Vortech Engineering 4FT020-010 User Manual

FORD 5.4L/6.8L

SUPER DUTY TRUCK

Supercharger System

Installation Instructions

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

1999-2001 MODEL YEARS

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • [phone]

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

P/N: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

®

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: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

© 2002 VORTECH ENGINEERING, LLC

of Vortech Engineering, LLC.

ii

Table Of Contents

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

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

IMPORTANT NOTES ........................................................................................................................iv

TOOL & SUPPLY REQUIREMENTS ................................................................................................ v

PARTS LIST-1999-2001 FORD SUPER DUTY 5.4L-STANDARD SYSTEM ....................................vi

PARTS LIST-1999-2001 FORD SUPER DUTY 6.8L-STANDARD SYSTEM ....................................viii

PARTS LIST-1999-2001 FORD SUPER DUTY 6.8L-H.O. w/CHARGE COOLER SYSTEM ............xi

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

2. HARMONIC BALANCER & CRANK PULLEY INSTALLATION ........................................... 2

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

4. OIL DRAIN LINE ..................................................................................................................4

5. FUEL PUMP INSTALLATION...............................................................................................5

6. PUMP RELAY INSTALLATION ............................................................................................7

7. IN-TANK FUEL PUMP REPLACEMENT ( H.O. Systems Only) ...........................................7

8. FUEL MANAGEMENT UNIT ................................................................................................8

9. WATER PUMP AND COOLER INSTALLATION (H.O. Systems Only).................................9

10. MOUNTING BRACKET & SUPERCHARGER INSTALLATION ...........................................11

11. AIR INLET ASSEMBLY ........................................................................................................11

12. DISCHARGE DUCTING ......................................................................................................12

13. CHARGE COOLER INSTALLATION (H.O. Systems Only)..................................................13

14. HOSE INSTALLATION & FILLING (H.O. Systems Only) .....................................................14

15. REASSEMBLY AND FINAL CHECK ....................................................................................15

APPENDIX ........................................................................................................................................17

A-1 V-10 FMU DIAGRAM.................................................................................................. 18

A-2 V-8 FMU DIAGRAM.................................................................................................... 19

A-3 MOUNTING PLATE AND SUPPORT PLATE ASSEMBLIES ..................................... 20

A-4 V-8 INLET AND DISCHARGE DIAGRAM-STANDARD SYSTEM ..............................21

A-5 V-10 INLET AND DISCHARGE DIAGRAM-STANDARD SYSTEM ............................ 22

A-6 BELT ROUTING DIAGRAM ....................................................................................... 23

A-7 CHARGE COOLER DIAGRAM ..................................................................................24

A-8 WATER HOSE DIAGRAM ..........................................................................................25

©2002 Vortech Engineering, LLC

iii

All Rights Reserved, Intl. Copr. Secured

07FEB02 V2.0

P/N: 4FT020-010

(99-01SuperDuty(4FT V2.0))

Ford 5.4L/6.8L Super Duty

IMPORTANT NOTES

1999-2001 Models

This kit requires ECM modification and the installation of a Vortech ECM Module. The
ECM must be sent directly to Vortech by the installing customer (the charge for this
service with module installation has been included in the purchase price).

• Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1)

Vortech ECM Module.

• The modules are made specifically for each individual vehicle with respect to the

factory ECM calibration.

• Simply contact the Vortech Service Department at [phone] to request a

Return Authorization Number (see ECM Module Credit Tag for more details).

- Mail to Vortech the enclosed "ECM Module Credit Tag" (send original tag - no

photocopies will be accepted) and ECM in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Vortech will give an

estimate at the time of your order.

Your Vortech ECM Module comes with a twelve (12) month limited warranty from the
original date of purchase of your supercharger system (see Owner's Manual for
details).

P/N: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

iv

1999-2001

FORD SUPER DUTY V-10

Installation Instructions

1999-2001 50 State Smog Legal, as per CARB EO #D-213-17

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH

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 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 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 at least every 3,000 miles. 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 2 years or 30,000 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 30,000 miles.

®

V-2® Supercharger!

TOOL & SUPPLY REQUIREMENTS:

• Metric and standard - socket set, wrench set

• Ratchet - 1/2” drive

• Extension

• 1/2" drive breaker bar

• Ford springlock 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

• Harmonic balancer puller and installer

• 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

©2002 Vortech Engineering, LLC

v

All Rights Reserved, Intl. Copr. Secured

07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

P/N: 4FT020-010

1999-2001 Ford Super Duty 5.4L

Part No. 4FT218-010/018SQ

®

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 Quantity

4FT120-020 ECM CHIP PKG/SHIPPING ASSY 1
2E228-340 V2 SQ SUPER DUTY 5.4L 1

2E128-340 S/C S.D. 5.4 V-2SQ SATIN 1
2A038-333 S/C PULLEY Ø3.33" 8 GROOVE 1
8R101-002 8-RIB PULLEY RET.ASSY 1

4FT111-062 CRANK PULLEY ASSY 5.4 1

4FT016-031 5.4 CRANK PULLEY 1
4FT016-021 DAMPER 5.4 MACHINED 1
4FT017-010 SPCR, CRNK PULLEY 1

2A048-730 BELT, K080730 GATES 1
7C120-065 M12 x 1.5 x 65mm HHCS 1
7C100-040 M10 x 1.5 x 40mm SHCS 3
7K437-001 7/16" AN WASHER 3

4FT111-054 MNTG. BRKT. ASSY 1

4FM016-031 IDLER 8-RIB GROOVED 1

4FA016-171 DUST COVER 3
4FT017-070 SPACER, IDLER S.D. 1

7A437-250 7/16-14 x 2.5" HXHD 1
7F437-000 7/16-14 NUT NYLOCK 1

7J438-081 7/16 WASHER SAE 1
4FT110-044 MAIN BRKT ASSY, WELDED 1
4FT010-034 SUPPORT PLATE 1

7C100-085 M10 x 1.5 x 85mm HXHD 1
7C100-110 M10 x 1.5 x 110mm HXHD 2

7J010-002 M10 WASHER 3

7A375-178 3/8-16 x 1.75" HXHD GR8 5
7K375-030 3/8 WASHER AN 5

4FM011-052 5.4 SPRING TENSIONER 1

7C010-045 M10 x 1.5 x 45mm HXHD 1
4FA016-170 IDLER 8-RIB SMOOTH 1
4FA016-171 DUST COVER 1
4FT017-060 SPACER, SPRING TENSIONER 1

7A375-400 3/8-16 x 4" HXHD PLTD 1

7F375-017 3/8-16 NUT NYLOCK 1

7K375-030 3/8 WASHER AN 2

7A250-075 1/4-20 x .75" SHCS 2

7J250-001 1/4 WASHER PLTD 2

4FT010-020 DAMPER BRKT. S.D. 1

4FM017-020 5.4 SPCR LONG 1

7C140-035 M14 x 2.0 x 35mm, HXHD PLTD 1

7J438-091 9/16" WASHER SAE PLTD 1

4FT010-050 BRKT, WIRNG HRNS S.D. 1

7A250-075 1/4-20 x .75" SHCS PLTD 2

7J250-001 1/4 WASHER PLTD 4

7F250-021 1/4-20 NUT NYLOCK 2

5W018-070 WIRE 22-18GA GREEN 6"
5W018-030 WIRE 22-18GA GRAY 6"
5W001-012 SOLDERLESS CONNECTORS 22-18GA 4

7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 3

7K375-030 3/8 WASHER AN 6

7F375-017 3/8-16 NUT NYLOCK 3

7C012-035 M12 x 1.75 x 35mm HXHD 3

7J012-092 M12 WASHER 3

Part Number Description Quantity

4FT130-026 OIL FEED ASSY. SUPER DUTY 1

7U030-026 1/4" x 25" OIL FEED HOSE 25"
7P250-034 STREET TEE 1
7P250-082 1/4"NPT x -4 x 90° FITTING 1
7P525-067 CRIMP FERRULES 2
7P250-066 #4 SWIVEL x 1/4 HOSE BARB 2
7U100-055 6" TIE WRAPS 4
7P125-026 1/8 NPT x #4 X 90° FITTING 1

4FT238-068 FMU ASSY SUPER DUTY 1

4FT145-020 FUEL LINE, FEMALE 7" 1

4FD145-010 FUEL LINE, MALE 17" 1

7U030-046 5/32" X 18" VACUUM LINE 18"
7P156-082 5/32" TEE 1
7U100-055 6" TIE WRAPS 2
6Z110-136 7:1 FMU 1

8F203-265 FUEL PUMP ASSY. 1

5W001-001 WIRE TAP 1
5W001-011 16-14 GA EYELET .25” HOLE 2

7E010-050 #12 x 1/2 SHEET METAL SCREW 1
7P312-003 5/16 FEMALE FUEL 1
7R004-003 14.5 STEPLESS CLAMP 2
7U100-044 TIE WRAP, 4” NYLON 3
7U100-055 TIE WRAP, 6” NYLON 4
7U031-018 5/16 FUEL HOSE HI-PRESSURE 11"

8F101-200 T-REX WIRING ASSY MUSTANG 1
5W001-014 FUSE HOLDER 10 GA WIRE 1
5W001-015 FUSE, BLADE TYPE 20 AMP 1
5W001-010 16-14 GA FEMALE SLIDE 1

8F001-002 155 INLINE FUEL PUMP 1

7R003-027 ADEL CLAMP 1

7R001-008 #8 STNLS HOSE CLAMP 2

7E010-075 #12 x 3/4” SHEET METAL SCREW 1

7P500-004 FITTING, FUL.ADAPT.1/2 1
5W001-017 LARGE RING TERMINAL 1
5W001-019 SOLDERLESS CONNECTOR 10-12 2

7U030-050 12mm FUEL HOSE 16"
5W001-042 12-10 GA 3/16” RING TERMINAL 2

7A250-100 1/4-20 x 1” FLAT ALLEN 1

7J250-001 1/4 SAE WASHER, PLATED 2

7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1
5W001-040 12-10 GA FEMALE SLIDE 2

4FT130-036 OIL DRAIN ASSY. SUPER DUTY 1

7P100-121 SEALING NUT 1

7P375-045 45° STREET ELBOW 1

7P375-017 3/8 NPT HOSE BEAD x 1/2 BEADED 1

7U030-036 1/2" OIL DRAIN HOSE x 1' 1

7R001-008 #8 HOSE CLAMPS 2

7R003-027 ADEL CLAMP 1

7R001-008 #8 HOSE CLAMPS 2

4FT011-032 CROWS FOOT, WATER PUMP 1
4FT011-022 CROWS FOOT, FORD V-8 1

P/N: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

vi

1999-2001 Ford Super Duty 5.4L

Part No. 4FT218-010/018SQ

®

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 Quantity

4FT112-010 AIR INLET ASSY 1

4FT012-030 DUCT, INLET Ø3.5” S.D. 1
7R002-056 #56 GOLDSEAL HOSE CLAMP 2
7R002-052 #52 GOLDSEAL HOSE CLAMP 2
8H040-045 AIR FILTER F-150 1
4FT110-010 BRKT ASSY, MAF SUPERDUTY 1
7P375-106 PCV VALVE, F150, 3/8” INLET 1
7P625-016 5/8” UNION 1
7U133-024 5/8” MOLDED ELBOW HOSE 1
7A250-075 1/4-20 x 3/4 SHCS PLATED 4
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 4
7J250-001 1/4 SAE WASHER, PLATED 8
7S350-200 3-1/2 x 2 SLEEVE 1
7U035-001 3-1/2” FLEX HOSE 15"

4FT112-020 AIR DISCHARGE ASSY 1

4FT012-020 DISCH. DUCT 5.4 SUPER DUTY 1
8D001-001 BYPASS VALVE 1
7U034-016 1” GS HOSE 3"
7R002-016 #16 GOLDSEAL HOSE CLAMP 5
7U133-090 RUBBER ELBOW, Ø1.0” x 90° 1
7U030-046 5/32” VACUUM LINE 25"
7S275-200 2-3/4 x 2 SLEEVE 2
7R002-044 #44 GOLDSEAL HOSE CLAMP 3
7R002-048 #48 GOLDSEAL HOSE CLAMP 1
7P750-102 3/4NPT x 1” x 90° HOSE FITTING 1
7U034-016 1” GS HOSE 3"

vii

©2002 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured

07FEB02 V2.0

P/N: 4FT020-010

(99-01SuperDuty(4FT V2.0))

1999-2001 Ford Super Duty 6.8L

Part No. 4FT218-020/028SQ

®

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 Quantity

4FT120-020 ECM CHIP PKG/SHIPPING ASSY 1
4FT130-036 OIL DRAIN ASSY. SUPER DUTY 1

7P100-121 SEALING NUT 1
7P375-045 45° STREET ELBOW 1
7P375-017 3/8 NPT HOSE BEAD x 1/2 BEADED 1
7U030-036 1/2" OIL DRAIN HOSE x 1' 1
7R001-008 #8 HOSE CLAMPS 2

4FT112-030 DISCHARGE ASSY 6.8 SUPER DUTY 1

7R002-072 #72 HOSE CLAMPS 2
7S450-200 4 1/2 x 2 SLEEVE 1

4FT012-010 DISCHARGE DUCT 1

7S300-275 REDUCER Ø3.00 x Ø2.75 1
7R002-048 #48 HOSE CLAMP 1
7R002-044 #44 HOSE CLAMP 1
8D001-001 BYPASS VALVE 1
7R002-016 HOSE CLAMPS #16 4
7U030-046 5/32" VAC LINE x 25" 25"
7U133-090 HOSE, RUBBER ELBOW Ø1" x 90° 1
7U034-016 1" HEATER HOSE X 3" 3"

4FT111-052 CRANK PULLEY ASSY 6.8 V-10 1

7K437-001 7/16 AN WASHER 3
4FT016-011 DAMPER V-10 MACH 1
4FT016-031 CRNK PULLEY 8 - RIB MACH 1
4FT017-010 SPACER, CRNK PLLY V-10 1

7C120-065 M12 x 1.5 x 65mm HHCS 1

7C100-040 M10 x 1.5 x 40mm SHCS 3

2A048-733 BELT, K080733 GATES 1
4FT017-011 SPACER, FAN V-10 1

2E228-330 V2SQ S.D. 6.8L 1

2E128-330 S/C S.D. 6.8 V-2SQ SATIN 1

2A038-347 S/C PULLEY Ø3.47" 8 GROOVE 1

8R101-002 8-RIB PULLEY RET. ASSY 1

4FT112-010 AIR INLET ASSY. 1

4FT012-030 CAST AIR INLET 1

7S350-200 3.5"X2" SLEEVE 1
7R002-056 HOSE CLAMPS #56 2
7R002-052 HOSE CLAMPS #52 2
7U035-001 3.5" FLEX HOSE x 15" 15"
8H040-045 AIR FILTER 1

4FT110-010 MAF BRKT ASSY 1

7P375-106 PCV VALVE 1
7P625-016 5/8" UNION 1
7U133-024 5/8" MOLDED ELBOW HOSE 1
7A250-075 1/4-20 x 3/4" SHCS 4
7F250-021 1/4-20 NYLOCK NUTS 4

7J250-001 1/4" WASHERS 8

Part Number Description Quantity

4FT111-054 MNTG. BRKT. ASSY 1

4FM016-031 IDLER 8-RIB GROOVED 1

4FA016-171 DUST COVER 3
4FT017-070 SPACER, IDLER SUPER DUTY 1

7A437-250 7/16-14 x 2.5" HXHD PLTD 1
7F437-000 7/16-14 NUT NYLOCK 1

7J438-081 7/16 WASHER SAE PLTD 1
4FT110-044 MAIN BRKT ASSY, WELDED 1
4FT010-034 SUPPORT PLATE 1

7C100-085 M10 x 1.5 x 85mm HXHD PLTD 1
7C100-110 M10 x 1.5 x 110mm HXHD PLTD 2

7J010-002 M10 WASHER 3

7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 5
7K375-030 3/8 WASHER AN 5

4FM011-052 5.4 SPRING TENSIONER 1

7C010-045 M10 x 1.5 x 45mm HXHD PLTD 1
4FA016-170 IDLER 8-RIB SMOOTH 1
4FA016-171 DUST COVER 1
4FT017-060 SPACER, SPRING TENSIONER 1

7A375-400 3/8-16 x 4" HXHD PLTD 1

7F375-017 3/8-16 NUT NYLOCK 1

7K375-030 3/8 WASHER AN 2

7A250-075 1/4-20 x .75" SHCS PLTD 2

7J250-001 1/4 WASHER PLTD 2

4FT010-020 DAMPER BRKT. SUPER DUTY 1

4FM017-020 5.4 SPCR LONG 1

7C140-035 M14 x 2.0 x 35mm, HXHD PLTD 1

7J438-091 9/16" WASHER SAE PLTD 1

4FT010-050 BRKT, WIRNG HRNS S.D. 1

7A250-075 1/4-20 x .75" SHCS PLTD 2

7J250-001 1/4 WASHER PLTD 4

7F250-021 1/4-20 NUT NYLOCK 2

5W018-070 WIRE 22-18GA GREEN 6"
5W018-030 WIRE 22-18GA GRAY 6"
5W001-012 SOLDERLESS CONNECTORS 22-18GA 4

7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 3

7K375-030 3/8 WASHER AN 6

7F375-017 3/8-16 NUT NYLOCK 3

7C012-035 M12 x 1.75 x 35mm HXHD 3

7J012-092 M12 WASHER 3

4FT130-026 OIL FEED ASSY. SUPER DUTY 1

7U030-026 1/4" x 25" OIL FEED HOSE 25"

7P250-034 STREET TEE 1

7P250-082 1/4"NPT x -4 x 90° FITTING 1

7P525-067 CRIMP FERRULES 2

7P250-066 #4 SWIVEL x 1/4 HOSE BARB 2

7U100-055 6" TIE WRAPS 4

7P125-026 1/8 NPT x #4 x 90° FITTING 1

4FT011-032 CROWS FOOT, WATER PUMP 1
4FT011-012 CROWS FOOT, FORD V-10 1

P/N: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

viii

1999-2001 Ford Super Duty 6.8L

Part No. 4FT218-020/028SQ

®

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 Quantity

4FT238-068 FMU ASSY SUPER DUTY 1

4FT145-020 FUEL LINE, FEMALE 7" 1
4FD145-010 FUEL LINE, MALE 17" 1

7U030-046 5/32" x 18" VACUUM LINE 1.5’
7P156-082 5/32" TEE 1
7U100-055 6" TIE WRAPS 2

6Z110-136 7:1 FMU 1

8F203-265 FUEL PUMP ASSY. 1

5W001-001 WIRE TAP 1
5W001-011 16-14 GA EYELET .25” HOLE 2

7E010-050 #12 x 1/2 SHEET METAL SCREW 1
7P312-003 5/16 FEMALE FUEL 1
7R004-003 14.5 STEPLESS CLAMP 2
7U100-044 TIE WRAP, 4” NYLON 3
7U100-055 TIE WRAP, 6” NYLON 4
7U031-018 5/16 FUEL HOSE HI-PRESSURE 11"

8F101-200 T-REX WIRING ASSY MUSTANG 1
5W001-014 FUSE HOLDER 10 GA WIRE 1
5W001-015 FUSE, BLADE TYPE 20 AMP 1
5W001-010 16-14 GA FEMALE SLIDE 1

8F001-002 155 INLINE FUEL PUMP 1

7R003-027 ADEL CLAMP 1
7R001-008 #8 STNLS HOSE CLAMP 2
7E010-075 #12 x 3/4” SHEET METAL SCREW 1

7P500-004 FITTING, FUL.ADAPT.1/2 1
5W001-017 LARGE RING TERMINAL 1
5W001-019 SOLDERLESS CONNECTOR 10-12 2

7U030-050 M12 FUEL HOSE 16"
5W001-042 12-10 GA 3/16” RING TERMINAL 2

7A250-100 1/4-20 x 1” FLAT ALLEN 1

7J250-001 1/4 SAE WASHER, PLATED 2
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1

5W001-040 12-10 GA FEMALE SLICE 2

©2002 Vortech Engineering, LLC

ix

All Rights Reserved, Intl. Copr. Secured

07FEB02 V2.0

P/N: 4FT020-010

(99-01SuperDuty(4FT V2.0))

1999-2001 Ford Super Duty 6.8L

w/Charge Cooler System

®

ENGINEERING, LLC

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

Part Number Description Quantity Part Number Description Quantity

008110 SMALL SILVER DIE CUT 2
008130 LICENSE PLATE FRAME 1
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 M6 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, UL1015 3'
7A250-050 1/4-20 x .50" SHCS 2
7A250-075 1/4-20X3/4 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 1

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, PIERBURG 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
4FT111-052 CRANK PULLEY ASSY 6.8 V-10 1

7K437-001 7/16 AN WASHER 3

4FT016-011 DAMPER V-10 MACH 1
4FT016-031 CRNK PULLEY 8 - RIB MACH 1
4FT017-010 SPACER, CRNK PLLY V-10 1
7C120-065 M12 x 1.5 x 65MM HXHD PLTD 1
7C100-040 M10 x 1.5 x 40MM SHCS PLTD 3
4FT017-011 SPACER, FAN V-10 1

2E228-370 V2SQ SUPERCHARGER S.D. 6.8L H.O. 1
4FT111-054 MNTG. BRKT. ASSY 1

4FM016-031 IDLER 8-RIB GROOVED 1
4FA016-171 DUST COVER 1
4FT017-070 SPACER, IDLER S.D. 1
7A437-250 7/16-14 x 2.5" HXHD PLTD 1
7F437-000 7/16-14 NUT NYLOCK 1
7J438-081 7/16 WASHER SAE PLTD 1
4FT110-044 MAIN BRKT ASSY, WELDED 1
4FT010-034 SUPPORT PLATE 1
7C100-085 M10 x 1.5 x 85MM HXHD PLTD 1
7C100-110 M10 x 1.5 x 110MM HXHD PLTD 2
7J010-002 M10 WASHER 3
7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 5
7K375-030 3/8 WASHER AN 5
4FM011-052 5.4 SPRING TENSIONER 1
7C010-045 M10 x 1.5 x 45MM HXHD PLTD 1
4FA016-170 IDLER 8-RIB SMOOTH 1
4FA016-171 DUST COVER 1
4FT017-060 SPACER, SPRING TENSIONER 1
7A375-400 3/8-16 x 4" HXHD PLTD 1
7F375-017 3/8-16 NUT NYLOCK 1
7K375-030 3/8 WASHER AN 2
7A250-075 1/4-20 x .75" SHCS PLTD 2
7J250-001 1/4 WASHER PLTD 2
4FT010-020 DAMPER BRKT. S.D. 1
4FM017-020 5.4 SPCR LONG 1
7C140-035 M14 x 2.0 x 35MM, HXHD PLTD 1
7J438-091 9/16" WASHER SAE PLTD 1
4FT010-050 BRKT, WIRNG HRNS S.D. 1
7A250-075 1/4-20 x .75" SHCS PLTD 2
7J250-001 1/4 WASHER PLTD 4
7F250-021 1/4-20 NUT NYLOCK 2
5W018-070 WIRE 22-18GA GREEN 6"
5W018-030 WIRE 22-18GA GRAY 6"
5W001-012 SOLDERLESS CONECTORS 22-18GA 4
7A375-178 3/8-16 x 1.75" HXHD PLTD GR8 3
7K375-030 3/8 WASHER AN 6
7F375-017 3/8-16 NUT NYLOCK 3
7C012-035 12MM x 1.75 x 35MM HXHD 3
7J012-092 12MM WASHER 3

4FT130-026 OIL FEED ASSY. S.D. 1

7U030-026 1/4" x 25" OIL FEED HOSE 25"
7P250-034 STREET TEE 1
7P250-082 1/4"NPT x -4 x 90° FITTING 1
7P525-067 CRIMP FERRULES 2
7P250-066 #4 SWIVEL x 1/4 HOSE BARB 2
7U100-055 6" TIE WRAPS 4
7P125-026 1/8 NPT x #4 x 90° FITTING 1

4FT011-032 CROWS FOOT, WATER PUMP 1
4FT011-012 CROWS FOOT, FORD V-10 1

Part No. 4FT218-030/038SQ

PARTS LIST

P/N: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

x

1999-2001 Ford Super Duty 6.8L

w/Charge Cooler System

®

Part No. 4FT218-030/038SQ

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 Quantity Part Number Description Quantity

4FT238-068 FMU ASSY S.D. 1

4FT145-020 FUEL LINE, FEMALE 7" 1
4FD145-010 FUEL LINE, MALE 17" 1
7U030-046 5/32" x 18" VACUUM LINE 18"
7P156-082 5/32" TEE 1
7U100-055 6" TIE WRAPS 2
6Z110-136 7:1 FMU 1

8F203-265 FUEL PUMP ASSY. 1

5W001-001 WIRE TAP 1
5W001-010 16-14GA FEMALE SLIDE 1
5W001-011 16-14 GA EYELETS 2
5W001-014 FUSE HOLDER 1
5W001-015 20A BLADE TYPE FUSE 1
5W001-017 12 GA LARGE RING TERMINAL 1
5W001-019 12 GA SOLDERLESS CONCTR 1
5W001-040 12 GA FEMALE SLIDE 2
5W001-042 12 GA 3/16" RING TERMINAL 2
7A250-100 1/4-20 x 1" CAP SCREW 1
7E010-050 #12 X 1/2" SHET METAL SCREW 1
7E010-075 #12 X 3/4" SHEET METAL SCREW 1
7F250-021 1/4-20 NUT NYLOCK 1
7J250-001 1/4 WASHER PLTD 2
7P312-003 5/16" FEMALE FUEL CONNECT 1
7P500-004 FTNG FUEL ADAPTER 1/2" 1
7R001-008 #8 HOSE CLAMPS 2
7R003-027 ADEL CLAMP 1
7R004-003 14.5 STEPLESS CLAMPS 2
7U030-050 12MM x 16" FUEL HOSE 1
7U031-018 5/16" X 11" HIGH PSI FUEL LINE 11"
7U100-044 4" TIE WRAPS 3
7U100-055 6" TIE WRAPS 4
8F001-002 155 INLINE FUEL PUMP 1
8F101-200 T-REX WIRING ASSY 1

4FT130-036 OIL DRAIN ASSY. S.D. 1

7P100-121 SEALING NUT 1
7P375-045 45° STREET ELBOW 1

7P375-017 3/8 NPT HOSE BEAD x 1/2 BEADED 1
7U030-036 1/2" OIL DRAIN HOSE x 1' 1
7R001-008 #8 HOSE CLAMPS 2

4FT112-050 AIR INLET ASSY. GEN II 1

4FT012-030 CAST AIR INLET TUBE 1
7S350-200 3.5" x 2" SLEEVE 1
7R002-056 HOSE CLAMPS #56 2
7R002-052 HOSE CLAMPS #52 2
7U035-001 3.5" FLEX HOSE x 15" 15"
8H040-050 AIR FILTER 1
4FT110-030 MAF BRKT ASSY GEN II 1
7P375-106 PCV VALVE 1
7P625-016 5/8" UNION 1
7U133-024 5/8" MOLDED ELBOW HOSE 1
7A250-075 1/4-20 x 3/4" SHCS 4
7F250-021 1/4-20 NYLOCK NUTS 4
7J250-001 1/4" WASHERS 8
008721 FINISHING PLUGS STEEL 2

4FT104-010 H.O. SUPPORT PARTS 1

7R002-016 HOSE CLAMPS #16 5
7R002-044 #44 HOSE CLAMP 1
7R002-048 #48 HOSE CLAMP 1
7R002-072 #72 HOSE CLAMPS 2
7S300-275 REDUCER Ø3.00 X Ø2.75 1
7S450-200 4 1/2 x 2 SLEEVE 1
7U030-046 5/32" VAC LINE X 25" 25"
8D001-001 BYPASS VALVE 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

©2002 Vortech Engineering, LLC

xi

All Rights Reserved, Intl. Copr. Secured

07FEB02 V2.0

P/N: 4FT020-010

(99-01SuperDuty(4FT V2.0))

P/N: 4FT020-010
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
07FEB02 V2.0

(99-01SuperDuty(4FT V2.0))

xii