F-150 Roush Supercharger Installation

Our quest to build the baddest truck to give away for our 2005 sweepstakes started with a stock 4x4 Crew Cab F150. First, we lifted the truck with a Pro-comp suspension lift system. Then we dressed up the exterior with Roush truck accessories, huge fender flares, and big off-road wheels and tires. This thing was big and intimidating. But we didn’t want it to just be big; we wanted it to be fast! So, we contacted Roush, who hooked us up with 112 extra horsepower coming from its new F-150 supercharger kit.

The Roush Supercharger

The Installation

This is a torque wrench. Make sure you use the proper tools when doing this installation.

The Roush supercharger is available for the 2004-2006 Ford F150 and comes with all instructions and hardware required for installation. The instructions include a complete list of all tools required, as well as pictures of each step in the installation process. Follow them to a "T".

For better access to the engine compartment and for better lighting, we removed the hood and headlights prior to installation. Enough talk, let's check out the installation.

Section A: Disassembly

1. For safety reasons, disconnect the negative battery terminal.	2. Unbolt the PCM (Powertrain Control Module) and remove it from the vehicle. It will be shipped to Roush for reprogramming.
3. After removing the stock air intake tube and air cleaner, remove the radiator cover.	4. After draining the radiator, remove the upper radiator hose as well as the radiator hose support bracket.

5. Using a fan removal tool, disconnect the fan from the water pump.

6. Once the fan is removed, you can then unbolt the fan shroud from the radiator. 7. After disabling the belt tensioner, you can remove the alternator and the alternator support bracket.

8. Remove the heater hose from the water crossover located behind and to the passenger side of the alternator.	9. After disconnecting the TPS (Throttle Position Sensor) and ETC (Electronic Throttle Control) from the throttle body, it is removed from the intake.
10. Double check that the battery is disconnected and separate the fuel line from the fuel rail. Wrapping the connection in rags prior to separation is recommended.	11. After removing the IPS (Injector Pressure Sensor) and ground strap from the fuel rail and the wiring connectors on the injectors, unbolt and remove the fuel rail.
12. After removing the 10 intake manifold bolts and lifting the manifold slightly (without removing it), remove the water crossover.	13. After disconnecting the brake booster, remove the factory intake manifold.

14. Remove the wiring harness from the back of the stock intake manifold. It will be installed onto the new Roush intake manifold.

Section B: Modifications

15. To accomodate the supercharger drive belt and pulleys, 31mm must be trimmed from the fan shroud.

16. After trimming the fan shroud, smooth any rough edges with a sander or file.

17. Install the intake wiring harness, along with the new boost solenoid, onto the back of the new Roush intake manifold.

18. Insert the supplied crush limiters into the intake manifold gaskets.

This is Jimmy, Stylin' Trucks' videographer. He directed the Roush Installation Video

19. Install the throttle body spacer, along with the supplied gasket, onto the supercharger.

20. Install your factory throttle body to the throttle body spacer. Use the same O-ring gasket that was on your factory intake manifold.

21. In order to clear the front casing of the supercharger, the green plastic adaptor must be removed from the alternator.

23. Using the supplied hardware and pieces, assemble the new Roush airbox. [Editor's note: Staring seductively into the camera is a rookie move and should be avoided at all costs.]

24. Install the factory mass airflow sensor into the new Roush intake tube.

Section C: Installation

25. After confirming that your intake manifold gaskets are in place, put the intake manifold down onto motor.	26. After installing the water crossover, tighten the intake manifold bolts down in order.
27. Install the fuel rail onto the new intake manifold after lubricating the injector O-rings. Then bolt it down.	28. Now it's time to install the Roush supercharger assembly. Be sure to line up the bolt holes and lower the supercharger straight down.
29. Install the modified alternator back onto the engine.	30. Using a breaker bar, loosen the tensioner and install the serpentine belt.
31. Once the crank pulley adaptor is installed, install the Roush supercharger drive pulley and bracket.	32. Install the front bridge. This includes the new belt tensioner for the Roush supercharger drive pulley.
33. After installing the fan adaptor, you can now install the fan and fan shroud.	34. Before installing the new Roush radiator hose, use a breaker bar and install the Roush supercharger drive belt.

35. Once you have made the appropriate intake system connections, you can install the new Roush airbox.	36. Install the new Roush intake tube between the Roush airbox and the factory throttle body, now located on top of the Roush supercharger.
37. Install the new high-flow air filter.	38. Reconnect your battery. Now is the time to double check all of your clamps and bolts.

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