We had originally ordered our ProCharger with a vertical-mount, three-core intercooler but decided to change that during the installation. We liked the idea of hiding the intercooler in the front fascia, and the fact it'd be out of the way. However, it required quite a bit of trimming to both the bumper support and the headlight support that the owner did not approve of, so we simply exchanged it for a horizontally mounted unit.
These are in fact, more efficient than the front-mounted pieces, but they reside rather low to the ground. We measured 3.5 inches of clearance with the stock suspension, so if you have lowered your car, you may want to consider this. We've put over 200 miles on it since installation and the only time we scraped it was coming out of some steep driveways (we forgot it was down there). On the highway, it was subjected to some pretty good shots from our strafed and pothole-ridden New Jersey interstates, but never touched the pavement.
In the engine compartment,...
In the engine compartment, we drained the coolant, removed the clutch fan, shroud, and serpentine belt, and then the A/C compressor. Our aftermarket Sanden unit would not work with the ProCharger bracket, so we substituted a stock one later.
One hole on the bracket needs...
One hole on the bracket needs to be drilled out. Use the supercharger bracket as a template.
Mounting the bracket is relatively...
Mounting the bracket is relatively simple. The inner fender may need to be pushed back via gentle taps with a large hammer. Ours needed minimal modification. The large hole is covered with a factory plastic grommet. Once removed, the opening will also need to be modified to accept the large inlet hose.
The supercharger comes with...
The supercharger comes with this adjustable idler pulley, which installs easily.
Not wanting to get any gunk...
Not wanting to get any gunk or gasoline on our pretty polished supercharger, Dan removed the upper intake plenum and then the fuel rails so we could exchange the injectors and mount the fuel regulator.
The regulator goes on with...
The regulator goes on with three small Allen-head bolts. This is much easier to do with the fuel rails off of the engine.
Brothers Performance Warehouse...
Brothers Performance Warehouse also supplied our Ford Racing 42-pound injectors (the green ones) and our Pro-M Bullet mass air meter. This style of blow-through meter is preferred with an intercooled application to provide better idle characteristics. The injectors (PN FMM9593F302) cost $419.99, while the meter (PN PRO7542ATI) costs $249.99.
Injector installation is easy....
Injector installation is easy. Work out the old injectors, lube the O-rings on the new ones and work them in. Install the fuel rail with the four bolts and make sure that all of the injectors seat properly and that you have plugged all of them back in. Priming the fuel system before start-up will let you check for any leaks.
Mounting the head unit requires...
Mounting the head unit requires one to "clock" or arrange the blower outlet. Loosening up these perimeter bolts allows you to turn the case so that the outlet points in the right direction. Ours was to point due south, as the outlet discharges into the intercooler tubing, which runs under the framerail and into the intercooler itself.