Maxflow® Power Cooler® Installation Instructions 1997-2003 Ford 5.4 F-150/Expedition P/N: 8N301-300/308 VORTECH ® ENGINEERING, LLC 1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • 805 247-0226 FAX: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST PN: 8N020-130 v1.
FOREWORD Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please read 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. © 2005 VORTECH ENGINEERING, LLC All rights reserved.
TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v PARTS LIST - 1997-2003 5.4L Ford F-150/Expedition . . . . . . . .
NOTICES (Read before installation is started) Included in this kit is a smaller than originally supplied supercharger pulley. This new pulley is recommended to achieve the best performance results. Removal of the factory sealed pulley will reduce the supercharger warranty from three years to one year unless the supercharger unit (with the original pulley still attached) and new pulley are sent into Vortech for removal, installation and re-sealing.
Vortech Maxflow Power Cooler© Installation Instructions 1997-2003 5.4L F-150/Expedition Congratulations on selecting the best performing and most efficient aftercooler today... the Vortech Maxflow Power Cooler! Before beginning this installation, please read through this entire instruction booklet The Vortech Maxflow Power Cooler system was designed as a street/strip oriented aftercooler, specifically for use on 1997-2003 5.4L F-150/Expedition vehicles equipped with a Vortech supercharger.
1997-2003 Ford F-150/Expedition 5.4L Charge Cooler Upgrade System Part No.
1. Preparation and Removal A. Disconnect and remove the negative battery terminal. B. Remove the supercharger discharge tube and bypass valve assembly. C. Remove and set aside the supercharger inlet elbow and flex tube. D. Remove the supercharger drive belt and supercharger. Set aside. NOTE: E. Temporarily cap oil feed and oil drain to protect your engine from foreign particles. Remove the FMU, disconnect the lines noting their position for re-assembly.
2. Supercharger Reclocking A. Loosen and remove the six 1/4-20 cap screws and retaining plates that hold the compressor housing to the gearcase. B. Carefully rotate the compressor housing to the specified location as shown. (See Fig. 2-a.) NOTE: If the compressor housing does not rotate freely relative to the gearcase, DO NOT FORCE IT. SERIOUS SUPERCHARGER DAMAGE MAY OCCUR. The machined mating surfaces are designed to prevent pressurized air from escaping and have minimal tolerances.
3. Discharge Installation A. Locate the supplied Ø2.75" straight discharge duct. Using a Ø2.75" x 2.0" silicone sleeve connect the end closest to the bypass bung to the discharge of the supercharger. Secure this end with #44 hose clamps. At this time, snug the hose clamps to leave the ability to fine tune the discharge assembly. (See Fig. 3-a.) B. Locate the Ø2.75 x 90° discharge tube. Using a Ø3.0" to 2.75" reducer and silicone sleeve, connect the lightly curved end to the throttle body.
4. Water Reservoir/Pump Installation A. Locate the front bumper/fender support brace from underneath the front passenger’s side fender well. (See Fig. 4-a.) B. Remove the two screws securing the brace, then remove the brace. C. Using an adel clamp mount the supplied water pump to the triangle water tank. (See Fig. 4-b.) D. Drill through the two 1/2"NPT ports in the water reservoir if necessary. Be careful not to contact the threads. Blow out any debris from inside the tank.
5. Water Cooler Installation A. If not already removed, take off the plastic cover over the radiator. This will allow access to the area behind the grill and in front of the radiator. B. Locate the supplied Setrab cooler and Lshaped brackets. Attach the brackets to the top of the tabs on the Setrab cooler. (See Fig. 5-a.) C. Position the cooler behind the grill with the L-shaped tabs pointing upward.
P/N: 8N020-130 © 2005 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured. 19SEP05 v1.0 97-03F150PwrClr(8N020-130v1.0) 6 WATER PUMP 1/2"NPT x 3/4" BARB x 90° WATER RESERVOIR 3/4" HOSE MENDER 1/2"NPT x 3/4" BARB x 90° Fig.
6. Water Pump Wiring A. Locate the supplied 14GA red wire and wire loom. Route the wire from the water pump over to the power distribution box on the driver’s side. Use the supplied loom and tie-wraps to secure the wire. B. Use the supplied slide connectors to attach the red wire to the (blue/green) positive wire on the water pump. C. Connect the brown wire to a good ground with the supplied black wire, ring terminal and slide connectors. D.
7. Fuel Management Unit Recalibration A. Remove the six allen-head screws on top of the fuel management unit (FMU). WARNING: B. C. D. E. Do not remove the four screws holding the valve body. Once taken apart, the valve would have to be replaced. Remove the diaphram and 7:1 disk (2.038" O.D.) and ring from inside of the FMU. Install the replacement 8:1 ring (with notched part facing down) around the four screws inside the FMU. (The 8:1 components are larger in diameter that their 7:1 counterparts.
8. Reassembly and Final Check WARNING: Custon ECM calibration by a competent tuner is suggested before operation at wide open throttle. A. Reconnect the battery. B. Check all fittings, nuts, bolts and clamps for tightness. Pay particular attention to the oil and fuel lines, especially around moving parts, sharp edges and exhaust headers. Make sure all wires and lines are properly secured with clamps or tie-wraps. C.
VORTECH ® ENGINEERING, LLC 1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • 805 247-0226 FAX: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST PN: 8N020-130 v1.
