With Roush now offering a polished version of their ROUSHCharger, the upgrade from the standard black crinkle finish compressor unit has become very popular. You can buy a complete system or just the supercharger unit for a swap. The following is a step by step "how-to" for doing such a swap on an existing ROUSHCharged Mustang. Special thanks to Kandy for submitting this article!
Removing Your Roush Supercharger Head Unit
Tools Needed
• 1/4” and 3/8” Metric and standard wrench and socket set with extenders.
• Screwdriver set
• Needle nose and standard pliers
• 3/8" Drive Torque Wrench (7-35 ft-lb range)
Supplies Needed
• Paper tape
• Sharpie/Marker
• Sandwich/snack baggies
• Sticky notes
• Fuel rail lube
• Anti-seize
Estimated Time for Project
Approximately 4-5 hours.
References
All diagrams were extracted from the Roushcharger Kit Installation Guide, part number 1305-R07000004-AA. For additional installation instructions please use the complete Roushcharger Installation Guide which can be downloaded at: http://www.fnsweet.com/docs/2005-06MustangRoushcharger.pdf
Getting started Cover fenders to avoid scratches. Have a marker and baggies ready to label bolts as you remove them.
Remove CAI Tube
a. 2 5/16” bolts
b. Unclip wiring connectors
With CAI Tube removed
Remove Alternator Bracket
c. 1 bolt, 2 nuts
Alternator Bracket removed
Detach Hoses from Throttle Body Spacer (label)
d. 5 hoses, all different clamps!
e. Label well!
Hoses removed and labeled:
Detach small rubber tube from top port of the Bypass Valve on the Head Unit
Detach Fuel Rail Driver side:
f. Unsnap connectors (label)
g. Remove 2 5/16” bolts
h. Pop out injectors
Remove Throttle Body
i. 4 13mm bolts
j. 2 Connectors
Separated with Throttle Body gasket visible
Loosen Head Unit
k. 6 13mm bolts
Slip off belt from s/c pulley
l. Tilt head unit slightly forward to loosen tension on the belt
Detach Fuel Rail, passenger side:
m. Take wiring harness off the front bolt
n. Remove front 5/16” bolt
o. Slide Head Unit slightly to the drivers side to gain better access to back bolt
p. Remove back 5/16” bolt
Carefully lift off Head Unit and Throttle Body Spacer.
Pop Fuel Rail Injectors back into place
Cover Intake with paper tape or cardboard while Head Unit is off.
Reinstalling Your Roush Supercharger Head Unit
Re-attach the throttle body spacer to the head unit.
a. Insert the throttle body spacer gasket
b. Torque (6) 10 mm bolts 25 Nm (18 lb-ft) in sequence. 
Slide the head unit and throttle body spacer back in place – do not tighten yet
Re-install fuel rails
c. Lube o-rings with assembly lube and ensure injectors are properly seated.
d. Beginning with the back bolt on the passenger side, Torque all (4) 5/16” bolts to 12Nm (9 lb-ft)
Tip: To access the back passenger bolt, slide the head unit toward the driver side to give you more room to work.
e. Connect the IPS, ACT and all 8 (4 on each side) coil connectors
Torque the (6) 13mm head unit bolts to 30Nm (22 lb-ft) using the sequence below
Re-install the serpentine belt following the diagram below.
f. Using a ½” socket driver or breaker bar, place the square drive in the indent on the idler tension arm (noted in red below).
g. Press down to release the tension, and then slip the belt over the supercharger pulley.
h. Ensure the belt is aligned and feeding correctly
Re-attach the Alternator bracket to the head unit. Torque the nuts to 12Nm (9 lb-ft) and the bolt to 25Nm (18 lb-ft).
Attach the Throttle body to the Throttle Body Spacer.
i. Insert throttle body gasket
j. Torque (4) 8mm bolts to 12Nm (9 lb-ft).
Tip: Use lots of anti-seize here!! The steel bolts into aluminum case caused lots of flashing in the threads.
k. Connect throttle body wiring on both sides
Re-connect the CAI Tube
l. Torque support bracket bolts to 9Nm (80 lb-in)
m. Plug in the MAF sensor
n. Connect the vent tube from the valve cover to the CAI
Connect hoses to Throttle Body Spacer
o. Connect the bubbler hose from the lower intake manifold into the lower right fitting
p. Re-attach the PCV purge tube into the lower left fitting
q. Attach the VMW hose to the upper left fitting
r. Attach the Bypass Vacuum to the upper right fitting
s. Attach the rubber tube to the Bypass Actuator on the head unit
t. Attach the Brake Booster hose to the center open fitting
You’re done!!
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