Ford Ford 4.6/5.4 2V - Manuals

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Manual Ford Ford 4.6/5.4 2V

Summary

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) Proper installation of this supercharger kit requires general automotive mechanicknowledge and experience. Please browse through each step of this instruction manualprior to ...

Page 3 - iii; Table Of Contents

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) iii Table Of Contents FOREWORD ..................................................................................................................................... ii TAB...

Page 4 - iv; DISCLAIMER; * Only applies to vehicles equipped with automatic transmissions.; NOTE: This listing is provided solely for informational purposes.

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) iv SUPERCHARGED F-150/F-250/EXPEDITION/NAVIGATOR DISCLAIMER Towing, racing performance driving, hard accelerations, and other heavy/severe duty drivingactivities place extra ...

Page 5 - factory ECM calibration.; IMPORTANT NOTES; to an improperly installed/mishandled ECM module or ECM.

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) v This kit requires ECM modification and the installation of a Vortech/Superchips ECMModule. The ECM must be sent directly to Vortech by the installing customer (the charg...

Page 6 - The engine must have stock compression ratio.; TOOL & SUPPLY REQUIREMENTS; Installation Instructions

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger SystemOwner's Manual which includes the Limited Warranty P...

Page 7 - vii; PARTS LIST

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) vii Part No. 4FM218-010S/018S PARTS LIST Part Number Description Quantity 8F203-265 FUEL PUMP ASSEMBLY 1 5W001-001 Wire Tap 1 5W001-011 16-14 Ga. Eyelets 2 7E010-050 #12 x...

Page 8 - viii

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) Part No. 4FM218-020/028S PARTS LIST Part Number Description Quantity 4FM112-040 AIR INLET ASSEMBLY 1 4FM010-050 MAF Bracket Assembly 1 8H040-045 3-3/4" Flanged Air Filter...

Page 9 - COMPONENT REMOVAL AND PREPARATION; Remove the passenger side front kick panel from

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 1 *4.6 MODELS ONLY A. Disconnect the negative battery cable. B. Remove the throttle body/throttle linkage cover. C. Detach the crankcase ventilation tube from the driver's...

Page 10 - DRIVER’S

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) A. Unplug the connector on the oil pressure sending unit. Remove the sending unit from the engine block. (Theunit is located on the left front side of the engine, justabove t...

Page 11 - OIL DRAIN; To provide a proper oil drain for the supercharger it is; OIL PAN; • Using a light amount of oil on the threads for lubrication,; x #4 fitting into the threaded; • Reassemble the oil filter base and bracket and secure

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 3 3. OIL DRAIN A. To provide a proper oil drain for the supercharger it is necessary to make a hole in the oil pan. The best wayto provide this hole is to punch the hole r...

Page 12 - FRONT VIEW; VIEW FROM PASSENGER SIDE; NOTE: This method of rolling over the lip of the

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 4 E. Thoroughly clean the threaded area. Apply a small amount of silicone sealer to the new threads. Applymore sealer to the 3/8" NPT x 1/2" inverted flare fittingand...

Page 13 - CRANKSHAFT PULLEY/SUPERCHARGER DRIVE PULLEY; Remove the rubber inspection plug on the left rear of; NOTE: This process can be done with the fan

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 5 4. CRANKSHAFT PULLEY/SUPERCHARGER DRIVE PULLEY A. Remove the rubber inspection plug on the left rear of the block to make the flexplate accessible. Using an18mm socket a...

Page 14 - FUEL PUMP; NOTE: Due to the various fuel tank configurations and

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 5. FUEL PUMP A. Release any pressure from the fuel tank by momentarily loos- ening the filler cap. B. Disconnect the line from the tank to the fuel filter by carefully removi...

Page 15 - FUEL PUMP RELAY; NOTE: Double check that all wires are con-; nected to their proper relay lug.

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 6. FUEL PUMP RELAY A. Remove the power distribution box from its mount- ing bracket. Remove the bottom cover and the sidepanel exposing the main power lugs, the bottom oft...

Page 16 - WIRE SUPPORT

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 7. WIRE PREPARATION (4.6 models only) A. To accommodate the installation of the supercharger and the relocation of the coil, it will be necessary tomodify the coil and cam tr...

Page 17 - NOTE: The use of blue Loctite is recommended

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) A. Attach the supplied power steering reservoir/coil bracket to the main mounting plate using the 1/4-20x 3/4” bolts, nuts and washers (see photo). B. Using the supplied 1...

Page 18 - NOTE: The most forward mounting boss; mended for all idler bolts.

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) A. To prepare the mounting location for the main mount- ing plate, remove the three 10mm factory stud/boltslocated on the driver side engine front cover. B. Reinstall the acc...

Page 19 - H. Install the supplied support strap between the back of; Attach the supplied power steering reservoir bracket; K. Extend the stock power steering return hose using

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 11 H. Install the supplied support strap between the back of the main mounting bracket and the boss on top of thethermostat housing. Secure both ends using the sup-plied 6...

Page 20 - EGR CONTROL MOUNTING AND MAIN MOUNTING PLATE SUPPORT

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 10. FUEL MANAGEMENT UNIT (FMU) A. Using a spring lock disconnect tool, disconnect the fuel return line at the fuel rail. B. Connect the FMU inlet hose to the fuel rail. Route...

Page 21 - FUEL MANAGEMENT UNIT

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 13 ENGINE FUEL FEED LINE FUEL RETURN LINE FUEL TANK FUEL MANAGEMENT UNIT (FMU) T-REX FILTER FACTORYSPRINGLOCKCONNECTOR VACUUM LINE FACTORYREGULATOR INLET OUTLET FACTORYQUI...

Page 22 - NOTE: The oil drain line must be routed in a

P/N: 4FM020-010© 2003 Vortech Engineering, LLCAll Rights Reserved. Intl. Copr. Secured20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 11. IDLE AIR CONTROL RESONATOR AND CRANKCASE VENT HOSE REROUTING 14 A. Attach the supplied 3/4” x 90 ° rubber elbow to the idle control motor near the throttle body. (See Fig...

Page 23 - M. Connect the oil drain hose down to the oil pan tube previ-

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 15 4.6L MODELS ONLY VORTECH TENSIONER IDLER TENSIONER AIR CONDITIONER HARMONIC BALANCER/ CRANK PULLEY POWER STEERING PUMP VORTECH SMOOTH IDLER PULLEY VORTECH RIBBED IDLER ...

Page 25 - MASS AIR FLOW SENSOR REMOVAL, MOUNTING AND ASSEMBLY; AIR TEMPERATURE

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 13. MASS AIR FLOW SENSOR REMOVAL, MOUNTING AND ASSEMBLY 17 A. Separate the mass air flow sensor from the air inlet canister. B. Assemble the mass air sensor and the mass a...

Page 27 - PLEASE TAKE SPECIAL NOTE: Operating the vehicle; ceived back from Vortech with the ECM mod-

P/N: 4FM020-010 © 2003 Vortech Engineering, LLC All Rights Reserved. Intl. Copr. Secured 20OCT03 v3.1 4.6/5.4Exped/Nav(4FM v3.1) 16. FINAL CHECK A. Reconnect the battery. B. If your vehicle has gone over 20,000 miles since its last spark plug change, you will need to change thespark plugs now before...

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