It was without a doubt the more challenging part of the installation. D'Amore used a special cutter that made the front cover look as if Ford cast the piece with the shortened bosses and cut ribs. It added more time to the installation, but the custom cuts were a nice touch.
Roush offers the supercharger...
Roush offers the supercharger system with tuning (stick-only at the time of this writing) and as a tuner kit. We sampled the tuner kit and D’Amore custom tuned the vehicle using SCT software. Final results are 510 rwhp and 476 lb-ft of torque with a max boost reading of 7.8 psi and just 16 degrees of ignition timing.
Dmytrow alluded earlier that parts of the system are a carryover from the previous Roushcharger system for the 4.6L Three-Valve, but the team did have to design several other parts and pieces. In addition to the new FEAD, Roush designed new fuel rails, fuel injectors, throttle spacer, wiring, and PCV and vacuum systems. The supercharger housing is a new casting to fit properly under the hood and on top of the engine. The intake manifold is new, given the new head design on the Coyote 5.0L, but the same air-to-water intercooler is utilized. The lines, intercooler pump and mount, heat-exchanger, reservoir, and all the little other parts and pieces are a direct carryover from the Three-Valve since the electric fan, radiator, chassis, and bumper are identical to the 2010 model.
The system was installed out-of-the-box, save for a custom JDM tune. "We could change the pulley for more boost or add headers and X-style exhaust, but we would be pushing the fuel system past its capabilities," commented D'Amore. He says those limits are 520 rwhp for auto cars and approximately 560 rwhp for a manual-transmission-equipped Coyote 5.0L.
The Roushcharger comes with a set of 47--lb-hr fuel injectors, but relies on the stock fuel pumps. He continued: "We are designing an easy-to-install fuel system and eventually we will be upping the boost, adding exhaust, and bolting on a larger throttle body and elbow."
The kit produced a peak of 7.8 psi of boost on the completely stock engine (right down to the factory headers, catalytic converters, and mufflers). The Roushcharger brought output to an impressive 510 rwhp and 476 lb-ft of torque. Due to deadlines we didn't get over to Englishtown Raceway Park or Atco Raceway for on-track results, but that will happen in the near future.
"Typically a street car with an automatic and that level of power will go 10.90s with a good set of tires," notes D'Amore. We agree with his assessment based our own experience with several different project vehicles.
Keep tuned to these pages as we plan on following along as D'Amore gets after this '11 Mustang GT with more boost and power.
4a The manifold is bolted...
4a The manifold is bolted down using three manifolds bolts and two fuel injector rail bolts per side. The metric system is used to torque down the manifold. The fuel rails re-use the OEM bolts and are hit with 10 Nm, followed by a 90-degree turn...
4b ...The manifold bolts...
4b ...The manifold bolts are supplied by Roush and receive a 10Nm torque rating, followed by an additional 45-degree turn. Use the step method and begin tightening the bolts from inside-to-outside.
5 Jeff Stich of JDM Engineering...
5 Jeff Stich of JDM Engineering lowers the Roushcharger on to the lower manifold. It is torqued down using the step method—10 Nm, 20 Nm, and finally 30 Nm. A bolt-on pulley has been incorporated into this version of the Roushcharger so enthusiasts have the option of turning up the boost. Doing so will void Roush’s warranty on the product.
6 The inlet elbow that connects...
6 The inlet elbow that connects the throttle body to the Roushcharger features a split opening. JDM offers a D-shape elbow that has proven to pick up on rwhp in TVS supercharger applications on Shelby GT500s, as well as on Roush Stage 3 and 427R vehicles.
7 Roush includes a dual-bore...
7 Roush includes a dual-bore GT500 throttle body in the system. Each bore measures 60mm. This is one of the parts on D’Amore’s replacement list once the JDM fuel system upgrade kit is complete. Plans are to swap on a larger L&M Airflow dual-bore throttle body, which is a proven upgrade in positive-displacement blowers.
8 A new wiring harness is...
8 A new wiring harness is included in the Roush kit due to the throttle body relocation. You have to re-pin the factory harness to mate with the Roush extension for the throttle position sensor connector and canister purge valve connector.
11 The heat exchanger is...
11 The heat exchanger is mounted in the front grill area, which is typical for these supercharger applications. It provides ample airflow over the fins and its location doesn’t cause any cooling issues with the vehicle’s factory radiator.
12 D’Amore gapped the spark...
12 D’Amore gapped the spark plugs at 0.030-inch, this differs from the instructions which call for a 0.040-inch gap.
13 The finished product looks...
13 The finished product looks factory-installed. Roush utilizes the factory airbox and JDM Engineering has proven it is not a restriction in its drag racing vehicles. The shop’s ’10 Roush 427R vehicle has gone 9.70s at 143 mph using the same airbox.
9a The hardest part of the...
9a The hardest part of the installation is the grinding and cutting on the front engine cover. The supercharger system requires the removal of a few pulley bosses and some ribbing...
9b ...Roush provides excellent...
9b ...Roush provides excellent instructions to perform this task but the JDM staff when far beyond the instruction manual. D’Amore purchased a special cutter, and the finished front cover looked like it was cast without the bosses or ribs.
10 The supercharger tensioner...
10 The supercharger tensioner is bolted on the first sheave, which is used to drive the A/C compressor. The removal of the bosses and ribs is required so this bracket can be bolted on. As you can see in the lower left corner of the bracket, this is where the transmission cooler lines mount to the cover. D’Amore was forced to relocate these lines out of the way of the bracket.