Big Boost Install
Supercharger Install
Kenne Bell Supercharger, 2002 Dodge Dakota/Durango 4.7
or this installation, we chose a 2002 Dodge Durango
equipped with the Magnum 4.7 SOHC engine, one of the
most common powertrains in the Durango, Dakota, Ram, and
Grand Cherokee. Kenne Bell specializes in Dodge products and
remains one of the few manufacturers that make superchargers for
Dodge applications.
The Kenne Bell kit is a complete system and includes upgraded
fuel injectors, a knock sensor, and an updated engine management
computer. Though possible for a novice mechanic, Kenne Bell suggests professional installation.
F
To complement the “hot rod” theme of the Durango, we chose a polished supercharger housing, which is sure to turn heads any time the
hood is open. The increase in performance is likewise head-turning,
bumping output from 235 to an estimated 325 hp, generating more
than 400 lb/ft of torque.
NOTE: Always refer to the instructions provided by the manufacturer. Kenne
Bell includes detailed technical instructions with its kits, and you should
contact the manufacturer directly for any questions regarding installation. This installation is provided as an illustrative guide only.
Install Tip:
Removing the front bumper and fan shroud
will make installation much easier. This is also
a good time to mount the new intake filter
assembly under the driver’s side headlamp.
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TSP
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April / May 2003
Step 1
Remove stock airbox and battery.The stock airbox
will not be re-used. Remove throttle body from
manifold and set aside. Remove stock intake manifold. Remove coil/plug wires from harness and disconnect injector harnesses from the injectors.Release
belt tensioner and remove stock serpentine belt.
Step 2
Cover open intake ports with tape. Remove alternator and move A/C compressor out of the way,and
disassemble necessary components according to
instructions. Flip fuel rail around so the open end is
facing forward. Install T-fitting into fuel line for auxiliary injectors, and re-connect fittings.
Editor’s Note: The A/C compressor bracket will have to be modified slightly to
accommodate the supercharger. After cutting, be sure to clean up any sharp edges
with a file, and clean metal shavings off
the part before re-installing. Be extra
careful when moving the compressor, as
the refrigerant is under pressure and is
expensive to replace if a leak occurs.
Step 3
Transfer silicone O-rings from stock manifold and
throttle body to supercharger manifold assembly. Cover
throttle body opening on supercharger opening with
tape.Connect fuel line and electrical connectors to auxiliary injector block. It’s easier to do these steps prior
to permanent installation of the supercharger.
Step 4
Just prior to installation, remove tape from intake
ports and position supercharger assembly on engine.
Tighten bolts and studs in a criss-cross pattern.
Torque to 105 in./lbs.(not ft./lbs.).Hand-tighten driver-side rear intake manifold bolt with a 100 box-end
wrench,and re-torque other manifold fasteners.
Step 5
Re-install fuel line to main injector rail. The line
should simply click into place without tools.Pull back
slightly to ensure line is properly connected.
Step 6
Attach throttle cable and cruise control cable bracket to supercharger assembly. Apply a small amount
of Loctite 518 to the supplied bolts and torque to
105 in./lbs. Re-attach all electrical harnesses and
hoses to throttle body, and re-install throttle body.
Tighten bolts to 105 in./lbs.
Step 7
Install supercharger support brace and alternator
bracket to front of engine.Tighten bolts sequentially
according to instructions, to properly “seat” the
braces. Re-connect harnesses to A/C compressor
and alternator.
Step 8
Install new concentric idler and 76mm idler pulleys.
Tighten concentric idler to 50 ft./lbs.,and 76mm idler
to 19 ft./lbs. after new belt and supercharger pulley
have been installed.
Step 9
Be sure bushing is installed at front of supercharger, and install supercharger pulley using the special
provided tool and an 8 mm Allen wrench.Torque to
59 ft./lbs.
Step 10
Cut end of the intake air temperature wire, solder
with new extension wire, and cover connection
with heat-shrink tubing.
Step 11
Install new MAF sensor (included in kit) and adapter
boot onto throttle body. Connect 4-inch flex tube
to MAF and to new air filter on driver’s side. Kenne
Bell recommends replacing the stock battery with
an Optima or other compact battery that will allow
clearance for the flex tube.
Step 12
Install the new thermostat.Transfer thermostat gasket from factory thermostat on to new thermostat.
Carefully follow removal and installation instructions,
or a coolant leak could result.
Editor’s Note:
When re-installing coil/plug wires, it is
important to sparingly apply dielectric
grease to the inside of the boot and
around the O-ring. This will prevent the
boots from bonding to the spark plug, and
will make future servicing and maintenance
much easier. Kenne Bell notes that the
coil/plug wires are expensive to replace.
Step 13
Locate the PCM (engine computer) on the passenger-side inner fender. Unplug connectors according
to instructions.
Step 14
Remove the tape from the wiring where it meets
up with the harness.Locate wires specified in instructions and solder extensions. Be sure to slip shrink
tubing onto wires before soldering.
Step 15
Locate an area adjacent to the PCM, and mount
Kenne Bell Optimizer computer. Re-install cruisecontrol actuator on top of optimizer.
Step 16
Install the knock sensors on the engine. It’s important that the knock sensor wires be kept away from
other wires, as stray inductive current may unnecessarily retard timing.
Step 17
The knock alert system includes a cab-mounted LED
monitor. Some amount of “noise” on meter is normal. If knock activity is excessively high under normal
conditions, contact Kenne Bell tech support.
Step 18
Sensor should be mounted in a location where it will
be clearly visible to the driver during everyday driving.
Editor’s Note: It’s very important that
the knock sensor wiring be connected
correctly. Improper function of the knock
alert system could cause serious engine
damage. Installation instructions include
detailed directions on the wiring and
installation of the knock sensor.
The kit as it looks installed in the
engine bay.The compressor housing is
available in either black anodized or
polished finishes, depending on the
look your customer wants under the
hood of their vehicle.
Post-installation Checklist
• Be sure that all hoses, sensors, and wiring are properly connected
and secured according to instructions.
• Before starting engine, be sure to fill supercharger gearcase with
provided oil. Use supercharger dipstick as a guide. DO NOT POUR
ENTIRE BOTTLE INTO SUPERCHARGER.
• Start vehicle, and allow it to idle for a few minutes. You should
not smell any strong fuel odors or see any leakage. If you do,
turn off the vehicle and re-check the fuel line connections.
•Take the vehicle out for a test drive. Drive normally (not in boost) to
check overall ‘drivability.’ If the vehicle is behaving abnormally, go
back and check sensor, vacuum, and injector connections. Make
sure coil/plug wire units are securely attached to spark plugs.
• If vehicle appears to drive normally, drive vehicle more aggressively to test the function of the supercharger system. Pay attention to the knock sensor. At wide-open throttle, vehicle should
not knock or ping excessively. If it does, Kenne Bell recommends
adding a can of NOS Octane Booster per 20 gallons of fuel.
Always use the highest-octane fuel available.