an ISO 9001:2008 Registered Company SMALL BLOCK FORD SERPENTINE DRIVE SYSTEM WITH & WITHOUT POWER STEERING 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 1 OF 10
PAGES 1. COVER 2. TABLE OF CONTENTS/INFORMATION 3. REMOVAL OF OEM BELT SYSTEM FIGURE 1 4. & SEAL INSTALLATION FIGURES 2, 3 & 3a 5. FRONTRUNNER MAIN BRACKET & WATER PUMP INSTALLATION FIGURES 4 & 5 6. COMPRESSOR & COMPRESSOR BLOCK FITTING w/ HARDLINE INSTALLATION FIGURES 6 & 7 7. ALTERNATOR & TENSIONER INSTALLATION FIGURES 8 & 9 8. WATER PUMP & CRANKSHAFT PULLEY INSTALLATION POWER STEERING PUMP INSTALLATION FIGURES 10 & 11 9. BELT INSTALLATION FIGURES 12 & 13 10. FINAL STEPS FIGURE 14 SERVICE INFO: Table of Contents IMPORTANT NOTICE-PLEASE READ FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING: EVACUATE THE SYSTEM FOR 35-45 MINUTES WITH SYSTEM COMPONENTS (DRIER, COMPRESSOR, EVAPORATOR AND CONDENSER) AT A TEMPERATURE OF AT LEAST 85 F. ON A COOL DAY THE COMPONENTS CAN BE HEATED WITH A HEAT GUN OR BY RUNNING THE ENGINE WITH THE HEATER ON BEFORE EVACUATING. LEAK CHECK AND CHARGE TO SPECIFICATIONS. THE PROPER AMOUNT OF REFRIGERANT IS CRITICAL TO PROPER SYSTEM OPERATION. VINTAGE AIR RECOMMENDS OUR SYSTEM BE CHARGED BY WEIGHT WITH A QUALITY CHARGING STATION OR SCALE. REFRIGERANT CAPACITIES FOR VINTAGE AIR SYSTEMS (FOR OTHER SYSTEMS, CONSULT MANUFACTURER GUIDELINES) 134a SYSTEM CHARGE WITH 1.8 lbs. (1 lb. 12 oz.) OF REFRIGERANT LUBRICANT CAPACITIES NEW COMPRESSOR - NO ADDITIONAL OIL NEEDED USED COMPRESSOR - CONSULT VINTAGE AIR 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 2 OF 10 2
READ INSTRUCTIONS COMPLETELY AND THOROUGHLY BEFORE INSTALLING THE VINTAGE AIR FRONTRUNNER SYSTEM. FOLLOW INSTRUCTIONS STEP-BY-STEP FOR PROPER INSTALLATION. REMOVAL OF OEM FRONT BELT SYSTEM * DISCONNECT NEGATIVE BATTERY CABLE. * DRAIN RADIATOR FLUID. * DRAIN ENGINE OIL. * REMOVE FAN, FAN SHROUD AND BELTS. * REMOVE ALTERNATOR AND A/C COMPRESSOR AND BRACKETS. * REMOVE CRANKSHAFT PULLEY AND HARMONIC BALANCER. NOTE: THIS SYSTEM IS DESIGNED TO USE THE STOCK FORD HARMONIC BALANCER. BEFORE YOU REMOVE THE HARMONIC BALANCER, VERIFY THAT THE DIMENSIONS FROM THE FACE OF THE BLOCK TO THE MACHINED PULLEY MOUNTING SURFACE OF THE BALANCER IS 4.813" (4 13/16"). MEASURE AS SHOWN IN FIGURE 1, BELOW (MEASURE FROM THE SHADED SURFACES). IF USING A FORD MOTOR SPORTS BALANCER, YOU MUST PURCHASE A FORD MOTORSPORTS BALANCER SPACER KIT (199002-HFA)FROM VINTAGE AIR. * REMOVE OEM WATER PUMP AND THERMOSTAT. * REMOVE MOTOR MOUNT BOLTS AND LIFT ENGINE HIGH ENOUGH TO DROP OIL PAN. * USING THE PROPER EQUIPMENT, SUPPORT ENGINE. * DROP THE OIL PAN. NOTE: MAKE SURE YOU DO NOT DAMAGE OIL PAN. * REMOVE OEM TIMING COVER AND TIMING POSITION INDICATOR (RETAIN INDICATOR). * REMOVE ALL EXCESS TIMING COVER MATERIAL FROM THE FRONT OF THE BLOCK. MEASURE FROM THIS SURFACE 4.813" (4 13/16") MEASURE FROM THIS SURFACE SQUARE RULER/STRAIGHT EDGE FIGURE 1 3 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 3 OF 10
OPTIONAL DIPSTICK INSTALLATION TO INSTALL DIPSTICK, REFER TO INSTALLATION INSTRUCTIONS SUPPLIED WITH DIPSTICK KIT. & SEAL INSTALLATION USING A SUITABLE SEAL INSTALLATION TOOL, INSTALL THE CRANKSHAFT SEAL (SUPPLIED) IN THE FRONTRUNNER MAIN BRACKET. NOTE: THE SEAL CAN NOT BE HAMMERED IN. IF YOU DO NOT HAVE THE CORRECT SEAL INSTALLATION TOOL, TAKE BRACKET AND SEAL TO YOUR LOCAL AUTOMOTIVE PARTS RETAILER TO HAVE SEAL INSTALLED. USING A SUITABLE ADHESIVE, APPLY A BEAD OF ADHESIVE TO THE BACK SIDE OF THE FRONTRUNNER MAIN BRACKET MOUNTING SURFACE. INSTALL THE TIMING COVER (SUPPLIED) AS SHOWN IN FIGURE 2, BELOW. APPLY A BEAD OF ADHESIVE TO THE BACK SIDE OF THE WATER PUMP MOUNTING SURFACE. INSTALL THE WATER PUMP (SUPPLIED WITH WATER PUMP) AS SHOWN IN FIGURE 2, BELOW. TIMING COVER DIPSTICK MOUNTING LOCATION ON BACK SIDE OF FRONTRUNNER MAIN BRACKET WATER PUMP CRANKSHAFT SEAL FIGURE 2 WATER PUMP USING A SUITABLE HIGH TEMP RTV SILICONE, APPLY SILICONE TO THE TIMING COVER/OIL PAN LOCATORS ON THE BOTTOM SIDE OF THE FRONTRUNNER MAIN BRACKET. SEE FIGURE 3, BELOW. USING A SUITABLE ADHESIVE, APPLY A BEAD OF ADHESIVE TO THE OIL PAN SURFACE AS SHOWN IN FIGURE 3a AND INSTALL THE OIL PAN (SUPPLIED). SEE FIGURE 3a, BELOW. SILICONE FIGURE 3a ADHESIVE OIL PAN FIGURE 3 OIL PAN 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 4 OF 10 ADHESIVE 4
NOTE: RUN A TAP THROUGH ALL MOUNTING HOLES IN BLOCK PRIOR TO INSTALLATION. ALL BOLTS WILL USE A 3/8" 12 POINT SOCKET/WRENCH. APPLY ANTI-SEIZE TO ALL THREADS BEFORE INSTALLATION. FRONTRUNNER MAIN BRACKET & WATER PUMP INSTALLATION INSTALL THE FRONTRUNNER MAIN BRACKET. NOTE: MAKE SURE THE TIMING COVER/OIL PAN IS ALIGNED PROPERLY. SECURE THE FRONTRUNNER MAIN BRACKET USING BOLTS WITH AN WASHERS AS SHOWN IN FIGURE 4, BELOW. NOTE: INSTALL TIMING INDICATOR AS SHOWN BELOW. INSTALL OIL PAN. NOTE: MAKE SURE THE OIL PAN IS ALIGNED PROPERLY. FRONTRUNNER MAIN BRACKET (4) 184251-ISD 5/16-18 x 2 ½" SS 12 PT BOLTS w/ (4) 18544-WNS TIMING INDICATOR OIL PAN FIGURE 4 NOTE: DUE TO THE SLIGHT VARIATIONS OF BLOCK CASTINGS, BOLTS MAY BOTTOM OUT BEFORE BRACKET IS TIGHT. IT MAY BE NECESSARY TO TRIM THE BOLTS APPROX. 1 THREAD. INSTALL THE WATER PUMP. NOTE: MAKE SURE THE WATER PUMP IS ALIGNED PROPERLY. SECURE THE WATER PUMP USING BOLTS WITH AN FLAT WASHERS AS SHOWN IN FIGURE 5, BELOW. INSTALL THE HARMONIC BALANCER. NOTE: IF USING A FORD MOTORSPORTS BALANCER SEE INSTRUCTIONS WITH HARDWARE KIT 199002-HFA. 184425-ISD 5/16-18 x 4 ¼" SS 12 PT BOLT w/ 18544-WNS 5/16" AN FLAT WASHER (2) 184125-ISD 5/16-18 x 1 ¼" SS 12 PT BOLT (2) 184325-ISD 5/16-18 x 3 ¼" SS 12 PT BOLTS 184425-ISD 5/16-18 x 4 ¼" SS 12 PT BOLT w/ 18544-WNS 5/16" AN FLAT WASHER 5 HARMONIC BALANCER (2) 184325-ISD 5/16-18 x 3 ¼" SS 12 PT BOLTS 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 5 OF 10 FIGURE 5 184225-ISD 5/16-18 x 2 ¼" SS 12 PT BOLT w/ 18544-WNS 5/16" AN FLAT WASHER
COMPRESSOR & COMPRESSOR BLOCK FITTING w/ HARDLINES INSTALLATION INSTALL COMPRESSOR SECURING USING BOLTS AND NUTS WITH AN FLAT WASHERS AS SHOWN IN FIGURE 6, BELOW. COMPRESSOR (2) 186018-NSD FITTING COVER 5/16-18 NYLOC NUTS (2) 184425-ISD 5/16-18 x 4 ¼" SS PT BOLTS NOTE: APPLY A BEAD OF ANTI-SEIZE ON THE BOLT THREADS FIGURE 6 APPLY A COAT OF PAG OIL AROUND O-RINGS COMPRESSOR FITTING COVER REMOVE THE COMPRESSOR FITTING COVER (DISCARD COVER AND SCREWS) AND APPLY A COAT OF PAG OIL AROUND O-RINGS. SEE FIGURES 6 & 7. USING (2) 8mm-1.25 x 20mm SS SOCKET HEAD CAP SCREWS, INSTALL THE COMPRESSOR BLOCK FITTING WITH HARDLINES AS SHOWN IN FIGURE 7. SECURE THE HARDLINES TO THE FRONTRUNNER MAIN BRACKET USING THE HARDLINE BRACKET AND A 1/4-20 x 3/4" SS FLAT SOCKET CAP SCREW. SEE FIGURE 7. FIGURE 7 (2) 184120-HMS 8mm-1.25 x 20mm SS SOCKET HEAD CAP BOLTS HARDLINE BRACKET 18011-VUB 1/4-20 x 3/4" FLAT SOCKET CAP SCREW 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 6 OF 10 6
ALTERNATOR INSTALLATION INSTALL ALTERNATOR AND SECURE USING BOLTS WITH AN FLAT WASHSERS AS SHOWN IN FIGURE 8, BELOW. 184426-ISD 3/8-16 x 4 ¼" SS 12 PT BOLT w/ 18543-WNS 3/8" AN FLAT WASHER ALTERNATOR 184125-ISD 5/16-18 x 1 ¼" SS 12 PT BOLT w/ 18544-WNS 5/16" AN FLAT WASHER FIGURE 8 TENSIONER & TENSIONER COVER INSTALLATION SEE TENSIONER COVER INSTALLATION INSTRUCTION SUPPLIED WITH COVER. REMOVE TENSIONER ROLLER & INSTALL TAPERED BLOCK NUT INTO THE BACK SIDE OF TENSIONER (LIGHTLY TAP INTO PLACE). NOTE: IT MAY BE NECESSARY TO USE A FILE AND REMOVE EXCESS METAL FLASHING AROUND SQUARE OPENING FOR THE TAPERED BLOCK NUT TO FIT PROPERLY. REINSTALL TENSIONER ROLLER TO TENSIONER. INSTALL TENSIONER USING A 3/8-16 x 2 ½" SS 12 PT BOLT AND 3/8" AN FLAT WASHER AS SHOWN IN FIGURE 9. TENSIONER 18369-VHS 3/8-16 x 2 ½" SS 12 PT BOLT w/ 18543-WNS 3/8" AN FLAT WASHER FIGURE 9 7 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 7 OF 10
WATER PUMP & CRANKSHAFT PULLEY INSTALLATION INSTALL CRANKSHAFT PULLEY USING (4) 3/8-16 x 1 ¼" SS 12 PT BOLTS AND (4) 3/8" AN FLAT WASHERS AS SHOWN IN FIGURE 10, BELOW. INSTALL WATER PUMP PULLEY USING (4) 5/16-24 x 3/4" 12 PT BOLTS AS SHOWN IN FIGURE 10, BELOW. (4) 184075-ISD 5/16-24 x 3/4" SS 12 PT BOLTS THIS FEATURE MUST FACE OUT (4) 184126-ISD 3/8-16 x 1 ¼" SS 12 PT BOLTS w/ (4) 18543-WNS 3/8" AN FLAT WASHERS 3.2 (FROM THE REAR OF PULLEY TO THE REAR OF PUMP) FIGURE 10 WITH POWER STEERING INSTALLATION USING A POWER STEERING PUMP PULLEY INSTALLER, INSTALL THE POWER STEERING PUMP PULLEY ON POWER STEERING PUMP LEAVING PULLEY IN-LINE WITH THE WATER PUMP PULLEY. INSTALL POWER STEERING PUMP USING BOLTS & NYLOC NUTS WITH AN FLAT WASHERS AS SHOWN IN FIGURE 11. FIGURE 11 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 8 OF 10 (2) 186018-NSD 5/16-18 NYLOC NUTS (2) 184350-ISD 5/16-18 x 3 ½" SS 12 PT BOLTS NOTE: APPLY A BEAD OF ANTI-SEIZE ON THE BOLT THREADS. 8
WITH POWER STEERING SERPENTINE BELT INSTALLATION INSERT A 1/2" DRIVER RATCHET OR BREAKER BAR INTO SOCKET ON TENSIONER. ROTATE CLOCKWISE UNTIL IT STOPS AND INSTALL BELT AS SHOWN IN FIGURE 12, BELOW. NOTE: TO INSTALL BELT, ROTATE TENSIONER AND INSTALL THE BELT AROUND THE CRANKSHAFT PULLEY FIRST. NEXT ROUTE THE BELT AROUND THE ALTERNATOR, THEN THE COMPRESSOR. LASTLY SLIDE THE BELT UNDER THE WATER PUMP PULLEY. SOCKET FIGURE 12 WITH POWER STEERING 60" BELT WITHOUT POWER STEERING SERPENTINE BELT INSTALLATION INSERT A 1/2" DRIVER RATCHET OR BREAKER BAR INTO SOCKET ON TENSIONER. ROTATE CLOCKWISE UNTIL IT STOPS AND INSTALL BELT AS SHOWN IN FIGURE 13, BELOW. NOTE: TO INSTALL BELT, ROTATE TENSIONER AND INSTALL THE BELT AROUND THE CRANKSHAFT PULLEY FIRST. NEXT ROUTE THE BELT AROUND THE ALTERNATOR, THEN THE COMPRESSOR. LASTLY SLIDE THE BELT UNDER THE WATER PUMP PULLEY. SOCKET WITHOUT POWER STEERING 57 ½" BELT FIGURE 13 9 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 9 OF 10
FINAL STEPS INSTALL THE TENSIONER COVER & COMPRESSOR COVER (SEE INSTRUCTIONS SUPPLIED WITH COVERS). SEE FIGURE 14. CONNECT HEATER HOSES TO WATER PUMP. RECONNECT ALL ELECTRICAL CONNECTORS. NOTE: CHARGING SYSTEM MUST BE PROPERLY WIRED TO ACCEPT ONE-WIRE INTERNALLY REGULATED ALTERNATOR. CONNECT NEGATIVE BATTERY CABLE. FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN A/C MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY. DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS. VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIOR TO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 2) OF THIS INSTRUCTION MANUAL. COMPRESSOR COVER TENSIONER COVER FIGURE 14 904100 REV E 01/20/15, SBF FRONTRUNNER w & wo POWER STEERING INST PG 10 OF 10 10