**NOTE: PART 1 of 3 (30 image limit on this blog)
Thought I should post up a "Complete How-To Supercharge the 4.0L". If anyone is interested in supercharging an 05-10 4.0L V6... this blog is for you. This was a pretty simple build that I was able to achieve in only about a day's work (+ some data logging). I also needed to get some injectors and tune after and was good to go with around an extra 100 hp
You can find the dyno sheet here: 05 Mustang 4.oL V6 w/ 94 T-bird M90 - Dyno Sheet
(Dyno was with: Moddbox Install Kit, 47lb Ford Racing Injectors, #6NGK plugs, 91 Octane & 94 Salvage T-Bird Supercharger)
Ok... here it goes:
COMPLETE How To Install: M90 on 4.OL V6 SOHC - Mustang 05-10
EGR – Exhaust Gas Recirculation
HVAC – Heating Ventilation & Air Conditioning
IAC – Idle Air Control
MAF – Mass Air Flow
TPS – Throttle Position Sensor
Vac - Vacuum
Standard metric socket set
Hex key set
T-30 Torx bit
Flat head screw driver
Pneumatic or electric hammer drill
Rat tail file
Propane torch or similar heating device
STOCK REFERENCE DIAGRAMS
Stock Intake Pipe & Air Box Reference Diagram
Stock Exhaust Gas Re-circulation (EGR) Reference Diagram
Throttle & Stock Intake Manifold Reference Diagram
Ignition Coil Reference Diagram
Belt Diagram Reference Diagram (Dark Belt Showing the Supercharged Orientation)
MODDBOX SUPERCHARGER KIT PARTS
*several parts not shown. Refer to installation manual and parts list for more details.
ModdBox Supercharger Bypass Valve
ModdBox 255lph Fuel Pump
Moddbox 5.5 & 8.0 psi Pulleys
ModdBox Quick Change Pulley Adapter
ModdBox Plenum Bottom Plate
ModdBox Plenum Top Plate
ModdBox Intake Manifold
ModdBox Stainless EGR Extension
Black Silicone Liquid Gasket
Moddbox 6PK Serpentine Belt
Note: The installation has been broken up into two parts: (1) the fuel pump installation, and (2) the supercharger install.
PART 1 - FUEL PUMP INSTALLATION (1.5 hours)
WARNING: Gasoline vapors are explosive!
Caution: When replacing the fuel pump, perform all work in a well ventilated area away from sparks or open flame. Eye protection and rubber gloves are highly recommended. Avoid inhaling fuel fumes.
If fuel is ingested, seek medical attention immediately. To avoid a fire hazard, disconnect the negative battery cable when instructed. Failure to perform any service or repair in a safe manner may cause serious personal injury or death.
Relieve the fuel system pressure. This can be done by a variety of methods. It is recommended that you remove the fuel pump fuse and start your vehicle. The engine will run, shutter, then stall. Remove your key from the ignition and re-install your fuel pump fuse.
Remove the negative battery cable. Secure it to the side of the battery to prevent any accidental contact with the negative terminal.
Gain access to your vehicle's fuel pump assembly as required (fuel pump is located under the driver side back seat). Use a vacuum and/or a brush and clean off the top of the tank. Disconnect your fuel lines and remove the retaining ring. Caution: Do allow dirt or deleterious substances into your fuel tank.
Remove the fuel pump assembly.
Remove the Stock Fuel Pump Filter.
Un-bolt the ground wire and remove the pump retaining cap.
Remove the bottom pump cover.
Unplug the Stock Fuel Pump and disconnect the Fuel Line. It is recommended to use the stock fuel line. Be careful not to damage the fuel line during removal.
Remove the stock fuel pump and dispose of it appropriately.
Cut the bottom of the Rubber Retaining Gasket so that it can be used as a sleeve for your new 255lph Moddbox Fuel Pump.
File or cut the Stock Fuel Pump Assembly Retaining Cap to accomodate the new 255 lph ModdBox Fuel Pump.
Re-assembly the Fuel Pump Assembly and install the new pump. Reuse the stock fuel line and the provided stainless hose clamp Caution. Do not forget to re-connect the ground wire.
Press the provided In-tank Fuel Filter onto the new fuel pump.
Remove the Stock Fuel Pump Electrical Plug. Install the provided plug for the ModdBox pump by splicing in the wires as shown. lug in the new Pump and replace the Fuel Pump Assembly and secure the retaining ring. Re-connect your fuel lines. Caution: Be sure the plug has seated securely. Failure to do so may require you to re-access your pump assembly for inspection.
PART 2 - SUPERCHARGER INSTALLATION (5-6 hours)
Note: Prior to proceeding, you may want to test your fuel pump installation. If you choose to test the fuel pump installation, be sure to remember to disconnect your battery prior to proceeding. Disconnect TPS plug and Electronic Throttle Plug.
Disconnect MAF plug.
Disconnect Crank Case Vent hose from the Intake Hose.
Disconnect EGR plug and EGR vac line. Remove the EGR valve and set aside for future use.
Disconnect Spark Plug Wires and remove the Plug Wire Retaining Clip from the top of the Stock Intake Manifold. Disconnect the Vac Line and Fuel Vapor Return Line as shown. Mark them with tape if necessary.
Disconnect Electrical Plug Mount from Stock Intake Manifold. Use the supplied short plastic straps to secure this to your wiring harness or fuel rail as required.
Disconnect the passenger side Crank Case Ventilation Tube.
...see part 2 of 3.