Official Powerdyne Model BD Supercharger and Kit Limited Warranty

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2 Official Powerdyne Model BD Supercharger and Kit Limited Warranty Powerdyne Automotive Products Inc. warrants your new Powerdyne model BD Supercharger and installation kit to be free of defects in workmanship and materials for a period of three years (36 months) from the date of purchase by the original end user. Repaired superchargers are warranted for 6 months from the date of repair. Prior factory authorization must be obtained to return any part for warranty inspection. Supercharger or kit parts authorized to be inspected for repair or replacement under warranty must be shipped freight prepaid to Powerdyne. Determination of actual warranty qualifications rests solely with Powerdyne. Superchargers will not qualify for warranty if the supercharger pulley has been removed or changed, or if the pulley warranty seal has been broken or tampered with and/or if the kit parts have been altered or improperly installed. Superchargers used for racing, amateur or professional, are specifically excluded from any warranty protection. Authorized warranty is limited to repair or replacement only, with no refunds or credits allowed. Warranted superchargers will continue to be protected under the original 3-year warranty, or the 6-month repair warranty, whichever is longer. Supercharger or kit repairs under warranty will be returned to the owner with ground transportation charges prepaid by Powerdyne, within the continental US, or to the point of embarkation within the continental US, via UPS ground (or similar), service; owner will be responsible for any other charges in service requested or freight charges outside the continental US. Superchargers or parts authorized to be returned and inspected which do not qualify for warranty, and are not repaired at the owner s expense, will be subject to a $ (US) inspection fee and returned to the owner transportation charges collect. Powerdyne offers no performance or merchantability warranties, neither offered nor implied. Also, because superchargers are high performance modifications designed to change the performance of engines for which they are designed, and because Powerdyne has no control over the adequacy and correctness of the installation and actual use, Powerdyne expressly disclaims and responsibility or liability for possible engine damage, or any consequential damages which may occur. This warranty is the sole and exclusive warranty offered by Powerdyne Automotive products Inc. No employee or agent may enlarge or modify its terms and/or conditions. Warranty Procedure Telephone Powerdyne Automotive Products at (661) , during California business hours of 8am to 3pm, Monday through Friday, with the following information: 1. Serial number of the supercharger. 2. Description of the problem. 3. Make, Model, and Year of the vehicle. 4. Your name, shipping address (No PO Boxes allowed), and your daytime telephone number. 5. A copy of your original purchase invoice. Upon receipt of the above, if warranty service is appropriate, a Powerdyne Return Authorization Number will be assigned. You should then send the supercharger or other defective part, with all of the above information to: Powerdyne Automotive Products Inc. Attn: Repair Dept. 104-C East Avenue K-4 Lancaster, CA The return authorization number must be included on the package. Freight collect shipments will be refused and returned to the sender at the sender s expense.

3 Custom Tuning Sheet Kit Part Number: Blower Serial #: Computer Code: Ph: Fx: Date: / / *Chip voucher void if not redeemed within 90 days of purchase* Vehicle Year: Make: Model: 1or 2 Fuel Cells: VIN #: Fuel Octane: Engine: Throttle Body: MAF Sensor Make: Heads: Intake: Size: Cam/s: Lift Duration / Fuel Injector Make: Header: Cat-Back Type: Powerdyne Part: Cats: 19lb 24lb 30lb 36lb 38lb 42lb Boost: PSI Fuel Pump: Other: Transmission: Rear End Gear: Auto: Man: Tire Size: / / Nitros / HP: Wet: Dry: Comments: Customer Name: Address: City / State / Zip: Phone Number: Powerdyne Automotive Products includes a computer chip or programmer in this kit. Please fill out this certificate and fax to the number above to receive your part. Limit one (1) chip or programmer per serial number. Please allow up to two (2) business weeks for delivery. Leave space blank if that item is stock on your vehicle.

4 Powerdyne Automotive Products Inc. Installation Instructions, 2004 FORD F-150 with 5.4L 3V engine. This manual is intended for the installation of Powerdyne Supercharger kit, Part Number K on Ford F-150 with the 5.4L 3V motor, model years 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. It is very important that these instructions be followed exactly. IF YOU HAVE NOT YET RE- CEIVED YOUR CUSTOM PROGRAMMED TUNE, DO NOT BEGINE THIS INSTALLATION. Premium unleaded fuel with an octane rating of 92 or higher must be used with this Supercharger installed at all times. Failure to use the proper fuel may cause detonation (pinging) and cause severe engine damage. Never change the crank Pulley or the Supercharger Pulley as this will void the factory warranty (see warranty document on the preceding page) and may cause severe engine damage. Component Removal: A. Disconnect negative battery cable from battery. B. Remove the factory air filter enclosure and air intake tube.. C. Disconnect cam sensor connector from cam sensor on driver side front cover. D. Remove fan shroud and factory fan. Step 1. Install the supercharger crankshaft pulley using 3-10mm x 25mm bolts provided in the kit. (refer to fig. 1) To help you with the installation, please read the entire step before proceeding with that step. Only install this kit on an engine with 0 (zero) fuel pressure to avoid fire, injury and possible damage. Make sure that you have a chemical fire extinguisher handy when installing and/or testing any part of the fuel system. DO NOT install any part of the fuel system, or break open any fuel lines near to any source of heat or flame such as a water heater or cigarette. If you are not a qualified mechanic do not attempt this installation. Instead take the vehicle to a qualified mechanic. FIG.#1 2

5 Step 2. Remove intake support bracket and mounting bolt with stud but leave the power steering reservoir bracket in place. (Refer to figure 2). FIG.#2 FIG.#3 Step 4. Install the ribbed pulley and idler shaft below the cam position sensor on the mounting plate using the 2.75 x 3/8-16 allen bolt, washer and pulley retainer. (Refer to figure 4). Step 3. Install the provided supercharger mounting bracket using the.25 spacer, 10mm x 45mm bolt and washer in the lower hole and the 1.60 spacer, 8mm x 110mm and washer in the lower right hole. Use the.450 spacer between the power steering reservoir bracket and the engine and the.770 spacer between the power steering reservoir bracket and the supercharger mounting plate and a 8mm x 120mm bolt and washer in the upper hole. Make sure the cam position sensor wire is routed behind the mounting plate. (Refer to figure 3 and illustration 1 on the next page). 3 FIG.#4

6 Step 5. Install seven 3/8-16 x 2.0 allen bolts, washers and 1.0 spacers loosely in the supercharger mounting holes. (Refer to figure #5). Step #7. Install the discharge tube from the supercharger outlet to the throttle body using the silicone sleeves and hose clamps provided. (Refer to figure #7). FIG.#5 Step 6. Install the supercharger to the mounting bracket and tighten evenly. (Refer to figure #6). FIG.#7 Step 8. Install the provided K belt and supercharger tensioner and tighten. (Refer to figure 8) FIG.#8 FIG.#6

7 Step 9. Install the 90 degree plastic elbow to the inlet of the supercharger pointing towards the passenger side of the vehicle using the 3.5 x 2.0 silicone sleeve and two #56 hose clamps. (Refer to figure#9). Step 11. Install four air filter mounting to the intake manifold and supercharger mounting bolt. (Refer to figure 11) FIG.#9 Step 10. Install the cast aluminum elbow and flex hose to the bottom of the factory air filter enclosure using the hose clamps provided. (Refer to figure #10). FIG.#11 Step 12. Install the air filter enclosure to the brackets with hardware provided and connect the flex hose to the plastic intake elbow using the hose clamps provided. Install your new high flow air filter. Re-install your fan and shroud. Remove the factory flex hose from the intake tube and replace with flex hose and clamps provided. (Refer to figure 12) FIG.#10 FIG.#12

8 Step 13. Install the supplied bypass valve with the short hose going to the 90 degree fitting on the intake elbow and the long end going to the discharge tube. Use the supplied vacuum line and vacuum tee to connect to manifold vacuum at the fuel pressure regulator on the fuel rail. (Refer to figure #13). Step 14. Re-connect the mass air wire harness to the air filter enclosure you may need to unwrap the tape and remove the wire from the factory wire loom for it to reach to the mass air meter connection. Step 15. Install your performance program by carefully following their instructions. (Note: do not run the vehicle until the computer program is installed). Check all wiring, hoses and fuel lines for clearance of moving parts, sharp edges and heat sources that may cause damage. Reroute if necessary. Turn ignition to key on but do not start. This will energize the fuel pump and allow you to check for any fuel leaks. If any fuel leaks are detected correct the problem before starting the engine. Start the engine and check for proper belt alignment and tension. Note over time your supercharger belt may stretch slightly. Check belt periodically and adjust tension as needed. Your supercharger kit is now complete. Suggested add on. Although your Powerdyne supercharger is designed to work flawlessly on a stock vehicle to maximize a good set of headers and a cat back exhaust system would be beneficial.