Vortech Engineering Automobile Parts 4fc020 010 User Manual

For

d 5.0 and 5.8

onco/F-Series/Lightning

Super

char

Installation Instructions

ger System

’87-’96 5.8L F-Series T

’93-’95 5.8L Lightning T

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

’87-’96 5.0L F-Series T

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

ENGINEERING, INC.

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

Table Of Contents

FOREWORD........................................................................................................................... i

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

IMPORTANT NOTICES .......................................................................................................... iii

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

10.

11.

12.

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.

16.

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

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

P/N: 4FC020-010

13SEP00 V1.3 (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. Refer to page 5, item 8 of this manual.

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.

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

iii

^SC^PR^ECA^IAN^{L N}E^OTI^IG^CEN^COIT^NCI^EO^RN^NINS^GY^THS^ETEM

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 pre-

paid 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.

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

SPECIAL NOTICE CONCERNING THE

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

ofAutotronic 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 shallAutotronic Controls

Corporation 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

pre-paid with proof of purchase to:

Autotronic Controls Corporation

Customer Service Department

12120 Esther Lama

Suite #114

El Paso, Texas, 79936

(915) 855-7123 Technical

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.

P/N: 4FC020-010

13SEP00 V1.3 (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. Thisproductisintendedforuseonhealthy, wellmaintainedengines. Installationonaworn-

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.

Installationonnewvehicleswillnotharmoradverselyaffectthebreak-inperiodsolongasfactorybreak-

in 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. Alwayslistenforanysignofdetonation(pinging)anddiscontinueharduse(noboost)untilproblem

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

originalheatrangeplugsasspecifiedbythemanufacturerandresettimingtofactoryspecifications

(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

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

1987-1996 FORD 5.8 TRUCK

Part No. 4FC218-030SQ

PARTS LIST

ENGINEERING, INC.

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

2E228-030

2E128-030

2A036-287

8R101-001

SUPERCHARGER ASSEMBLY

V-2 SQ Supercharger

2.87” supercharger drive pulley

6 rib pulley retainer assembly

4FC238-068

6Z110-111

FMU (WITH LINES)

12:1 black fuel management unit

Male fuel line assembly

Female fuel line assembly

5/32” x 48” vacuum line

6” nylon tie wraps

4FC145-156

4FC146-166

4FC049-196

7U100-055

7E010-046

4FC111-021

4FC011-021

4FC010-034

7A375-100

7K375-040

MOUNTING BRACKET ASSEMBLY

Mounting bracket

#8 x 3/4” sheet metal screws

Mounting plate

3/8-16 x 1" bolts

3/8" AN washers

4FB101-002

8F001-002

7R003-008

7R003-024

7R001-004

7U100-055

5W001-011

5W001-010

5W118-021

5W118-034

5W001-002

7P312-003

7P156-082

7U129-012

7U100-066

5W001-012

8D002-001

5W001-015

5W001-014

7P125-105

7J010-001

7F010-032

7C011-075

7U131-024

7U132-050

7P500-004

FUEL PUMP ASSEMBLY

155 Inline fuel pump

1/2" adel clamp

4FC116-081

4FC016-081

7U313-124

7J312-000

7L312-000

7F312-021

4FC040-160

WATER PUMP PULLEY ASSEMBLY

Water pump pulley

5/16-24 x 2.5” studs

5/16" washers

1-1/2" adel clamp

#4 hose clamps

6” nylon tie wraps

16-14GA eyelets

5/16" lock washers

5/16-24 nuts

Water pump pilot

16-14GA female slides

10" 18GA black wire

156" 18GA red wire

Fuse tap

5/16” female fuel connector

5/32” tee

5/32" x 12” vacuum hose

11” nylon tie wrap

22GA red solderless connector

Fuel pressure switch

20A blade type fuse

Fuse holder

4FC112-010

4FC013-021

7S350-200

4FA012-012

4FC012-010

7R002-056

7R002-052

AIR INTAKE ASSEMBLY

Air filter cover

3-1/2” x 2” sleeve

90° intake elbow

3-1/2” x 20" flex hose

#56 hose clamps

#52 hose clamps

4FC112-020

4FC012-030

7S225-125

7S275-200

7R002-044

7R002-036

AIR DISCHARGE ASSEMBLY

Discharge duct

2-1/4” x 1-1/4” sleeves

2-3/4” x 2” sleeve

#44 hose clamps

#36 hose clamps

1/8” NPT to 5/32” barb

#10 washers

10-32 nuts

10/32” x 3/4” bolts

5/16” x 24” fuel hose

12mm x 30” fuel hose

Fuel fitting adaptor

4FC116-011

4FC016-011

4FC017-041

7A375-325

7J375-044

7L375-075

2A046-580

CRANK PULLEY ASSEMBLY

Crank pulley

Crank pulley spacer

3/8-16 x 3-1/4” bolts

3/8" SAE washers

3/8" lock washers

4060580 Goodyear belt

5A101-001

7P156-082

5A002-002

5A001-001

7U129-024

STAND ALONE ASSEMBLY

5/32” tee

EFI Ford wiring harness

Stand alone ignition retard

5/32” x 24” vacuum line

4FC130-026

4FC047-176

7P125-103

7P250-066

7P525-067

7P250-122

7P250-123

7P250-036

OIL FEED LINE ASSEMBLY

1/4” x 22" oil feed line

-4 x 45° 1/8” NPT male elbow

#4 swivel x 1/4” hose barb fittings

.500 crimp ferrules

4FE111-032

7J012-092

4FA011-032

4GF116-160

2A017-010

7C012-020

7C012-022

7G010-175

BELT TENSIONER ASSEMBLY

12mm washers

Tensioner plate

Idler ribbed pulley assembly

Idler pulley spacer

12mm 1.75 x 20mm bolts

12mm 1.75 x 22mm thin head bolt

12mm x 1.75 nut

AN917 1/4" pipe thread tee

1/4" NPT x 1-1/2” nipple

#4 flare to 1/4” NPT fitting

4FC130-036

4FC048-186

7P375-033

7P375-017

7R001-008

7P100-121

OIL DRAIN ASSEMBLY

1/2" x 16” oil drain line

3/8” NPT x 3/8” NPT street elbow

3/8” NPT x 1/2” straight hose barb

#8 hose clamps

Sealing nut

P/N: 4FC020-010

13SEP00 V1.3 (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

Part Number

Description

Quantity

4FC139-096

7U100-055

7U030-056

7U375-052

8H040-020

PCV BYPASS KIT

6" nylon tie wraps

3/8" x 40" PCV hose

3/8" vacuum cap

3/8" inline filter

2E228-130

2E128-030

2A036-287

8R101-001

SUPERCHARGER ASSEMBLY

V-2 SQ Supercharger

2.87” supercharger drive pulley

6 rib pulley retainer assembly

4FC111-021

4FC011-021

4FC010-034

7A375-100

7K375-040

MOUNTING BRACKET ASSEMBLY

Mounting bracket

4FC130-036

4FC048-186

7P375-033

7P375-017

7R001-008

OIL DRAIN ASSEMBLY

1/2" x 16” oil drain line

3/8” NPT x 3/8” NPT street elbow

3/8” NPT x 1/2” straight hose barb

#8 hose clamps

Mounting plate

3/8-16 x 1" bolts

3/8" AN washers

4FC112-015

4FA012-013

4FC012-010

4FC013-021

7P375-097

7R002-052

7R002-056

7S350-200

AIR INTAKE ASSEMBLY

90° intake elbow with boss

3-1/2” x 20" flex hose

Air filter cover

3/8" NPT x 3/8" barb

#52 hose clamps

4FC130-026

4FC047-176

7P125-103

7P250-066

7P525-067

7P250-122

7P250-123

7P250-036

OIL FEED LINE ASSEMBLY

1/4” x 22" oil feed line

-4 x 45° 1/8” NPT male elbow

#4 swivel x 1/4” hose barb fittings

.500 crimp ferrules

AN917 1/4" pipe thread tee

1/4" NPT x 1-1/2” nipple

#4 flare to 1/4” NPT fitting

#56 hose clamps

3-1/2” x 2” sleeve

4FC112-040

4FC012-040

4FC012-050

7P156-082

7P750-102

7R002-016

7R002-044

7R002-048

7S275-200

7S275-300

7S300-200

7U030-046

7U034-016

8D001-001

AIR DISCHARGE ASSEMBLY

Discharge tube A

Discharge tube B

5/32 tee

3/4 NPT x 1" 90° hose fitting

#16 hose clamps

#44 hose clamps

#48 hose clamps

2-3/4” x 2” sleeve

2-3/4” x 3” sleeve

3” x 2” sleeve

5A101-006

5A001-009

5A002-002

5W001-001

5W001-009

5W001-010

5W001-011

5W001-017

5W001-019

7E010-048

7P250-125

7U030-030

7U375-001

7U375-002

5W018-010

5W018-240

5W018-060

5W018-020

5W012-000

HI-6TR ASSEMBLY

Crane HI-6TR ignition system

EFI Ford wiring harness

Wire taps

16-14GA male slides

16-14GA female slides

16-14GA eyelets

Large ring terminals

12-10GA solderless connector

#10 x 3/4" sheet metal bolts

1/4" tee

5/32" x 24" vacuum line

1" x 3" heater hose

1" x 4-1/2" heater hose

Bypass valve

1/4" x 24" vacuum hose

36" velcro-hook

4FC238-068

6Z110-111

4FC145-156

4FC146-166

4FC049-196

7U100-055

7E010-046

FMU (WITH LINES)

12:1 black fuel management unit

Male fuel line assembly

Female fuel line assembly

5/32” x 48” vacuum line

6” nylon tie wraps

36" velcro-latch

18GA x 30" red wire

18GA x 30" white/yellow wire

18GA x 30" orange wire

18GA x 30" black wire

18GA x 24" red wire

#8 x 3/4” sheet metal screws

4FC116-081

4FC016-081

7U313-124

7J312-000

7L312-000

7F312-021

4FC040-160

WATER PUMP PULLEY ASSEMBLY

Water pump pulley

5/16-24 x 2.5” studs

5/16" washers

4FB101-002

8F001-002

7R003-008

7R003-024

7R001-004

7U100-055

5W001-011

5W001-010

5W118-021

5W118-034

5W001-002

7P312-003

7P156-082

7U129-012

7U100-066

5W001-012

8D002-001

5W001-015

5W001-014

7P125-105

7J010-001

7F010-032

7C011-075

7U131-024

7U132-030

7P500-004

FUEL PUMP ASSEMBLY

155 Inline fuel pump

1/2" adel clamp

1-1/2" adel clamp

#4 hose clamps

6” nylon tie wraps

16-14GA eyelets

5/16" lock washers

5/16-24 nuts

Water pump pilot

16-14GA female slides

10" 18GA black wire

156" 18GA red wire

Fuse tap

5/16” female fuel connector

5/32” tee

5/32" x 12” vacuum hose

11” nylon tie wrap

22GA red solderless connector

Fuel pressure switch

20A blade type fuse

Fuse holder

4FE111-032

7J012-092

4FA011-032

4GF116-160

2A017-010

7C012-020

7C012-022

7G010-175

BELT TENSIONER ASSEMBLY

12mm washers

Tensioner plate

Idler ribbed pulley assembly

Idler pulley spacer

12mm 1.75 x 20mm bolts

12mm 1.75 x 22mm thin head bolt

12mm x 1.75 nut

4FC116-011

4FC016-011

4FC017-041

7A375-325

7J375-044

7L375-075

2A046-580

CRANK PULLEY ASSEMBLY

Crank pulley

1/8” NPT to 5/32” barb

#10 washers

Crank pulley spacer

3/8-16 x 3-1/4” bolts

3/8" SAE washers

3/8" lock washers

4060580 Goodyear belt

10-32 nuts

10/32” x 3/4” bolts

5/16” x 24” fuel hose

12mm x 30” fuel hose

Fuel fitting adaptor

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

viii

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

Part Number

Description

Quantity

2E228-030

2E128-030

2A036-312

8R101-001

SUPERCHARGER ASSEMBLY

V-2 SQ Supercharger

3.125” supercharger drive pulley

6 rib pulley retainer assembly

4FC238-068

6Z110-111

4FC145-156

4FC146-166

4FC049-196

7U100-055

7E010-046

FMU (WITH LINES)

12:1 black fuel management unit

Male fuel line assembly

Female fuel line assembly

5/32” x 48” vacuum line

6” nylon tie wraps

4FC111-021

4FC011-021

4FC010-034

7A375-100

7K375-040

MOUNTING BRACKET ASSEMBLY

Mounting bracket

#8 x 3/4” sheet metal screws

Mounting plate

3/8-16 x 1" bolts

4FB101-002

8F001-002

7R003-008

7R003-024

7P500-004

7R001-004

7U100-055

5W001-011

5W001-010

5W118-021

5W118-034

5W001-002

7P312-003

7P156-082

7U129-012

7U100-066

5W001-012

8D002-001

5W001-015

5W001-014

7P125-105

7J010-001

7F010-032

7C011-075

7U131-024

7U132-050

FUEL PUMP ASSEMBLY

155 Inline fuel pump

1/2" adel clamp

3/8" AN washers

4FE112-010

4FA012-012

4FC012-010

4FC013-021

7P625-002

7R001-008

7R002-052

7R002-056

7S300-075

7S350-200

7U100-050

7U033-000

AIR INTAKE ASSEMBLY

90° intake elbow

1-1/2" adel clamp

Fuel fitting adaptor

#4 hose clamps

6” nylon tie wraps

16-14GA eyelets

3-1/2” x 20" flex hose

Air filter cover

5/8" hose barb

#8 Stainless hose clamps

#52 hose clamps

16-14GA female slides

10" 18GA black wire

156" 18GA red wire

Fuse tap

5/16” female fuel connector

5/32” tee

5/32" x 12” vacuum hose

11” nylon tie wrap

22GA red solderless connector

Fuel pressure switch

20A blade type fuse

Fuse holder

#56 hose clamps

3" x 3/4" orange sleeve

3-1/2” x 2” sleeve

5/8" grommet

5/8" x 40" PVC hose

4FC112-020

4FC012-030

7S225-125

7S275-200

7R002-044

7R002-036

AIR DISCHARGE ASSEMBLY

Discharge duct

2-1/4” x 1-1/4” sleeves

2-3/4” x 2” sleeve

#44 hose clamps

#36 hose clamps

1/8” NPT to 5/32” barb

#10 washers

10-32 nuts

4FC116-011

4FC016-011

4FC017-041

7A375-325

7J375-044

7L375-075

2A046-580

CRANK PULLEY ASSEMBLY

Crank pulley

10/32” x 3/4” bolts

5/16” x 24” fuel hose

12mm x 30” fuel hose

Crank pulley spacer

3/8-16 x 3-1/4” bolts

3/8" SAE washers

3/8" lock washers

4060580 Goodyear belt

5A101-001

7P156-082

5A002-002

5A001-001

7U129-024

STAND ALONE ASSEMBLY

5/32” tee

EFI Ford wiring harness

Stand alone ignition retard

5/32” x 24” vacuum line

4FC130-026

4FC047-176

7P125-103

7P250-066

7P525-067

7P250-122

7P250-123

7P250-036

OIL FEED LINE ASSEMBLY

1/4” x 22" oil feed line

-4 x 45° 1/8” NPT male elbow

#4 swivel x 1/4” hose barb fittings

.500 crimp ferrules

4FE111-032

7J012-092

4FA011-032

4GF116-160

2A017-010

7C012-020

7C012-022

7G010-175

BELT TENSIONER ASSEMBLY

12mm washers

Tensioner plate

Idler ribbed pulley assembly

Idler pulley spacer

12mm 1.75 x 20mm bolts

12mm 1.75 x 22mm thin head bolt

12mm x 1.75 nut

AN917 1/4" pipe thread tee

1/4" NPT x 1-1/2” nipple

#4 flare to 1/4” NPT fitting

4FC130-036

4FC048-186

7P375-033

7P375-017

7R001-008

7P100-121

OIL DRAIN ASSEMBLY

1/2" x 16” oil drain line

3/8” NPT x 3/8” NPT street elbow

3/8” NPT x 1/2” straight hose barb

#8 hose clamps

4FC116-081

4FC016-081

7U313-124

7J312-000

7L312-000

7F312-021

4FC040-160

WATER PUMP PULLEY ASSEMBLY

Water pump pulley

5/16-24 x 2.5” studs

5/16" washers

Sealing nut

4FC114-033

4FC014-010

7R002-024

RADIATOR HOSE ASSEMBLY

Stainless radiator pipe

#24 hose clamps

5/16" lock washers

5/16-24 nuts

Water pump pilot

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

1. COMPONENT REMOVAL

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. RemovetheA/Ccompressorfromthemount-

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

Teflontape. Applyonlymotoroil

to flare fittings. Never over-

tighten 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.

FRONT

Figure: 2-a

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

3. OIL DRAIN FITTING

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

usingadrillorchassispunch.Deburthehole

completely. Thoroughly clean the valve

cover.

LEFT

VALVE

COVER

FORWARD FROM

HOLE 4-1/2"

HOLE 4-3/4"

OIL

FILLER

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

UP 3/4"

FROM FLANGE

tighten.

E. Inserttheelbowfittingthroughtheholeinthe

valve cover so the hose fitting points for-

ward. 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.

FRONT OF ENGINE

Figure: 3-a

F. Reinstall the valve cover.

4. CRANKSHAFT PULLEY

FACTORY PULLEY

NEW ADDITIONAL PULLEY

A. Removethecrankshaftpulleyfromthe

SPACER

engine.

B. Place the Vortech provided crank pul-

ley spacer and crank pulley into the

stock pulley just removed. (SeeFigure

4-a.)

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.

3 BOLTS: 3/8-16 x 2-3/4”

Figure: 4-a

5. MAIN BRACKET INSTALLATION

NOTE: For5.0applications,thewaterpump

bolt/studmustbemodified.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.

A. Mount the Vortech main mounting bracket

to engine using the original fasteners.

B. Remount the power steering pump to the

new bracket using the original fasteners.

C. Reinstall the air conditioner compressor to

the new bracket using the original fasteners.

(See Figure 5-a.)

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.

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

5. MAIN BRACKET INSTALLATION, CONT'D.

D. Reinstall the power steering pump pulley.

Make sure that the pulley is properly placed

onthepumpshaftsothattheendoftheshaft

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.

5.0 and 5.8

Configuration

5.8 Lightning

Configuration

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

interferewiththemountingplate

when installed.

NOTE: OnLightningapplications,itwill

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

securewithfive3/8-16x1"boltsandANtype

washers provided in the kit.

NOTE: Thesuperchargerdischargehas

adifferentpositionforeitherthe

standard or Lightning appli-

cations (see Figure 6-a).

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

ofthehose. Thedrainhoseshouldberouted

so that it gradually flows downward with

minimal dips and no kinks.

CUT OUT

NOTCH

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

oilfeedfittingonthesuperchargerand"clock"

it so that it points to the 4:00-5:00 position

(lower right). Use Teflon paste.

LIGHTNING COIL BRACKET

F. Attachtheoilfeedlineandsecureawayfrom

all moving parts and the exhaust manifold

with tie wraps.

Figure: 6-b

P/N: 4FC020-010

13SEP00 V1.3 (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.)

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

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 over-

tighten these screws, torque to 6-8 ft/lbs.

D. Once proper alignment has been achieved,

slide the sleeves onto the plenum and se-

cure with the hose clamps.

Figure: 5-b - 5.8 Lightning

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

8. WATER PUMP PULLEY AND FAN ASSEMBLY

NOTE: On1993andlatermodelyears, itwillbe

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 pro-

vided.

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. Inthemiddleofthestraighthosesection

over the radiator fan, remove a 3" sec-

tion.

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

P/N: 4FC020-010

13SEP00 V1.3 (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-

fullyremovingthewhiteretainingtab. 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. Connectthefuelpumpoutlettothefilterinlet

with the 5/16" hose. Use the supplied Ford

fuel connector and hose clamp.

E. Attachthenegativepumpterminaltoaclean

ground fastener with the wire provided.

F. MounttheHobbsswitchwiththe11"tiewrap

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.

5/16”

HOSE

VORTECH FUEL PUMP

FUEL PUMP

GROUND (-)

HOBBS SWITCH

STOCK

FUEL FILTER

EXISTING

LINE TO

RAIL

ADAPTER

FITTING

EXISTING FEED LINE

FROM TANK

3/8” FUEL LINE

Figure: 10-a

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

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 regula-

tor near the fuel rail.

C. Snap the Vortech fuel line with the male

springlock connector into the regulator out-

let. Attach the other end to the Vortech fuel

management unit inlet. Route the line over

the brake booster and through the existing

clamps.

CONNECT TO MANIFOLD

VACUUM/PRESSURE

INLET

(FUEL LINE

FROM

STOCK

OUTLET

(FUEL FROM

HERE

REGULATOR)

RETURNS

TO TANK)

Figure: 11-a

D. Snap the second line with the female

springlockconnectorontothefuelreturnline

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.

BYPASS VALVE

(LIGHTNING ONLY)

MANIFOLD VACUUM TREE

FMU

NOTE: Make sure you have routed all

fuel lines away from all moving

parts, sharp edges, exhaust

pipesandmanifolds. Securethe

fuel lines with the tie wraps and

hose clamps provided.

TOP VIEW

Figure: 11-b

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

intake manifold fitting and secure (see Fig-

ures 11-a, 11-b, 11-c).

FUEL

MANAGEMENT

UNIT (FMU)

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

filterandelbowandsecurewithhoseclamps.

ENGINE

VORTECH

FUEL

PUMP

FUEL

PUMP

FUELTANK

Figure: 11-c

P/N: 4FC020-010

13SEP00 V1.3 (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 ele-

ment, 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

barbfittingintotheholepreviouslydrilled

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 se-

cure 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

filterandelbowandsecurewithhoseclamps.

IMPORTANT: On Lightning appli-

cations, it is necess-

arytoremovethetube

from the valve cover

to the throttle body.

1. Plug the breather tube at the throttle

body with the rubber cap provided.

2. Connecttheventtubeontheoilfillercap

to the fitting on the air box with the filter,

hose, and clamps provided.

3. If necessary, trim the hose and secure

with the tie wraps.

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

13. 5.8 LIGHTNING SUPPLEMENTAL INSTALLATION INSTRUCTIONS

FOR THE BYPASS VALVE

DISCHARGE TUBE

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. Placethehoses, asshown, onthevalveand

secure with the clamps provided.

D. Install the valve with the hoses connected,

betweentheinletelbowanddischargetube.

Secure hoses with the clamps.

BYPASS VALVE

E. Attach one end of the small sensor hose

onto the valve.

CONNECT TO MANIFOLD PRESSURE

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

bypass valve to the intake manifold vacuum

fitting. See Figure 11-b on page 7.

INLET ELBOW

G. Make sure everything is secure and that no

fuel lines or wires have been accidentally

moved into harm's way.

Figure: 13-a

14.1 IGNITION/BOOST CONTROL UNIT INSTALLATION

(NON-LIGHTNING TRUCKS ONLY)

A. The Ignition/Boost Control unit has been

prewiredforinstallationconvenience.Instal-

lation is a simple matter of disconnecting the

MANIFOLD

VACUUM

MSD

stock connector at the ignition coil and plug-

ging in the new adapter. Then plug the stock

connector into the adapter.

FMU

B. The nextstepistoprovideagoodgroundfor

the black wire and mounting the box in as

coolaplaceaspossibleunderthehood. The

box should be mounted with the aluminum

cover on the bottom.

Figure: 14-a

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

the FMU vacuum line and connect to the

Ignition/BoostControlUnit(seeFigure14-a).

D. Route the Ignition/Boost Control wires

through the firewall from the interior side.

Mounttheknobinaneasilyaccessibleplace.

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.

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

14.1 IGNITION/BOOST CONTROL UNIT INSTALLATION (NON-LIGHTNING

TRUCKS ONLY), CONT'D.

BOOST

RETARD

TO MANIFOLD

VACUUM

BOOST

RETARD

GROUND

CONNECTOR

BLACK

SUPERCHARGERS

Ignition/Boost

Control

MANUFACTURED FOR

VORTECH SUPERCHARGERS

MSD

MAGNETIC

PICKUP

CONNECTOR

(NOT USED)

IGNITION

COIL

WHITE

RED

WHITE

RED

ORANGE

BLACK

ORANGE

FROM

FACTORY

COIL

HARNESS

Figure: 14-b

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

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

HEAVY RED

TO BATTERY +

HEAVY BLACK

TO GROUND –

WIRE TAP

RED

WHITE

BLACK

ORANGE

RANE

CAPACITIVE DISCHARGE IGNITION

WITH AUTO-SEQUENCE REV LIMITER

HI-6R

C^cams

GREEN (TAPE UP)

*GREY MAGNETIC

TRIGGER HARNESS (TAPE UP)

CONNECT TO

COIL

SUPPLIED

MAP SENSOR

YELLOW (TAPE UP)

BLACK (GROUND)

3 WIRE HARNESS

RANE

ELECTRONICS

MANIFOLD

VACUUM

HI-6R

TIMING RETARD CONTROL

*NOTE: CABLE CONTAINS RED AND BLACK

LEADS. MAKE SURE LEADS DO NOT

CONTACT EACH OTHER AND SHORT UNIT

WHEN TAPING UP

Figure: 14A-a

P/N: 4FC020-010

13SEP00 V1.3 (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

justbeyondthepointofdetonation.Usethird

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.Itisrecommendedthat

instockstreetapplications,

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.

MAX. RETARD = 15°

10 psi at

1/2° per lb.

5 7 10

PSI BOOST

Figure: 15-a

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

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. Rechecktobesurethatnohoses,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

specificationsbeforecommencingtestdrive.

G. PLEASE TAKE SPECIAL NOTE: Operat-

ing the vehicle without ALL the subassem-

blies 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. ReadtheSTREETSUPERCHARGERSYS-

TEM OWNER'S MANUAL AND RETURN

THE WARRANTY REGISTRATION FORM

within thirty (30) days of purchasing your

supercharger system to qualify.

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

ENGINEERING, INC.

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

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

P/N: 4FC020-010

13SEP00 V1.3 (86-93 5.0 Lt Truck(4FC))

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