Step 1

Disconnect negative terminal from battery using 8 mm wrench.

Step 2
Drain cooling system by un-screwing the drain plug on the passenger of the radiator. This is best accessed through the fender well. Attaching a length of 5/16 ID hose to the drain nipple will help guide the coolant into the container. R Removing the coolant bottle cap will aid in the draining of the coolant. Once drained, replace the drain plug and the coolant bottle cap.

Step 3
Cover the tops of the fenders and the bumper with protective wrap.

Step 4
Loosen screws on the band clamps on both ends of air intake duct. Remove PCV hose from air intake duct. Remove break booster hose from air intake duct. Remove entire air intake duct from engine.

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Step 5
Disconnect throttle body electrical connector. you will need to slide the red lock sideways first in order to remove the connector.

Step 6
Disconnect purge valve electrical connector.

Step 7
Disconnect PCV hose connection at the intake manifold.

Step 8
Disconnect heater hose connection on drivers side of engine and move the hose close to the battery, out of the way.

Step 9
Disconnect purge valve hose and hose support and move hose out of way.

Step 10
Remove drives side fuel rail insulation.

Step 11
Remove passenger side fuel rail insulation.

Step 12
Disconnect brake booster hose connection.

Step 13
Disconnect fuel line connection at the fuel rail. be careful to protect against fuel spray, as there may be pressure in the fuel system.

Step 14
Remove the four bolts that secure the fuel rail assembly to the intake manifold, using a 10 mm socket.

Step 15
Disconnect the eight injector connector from the injectors.

Step 16
Remove the fuel rail assembly with the injectors.

Step 17
Loosen the six intake manifold bolts using an 8 mm socket. Note: The bolts do not come out of the intake manifold assembly.

Step 18
Remove intake manifold assembly from engine.

Step 19
Remove all eight injectors by first removing the injector retaining clip with a screwdriver.

Step 20
Install new injectors using a small amount of petroleum jelly to lubricate O-Rings.

Step 21
Re-install injector retainer clips.

Step 22
Install fuel rails as shown in photo, pushing injectors down into seats.

Step 23
Install four M6 X 80 mm SHCS and M6 washer onto the injector bracket hole.

Step 24
Remove the eight intake seals from the stock intake.

Step 25
Install the eight intake seals into the grooves on the supercharger intake manifold.

Step 26
Remove the four bolts retaining the throttle body onto the stock intake using 8 mm socket.

Step 27
Remove the stock seal from the original intake manifold using 8 mm socket.

Step 28
Remove the two bolts securing the purge valve to the stock intake manifold using an 8 mm socket.

Step 29
Remove the bolt securing the PCV nipple to the stock intake using an 8 mm socket.

Step 30
Using a utility knife, cut the plastic fuel line, where it attaches to the steel line at the firewall. Remove the plastic line.

Step 31
Cut the plastic line with a utility knife where it attaches to the fuel rail connector, and discard the plastic line.

Step 32
Connect the supplied 5/16 fuel line to the fuel rail connector, and install the supplied fuel hose clamp and tighten.

Step 33
Connect the other end of the supplied fuel line to the steel fuel line at the firewall, and install the supplied fuel hose clamp and tighten.

Step 34
Remove the protective tape from the rear of the supercharger.

Step 35
Install the supplied vacuum nipple to the intake manifold using a small amount of red threadlocker.

Step 36
Install the supplied O-Ring to the rear of the supercharger. A small amount of petroleum jelly may help in holding the O-Ring in place.

Step 37
Install the inlet elbow at the rear of the supercharger.

Step 38
Install the three M8 X 25 SHCS and M8 washers and tighten.

Step 39
Install the M8 hex nut onto the stud and tighten with a 13mm wrench.

Step 40
Install the PCV nipple and secure with the supplied M6 X 16 SHCS and M6 washer.

Step 41
Connect supplied vacuum line to the bypass valve nipple.

Step 42
Connect other end of vacuum line to the nipple on upper rear of intake manifold.

Step 43
Installed supplied NPT elbow to inlet elbow using a small amount of red thread locker.

Step 44
Install supplied brake booster hose nipple onto the NPT elbow using a small amount of red threadlocker.

Step 45
Install purge valve onto intake elbow with original bolts using an 8 mm socket.

Step 46
Loosen the knock sensor bolts and adjust the rotation of the sensors to place them as close as possible to the cylinder heads. It may be necessary to remove some of the wire harness cover between the two sensors in order to rotate the sensors to the correct location. Torque the sensors to 177 lb / in (20 Nm).

Step 47
Install the supercharger/intake manifold assembly onto the engine. This is a tight fit, so go slowly. Once in place, the fuel rail bolts should start into the threaded holes on the cylinder heads.

Step 48
Tighten the four M6 X 80mm SHCS securing the fuel rails, using an M4 allen socket.

Step 49
Install the six M6 X 40mm SHCS and M6 washers into the intake manifold and tighten using an M4 allen socket.

Step 50
Connect the eight fuel injector electrical connectors.

Step 51
Remove the two thermostat housing bolts using an 8mm socket.

Step 52
Remove the two water outlet housing bolts using a 10mm socket.

Step 53
Remove the radiator hose from the water outlet housing with adjustable pliers.

Step 54
Remove the original hose clamp from the radiator hose. The clamp is bonded to the hose, so you must carefully cut the clamp away from the hose.

Step 55
Install the hose onto the water outlet housing, using the supplied HS24 hose clamp. Note: How the hose sits approximately inch further out on the outlet housing. Tighten clamp.

Step 56
Release tensioner with a Johnson bar and a 15mm socket. Remove the drive belt.

Step 57
Remove top water pump bolt using a 10mm wrench.

Step 58
Remove water pump pulley bolts using a 10mm socket. Remove pulley.

Step 59
Install supercharger belt idler pulley and bracket using a 6mm allen socket.

Step 60
Re-install water pump pulley using a 10mm socket.

Step 61
Install supercharger drive belt per diagram.

Step 62
Install O-Ring on water pump outlet spacer using a small amount of petroleum jelly to hold the O-Ring in place during assembly.

Step 63
Install spacer between water pump outlet and water pump with the O-Ring towards the engine using the M6 X 75mm SHCS and 6mm washers. Tighten with 4mm allen socket.

Step 64
Re-install water outlet housing to drivers side cylinder head using 10mm socket. Check for adequate clearance between radiator hoses and supercharger drive belt.

Step 65
Re-connect heater hose to drivers side head, routing the hose over the supercharger.

Step 66
Remove passenger side PCV hose from valve cover and cut tube on both ends to enable hose to be removed from the fittings.

Step 67
Push PCV fittings onto each end of supplied 5/8 ID hose. Install heat shrink bands to secure hose ends using a heat gun to shrink the bands into place.

Step 68
Install one end of PCV hose onto nipple on passenger valve cover and install other end onto PCV nipple located on supercharger inlet elbow.

Step 69
Install original throttle body seal into groove in supercharger inlet elbow.

Step 70
Install throttle body onto inlet elbow using original bolts and an 8mm socket.

Step 71
Cut brake booster hose to shorten length in order to connect to barb fitting on supercharger inlet elbow.

Step 72
Push hose onto barb and retain using original clamp.

Step 73
Cut hose at end of purge valve line, in order to remove purge valve fitting.

Step 74
Cut purge valve hose shorter and connect purge valve fitting. Connect purge valve line to purge valve.

Step 75
Cut throttle body wiring approx. 6 inches back from connector.

Step 76
Cut purge valve wiring approx. 6 inches back from connector.

Step 77
Use supplied wiring extensions and connectors to lengthen the throttle body harness and the purge valve harness.

Step 78
Use supplied split loom to cover wiring once extensions have been spliced in.

Step 79
Route wiring for throttle body and purge valve down passenger side valve cover, around rear of supercharger and connect each to proper connector. Secure wiring loom with supplied tie wraps.

Step 80
Connect intake sensor harness supplied to the IAT sensor on the rear of the supercharger intake.

Step 81
Route the wiring towards the air filter box. Connect the blue wire from the mass air flow sensor wire harness using the supplied scotchlock connector.

Step 82
Cut the purple wire in the mass air flow sensor wire harness and connect the purple wire from the intake air sensor harness to the purple wire on the wire harness. Seal the harness with supplied electrical tape. Cover wiring with supplied split loom and secure harness with supplied tie wraps.

Step 83
Install air inlet ducts and tubing connectors as shown in photos. Attach with supplied HS56 hose clamps and tighten with screwdriver.

Step 84
Connect supplied 5/8 PCV hose to two supplied PCV connectors as shown in photo.

Step 85

(no photo)

Use supplied heat shrink tubing to secure PCV hose to connectors.

Step 86 photo

Step 86
Install completed PCV hose assembly as shown in photo.

Step 87
Install intercooler water pump onto heat exchanger as shown in photo using supplied HS36 hose clump. Tighten clamp with a screwdriver.

Step 88
Cut approx. 2 inches off short leg of supplied hose.

Step 89
Install hose as shown in photo using supplied HS12 hose clamps. Tighten clamps with a screwdriver.

Step 90
Remove two upper front bumper bracket bolts using 13/16 socket.

Step 91
Remove horn bracket mounting bolt using 10mm socket.

Step 92
Bolt heat exchanger to upper radiator support using the original bolt and a 10mm socket. (no photo)

Step 93
Drill 3/16 hole in upper radiator support being careful to ensure the heat exchanger is level.

Step 94
Use supplied X 1 self tapping screw and fender washer to mount drivers side upper strap to radiator support using an 11mm socket.

Step 95
Tighten original upper bumper nuts to secure lower heat exchanger brackets using 13/16 socket.

Step 96
Photo shows installed heat exchanger.

Step 97
Bolt horn bracket on to passenger side upper heat exchanger bracket using supplied X 1 bolt, nylock nut and washers with an 11mm socket.

Step 98
Drill holes into radiator shroud using 3/16 drill bit to mount intercooler bottle bracket.

Step 99
Rivet bracket in place using 3/16 supplied rivets.

Step 100
Bolt bottle to bracket using M6 X 25 bolt and washer.

Step 101
Cut a 30 inch length of hose from the supplied hose, connect one end of hose to lower nipple of intercooler bottle and the other end to intercooler pump. Secure with supplied HS12 hose clamps and tighten with screwdriver.

Step 102
Cut an 18 inch length of hose and a 3 inch length of hose from the supplied hose. Connect one end to upper nipple of intercooler bottle and the other end to the 90 degree fitting. The 3 inch hose connects the other side of the 90 degree fitting to the vertical intercooler nipple on the front of the intake manifold. Use supplied HS12 hose clamps to secure the hoses. Tighten with a screwdriver.

Step 103
Cut a 32 inch length of hose and a 3 inch length of hose and a 6 inch length of hose from the supplied hose. Connect the 3 inch piece on one end of the 32 inch hose using a supplied 90 degree fitting and the 6 inch piece on the other end of the 32 inch hose. Connect the 6 inch hose to the lower heat exchanger nipple and the 32 inch hose through the radiator support to route. Connect the 3 inch hose to the 45 degree intercooler nipple located at the screwdriver.

Step 104
Using a trim tool, remove the upper radiator support trim panel.

Step 105
Drill a 3/16 hole in the passenger side fuse box bracket next to the hole for the trim clip.

Step 106
Attach the relay using the supplied 3/16 rivet.

Step 107
Connect the 10 gauge red wire with the male spade connector to the lower left pin in cavity 9.

Step 108
Connect the ring terminal of the 10 gauge red wire to the positive terminal inside the fuse box. Tighten nut with a 10mm socket.

Step 109
Connect ground wire ring terminal to negative terminal of battery cable using a 10 mm socket.

Step 110
Connect water pump electrical connector to the water pump and route wiring close to radiator support. Use tie wraps to secure wiring.

Step 111
Re-install upper radiator support trim panel using original trim clips.

Step 112
Connect negative terminal to battery, tighten with 8mm socket.

Step 113
Connect handheld programmer to OBD connector under dash. Follow directions on programmer to install custom tune. Ensure battery is fully charged before starting download.

Step 114
Fill radiator bottle with 50/50 mixture of Ford antifreeze and water.

Step 115
Fill intercooler bottle with 50/50 mixture of Ford antifreeze and water. Turn ignition key to run position and verify that the coolant is circulating through bottle.

Step 116
Fill truck with 91 octane fuel. Start engine and warm up truck fully. Check fluid levels.