Vortech install on 04 EB 5.4L

[joezek]

Hey all, I'm looking for input from anyone who's already done what I'm about to do. I just bought a used Vortech kit (which was missing some parts). It was a V-1 kit for a 97-03 5.4L, and they had upgraded the blower to a V-2 (quiet) blower. The blower looks like it's brand new off the shelf, looks awesome internally.

I already have an SCT tuner and a local shop to dyno and tune it after the install. I'm looking to add an air to air intercooler behind the grill, and also aiming for approx 9-10 psi. I ordered 39# injectors, they're not here yet. I'm planning on installing the inline fuel pump that came with the kit, but not the 8:1 FMU since I'm replacing the injectors and tuning it professionally.

Things I'm missing from the kit are the harmonic balancer, lower pulley (ordered), and the oil supply/return kits for the blower. I spoke to Vortech and they say I can use the stock balancer, it just has to be notched a little to fit the pulley. Their balancer is a stock Ford one that's been notched...and no longer available from Vortech.

I'm planning on trying to either keep the stock air filter housing which plugs into the fender for cold outside air- or at least make an inlet in the fender that gets outside air.

I've noticed on some of the newer installs that people are returning the oil into the valve cover instead of the oil sump. Looks a lot easier to install. Any reason I can't do that on the 2004 2V engine?

Since I'm wanting to NOT use the kit's FMU, should I not use the included inline fuel pump? Will the stock pump work ok with the 39 lb injectors?

I'm guessin that I should have approximately 350-400 hp and 450-500 torque when done. I'm not making a race car, or the "fastest" truck around, just playing around a little- so I'm not planning on going broke to extract every last HP out of it. The intercooler is very important to keeping it streetable and reliable, I can't believe Vortech thought it didn't need one.

BTW I need to update my signature pic, that truck was totaled, I have a red 04' 4WD now. I had a local shop do custom dual exhaust also, very cool looking- pics are needed to explain how they routed the pipes with the spare tire in the way....

 

[tallsville]

cant wait to see the pics of the exhaust.

 

[toms89]

With no fmu you need to make sure your fuel injectors and pump are sized large enough to supply the fuel necessary at your power level. Stock.....lightnings come with 42# injectors and dual fuel pumps. If the return is lower than the blower I would guess the valve covers would work. I would make sure it is not dumping right on a valve and preferably near a drain hole in the heads. At low boost levels the vortech is efficient enough to not to need an intercooler. I personally would want one at 8psi and above.


I am runnning a 340lph stealth single fuel pump using a 30amp feeder. I am also running stock lightning injectors but am right at the limit at my power level.

I also have a 5.0 mustang with a V2 vortech and absolutely love it. It has a vortech powercooler on it (air to water intercooler ) and found it effective for use on the street. If the kits were still available I might have had one on my expy.

 

[joezek]

I had looked up the stock Lightning injector part #'s and all the specs I could find said they were only 24#, and my stock 5.4L were 19.04#. They must rate them differently and at different psi's. The ones I bought are brand new Motorcraft 4.6L supercharged mustang stock injectors, rated 39#.

I would guess that since Vortech thought the stock 19 lb injectors were good enough, then the 39lb should be plenty, but maybe I'll still need an FMU?

 

[toms89]

I had looked up the stock Lightning injector part #'s and all the specs I could find said they were only 24#, and my stock 5.4L were 19.04#. They must rate them differently and at different psi's. The ones I bought are brand new Motorcraft 4.6L supercharged mustang stock injectors, rated 39#.

I would guess that since Vortech thought the stock 19 lb injectors were good enough, then the 39lb should be plenty, but maybe I'll still need an FMU?

Think your looking at gen 1 lightnings... early 90's (Naturally aspirated). I can guarantee Gen 2 lightnings 99-04 with the 5.4 and eaton supercharger use 42# injectors stock. Gen 2 lightnings share drivetrain with gen 1 expys. Expys have nothing in common with gen 1 lightnings. I used 38# lucas injectors in my stang but needed 4 to 1 fmu to supply the fuel necessary with those. FMU will make the injector act as a larger injector because of the increase in fuel pressure. Vortech kits are also supplied with a specific boost (pulley ratio) in mind... if you exceed it they will tell you you need to upgrade fuel system, motor, drivetrain, etc....

Did not see it mentioned but you will need new mass air sensor calibrated for your injectors. You will peg stock meter. Stock lightning meter calibrated for 42# injectors of course can be used and recalibrated in the tune for your injectors. Its likely the least expensive solution you will find that will work but there are other options out there. Don't really know what the stock fuel pump capacity is but seriously doubt it is sufficient.

 

[joezek]

I'm running into another small problem/question. I can't seem to figure out which intercooler size will work best. I'm assuming a 2.5" in/out is fine since this engine won't go above 5,000 rpms. I'm not building a drag racer, but want it to be built properly and efficiently. Not sure what CFM I'll require since it's low rpm range. My goal is 9-10 psi and hopefully around 400 hp.

Didn't know about the MAF, thanks for the advice. The Vortech kit came with a 8:1 FMU and 155 LPH inline pump. They didn't mention changing the MAF, I guess since it's using stock injectors.

That inline pump it came with is bad so I need a new one. Supposedly 155 is not nearly enough for 400 HP, but it was intended to be installed inline. Should I get another 155 or a 255 and install inline? Also, seems like all the other inline pumps are 85 psi, is that a problem?

 

[joezek]

I talked with my guy who's doing the computer programming for me on the dyno today. He said the old school way of tuning was using a FMU and the "recalibrated" MAF sensors- but that was before it was so common to reprogram the computer. He's going to just reprogram the fuel curve, injector pulswidth etc. to get the correct A/F ratio. Its much easier, safer, and cheaper to do it this way instead of buying another MAF and then still having to reprogram everything.

Also, did some researching and several reputable sources and performance calculators all agreed that 39# injectors are great all the way up to 442 HP. I'm planning on replacing the in tank pump with the Stealth 340 unit, so the amount of fuel available should be waay into the safe zone for the 400 HP range I'm expecting.

I found a few online HP/CFM calculators for intercooler volumes. According to them, a 5.4L engine stock producing 260 HP at 5,000 RPM uses 421 CFM. At 9 PSI and 400 HP, the same engine uses 695 CFM. So I guess I'll look for an intercooler slightly larger than that capacity, with 2.5" in/out, and go for a shorter lenght but taller height.

How hard was it to drop the tank and replace that pump? Any tricks or does it really just bolt right in place of the stock pump?

 

[toms89]

I talked with my guy who's doing the computer programming for me on the dyno today. He said the old school way of tuning was using a FMU and the "recalibrated" MAF sensors- but that was before it was so common to reprogram the computer. He's going to just reprogram the fuel curve, injector pulswidth etc. to get the correct A/F ratio. Its much easier, safer, and cheaper to do it this way instead of buying another MAF and then still having to reprogram everything.

Also, did some researching and several reputable sources and performance calculators all agreed that 39# injectors are great all the way up to 442 HP. I'm planning on replacing the in tank pump with the Stealth 340 unit, so the amount of fuel available should be waay into the safe zone for the 400 HP range I'm expecting.

I found a few online HP/CFM calculators for intercooler volumes. According to them, a 5.4L engine stock producing 260 HP at 5,000 RPM uses 421 CFM. At 9 PSI and 400 HP, the same engine uses 695 CFM. So I guess I'll look for an intercooler slightly larger than that capacity, with 2.5" in/out, and go for a shorter lenght but taller height.

How hard was it to drop the tank and replace that pump? Any tricks or does it really just bolt right in place of the stock pump?

Yep.... FMU's are definately old school way of doing it.

The mass air sensor has a designed voltage range from 0 to 5 volts that the computer recognizes that is adjusted for in the tune based on injector size, etc... The ecu will not recognize anything more than 5 volts so it basically "pegs" the reading at 5 volts if airflow exceeds it design limitations and it can no longer be accurately compensated for in the tune (its stuck at 5 volts) and the motor will go lean. Nothing can be done in the tune to overcome this hardware limitation. Thats why you go to a "larger" mass air sensor. It extends its airflow range but at the expense of loosing definition. Thats why one size does not fit all. You get one that is calibrated to run from 0 to 5 volts based on your potential airflow (hp level) and have it tuned for your setup. I would be surprised if you do not peg your stock meter. I was pegging a stock lightning meter with my modifications and went with an sct 2600.

The stealth fuel pump bolts right in but recommends running a 30amp feeder to it. I did this and just used a relay powered by the original fuel pump feeder to keep the ecu on/off control and inertia switch safety intact. Biggest recommendation....make sure you run your tank near empty first..

When empty it is fairly light and can be handled much easier.

 

[01yellerCobra]

The blue 39lb injectors flow the same as green top 42's. Ford flowed them at a different pressure level to come up with 39lb/hr. I personally ran the 39's into the high 400's on a 4.6. My buddy is a couple hp shy of 500 with them, but they're done and he needs bigger injectors.



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[joezek]

Great info guys thanks. I'm looking on ebay and amazon, there's a ton of MAF sensors all 90mm. Is there one thats better than the other? Am I better off just going to the parts store in town and buying one?

 

[toms89]

Great info guys thanks. I'm looking on ebay and amazon, there's a ton of MAF sensors all 90mm. Is there one thats better than the other? Am I better off just going to the parts store in town and buying one?

I personally feel the ford lightning 90 mm mass air meter is your best option. It should cover the range your looking at and is inexpensive. You could ask your tuner... he may have a preference.

 

[joezek]

Exhaust pics

I finally got some pics of the exhast online... here they are







The guy who did it is very picky about making perfect "Factory like" fit. They don't rub anything or make any noises at all. The center of the rear is solid mounted to the chassis so it doesn't move, so we were able to run te exhaust directly under it without worrying about bumps causing the suspension to move into the pipes.

 

[tallsville]

exhaust looks good. i think i'll try and redo mine by the end of next year. but try and go over the rear. need the clearance since i do go offroad.

 

[joezek]

The exhaust guy does a lot of custom work for the local hot rodders, and that was the easiest way for him. He said if he had more time (and more money) he could try running two pipes in the stock single pipe location and dumping them both out on one side. For me, I like the look and sound from one pipe on each side of the truck. I still have all 4 cats for now. After the Supercharger install is done I may get rid of the rear cats. It's above the stock sway bar but aft of that it does drop down about 2 inches before curving back up and out. I don't off road a whole lot, and when I do I have to be a little careful.

 

[frankie paladin]

I can't wait to hear how this works out. I have a Vortech V-3 Si in my '06 Mustang and its awesome. I always wanted to drop a Whipple in my truck, but the car needed it more. Good luck with the upgrade!!

 

[GAINMOB]

its not pretty...lol...more push for me to get mine this spring

 

[joezek]

its not pretty...lol...more push for me to get mine this spring

You don't normally see the two pipes under the truck when its on the road. You just see the outlets by the rear fenders. That's why I took that picture looking under the rear of the truck from behind, so that you could understand how the guy was able to route two pipes.

BTW, since this install I've seen another Ford SUV, I can't remember which model it was, but it was pretty new, and Ford did almost the same exact thing on it by running dual pipes up the middle and splitting out the back like mine. The only difference was that Ford had it perfectly centered there bends looked smoother because it was a one piece design, obviously engineered by the factory.

 

[joezek]

I have a new problem, the harmonic balancer was missing from the kit. Its discontinued from Vortech. Vortech told me that on the 2005 5.4 kit they no longer need to replace the balancer because it's already shaped to fit their pulley and it bolts right on. Since Vortech no longer makes it, does anyone know if I can buy a 2005 harmonic balancer and install it on my 2004 2V engine???

 

[toms89]

With the lightning setup various pulleys bolt right up to the stock balancer. I got mine through auto specialties I believe. Not familiar with how the vortech kit is set up.

Try to pm 1997SCEBFEX as he has a vortech installed on his expy. He would likely be able to answer any questions you may have.

 

[toms89]

With me giving advise on properly sizing fuel injectors and pump for hp level I decided to go back and check mine since I added boost from original build. Turns out I am at or near 100% duty cycle at my peak hp using the fuel calulators. Not good. May have been the underlying issue at my last track outing.

Figuring 15-20% drivetrain loss puts me between 566-600 flywheel horsepower. Considering it is a large 4wd the drivetrain losses may be greater. (More rotating mass) This puts me right at 100% duty cycle with .55 bsfc for superchargers. Your shooting for 80% duty cycle max. 52# injectors is what it recommends in my case.... as long as I dont mod it any more or have better air than the day it was dyno'd

Think I will get some 60# injectors and be done with it. It will be interesting to see if it effects my top end.