Home

Installation Instructions

1. Disconnect the brake booster vacuum hose from the intake manifold This port is located directly behind the throttle body Refer to 19 in figure shown below Disconnect the heater feed and return hoses located at the front of both the LH and RH cylinder head intake flanges Position these hoses aside by tucking them up underneath the edge of the hood near the windshield wipers Refer to 20 in figure shown below Remove the 2 nuts and support bracket that retained the RH heater hose above the RH fuel rail This hardware will not be reused Refer to 21 in figure shown below Remove the steel section of the brake booster vacuum line from the rubber hose at the joint found at the rear of the intake manifold Discard the steel and forward rubber section of this assembly as it will not be reused Refer to 22 in figure shown below 1311 TVSCALIM 10 11 11 Page 15 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 24 Remove the 2 nuts and support bracket that retained the LH heater hose above the LH fuel rail This hardware will not be reused Refer to 23 in figure shown below 25 Remove the 3 8 engine coolant degas hose from both the engine and the degas bottle 26 Carefully detach the 4 wiring harness retainers from the rear of the intake manifold The two outer clips will be reused once the new manifold is installed to retain the harness 1311 TVSCALIM 10 11 11 Page 16 of 72 1 8
2. 42 Intercooler Radiator Assembly Mounting esee nnne 43 Electric Water Pump Mounting Bracket and 44 Induction Resonance Tube Delete 49 Intake Manifold and Supercharger Installation ss 50 Em i Pie T 56 Sole IRI a cic T Tm 61 Alr induci n m 64 gita ebd EU T TT 67 1311 TVSCALIM 10 11 11 Page 2 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE EMGIMEERING PREMIUM FUEL REQUIRED PACKAGING LIST FOR 1311 TVSCAL SUPERCHARGER KIT Part Ref Description FRPP Part Number Qty Air Induction Upper Airbox Lid 13109643HC Clean Air Tube 13119B659 Part Ref Description FRPP Part Number Qty HardwareKitA Induction 13112TVSHKA 1 Part Ref Description FRPP Part Number Qty 6 FuelChargingAssembly HBT 13 8 0 0 0 0 O 13M9F72 1 9 Throttle Body Assembly Dual 60mm 07060150 1 12 FuelnjctrCip 1811 90995 8 8 opark Plug 0 9mm gap CYFS12YP BL3E 12405 BA Part Ref Description FRPP Part Number Qty __ Hardware KitB FuelCharging 1311TVSHKB 1 Gasket Throttle Body Spacer to Supercharger Bolt Throttle Body to Spacer amp
3. PREMIUM FUEL REQUIRED Electric Water Pump Mounting Bracket and Hoses 1 Install the Intercooler Pump Inlet Hose 13108D029 from the degas bottle outlet port to the front of the LTR by routing the hose around the lower radiator hose T joint and along the frame rail secure the hose to the bottom of the degas bottle using 1 4 constant tension clamp CT19x12 BO Orient the clamps so the on the hose is in the center of the clamp tangs 2 Install the modified LH side radiator side shield See Appendix A and route the Intercooler Pump Inlet Hose installed in the previous step through the new hole in the shield and secure the shield to the chassis using the take off push pins NOTE The bumper beam has been removed for clarity 1311 TVSCALIM 10 11 11 Page 44 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 3 Install the modified RH side radiator side shield See Appendix A Secure the shield to the chassis using the take off push pins s rs a CT L4 EN NOTE The bumper beam has been removed for clarity 4 Remove the 2 upper inner front bumper beam bolts 5 Install the 2 Long Bumper Bolts R18020007 from Hardware Kit E in place of the 2 which were just removed and torque to 25 Nm Install the Intercooler Pump Mounting Bracket 13108C419 behind the bumper onto the long bumper bolts using 4 M8 nuts W520413 from Hardware K
4. Supercharger M6 x 32 5 818020009 8 Bolt Intake to Cylinder Heads M6 x 40 818020004 6 Bolt Supercharger to Intake M8 x 53 Bolt Evaporative Emission Canister Valve to Spacer M6 x 35 5 N808429 Part Ref Description FRPP Part Number Qty Upper FEAD Bracket 13118B653U FEAD Tensioner Bracket Assembly 13118B603 Serpentine FEAD Belt K060825 1311 TVSCALIM 10 11 11 Page 3 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE EMGIMEERING PREMIUM FUEL REQUIRED Part Ref Description FRPP Part Number Qty Hardware Kit C FEAD 19146066FRTHKC 1 Pulley Idler B S 76mm 900873 2 Bolt Idler M8 x 28 large washer R18020060 2 Bolt Upper FEAD to Engine and Intake M8 x 84 W704752 2 Bolt Lower Bracket to Upper Bracket M8 x 41 705128 1 Bolt Lower Bracket to Engine M8 x 120 N811328 2 Part Ref Description FRPP Part Number Qty PCV amp Vacuum PCV amp Vacuum 00 Evaporative Emission Canister Purge Valve Line 7 32 Vacuum Hose Supercharger Bypass Length 105mm R18140001 Vacuum Harness Supercharger Bypass Reference 7R3V 9E498 BB Part Ref Description FRPP Part Number Qty Part Ref Description FRPP Part Number Qty Decals Llabels amp Instructions Decal 2011 Belt Routing Diagram Decal Premium Fuel Only Cluster PCM Shipping Box w Label 2011 R2300 Warranty 1311 TVSCALIM_10 11 11 Page 4
5. side radio capacitor The single connector will be routed to the intercooler pump in Section D of this manual 1311 TVSCALIM 10 11 11 Page 30 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Air Charge Temperature ACT Wirin 1 Unplug the 3 PCM connectors by pushing the gray connector lock arms towards the front of the vehicle You will be working with the bottom 70 pin or cowl connector only 2 a Remove the pin locking device as shown in figures 2 and 3 Also remove the wire support on the back of the connector figure 5 by removing the tape and using a small screwdriver to lift the locking tabs T Figure 2 Figure 3 The ACT sensor loom part 1311 2A690 AA will have the ACT sensor connector at one end On the other end will be 2 wires one with a blunt end and the other with a pin already crimped on The blunt wire will be spliced into the wire located in pin C 56 of the cowl connector The wire with the pin will be inserted into location C 36 of the cowl connector There are small numbers on the back of the connector noting location Figure 4 below will also help to identify the pin locations 70 Way Key D Figure 4 PCM Pin Locations for Cowl Connector Front View side that connects to PCM 1311 TVSCALIM 10 11 11 Page 31 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING DUM FUEL REQUIRED b Remo
6. of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE EMGIMEERING PREMIUM FUEL REQUIRED Part Ref Description FRPP Part Number Qty Intercooler System MEE Degas Bottle Intercooler Electric Water Pump with Bracket Bracket Intercooler Pump Mounting Intercooler Low Temp Radiator LTR Part Ref Description FRPP Part Number Qty Hardware Kit E Intercooler System 13116066FRTHKE 1 1 1 60 Rubber Grommet LTR Isolator 07060107 4 4 1 Clamps Hoses Constant Tension Bolt Long Bumper Bolts 8 x 35 Bolt LTR to Brackets 4 amp I C Pump to Bracket 2 M8 x 25 66 Nut I C Pump Mounting Bracket to Bumper Bolts M8 Bolt Degas Bottle Mounting amp LTR Bracket to Chassis M6 x 22 68 J Clip Degas Bottle amp Pump Bracket Mounting M6 Short 69 NVH Isolator I C Pump to Bumper Beam 131082419 70 NVHisoatr lCPumptoLTR 19108Y419 1 Nut I C Wiring Relay to Chassis M6 W520402 1 If you are missing any items please call us toll free at 1 800 59 ROUSH 1311 TVSCALIM 10 11 11 Page 5 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED EQUIPMENT AND SUPPLIES REQUIRED e 1 4 and 3 8 Drive Ratchets with Extensions e Metric and Standard Socket Sets short and deep recommended e 1 2 Drive Ratchet or Breaker Bar e Metric and Standard Wrench Sets e 3 8 Drive Torque Wrench 7 35 ft lb ra
7. 00 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 2 Remove and discard the LH and RH fuel rail insulators Disconnect the 8 fuel injector electrical connectors 28 Remove the 4 fuel rail bolts These bolts will be reused NOTE It is not necessary to remove the fuel rail from the intake manifold assembly 29 Remove the 6 intake manifold mounting bolts and remove the intake manifold and fuel rail assembly from the vehicle This hardware will not be reused Procedures 26 28 30 Clean the intake mounting surfaces and apply tape over the open intake ports to prevent engine contamination 1311 TVSCALIM 10 11 11 Page 17 of 72 1 800 59 ROUSH 31 32 33 34 35 36 37 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Remove the engine coolant degas bottle Remove the Front End Accessory Drive FEAD belt Rotate the FEAD Tensioner counter clockwise to release the belt tension and remove the belt Remove the 4 bolts securing the Water Pump Pulley to the engine Cut and remove the A C compressor belt Discard belt Remove the upper radiator hose Remove the electric fan and shroud assembly from the vehicle Unclip the engine electrical harness retention clips that retain the engine harness to the top corners of the right hand passenger side front cover 1311 TVSCALIM 10 11 11 Page 18 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE E
8. 1 TVSCALIM 10 11 11 Page 68 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 13 Place the Premium Fuel clear decal with white lettering on the instrument cluster bezel on the flat area below the small center gauges as shown 14 Place the A R B EO label 1312 9A095EO in an area that is visible under the hood This could be on the front side of the shock tower or along the radiator close out panel 1311 TVSCALIM 10 11 11 Page 69 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING DU FUEL REQUIRED APPENDIX SIDE SHIELD MODIFICATIONS 1 Remove the LH radiator side shield from the vehicle by removing the two push pin retainers 2 Cut the rubber edge of the side shield in three 3 places as shown Cut along plastic edge M DI 35r mm ee MM LAE m ded 1311 TVSCALIM 10 11 11 Page 70 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING uU FUEL REQUIRED Using a hole saw drill a 1 3 8 hole through the plastic portion of the shield 180mm from the end as shown CC MG 4 Re install the LH radiator side shield using the take off push pins 5 Remove the RH radiator side shield from the vehicle by removing the two push pins 1311 TVSCALIM_10 11 11 Page 71 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 6 Cut the rubber edge of the side shie
9. AL IN THESE AREAS UNTIL THEY ARE FLUSH WITH THE FRONT COVER SURFACE 1311 TVSCALIM 10 11 11 Page 24 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING DU FUEL REQUIRED TPS ETC Wiring 1 If you have not already done so remove the upper radiator cover by removing the 8 push pins 2 Locate the Throttle Position Sensor TPS connector and harness at the front of the passenger side cylinder head Use a proper de pinning tool to remove the connector from the harness 1311 TVSCALIM 10 11 11 Page 25 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING DU FUEL REQUIRED 3 Depress the locking tab and separate the empty female 1 x 6 connector from the new TPS ETC Extension harness 1311144595 It will be used in the next step 4 Populate the new connector such that the yellow with violet wire is in position 1 the blue with green wire is in position 2 the brown wire is in position 3 the blue with orange wire is in position 4 the yellow wire is in position 5 and the green with violet wire is in position 6 Install the red plastic lock into the connector to secure the wires in place 1311 TVSCALIM 10 11 11 Page 26 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING DU FUEL REQUIRED 5 Connect the TPS ETC extension harness to the newly installed connector The wire colors on each side of the connector pair should align Route the harness along the main wiring harness to the rear of
10. Assembl 1 Remove the Evaporative Emission Canister Purge Valve from the stock intake manifold 2 Install the valve into the new Throttle Body Spacer using 2 M6 x 1 0 x 35 5 mm bolts N808429 found in Hardware Kit B 1311 TVSHKB Torque bolts to 10 Nm 1311 TVSCALIM 10 11 11 Page 39 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 3 Connect the supercharger boost bypass actuator hose R18140001 to the throttle spacer 4 Connect the marked end of the modified brake booster hose to the throttle spacer 1311 TVSCALIM 10 11 11 Page 40 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Fuel Rail Assembly 1 Carefully install the eight 8 new Anti Rotation Fuel Injector Clips 1311 9C995 onto the new Fuel Injectors M 9593 LUA7ROU 2 Apply assembly lube to the injector O rings and install the injectors into the new Fuel Rail 13119F792 NOTE Verify that the anti rotation clips are properly aligned and fully engaged into the fuel rail injector cups 1311 TVSCALIM 10 11 11 Page 41 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED SECTION D INSTALLATION The following section will guide you through the final installation of the kit into the vehicle If you need to stop during any part of the installation make sure you cover any open ports in the cylinder heads or intak
11. INEERING PREMIUM FUEL REQUIRED 3 Mount the Upper LH LTR Bracket 13108K242 to the upper LH corner of the LTR using 1 M8 x 1 25 x 2bmm bolt W500224 These can be found in Hardware Kit E 13116066FRTHKE Align the edges of the bracket such that they are flush with the mounting tab on the LTR Torque bolt to 25 Nm 4 Repeat step 3 for each of the remaining LTR Brackets 13108K243 will go to the upper RH corner 13108K244 to the lower LH corner and 13108K245 to the lower RH corner of the LTR These can be found in Hardware Kit E 13116066FRTHKE 1311 TVSCALIM 10 11 11 Page 36 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 9 Install the Intercooler Pump to LTR NVH Isolator 13108Y419 on the front face of the LTR The pad should be stuck to the LTR so that it is 170mm from the top and 140mm from the right side 1311 TVSCALIM 10 11 11 Page 37 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Intake Manifold Build Up 1 Remove Fuel Charging Assembly 13119H487 from the packaging 2 Attach the rubber hose from the PCV Purge Hose 13116K817 to the bubbler fitting 3 8 barb on the bottom of the fuel charging assembly and secure it with the supplied clamp Install clamp in this location 1311 TVSCALIM 10 11 11 Page 38 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Throttle Body Spacer
12. ING PREMIUM FUEL REQUIRED 3 Using an 8mm wrench disconnect the negative amp positive connections to the battery 4 Remove the 8 push pin retainers by pulling the center pin and remove the radiator trim cover 5 Disconnect the PCM Powertrain Control Module connectors by lifting the grey levers over the connector back shell and lifting the connectors from their sockets Remove the PCM by removing two 10mm bolts and pulling the PCM forward and lifting out of the engine compartment Follow the instructions on the next page as soon as possible to help minimize the amount of time you are without a PCM Connector Locations Retaining Bolts Important Be sure to write your VIN number and phone number in case we need to contact you for additional vehicle information on the PCM using a permanent marker 1311 TVSCALIM 10 11 11 Page 10 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED INSTRUCTIONS FOR RETURNING THE PCM TO ROUSH FOR CALIBRATION Outlined below are the instructions for returning your stock powertrain control module PCM to Roush Performance Products so we can install our calibration to make the engine run properly with the new components Please complete the Warranty Registration Card and include it along with the PCM in the prepaid shipping box The prepaid shipping box is set up for next day delivery to us Once we receive your PCM we will reprogram and
13. ING PREMIUM FUEL REQUIRED SECTION A DISASSEMBLY The following section will guide you through the disassembly of the stock components Special care should be taken to label fasteners and parts that are taken off during this procedure since many will be reused 1 Cover both fenders with fender covers to protect the vehicle finish 2 Release the fuel system pressure NOTE The following procedure is taken directly from the Ford Service Manual AN WARNING Fuel in the fuel system remains under high pressure even when the engine is not running Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved Failure to do so can result in personal injury AN WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components Highly flammable mixtures are always present and can be ignited resulting in personal injury a Disconnect the Fuel Pump Control Module electrical connector NOTE The Fuel Pump Control Module is located in the spare tire stowage compartment b Start the engine and allow it to idle until it stalls C After the engine stalls crank the engine for approximately 10 seconds to make sure the fuel injector supply manifold pressure has been released d Turn the ignition switch to the OFF position 1311 TVSCALIM 10 11 11 Page 9 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEER
14. Idler Pulleys 900873 onto the machined posts of the Upper FEAD Bracket Secure the pulleys using 2 M8 x 1 25 x 28mm idler bolts R18020060 found in Hardware Kit C Torque bolts to 25 Nm 4 Loosely install the FEAD Tensioner Bracket Assembly 13118B603 onto the front cover using 2 M8 x 1 25 x 123mm R18020055 bolts found in Hardware Kit C leaving at least a 10mm gap between the two new FEAD brackets Leave a 10mm gap between these bosses Ps to allow for the FEAD belt to be installed 1311 TVSCALIM_10 11 11 Page 57 of 72 1 800 59 ROUSH SH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 5 Route the FEAD belt K060825 Do not route the belt onto the supercharger pulley 6 Install 1 M8 x 1 25 x 41mm W705128 bolt found in Hardware Kit C to fasten the Tensioner Bracket to the Upper FEAD Bracket Torque all three Tensioner Bracket bolts to 25 Nm 1311 TVSCALIM 10 11 11 Page 58 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED f Using a 17mm socket rotate the new tensioner clockwise to install the belt on to the supercharger pulley Inspect each pulley to ensure the belt is properly seated Use this nut to rotate the tensioner and enough slack to install the FEAD belt 1311 TVSCALIM 10 11 11 Page 59 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 9 Re install the stock FEAD Belt by rotating th
15. NGINEERING PREMIUM FUEL REQUIRED SECTION B MODIFICATIONS The following section will guide you through the required modifications of existing components and build up of the assemblies used to complete the installation With the exception of the wiring modifications and intercooler pump bracket mounting all of this work can be performed away from the vehicle Airbox Modification 1 Remove the MAF sensor from the stock airbox cover and install into the new upper airbox lid 13109643HC using the two factory fasteners Torque screws to 1 8 2 2 Nm 2 n order for the new airbox lid to be secured to the lower airbox tray properly the inboard retaining clip needs to be modified Remove the inboard clip from the tray and use a saw or grinder to remove part of the clip as shown Deburr all sharp edges BEFORE Modify this clip CUT BRACKET Linz IL F i ALONG THE 1311 TVSCALIM 10 11 11 Page 19 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Brake Booster Hose Modification 1 Remove the factory brake booster hose that is still connected to the booster 2 Cut 30mm off of the end of the hose that was connected to the brake booster and 40 mm off of the opposite end that was connected to the steel tube as shown below Place a piece of tape or a mark on the end of the hose that was cut by 30mm This end of the hose will connect to the throttle body spacer upon
16. THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 2011 Mustang GT ROUSHcharger Kit P N 1311 TVSCAL EO D 418 20 Installation Instructions Application 2011 Ford Mustang GT with 5 0L 4 Valve Engine w Manual Transmission Important Notes Before installing your Mustang ROUSHcharger Kit please read the installation manual and verify that all items are present If you are missing hardware or have any questions please contact ROUSH Performance at 1 800 59 ROUSH Premium fuel 91 octane or higher is required to prevent spark knock or detonation under certain operating conditions The use of fuel additives ie octane boosters is not recommended There is a possibility that these chemicals can damage your engine and cause drivability issues with your vehicle The installation of the ROUSHcharger kit requires customers to remove and re gap the factory spark plugs for optimum performance Operating your engine without the Roush PCM recalibration will result in engine damage or failure and will void your warranty 1311 TVSCALIM 10 11 11 Page 1 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED TABLE OF CONTENTS PACKAGING LIST FOR 1311 TVSCAL SUPERCHARGER 3 EQUIPMENT AND SUPPLIES REQUIRED eene 6 GLOSSARY OF TERMS einen nasse ses ese innen ns esee eee r
17. any time SAFETY PRECAUTIONS STOP CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS AND WARNINGS BEFORE PROCEEDING WITH THE INSTALLATION Appropriate disassembly assembly methods and procedures are essential to ensure the personal safety of the individual performing the kit installation Improper installation due to the failure to correctly follow these instructions could cause personal injury or death Read each step of the installation manual carefully before starting the installation Always wear safety glasses for eye protection Place the ignition switch in the OFF position Always apply the parking brake when working the vehicle Block the front and rear tire surfaces to prevent unexpected vehicle movement Operate the engine only in well ventilated areas to avoid exposure to carbon monoxide Do not smoke or use flammable items near or around the fuel system Use chemicals and cleaners only in well ventilated areas Batteries produce explosive hydrogen gas which can cause personal injury Do allow flames sparks or flammable sources to come near the battery Keep hands and any other objects away from the radiator fan blades Keep yourself and your clothing away from moving parts when the engine is running Do not wear loose clothing or jewelry that be caught in rotating or moving parts 1311 TVSCALIM 10 11 11 Page 8 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEER
18. ate the stud next to the underhood fuse box near the passenger side headlight Remove the wiring harness from this stud The harness will be re atteched to this stud in a later step 2 Install the relay from the Intercooler Pump Wiring Harness 13118W501 onto the stud Install the fuse on top of the relay onto the same stud Use 1 M6 nut W520412 from the Intercooler Hardware Kit 13116066FRTHKE to secure the relay and fuse to the stud Torque the nut to 10 Nm Reinstall the wiring harness from previous step to the stud for proper retention 1311 TVSCALIM 10 11 11 Page 29 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 3 Route the red wire part of the Intercooler Pump Wiring Harness installed above to the positive post at the rear of the fuse block Remove the nut from the positive post and install the red wire eyelet Reinstall the nut onto post Torque to 10 Nm 4 Route the other bundle of wires coming from the relay around the front of the fuse box along the factory forward lamp harness Remove 1 bolt securing the factory ground wires to the chassis behind the headlight Replace the bolt to secure the factory grounds including the grounding eyelet from with the intercooler pump harness 5 Route the single wire with two electrical connectors along the factory engine harness to the rear of the passenger side cylinder head Connect these two connectors inline with the passenger
19. convolute Torque the knock sensor bolts to 25Nm T 7 F iy ee EN c Gs EUR Y vt 5 Ss 1 Remove Clips Here ar ni p E i v Changing the Factory Spark Plugs 1 Disconnect the electrical connectors for each ignition coil 8 places and remove the fastener holding the coil on plug in place Remove the ignition coil on plug A slight twisting motion will break the seal and ease removal Remove the factory spark plugs 8 places and set aside These will not be re used 2 Install the eight 8 provided spark plugs CYFS12YP which are gapped to 0 9 mm Torque to 14 Nm 124 Ib in Install the ignition coil on plugs Apply a small amount of dielectric grease to the inside of the coil on plug boots before attaching to the spark plugs Torque the bolts to 6 Nm 53 Ib in Re install the coil on plug covers 1311 TVSCALIM 10 11 11 Page 34 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED SECTION C SUBASSEMBLY Intercooler Low Temperature Radiator LTR 1 Insert 1 Rubber Grommet R07060107 found in Hardware Kit E 13116066FRTHKE into each mounting tab on the Low Temp Radiator LTR 13108K229 Upper RH Upper LH 2 Push 1 Sleeve R07060108 found in Hardware Kit E 13116066FRTHKE into each of the rubber grommets previously installed 1311 TVSCALIM 10 11 11 Page 35 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENG
20. e PCM to us another way the address for the PCM re flash only is Roush Powertrain Development Building 5 attn PCM Flash 777 Republic Drive Allen Park MI 48101 2011 5 0L 4V Mustang TVS2300 ROUSHCharger Kit Manual Transmission Customer Name Contact Number VIN 1311 TVSCALIM_10 11 11 Page 11 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 6 Raise the front of the vehicle using the Ford recommended lifting points and place onto safety stands With the tires lifted off of the ground remove the front wheels Remove the 3 forward Phillips head screws from each front wheel liner Using a Phillips head screwdriver turn the 5 inner fender push pins turn to release the centers Remove the pushpins and then remove the forward inner fenders Remove the 3 lower close out to radiator support screws 7mm socket Remove the 2 upper bumper cover screws near the headlights 10mm socket Remove the 4 front fender to bumper cover nuts inside the forward wheel well 10mm socket Reach inside the front wheel wells and unplug the front turn signals Lift the front bumper cover slightly and pull partially off of the vehicle Unplug the fog lights and set the front bumper cover aside 8 Remove the 4 push pins that retain the impact absorber to the front bumper beam and set the absorber aside 9 Carefully remove the radiator cooling module side shields that are mounted to
21. e manifold to prevent foreign material from contaminating your engine Intercooler Reservoir Mountin 1 Install the Intercooler Degas Bottle 13108D080 with Degas Bottle Cap 9C3Z 8101 B onto the fan shroud using 1 M6 x 1 0 x 22 mm bolt R18020057 from Hardware Kit E Use the bottle as a template to mark the second mounting hole with a paint pen Remove the bottle and drill a 5 16 hole through the fan shroud 2 Install 1 M6 J Clip N623332 from Hardware Kit E onto the fan shroud Reinstall the fan shroud and bolts and torque to 10 Nm Reinstall the intercooler degas bottle using 2 M6 x 1 0 x 22 mm bolts R18020057 and torque to 10 Nm 1311 TVSCALIM 10 11 11 Page 42 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Intercooler Radiator Assembly Mountin 1 Remove the stock radiator side shields See Appendix A The push pins will be reused 2 Remove the 2 upper bolts and 2 lower nuts used to secure the air conditioning condenser core to the vehicle The nuts will be reused 3 Install the new LTR assembly into the vehicle using 2 M6 x 1 0 x 22 mm bolts R18020057 found in Hardware Kit E 13116066FRTHKE at the top into the radiator and the two nuts that were removed in the previous step at the bottom Torque the two bolts and two nuts to 10 Nm 1311 TVSCALIM 10 11 11 Page 43 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING
22. e tensioner counter clockwise and routing the belt as per the stock Ford belt routing 1311 TVSCALIM 10 11 11 Page 60 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Coolant Hoses 1 Install the Intercooler LTR Outlet hose 13118D030 Route the hose from the LTR behind the passenger side headlamp to the lower intercooler turret on the front of the intake manifold Secure the hose using 2 4 constant tension clamps Orient the clamps so the I on the hose is in the center of the clamp tangs Side Shield View from underneath Rad Dra front passenger side Petcock 2 Install the Degas Bottle Inlet Hose 13118D031 from the upper intercooler turret to the upper degas bottle fitting using 2 5 constant tension clamps Orient the clamps so the T on the hose is in the center of the clamp tangs 1311 TVSCALIM 10 11 11 Page 61 of 72 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING DU FUEL REQUIRED 3 Reinstall the upper radiator hose 4 Reinstall the factory degas bottle onto the fan shroud and torque the bolt to 10Nm 9 Before reinstalling the factory heater feed and return hoses you must first install the protective sleeve material supplied with this kit in the areas shown below a Install one length of protective sleeve 1311 18K579SLV onto the passenger side heater hose Slide it over the quick connect fitting and along the heater hose A
23. efully place on top of the intake manifold Ensure that the supercharger is fully seated on the intake mounting dowels Remove protective shipping covers 6 Install the ten 10 M8 x 53 fasteners N808130 provided found in Hardware Kit B 1311 TVSHKB into the mounting holes Torque fasteners in three steps 10Nm 20Nm and 30Nm in the sequence shown 8 Connect the supercharger bypass reference vacuum line 7R3V 9E498 BB to the bottom fitting on the supercharger bypass actuator Route this underneath the heater hose amp fuel line 1311 TVSCALIM 10 11 11 Page 51 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 9 Install the throttle spacer to supercharger gasket R07060152 between the throttle body spacer assembly and the supercharger and mount the spacer using 4 M6 x 32 fasteners R18020009 These parts can be found in Hardware Kit B 1311 TVSHKB Torque the fasteners to 10 Nm 10 Connect the boost bypass hose from the throttle body spacer to the top port of the supercharger bypass actuator 11 Connect the brake booster vacuum line to the check valve on the brake booster 1311 TVSCALIM 10 11 11 Page 52 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 12 Connect the new Evaporative Emission Canister Purge Valve electrical connector 13 Install the new Evaporative Emission Canister Purge Valve Line BR3V 9G271 CB from the f
24. ennes 7 INFORMATION ABOUT THE SUPERCHARGER BYPASS OPERATION 7 BIENES ME ZIBSIBdVIP mum 8 oAFELECPISECAU TIO emissus adito 8 DISASSEMBLY 9 TON B MODIFICAHONS E 19 Niere dii eelilrerzuro RB nm 19 Brake Booster Hose tipa biduo rune bbidstca OHNE Esc div vea bun bU I REP UNS IM UNE 20 Front Cover Modification MENT 21 IFETO YIAN ea RE E E EEOAE EA 25 Canister Furge mr i e EEE ETa 27 Intercooler Pump 29 Air Charge Temperature Wiring essen nnne nennen enne 3 Mass Air Flow Wiring 33 Knock Sensor Orientation 34 Changing the Factory Spark Plugs for Optimum 34 IN SUBSADSOEIVEBLI T 35 Intercooler Low Temperature Radiator _ 35 Iritake Manifold 38 Throttle Body Spacer 39 Nuts PAS STUN NR 41 SECTION D INSTALUATION eee ee PUMP NUS UM 42 Intercooler Reservoir
25. f these components will be reused 15 Remove the MAF mass air flow sensor connector by pulling the red locking tab back and pressing the black release tab Release the locking tabs securing the upper airbox lid to the lower airbox Disconnect the MAF wiring harness retainer from the front edge of the upper airbox lid and remove the lid from the vehicle The airbox lid will not be reused E SEI f hames Roraimertocaron A Harness aero Disconnect MAF Connector 1311 TVSCALIM 10 11 11 Page 14 of 72 1 800 59 ROUSH 16 17 18 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Disconnect the throttle body electrical connector Pull the red locking tab back press the black release tab to disengage the lock Refer to 15 in figure shown below Disconnect the VMV evaporative emission canister purge valve tube and electrical connector Remove the VMV tube retainer from the front left hand cam cover Disconnect the remainder of the tube at the fitting located behind the inner fender below the brake booster This tube will not be reused Refer to 16 in figure shown below Remove the PCV Purge line from the intake manifold and right hand cam cover This line will not be reused Refer to 17 in figure shown below 19 20 21 22 23 Procedures 15 17 Disconnect the fuel supply hose from the fuel rail Refer to 18 in figure shown below
26. gauge kit is going to be installed onto the vehicle the above grommet can be left out as the boost gauge kit has a pre installed grommet on the vacuum line that will go in this location 1311 TVSCALIM 10 11 11 Page 49 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Intake Manifold and Supercharger Installation 1 Remove the tape from the cylinder heads and clean the cylinder head to intake manifold mating surfaces 2 Install the intake manifold using six 6 M6 x 1 0 x 40 mm bolts R18020004 found in Hardware Kit B 1311 TVSHKB Install these fasteners in the positions shown and tighten the sequence in two stages Stage 1 torque bolts to 10 Nm Stage 2 tighten bolts an additional 45 degrees Reinstall the engine wiring harness retention clips at the rear of the intake manifold Wiring Retainers Here 3 Lube the fuel injector o rings with assembly lube Install the fuel rail and injectors into the intake manifold using the take off bolts Be sure each injector is properly seated into the intake manifold Tighten the bolt pattern in two stages Stage 1 torque bolts to 10 Nm Stage 2 tighten bolts an additional 90 degrees 1311 TVSCALIM_10 11 11 Page 50 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 4 Connect the eight fuel injector connectors 5 Remove the supercharger assembly 13116F066 from the protective packaging and car
27. ion of supercharger bypass systems The supercharger is a positive displacement pump that is so long as it is rotating it is always pumping air During low demand or high vacuum operation i e idle deceleration and light throttle cruise the pumping action is undesirable as it creates unwanted heat and noise The bypass circuit when open prevents any pressure buildup across the supercharger and allows air to circulate through the rotors allowing the supercharger to idle freely during these conditions This results in reduced noise and by reducing heat buildup in the intake significantly improves street and strip performance As throttle demand increases the bypass circuit is closed resulting in full performance from the supercharger The bypass circuit is never used to limit or control boost during full throttle operation and defeating or altering the bypass function will not result in improved performance in any condition and will result in poor drivability 1311 TVSCALIM_10 11 11 Page 7 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED LIMIT OF LIABILITY STATEMENT The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability Ford Racing Performance Parts reserves the right to revise the information presented herein or to discontinue the production of parts described at
28. it E 13116066FRTHKE Torque these nuts to 25 Nm OOo 0 f D GITE E M hu am View from inside engine bay looking down 1311 TVSCALIM 10 11 11 Page 45 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 6 Install the Intercooler Pump to Bumper Beam NVH Isolator 131082419 found in Hardware Kit E on the rear of the bumper beam such that the edge of the pad is 220mm from the driver side bumper beam mounting plate and 60mm from the front edge View from in front of vehicle looking down at bumper beam 7 Connect the Intercooler Pump to LTR hose 13108K236 to the Intercooler Pump and Bracket assembly 392022009 Orient the hose so the is aligned with the arrow on the pump outlet port Secure the hose to the pump using 1 4 constant tension clamp CT19x12 BO Orient the clamp so the on the hose is the center of the clamp tangs 1311 TVSCALIM_10 11 11 Page 46 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 8 Secure the Intercooler Pump and hose to the Intercooler Pump Mounting Bracket using 2 M8 x 1 25 x 25 mm bolts W500224 from Hardware Kit E so the outlet is facing away from the two holes that are in the bracket Torque bolts to 25 Nm H J i EE View from inside engine bay a looking toward the ground 9 Connect the Intercooler Pump to LTR hose to LTR inlet port using 1 3 constant
29. itting below the brake booster to the relocated Purge Valve on the Throttle Body Spacer P Pe g RR 9 E 1 800 59 ROUSH Page 53 of 72 1311 TVSCALIM 10 11 11 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 16 Connect the PCV Purge Line 13116K817 to the PCV Valve on the passenger side cam cover and the port on the supercharger 17 Install the Throttle Body Gasket R07060153 in the Throttle Body Spacer Use 4 M6 x 1 0 x 32 5 mm bolts R18020009 to secure the Throttle Body Assembly R07060150 to the Spacer Torque bolts to 10 Nm These be found in Hardware Kit B 1311 TVSHKB 1311 TVSCALIM 10 11 11 Page 54 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 18 Connect the TPS and ETC Throttle Body electrical connectors 1311 TVSCALIM 10 11 11 Page 55 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED FEAD Assembly 1 Remove the 4 bolts and 1 stud from the front cover as shown These two bolts will be reused 2 Install the Upper FEAD Bracket 13118B653U using 2 M8 x 1 25 x 57mm bolts that were removed in the previous step and 2 M8 x 1 25 x 84mm bolts W704752 from Hardware Kit C 13116066FRTHKC Torque bolts to 25 Nm Shorter 57mm bolts here eu 1311 TVSCALIM 10 11 11 Page 56 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 3 Install 2
30. ld in three 3 places as shown Cut along plastic edge 425mm T Re install the RH radiator side shield using the take off push pins 1311 TVSCALIM_10 11 11 Page 72 of 72 1 800 59 ROUSH
31. n Air Tube in the vehicle using 2 hose clamps R07130015 from Hardware Kit A Torque clamps to 3 Nm 4 Connect the open end of the supercharger bypass reference line 7R3V 9E498 BB to the fitting on the clean air tube 1311 TVSCALIM 10 11 11 Page 65 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 9 Install the PCV Fresh Air Inlet tube 13116758 by connecting the 90 deg fitting to the driver side cam cover and angled fitting to the PCV fitting in the clean air tube 1311 TVSCALIM 10 11 11 Page 66 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE EMGIMEERING PREMIUM FUEL REQUIRED Final Assembly 1 2 Fil the engine cooling system using a proper coolant mixture to the marked level on the radiator degas bottle Using the same coolant mixture fill the intercooler system The coolant should be approximately one inch below the top of the cap Important Both coolant systems can trap a large amount of air It is very important to verify that the air is purged and that coolant is flowing properly through both systems Roush recommends vacuum filling both systems to properly evacuate the trapped air 3 Reinstall front bumper cover lower close out panel and inner fenders by reversing the removal procedures Reinstall the front wheels tires Torque wheel lugs to the factory Ford specifications Inspect all underhood wiring harnesses for potential interference issue
32. nge e Short Phillips head Screwdriver e 5 86 Fuel Line Removal Tool e 20 Torx Bit Screwdriver or Socket e 95 16 Drill Bits and Drill motor e Coolant meeting Factory Ford specification for 2011 Mustang GT e Scale Tape Measure or Other Measuring Device e Assembly Lubricant White Lithium Grease or Petroleum Jelly e Electrical Tape e Sharp Knife or Razor Blade e Solder amp Soldering Iron e Heat Gun or Small Torch for Heat Shrink Tubing e Tie Straps Zip Ties e Trim Pad Tool for pushpin removal e Fender Cover 2 e Medium Strength Thread Locker Loctite 242 blue or equivalent 1311 TVSCALIM_10 11 11 Page 6 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED GLOSSARY OF TERMS ACT Air Charge Temperature Sensor From the factory this function is integrated into the MAF sensor With this kit a separate ACT sensor is installed into the intake manifold ETC Electronic Throttle Control MAFS Mass Air Flow Sensor PCM Powertrain Control Module a k a ECM ECU PCU EEC PCV Positive Crankcase Ventilation TPS Throttle Position Sensor VMV Vapor Management Valve aka Canister Purge Valve Breakout Point A place in an electrical harness where the wiring for an individual component leaves breaks out of the main harness to attach to an individual component INFORMATION ABOUT THE SUPERCHARGER BYPASS OPERATION There is a great deal of misinformation about the funct
33. pply electrical tape over either end of the protective sleeve to secure its position on the hose 1311 TVSCALIM 10 11 11 Page 62 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED b Install the other length of protective sleeve 1311 18K579SLV over the quick connect fitting and along the heater hose on the drivers side Apply electrical tape over either end of the protective sleeve to secure its position on the hose Install the 3 8 Engine Bottle Degas Hose 13118276 from the engine degas bottle to the fitting on the driver side cylinder head Secure with the constant tension clamps removed from the factory hose Ensure both 3 4 intercooler hoses the degas hose and all clamps and wiring have been installed to provide maximum clearance to the supercharger belt 6 1311 TVSCALIM 10 11 11 Page 63 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Air Induction System 1 Install the Upper Airbox Lid 13109643HC onto the lower airbox using the factory clips Connect the MAF wiring harness to the MAF sensor 2 Insert the Vacuum Fitting 383004 S from Hardware Kit A into the Clean Air Tube 13119B659 in the orientation shown Big end of vacuum fitting to be installed in clean air tube 1311 TVSCALIM 10 11 11 Page 64 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 3 Install the Clea
34. re assembly WARNING THIS KIT IS ONLY INTENDED FOR USE ON VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION REQUIRE THE USE OF A BRAKE ASPIRATOR 1311 TVSCALIM 10 11 11 Page 20 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Front Cover Modification 1 Using a grinder or cut off wheel modify the front cover in the areas shown The two bosses located at A amp B need to be reduced in height such that they are flush or lower than the height of the nearby rib structure The portions of the rib structure C D E amp F need to be removed completely cut just above flush to the surface of the front cover Be careful not to remove too much material in these areas as permanent damage to the front cover could occur The boss located at G needs to be reduced in height and cut in half 1311 TVSCALIM 10 11 11 Page 21 of 72 1 800 59 ROUSH 1311 TVSCALIM 10 11 11 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED CROSS HATCHED SURFACES A amp MUST BE LOWER THAN OR EQUAL TO THIS RIB HEIGHT Page 22 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED REMOVE MATERIAL Y OFF OF BOSS G UNTIL THE 20mm HEIGHT IS ACHIEVED 1311 TVSCALIM_10 11 11 Page 23 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED REMOVE MATERI
35. return it back to you the same day for next day delivery Operating your engine without our calibration will result in engine damage or failure and Will void all warranty Note It is important to reinstall the PCM in the vehicle it came from to prevent setting a trouble code and having to relearn the anti theft code which can only be performed using specialized Ford Service Bay tools e f you havent already done so write your vehicle identification number VIN and phone number on the PCM using a permanent marker e Remove the bubble wrap from inside the supplied shipping box and wrap it around the PCM to help prevent it from being damaged during shipping e Place the wrapped PCM in the shipping box 13106066M90SB e Complete the Warranty Registration Card 131019A505 and include it in the shipping box along with the PCM e Fill in your name and address in the FROM area of the shipping label that is located inside the box Follow the instructions on the box for sealing it shut e Peel the right label off and attach to the box where indicated e Retain the left side label for your records e Schedule a FEDEX Package Pick up by calling 1 800 463 3339 and select OPTION 0 to speak directly to an agent DO NOT use the automated option to schedule a pick up e Inform the agent you have a Prepaid FEDEX billable stamp package and you need a pick up e If there are any issues with the shipping box we supply and you want to ship th
36. rin 1 Locate the MAF wire harness connector and de pin the factory MAF connector using a proper de pinning tool Remove the pin locking device from the front face of the connector and remove the connector from the harness retain the pins crimped to each wire as shown 2 Insert the pins from the factory connector into the female connector provided on the end of the MAF Extension Harness 131112B579W The following color wires go into the following positions on the clip Violet with Grey position Z2 Grey with Yellow position 3 Blue with White position Z4 Yellow with Violet position 5 NOTE Positions 1 amp 6 are not used 3 Perform a visual inspection of the newly pinned connector to ensure that wire colors match on both sides of the harness Re install the pin locking device on the front face of the connector 1311 TVSCALIM 10 11 11 Page 33 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 4 Connect the new MAF extension harness to the new connector and route the MAF extension harness around the outer perimeter of the lower air filter tray Knock Sensor Orientation Adjustment 1 Loosen the two bolts which retain the knock sensors to the engine block and rotate the RH and LH knock sensor toward the RH and LH cylinder heads respectively In order to do so first remove the 90 degree plastic wiring retainer clipped to the connector and taped to the wiring
37. s Use zip ties to safely position the harness away from any areas of concern Reinstall the radiator trim cover by reversing the removal instructions Reinstall the battery connections by connecting the positive cable first then connecting the negative cable Reconnect the fuel pump control module electrical connector located in the spare tire stowage compartment In order to complete the installation of this kit you must complete the PCM Removal Steps and the Shipping instructions found on pages 10 amp 11 of these instructions DO NOT ATTEMP TO START OR TO DRIVE THE VEHICLE UNTIL THE REPROGRAMED PCM HAS BEEN RETURNED AND RE INSTALLED CORRECTLY INTO THE VEHICLE OPERATING THE ENGINE WITHOUT THE RECALIBRATED PCM WILL RESULT IN ENGINE DAMAGE OR FAILURE AND WILL VOID THE WARRANTY 10 Once the PCM has been successfully re installed start the engine and check for unusual noises dash service lights and unusual operation If problems are detected immediately stop the engine or vehicle diagnose and repair the problem 1311 TVSCALIM 10 11 11 Page 67 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE EMGIMEERING PREMIUM FUEL REQUIRED 11 The Belt Routing Diagram 13116E072 is to be placed on the underside of the hood on the driver side opposite of the factory Vehicle Emission Control Information decal 12 Place the Premium Fuel white decal with black lettering on the arm door of the fuel filler door as shown 131
38. tension clamp Orient the clamp so the on the hose is in the center of the clamp tangs Bumper beam removed for clarity 1311 TVSCALIM 10 11 11 Page 47 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 10 Connect the Intercooler Pump Inlet Hose to the inlet port on the intercooler pump Secure the hose to the pump using 1 4 constant tension clamp Orient the clamp so the on the hose is in the center of the clamp tangs View from in front of vehicle looking down at bumper beam 11 Route the remainder of the Intercooler Pump Wiring Harness next to the headlight and radiator and through the hole in the RH Radiator Side Shield Connect the wiring harness to the pump and secure the harness to the bracket by pushing the push pins on the harness into the holes in the mounting bracket RH Side a 1 12 Reinstall the impact absorber onto the front bumper beam using the take out pushpins Note Route all intercooler hoses very carefully It is critical for intercooler performance that these hoses are not kinked once installed into the vehicle 1311 TVSCALIM 10 11 11 Page 48 of 72 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Induction Resonance Tube Delete Grommet 1 Install the Induction Resonance Tube Delete Grommet W651016 in the hole that was exposed when the boom tube was removed NOTE If the ROUSH boost
39. the driver side cam cover Use tape or zip ties to secure the extension harness to the main harness Canister Purge Valve Wiring 1 Locate the Canister Purge Valve electrical connector at the front of the passenger side cylinder head Remove and discard the 90 degree wire retainer Use a proper de pinning tool to remove the connector from the harness Discard retainer Page 27 of 72 1 800 59 ROUSH 1311 TVSCALIM 10 11 11 ROUSH OF PERFORMANCE ENGINEERING DU FUEL REQUIRED 2 Depress the locking tab and separate the empty female 1 x 2 connector from the Canister Purge Valve Extension harness 131196866 This connector replaces the connector removed in the previous step Carefully pull the white locking tab forward to allow wires to be installed into the connector Populate the new connector such that the white with brown wire is in position 1 and the green wire is in position 2 Depress the white locking tab to secure the wires 3 Connect the Canister Purge Valve Extension harness to the newly installed connector The wire colors on each side of the connector pair should align Route the harness along the main wiring harness to the rear of the driver side cam cover Use tape or zip ties to secure the extension harness to the main harness 1311 TVSCALIM 10 11 11 Page 28 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Intercooler Pump Wiring 1 Loc
40. the left amp right hand side of the A C Condenser See Appendix A Note The LH shield engages the air inlet system 10 With the engine cool remove the cap on the engine coolant degas bottle and drain the coolant using the petcock located on the lower passenger side of the radiator TIP Connect a 3 8 hose to the drain fitting next to the petcock and run into a clean drain pan or bottle Use a 4 wrench to open petcock and allow coolant to drain out of the fitting Drain Petcock 1311 TVSCALIM 10 11 11 Page 12 of 72 1 800 59 ROUSH f equipped remove the 4 nuts and the strut tower cross brace Reinstall the 4 nuts and torque to 35Nm The strut tower cross brace cannot be reused after the supercharger has been installed zin A 289 feme Ve EC os E ca in ANSA pie 1 224 aj Is 12 Remove the engine appearance cover The cover cannot be reused after the supercharger has been installed 1311 TVSCALIM 10 11 11 Page 13 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED 13 Remove the M6 bolt that secures the induction resonance tube to the driver side fender near the cowl Remove the tube from the cowl 14 Disconnect the PCV Fresh Air Inlet tube from the left hand cam cover and clean air tube Remove the clean air tube from the throttle body and airbox Remove the clean air tube and the induction resonance tube from the vehicle Neither o
41. ve pin C 56 from the connector by gently moving the locking tab away from the pin on the front of the connector and pulling the wire out of the back of the connector Remove the insulation from a 1 2 section of the pin C 56 wire and 1 2 of the end of the blunt wire on the ACT loom Solder the two wires together and seal them with the supplied shrink wrap Reinsert the spliced wire into the C 56 location Note the orientation of the pins on the front of the connector and reinstall the pin in the same way If the pin is turned it will not lock The finished inserted splice is shown in figures 5 and 6 green wire with black shrink wrap C Insert the ACT loom wire with the pin into the empty C 36 location of the connector The back of the connector may have a blank cover at the C 36 location Carefully push this blank cover in with a small screw driver or punch to allow you to insert the pin Note the orientation of the pins on the front of the connector and install the new pin in the same way x Figure 5 Figure 6 3 a Reinstall the pin locking device by snapping it into place Reinstall the wire support on the back of the connector and wrap with tape as before b Reconnect the PCM connectors and route the ACT loom wire along the top of the cylinder head as shown in figure 7 Figure 7 1311 TVSCALIM 10 11 11 Page 32 of 72 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING PREMIUM FUEL REQUIRED Mass Air Flow MAF Wi

Installation Instructions

Contents

Download Pdf Manuals

Related Search

Related Contents