Highly Styled, Low Cost Serpentine Drive

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Patrick Blankenship
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1 Highly Styled, Low Cost Serpentine Drive Installation Instructions Ford 460 Big Block Kit #30275 (with Power Steering) and #30270 (without Power Steering)

2 Included Parts List Main Front Bracket Kit P/N A... Main Front Bracket Body A... Idler Pulley Body A... Idler Pulley Cap 6 - S x 3 8" SHCS 4 - S "-18 x 7 8" SHCS 6 - S "-18 x 1 1 2" SHCS 1 - S "-18 x 4" SHCS 4 - S "-18 x 4 1 2" Threaded Stud 2 - S "-16 x 1 3 4" SHCS 1 - S "-16 x 5 1 2" SHCS 1 - S M8mm x 25mm SHCS 2 - S M8mm x 35mm SHCS 7 - S " ID SAE Flat Washer 2 - S " ID x 3 4" OD Flat Washer 4 - S " Threaded Spacer Stainless 2 - MM Alum Bolt Cap Alternator Rear Support P/N A... Alt Rear Support Bracket Body 1 - AC " Spacer Alum 1 - S "-14 x 1" SHCS 1 - S " OD Threaded Bushing 1 - S " SAE Flat Washer A/C Rear Support P/N A... A/C Rear Support Bracket Bolt 1 - TP Spacer 3 8" ID x.700 Lg 1 - S "-18 x 2" Hex Head Bolt 1 - S "-16 x 1" SHCS 1 - S "-14 x 1" SHCS 1 - S " ID x 3 4" OD Flat Washer 1 - S " ID SAE Flat Washer Adjustment Tool P/N MM Right Hand Rod End Alum 1 - MM Left Hand Rod End Alum 1 - MM " Threaded Rod Power Steering Bracket P/N (For Kit With P/S) A... Power Steering Bracket Body A... Idler Pulley Body A... Idler Pulley Cap Body 1 - TP " ID Spacer.400" Lg 3 - S x 3 8" SHCS 3 - S "-18 x 7 8" SHCS 1 - S "-18 x 2 1 4" SHCS 3 - S M8mm-1.25 x 25mm SHCS 1 - S " ID x 3 4" OD Flat Washer Pulley Kit P/N A... Crank Pulley Body A... Water Pump Pulley Body A... Alt Pulley Body A... Alt Fan Body A... Alt Pulley Cap A... Water Pump Pulley Cap A... A/C Cover Body 3 - S x 1" SHCS 4 - S "-24 x 7 8" SHCS (Fine Thread 4 - S "-16 x 1" SHCS 3 - S M6mm-1.0 x 16mm Button Head Bolt 1 - S " Lock Washer A... Power Steering Pulley (Press Fit) A... Power Steering Pulley Cap 3 - S x 3 8" SHCS Accessories 1 - P Water Pump Big Block FORD 1 - P A/C Compressor 1 - P A/C Line Kit 1 - P Amp Alternator 1 - P Power Steering Pump Remote (For Kit With P/S) Required Tools and Materials RTV Silicone Loc-Tite Thread Locker Gasket Scraper, Steel Wool or Sandpaper to clean gasket surfaces 3 16" Allen Head Driver 5 16" Allen Head Driver 1 4" Allen Head Driver 6mm Allen Head Driver 5 8" Combo Wrench 9 16" Combo Wrench 11 16" Combo Wrench 3 4" Combo Wrench Socket Wrench & Extension 10mm 12pt. socket 12mm 12pt. socket

Preparing to Install Disconnect the battery to prevent accidental engagement of starter motor. Drain coolant from system If your A/C is intact and charged it must be evacuated.

3 Preparing to Install Disconnect the battery to prevent accidental engagement of starter motor. Drain coolant from system If your A/C is intact and charged it must be evacuated. This is best done by a professional garage with proper recycling equipment Installing the Kit A H Remove the existing alternator, air conditioning compressor and associated brackets. Remove all pulleys and water pump. Remove all traces of old gasket and sealer with gasket scraper and steel wool pad. Clean threads in block by chasing with appropriate thread chasers. I J C Diagram 1. K G B D F E Ensure the sealing face of the coolant outlets are clean, flat and free of old gasket material. Assemble Water Pump (P167) to block along with proper gaskets and a thin coat of RTV silcone sealant. Refer to Diagram 1 for proper bolt location 2. E,F,G,H,I,K, x 1 1 2" SHCS (S150) and a 5 16 Flat washer (S660) J x 4 SHCS (S170) and 5 16 Flat Washer (S660) A,B,C,D,... (4) 4 1 2" Threaded Studs (S210) A.B.C.D... (4) Tapped Studs As Shown (S769) Fig 2. Install (4) threaded studs (S210) into water pump holes A,B,C,D Leaving 1 2 inch exposed thru the water pump. Now install the (4) threaded spacers (S769) onto the studs and tighten.

FIG 3. Installing the rear Alternator Support and Rear A/C Support to the head.

(1) 3 8 Washer (S666) or (1) 7 16 x 1 SHCS (S344) and (1) 7 16 Washer (S672) do not tighten at this time. 3. Adjustment Screw S452 FIG 4.

Use (4) 5 16 x 7 8 SHCS (S144) to install the Main Front Bracket (30271- A) to the Mounting studs but at

Install the Alternator (P572) using (1) 3 8 x 5 1 2" SHCS (S280) and align the rear support bracket.

Use the Ajustment screw (S452) in the rear support bracket to take up any slack in the alternator Adjust

4 FIG 3. Installing the rear Alternator Support and Rear A/C Support to the head. First install the rear Alternator Support (30272-A) Using (1) 7 16 x 1" SHCS (S344) and (1) 7 16 Flat Washer (S672) Do not Tighten at this time. Now install the 5 18 x 1 2" long Ajustment screw (S452) into the rear support Bracket as shown. Screw in till flush. Mount the rear A/C support Bracket (30273-A) to the left side of the head using (1) 3 8 x 1 SHCS (S248) and (1) 3 8 Washer (S666) or (1) 7 16 x 1 SHCS (S344) and (1) 7 16 Washer (S672) do not tighten at this time. 3. Adjustment Screw S452 FIG 4. Installing the Main Front Plate. Use (4) 5 16 x 7 8 SHCS (S144) to install the Main Front Bracket ( A) to the Mounting studs but at this time leave 1 8 of a inch play for later installation of the Alt & A/C units FIG 5. Install the Alternator (P572) using (1) 3 8 x 5 1 2" SHCS (S280) and align the rear support bracket. Use the (A ) Alum. Spacer between the rear support and the rear of the alternator Unit. Use the Ajustment screw (S452) in the rear support bracket to take up any slack in the alternator Adjust S452 to take up space FIG 6. Tighten the rear support bracket to the block. 6. FIG 7. Installing the A/C unit (P412). Use a M8 x 1.25 x 25mm SHCS (S551) thru the front main plate. Align the rear support and install a 5 16 x 2" Hex Head Bolt (S216) thru the rear ear of the A/C unit using the TP Spacer Between the Rear Support and the rear ear of the A/C unit. Do not Tighten at this time. 7.

Alternator & A/C units letting them lean inward

This is the proper set up showing a side view

Now tighten the Rear support bolt into the Rear

Now that you have Proper alignment of the rear

5 FIG 8. Tighten the front Main Plate and swing up the Alternator & A/C units letting them lean inward at this time. 8. FIG 9. This is the proper set up showing a side view of the A/C unit with proper spacing. 9. FIG 10. Now tighten the Rear support bolt into the Rear Support bracket. 10. FIG 11. Now that you have Proper alignment of the rear support for the A/C unit Tighten as shown. 11. FIG 12. Install the Crank Pulley (1881-A) As shown using (4) 3/8 x 1" SHCS (S248). 12.

using (4) 5 16 x 7 8 SHCS (S186) 13. 14. FIG 14.

x 1 3 4" SHCS (S254) and two 3 8" Washers (S666) FIG 15.

using (3) M8 x 1.25 x 25 mm SHCS (S551). 15. 16. FIG 16.

3 8 x 2 1 4" SHCS (S260) and a 3 8" washer (S666) use a TP3-.

6 FIG 13. Install The Water Pump Pulley (1882-A) and the water pump Cap (313-A) using (4) 5 16 x 7 8 SHCS (S186) FIG 14. Install the Two Idler Pulleys (740-A) to the main bracket using (2) 3 8 x 1 3 4" SHCS (S254) and two 3 8" Washers (S666) FIG 15. Mount the Power steering Unit to the Power steering bracket (30274-A) using (3) M8 x 1.25 x 25 mm SHCS (S551) FIG 16. Mount the Power Steering Unit (P315) to the main bracket as shown using (3) 5 16 x 7 8" SHCS (S144). FIG 17. Mount the idler Pulley (740-A) to the Power Steering Bracket using (1) 3 8 x 2 1 4" SHCS (S260) and a 3 8" washer (S666) use a TP Spacer Between the Idler pulley and the Power steering bracket FIG 18. Install the Power Steering Pulley (618-A) using a proper install tool for press fit remote style pumps. Press pulley on till it is flush with the shaft.

FIG 19. Install the Alternator Fan (221), Alt Pulley (208-A) and cover (307-A). Slide the fan over the shaft followed by the Alt Pulley.

Now install (3) Idler Caps, and P/S Cap with 8-32 x 3 8" SHCS (S022). Next install Alt Cap with 8-32 x 1" SHCS (S028). 19. 20. FIG 20.

25 x 35 MM SHCS (S553) through the bushings and into the top mounts of the alternator and A/C units. 21. FIG 22.

lbs. Use the holes in the adjustment tool to tighten both 8mm socket head cap screws when correct belt tension has been achieved. Remove the adjustment tool and keep for future use. 22.

7 FIG 19. Install the Alternator Fan (221), Alt Pulley (208-A) and cover (307-A). Slide the fan over the shaft followed by the Alt Pulley. Use the lock washer (S685) and lock nut (we Recommend an impact to install.) Install A/C Cover (394-A) with (3) M6 x1.0 x 16mm button head bolts (S520). Now install (3) Idler Caps, and P/S Cap with 8-32 x 3 8" SHCS (S022). Next install Alt Cap with 8-32 x 1" SHCS (S028) FIG 20. Installing the belt Dayco P/N (79 1 2" Belt) or (non P/S) 70" Belt FIG 21. After Installing the belt use the (2) Alum. Bushings (MM100) and (2) M8 x 1.25 x 35 MM SHCS (S553) through the bushings and into the top mounts of the alternator and A/C units. 21. FIG 22. Slip the supplied March Adjustment Tool (30436) over the two (MM100) bushings at the Alternator an A/C sides. Use a wrench to turn the adjustment tool outward to tighten the serpentine belt to 100 ft. lbs. Use the holes in the adjustment tool to tighten both 8mm socket head cap screws when correct belt tension has been achieved. Remove the adjustment tool and keep for future use. 22. TIP: Your Serpentine belt is tight when it can t be moved by more then 1/2" inch at it s longest span between pulleys. The belt should not be able to be twisted by more then half a turn. Check and tighten all bracket bolts and alternator and A/C lower mounting bolts, turn engine over once by hand to check for any belt rubbing and proper belt alignment. Run engine three minutes and check belt tension again. Final Assembly If you are going to be installing your air conditioning hoses and charging the system at this time, remove the cover plate on top of the compressor body. Install the (P417) A/C adapter lines, hoses and connect clutch wire and charge system. Important:If you are NOT installing hoses and charging the system at this time, leave cover plate on compressor. Do not connect the clutch wire or apply power to clutch wire without the hoses connected and the system charged Serious damage will occur to compressor.

Highly Styled, Low Cost Serpentine Drive

Revised 2-27-08 Highly Styled, Low Cost Serpentine Drive Installation Instructions Ford 460 Big Block Kit #30275 (with Power Steering) and #30270 (without Power Steering) Included Parts List Main Front