ROUSH Charger supercharger kit Installation Instructions
The ROUSHCharger supercharger kit is a performance upgrade designed for the 2005-06 Ford Mustang GT 4.6L 3-Valve (with manual & automatic transmissions). The kit includes a supercharger, intercooler, and various other components to enhance engine power and performance. It is important to note that premium fuel (91 octane or higher) is required to prevent engine damage or failure. Also, the use of fuel additives is not recommended as they can damage your engine.
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PREMIUM FUEL REQUIRED
2005-06 Ford Mustang GT ROUSHCharger Kit
P/Ns: 13056066M90 (Black) & 13056066M90C (Chrome)
EO#: D-418-13
Installation Instructions
Applications:
2005-06 Ford Mustang GT 4.6L 3-Valve (w/ Manual & Automatic Transmissions).
Important Notes:
; Before installing your Mustang ROUSHcharger Kit, please read the installation manual and verify that all items are present. Contact ROUSH Customer Service at 1-800-59-ROUSH, 9:00
AM to 5:00 PM weekdays, for any questions regarding fit or instructions that are unclear to you.
; Premium fuel (91 octane or higher) is required to prevent “spark-knock” or detonation under certain operating conditions.
; The use of fuel additives (ie. octane boosters) is not recommended. There is a possibility that these chemicals can damage your engine and cause drivability issues with your vehicle.
; Operating your engine without the ROUSH PCM recalibration will result in engine damage or failure and will void your warranty.
13056066M90IM-AA_20090428PS Page 1 of 73 1-800-59-ROUSH
PREMIUM FUEL REQUIRED
TABLE OF CONTENTS
PACKAGING LIST FOR COMPLETE ROUSHCHARGER KIT................................................ 3
EQUIPMENT AND SUPPLIES REQUIRED ........................................................................... 17
GLOSSARY OF TERMS........................................................................................................ 18
INFORMATION ABOUT THE SUPERCHARGER BYPASS OPERATION ............................ 18
LIMIT OF LIABILITY STATEMENT ........................................................................................ 19
SAFETY PRECAUTIONS ...................................................................................................... 19
SECTION A – DISASSEMBLY............................................................................................... 20
SECTION B – MODIFICATIONS ........................................................................................... 30
Alternator Modification........................................................................................................ 30
Coolant Hose Hanger Modification ..................................................................................... 31
Airbox Modification ............................................................................................................. 32
Heater Tube Assembly Modification ................................................................................... 34
Wiring Harness Modifications ............................................................................................. 35
SECTION C – SUBASSEMBLY ............................................................................................. 41
Intake Manifold Build Up..................................................................................................... 41
Fuel Rail Assembly............................................................................................................. 42
SECTION D – INSTALLATION .............................................................................................. 43
Intercooler Reservoir Mounting........................................................................................... 43
Intercooler Radiator Assembly Mounting ............................................................................ 46
Electric Water Pump Bracket Mounting .............................................................................. 49
Electric Water Pump Harness............................................................................................. 52
Spark Plug Installation ........................................................................................................ 54
Intake Manifold and ROUSHCharger Installation ............................................................... 54
FEAD Assembly ................................................................................................................. 59
Air Intake System ............................................................................................................... 63
Coolant Hoses .................................................................................................................... 65
Air Induction System........................................................................................................... 67
Battery and Tray ................................................................................................................. 68
Vacuum System Connections............................................................................................. 68
Coolant Fill and Final Assembly ......................................................................................... 70
CARE AND MAINTENANCE OF OPTIONAL POLISHED ROUSHCHARGER...................... 73
WARRANTY........................................................................................................................... 73
13056066M90IM-AA_20090428PS Page 2 of 73 1-800-59-ROUSH
PREMIUM FUEL REQUIRED
PACKAGING LIST FOR COMPLETE ROUSHCHARGER KIT
1
2 3 4 5
6 7 8 9
Part Ref Description
Induction Kit
1 Clean Air Tube
2 Coupler - Throttle Body End
3 #72 Hose Clamp (Throttle Body)
4 Hump Hose – Air Box End
5
6
#56 Hose Clamp (Tube side)
#52 Hose Clamp (Air Box side)
7
8
9
10
11
12
SAE Fitting - PCV Insert
Rubber Grommet - PCV Insert
1/4 20 X 5/8 Screw (Support Bracket)
1/4 Washers (Support Bracket)
#8 Washers (MAF)
8/32 Screws (MAF)
10 11 12
RPP Part Number
R07060059
R07060026
R07060029
----
R07060030
----
----
----
----
----
----
----
----
2
2
2
2
1
1
1
1
Qty
1
1
1
2
1
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PREMIUM FUEL REQUIRED
14
13
15
Part Ref Description
Hardware Kit A - Air Box Modifications
13
14
Air Inlet
Bellmouth Insert
15 Adhesive - Loctite 4210 (3gm Tube)
16
17
18
Part Ref Description
Hardware Kit B - Induction
16 MAF Block-Off Plate w/ Gasket
17
18
Bracket- Tube Support
Bolts - Support Bracket to Intake (M6 x 1.0 x 13)
RPP Part Number
R07060060
R07060061
R07060062
R18090001
Qty
1
1
1
1
RPP Part Number
R07060064
R07060065
R07060066
N605771-S309
Qty
1
1
1
2
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PREMIUM FUEL REQUIRED
NOTE: The Fuel Charging Assembly (R07060083) is shown above. It has been preassembled by ROUSH to ensure quality and simplify installation. It consists of parts 19
thru 34 which are shown individually below for reference only.
19 20
21
Part Ref Description
Fuel Charging Assembly
19 Upper Intake Manifold
20 Lower Intake Manifold
21
RPP Part Number Qty
R07060083 1
R07060034 1
R07060039 1
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PREMIUM FUEL REQUIRED
26
22 25
27 28
29 30 31
32 33 34
Part Ref Description
Fuel Charging Assembly…Continued
22
23
24
25
26
27
28
29
ACT Sensor
Fitting - 90 deg. IPTS Reference (1/4")
Fitting - 90 deg. PCV Bubbler (3/8")
Gasket - Upper to Lower
Gasket - Intake Manifold Ports
Gasket - Water Crossover Right
Gasket - Water Crossover Left
Billet Tube - Intercooler Floating Tubes
30
31
O-Ring - Floating Tube
Bolt - Intercooler to Intake (M5 x 0.8 x 16)
32
33
34
Bolt - Upper to Lower Intake (M6 x 1.0 x 33)
Dowel - Intake to Supercharger
Washer - Intercooler to Intake
RPP Part Number Qty
R07060083 1
F6SF-12A697-AB 1
53525K11
391273-S100
G1ZE-9461-BB
R07060045
1
1
1
8
R07070001
R07070002
G1ZE-9L442-AA
2-115
SCS-05016-YZ
N808429-S437
388192-S
11-452-0033
1
1
2
4
11
12
2
11
13056066M90IM-AA_20090428PS Page 6 of 73 1-800-59-ROUSH
35
PREMIUM FUEL REQUIRED
36
37
Part Ref Description
35 Throttle Spacer
36 ROUSHCharger – Black
Optional ROUSHCharger – Chrome
37 Fuel Rail
RPP Part Number Qty
R07060041 1
R07050086 1
R07050120 1
R07110001 1
13056066M90IM-AA_20090428PS Page 7 of 73 1-800-59-ROUSH
38
41
PREMIUM FUEL REQUIRED
39
40
42
46
45
43 44
Part Ref Description
Hardware Kit C - Intake
38 Spark Plugs
39
40
Fuel Injectors
Gasket - Intake to Supercharger
41 Gasket - Supercharger to Spacer
42 Bolt - Heater Supply Tube Mounting (M6 x 1.0 x 13)
43 Bolt - Spacer to Supercharger (M8 x 1.25 x 33)
44 Bolt - Supercharger to Intake (M8 x 1.25 x 38)
45 Bolt - Throttle Body (M6 x 1.0 x 33)
46 Bolt - Intake to Cylinder Heads (M6 x 1.0 x 40)
*Note: Spark plugs will be shipped with your re-flashed PCM as required.
RPP Part Number Qty
R07060046 1
R07030001 0*
R14010001
G1ZE-9H486-BA
G1ZE-9L437-BA
N605771-S309
8
1
1
2
N808920-S309
W705128-S437
N808429-S437
R18020004
6
6
4
11
13056066M90IM-AA_20090428PS Page 8 of 73 1-800-59-ROUSH
47
PREMIUM FUEL REQUIRED
49
50
51
48
52 53 54
55 56
57
58
Part Ref Description
47 Alternator Bracket
48 Serpentine FEAD Belt
49
50
51
Hardware Kit D - FEAD
Pulley - Idler B/S 76mm Flanged
Bracket - Intake to Alternator Rear
Bracket - Supercharger Studs to Alternator Bracket
52
53
Bolt - Alternator Support Bracket Rear (M8 x 1.25 x 20)
Bolt - Idler (M8 x 1.25 x 28 large washer)
54
55
56
57
58
Bolt - Alternator Support Brkts to Intk & FEAD Brkt (M8 x 1.25 x 25)
Bolt - FEAD Bracket to Intake (M8 x 1.25 x 38)
Bolt - Alternator (M8 x 1.25 x 55)
Nut - Supercharger to Alternator Support Bracket Front (M6)
Nut - Alternator (M8)
RPP Part Number
R07020013
R07020015
R07020064
R07020049
R07020017
R07020018
R18020005
R18020060
W500224-S309
W705128-S437
N808130-S309
W520412-S309
W520413-S309
2
2
2
2
2
1
1
2
Qty
1
1
1
2
1
13056066M90IM-AA_20090428PS Page 9 of 73 1-800-59-ROUSH
PREMIUM FUEL REQUIRED
59
60
61
Part Ref Description
Hardware Kit E - PCV & Vacuum
59 PCV Purge
60
61
Vacuum Hose - Supercharger Bypass Circuit
Vacuum Cap – Throttle Spacer
RPP Part Number
R07040005
R07040006
R18140001
R07040040
Qty
1
1
1
1
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PREMIUM FUEL REQUIRED
63
62
64
Part Ref Description
Hardware Kit F - Wiring
62
63
64
Electrical Jumper - Intercooler Pump
Electrical Jumper - ACT
Alternator Charge Harness
RPP Part Number
R07080004
Qty
1
R07080006 1
1104-12B637-BA 1
R07080015 1
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PREMIUM FUEL REQUIRED
65
67 69
66
68 70
Part Ref Description
65 Box- PCM Return
66 Installation Manual
Hardware Kit G - Decals
67
68
69
70
Decal - Premium Fuel Only (IP Cluster)
Decal - Premium Fuel Only (Fuel Door)
Decal - 2005 Mustang Supercharged Belt Routing Diagram
E.O. Decal (2005-09 Models)
Warranty Card
RPP Part Number Qty
R07140023 1
13056066M90IM 1
R07040052 1
R07110004 1
R07110003 1
13106E072 1
R09000009 1
131019A505 1
13056066M90IM-AA_20090428PS Page 12 of 73 1-800-59-ROUSH
PREMIUM FUEL REQUIRED
71
72
73
74
Part Ref Description
Hardware Kit I - Hose, Tubing, and Clamps
71
72
73
74
Bypass Circuit Radiator Hose
Clamps - 1.25" Radiator Hose
Tube Assembly - Intercooler
Tube - Heater Supply
RPP Part Number
R07010001
R07070004
R07070005
R07070014
Qty
1
1
2
1
1
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PREMIUM FUEL REQUIRED
75
76
77
78
79
80
81
83
Part Ref Description
Hardware Kit I - Hose, Tubing, and Clamps…Continued
75 3/4" Hose - LTR Outlet
76
77
3/4" Hose - Degas Outlet
3/4" Hose - Degas Inlet
78
79
80
81
82
83
3/4" Hose - LTR Inlet & I/C Outlet
3/4" Hose - Intercooler Inlet
3/4" Hose - Heater Supply
Clamps - 3/4" Hoses (Constant Tension)
Clamps - PCV Bubbler
PCV Bubbler Hose
82
RPP Part Number
R07010001
R07040007
83 Qty
1
1
1
1
2
1
1
14
2
1
13056066M90IM-AA_20090428PS Page 14 of 73 1-800-59-ROUSH
84
PREMIUM FUEL REQUIRED
85
86
87
88
Part Ref Description
84 Degas Bottle
85 Degas Bottle Cap
86 Intercooler Electric Water Pump
87 Bracket - Intercooler Pump Mounting
88 Intercooler Low Temp Radiator (LTR)
RPP Part Number
R07070007
XL3Z-8100-AA
F8YZ-8501-AA
R07070015
R07070047
Qty
1
1
1
1
1
13056066M90IM-AA_20090428PS Page 15 of 73 1-800-59-ROUSH
PREMIUM FUEL REQUIRED
89
90 91
92
94
93
96
95 97
Part Ref Description
Hardware Kit J - Intercooler Circuit Fasteners
89 J-Clip - Degas Bottle & Pump Bracket Mounting (M6 Short)
90 Double-Sided Tape - Degas Bottle Mounting
91 Cap Screw - Degas Bottle Mounting (M6 x 1.0 x 8)
92 Washer - M6
93 Bolt - Pump Bracket (2) & I/C Tube Assembly Mounting (1) (M6 x 18)
94
95
Bolt - Degas Bottle Mounting (M6 x 1.0 x 33)
Bolt - Long Bumper Bolts (M8 x 1.25 x 35)
RPP Part Number Qty
R07070016 1
N623332-S301
R07030002
R18020010
R18030002
N605891-S437
N808429-S437
R18020007
4
1
1
1
3
2
4
96 Bolt - 9N491 Tube Assembly Mounting (M16 x 40) R18020006 1
97 Nut - LTR Mounting (4) & Pump Bracket (1) (M8) W520413-S309
If you are missing any items, please call us toll free at 1-800-59-ROUSH.
5
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PREMIUM FUEL REQUIRED
EQUIPMENT AND SUPPLIES REQUIRED
• 1/4” and 3/8” Drive Ratchets with Extensions
• Metric and Standard Socket Sets (short and deep recommended)
• 1/2” Drive Ratchet or Breaker Bar
• Metric and Standard Wrench Sets
• 3/8” Drive Torque Wrench (7-35 ft-lb range)
• Short Phillips-head Screwdriver
• Hex Key Set
• Teflon pipe sealing tape or equivalent
• 5/8” Fuel Line Removal Tool
• T-20 Torx Bit Screwdriver or Socket
• Soldering Iron and Solder
• Wire Crimpers “W” type for OEM-style wiring connectors
• 1/8”, 9/64”, and ¼” Drill Bits and Drill motor
• Coolant (meeting G-05 specification)
• 6” Scale, Tape Measure, or Other Measuring Device
• Brake Parts Cleaner
• Assembly Lubricant (White Lithium Grease or Petroleum Jelly)
• Sharp Knife or Razor Blade
• Tie Straps (Zip Ties)
• Trim Pad Tool (for pushpin removal)
• Fender Cover (2)
• Medium Strength Thread Locker – Loctite 242 (blue) or equivalent
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PREMIUM FUEL REQUIRED
GLOSSARY OF TERMS
ACT Air Charge Temperature Sensor (From the factory, this function is integrated into the
MAF sensor. With this kit, a separate ACT sensor is installed into the intake manifold)
CMCV Charge Motion Control Valve (Located on the back of the base intake manifold. This feature is not used with the ROUSHcharger)
ETC
IPTS
MAFS
PCM
PCV
SCBP
Electronic Throttle Control
Injection Pressure and Temperature Sensor
Mass Air Flow Sensor
Powertrain Control Module (a.k.a. ECM, ECU, PCU, EEC)
Positive Crankcase Ventilation
Supercharger Control Bypass Solenoid (A 3-way electronic vacuum control solenoid that allows the PCM to control the ROUSHcharger bypass to reduce heat buildup and noise during low throttle operation)
TPS
VMV
Throttle Position Sensor
Vapor Management Valve (Located on driver side strut tower)
Breakout Point A place in an electrical harness where the wiring for an individual component leaves
(breaks out of) the main harness to attach to an individual component.
INFORMATION ABOUT THE SUPERCHARGER BYPASS OPERATION
There is a great deal of misinformation about the function of supercharger bypass systems. The supercharger is a positive-displacement pump; that is, so long as it is rotating, it is always pumping air.
During low demand or high vacuum operation (i.e. idle, deceleration, and light throttle cruise), the pumping action is undesirable as it creates unwanted heat and noise. The bypass circuit, when open, prevents any pressure buildup across the supercharger and allows air to circulate through the rotors, allowing the supercharger to “idle” freely during these conditions. This results in reduced noise, and by reducing heat buildup in the intake, significantly improves street and strip performance. As throttle demand increases, the bypass circuit is closed, resulting in full performance from the supercharger. The bypass circuit is never used to limit or control boost during full-throttle operation and defeating or altering the bypass function will not result in improved performance in any condition, and will result in poor drivability.
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PREMIUM FUEL REQUIRED
LIMIT OF LIABILITY STATEMENT
The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability. Roush Performance Products
(RPP) reserves the right to revise the information presented herein or to discontinue the production of parts described at any time.
SAFETY PRECAUTIONS
STOP!
CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS AND WARNINGS
BEFORE PROCEEDING WITH THE INSTALLATION!
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual performing the kit installation. Improper installation due to the failure to correctly follow these instructions could cause personal injury or death. Read each step of the installation manual carefully before starting the installation.
1. Always wear safety glasses for eye protection.
2. Place the ignition switch in the OFF position.
3. Always apply the parking brake when working on the vehicle.
4. Block the front and rear tire surfaces to prevent unexpected vehicle movement.
5. Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
6. Do not smoke or use flammable items near or around the fuel system.
7. Use chemicals and cleaners only in well-ventilated areas.
8. Batteries can produce explosive hydrogen gas which can cause personal injury. Do not allow flames, sparks or flammable sources to come near the battery.
9. Keep hands and any other objects away from the radiator fan blades.
10. Keep yourself and your clothing away from moving parts when the engine is running.
11. Do not wear loose clothing or jewelry that can be caught in rotating or moving parts.
WORK SAFELY!
Perform this installation on a good clean level surface for maximum safety and with the engine turned off.
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PREMIUM FUEL REQUIRED
SECTION A – DISASSEMBLY
The following section will guide you through the disassembly of the stock components. Special care should be taken to label fasteners and parts that are taken off during this procedure since many will be reused:
1. Cover both fenders with fender covers to protect the vehicle finish.
2. Release the fuel system pressure (NOTE: The following procedure is taken directly from the Ford
Service Manual).
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to do so can result in personal injury.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in personal injury.
a. Remove the fuel pump module fuse.
NOTE: The fuel pump module fuse is located in the underhood fuse box, location F41.
13056066M90IM-AA_20090428PS Page 20 of 73 1-800-59-ROUSH
PREMIUM FUEL REQUIRED b. Start the engine and allow it to idle until it stalls. c. After the engine stalls, crank the engine for approximately 10 seconds to make sure the fuel injector supply manifold pressure has been released. d. Turn the ignition switch to the OFF position. e. Reinstall the fuse that was removed in step a.
3. Using an 8mm wrench, disconnect the (-) negative & (+) positive connections to the battery.
Remove the battery hold down bolt using an 8mm socket wrench. Remove the hold down & battery. With an 8mm socket wrench, remove the 3 bolts holding the battery tray to the vehicle.
Remove the battery tray.
Battery Tray Bolts
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PREMIUM FUEL REQUIRED
4. Disconnect the 3 PCM (Powertrain Control Module) connectors by lifting the grey levers over the connector back shell and lifting the connectors from their sockets. Remove the PCM by removing two 10mm bolts and pulling the PCM forward and lifting out of the engine compartment. Follow the instructions on the next page as soon as possible to help minimize the amount of time you are without a PCM.
Connector
Locations
Retaining Bolts
Important: Be sure to write your VIN number and phone number (in case we need to contact you for additional vehicle information) on the PCM using a permanent marker.
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PREMIUM FUEL REQUIRED
INSTRUCTIONS FOR RETURNING THE PCM TO ROUSH FOR CALIBRATION
Outlined below are the instructions for returning your stock powertrain control module (PCM) to Roush
Performance Products so we can install our calibration to make the engine run properly with the new components. Please complete the “Warranty Registration Card” and include it, along with the
PCM, in the prepaid shipping box. The prepaid shipping box is set-up for next day delivery to us.
Once we receive your PCM, we will reprogram and return it back to you the same day for next-day delivery. Operating your engine without our calibration will result in engine damage or failure and
will void all warranty.
Note: It is important to reinstall the PCM in the vehicle it came from to prevent setting a trouble code and having to relearn the anti-theft code which can only be performed using specialized Ford Service Bay tools.
• If you haven’t already done so, write your vehicle identification number (VIN) and phone number
• on the PCM using a permanent marker.
• Remove the bubble wrap from inside the supplied shipping box and wrap it around the PCM to help prevent it from being damaged during shipping.
Place the wrapped PCM in the shipping box (R07140023).
• Complete the “Warranty Registration Card” (131019A505) and include it in the shipping box along with the PCM.
• Fill in your name and address in the FROM area of the shipping label that is located inside the box. Follow the instructions on the box for sealing it shut.
• Peel the right label off and attach to the box where indicated.
• Retain the left side label for your records.
• Schedule directly to an agent. DO NOT use the automated option to schedule a pick up.
• Inform the agent you have a Prepaid FEDEX billable stamp package and you need a pick-up.
• If there are any issues with the shipping box we supply and you want to ship the PCM to us another way, the address for the PCM re-flash only is: Roush Powertrain Development, Building
57 – attn: PCM Flash, 777 Republic Drive, Allen Park, MI 48101
2005-06 Mustang ROUSHCharger Kit
Customer Name: ________________________ Contact Number: ________________________
VIN: ________________________
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PREMIUM FUEL REQUIRED
5. With the engine cool, remove the cap on the engine coolant degas bottle and drain the coolant using the petcock located on the lower passenger side of the radiator.
TIP: Connect 3/8” hose to the drain fitting next to the petcock and run into a clean drain pan or bottle. Use a ¾” wrench to open petcock and allow coolant to drain out of the fitting.
Drain Petcock
6. Disconnect the PCV vent tube from the right-hand cam cover and clean air tube. Using an 8mm nut driver, loosen the 2 clamps at either end of the clean air tube. Remove the clean air tube from the throttle body and airbox.
Clamps
PCV Vent
Tube
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PREMIUM FUEL REQUIRED
7. Remove the MAF (mass air flow) connector by pulling the red locking tab back and pressing the black release tab. With a 10mm socket wrench, remove the airbox hold down bolt. Firmly grasp the airbox and pull up to remove it from the vehicle.
Hold down bolt
MAF Connector
8. Disconnect ETC (electronic throttle control) & TPS (throttle position sensor) connectors from the throttle body (Pull the red locking tab back; press the black release tab to disengage the lock).
Remove the throttle body using an 8mm socket wrench (for the top two bolts) and a 10mm socket wrench (for the bottom two nuts). Remove the throttle body and the throttle body gasket from the intake manifold. Wipe the seal clean and dry and install it into the machined groove in the new throttle body spacer (P/N R07060041).
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9. Remove the PCV line from the intake manifold and left-hand cam cover. Remove the VMV line from the intake manifold and position out of the way. Remove the vacuum line and electrical connector from the IPTS on the fuel rail and save for reuse. Remove the black safety clip from the fuel line connection. Place rags under the fuel rail, using a 5/8” fuel line tool (wrap additional rags around the tool) and disconnect the fuel line from the fuel rail. There will be some release of pressurized fuel, so be careful and proceed slowly.
VMV Line
IPTS
Fuel Rail Disconnect
PCV Line
10. Disconnect the alternator harness from the positive battery terminal and remove the harness clips from the fuel rail studs.
.
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PREMIUM FUEL REQUIRED
11. Disconnect the wiring connectors from the fuel injectors (8). Remove the four 8mm stud bolts holding the fuel rail to the intake manifold and remove the fuel rail assembly with injectors. There may be some additional fuel leakage around the injectors. Clean all excess fuel before proceeding. Remove injectors and retainer clips from the fuel rail. Save the retainer clips for reuse.
Fuel Rail Holdown Studs
Retainer Clip
12. Disconnect the CMCV connector located in the center rear of the intake manifold. Remove the brake booster vacuum line from the intake manifold. Pull the wiring harness off of the stud bolt on the driver side rear of intake manifold. Remove the ten fasteners which used to bolt the intake manifold to the cylinder heads. Save the rear stud for reuse. Remove the intake manifold. Use tape or equivalent to cover the cylinder head ports to prevent engine contamination.
Brake Booster Hose
Intake Manifold Bolts
Stud
CMCV Connector
Wire Harness hold down
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13. Release the accessory drive belt by rotating the tensioner clockwise with a ½ “ breaker bar or ratchet and slip the belt off the water pump pulley and remove the belt completely. Disconnect the regulator connector and the battery cable from the alternator. Using a 10mm socket wrench, remove the four upper support bracket bolts. Remove the two 15mm alternator nuts and remove the alternator.
14. Remove the factory coolant fill plug from the water crossover using a ¼” ratchet. Remove the upper radiator hose from the front of the water crossover (do not remove from the radiator).
Completely remove the bypass circuit radiator hose. On the back side of the water crossover, disconnect the heater hose. Remove the water crossover using a 10mm socket wrench.
Crossover Tube Bolts
Upper Rad Hose
Heater Hose
Thermostat Hose
Factory Coolant Fill Plug
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15. Disconnect the rubber portion of the heater hoses from the metal tubes at the rear of the righthand cylinder head. Remove the heater tube assembly from the engine by removing the stud on the back side of the passenger cylinder head and sliding off the water pump fitting in the block.
Stud Bolt
Disconnect Heater Hoses Here
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SECTION B – MODIFICATIONS
The following section will guide you through the required modifications of existing components and build up of the assemblies used to complete the installation. With the exception of the wiring modifications and intercooler pump bracket mounting, all of this work can be performed away from the vehicle.
Alternator Modification
1. In order for the alternator to be installed in its new location, two of the original mounting ears must be removed. Using a band saw or similar cutting tool, remove the mounting ears shown. Be careful to avoid getting debris inside of the alternator when removing these features.
Before After
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Coolant Hose Hanger Modification
1. Locate the coolant hose hanger on the front of the engine and remove.
2. Remove the highlighted section of the bracket as illustrated below. Doing so is necessary to provide clearance to the new alternator mounting bracket.
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Airbox Modification
1. Remove the MAF sensor from the stock airbox cover and install into the new clean air tube
(R07060026) using the two #8-32 screws and #8 washers provided in the induction kit. Install the rubber grommet and the SAE-style PCV fitting into the clean air tube. Install the tube support bracket (R07060066) in Hardware Kit B with the ¼-20x3/4” bolts and washers in the Induction Kit.
2. Using the take out screws from the MAF, install the MAF block off plate w/gasket (R07060065) from Hardware Kit B onto the cover of the airbox. Torque the screws to 1.8 – 2.5 Nm.
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3. Remove the dirty air inlet from the airbox. Install the supplied larger cross-section dirty air inlet
(R07060061). It may be necessary to clip off the top of the hook to ease installation. Be careful not to crack or damage the new dirty air inlet during installation.
Clip along the line shown to ease assembly
4. Remove the airbox cover and stock air filter. Thoroughly clean the inside of the airbox cover with brake clean or equivalent. Spray brake clean on a shop rag and clean the bellmouth insert
(R07060062) on the rear face. Allow both parts to fully dry. Carefully install the bellmouth insert into the airbox cover using the supplied adhesive (Loctite 4210). Apply the adhesive generously to the bellmouth and apply pressure for approximately one hour to allow the glue to set up. Do not attempt to move the bellmouth once it sets as the adhesive takes a full twenty four hours to fully cure and must not be disturbed. Reinstall the air filter and reassemble the airbox.
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Heater Tube Assembly Modification
1. The upper tube and hose on the heater tube assembly is not used (a new tube is supplied in the kit). Using a die grinder or air saw, cut the brackets that connect the two tubes together and deburr all sharp edges. Retain the lower tube which connects to the water pump and the mounting bracket for reinstallation.
Discard this tube
Cut
Save
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Wiring Harness Modifications
The following details the modifications to the factory engine harness which are necessary to complete the installation of this kit. These modifications should be done without removing the harness from the engine as it will be easier to verify final locations of the break out points. Extreme care must be taken to insure that wiring and/or its insulation is not accidentally damaged while removing the convoluted tubing. All of the convoluted tubing and various clips that are removed while making these changes are intended to be reinstalled in the same place unless otherwise noted.
TPS
ETC
MAF
Connectors for Wiring Circuits that will need to be modified
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1. Make a note of the locations of the harness retaining clips and breakout points. With the harness still fastened to the engine with the factory retainers, carefully cut the tape off of the convoluted tubing and wiring harness on the drivers side of the engine (where the MAF & ETC branch out of the main harness) using a razor or utility knife. This area is highlighted in the following diagram.
The convoluted tubing is split from the factory so follow the split. Lift the wiring out of the convoluted tubing without disturbing the factory retainers wherever possible. Expose all of the internal wiring from the MAF/ETC split all the way around to the rear of the passenger side cam cover and past the rear retainer.
Pull wiring out from this section.
2. Locate the 6-wire MAF sensor connector. Looking into the face of the connector with the release tab positioned up, the first two wires in the connector (IAT) from the right are grey and grey w/ red tracer. Cut both of these wires approximately 5 to 6 inches from the back of the connector.
MAF Connector
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3. Seal the connector side of both cut IAT wires with pieces of heat shrink provided in the ACT electrical jumper (R07080010) in Hardware Kit F. Place two pieces of heatshrink tubing halfway onto the ends of the wires to be sealed and heat with a heat gun until it stops shrinking and sealant flows out from the open end of the tubing.
Sealing cut wire ends with Heat Shrink tubing
4. Drag the 2 IAT wires out of the harness back from the MAF connector so that they break out with the #7 Coil Connector. Strip a ¼ inch of insulation from the end of each wire. Slide a short length of heat shrink tubing over both wires. Now using the Electrical Jumper (ACT) from the kit
(R07080010) lay the striped end of the Gray (IAT) wire into one side of the provided splice connector. From the Electrical Jumper (ACT) slide the ACT SIGNAL wire into the other side of the splice connector, and crimp using a W type crimping tool. Using a clean hot soldering iron, heat the wires (not the solder) in the splice connector until they are hot enough to melt the solder touched to them. Repeat the above for the IATRTN – ACT GROUND. Slide the heat shrink tubing over the solder joints and heat to shrink with a heat gun. Wrap ACT harness with tape.
#7 Coil
ACT Wire breakout point
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5. Drag the remaining MAF wiring/connector out of the harness and back toward the dash panel, moving the MAF breakout point to before the driver side rear intake harness retainer. Remove the driver side rear intake harness retainer and turn it backwards. Wrap MAF harness with tape.
This will provide additional length to reach the new MAF position in the clean air tube.
Location before
Location after
6. Pull the 2-wire ETC (electronic throttle control) wiring loose from the main harness and drag it back to the middle rear of the engine (same location as the MAF wiring in the previous step). At the middle rear of the engine, fold the ETC wiring back onto the still covered portion of the harness and route the ETC wiring with the harness over the breakout point near the #3 coil.
Wrap the ETC harness to the existing harness with electrical tape.
#3 Coil
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7. Slide the driver side of the harness back into its convoluted tubing and re-tape.
8. Locate the TPS (Throttle position sensor) connector and harness at the front of the passenger side valve cover. Remove the harness retainer for the timing cover bolt.
TPS wiring/connector
Harness Retainer
9. Starting at the factory breakout point for the TPS, remove the electrical tape and convoluted tubing back to the #1 coil breakout point.
#1 Coil
Strip off this section of tape and convoluted tubing
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10. Pull the 4-wire TPS wiring/connector to near the #1 Coil breakout point.
11. Fold back the TPS leads to the break from the main harness near the #3 coil and tape onto existing still taped harness. Reinstall any convoluted tubing and re-tape the rest of the harness.
12. Make sure there is at least 10” of free hanging lead for the TPS and ETC branches and wrap each with electrical tape.
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SECTION C – SUBASSEMBLY
Intake Manifold Build Up
1. Remove Fuel Charging Assembly (R07060083) from packaging.
2. Install the 3” long ¾” Heater Supply Hose and (1) ¾” Constant Tension Clamp (81) onto the heater Supply Tube (R07070014) from the Intercooler Hose Kit (R07010001). Place (1) ¾” CT clamp (81) over the intake manifold heater fitting. Install the Heater Supply Tube using (2) M6 x
1.0 x 13 mm bolts (N605771) from Hardware Kit C and torque to 8 – 12 Nm. Position the remaining loose hose clamp onto the hose and orient clamps as shown.
Heater Supply Tube Bolts
Intake Heater
Fitting
3. Attach PCV Bubbler Hose (R07040007) to the bubbler fitting and install PCV Bubbler Clamps to each end of the hose (all parts are from Intercooler Hose Kit).
PCV Bubbler Hose
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4. Inspect the Factory Coolant Fill Plug O-ring (removed from the stock water crossover). If the Oring was damaged during removal you must replace the O-ring. Lube the O-ring and install the
Factory Coolant Fill Plug into the new upper intake manifold. Torque to 12 – 18 Nm.
Fuel Rail Assembly
1. Install the take off injector clips onto the new Fuel Injectors (R14010001) from Hardware Kit C.
Apply assembly lube to the injector O-rings and install them into the new Fuel Rail
(R07110001). Verify that the injector clips are properly seated onto the fuel rail injector cups.
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SECTION D – INSTALLATION
The following section will guide you through the final installation of the kit into the vehicle. If you need to stop during any part of the installation, make sure you cover any open ports in the cylinder heads or intake manifold to prevent foreign material from contaminating your engine.
Intercooler Reservoir Mounting
1. Using the Intercooler Degas Bottle (R07070007) with Degas Bottle Cap (XL3Z-8100-AA) as a template, place the bottle on the flat part of the electric fan shroud between the power steering reservoir and the engine coolant degas bottle. With the edge of the bottle at the edge of the electric fan shroud, mark the two mounting holes with a paint pen and drill two 5/16” holes through the fan shroud.
Mark and Drill here
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2. Cut out the following template and use it to mark the third mounting hole and drill to 5/16”.
Mark and drill to 5/16”
3. Clean the mating surfaces of the degas bottle and fan shroud with brake cleaner or rubbing alcohol. Peel and stick one side of the Double-Sided Tape (R07030002) provided in Hardware
Kit J, to the underside of the degas bottle.
Double-Sided Tape
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4. Remove the upper fan shroud bolts and force the shroud toward the rear of the vehicle. Install
(2) J-Clips (N623332) from Hardware Kit J. Peel the second side of the double-sided tape and set the bottle on the fan shroud. Secure the intercooler degas bottle using (2) M6 x 1.0 x 33 mm bolts (N808429), and (1) M6 x 1.0 x 8 mm cap screw (R18020010) with washer
(R18030002) from Hardware Kit J and torque to 8 – 12 Nm. Reinstall the upper fan shroud bolts and torque to 8 – 12 Nm.
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Intercooler Radiator Assembly Mounting
1. Remove the six push pin retainers highlighted below by pulling the center pin and remove the radiator trim cover.
Push Pin retainers
2. Raise the vehicle and remove both front tires. Remove the three forward Phillips-head screws from each front wheel liner. Using a Phillips-head screwdriver, turn the five inner fender push pins ¼ turn to release the centers. Remove the pushpins and then remove the forward inner fenders.
Inner Fender Push Pin Locations
3 Phillips head screws
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3. Remove the three lower close-out to radiator support screws (7mm). Remove the two upper bumper cover screws near the headlights (10mm). Remove the four front fender to bumper cover nuts inside the forward wheel well (10mm).
Upper Bumper
Cover Screws
Close-out screws
Fender to Bumper
Cover Nuts
4. Reach inside the front wheel wells and unplug the front turn signals (there are four connectors total). Lift the front bumper cover slightly and pull partially off of the vehicle. Unplug the fog lights and set the front bumper cover aside.
5. Remove the four push pins that retain the impact absorber to the front bumper beam and set the absorber aside.
Push Pins
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6. Remove the four inner front bumper beam bolts. Save one bolt for reuse later.
Inner Bumper Bolts
7. Install (4) Long Bumper Bolts (R18020007) from Hardware kit J in place of the four which were just removed and torque to 20 – 30 Nm. Install the Intercooler Radiator Assembly (R07060084) behind the bumper onto the new long bumper bolts. Install (4) LTR Mounting Nuts (W520413) from Hardware Kit J on the exposed end of the long bumper bolts and torque to 20 – 30 Nm.
Retaining Nut
Intercooler Radiator Assembly
Inner Bumper Bolt
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8. Reinstall the impact absorber onto the front bumper beam using the take out pushpins.
9. Install the 12 ½” LTR Inlet Hose on the driver side of LTR with (1) ¾” constant tension clamp (81) and leave hanging. Install the 33 ¾” LTR Outlet Hose on the passenger side of the LTR with (1)
¾” constant tension clamp (81) and route up through the fender and into the engine compartment as illustrated below.
Electric Water Pump Bracket Mounting
1. Cut out the following template. Line up the template with the tie down bracket inside the driver side wheel well. Center punch the “X”s marked on the template into the frame rail of the vehicle.
Drill two ¼” holes through the frame rail and de-burr the holes.
Cut this out and use as a template to locate holes
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2. Install (2) J-Clips (N623332) from Hardware Kit J and mount the Intercooler Pump Mounting
Bracket (R07070015) using (2) M6 x 1.0 x 18 mm bolts (N605891) onto the body. Torque bolts to
8 – 12 Nm .
Slide the Intercooler Pump (F8YZ-8501-AA) into the bracket and secure using the bumper bolt removed earlier and a M8 nut (W520413) from Hardware Kit J. Torque the nut and bolt to 8 – 12 Nm.
Use take off bumper bolt in this location
3. Connect the 12 ½” LTR Inlet Hose (previously installed to LTR) to the outlet of the pump with (1)
¾” constant tension clamp (81). Install the 31” Degas Bottle Outlet Hose onto the pump inlet with
(1) ¾” constant tension clamp (81). Route the Degas Bottle Outlet Hose up through the fender to the Degas Bottle as illustrated. Connect this hose to the bottom outlet of the Degas bottle using
(1) ¾” constant tension clamp (81).
Note: Route all intercooler hoses very carefully. It is critical to the intercooler
performance that these hoses are not kinked once installed into the vehicle.
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Electric Water Pump Harness
1. Locate the square 12-pin (2005 model year) or 16-pin (2006 model year) connector near the three processor connectors. Unplug the connector and remove the short section of convoluted tubing and electrical tape from the harness immediately behind the chassis side connector.
Locate the red wire in pin location #10 (2005 model year) or pin location #2 (2006 model year).
Cut this red wire about 1 1/2 inches back from the connector.
2005 model
12-pin connector (2005 model)
16-pin connector (2006 model)
2006 model
2. Seal the connector end of the red wire using one piece of heat shrink provided with the
Intercooler Pump Wiring Harness Kit (R07080006).
Sealing cut wire ends with Heat Shrink tubing
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3. Strip approximately 3/8” of insulation off the harness side of the red wire. Place a piece of supplied heat shrink tubing over the non-terminated end of the Intercooler Pump Wiring Harness.
Strip approximately 3/8” of insulation off the end of the intercooler wire and connect to the red wire using the provided splice connector from the Intercooler Pump Wiring Harness Kit and crimp using a W-type crimping tool. Using a clean, hot soldering iron, heat the wires (not the solder) in the splice connector until they are hot enough to melt the solder touched to them. Slide the heat shrink tubing over the solder joint and heat to shrink with a heat gun. Reinstall the convoluted tubing and tape removed from the factory harness.
4. Plug the connector back together. Route the remainder of the Intercooler Pump Wiring Harness over the radiator (following the existing harness) behind the headlamp on the driver side and into the inner fender area where the water pump bracket is mounted. Remove the top water pump bracket mounting bolt and install the wiring harness ground eyelet and re-torque the fastener.
Connect the wiring harness to the electric water pump.
Ground the pump wiring harness to the body in this location.
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Spark Plug Installation
1. Remove the ignition coils using a 7mm socket. Remove the original spark plugs using a 9/16” socket (spark plug type preferred). Install the new Spark Plugs (R07030001)*. Torque to 30 – 38
Nm.
*Note: Spark plugs will be shipped with your re-flashed PCM as required.
2. Reinstall the coils. Torque the coil bolts to 5 – 7 Nm.
Intake Manifold and ROUSHCharger Installation
1. Install the modified heater tube assembly using the take out stud bolt. Be sure to lube the Orings with assembly lube before installing the heater tube to the water pump fitting in the block.
Torque the stud to 8 – 12 Nm.
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2. Remove the tape from the cylinder heads and clean the cylinder head to intake manifold mating surfaces using brake clean or rubbing alcohol.
3. Set the intake manifold assembly down onto the cylinder heads. Be careful not to damage your sealing surfaces or gaskets during this step. Insert (2) intake mounting bolts (R18020004) from
Hardware Kit C into Holes A and B (shown below) and start the threads by hand. Do NOT tighten these fasteners. The intake must remain free to move along the cylinder head surfaces.
Hole A Hole B
4. Install the Alternator Bracket (R07020013) onto the studs previously used to mount the alternator to the cylinder block and temporarily secure the bracket using the stock nuts.
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5. Use the FEAD bracket rear mounting bosses to properly align the intake manifold on the cylinder head surfaces by shifting the manifold from front to back and side to side. When you are finished, these features should be aligned in both the for-aft and side-to-side directions.
6. Once aligned, fasten the intake manifold using (11) M6 x 1.0 x 40mm bolts (R18020004) from
Hardware Kit C and the stock driver side rear stud (used to retain the wiring harness). Install these fasteners in the positions shown below and torque to 8 – 12 Nm in the sequence shown.
Remove the alternator bracket from the engine as it will be installed in a later step.
Stud
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7. Install the Intercooler Tube Assembly (R07070005) from Kit I onto the passenger side cylinder head using the M16 x 40mm Tube Mounting Bolt (R18020006) for the rear and (1) M6 x 1.0 x 18 mm I/C Tube Mounting Bolt (N605891) for the front from Hardware Kit J. Torque the M16 bolt to
45 Nm and the M6 bolt to 8 – 12 Nm. Carefully manipulate the wiring harness in the area shown.
Route the engine wiring harness between the tube assembly and coil #4 in
this area.
Route the engine wiring harness along the tube assembly in this area and zip tie to prevent damage to wiring. Pull the retainer clip from the
PCM bracket and secure the harness using zip ties away from all body-
mounted components.
M6x18 Bolt
M16x40 Bolt
8. Install intake to ROUSHcharger gasket (G1ZE-9H486-BA) over the dowels in the upper intake.
Remove the ROUSHcharger (R07050036) from the packaging and install using (6) M8 x 1.25 x
38mm bolts (W705128) provided in Hardware Kit C. Torque to 20 – 30 Nm in the sequence shown.
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9. Lube the fuel injector o-rings with assembly lube. Install the fuel rail and injectors into the intake manifold using the take off stud bolts and torque to 8 – 12 Nm. Be sure each injector is properly seated into the intake manifold.
10. Connect the IPTS, ACT, and all eight fuel injector and coil connectors. Route the MAF wiring across the manifold on the driver side between the valve cover and the fuel rail.
Fuel Injector Connection
(Coils similar)
ACT Connection
IPS Connection
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FEAD Assembly
1. Install the Alternator Bracket (R07020013) onto the studs previously used to mount the alternator. Position the bracket onto alternator studs and loosely secure with the take-off M8 nuts. Use (2) M8 x 1.25 x 38mm bolts (W705128) from Hardware Kit D and to secure the alternator bracket to the intake manifold. Torque all nuts and bolts to 20 – 30 Nm.
2. Install the Supercharger Studs to Alternator Bracket (R07020018) from Hardware Kit D using
(2) M6 nuts (W520412) and (1) M8 x 1.25 x 25mm bolt (W500224) also from Hardware Kit D.
Torque the nuts to 8 – 12 Nm and the bolt to 20 – 30 Nm.
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3. Insert (2) M8 x 1.25 x 55mm Bolts (N808130) and (2) M8 Nuts (W520413) from Hardware Kit D through the alternator bracket. Be sure to leave enough room to insert the alternator. Slide the alternator onto the bolts and torque to 20 – 30 Nm.
4. Install the Rear Alternator Support Bracket (R07020017) using (1) M8 x 1.25 x 20mm bolt
(R18020005) into the alternator and (1) M8 x 1.25 x 25mm bolt (W500224) into the intake (all parts are from Hardware Kit D). Torque to 20 – 30 Nm.
WARNING: Do not put any bolt longer than 20mm into the back of the alternator
W500224
R18020005
20mm MAX
Length
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5. Using the alternator battery cable (R07080015) from Hardware Kit F, locate the dash panel retainer (Christmas tree) and clip to the factory dash panel tab. Route the harness under the fuel rail crossover hose and install the stud retainers onto the fuel rail studs. Connect the four-pin connector from the battery cable to the four-pin connector clipped to the engine wiring harness
(located near injector number one). Route both the battery and regulator ends of the harness across the front of the intake manifold (beneath the supercharger nose piece). Continue routing both ends between the rear alternator support bracket boss and the supercharger, around the front of the fuel rail mounting boss, under the fuel rail between injectors #5 and #6, and underneath the engine harness. Connect the alternator battery cable to the alternator stud and torque to 8 – 12 Nm. Plug in the alternator regulator connector.
Note: If alternator cable is rubbing on any sharp edges, carefully bend the cable to provide adequate clearance.
Dash Panel Retainer
Fuel Rail Stud
Retainers
6. Install FEAD Pulleys (R07020049) to the alternator bracket using (2) M8 x 1.25 x 28mm Idler bolts (R18020060). All parts can be found in Hardware Kit D. Torque bolts to 20 – 30 Nm.
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7. Install the FEAD belt (R07020015) as shown. Using a ½ inch drive breaker bar or ratchet, rotate the belt tensioner clockwise and install the supplied belt.
8. Reinstall the modified coolant hose hanger bracket and radio noise capacitor using the take-off
M8 nut. Before tightening, ensure there is sufficient clearance to all FEAD components.
Torque the nut to 20 – 30 Nm.
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Air Intake System
1. Install the S/C to Spacer Gasket (G1ZE-9L437-BA) from Hardware Kit C and Throttle Body
Spacer (R07060041) using (6) Spacer to S/C Bolts (N808920) from Hardware Kit C. Torque bolts to 20 – 30 Nm in sequence.
5
3
1
6
2
4
2. Install the throttle body to the throttle spacer (the gasket was installed earlier when removing it from the stock intake manifold) using (4) M6 x 1.0 x 33mm Throttle Body Bolts (N808429).
Torque bolts to 8 – 12 Nm.
Note: Mount the Throttle Body so that Electronic Throttle Control Motor is on the driver side.
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3. Connect the newly relocated throttle body wiring.
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Coolant Hoses
1. Reconnect the stock heater hoses at the back of the passenger side cylinder head using the original clamps. Install the 8” Intercooler Inlet hose and the 12 ½” Intercooler Outlet hoses using (4) ¾” constant tension clamps (81) from the intercooler hose kit.
Note: Ensure that the alternator charge harness installed in step #5 on page #57 is routed over both intercooler hoses once installed.
2. Connect the LTR Outlet hose routed from behind the passenger side headlamp to the lower
Intercooler tube using (1) ¾” constant tension clamp (81). Install the 17 ½” Degas Inlet hose from the upper intercooler tube to the upper degas bottle fitting using (2) ¾” constant tension clamps (81) from the intercooler hose kit. Install the new Bypass Circuit Radiator Hose
(R07070004) using (2) 1 ½” worm drive clamps from the intercooler hose kit.
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3. Reconnect the upper radiator hose to the intake manifold.
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Air Induction System
1. Install the airbox assembly by reversing the removal instructions. Torque retaining bolt to 8 –
12 Nm.
2. Install the throttle body end coupler (R07060029) with (1) #72 hose clamp from the Air
Induction Kit. Install the hump hose (R07060030) on the airbox (round) end of the clean air tube using (1) #56 hose clamp. Place the #52 hose clamp over the end of the hump hose and the second #72 hose clamp over the throttle body end of the tube. Slide the hose ends into place and start the (2) M6 x 1.0 x 13mm support bracket bolts (N605771) from Hardware
Kit B into the manifold. Position the couplers and tighten the clamps to 2 – 4Nm. Torque the support bracket bolts to 8 – 12 Nm. Plug in the MAF sensor.
3. Connect the factory crankcase vent tube from the valve cover (near the oil fill) to the clean air tube. It is necessary to rotate the end fittings to achieve the desired routing illustrated below.
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Battery and Tray
1. Install the battery tray by reversing the removal instructions. Torque the battery tray bolts to 8 –
12Nm.
2. Place the battery in the tray and secure with battery hold down. Torque the battery hold down bolt to 8 – 12 Nm. Reinstall the heat protecting battery wrap over the battery.
Vacuum System Connections
1. Connect the bubbler hose from the lower intake manifold to the throttle spacer (lower right 3/8” fitting) and secure 3/8” hose clamp from Hardware Kit I.
2. Remove the 1/8” IPTS hose from the stock brake booster hose (at the plastic junction point).
Install the 1/8” take-off IPTS hose onto the IPTS (fuel rail sensor) and vacuum/boost 90 degree fitting on the manifold as shown below and insert the retaining clip onto the rear fuel rail stud bolt.
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3. Install the new PCV purge tube (R07040006) from Hardware Kit E to the 5/8” SAE-style fitting on the throttle body spacer (lower left fitting). Reinstall the stock VMV hose to the upper front
3/8” SAE-style fitting.
4. Install the fuel line to the fuel rail and secure using the safety clip.
5. Install the 3/8” Vacuum Cap (R07040040) over the rear- most nipple on the throttle Spacer.
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6. Connect the brake booster hose to the last open throttle body spacer fitting (top center port).
Connect the supplied vacuum hose (R18140001) between the upper port on the bypass actuator and the open tee fitting on the brake hose.
Coolant Fill and Final Assembly
1. Fill the engine cooling system (using a proper G-05 coolant mixture) to the marked level on the radiator degas bottle.
2. Using the same coolant mixture, fill the intercooler system. The coolant should be approximately one inch below the top of the cap.
Important:
Both coolant systems can trap a large amount of air. It is very important to verify that the air is purged and that coolant is flowing properly through both systems.
ROUSH Performance recommends vacuum filling both systems to properly evacuate the trapped air.
3. Reinstall front bumper cover and inner fenders by reversing the removal instructions.
4. Reinstall the front wheels/tires.
5. Reinstall the newly flashed PCM by reversing the removal instructions.
6. Reinstall the battery connections. Connect the positive cable first. Connect the battery end of the alternator charge harness using the same stud and nut which retained the factory harness.
Connect the negative cable to the battery.
7. Inspect all underhood wiring harnesses for potential interference issues. Use zip ties to safely position the harness away from any areas of concern.
8. Start the vehicle and check for fluid leaks, unusual noises, dash service lights, and unusual operation. If problems are detected, immediately stop the engine or vehicle, diagnose and repair the problem.
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9. The “Premium Fuel” clear decal with white lettering (R07110004) is to be installed on the instrument cluster bezel, on the flat area below the small center gauges.
Tachometer Speedometer
Place Decal Here
10. The “Premium Fuel” white decal with black lettering (R07110003) is to be placed on the lower half of the inside of the fuel filler door.
Place Decal Here
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PREMIUM FUEL REQUIRED
11. The Belt Routing Diagram (13106E072) is to be placed on the underside of the hood, on the driver side, opposite of the factory Vehicle Emission Control Information decal.
Place Decal Here
12. The E.O. Decal is to be placed on driver side strut tower, adjacent to the air filter assembly.
Place Decal Here
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PREMIUM FUEL REQUIRED
CARE AND MAINTENANCE OF OPTIONAL POLISHED ROUSHCHARGER
The optional polished ROUSHCharger unit is uncoated, polished aluminum. As such, it will occasionally require polishing using a quality aluminum polishing compound to maintain its luster.
Many “spray-on” aluminum cleaners contain caustic chemicals and may discolor or damage the finish of the ROUSHcharger and, as such, are not recommended.
WARRANTY
All retail parts carry a 90-day warranty from the date of purchase. This warranty covers defects in materials or workmanship, and does not include (i) normal wear and tear, environmental conditions, improper installation; (ii) road hazards, misuse, abuse, neglect, accidents, collision, fire, theft, freezing, vandalism, riot, explosion, or objects striking the vehicle; (iii) misusing the vehicle, such as driving over curbs, overloading, racing, or using the vehicle as a stationary power source; (iv) altering, disassembling or modifying the parts; (v) defects caused or induced by failures, breakdowns, or damage by other parts, components or the vehicle; (vi) subjecting the parts to excessive moisture or water or any motor vehicle fluids (e.g.: oil, anti-freeze, battery acid, brake fluid, etc.); (vii) acts of God, natural disasters and other similar causes beyond the reasonable control of ROUSH; or (viii) application of chemicals that affect the parts. This Limited
Warranty does not cover surface deterioration of paint, trim, and appearance items that result from use and/or exposure to the elements, such as stone chips, scratches, bird droppings, lightning, hail, windstorm, dings, dents, earthquake, road salt, tree sap, water or flood.
ROUSH SHALL NOT BE LIABLE TO REIMBURSE CUSTOMER/DEALER FOR INCIDENTAL
OR CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION OR USE OF
ANY PRODUCT SOLD THROUGH THIS CATALOG OR ARISING OUT OF ANY BREACH OF
WARRANTY. EXCEPT AS MAY BE STATED IN THIS CATALOG, ROUSH DISCLAIMS ALL
EXPRESS AND IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL
ROUSH’S LIABILITY EXCEED THE PRICE PAID BY CUSTOMER/DEALER FOR PRODUCTS
SOLD REGARDLESS IF ROUSH HAS BEEN ADVISED IN ADVANCE OF ANY POTENTIAL
PROBLEM OR IF A CLAIM IS BASED ON CONTRACT, TORT, STRICT LIABILITY, PRODUCT
LIABILITY OR OTHERWISE. SOME STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF IMPLIED WARRANTIES OR THEIR DURATION, OR LIABILITY FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSIONS OR
LIMITATIONS MAY NOT APPLY.
This ROUSH Supercharger kit is designed and tested to function properly only on vehicles as they are equipped from the factory (completely stock powertrain). The use of aftermarket parts and equipment such as: cams, headers, nitrous oxide systems, other bolt-on performance parts, or any other performance parts not sold by, manufactured by, or approved of in writing by
ROUSH, will result in powertrain and supercharger kit damage and will not be the responsibility of ROUSH in any way.
If you have any questions or concerns please call 1-800-59-ROUSH.
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Key features
- supercharger
- intercooler
- premium fuel
- performance upgrade
- increased horsepower
- increased torque
- improved throttle response