Explorer, Ranger 4.0! Instacharger #1590

Explorer, Ranger 4.0! Instacharger #1590

IINS-O50 I
Explorer,
#1590
PARTS
Ranger 4.0!
Instacharger
INCLUDED
1 -Supercharger Assembly
1 -Cable Bracket
1 -Coil Moutn Weldment
2 -Stock
1 -Split Plenum Gasket
7 -5116" Studs
7- 5/16" -24 Hexnut
1 -TB Gaseket
2 -IAC Bolts M6 x 20
4 -TB Bolts M6 x 30 SS SHCS
1 -IAC Gasket
1- Brass Tee
1 -Fuel Line (Male)
1 -Fuel Line (Female)
2 -Supercharged Emblems
1 -FMU Instructions
1 -Fuel Manifold Unit
1 -Ignition
2- 1/4" -20 x 1/2" Hexbolt
6 -FHSCS, MB x 40mm
2 -Hexbolt, M6 x 10mm
1 -Plenum
Plenum Gaskets
Module
Base
Step 1
Disconnectthe negativebatterycable,set the parkingbrakeand removethe serpentinebelt.
Step 2
Removethe flexibletube from the throttle body and air box. Disconnectthe PVCtube andthe inlet air temperature sensorif applicable.
Removeplasticcoveron the left side of the throttle body.Unlockthe cablebracketfrom the intakeand set aside
Disconnectall electronicand vacuumconnectionsand the EGRtube from the upperintake.
Step
3
Step
4
Disconnectplug wires from the coil and removethe coil and bracketassembly.
Step
5
Removethe upperintakeand disconnectthe fuel line gong to the fuel pressureregulatorand set aside.Remove
studs securingfuel rail castingthen lift castingup in orderto replacethe gasketbetweenthe fuel rail and lower
manifoldwith a suppliedgasket.
Step
6
Installsuppliedstuds in lower intakeplenumcasting(CST-16)and securewith a small amountof loctite.Set
CST-16 into placeusingsuppliedgasketand flatheadsocketheadcap screws.
NOTE
Onsome models it may be necessaryto slightly reroute some
of the factory wiring in order to clear the CST-16plenum.
Tightenfastenersto 20 ft Ib torqueafter you havemadesurethat all injectorsand wiring are clearof the
new intake.
Step
7
Removethe idle air controlvalveand install on the superchargerassemblyusingsuppliedgasket.
..
MORE ON
THE BACK
IMPORTANT-AIIappropriatesafetyequipment(e.i., gloves,tools) must be usedduringthe installationof this product(s).
BBKPerformance,Inc acceptsno responsibilityfor injuries resultingin the installationof any product(s).
IINS-O50 I
NOTE
Onsome models with a compositeintake the IAC valve
must point toward the firewall to operateproperly.
Removethe vacuumtree (aluminumintake)or usethe suppliedvacuumtree (compositeintake)and install into
tappedhole nextto IACvalve.Removeinlet air temperaturesensorand install in remaininghole if applicable.Use
the suppliedplug in remaininghole if idle air temperaturesensoris in inlet tube.
Step 8
Placegasketson lower intakeusingsealanton both sidesof the gasket.
Step 9
Installthe suppliedEGRtube on the superchargerassembly.
Step 10
Installthrottle bodyonto superchargerassemblyusing suppliedgasketsand hardware(4) M6 x 30 stainless
socketheadscrews.
Step 11 Lowerthe superchargerassemblyonto the lower intakecastingtaking careto routethe EGRtube into placeat the
sametime. Securewith supplied5/16" nuts and torqueto 15-20ft Ib. Re-attachthe fuel line to the regulatorat
this time.
Step 12
Reconnectall electronicconnectors,vacuumtubesand EGRconnectionsthat were disconnected.On some
modelsthe wiring to the IPS sensormay needto be lengthenedin order to reachthe newthrottle body location.
Step 13 Disconnectthe throttle and speedcontrol cablefrom the factory bracketand reconnectthem to the new bracket.
The speedcontrol modulemay haveto e relocatedon some modelsusingthe suppliedbracket.
Step 14
Takea 16" pieceof vacuumhoseand run it betweenthe vacuumport on the fuel pressureregulatorand one of
the suppliedboost ports on the SCassemblyand plug the disconnectedvacuumline with a suitableplug.
Step 15 Removethe coil from the factory bracketand reattachto the suppliedbracketand attachto the SCassembly.
Reconnectsparkplug wires at this time.
NOTE
Onmodels wherethe sparkplug route betweenthe intake ports,
wires from a '94 model will be needed.All models will
require a more direct path to reach the coil pack.
Step 16 Collapsethe factorytensionerand installthe suppliedbelt accordingto the belt routing diagram.
Step 17 Installair tube usingsuppliedrubberhosesand clamps.Install inlet air sensorin tube if applicable.
Step 18 Installsuppliedfuel managementunit into the returnfuel line connection(at driver'ssideframe rail nextto power
steeringpump) usingsuppliedbraidedfuel lines.
IRED
YELLOW
IrAN
GRAY/BLACK
~~~~~ryPo~!!!y~~ (+1?y)
PositiveSideof Crank
PositionSensor
ConnectTo YellowWire
Negative Side of Crank
~~~~~2~~!~
p~t! o"t~eE,g~
BLUE
BlueWire On Boost
RetardControl
BROWN
Brown Wire On Boost
Retard Control ...