Supercharger Installation Manual - :::by Stein Design: Web Site

Installation Manual: Lightning/Harley Supercharger System(R10) Last Updated: August 2nd, 2006

Supercharger Installation Manual

Ford Lightning/Harley Truck 5.4L 16 Valve 1999-2004 Model Years

Engine: Ford 5.4L 16 Valve Model Years: 1999-2004

Revision #9 June 6th, 2006

CALIFORNIA AIR RESCOURCE BOARD EXECUTIVE ORDER #D-231-24

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Table of Contents

Introduction.........................................................................................................3

Kit Components......................................................................................................................... 3 Supercharger Oil..................................................................................................................... 3

Recommended Tools................................................................................................................ 4 Pre-Installation Checklist ...................................................................................4

Supercharger Installation Instructions .............................................................5 Illustrated Installation Guide.................................................................................................... 6

Maintenance and Service .................................................................................28 Maintenance............................................................................................................................. 29 Servicing Your Supercharger ................................................................................................ 30

Post-Installation Checklist ...............................................................................31 Checklist Review..................................................................................................................... 31

Symbol Key

Throughout this installation guide you will see the following symbols used:

NOTE Used to indicate tips and information to aid in installation, maintenance, or use of the supercharger. !! CAUTION !! Used to indicate precautions that must be taken to avoid damage to the supercharger and associated components.

WARNING!! Used to indicate precautions that must be taken to avoid bodily injury as well as damage to the supercharger and associated components.

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Introduction This supercharger was created for the 5.4L Ford SVT Lightning and Ford Harley Truck, model years 1999-2004. It has been designed and tested specifically for this application. Before beginning installation of this supercharger, first read this section carefully then complete the Pre-Installation Checklist.

Kit Components Before beginning installation, be sure you have identified all components of your Whipple 5.4L Lightning/Harley Supercharger Kit. Check the supplied packing slip.

Supercharger Oil

As described in the Illustrated Installation Guide, the supercharger must be filled with oil prior to use. This supercharger is shipped without oil inside. The oil is in a separate bottle supplied with your kit and you will be instructed to add it in the Illustrated Installation Guide.

Warning label attached to Supercharger housing

!! CAUTION !! Do not attempt to start the engine before adding the supplied Supercharger Oil to the supercharger!

Tie Straps These will be useful for securing the wiring harness away from the installation area as directed in the Illustrated Installation Guide. They are inexpensive and will be very handy during installation. Motor Oil Motor oil will be useful as a lubricant and should be readily available during installation. Adhesives and Chemicals Thread locking chemicals such as Loctite #242 and #262 will be required during the installation. Some other helpful chemicals is pipe thread sealant such as pipe Teflon and carbureted cleaner. A Clean Blanket, Towel, or Tarp This will be used to protect the supercharger, engine, and related components when the grinder is used during installation.

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Vacuum A vacuum is necessary to clean up any debris resulting from grinder use. Clean Shop Towels Use these to keep the installation area clean.

Recommended Tools The following items are not included in this supercharger kit and it is strongly recommended that they're used for ease of installation or maximum performance: Fuel Pressure Gauge As described in the Pre-Installation Checklist, a quality fuel pressure gauge is an important part of proper supercharger operation. It is strongly recommended that a fuel pressure gauge is installed on the vehicle prior to supercharger installation. Fuel Line Removal Tool You will need to remove the factory fuel line and fuel rail, this requires a special tool, contact your local parts store or Ford parts dealer. Torque Wrench You will need a quality torque wrench to ensure proper tightening of bolts.

Pre-Installation Checklist Before installing your Whipple Lightning Supercharger Kit, complete the following checklist.

!! CAUTION !! Failure to complete the Pre-Installation Checklist may result in severe engine damage after installation is complete.

1. If you purchased a complete Whipple/FRPP Lightning kit, ensure that you have used your FRPP flash tool voucher and you have received your FRPP flash tool before you start your installation.

2. Verify Condition of Vehicle: Before the supercharger kit is installed, ensure the engine runs smoothly and that

the factory malfunction indicator light (MIL) is off. Only install the supercharger kit if the engine runs smoothly and the MIL is off.

!! CAUTION !! This product is intended for use only on stock, unmodified, well-maintained engines. Installation on a worn-out or modified engine is not recommended without factory computer and fuel system modifications.

3. Check Vehicle Fuel Pressure: Fuel pressure is critical to proper supercharger operation and must be checked during wide-open-throttle operation when the fuel tank is 1/8th full. The fuel pressure should meet all factory specifications.

4. Verify Fuel Octane: Ensure fuel of 91-octane or higher is in the vehicle fuel tank. If the octane grade is not

known, drain the fuel tank completely and fill to 1/8th with fuel of 91-octane or higher.

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!! CAUTION !! Use only 91 octane fuel or higher. If fuel of less than 91-octane is present in the vehicle fuel tank, the tank must be completely drained and refilled with 91 or higher octane to 1/8th of a tank.

5. Assess Cleanliness of Installation Area: Make sure your work area and the underhood area are free from debris. This supercharger is a high-quality, close-tolerance compressor and must not be subjected to contamination by dirt or any type of foreign material.

!! CAUTION !! DO NOT remove the protective seal on the supercharger prior to installation. Foreign material entering the supercharger will automatically void all warranties.

6. Identify Supercharger Kit Components: Before beginning installation, identify all the components of your Whipple Supercharger Kit and ensure all items are present and undamaged.

7. Read Illustrated Installation Guide: Be sure to read through the Illustrated Installation Guide starting on

page 6 before beginning supercharger installation. Familiarize yourself with the components and tools you will use and the procedures before you start for faster and easier installation.

Supercharger Installation Instructions

Vehicle: 1999-2004 Ford Lightning/Harley SC Upgrade Kit Engine: 5.4L Before you begin installing the Whipple Supercharger, make sure you have completed the Pre-Installation Checklist. Be sure you have:

1. □ Verified the Condition of the Vehicle

2. □ Checked the Vehicle Fuel Pressure

3. □ Verified the Fuel Octane

4. □ Assessed the Cleanliness of the Installation Area

5. □ Identified the Supercharger Kit Components

6. □ Read and Understood the Illustrated Installation Guide Have you completed all items in the Pre-Installation Checklist?

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NOTE **NOTICE: Installation of Whipple Supercharger products signifies that you have read this document and have agreed to the terms stated within. It’s the purchaser’s responsibility to follow all installation instruction guidelines and safety procedures supplied with the product as it’s received by the purchaser to determine the compatibility of the product with the vehicle or the device the purchaser intends to install the product on. Whipple Superchargers assumes no responsibility for damages occurring from accident, misuse, abuse, improper installation, improper operation, lack of reasonable care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products. There are no warranties expressed or implied for engine failure or damage to the vehicle in any way, loss of use or inconvenience or labor reimbursement. This includes merchantability and fitness.

Be sure you have read and understand the Introduction section and have completed the Pre-Installation Checklist, then proceed to the Illustrated Installation Guide.

Illustrated Installation Guide It is strongly recommended that you read through this guide before you begin installing the Whipple Supercharger. 1. Disconnect ground cable from battery.

2. Using an air hose, blow off any loose dirt or debris from engine compartment.

3. Fine the factory spigot for coolant draining on the factory heat exchanger (located on passenger side of HE) and

drain coolant from heat exchanger/intercooler system.

4. Find the factory coolant drain spigot located on the passenger side of the factory radiator. Drain coolant and store

for later use.

5. Remove factory intercooler water reservoir.

6. Disconnect the following factory electrical connectors:

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Mass Air Flow (MAF) sensor.

Inlet Air Temperature (IAT) sensor.

7. Remove factory air box cover and inlet air tube from throttle body. You will have to remove the following hoses:

IAC rubber hose feed from both the air inlet tube and 90 deg rubber fitting on IAC motor.

90 deg. Vacuum hose.

Driver side valve cover breather tube.

8. Remove factory lower air box from inner fender including the rubber inlet adapter.

9. Remove MAF sensor from air box cover.

10. Remove IAT sensor from lower air box.

11. Remove the factory throttle cable and cruise control cable from throttle body and anchor bracket.

12. Disconnect the following factory electrical connectors:

Throttle Position Sensor (TPS) (3-pin connector).

Idle Air Control (IAC) motor (2-pin connector).

Exhaust Gas Recirculation (EGR) solenoid (2-pin connector) (1=RD/YH, 2=BN/PK).

Differential Pressure Feedback EGR sensor (DPFE) (3-pin connector) (1=BN/LG, 2=GY/RD, 3=BN/WH).

Bypass boost solenoid (2-pin connector) (1=RD/YH, 2=LG/DG).

Manifold Air Pressure (MAP) sensor (3-pin connector) (1=BN/WH, 2=GY/RD, 3=DB/LG).

13. Remove factory throttle body from supercharger inlet adapter.

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Remove factory throttle bracket adapter from throttle body.

14. Remove EGR valve from engine.

Remove 90deg. hose from top of EGR valve.

Remove rubber hoses from EGR tube.

Remove vacuum lines (2) from EGR solenoid.

Remove EGR nut from factory exhaust manifold.

Remove EGR tubing/nut from EGR valve.

Remove EGR valve from supercharger inlet adapter.

15. Remove IAC motor from supercharger inlet adapter.

16. Remove vacuum lines from:

Supercharger inlet (passenger side) (2 reds, 1 black).

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Supercharger inlet (driver side) (EGR rubber hose, brake booster).

From supercharger bypass valve actuator.

17. Remove PCV vent hose from supercharger inlet adapter.

18. Remove power steering reservoir from thermostat housing by loosening the (1) bolt shown:

Remove power steering reservoir from support bracket. Support bracket from block does not have to be

removed although it can be by loosening the bolts and sliding bracket up.

Remove the factory upper radiator hose from engine.

Replace the factory thermostat with the supplied 160deg thermostat.

19. Remove supercharger belt by loosening the factory spring loaded tensioner:

Fish the belt around the fan blade or remove fan to pull belt off.

20. Remove intercooler hose feed and return hoses and bracket from supercharger mounting bolts (2 nuts).

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Remove hard IC lines from engine, they will not be utilized.

21. Remove EGR solenoid, Vent solenoid, Bypass boost solenoid bracket from driver side of supercharger.

22. Remove supercharger assembly from intercooler adapter housing by removing the 8 bolts.

23. Remove gasket from intercooler adapter housing.

24. Remove vacuum/boost line from intercooler adapter housing (1 black, 1 red)

25. Remove intercooler adapter housing from intake manifold.

26. Remove dows (2) from bottom side of intercooler adapter housing.

27. Inspect intercooler adapter housing adapter gasket, replace if damaged, re-utilize if it’s looks ok.

28. Remove intercooler feed/return 90deg hoses from inlet/discharge tubes.

29. Remove intercooler core from factory intercooler adapter housing by removing the (11) mounting bolts.

30. Remove carbon gasket from intercooler core mounting flange.

31. Mount intercooler core to new Whipple intercooler adapter housing:

Install intercooler core to new supplied intercooler adapter housing carbon gasket #1L3Z-9M436-AA.

Apply light amount of red Loctite #262 to threads of supplied (10) 5mm x 16mm socket head cap screws.

Use the supplied (10) 5mm x 16mm socket head cap screw and (10) 5mm AN washers.

Torque to 8 ft. pounds.

Reinstall factory 90deg rubber inlet/discharge hoses facing passenger side as was stock. Utilize factory

clamps.

Install supplied 5/8” barbed fittings into 90deg rubber inlet/discharge hose ends and secure with supplied

clamp.

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32. Install dows into Whipple intercooler adapter housing, tap into place with soft rubber hammer or equivalent.

33. SPARK PLUGS. This is the best time to install/replace the factory spark plugs. Install spark plugs (NGK BP7EFS)

with light amount of anit-seaze on threads (do not get on electrode). Torque to 25 ft. pounds.

34. Mount assembled intercooler adapter housing to factory intake manifold:

Reutilize factory steel stamped gasket between factory intake manifold and intercooler adapter housing.

Utilize the supplied (12) 10mm x 35mm socket head cap screws to secure adapter housing.


Connect factory vacuum/boost 90deg hose to 3/8” barb fitting.

Install supplied preformed 5/8” ID hose (Whipple PN#54201010) (Ford PN #U036 49602) to barb fittings

you installed in factory 90deg hoses. Secure hose to barb fittings using supplied pinch clamps. Route

hoses along passenger side of engine for later installation.

35. Rotate factory fuel PSI regulator nipple so that it faces directly back to the firewall.

36. Remove boost bypass solenoid from factory bracket.

37. Remove MAP sensor from factory bracket.

38. Install boost bypass solenoid to new supplied Whipple bracket, install by sliding into place.

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39. Install the MAP sensor to the new supplied Whipple bracket. Utilize the supplied (2) 10/32” x ½” socket head cap

screws and secure with the 10/32” nyloc jam nut.

40. Install new supplied boost bypass solenoid/MAP sensor bracket to driver side rear injector rail boss. Remove

factory bolt that secures the factory resistor, install the new bracket over the resistor and secure with factory bolt.


Plug in MAP sensor electrical connector to sensor.

Plug in boost bypass solenoid electrical connector.

41. Remove EGR solenoid from factory bracket.

42. Remove DPFE sensor from factory bracket.

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43. Install EGR/DPFE solenoid/sensor to new supplied bracket.

Utilize the supplied (3) 10/32” x ½” socket head cap screws to first secure the outer bolt for the EGR

solenoid. Secure with the supplied 10/32” nyloc nut on the backside.

Sandwich the DPFE sensor on top of the EGR solenoid and secure with the supplied 10/32” x ½” socket

head cap screw. Secure with the supplied 10/32” nyloc nut.

Install the supplied 10/32” x ½” socket head cap screw with the supplied .25” spacer behind the outer

DPFE mounting flange. Secure with the supplied 10/32” nyloc nut.

44. Remove factory spring loaded tensioner (from supercharger belt system).

You will need to remove the stop on the tensioner to gain more travel. Grind or file tensioner stop flat to

gain more travel. Re-install the belt tensioner. Torque to 20ft lbs

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45. Prepare cold air intake system:

Install IAT sensor into cold air intake by inserting and twisting until it locks in place.

(99-00 Models 90mm MAF included with kit) Install 90mm MAF sensor to air box and install the supplied

air filter billet venture on the inside of the air box, utilize the supplied (4) 6mm x 16m socket head cap

screws.

46. Install cold air intake system:

Apply light amount of grease/silicone into the factory rubber air filter box mounts.

Remove the factory cruise control motor mounting bolts from inner fender.

Install new cold air intake box by pushing dows thru the rubber grommets.

Feed the cruise control cable through the allocated round hole.

Install the supplied rubber grommet around cruise control cable (cut grommet so it slips over cable easy)

and slide up into the air box until it’s secure.

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Reinstall the cruise control motor (sandwich on top of the cold air intake box mounting flange) with the

factory bolts.

Install the new supplied high-flow air filter by sliding over the billet venturi and securing with the supplied

clamp.

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47. Install EGR/DPFE bracket to brake booster master cylinder stud and secure with supplied (1) 10mm nyloc nut.

Secure bracket to pre-installed bracket located on cold air intake box by installing the power steering

reservoir to the bracket. Utilize the factory power steering reservoir mounting bolts to secure.

Remove factory plastic wiring harness cover on driver side.

Cut small amount of electric tape from EGR solenoid and DPFE sensor loom so you can route wires

towards the driver side.

Cut to factory plastic wiring harness cover on driver side to clearance for the EGR solenoid and DPFE

sensor, approximately .50”H x 3.0” L rectangle notch.

Plug in the EGR solenoid electrical connector.

Plug in the DPFE electrical connector. Note: Some will need to slightly cut the factory plastic wire loom

cover to give the wires an extra 1-2”.

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o Reinstall factory plastic wiring harness cover and secure with zip tie.

48. Vacuum/boost hose pre-routing. WARNING!! Make sure to pre-install all rubber lines that go the

backside of the supercharger inlet, as access to these fittings later will be very difficult.

Locate the plastic/rubber vacuum hose junction just behind the battery. Remove the (2) black plastic lines

coming from the hose loom.

Install the supplied 7/32” x 24” line to the 7/32” barb behind the battery.

Route the 7/32” rubber vacuum lines around the back of the engine.

Install the 5/32” x 30” rubber hose to the bottom port facing forward on the boost bypass solenoid.

Remove the rubber 90deg 7/32” to 5/32” from the factory bypass actuator bottom port.

Install supplied 5/32” plastic hose coupler into factory rubber 90deg barb.

Install supplied 5/32” hose to plastic hose coupler.

Install factory rubber 90deg 7/32” to 5/32” fitting onto Whipple bypass valve actuator, install on the

passenger side port, facing down.

Install supplied 5/32” hose from the 7/32” to 5/32” rubber 90deg fitting and route to middle nipple facing

forward (counting the top that faces up) boost bypass solenoid.

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Install supplied 7/32” x 36” rubber hose to bottom/inside port of Whipple bypass actuator (facing up) and

route to front/driver side of engine for later installation into air inlet.

BOOST BYPASS SCHEMATIC

Inside port

Outside port

Upper side port

Lower side port

Top port

Bypass actuator

Boost bypass

solenoid

Reducer elbow from

vehicle

5/32" x 18"

5/32" 30"

7/32" x 36"

Goes to 7/32

fitting on air tube

5/32" x 14"

7/32" x 4"

Goes to 7/32 fitting on

supercharger intakeGoes to factory

vac. line

7/32" x 25"

Goes to factory vac. line

Remove the factory rubber boot from the PCV tube.

Install the supplied 3/8” x 20” rubber hose with 90deg rubber fitting onto factory PCV tube and route to

backside/driver side of engine.

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49. Install the 3/8” rubber hose you pre-routed from the PCV valve to the Whipple SC inlet 90deg 3/8” barbed fitting.

PCV VALVE SCHEMATIC

3/8" vac. hose 30" long

Goes to factory PCV

Goes to 3/8" 90deg fitting on supercharger intake

50. Vacuum/boost hose routing:

Install the factory 3/8” rubber 90deg hose on the 3/8” straight barb fitting on the Whipple intercooler

adapter housing to the factory fuel PSI regulator nipple.

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51. Mount factory IAC motor to bottom side of Whipple supercharger inlet housing using the supplied gasket

PN#E83Z-9F670-A and the supplied (2) 6mm x 20mm hex head bolts.

52. Install the supplied o-rings to bypass valve. Apply heavy amount of lubricant such as engine oil or grease.

53. Install supplied gasket to intercooler housing to supercharger mounting flange, you may use a small amount of

gasket cinch to help keep the gasket from moving from it’s location. You may also use anerobic sealant, Permatex

#510 or Loctite #518 for sealing if a gasket is not available.

54. Install Whipple supercharger assembly to intercooler housing by sliding over the Whipple bypass valve orings.

Secure supercharger using the supplied (2) 8mm x 25mm (back holes) and (2) 8mm x 30mm (front holes)

6-point hex bolts. Torque to 25 ft. pounds.

WARNING!! Verify that the intercooler inlet/outlet hoses do not interfere with the bypass actuator

arm. If so, reposition hose so that there is no possible interference.

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55. Mount EGR valve to Whipple supercharger inlet utilizing the supplied (2) 8mm x 30mm socket head cap screws.

Route the supplied 5/32” x 8” rubber hose from the EGR solenoid top port to the top of the EGR valve port.

Install factory 3/8” rubber hose from brake booster to Whipple SC inlet 3/8” barbed straight fitting (front fitting).

56. Install the supplied 3/8” plastic hose coupler and rubber 90deg fitting into factory 3/8” rubber hose coming from the

EVAP service port (green fitting) to the Whipple SC inlet 3/8” straight fitting (middle fitting).

Goes to EGR valve

Goes to 5/32" 90deg fitting on supercharger

intake.

Goes to factory Evap .

EGR SOLENOID SCHEMATIC

EGR solenoid

5/32" x 2"

5/32" x 12"

5/32" x 22"

5/32" x 5"

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57. Install the supplied 5/32” x rubber hose from the 7/32” to 5/32” tee to the top port (faces up) of the boost bypass

solenoid.

58. Install the supplied EGR tube from the factory exhaust manifold to the EGR valve. Reinstall the factory lines from

the DPFE sensor.

59. Install the factory throttle body.

Utilize the supplied gasket PN#.

Utilize the factory bolts (4) to secure throttle body (use dual thread bolts on bottom) and torque to 15 ft.

pounds.

Install factory throttle cable bracket to bottom bolts of throttle body, utilize factory nuts to secure bracket.

Torque nuts (2) to 15 ft. pounds.

60. Extend the factory TPS and IAC wires. Use the supplied wires and butt connect/heat shrink wires or solder/heat

shrink wires.

61. Plug in the TPS sensor and IAC connectors.

62. Install the 90deg air inlet tube from the factory MAF to the throttle body using the supplied hump hose to the

throttle body and the hose to the MAF. Secure with supplied hose clamps.

63. Install breather hose from driver side valve cover breather to the 5/8” barb fitting on the plastic SC inlet.

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64. Install the supplied u-bend 5/8” hose from the IAC motor boss to the 5/8”” barb fitting on the plastic SC inlet.

65. Review the supplied componets for the front support system. The idea of the front support is to hold the drive

snout from pulling down, it’s very important that the mid-piece is meeting the bottom of the drive snout and in line

with the lower support piece.

R
TOP COLLA MID-PIECE
LOWER SUPPORT

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66. For proper installation, install the lower support and mid-piece so it’s sitting flush on the Ford front idler plate. Install the (3) 8mm x 20mm hex head (with flange), but leave loose for the time being.

67. Install the top collar. Slowly tighten the top (2) 6mm x 18mm socket head allen bolts which will pull the mid-piece up and secure to the front drive snout. It’s critical that it stays parallel to the lower support bracket.

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68. Now that the top collar and mid-piece are secure, push the lower support down so it’s flush with the factory idler plate.

69. Once it’s flush, tighten the hex head flanged 8mm bolts, torque to 20ft/lbs. 70. Now install the radiator hose, this must be cut and shortened so the front support is not resting against hose. To

shorten, cut just after the 90deg radius from the thermostat housing.

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71. Once the radiator hose is in place, use a large set of channel locks to bend the factory radiator hose support bracket back towards the engine. This will help keep the hose away from the front support.

72. Reinstall factory belt (note that it is easier to install the belt over the SC pulley guards and then slide over the

smooth idlers).

73. Reinstall factory intercooler water reservoir.

74. Install factory intercooler water reservoir inlet/outlet hoses to previously installed (#1811) intercooler hoses by

cutting the #1811 hose to fit. Utilize the supplied 5/8” barb and clamps to secure hose.

75. Re fill engine coolant system and i/c cooling (50/50 mix) system.

76. The battery cable can now be re connected.

77. Install the supplied C.A.R.B. 50-state emissions sticker in a visible location on the factory radiator shroud. To

properly install, use a light abrasive material such as scotch-brite to scuff the mounting area. Clean the area off

and install the sticker.

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78. Fill the new s/c compressor with oil per supplied instructions.

Make sure the SC is sitting square/flat. Remove -4AN allen plug and fill SC with WHIPPLE SC OIL ONLY!! Fill to the middle of the sight glass. NOTE: The W140AX compressor takes a maximum of 5.8 fl/oz. Reinstall -4AN allen plug. NOTE: After running the SC, the oil level will lower due to oil filling the bearings. The proper level should be between the bottom of the sight glass and the middle. Change SC oil every 100,000 miles and only use WHIPPLE SC OIL ONLY!!

!! CAUTION !! Severe damage to the compressor will occur if you overfill the supercharger front gear case.

WHIPPLE SC OIL LEVEL

Fill to center of oil sight glass. 5.8 fl/oz. or 155cc. DO NOT OVERFILL, WILL VOID WARRANTY!!

OIL FILL P LUG

M AXIM UM OIL LEVEL

M INIM UM OIL LEVELOIL LEVEL OPERATING RANGE


79. Start engine and check for any fuel or coolant leaks. Top off engine coolant and intercooler coolant tanks while

engine is running.

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80. WARNING!! Verify the bypass actuator is working properly. To monitor, look at the bypass arm when the

motor is not running. Start engine and verify that the actuator arm has opened. This arm will be extended when

the engine is above 1” of vacuum (boost) and will be open when there is more than 1” of engine vacuum.

CLOSED OPEN

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Maintenance and Service Be sure to follow the maintenance and service recommendations below to optimize the life and performance of your Whipple-supercharged Lightning/Harley.

Maintenance

For best performance and continued reliability it is essential to adhere to the following guidelines:

1. Use only premium grade fuel (91-octane or higher).

2. Always listen for any sign of spark knock or pinging. If present, discontinue use immediately and consult your

vehicle owner’s manual.

3. Do not overfill the supercharger front gear case.


4. Do not operate the vehicle at large throttle opening if the MIL lamp is on steadily. This indicates an electronic

engine control malfunction: reduce throttle opening and consult your vehicle dealer.

!! CAUTION !! TUNER KITS When installing the Whipple SC, the vehicle’s stock computer program is not accurate for the new SC and failure to recalibrate properly may cause serious damage to the engine and/or drivetrain.

!! CAUTION !! COMPLETE KITS WITH FRPP FLASH TOOL When installing the Whipple SC, modifying the supplied flash calibration may cause serious damage to the engine and/or drive-train.

BYPASS ACTUATOR ROUTING

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WARNING!! For systems that remove Ford factory boost solenoid system ONLY

1. If you remove the factory Ford boost solenoid system, then it is very important to re-route the bypass actuator properly. Incorrect routing can result in supercharger failure which will not be warrantied!

2. Locate the actuator on the passenger rear side of supercharger. 3. Disconnect the hose to the bottom port of actuator and leave this port open, do not cap. 4. Route a dedicated boost line from intake manifold, above or below intercooler to top port of actuator.

Secure lines with tie wraps.

TOP PORT

BOTTOM PORT

Route to 7/32" dedicated boost line (above or

below IC)

Leave bottom port open to atmosphere (DO NOT

PLUG)

BYPASS ACTUATOR TESTING

TOP PORT

BOTTOM PORT

Leave bottom port open to atmosphere (DO NOT

PLUG)

1. Move actuator arm into actuator .2. Plug top port with finger while actuator is pressed in.3. Let go of actuator arm while finger is still on top port.4. If actuator is good , actuator arm will stay in the same position until you remove your finger. If bad, it will come back to it’s relaxed position. IF BAD, REPLACE IMMEDIATELY

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Servicing Your Supercharger It is recommended that the following items be inspected at normal service intervals:

1. Check the supercharger oil level at every engine oil change. Add Whipple SC oil to the supercharger if

required.

2. Check the supercharger/accessory drive belt. Adjust or replace as required.

3. Change the oil in the supercharger every 100,000 miles. Use Whipple SC oil only.

4. Test the bypass actuator every 10,000 miles.

5. HIGH HP trucks with Ford boost solenoid removed should inspect the actuator every 5,000 miles.

Follow these guidelines to properly maintain your Whipple-

Supercharged Lightning/Harley.

Post-Installation Checklist After installing the Whipple supercharger kit it is essential that the following checklist be completed.

!! CAUTION !! Failure to complete the Post-Installation Checklist may result in severe engine damage.

1. Review Maintenance and Service Recommendations: Read through the section and familiarize yourself with the steps you must take to ensure your Whipple-supercharged truck/SUV will continue to operate with optimum performance.

2. Verify Fuel Octane: When you re-fuel your truck/SUV, ensure you use fuel of 91-octane or higher. It will always

be beneficial to run 92-94 octane when available.

!! CAUTION !! Use only 91-octane fuel or higher. If fuel of less than 91-octane is present in the vehicle fuel tank, the tank must be completely drained and refilled with 91 or higher octane to 1/8th of a tank.

3. Check Vehicle Fuel Pressure: Fuel pressure is critical to proper supercharger operation and must be checked

during wide-open-throttle operation when the fuel tank is 1/8th full. Fuel pressure should meet all factory specifications.

Checklist Review

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Have you completed the Post-Installation Checklist? Be sure you have:

1. □ Reviewed the Maintenance and Service Recommendations

2. □ Verified the Fuel Octane

3. □ Checked the Vehicle Fuel Pressure

Have you completed all items in the Post-Installation Checklist?

NOTE There are no warranties expressed or implied for engine failure or damage to the vehicle in any way during supercharger installation or use.

If you have completed the Post-Installation Checklist, you have successfully installed your Whipple Lightning/Harley Supercharger Kit.

Congratulations! Your supercharger installation is now complete.

Important information

PULLEY SIZE VS. BOOST SC Pulley 7.5" Crank (stock) 9.0 Crank

Boost Ratio Boost Ratio 3.50" 10.0 2.14 14.5 2.57 3.25" 11.5 2.31 16.5 2.77 3.00" 13.5 2.50 18.5 3.00 2.75" 15.5 2.73 21.0 3.27 2.50" 17.5 3.00 23.0 3.60 Boost measurements are made at 5000rpm.

Compressor RPM = (Crank pulley/SC pulley)*Engine RPM BOOST LEVELS All Whipple kits are shipped with 11.5psi pulleys for stock engines. Additional pulley’s are available for higher boost levels. With proper PCM calibration, the factory engine has proven to withstand 15psi before detonation on 91-octane fuel. With additional modifications, 17psi is achievable on 91 octane but must have a custom calibration for the octane level. Vehicles that run 93-94 octane can run 17psi before detonation with proper tuning. The Whipple Supercharger has the ability to produce over 700RWHP but additional modifications are needed to achieve such power levels. With stock engines, the Whipple/Ford Racing flash tool has been calibrated for 91 octane and the supplied 3.385” SC pulley. This will produce approximately 11.5psi at sea level. Stock engines may run 3.25” SC pulley’s (12.5psi) to temperatures of 0 degree’s Fahrenheit, any cooler will result in a lean and potentially damaging effect. Stock engines may run a 3.00” SC pulley (13.5psi) down to 40 degree’s Fahrenheit, any cooler will result in a lean and potentially damaging effect. Please note that increased performance may shorten the transmission life and may need upgrading when running smaller than the 3.385” SC pulleys. FUEL SYSTEM The factory fuel system (flow only) is ok and needs no additional changes for boost levels up to 15psi. The factory fuel system including the pump and injectors are adequate for 15psi on stock engines. Engines that run more than 15psi

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or are heavily modified need larger injectors and more fuel flow. Whipple Superchargers recommends going to 60lb fuel injectors (available from Whipple). “TUNER KITS” FACTORY PCM CALIBRATION If you have a “TUNER KIT” (no computer or fuel system included), then you must have your factory PCM tuned by a professional tuner. This includes fueling, spark, transmission as well as many other functions. You must contact your preferred tuning specialist for a custom tune, failure to do so may lead to severe power-train damage. AIR FUEL RATIO Air fuel ratio is the measurement of the amount of air and fuel being burned during the combustion process. There are currently many different air fuel-monitoring systems and accuracy is not always guaranteed. Wide band oxygen sensors vary over time and deteriorate with uses of leaded gasoline. Whipple only uses Horiba wide band analyzers and UEGO 6-wire sensors, the most accurate available. Our sensors are checked after every use and transfer functions are changed every time so make sure you’re using an accurate meter. Whipple has found that 12.6:1 is approx. the best a/f for power. Be very careful though, too lean of an air fuel ratio increase cylinder temps and increase the chance of detonation, which is detrimental to engine life. Under high boost applications such as 13-15PSI, Whipple recommends 12:25:1. For levels above 15psi, you should never run leaner than 12.25:1 unless you’re using 100+ octane and are monitoring detonation/knock. Race gas setups can run 12.6:1 up to 21psi. Once again, this is based with a very accurate a/f meter so this should only be used as a rule of thumb because most meters will vary. SPARK PLUGS Factory spark plugs are acceptable for up to 10psi. Any boost level beyond 10 should only be run with Denso Iridium NGK plugs, which offer superior performance. We recommend a Denso Iridium IT20 (stock gapping) for 14-20psi and the Denso Iridium IT22 (stock gapping) for boost levels over 20psi. Whipple also recommends the NGK BP7EFS plugs gapped to .035” which will help prevent detonation. ENGINE COOLANT For boost levels above 15psi, Whipple recommends running a 75/25 mix of distilled water and coolant vs. the factory 50/50. We also recommend 1-2 bottles of Red Line Water Wetter coolant additive. This will reduce air bubble insulation, which increases overall engine temp. INTERCOOLER COOLANT AND COOLERS The factory intercooler system is very well designed and Whipple saw no increased benefits from any changes below 13psi of boost. For systems that run more than 13psi, Whipple recommends changing the 50/50 factory ratio to 75/25 distilled water and factory Ford coolant. We also recommend 1 bottle of Red Line Water Wetter coolant additive. If you are running above 15psi, a higher capacity heat exchanger such as Fluidyne’s is a good choice as well as a larger capacity reservoir and electric fan kit. This will have a higher capacity to maintain low discharge temperatures. When going to larger capacity heat exchangers and reservoirs, you should install one extra bottle of Red Line Water Wetter (2 total). THROTTLE BODY Increased bore mono blades such as Billet Flow’s and Accufabs do have beneficial changes. In all cases, the large mono blade throttle bodies will have a significant throttle response increase at all given throttle positions and therefore will fill to most as increased power. Before 450hp, gains are very little in overall power output. After 450 hp, you begin to see an increasing performance gain, approx. 5hp @ 500hp and becomes significantly important at levels above 550hp. FUEL LEVEL Never operate at WOT when the vehicle fuel levels are below a ¼ tank. Low fuel levels could cause the fuel pump to cavitate and you’ll have fuel flow spikes resulting in lean conditions and consequently detonation.

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LIMITED WARRANTY

All merchandise manufactured by Whipple Industries has a limited warranty against defects in workmanship and materials to the original purchaser of the Whipple Supercharger System for one calendar year from Whipple Industries ship date. The limited warranty must be signed, dated and returned to Whipple Industries within 30 days of the Whipple Industries ship date and must be accompanied by a copy of the original sales invoice. This warranty is non-transferable. If an item is suspected of being defective, return it to Whipple Industries for inspection after obtaining the proper Return Authorization Number. If an item is determined to be defective, we will repair or replace it at our discretion within a period of one year from the shipping date on your invoice. Whipple Industries Inc. limited warranty specifially does not apply to products which have been (a) modified or altered in any way, (b) subjected to adverse conditions suach as misuse, neglect, accident, improper installation or adjustment, dirt, or other contaminants, water, corrosion or faulty repair; or (c) used in other than those specifically recommended by Whipple Industries Inc. All products designed for off-road use are considered racing parts and carry no warranty, either expressed or implied, as we have no control over how they are used. On warranty items, repair/replacements will be limited to parts manufactured by Whipple Industries and will not include claims for labor or inconvenience. All other merchandise distributed by Whipple Industries is warranted in accordance with the respective manufacturer's own terms of warranty. This warranty is expressly made in lieu of any and all other warranties expressed or implied, including the warranties of merchantability and fitness. Whipple Industries will not be responsible for any other expenses incurred by the customer under the terms of this warranty, nor shall it be responsible for any damages either consequential, special, contingent, expenses or injury arising directly or indirectly from the use of these products. Whipple Industries reserves the right to determine whether the terms of the warranty, set out above, have been properly complied with. In the event that the terms are not complied with, Whipple Industries shall be under no obligation to honor this warranty. By signing this form, you understand and agree to the terms above. NAME (Print) ADDRESS SIGNATURE CITY STATE ZIP DATE PHONE SC SERIAL # EMAIL VIN #

(Found on compressor bearing plate)

Page 3

(Optional)

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CONGRATULATIONS Your new Whipple Supercharger is engineered to significantly increase your engines power across a broad range of RPM’s. It is Whipple’s goal to improve your driving experience for many miles and years to come. Whipple Superchargers operate as an air pump and contain internal rotors that are driven by the engine’s crankshaft and serpentine belts. The supercharger compresses outside air and channels it into the engine’s intake ports. Because of their design, superchargers may generate some additional noise over the standard, normally aspirated induction system. At idle, you may hear a medium-pitch rattle from the supercharger main housing. This will diminish at about 400-500 rpm above idle. You may also experience a muffled high-pitched whine during acceleration. This is caused by the pumping action of the supercharger compressing air and only occurs during boost conditions. It is inaudible during part-throttle acceleration. These are normal noises associated with any supercharger and have no effect on supercharger performance or engine durability. Your supercharger is warranted by Whipple Superchargers. Note that Whipple Superchargers will not authorize any warranty repair work or supercharger replacement for normal noises.

Supercharger Installation Manual - :::by Stein Design: Web Site

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Transcript of Supercharger Installation Manual - :::by Stein Design: Web Site