Skyl3r
Active Member
- Joined
- September 26, 2016
- Messages
- 61
- Reaction score
- 18
- City, State
- Columbus, OH
- Year, Model & Trim Level
- 2005 Limited
Introduction
I decided to make this more of a tech and less of a "help me" thread. I won't remove any of the original posts, but I'll bump this first post down and include references to where in this thread certain details are.
What's Required
Parts Links
Steps To Install
Additional Info:
Pictures and additional info
Note on upgrading to a new MAF
I will update as I continue working. Stay tuned.
I decided to make this more of a tech and less of a "help me" thread. I won't remove any of the original posts, but I'll bump this first post down and include references to where in this thread certain details are.
What's Required
- Eaton M90 from the Saleen Series II
- Intake manifold from 01-04 Saleen (My understanding is 04 has the best airflow) I am using an 02 manifold
- Alternator relocation bracket from the series II setup. The piece is very simple. If anyone needs it, I could get all the dimensions and it could be made quite easily.
- 99-04 Mustang GT alternator
- Elbow - Will need modified some for vacuum lines
- Idler pulley and spacer
- Heat Exchanger and Intercooler (obviously) If you are purchasing parts separately, look for the chicane intercooler. It's supposed to be substantially better than the stock one.
- Bigger injectors. At the time of install I am using 32# FoMoCo injectors
- Fuel pump. I'm using a 255lph pump
- Blocking off or rerouting EGR
- Modifying cold air intake to fit
- Installing a wideband
- MAF Extender (I am using a DiabloSport Maf.ai extender)
Parts Links
- Saleen Intake Gasket Kit
- Alternator Pigtail
- 3" Idler Pulley
- Eaton M90 Smaller Pulley
- Zeitronix ZT-2 Wideband and Datalogger
- Diablosport Mustang MAFia F7370 (05-10 All)
Steps To Install
- Remove stock intake (cold air intake, throttlebody, upper and lower intake), fan and alternator
- Remove metal coolant pipe that runs under the lower intake. Replace this with coolant hose and some clamps (Saleen Series 2 on Explorer?)
- Pull off fuel rail and replace injectors with 32# or larger. Bolt it back down.
- Make sure the back of your saleen intake manifold has the plate that seals it in. I don't know what the stock one looks like, but this is what I made to replace it: https://i.imgur.com/0LcJy6U.jpg
- With the new intake gasket, use some RTV on the rear passenger side where there's a coolant passage in the engine that doesn't exist in the intake. I don't know what this is, but it didn't look like there was a passage for it on the old intake either. RTV got mine to seal fine. I just used high temp red RTV.
- Put the intake back on, torque it down to spec.
- Plug or install your boost gauge in the front port on the intake.
- Plug rear passenger side coolant passage on the intake.
- Deal with EGR (it either needs deleted or rerouted)
- Modify the elbow to have an extra vacuum port for the brake booster (https://i.imgur.com/dWEtsxv.jpg). Use a dab of RTV on the threads of the screws, they won't seal on their own.
- Bolt the elbow to the supercharger (before putting it on the car). I recommend using some RTV here. Mine did not seal well and I believe it is because the elbow is not constructed great.
- Bolt your mustang alternator on with idler pulley.
- Bolt the supercharger to the intake. Some of the bolts are near impossible to reach. Good luck!
- Use some string to find out what size belt you need to get. (I needed around 119") https://i.imgur.com/hfu1oxT.jpg Install the belt
- Install wideband O2 sensor. There's a spot where you can get to the exhaust through the wheel well. https://i.imgur.com/WrxD1GM.jpg
- Modify FIPK intake to fit, if you don't have an FIPK see note at the end for upgrading the MAF, as this will require a different intake solution. https://i.imgur.com/MvBoMjk.jpg
- Put your fan back in. Put the shroud over the fan back on.
- Flip your coolant hose that runs to the radiator in the front backwards and install it. Amusingly it gives just enough clearance for the supercharger snout when it's installed backwards. I cut a slot in the fan shroud and strapped it back though, just in case.
- To be continued.
Additional Info:
- EGR: It is important to note that you will need to delete EGR or find a way to relocate to the new position. It's not the same on the mustang. If you choose to delete, make sure it's legal where you are. (I'm not a lawyer. Please check your local laws and regulations on this)
- Reaching the bolts for the supercharger: It's next to impossible to reach the bolts on the elbow once the blower is on the engine. Unfortunately this means you have to bolt the elbow on *before* bolting the supercharger down. This means you gotta have very little hands to reach the bolts for the supercharger and you have to have the fuel rail in before putting the blower on
- Alternator: The explorer alternator will not work since it collides with the mustang intake manifold. You have to get a mustang alternator. The explorer electrical connector for the alternator won't plug into the mustang alternator, so you also need a pigtail, see below for information on that.
- Intake: Obviously the intake location is changed, so something custom has to be done. You can see my solution here https://i.imgur.com/MvBoMjk.jpg
- Elbow: I'm not sure if this is true of these elbows in general or if it was just mine, but these are relatively low quality parts. The throttlebody threads strip very easily and don't allow you to tighten it enough to get it to seal on the gasket. I used RTV.
- MAF: See note at end of this post for a note about installing a better MAF system from LSXkilr
Pictures and additional info
- Making the plate to fit the back of the manifold
- Sizes of Fittings required for intercooler
- Sizes of required bolts
- How to swap a smaller pulley onto the Eaton M90
- Blocking off EGR
- Installing Mustang style alternator plug
- Installing the Zeitronix wideband
- Using shorter GT500 LU47 Injectors on a 2v
Note on upgrading to a new MAF
FYI anyone else that is installing a blower (or thinking about one) Save yourself some headache down the road...
Buy a SCT BA series MAF I.e. BA2600 or BA3000 (not the BA5000 as a 4" pipe will be too much range with the slot meter)
-SCT 2900
-Oreilly S1094 pigtail.
This allows you to run a better inlet system.
I will update as I continue working. Stay tuned.
Hello,
I was able to pick up a series 2 saleen blower for a good price. It's a complete kit. Pump, injectors, intercooler, etc. I'm planning on putting on my 2005 Limited. Does anyone have any experience with this? Anything I should know?
I'll update this as I work on it. It's pretty cold here still, so it won't be immediate.
Some other things:
1. I'm planning to have Don LaSota from LaSota racing do my tune. He did my tune before and I was happy with it, so I'll probably stick with em.
2. I've read numerous times that the 5r55s and stock 4.6L 2v are good to ~400rwhp. I'd assume this applies to the Explorer as well? I'm unsure if I will build the engine. I'll have to see what ~350hp feels like first.
3. The install looks to be relatively straight forward. I assume the alternator relocation bracket and everything are just gonna work. I'll have to find a place for the degas bottle and figure out how to setup the CAI. I imagine those will be easy enough.
I was able to pick up a series 2 saleen blower for a good price. It's a complete kit. Pump, injectors, intercooler, etc. I'm planning on putting on my 2005 Limited. Does anyone have any experience with this? Anything I should know?
I'll update this as I work on it. It's pretty cold here still, so it won't be immediate.
Some other things:
1. I'm planning to have Don LaSota from LaSota racing do my tune. He did my tune before and I was happy with it, so I'll probably stick with em.
2. I've read numerous times that the 5r55s and stock 4.6L 2v are good to ~400rwhp. I'd assume this applies to the Explorer as well? I'm unsure if I will build the engine. I'll have to see what ~350hp feels like first.
3. The install looks to be relatively straight forward. I assume the alternator relocation bracket and everything are just gonna work. I'll have to find a place for the degas bottle and figure out how to setup the CAI. I imagine those will be easy enough.