Ford - Ranger - Workshop Manual - 1990 - 1994

F Exploord 4.0L Supe rer/R Insta rcharger anger llat Sy stem ion In struc tions FORD EXP 50 STFORD RA LORER 19 NG ATE S 9 MOG ER 1990 1-1994 MO -1 LEGA D L AS 994 MODE EL YEAR PER C S L ARB YEARS EO #D -21317 ® 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 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 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. © 2001 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 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) ii Table Of Contents FOREWORD ...................................................................................................................... ii TABLE OF CONTENTS ..................................................................................................... iii TOOL & SUPPLY REQUIREMENTS.................................................................................. iv NOTICE .............................................................................................................................. v PARTS LIST ....................................................................................................................... vi 1. PREPARATION/COMPONENT REMOVAL ............................................................ 1 2. OIL FEED LINE INSTALLATION ............................................................................ 1 3. OIL DRAIN FITTING ............................................................................................... 2 4. MOUNTING BRACKET INSTALLATION ................................................................ 4 5. FMU INSTALLATION .............................................................................................. 5 6. FUEL PUMP ........................................................................................................... 6 7. SUPERCHARGER INSTALLATION ....................................................................... 7 8. SUPERCHARGER DRIVE BELT ........................................................................... 7 9. AIR INLET DUCT ................................................................................................... 8 10. SUPERCHARGER DISCHARGE DUCT ................................................................ 9 11. FINAL REASSEMBLY & CHECK ........................................................................... 11 iii P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) FORD 1991-1994 4.0L EXPLORER/RANGER Installation Instructions Also applicable for the 1990-94 Mazda Navajo and 1994 Mazda B4000 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® V-2® Supercharger! NOTE: This supercharger kit is designed to fit on Ford Explorer/Mazda Navajo vehicles. This kit, with the addition of the Ranger Supplement assembly part number 4FD248-050, may be installed on 1990-1994 Ford Ranger and 1994 Mazda B4000 vehicles. 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 every 3,000 miles or less. 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 every 50,000 miles or earlier. TOOL & SUPPLY REQUIREMENTS • Factory Repair Manual • 3/8" socket and drive set: SAE & metric • Flat #2 screwdriver • Phillips #2 screwdriver • Large screwdriver or pry bar • Adjustable wrench • Open end wrenches: 3/8", 7/16", 9/16", 5/8", 3/4", 7/8 • Ford style Snap Lock fuel disconnect tool • 3/32" drill bit • Drill motor • Center punch • 11/16" Greenlee™ Punch • Silicone sealer Note: If your vehicle has in excess of 10,000 miles since its last spark plug change, then you may need: • Spark plug socket • 6 new OE heat range spark plugs P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) iv 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. v P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 1991-1994 EXPLORER/RANGER Part No. 4FD218-050SQ ® PARTS LIST 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 2E228-020 V-2 SUPERCHARGER ASSEMBLY 1 4FD111-021 4FD011-021 4FD110-043 4FD010-063 4FD015-136 7U250-020 7A375-124 7A375-100 7A375-075 7F375-016 7L312-000 7A375-325 7C080-050 7C010-035 7L375-075 7K375-040 4FD010-034 MOUNTING BRACKET ASSEMBLY Mounting bracket Welded bracket assembly Bracket C Support brace 11mm dowels 3/8-16 x 1-1/4" bolts 3/8-16 x 1" bolts 3/8-16 x 3/4" bolts 3/8-16 nuts 5/16 - split (lock) washers 3/8-16 x 3-1/4" bolts 8mm x 1.5 x 150 bolts M10-1.5 x 35mm bolt 3/8" lock washers 3/8" AN flat washers Mounting plate 1 1 1 1 1 2 4 5 9 3 4 1 4 1 3 13 1 4FD130-026 7U030-016 7P125-103 7P250-066 7P525-067 7P250-082 7P250-034 OIL FEED ASSEMBLY 1/4" oil feed x 23" -4 x 45° 1/8" NPT male elbow #4 swivel x 1/4" hoses, barb fit .500 crimp ferrules 1/4" NPT x -4 90° fitting 1/4" NPT x 1/4" NPT straight tee 1 1 1 2 2 1 1 4FD130-036 7P375-042 7P500-020 7P500-002 7P375-017 7P375-045 7P100-121 7R001-008 7U030-036 OIL DRAIN ASSEMBLY Male connector, inverted flair Tube nut, inverted flair 1/2" x 8" aluminum tube 3/8" NPT x 1/2" straight hose barb 3/8" NPT 45° street elbow Sealing nut #8 stainless hose clamps 1/2" x 5" oil drain hose 1 1 1 1 1 1 1 2 1 4FD112-010 4FD012-010 4FD012-020 4FD012-030 7R005-001 7S300-000 7R002-052 7S300-300 7S300-200 4FD050-010 4FD015-020 4FD015-010 7F250-040 7A250-175 7R002-048 7C060-010 7F006-093 7C080-023 7R002-044 7S275-200 4FD012-040 4FD012-050 4FD012-060 7S250-200 7R002-040 AIR PASSAGE ASSEMBLY Inlet duct A Intake tube A Intake tube B 208-91 3.75" T-bone clamp 3" 90° rubber elbow #52 hose clamps 3" x 3" sleeve 3" x 2" sleeves Air plenum Dual pipe bracket, adjustable Dual pipe bracket, fixed 1/4-20 nut plates, clip on 1/4-20 x 1-3/4" bolts #48 hose clamps 6mm x 1.0 x 16 flat allen 6mm nylock nut 8mm x 1.25 x 20 flat allen #44 hose clamps 2-3/4" x 2" sleeves Discharge tube A Discharge tube B Discharge tube C 2-1/2" x 2" sleeves #40 stainless hose clamps 1 1 1 1 1 1 2 1 2 1 1 1 2 2 6 1 1 1 4 2 1 1 1 3 6 2A046-103 BELT 1 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) vi 4FD238-068 FUEL MANAGEMENT UNIT (WITH LINES) 6Z110-111 12:1 black fuel management unit 4FD145-156 Fuel line assembly, male 4FD146-166 Fuel line assembly, female 7U030-046 5/32" x 32" vacuum line 7U100-055 6" nylon tie wraps 7E010-046 #8 x 3/4" sheet metal screws 1 1 1 1 1 7 2 4FD113-010 7U400-001 7P250-126 7P250-125 7U030-030 CHECK VALVE ASSEMBLY One-way valve 1/4" restrictor 1/4" tee 1/4" x 12" vacuum line 1 1 1 1 1 4FD101-002 8F001-002 7R003-024 7R001-004 7P500-014 7P312-003 7U100-055 5W001-011 5W001-010 5W001-002 5W018-021 7J010-001 7F010-032 5W018-036 7U031-018 7U030-010 7C011-075 FUEL PUMP ASSEMBLY 155 inline fuel pump 1-1/2" adel clamp #4 hose clamps Ford fuel fitting adapter 5/16" female fuel connector 6" nylon tie wraps 16-14GA eyelet 16-14GA female slides, insulated Fuse tap 18GA standard black wire #10 flat washers 10-32 nylock nut 18GA standard red wire 5/16" x 20" fuel hose 12mm x 20" fuel hose 10/32" x 3/4" bolt 1 1 1 5 1 1 8 1 3 1 1 2 1 1 1 1 1 1. PREPARATION/COMPONENT REMOVAL A. Disconnect the battery. B. Remove the air intake duct and valve cover breather hose. C. Remove the accessory drive belt. D. Rotate the vacuum reservoir located on top of the air conditioning condenser 180° (see Fig. 1-a), rerouting the vacuum line attached to the mounting tab. E. Remove the air conditioning compressor, but do not break open any lines. Disconnect the air conditioning line bracket located in front of the water pump. Remove the air conditioning clutch electrical connector. Temporarily secure the compressor on top of the radiator shroud to provide work area. Fig. 1-a 2. OIL FEED LINE INSTALLATION A. Remove the oil pressure sender (located near the power steering pump). B. Thread the 1/4" NPT street TEE into the oil pressure sender extension in the block. Position the tee so that the branch portion faces forward. C. Thread the 1/4" NPT x #4 flare 90° fitting into the upper branch so that the flare end points up toward the brake master cylinder. D. Thread the original pressure sender into the center branch and reconnect sender wire. NOTE: Keep all oil fittings and hoses absolutely clean. Use Teflon paste SPARINGLY ON THE MALE PIPE THREADS ONLY. NEVER use Teflon tape. Apply ONLY MOTOR OIL TO FLARE FITTINGS. NEVER OVERTIGHTEN FITTINGS. THREAD INTO OIL SENDING UNIT FITTING LOCATED IN BLOCK NEAR POWER STEERING PUMP Fig. 2-a E. Install the Vortech supplied oil line onto the flare fitting. Cover the loose end with a plastic bag for later assembly. 1 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 3. OIL DRAIN FITTING A. Remove the two vacuum lines on the EGR reference module and mark their position for reinstallation. Remove module and bracket. B. Remove EGR reference module from mount. Bend the mount down lengthwise so that the module will run perpendicular to the ground to accommodate the discharge tube. (See Fig. 3-a.) C. Remove the EGR tube coming from the exhaust. Disconnect the EGR guard, vacuum line and electrical connector. Remove the EGR valve and assembly and set aside for reinstallation later. Remove the guard/bracket. Cut off and discard the upper portion of the bracket in the area shown in Fig 3-b. D. Remove the breather line connecting the intake to the vapor canister (located on the left fender apron) for clearance. Remove three left side spark plug wires from the spark plugs and the PCV valve and line for access to the left valve cover. E. Remove the EGR tube from the exhaust manifold. F. Remove the left valve cover using care to save the gasket. G. An 11/16" hole must be punched or drilled. Measure and mark the hole location following the graphic on the next page. H. Make an 11/16" diameter hole at the mark using a drill or chassis punch. Deburr the hole completely. Thoroughly clean the valve cover. (See Fig. 3-c.) I. Install the 1/2" hose fitting into the 3/8" NPT x 45° elbow and tighten. J. Insert the elbow fitting through the hole in the valve cover so the barb points forward and slightly up from horizontal. Secure with the sealing nut provided in the kit. Make sure to place the sealing side of the nut against the valve cover surface. K. Reinstall the valve cover. (See Fig. 3-d.) L. Install the 1/2" oil drain hose piece and #8 clamps to drain fitting on valve cover. M. Reinstall the PCV valve and spark plug wires. Check and reposition any existing lines around the area. Fig. 3-a CUT HERE DISCARD THIS PORTION Fig. 3-b 11/16" HOLE Fig. 3-c OIL DRAIN FITTING Fig. 3-d P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 2 3. OIL DRAIN GRAPHIC Fig. 3-e 3 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 4. MOUNTING BRACKET INSTALLATION A. With the air conditioning compressor temporarily moved off to one side, install the two Vortech supplied 11mm dowel sleeves into the air conditioning compressor mount. (See Fig. 4-a.) B. Position the spacer and bracket on the air conditioning compressor mount as shown. (See Fig. 4-b.) C. Remove the factory dowel sleeves from the bottom of the air conditioning compressor and set aside. Install the compressor on top of the air conditioning mount and brackets. D. Install the factory dowel sleeves into the Vortech aluminum adapter bracket and install the bracket on top of the air conditioning compressor. Insert the four supplied 8mm x 150mm bolts and AN washers. Start all bolts before tightening in a crisscross sequence. Make sure all dowels and brackets are aligned properly. (See Fig. 4-c.) E. Using the supplied tie wraps, resecure the left side air conditioning line to prevent contact with the power steering pump or brake lines. F. Install the supercharger mounting plate using four 3/8-16 x 1" bolts, four AN washers, two 3/8"16 nuts and two 3/8" lock washers. G. Reroute and install air conditioning clutch wiring connector. (See Fig. 4-d.) NOTE: 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. 11mm DOWELS Fig. 4-a SPACER BRACKET FORWARD 11mm DOWELS Fig. 4-b Fig. 4-c Fig. 4-d P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 4 FMU INSTALLATION A. Locate the return fuel line spring lock connector (left side frame below master cylinder). Separate the return line with a spring lock disconnect tool. Snap the Vortech fuel line with the male spring lock connector into the fuel rail outlet. Attach the other end to the Vortech fuel management unit inlet. B. Snap the second line with the female spring lock connector onto the fuel return line that returns to the tank (see Fig. 5-a.) Connect the other end to the FMU outlet at the center fitting. (See Fig. 5-b.) CONNECT TO MANIFOLD VACUUM/PRESSURE INLET (FUEL LINE FROM STOCK REGULATOR) OUTLET (FUEL FROM HERE RETURNS TO TANK) Fig. 5-a EXPLORER/MAZDA NAVAJO FMU: FUEL MANAGEMENT UNIT (FMU) FUEL FEED LINE 1. Remove windshield washer fluid/coolant overflow reservoir by removing the two mounting bolts on the left side fender apron, disconnecting the fluid lines and wiring connection. 2. Mount the FMU behind the gas vapor canister bracket on the driver's side (FMU lines should be attached to the unit before it is mounted) using the sheet metal screws supplied in the kit. 3. Connect the 5/32" vacuum line from the FMU to the intake manifold vacuum tree (located at the top rear of the upper intake manifold) and secure. (See Fig. 5-c.) FUEL RETURN LINE 5. ENGINE VORTECH FUEL PUMP FILTER FUEL PUMP RANGER/MAZDA B4000 FMU: 1. Mount the FMU on the left side fender apron, forward of the starter relay (FMU lines should be attached to the unit before it is mounted), using the sheet metal screws supplied in the kit. 2. Connect the 5/32" vacuum line from the FMU to the intake manifold vacuum tree (located at the top rear of the upper intake manifold) and secure. (See Fig. 5-c.) NOTE: Make sure you have routed all fuel lines away from all moving parts, sharp edges, exhaust pipes and manifolds. Secure the fuel lines with the tie wraps provided. 5 FUEL TANK Fig. 5-b VACUUM TREE MANIFOLD TOP VIEW Fig. 5-c P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 6. 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 as shown. C. Mount the fuel pump on the frame near the filter using the supplied #10 nut and bolt. D. Connect the fuel pump inlet to the adapter with the 3/8" hose provided. E. Connect the fuel pump outlet to the filter inlet with the 5/16" hose. Use the supplied Ford fuel connector and hose clamp. NOTE: Make sure that the hoses are routed smoothly with no kinks or sharp bends and away from sharp objects. F. Attach the negative pump terminal to a clean ground fastener with the wire provided. G. Connect positive terminal on fuel pump to fuse box (30 amp A/C works well). H. Secure the fuel pump and hose with the clamps provided. I. After installation is complete, start engine and check system for leakage. 3/8" FUEL LINE VORTECH FUEL PUMP GROUND (-) FUSE BOX (+) STOCK FUEL FILTER TO RAIL 5/16" HOSE EXISTING FEED LINE FROM TANK ADAPTER FITTING Fig. 6-a P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 6 7. SUPERCHARGER INSTALLATION A. Reinstall the EGR valve by connecting the exhaust manifold tube first, then the valve. Tighten all the fittings, EGR bolts and connect all the vacuum lines. B. Reinstall the modified EGR guard. Reconnect all wires and vacuum lines. C. Mount the modified EGR reference module. Reconnect all wires and hoses. D. Mount the supercharger mounting brace from the back of the mounting plate to the cylinder head using the supplied 10mm x 1.5 bolt, 3/8-16 x 3-1/4" bolt, 3/8 x 16 nut and 3/8" lock washers. (See Fig. 7-a.) E. Align the drain tube according to Fig. 7-b.) F. Mount the supercharger by guiding the drain tube into the 1/2" drain hose on the valve cover. Secure the drain hose with the hose clamp. Fasten the supercharger to the mounting plate with the five 3/8-16 x 3/4" bolts and AN type washers provided. G. Install the 45° flare to the 1/8" pipe fitting into the oil feed on the supercharger and "clock" it to the 4 or 5 o'clock position. H. Attach the oil feed line and secure away from all moving parts and the exhaust manifold with tie wraps. I. On Explorer/Navajo applications, reinstall the washer/coolant tank and the necessary plumbing and wiring connections. Fig. 7-a Fig. 7-b 8. SUPERCHARGER DRIVE BELT A. The new longer accessory drive belt is routed the same as the original belt except for accommodation of the supercharger and idler pulleys. B. Route the belt around the outside of the supercharger drive pulley then around the inside of the idler pulleys as shown in Fig. 8-a). Fig. 8-a 7 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 9. AIR INLET DUCT A. Rotate the vacuum tree located on the rear left side of the intake manifold approximately 180° to gain clearance for the intake/discharge plenum. (See Fig. 9-c.) B. On automatic transmission equipped applications, the transmission vacuum line must be removed from the manifold, rerouted and formed to run along the firewall for plenum clearance. The rubber portion of the transmission vacuum line must be cut and the Vortech supplied restrictor and check valve assembly spliced into the two cut ends. (See Fig. 9-a.) C. Remove the plastic throttle cable retaining clip from the top of the intake manifold. D. Attach the two 1/4-20 nut plates to each of the supplied steel plenum mounting tabs. Mount the plenum mounting tab assemblies to the upper intake manifold. The thin, non-slotted tab is mounted to the upper manifold boss that is located near the idle-air motor using the supplied 6mm flat head screw. At the top rear of the upper intake manifold, install the thick, slotted tab with the 8mm flat head screw. (See Fig. 9-b.) E. Position the plenum bosses over the adjustable tabs and secure with 1/4-20 bolts. F. Mount the plastic intake duct to the supercharger inlet with the 3-1/2" T-bolt clamp, leaving the clamp loose. G. Secure intake tube 'B' to the plenum and plastic intake duct using 3" x 2" and 3" x 3" blue silicone sleeves and #48 clamps as shown in Fig. 10-a on the page 10. H. Position intake tube 'A', 3" x 2" silicone sleeve and #48 clamps onto the plenum. Mount the 3" 90° rubber elbow and #52 clamps into the mass air flow housing and connect to the intake tube. Connect the crankcase breather hose to the barb on intake tube 'A'. Fig. 9-c 8mm FLAT HEAD SNAP-ON NUT PLATE 6mm FLAT HEAD SNAP-ON NUT PLATE FRONT MOUNT TO TRANSMISSION MODULATOR Fig. 9-b 1/4" TEE RESTRICTOR TRANSMISSION VACUUM LINE FLOW TO VACUUM TREE ONE WAY VALVE Fig. 9-a P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 8 REAR MOUNT 1/4-20 BOLT 10. SUPERCHARGER DISCHARGE DUCT A. Slide a 2-3/4" x 2" sleeve and two #44 clamps onto the supercharger discharge. Use a 2-1/2" x 2" sleeve with #40 clamps on the discharge plenum. Install discharge tube A. Refer to Fig. 10-a on page 10. B. Mount discharge tubes B and C together using a 2-1/2" x 2" sleeve and #40 clamps. Slide a 23/4" sleeve onto the throttle body and a 2-1/2" sleeve onto the discharge plenum. Attach the discharge tube assembly to the plenum and throttle body using #40 and #44 clamps. C. Underhood lamp must be removed or relocated to provide adequate clearance for the supercharger. NOTE: Position the intake and discharge tubes as low as possible for hood clearance. Due to factory variations, on some models modification to hood insulation may be necessary. 9 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 10. SUPERCHARGER DISCHARGE DUCT 3" x 3" SLEEVE PLASTIC INTAKE DUCT DISCHARGE TUBE 'A' INTAKE TUBE 'B' 2-3/4" x 2" SLEEVE 2-1/2" x 2" SLEEVE 2-3/4" x 2" SLEEVE FRONT OF VEHICLE 2-1/2" x 2" SLEEVE DISCHARGE TUBE 'C' 2-1/2" x 2" SLEEVE INTAKE TUBE 'A' DISCHARGE TUBE 'B' VALVE COVER BREATHER HOSE BARB RUBBER ELBOW MAF SENSOR Fig. 10-a P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) 10 11. FINAL REASSEMBLY & CHECK A. Reconnect the battery. B. 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. C. Check all fluid levels, making sure that your tank(s) is filled with 92 octane or higher fuel before commencing test drive. D. Start engine and allow to idle a few minutes, then shut off. E. 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. F. PLEASE TAKE SPECIAL NOTE: Operating the vehicle without all of the subassemblies completely and properly installed may cause FAILURE OF MAJOR ENGINE COMPONENTS. G. Test drive the vehicle. H. Read the STREET SUPERCHARGER SYSTEM OWNER'S MANUAL AND WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify. 11 Fig. 11-a WARNING: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are completed including the final check. P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1)) ® 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 P/N: 4FD020-010 ©2001 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 31JUL01 V1.1(Explorer/Ranger(4FD V1.1))