This manual is intended for the installation of Powerdyne Supercharger kit, Part Number K10407-101 and K10410-101 on Ford F-150 and Expedition with the 4.7L and 5.4 liter motor, model years 1997-2000. This kit is designed to be 50 state smog legal and as of the writing of this manual C.A.R.B. (California Air Resources Board) exemption is pending. This kit already complies with EPA memorandum 1A, making it smog legal in 49 states providing your states pollution laws do not supercede EPA memorandum 1A.
Component Removal:
A. Disconnect negative battery cable from battery.
B. Remove cover from top of throttle body.
C. Disconnect mass air meter and inlet air temperature sensor from harness.
D. Remove crankcase ventilation tube from fresh air inlet tube.
E. Remove intake air temp (IAT) sensor from fresh air tube. Retain sensor for future use.
F. Remove mass air flow (MAF) meter from air filter enclosure and disconnect from wire harness. Retain MAF for future use.
G. Remove remaining part of air filter enclosure.
H. Disconnect cam sensor connector from cam sensor on driver side front cover.
I. You are now ready to begin the installation.
Step 1.(Refer to figure #1 & #2) Using the FRU bracket as a template, mark the mounting bracket hole locations on the passenger side of the firewall between the main fuse junction box and the throttle body. The bracket should be located approximately 1”Below the plastic harness cover. Drill the marked location with a 1/16” drill bit. Mount the FRU to the fire wall with the self tapping screws provided. Connect the provided fuel lines to the FRU. The male fuel line connects to the side (straight fitting) of the FRU. The female fuel line connects to the top (90 deg. Fitting) on the FRU. Relieve pressure from fuel rail at the service port. If you are unsure consult Ford shop manual for proper procedure. Disconnect fuel return line from fuel rail. Return line is closest to the drivers side fender. Connect the male fuel line to fuel rail and re-install safety clip. Connect female fuel line to tank return line. Tee into vacuum source at the fuel pressure regulator and run the provided 5/32” line to the bottom of the FRU.
Step 2. (Refer to figure #3 & #4) Remove power steering reservoir from factory mounting bracket (Do not remove hoses). Remove power steering reservoir bracket from engine and discard. Install provided power steering reservoir relocation bracket onto the studs mounting the brake master power steering reservoir bracket onto the studs mounting the brake master cylinder using the two (2) nuts provided. (Do not remove master cylinder or mounting nuts.) Mount the power steering reservoir to the new bracket with 1/4”-20 X 3/4” socket cap bolts, nuts and washers provided. Carefully ad- just dipstick tube to clear the power steering reservoir.
Step 3. (Use figures #5,#6 & #7) Install super- charger mounting plate on the driver side front timing cover using three (3) 10mm X 100mm hex head bolts and washers on the front side and three (3) .600 spacers between the mounting plate and timing cover provided in hardware kit (Do not tighten lower mounting bolt ). (98 01 models only) Lengthen cam sensor wires with 10” blue and green wire, butt connectors and convoluted tubing provided. Secure the wiring with insulated clamp to the front of the mounting bracket using the lower mounting bolt. Install supercharger onto mounting bracket with half moon spacer between the supercharger and mounting bracket using the seven (7) 3/8”- 16 X 1-5/8” socket cap screws and washers. (98 01 models only) Install IAT adapter on supercharger outlet with blue silicone sleeve and clamps . Install idle air bypass adapter to throttle body using short blue silicone sleeve and clamps. Connect idle air bypass tube to adapter using 3/4” hose and #10 clamps provided. Install cast discharge tube between idle air bypass adapter and IAT adapter using two (2) 3” X 2” blue silicone sleeves and clamps. Using a file remove barb from IAT sensor and thread sensor with 1/2”-13 die. Thread sensor into threaded hole and reconnect wire. (97 models install only idle air bypass between supercharger and discharge tube.)
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