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RPG Installs A Phase 2 ROUSHcharger Kit

Posted in How To: Engine on March 13, 2017
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To say that Roush has a lot of cache in performance and racing circles is a huge understatement. Jack and his trademark hat have more race wins than most teams have race entries. So when we heard the RPG guys were going to be installing a Phase 2 ROUSHcharger to a 5.0 engine-equipped truck, we wanted to watch the process.

We are fans of superchargers, and have a great deal of respect for Jack Roush and his accomplishments and the company that he’s built. So, we wanted to take a look at the system.

The Phase 2 ROUSHcharger comes as a kit. Some stock pieces are retained, but Roush provides everything you’ll need to supercharge your Raptor.

The heart of the system is the R2300 Supercharger. Delivering 8 pounds of boost increase, the R2300 Supercharger features what Roush calls TVS Technology, and they say that the Twin Vortices Series has four-lobe rotors with greatly enhanced thermal efficiency, thus enabling greater volumetric capacity at higher rpm. Cooling is done with a large aluminum intercooler intake manifold along with a low-temperature radiator with a nicely molded air duct and a high-capacity degas bottle.

To keep the R2300 filled with air and to take full advantage of that life-giving boost, other tricks include Roush-designed high-flow fuel injectors, a Roush 60mm dual-bore throttle body and an all-new, high-capacity, low-restriction air filter and complete induction system. Tuning is done with the all-important Roush Phase 2 calibration file that’s delivered with the exclusive Roush Diagnostic Tool (RDT).

As many engine-based electrical connections will be broken and then remade, the first step is to disconnect the battery.

And maybe the best part is that the Roush Phase 2 ROUSHcharger system is 50-state emission legal, according to the 2015-2016/CARB E.O.#D-418-27.

For $7,500 plus install, and you probably do want to have it installed, the Roush system is a great way to increase horsepower. Like every supercharger install we’ve ever seen, installing one is a hugely complicated process and this system is no different, but the results are always worth it. We want to thank the crew at RPG Offroad in Laguna Hills, California, for letting us shoot over their shoulders while they went about their business.

The coolant is drained.
Most of the upper engine components are removed.
The fuel rails are removed. Know that larger injectors will be used as well as the PCM being re-flashed.
Care is taken when removing the intake to keep anything from falling down into the engine during this step.
Tape is placed over the intakes to keep debris out of the engine while the rest of the modifications are done.
The grille is removed to allow for access to install the intercooler.
Most pulleys will be removed and replaced with Roush units. In some cases entire idler tension systems will be discarded.
The lower pulley is replaced.
Roush supplies a new electromagnet for the A/C pulley system.
Working on items like the A/C pulley is a delicate process, and exact tolerances need to be figured when the new pulley is being installed onto the A/C compressor.
The new belt will be routed differently than stock, so items like the mount for the idler tension system will be gently cut away. It will be ground flush with the block.
This mount too was cut away and ground smooth.
Vacuum lines, such as ones for the brake aspirator and EPDM aspirator to throttle-body spacer are modified with parts supplied by Roush.
Many electrical connections, such as this Throttle Position Sensor need to be modified from stock.
New Roush injectors and anti-rotation clips are installed onto the fuel rails
There’s some splicing of wires that has to happen, and they are connected before the intake is installed.
The knock sensors are oriented properly. Yes, it matters.
The TPS and Roush supercharger boost bypass actuator are installed onto the intake horn.
The intake manifold is installed.
With the new Roush injectors in place, the fuel rails are installed.
Care is taken to ensure that the injector leads are snapped tightly in place.
Prepping the supercharger for install includes attaching vacuum lines.
The Roush Phase 2 supercharger is set into place.
By using a rotating pattern when tightening the mounting hardware and working up from 10Nm, the hardware will eventually be tightened to 30Nm.
The new Roush 60mm dual-bore throttle body is installed.
Roush supplies new brackets to position the various pulleys.
The pulleys are then installed.
Onto the pulleys goes the new blue Roush drivebelt.
A bracket installed for the new intercooler tank.
The intercooler tank is installed.
An intercooler pump is installed and the hoses run to the tank.
The intercooler assembly is prepped.
Roush encases the intercooler with this neat scoop. Too bad you can’t see it once it’s installed.
The intercooler box is installed below the radiator and between the bumper horns.
With the intercooler in place, the pump is wired and hoses run up into the engine bay.
The hoses are attached to the intake manifold/intercooler.
The air cleaner assembly is installed.
The finished product. Know that this is an install best left to the experts, and the crew at RPG can get you the supercharger and install it for you, too.
This Roush supplied graph shows the Ford picked up nearly 300 hp.

Sources

Roush Performance
Livonia, MI
800-597-6874
http://www.roushperformance.com
RPG Off-Road
866-691-7750
rpgoffroad.com

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