Installation Instructions - FR SuperPack 600
Contents
1. sieeve RO7050051 13 AA_071707 Page 23 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr ANC EL PATS 16 Assemble the air tube and filter onto the airbox housing using two bolts N605771 and torque to 10 Nm RO7050051 13 AA_071707 Page 24 of 29 Premium Fuel Required TF ZAAC MINI C y PPL f2 fOr ANC EL PATS 18 Install the rubber grommets previously removed from the factory airbox into the holes located beneath the airbox rearward of the ABS module 19 Lower the complete airbox assembly into the vehicle using the two pegs as guides into the rubber grommets Use the take off airbox bolt and newly supplied ABS bracket bolt N808920 to secure the airbox in the vehicle Torque the M6 bolt to 10 Nm and the M8 bolt to 25 Nm EJ i AJ b oA TI 7 kag D j ae lt OQ M O SAn Cela A RO7050051 13 AA_071707 Page 25 of 29 Premium Fuel Required TF ZAAC MINI C y PPL f2 fOr ANC EL PATS 20 Install the stock rubber clean air tube onto the new clean air tube airbox assembly Tighten both ends using worm drive clamps and torque to 3 Nm 21 Re install the PCV line and vacuum harness onto the clean air tube Re install the MAF2. vacuum line connects LRM y A the bypass actuator to the clean air tube This will be disconnected from the supercharger later Qi S y Ak RIN RO7050051 13 AA_071707 Page 7 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr ANC EL PATS 6 Disconnect the electrical connector from the MAF sensor Disconnect the vacuum harness and PCV hose from the clean air tube Remove the clean air tube from the airbox and throttle body D NVE Disconnect vacuum tub e R07050051 13 AA_071707 Page 8 of 29 Premium Fuel Required TF ZAAC MINI C y PPL f2 fOr ANC EL PATS 7 Remove the airbox retainer bolt and assembly from the vehicle Airbox retainer bolt Sa fo ae J gt 8 Remove the three grommets MAF and MAF bolts from the factory airbox These will be reused later MAF sensor amp bolts RO7050051 13 AA_071707 Page 9 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr ANC EL PATS 9 Disconnect the throttle body wiring in two places ETC amp TPS connections Dis
3. 12 Remove the two degas bottle fasteners Make sure the cap is tightly secured Rotate the degas bottle out of the way to gain additional access to the FEAD belt tensioner K Sani IN Degas boittl a fasteners MENE 2 A a a 7 at AIA NREN Jeri i j HAE i PN 13 Use a 3 8 breaker bar to release the first sheave tensioner and remove the FEAD belt from the supercharger pulley 1 tensi RO7050051 13 AA_071707 Page 12 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr ANC EL PATS 14 Disconnect the wiring harness and vacuum tube from the fuel rail pressure sensor IPTS Disconnect the wiring harness from the ACT sensor TI z mad PTS vacuum ers pem e Ly IPTS wiring harness connector allan Ni 15 Disconnect all eight fuel injector wiring connectors RO7050051 13 AA_071707 Page 13 of 29 Premium Fuel Required TF ZAAC MINI C y PPL fe f OlelhM ANCE PATS 16 Remove the fuel rail mounting bolts Pull up on the fuel rail and all eight injectors to gain access to the supercharger Rotate the fuel rail around the fuel rail supply line and set aside on the driver side strut tower AN WARNING Do not smoke or carry lighted tobacco or open flame of any typed when working on or near any fuel related components Highly flammable mixture
4. TF ZAAC MINI C y PPL f2 fOr ANC EL PATS Installation Instructions FR SuperPack 600 P Ns M 6066 SGT Black M 6066 SGTP Polished Application 2007 Ford SVT Mustang EO D 418 7 Licensed by Roush Performance Products 28156 Plymouth Road Livonia MI 48150 Important Notes BEFORE INSTALLING the FR SuperPack 600 please register this product by following the steps listed on the yellow voucher card included with the kit PRODUCT REGISTRATION IS REQUIRED to receive the ProCal flash tool used to recalibrate the vehicle PCM Operating the engine without the PCM recalibration will result in engine damage or failure and will VOID THE WARRANTY Please read the installation manual carefully and verify that all items are present If you are missing hardware or have any questions please contact the Ford Racing Call Center at 1 800 367 3788 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 RO7050051 13 AA_071707 Page 1 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr ANC EL PATS PACKAGING LIST FOR COMPLETE KIT N a lt CARB E O D 418 7 Item Description Part Number Clean Air Tube RO7060101 Air Box Assembly RO7060106 High Fl
5. 4 Re install the FEAD belt over the supercharger pulley by using a breaker bar to release the tensioner D 9 YQ i Lg Y NAS mes f i P 4 a O ee y i e pe NER ge A Ss j S S ENS iy 2 fos by 7 N C4 Ss 23 SO 1 Ve oT es E e wt di A ee LU gt A i a P N Dy 1 E S io a R07050051 13 AA_071707 Page 17 of 29 Premium Fuel Required TEAC MINI C y PPL f2 fOr ANC EL PATS 5 Rotate the degas bottle back into place Re install the two fasteners used to secure the degas bottle in place and torque to 10 Nm RO7050051 13 AA_071707 Page 18 of 29 Premium Fuel Required TF ZAAC MINI C y PPL f2 fOr ANC EL PATS 6 Re install the PCV and PCV bubbler lines to the supercharger housing PCV bubbler er 7 Apply a thread sealing compound to the stock EGR bolts Install the ESM and torque the bolts to 25 Nm Connect ESM electrical harness and the EGR tube Torque the EGR tube to 35 Nm O ESM harness H ESM EGR tube OC rat Oe RO7050051 13 AA_071707 Page 19 of 29 Premium Fuel Required TF ZAAC MINI C y FPR Lf 2 fF OFM A INC Ee PATET S 8 Re install the vacuum harness to the ESM supercharger and supercharger
6. which can take anywhere between 5 minutes and 40 minutes depending on the type of PCM Please be patient and do not touch the key or turn on any accessories such as the radio while flashing is in process When the tool is finished flashing the PCM the solid yellow light will turn off RO7050051 13 AA_071707 Page 27 of 29 Premium Fuel Required TF ZAAC MINI C y PPL f2 f OlINM ANCE PATS and either a solid green or solid red with blinking yellow will result If the green light is on turn the ignition key to the OFF position remove the tool from the DLC and continue to STEP 6 If the red light is on an error has occurred and the PCM has not successfully been flashed Refer to the Light Status section below for diagnosis all Congratulations You have now successfully flashed the PCM Start the engine and enjoy Light Status Solid GREEN only Flashing process successfully completed Ready to begin flashing process and waiting for key FaN KEET omy to be turned to ON position Error encountered Count yellow blink sequence and refer to the following table for error code If the error code is not shown below call the Techline for further instructions at 1 800 FORD 788 Solid RED blinking YELLOW Error Code Diagnosis shale fer espn O Blinks Attempting to program second vehicle before Vehicle mismatch first vehicle has been returned to the stock calibration O 2 Switch position error Try again with th
7. electrical connector onto the MAF sensor Z Attach MA sensor wiring Attach supercharger bypass vacuum harness 22 Re install the strut tower brace and torque nuts to 35 Nm 23 Reinstall the battery connections Connect the positive cable first then the negative cable to the battery Check to ensure that the battery if fully charged 12 0V to 14 5V RO7050051 13 AA_071707 Page 26 of 29 Premium Fuel Required TF ZAAC MINI C y PPL fe f OlelhM ANCE PATS 24 VERY IMPORTANT THE FOLLOWING STEPS CAN ONLY BE COMPLETED ONCE YOU RECEIVE YOUR FORD RACING PROCAL FLASH TOOL PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION ProCal Calibration Flash Tool Instructions Please follow the directions below in order to make sure that your vehicle s powertrain control module PCM is successfully programmed flashed with the correct calibration Do not drive the vehicle until the programming operation has completed successfully Please read these instructions in their entirety prior to beginning the flash procedure If you have any questions or concerns please call the Ford Racing Techline at 1 800 FORD 788 if they are not addressed in this document This ProCal tool has been designed to deliver a performance calibration to your vehicle and keep a copy of your vehicle s stock calibration should you decide to remove the performance pack for any reason The tool will be locked to your vehicle
8. on driver side strut tower adjacent to the air filter assembly FORD RACING LIMITED WARRANTY A Limited Warranty is valid only when proof of purchase is registered by the installing dealer by contacting the Ford Racing Call Center at 1 800 367 3788 For warranty details please visit the website WWW FORDRACINGPARTS COM RO7050051 13 AA_071707 Page 29 of 29 Premium Fuel Required
9. until the stock calibration has been restored Once the original calibration has been restored to your vehicle the performance calibration and corresponding hardware can be installed on another vehicle of the same year make model PCM part number tire size and axle ratio Recalibration Procedure Before You Begin Check to see that the battery is fully charged at least 12 0 volts and all accessories radio interior fan headlights etc are switched off It is strongly recommended that the vehicle be connected to a battery charger during the flashing process to avoid potential low voltage issues Locate the on board diagnostic OBD II diagnostic link connector DLC located beneath the dashboard on the driver s side of the vehicle The exact location will vary with the model and year of the vehicle but will always be on the driver s side Hold the ProCal tool so that the side with the instructions on it is facing up and the LEDs and switch are facing you Slide the function switch to the LEFT toward center of unit to select the performance calibration or to the RIGHT toward edge of unit to select the stock calibration Connect tool to the vehicle diagnostic connector and wait another 5 seconds A blinking yellow light should appear which means the tool is ready to begin flashing the vehicle s PCM Turn key to ON position but do not start the engine The yellow light should stop blinking and stay on during the PCM flashing process
10. you through the final installation of this kit If you need to stop during any part of the installation make sure you cover any open ports in the cylinder heads or intake manifold to prevent foreign material from contaminating your engine 1 Install the new supercharger to the intake manifold using the stock fasteners Torque the fasteners to 5 Nm using the inside out pattern shown below Repeat this procedure and torque each fastener to 25 Nm iy I i YN BY ee Se ae ia ih ASA A JENCI TAWN A 1 PF ae Ll TA L AN KORSMO AAA i maha i Bilt li li iat MEET Ni APRE BARJE E gt er i 322 TO a NC R aS HA R07050051 13 AA_071707 Page 15 of 29 Premium Fuel Required VF ECAC MINIC gg PPL f2 fOr ANC EL PATS 2 Re install the injectors and fuel rail onto the intake manifold Torque fuel rail bolts to 10 Nm ae x eT A L i AA V a ZZ Y i 3 Connect fuel injector wiring harnesses fuel pressure regulator IPTS electrical harness vacuum harness and ACT wiring connector cer il Vacuum l al e wing Doni Lenee Ge a E i ASHH SSE Say A we t al R07050051 13 AA_071707 Page 16 of 29 Premium Fuel Required TF CAAC MINI C y PPL l2fF OllMANC EL PATS
11. F position Always apply the parking brake when working on 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 M Batteries can produce explosive hydrogen gas which can cause personal injury R07050051 Therefore do not 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 which can be caught in rotating or moving parts 13 AA_071707 Page 5 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr ANC EL PATS 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 section 310 00 AN WARNING Fuel in the fuel system remains under high pressure even when the engine is not running Before working on or discon
12. R07050051 13 AA_071707 Page 21 of 29 Re connect the electrical Premium Fuel Required TF ZAAC MINI C y PPL fe f Oleh ANCE PATS 12 Install the MAF sensor and bolts from the stock airbox into the new clean air tube RO 060101 Torque the bolts to 4 Nm Clean air tube Factory MAF Sensor 13 Install the clean air tube support bracket RO 060104 to the clean air tube and position using the alignment marks on both the bracket and the tube Secure the bracket to the tube using the bolt N605771 supplied in the kit NOTE Apply medium strength thread locking compound to the bolt threads prior to installation and torque this bolt to 10 Nm af ras RO7050051 13 AA_071707 Page 22 of 29 Premium Fuel Required TF ZAAC MINI C y PPL f2 f Ole ANCE PATS 14 Install the air filter RO7060131 to the clean air tube and torque the worm drive clamp to 3 Nm NOTE Align the metal strip on the air filter with the alignment mark on the clean air tube 15 Install the rubber grommet from the factory airbox into the new airbox housing RO7060106 NOTE Remove the metal sleeve to ease grommet insertion into the airbox Once the rubber grommet is firmly seated in position re install the metal sleeve into the grommet
13. bypass actuator NOTE Ensure the harness is properly routed and all connections are fully seated FA AN a FALLE AAN a 2 oe 77 Oder A FP oy FR IF Fil KY D gt 1 Z k AN A j e a UY rf x91 eee 7 Wi N ee a 9 Re install the stock throttle body spacer assembly to the supercharger using the stock bolts and torque to 10 Nm O A A A ANESS Cre Q Z el i EJ Throttle body SF spacer bolts EREB VAL EP 4 gt R07050051 13 AA_071707 Page 20 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2f OlMAN CLE PATS 10 Re install the brake booster hose and VMV to the throttle spacer harness to the ETC and TPS mounted on the throttle body T N Erre TH NY Attach brake booster mae 2 tip a N IT IN KOS _ X ETC amp TPS wiring A connections N Z By X f 4 Sy 79 A H we OWIES H Stock clean air tube
14. connect the brake booster and VMV hoses from the throttle body spacer Remove the throttle body spacer including throttle body from the supercharger rr lt say 1 rer yaaa 1 Disconnect brake VMV hose booster hose here _ 16 eee clas Segoe POY WS be N ISN te a AI a D AT 3 i N Di th oS lle A Yi S i k A i O i Throttle body gt spacer bolts D 7 s i R07050051 13 AA_071707 Page 10 of 29 Premium Fuel Required FP ECAC MINE g PPL f2 fOr ANC EL PATS 10 Remove the ESM EGR System Module electrical connector Remove the EGR tube nut from the ESM Remove the ESM bolts and assembly from the supercharger NOTE The ESM gasket will be reused It is important that it does not become damaged or lost a J esm KY py 4 Electrical harness p H Hiem l E zN NY k Ki ULA C oOo 7 Xi N PCV bubbler RO7050051 13 AA_071707 Page 11 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr lM ANC EL PATS
15. e switch in the other position 3 General software upload Call Techline at 1 800 FORD788 4 software download Sall Techline at 1 800 FORD788 6 Voltage read error Try again with battery charger connected Ez Hi PALAY ladenence Try again with battery charger connected 8 Lies i ee Check that correct battery is installed in vehicle that correct Check that correct battery is installed in vehicle is installed in vehicle The ProCal reprogramming voltage is not working Check vehicle DLC wiring oroper RO7050051 13 AA_071707 Page 28 of 29 Premium Fuel Required TF ZAAC MINI C y FPL f2 f OLRM ANCE FATS 25 Inspect all underhood wiring harnesses for potential interference issues Use zip ties to safely position the harness away from any areas of concern 26 Pressurize the fuel system Note This procedure was taken directly from the Ford service manual section 310 00 a Install the fuel pump module fuse Its location can be seen on pg 7 of this manual b NOTE It may take more than one key cycle to pressurize the fuel system Cycle the ignition key and wait 3 seconds to pressurize the fuel system Check for leaks before starting the engine c Start the vehicle and check the fuel system for leaks 27 7 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 28 Affix the E O Decal RO7040042
16. necting 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 Remove the fuel pump module fuse NOTE The fuel pump module fuse is located in the bussed electrical center location F41 e pactadi 7 i HL a L YUE wie ani el ol JTE callie RO7050051 13 AA_071707 Page 6 of 29 Premium Fuel Required TF ZAAC MINI C y PL f2 fOr ANC LE PATS b Start the engine and allow it to idle until it stalls c After the engine stalls crank the engine for approximately 5 seconds to make sure the fuel injector supply manifold pressure has been released d Turn the ignition switch to the OFF position 3 Disconnect the negative amp positive connections to the battery Cover the positive battery terminal to prevent any contact 4 Remove the factory strut tower brace es i ee E HI S NE EN NP z TAT O oy y py 4A Tay The a A BUN Ll tow M lex fu egy LTO pe 5 Carefully label each port before removing the vacuum harness from the vehicle ie supercharger housing ESM and supercharger bypass actuator EIA LAG NAV pee a A EAA j i NOTE A separate QS Ss DK A
17. ottle 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 RO7050051 13 AA_071707 Page 4 of 29 Premium Fuel Required TF ZAAC MINI C y PPL fe f OlelhM ANCE PATS 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 N WN A K N Always wear safety glasses for eye protection Place the ignition switch in the OF
18. ow Conical Air Filter w Worm Clamp RO7060131 Bolt Bracket to Tube amp Airbox M6 x 13 N605771 Bolt Airbox to ABS Bracket M8 x 33 N808920 EO Label R07040042 EE Clean Air Tube Support Bracket R07060104 R07050051 13 AA_071707 Page 2 of 29 Premium Fuel Required TF ZCAAC MINIC y PPWOLf2 fOr ANC HEL PATS DP FGACINGE FEO MENA Installation Instructions FR SuperPack 600 P Ns M 6066 SGT Black M 6066 SGTP Polished Application 2007 Ford Shelby GT500 EO D 418 7 Licensed by Roush Peformance Products 28156 Jo Road Livonia MI 48150 Important Notes on oY prEN erPack 600 pl ead the installation arefully an all e missing h a a E E EAR t the Ford Racing Da OSAA 11800 967 37 88 Premi m a oi octane ol m onee requi ci o prevent spark knock or detonation under certain oper conditions The fuel additives ie octane Planers is m ett recommended There is a possib nny tat t these chemi micals ca n damage peel engine and cause drivability issues with your vehicle register you with Ford Racing posadbell serach sara r ProCal flasi TE ool w ville used t to recalibrate your vehie cle s PCM Operating y engine without the S RO reca calibra will result in engine damage or failure and will v arp anty R07050051 13 AA_O7 1707 Page 1 of 35 Premium Fuel Required Item Description Part Number TVS2300 Supercharger Black Finish RO7050050 TVS2300 Supercharger Polished RO7050053 Regist
19. ration Warranty Voucher RO7140004 40004 2 Installation Instructions RO7050051 EE The ProCal flash tool is NOT included in the kit Once you register the product with Ford Racing this tool will be shipped to you R07050051 13 AA_071707 Page 3 of 29 Premium Fuel Required TF ZAAC MINI C y PPL fe f OlelhM ANCE PATS 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 3 8 Drive Ratchet or Breaker Bar e Metric and Standard Wrench Sets e Torque Wrenches e Short Phillips head Screwdriver e Hex Key Set e T 20 Torx Bit Screwdriver or Socket e Thread Sealing Compound e Medium Strength Thread Locker Loctite 242 blue or equivalent e Ford Service Manual GLOSSARY OF TERMS ACT Air Charge Temperature Sensor ETC Electronic Throttle Control IPTS Injection Pressure and Temperature Sensor 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 Located on driver side strut tower INFORMATION ABOUT THE SUPERCHARGER BYPASS OPERATION There is a great deal of misinformation about the function 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 thr
20. s are always present and can be ignited resulting in personal injury 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 NOTE Be careful not to get any contaminants in the injectors or into the boss on the intake manifold Be careful not to damage the O rings on the injectors Te i Nes 4a W as X lt 1 i Injector wiring a as Fuel rail bolts we 17 Remove the supercharger mounting fasteners and carefully remove the supercharger from the vehicle If the dowel pins did not remain in the intake manifold remove them from the Supercharger and re install into the intake Transfer the vacuum line attached to the supercharger bypass valve to the new supercharger NOTE Attempt to maintain the stock orientation and connect to the lower port RO7050051 13 AA_071707 Page 14 of 29 Premium Fuel Required TF CAAC MINIC y PPL f2 fOr lMVMANC EL PATS SECTION B INSTALLATION The following section will guide
Download Pdf Manuals
Related Search