Ford 7.5L Light Truck Supercharger System

Transcription

1 Ford 7.5L Light Truck Supercharger System Installation Instructions for F-Series Truck 50 State Smog Legal per CARB EO #D ENGINEERING, LLC 1650 PACIFIC AVENUE CHANNEL ISLANDS, CA (805) FAX (805) M-F 8:00 AM - 4:30 PM PST

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

3 Table Of Contents FOREWORD... ii TABLE OF CONTENTS... iii NOTICE... iv SPECIAL NOTICE CONCERNING THE MSD IGNITION... v TOOL & SUPPLY REQUIREMENTS... vi PARTS LIST... vii 1. AIR DUCT REMOVAL ALTERNATOR AND HOIST BRACKET REMOVAL THERMOSTAT HOUSING REPLACEMENT OIL RETURN FITTING SUPERCHARGER BRACKET OIL FEED LINE SUPERCHARGER INSTALLATION DRIVE BELT FUEL PUMP INLET/DISCHARGE DUCTING FUEL MANAGEMENT UNIT (FMU) IGNITION/BOOST CONTROL INSTALLATION IGNITION/BOOST CONTROL UNIT OPERATION FINAL CHECK... 9 iii

4 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. iv

5 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 of Autotronic Controls Corporation and/or Vortech Engineering, LLC. 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, LLC, 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: Autotronic Controls Corporation Customer Service Department Esther Lama Suite #114 El Paso, Texas, Phone: (915) Fax: (915) 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 directly at (805) , M-F 8AM - 4:30PM (PST). v

6 Installation Instructions for Part No. 4FB SQ L F-Series Truck - 50 State Smog Legal per CARB EO #D Congratulations on selecting the 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 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. 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 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 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 at least every 50,000 miles. TOOL & SUPPLY REQUIREMENTS 3/8" socket and drive set Flat #2 screw driver Large screw driver or pry bar Adjustable wrench 3/8" open end wrench 7/16" open end wrench 1/2" open end wrench 9/16" open end wrench 9/16" drill bit 3/32" drill bit Drill motor 3/8" NPT tap and handle 1-1/16" six point socket and drive set Ford Snaplock fuel fitting disconnect tool Teflon sealing tape or paste If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need: Spark plug socket NEW spark plugs vi

7 ENGINEERING, LLC FORD 7.5L TRUCK Part No. 4FB SQ 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 2E V-2 SUPERCHARGER ASSEMBLY 1 4FB AIR INTAKE ASSEMBLY 1 4FB Intake tube 1 7S /2 x 2 sleeve 1 7R #56 hose clamps 2 4FB '96 inlet supplement 1 4FB AIR DISCHARGE ASSEMBLY 1 4FB Discharge tube 1 7S /4 x 2 sleeves 2 7S /4 x 2 sleeve 1 7R #8 hose clamps 2 7P /2 NPT x 3/4 hose fitting 1 7R #36 hose clamps 4 7R #44 hose clamps 2 4FB THERMOSTAT HOUSING 1 4FB OIL FEED LINE ASSEMBLY 1 7U /4 x 44" oil feed hose 1 7P crimp ferrules 2 7P #4 swivel x 1/4 hose barb fittings 2 7P #4 flare to 1/4 NPT fitting 1 7P /8 NPT straight fitting 1 7P /4" NPT x 1-1/2" nipple 1 7P AN917 1/4" pipe thread tee 1 4FB OIL DRAIN ASSEMBLY 1 7U /2 X 14 oil drain hose 1 7P /8 NPT x 1/2 straight hose barb 1 7R #8 hose clamps 2 7P /8 NPT x 3/8 NPT street elbow 1 4FB FMU (WITH LINES) 1 6Z :1 black fuel management unit 1 4FB Male fuel line assembly 1 4FB Female fuel line assembly 1 7U /32 x 48 vacuum line 1 7P /32 tee 1 7E #8 X 3/4 sheet metal screws 2 Part Number Description Quantity 4FB MOUNTING BRACKET ASSEMBLY 1 4FB Mounting bracket 1 4FB Alternator bracket, lower spacer 1 4FB Mounting bracket brace 1 7A /8-16 x 1 bolts 5 7A /8-16 x 1-3/4 bolts 2 7J /8 SAE washers 11 7L /8 lock washer 1 7F /8-16 nuts 3 7A /8-16 x 2 bolts 4 7A /8-16 x 3-1/4" bolt 1 7A /8-16 X 1-1/2 bolt 1 7K /8" AN washers 5 4FB Alternator plate 1 5A STAND ALONE ASSEMBLY 1 7P /32 tee 1 5A EFI Ford wiring harness 1 5A Stand alone ignition retard 1 7U /32 x 24 vacuum line 1 4FB BELT/PULLEY ASSEMBLY 1 2A K Gates belt 1 4FA Smooth pulley tensioner 1 7J /16 USS washer 1 4FB FUEL PUMP ASSEMBLY 1 8F Inline fuel pump 1 7R /2 adel clamp 1 7R /2 adel clamp 1 7P Fuel fitting adaptor 1 7R #4 hose clamps 5 7U nylon tie wraps 6 5W GA eyelets 3 5W GA female slides 3 5W " 18GA black wire 1 5W " 18GA red wire 1 5W Fuse tap 1 7P /16 female fuel connector 1 7P /32 tee 1 7U /32 x 12 vacuum hose 1 7U nylon tie wrap 1 5W GA red solderless connector 1 8D Fuel pressure switch 1 5W A blade type fuse 1 5W Fuse holder 1 7P /8 NPT to 5/32 barb 1 7J #10 washers 6 7F nuts 3 7C /32 x 3/4 bolts 3 7U /16 x 24 fuel hose 1 7U mm x 30 fuel hose 1 vii

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9 1. AIR DUCT REMOVAL A. Remove rubber air ducts (2) between the throttle body and plastic air resonator. B. Remove the rubber molded air bypass tube between the idle air bypass valve and the air resonator and set aside. C. Remove the plastic resonator. 2. ALTERNATOR AND HOIST BRACKET REMOVAL A. Remove the stock alternator adjusting bracket, alternator pivot bolt and alternator belt. B. Remove all bolts holding the main alternator/ smog pump mounting bracket and move away to gain clearance to the front of the cylinder head and valve cover. Remove the engine hoisting bracket. C. Remount the main alternator/smog pump bracket and accessories with the original hardware. 3. THERMOSTAT HOUSING REPLACEMENT A. Drain approximately one gallon of coolant from the radiator. B. Remove the radiator hose from the thermostat housing. C. Remove the thermostat housing, clean the gasket area and replace with the Vortech housing and gasket. D. Plug the 3/8" NPT holes with the supplied plugs. 4. OIL RETURN FITTING A. Remove the passenger side valve cover. NOTE: It is necessary to unfasten the brackets holding the air tubes running from the smog pump over the valve cover so that they may be pushed aside. B. Drill a 9/16" hole in the front of the valve cover. Make sure that the hole is drilled in the flat area on the end of the valve cover. (See Fig. 4-a.) On some later model trucks, the valve covers are slightly different and may require different placement of the drain hole. C. Tap the 9/16" hole using a 3/8" NPT pipe tap. D. Install the supplied 90 elbow and hose fitting into the valve cover. The fittings should run almost horizontally pointing inward as shown in Fig. 6-b on page 2. E. Thoroughly clean the valve cover and gasket of any chips and reinstall the valve cover Fig. 4-a 1

10 5. SUPERCHARGER BRACKET A. Install the supercharger mounting bracket to the top two water pump bosses using the provided bolts. Loosely fit the bolts at this time. NOTE: See Fig. 5-a on page 3 for fastener locations. B. Install the alternator bracket to the bosses on the supercharger bracket with the bolts provided. Place the 1.50" spacer between the bracket and engine in the lowest hole and loosely secure it. C. Thread the adjuster bolt into the alternator and pull the alternator all the way up in the adjusting slot and secure it there temporarily by lightly tightening the bolt. Now secure all of the bolts in the supercharger and alternator brackets. Loosen the alternator and let it rest in the fully retracted position. D. Install the mounting bracket brace between the upper left-hand hole (driver s side) on the supercharger mounting bracket and the front intake manifold stud. Tighten bolts and nuts securely. 6. OIL FEED LINE A. Using a 1-1/16" socket (6 point), remove the oil pressure sender from the rear of the intake manifold. B. Thread the oil pressure sender into the end of the provided brass TEE fitting. Thread the 1/4" NPT nipple into the opposite end of the TEE. Screw the 1/4" NPT x #4 flare fitting into the remaining branch. (See Figs. 6-a, 6-b.) NOTE: All pipe threads require sealing tape or paste. However, flared fittings should be lightly oiled only. C. Screw the brass TEE assembly into the pressure sender hole in the block. The fitting should point towards the right side front tire (approximately nine o clock when viewed from above). TEE FITTING OIL DRAIN LINE OIL FEED LINE OIL PRESSURE SENDER Fig. 6-b Fig. 6-a 2

11 FASTENER SIZE AND LOCATION NOTE: Start and snug all fasteners before tightening. Recommended tightening torque: 24 ft/lbs. 3/8-16 x 1 3/4" 3/8-16 x 2" VORTECH 3/8-16 x 1" 4 PLACES SUPERCHARGER MOUNTING BRACKET 3/8-16 x 2" 3 PLACES 3/8-16 x 1 3/4" 3/8-16 x 1 1/2" ALTERNATOR ADJUSTING BRACKET PLACE TUBE SPACER UNDER BRACKET 3/8-16 x 3 1/4" Fig. 5-a 3

12 7. SUPERCHARGER INSTALLATION NOTE: It is necessary to remove the oil feed fitting in order to place the supercharger into the bracket. A. Fasten the oil drain line (1/2" I.D.) to the oil drain fitting on the supercharger and secure with the #8 clamp. NOTE: Position the clamp so the screw housing will not interfere with the mounting bracket. B. Install the supercharger to the bracket, taking care to route the drain hose towards the valve cover fitting. Secure the supercharger using the 3/8" bolts and AN washers provided. (See Fig. 5-a on next page.) Connect the drain line to the fitting on the valve cover. Make sure there are no crimps in the oil drain line and that it is routed steadily downward. NOTE: The oil drain hose may require slight trimming for proper fit. C. Connect the oil feed line (1/4" oil hose) from the newly installed brass TEE (below the oil pressure sender) to the oil spray fitting located on the side of the supercharger. Route the line on top of the intake manifold next to the (passenger s side) valve cover. Tighten fittings and lines securely. 8. DRIVE BELT A. Install the plastic idler pulley to the lower center boss on the supercharger with the 12 mm bolt. Be sure to place the thick washer/spacer between the pulley mount and supercharger. Secure the bolt. B. Route the supercharger drive belt over the front crankshaft pulley around the smog pump and alternator and the supercharger drive pulley. (See Fig. 8-a.) C. Tension the belt by adjusting the alternator position. Tighten the alternator pivot bolt and tensioning bolt securely. ALTERNATOR SMOG PUMP S/C IDLER WATER PUMP IDLER A/C PWR. STR. PUMP CRANK SUPERCHARGER BELT ROUTING Fig. 8-a 4

13 9. 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 carefully removing the white retaining tab. Attach the line to the adapter fitting. (See Fig. 9-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 the switch to the 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 STOCK FUEL FILTER GROUND (-) HOBBS SWITCH EXISTING LINE TO RAIL EXISTING FEED LINE FROM TANK ADAPTER FITTING 3/8 FUEL LINE Fig. 9-a 5

14 10. INLET/DISCHARGE DUCTING A. Connect the Y shaped plastic discharge tube between the stock throttle body and the discharge side of the supercharger using the sleeves and clamps provided. B. Modify the stock air bypass hose per diagram. (See Fig. 10-a.) C. Install the modified hose between the fitting on the discharge tube and stock fitting below the throttle body and secure with stock clamps. D. Connect the intake plenum to the inlet on the supercharger using the sleeve and clamp provided. (See Fig. 10-b.) E. Connect the stock rubber air cleaner tubes to the two openings on the intake plenum using the stock clamps. CUT TO 5-1/4" Fig. 10-a IMPORTANT: If the kit is being fitted to a 1996 or 1997 model, follow steps 1-5 below: 1. Remove the air filter cover/maf assembly. Drill a 7/8" hole into the rear portion of the cover (the side facing the brakemaster 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 breather to the air filter cover. Trim the hose length and secure with #8 clamps. 4) Slide the orange sleeve onto the MAF housing outlet. 5) Install the 3-1/2" flex hose between the MAF sensor and the supercharger air inlet. Fig. 10-b 6

15 11. FUEL MANAGEMENT UNIT A. Install the fuel management unit (FMU) on the firewall outward from the brake booster and below the hood hinge. Make sure to leave clearance for the hinge. B. Use a snaplock fitting tool to disconnect the fuel return line from the fuel rail and snap in the FMU inlet line. The inlet line runs to the outward fitting, not the center fitting. (See Fig. 11-a.) C. Connect the FMU outlet line to the return line. D. Secure both lines away from the exhaust header and pipe and away from all moving parts. Check that all fittings are secure. E. Connect the 5/32" vacuum hose between the FMU and the vacuum tree located on the front portion of the intake manifold. (See Fig. 11-b.) VACUUM TREE OUTLET (FUEL FROM HERE RETURNS TO TANK) INLET (FUEL LINE FROM STOCK REGULATOR) Fig. 11-b FUEL MANAGEMENT UNIT (FMU) MANIFOLD VACUUM ENGINE FUEL FEED LINE VORTECH FUEL PUMP FUEL RETURN LINE FUEL TANK FUEL PUMP Fig. 11-a 7

16 12. IGNITION/BOOST CONTROL INSTALLATION 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. (See Fig. 12-a.) 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. Connect the vent to manifold pressure by splicing into the FMU manifold pressure line with the supplied 5/32" hose and TEE. 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. BOOST RETARD 1 2 TO MANIFOLD VACUUM BOOST RETARD CONNECTOR 0 3 GROUND BLACK SUPERCHARGERS Ignition/Boost Control MANUFACTURED FOR VORTECH SUPERCHARGERS BY MSD IGNITION COIL MAGNETIC PICKUP CONNECTOR (NOT USED) WHITE RED ORANGE BLACK WHITE RED ORANGE FROM FACTORY COIL HARNESS Fig. 12-a 8

17 13. 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 of ignition retard to 3 of ignition retard for each pound of boost. (See Fig. 13-a.) C. The maximum amount of retard that is available is 15 total. D. Using the 1 per pound position as a starting point, 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. DEGREES OF RETARD 15 Example of Ignition Retard vs. Boost: 5 psi at 3 per lb. 7 psi at 2 per lb MAX. RETARD = psi at 1/2 per lb. CAUTION: It is extremely important that the boost retard never be turned to 0. It is recommended that in stock street applications, the knob be at no less than 1 /lb PSI BOOST Fig. 13-a WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check. 14. 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 filled with 92 octane or higher fuel before commencing test drive. 9

18 14. FINAL CHECK, cont'd. 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: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAIL- URE OF MAJOR COMPONENTS. H. Test drive the vehicle. I. The supercharger drive belt stretches initially and will require adjustment between 250 and 400 miles. J. Read the STREET SUPERCHARGER SYS- TEM OWNER'S MANUAL AND WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify. ENGINEERING, LLC 1650 PACIFIC AVENUE CHANNEL ISLANDS, CA (805) FAX (805) M-F 8:00 AM - 4:30 PM PST 10