock nut 1 7C080-023 8mm x 1.25 x 20 flat allen 1 7R002-044 #44 hose clamps 4 7S275-200 2-3/4" x 2" sleeves 2

4FD012-040 Discharge tube A 1 4FD012-050 Discharge tube B 1 4FD012-060 Discharge tube C 1

7S250-200 2-1/2" x 2" sleeves 3 7R002-040 #40 stainless hose clamps 6

2A046-103 BELT 1

Part Number Description Quantity

4FD130-026 OIL FEED ASSEMBLY 1

7U030-016 1/4" oil feed x 23" 1 7P125-103 -4 x 45° 1/8" NPT male elbow 1 7P250-066 #4 swivel x 1/4" hoses, barb fit 2 7P525-067 .500 crimp ferrules 2 7P250-082 1/4" NPT x -4 90° fitting 1 7P250-034 1/4" NPT x 1/4" NPT straight tee 1

4FD130-036 OIL DRAIN ASSEMBLY 1

7P375-042 Male connector, inverted flair 1 7P500-020 Tube nut, inverted flair 1 7P500-002 1/2" x 8" aluminum tube 1 7P375-017 3/8" NPT x 1/2" straight hose barb 1 7P375-045 3/8" NPT 45° street elbow 1 7P100-121 Sealing nut 1 7R001-008 #8 stainless hose clamps 2 7U030-036 1/2" x 5" oil drain hose 1

4FD238-068 FUEL MANAGEMENT UNIT (WITH LINES) 1

6Z110-111 12:1 black fuel management unit 1 4FD145-156 Fuel line assembly, male 1 4FD146-166 Fuel line assembly, female 1

7U030-046 5/32" x 32" vacuum line 1 7U100-055 6" nylon tie wraps 7 7E010-046 #8 x 3/4" sheet metal screws 2

4FD113-010 CHECK VALVE ASSEMBLY 1

7U400-001 One-way valve 1 7P250-126 1/4" restrictor 1 7P250-125 1/4" tee 1 7U030-030 1/4" x 12" vacuum line 1

4FD101-002 FUEL PUMP ASSEMBLY 1

8F001-002 155 inline fuel pump 1 7R003-024 1-1/2" adel clamp 1 7R001-004 #4 hose clamps 5 7P500-014 Ford fuel fitting adapter 1 7P312-003 5/16" female fuel connector 1 7U100-055 6" nylon tie wraps 8

5W001-011 16-14GA eyelet 1 5W001-010 16-14GA female slides, insulated 3 5W001-002 Fuse tap 1 5W018-021 18GA standard black wire 1

7J010-001 #10 flat washers 2

7F010-032 10-32 nylock nut 1 5W018-036 18GA standard red wire 1

7U031-018 5/16" x 20" fuel hose 1

7U030-010 12mm x 20" fuel hose 1

7C011-075 10/32" x 3/4" bolt 1

(Explorer/Ranger(4FD V1.1))

+ 12 hidden pages

Vortech Engineering 4FD020-010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual