Various electrical connectors are disconnected and then we’re ready to modify the fan shroud.
Use a caliper and marker, pen or grease pencil to measure out a line 31mm from the top surface
of the shroud all the way around. Then cut the shroud along the marked line with a cutting wheel
and sand off any rough edges.
A vacuum cap is installed on the open nipple on the brake booster steel tube and then we’re ready for minor surgery on the wiring harness.
Sensors for the Roushcharger are soldered into the factory harness, as well as for the boost dump control.
The battery, battery cover and windshield washer reservoir are
temporarily removed to make room for mounting the intercooler wiring harness and relay.
The wiring is routed along the firewall, the passenger inner fender and over the radiator.
After the wiring is installed the windshield washer fluid reservoir and battery are
reinstalled. The PCM is put back in and one of the PCM wiring connectors is modified.
Next, the power steering reservoir is relocated. This done by cutting off
the plastic side bracket on the reservoir, fastening the relocation bracket onto the factory
bracket, rerouting and reconnecting the hoses, and reattaching the reservoir to the new location.
Fill the power steering fluid reservoir with fluid to the fill level indicator. A supercharger
is a costly addition to a vehicle so don’t cheap out and use bargain basement fluids.
While treating yourself to the extra power of a Roushcharger treat your truck right with high
quality fluids. We used Royal Purple synthetic power steering fluid to reduce pump noise and protect the
life of the pump.
Next, the factory injectors are swapped out for higher flowing injectors.
Here comes the part where it starts looking like you have a supercharger…. the supercharger build-up!
The throttle body spacer and throttle body are installed on the top of the supercharger body.
The intercooler radiator (Roush calls it a low temperature radiator: LTR)
comes next. The LTR is then positioned between the main engine radiator and the condenser
while 4 mounting holes are marked in the radiator core support. Then four mounting holes
are drilled in the core support. The LTR is then bolted into place after routing its hoses
and the main engine radiator is bolted back in place.
The vehicle must be safely raised to install the intercooler pump on the
driver’s side frame rail. You may do this by crawling under the truck, but its going to be
a tight fit without putting the vehicle on a lift.