Complete How To: Supercharge 4.ol V6 Sohc - Mustang 05-10

Discussion in '2005 - 2009 Specific Tech' started by moddbox, May 8, 2014.


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  1. moddbox

    moddbox Member

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    **NOTE: PART 1 of 3 (30 image blog limit)

    Haven't seen a build blog quite like this yet... so here is the "Complete How-To Supercharge the 4.0L". If anyone is interested in supercharging a 05-10 4.0L V6... this blog is for you.

    This was a pretty simple build that I was able to achieve in about a full day's work (and achieved around +100hp). The cost of the Moddbox ran about $2200 and you can find it on ebay. I needed some injectors and tune after and was good to go :)


    You can find the dyno sheet here: 05 Mustang 4.oL V6 w/ Moddbox Kit-Dyno Sheet
    (Moddbox Install Kit, 47lb Ford Racing Injectors, #6NGK plugs, & a Salvage 94 T-Bird Supercharger)


    Ok... here it goes:





    COMPLETE HOW TO: Supercharge 4.OL V6 SOHC - Mustang 05-10


    The following Installation Instructions apply to the 2005-2010 Ford Explorer Mustang 4.0L SOHC models.



    You should read the entire instruction manual prior to proceeding with your installation.

    It is important to familiarize yourself with the ModdBox Supercharger Kit installation. It is the responsibility of the installer to properly install the Supercharger Kit. To ensure safety and proper installation, ModdBox recommends that this product only be installed by a qualified professional with access to pneumatic tools and a strong familiarity with automotive service procedures.



    91 or higher octane gasoline is required at all times.

    You must use fuel of 91 octane or higher. If your vehicle is not currently running 91 or higher octane, you must run your vehicle till empty and refill with the required octane at least 2 times prior to installation.



    Any previously installed aftermarket tuning equipment must be removed and the vehicle returned to an as stock condition before installing the supercharger.

    Any equipment that directly modifies the fuel mixture or ignition timing of the engine can cause severe engine damage if used in conjunction with the ModdBox Supercharger Kit. This includes, but is not limited to ignition boxes, air/fuel controllers, OBDII programmers, and any other device that modifies signals to and/or from the ECU. Aftermarket bolt-on equipment such as underdrive pulleys may conflict with the operation of the supercharger and must be removed prior to installation. Use of any of these products with the ModdBox Supercharger Kit could result in severe engine damage.





    REFERENCE ABBREVIATIONS



    EGR – Exhaust Gas Recirculation

    HVAC – Heating Ventilation & Air Conditioning

    IAC – Idle Air Control

    MAF – Mass Air Flow

    TPS – Throttle Position Sensor

    Vac - Vacuum





    TOOLS REQUIRED



    Standard metric socket set

    Hex key set

    Various pliers

    T-30 Torx bit

    Fluid funnel

    Oil pan

    Flat head screw driver

    Pneumatic or electric hammer drill

    Crescent wrench

    Utility knife

    Shop vacuum

    Rat tail file

    Propane torch or similar heating device

    Wire Strippers

    Wire Crimper



    STOCK REFERENCE DIAGRAMS

    Stock Intake Pipe & Air Box Reference Diagram

    [​IMG]



    Stock Exhaust Gas Re-circulation (EGR) Reference Diagram

    [​IMG]



    Throttle & Stock Intake Manifold Reference Diagram

    [​IMG]



    Ignition Coil Reference Diagram

    [​IMG]



    Belt Diagram Reference Diagram (Dark Belt Showing the ModdBox Orientation)

    [​IMG]



    SUPERCHARGER KIT PARTS

    *several parts not shown. Refer to installation the product for more details.
    ModdBox Supercharger Bypass Valve
    ModdBox 255lph Fuel Pump
    ModdBox 5.5.0 & 8.0 psi Supercharger 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




    INSTALLATION STEPS

    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.

    [​IMG]


    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.

    [​IMG]


    Remove the fuel pump assembly.

    [​IMG]


    Remove the Stock Fuel Pump Filter.

    [​IMG]




    Un-bolt the ground wire and remove the pump retaining cap.

    [​IMG]


    Remove the bottom pump cover.

    [​IMG]



    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.

    [​IMG]


    Remove the stock fuel pump and dispose of it appropriately.

    [​IMG]


    Cut the bottom of the Rubber Retaining Gasket so that it can be used as a sleeve for your new 255lph Moddbox Fuel Pump.

    [​IMG]


    File or cut the Stock Fuel Pump Assembly Retaining Cap to accomodate the new 255 lph ModdBox Fuel Pump.

    [​IMG]


    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.

    [​IMG]


    Press the provided In-tank Fuel Filter onto the new fuel pump.

    [​IMG]


    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.

    [​IMG]


    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.

    [​IMG]



    ... see Part 2 of 3
     
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  2. moddbox

    moddbox Member

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    Just posted a universal tuning blog. This is applicable for all custom supercharger/turbo installs and even naturally aspirated.
    Check it out here: Moddbox Tuning Blog
     
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