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1. E a 2 A k i a Wd EE El 1305SS TVSIM BA 20130911 Page 15 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 14 2005 06 VEHICLES ONLY Remove the upper radiator and bypass circuit hoses Remove the clamps from the upper radiator hose and save for later use On the back side of the water crossover disconnect the heater hose Remove the water crossover using a 10mm socket wrench SIE T dum puT uy cx m 5 b Thermostat Hose DUX T Vy f s zh rit Nate 0s L t Ir 1 E Imm e E E uy a AF 2 FL Pct i 14 2007 09 VEHICLES ONLY Remove the upper radiator hose On the back side of the water crossover disconnect the heater hose Remove the water crossover using a 10mm socket wrench amr mm Wu mr exkl Tq pr ee Cm Lg li ELLO Crossover Tube Bolts nT Pe 2 T T prt Duc DELI st E i TE hs z F i mah aa haa j mr p EIN PME Ae nce 1305SS TVSIM BA 20130911 Page 16 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 15 Disconnect the rubber portion of the heater hoses from the metal tubes at the rear of the right hand cylinder head Remove the heater tube assembly from the engine by removing the stud on the back side of the passenger cylinder head and sliding off the water pump fitting in the
2. Customers with 2009 vehicles must also refer to pages 79 84 for special instructions 1305SS TVSIM BA 20130911 Page 1 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES PACKAGING LIST Description RPP Part Number Qty Fuel Charging Fuel Charging S Manifold Assembly Fuel Charging Supercharger Assembly P51a w Bolt On Hub Bolts S C Pulley M6 x 14 N60571 6 Throttle Body Spacer Assembly Throttle Body Assembly Fuel Rail Spark Plugs FOR MY2005 2008 5 ONLY HTO032 8 Description RPP Part Number Qty Hardware Kit B Fuel Charging 13106066TVSHKB 1 Fuel Injectors R07110007 8 Fuel Injector Clip PCV Bubbler Hose 1 74 Hose Heater Jumper Hose 1 Clamp Hose Constant Tension 2 screw amp Washer T Body amp S C to Spacer M6 x 1 0 x 32 5 Bolt Fuel Charging To Cylinder Head M6 x 1 0 x 40 11 Bolt RH Fuel Rail To Upper Intake Manifold M6 x 1 0 x 22 2 Nut Heater Tube Mounting M6 Description RPP Part Number Qty Alternator Bracket R07020035 R07020043 Description RPP Part Number Qty Hardware Kit Single Sheave FEAD SSTVSHKT AA 1 Pulley Idler B S 76mm Flanged Bolt Rear Alternator Support Bracket M5 x 10 Nut Rear Alternator Support Bracket M5 Bolt Idler M8 x 28 large washer Bolt Alternator M8 x 55 Bolt Alternator Support Brkts to Intk M8 x 25 Bo
3. TLACIINIG s s INSTRUCTION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 21 STEP 34 Run wire labeled FUSE POWER 1 along the trunk wall into the back seat of the passenger side and along the wire track on the passenger side of the vehicle see Figs 22 24 Fig 23 Fig 24 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 13 of 15 M 9407 GTO5 Mustang GT Dual Fuel Pump Kit FC IUNE r INSTRUCTION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS 34A A hole will need to be placed in the grommet located in the lower area of the front wall on the passenger side in order to run the wire through see Fig 25 STEP 35 Lift vehicle and remove the right front tire from vehicle along with the rear fender well cover Continue to run wire along existing wire harness in fender well using wire ties to secure the wire along the existing wire harness see Fig 26 Fig 26 STEP 36 Remove innermost fastener on front fender well cover and continue to run wire into engine compartment The wire should come through the hole located near the washer fluid neck see Figs 27 28 Techline 800 FORD788 Factory Ford shop
4. 08 VEHICLES ONLY Insert 2 M8 x 1 25 x 55 bolts N808130 and 2 M8 nuts W520413 through the alternator bracket Be sure to leave enough room to insert the alternator Slide the alternator onto the bolts Ensure that the smart charge harness does not get pinched Torque to 20 30 Nm 2009 Vehicles please refer to Section E on Page 79 EN NE We RCM LAN 19 2005 08 VEHICLES ONLY Install the Rear Alternator Support Bracket R07020045 using the M8 x 1 25 x 20mm bolt R18020005 into the alternator and M8 x 1 25 x 25mm bolt W500224 into the intake Route the B cable in between this bracket and the alternator Torque bolts to 20 30 Nm 2009 Vehicles please refer to Section E on Page 79 WARNING Do not put any bolt longer than 20mm into the back of the alternator be zm ay U LL a mut x 47 a P JU 1 j l j i Mal il ly li i m Route B Cable MES qo w under this bracket 1305SS TVSIM BA 2013091 1 Page 63 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 20 2005 08 VEHICLES ONLY Connect the B cable to the stud on the back of the alternator using the take off nut Torque to 8 12 Nm Plug in the smart charge harness Ensure that there are no pinched wires around the alternator 2009 Vehicles please refer to Section E on Page 79 21 Inst
5. 2 M6 nuts W520412 to secure the new fuel pump driver module to an existing stud in the trunk as per the Ford installation manual Cylinder Head Modification 1 Cutout the following template Line up the template with the front of the right hand cylinder head Using a grinder with a sanding pad attachment sand down the front corner of the cylinder head up to the template Take special care that no shavings enter the engine cylinders Thoroughly clean engine upon completion of this modification ODIFY HEAD IN THIS AREA 1305SS TVSIM BA 2013091 1 Page 29 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES This page is intentionally left blank 1305SS TVSIM BA 2013091 1 Page 30 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES SECTION C SUBASSEMBLY Induction System 1 Install the stock MAF sensor using 2 M4 x 0 7 x 10 MAF bolts R07130007 into the new clean air tube R07060101 Torque bolts to 3 5Nm Clean air tube Factory MAF Sensor 2 nstall the clean air tube bracket R07130010 on the clean air tube and position using the alignment marks on both the bracket and the tube Secure the bracket to the tube using 1 M6 x 1 0 x 14 bolt N605771 supplied in the kit Apply medium strength thread locker to bolt threads prior to insta
6. INSTRUCTION SHEET 1305SS TVSIM BA 20130911 Page 87 of 87 1 800 59 ROUSH M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIINIG s INSTRUCTION SHEET Pe Fe COENA EO a NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Please contact the Techline for the most current instruction information 800 FORD788 PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION OVERVIEW The following information describes the procedure for the installation of the M 9407 GT05 dual fuel pump kit into 2005 07 Mustang GT WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL RESULTING IN PERSONAL INJURY OR A FIRE HAZARD WARNING DO NOT CARRY PERSONAL ELECTRONIC DEVICES SUCH AS CELL PHONES PAGERS OR AUDIO EQUIPMENT OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSON
7. THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES SECTION E 2009 VEHICLES ONLY VERY IMPORTANT NOTE The following section of this manual is ONLY required for those customers with 2009 model year vehicles Customers with 2005 08 vehicles should disregard this section REVISIONS TO SECTION C SUBASSEMBLY 2009 Vehicles Only The following steps must be completed by 2009 VEHICLES ONL Y 1 Remove the 2 nuts shown from the back of the modified alternator 1305SS TVSIM BA 2013091 1 Page 80 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 2 Install 2 hex nuts R07020053 in place of the 2 nuts removed in the previous step Torque hex nuts to 5 7 Nm BE CAREFUL NOT TO OVERTIGHTEN which can cause the studs inside the alternator to break 3 Secure the Rear Alternator Bracket RO7020056 to the rear of the alternator using 2 M5 x 0 8 x 10mm bolts R18020059 Torque bolts to 5 7 Nm BE CAREFUL NOT TO OVERTIGHTEN THESE BOLTS 1305SS TVSIM BA 2013091 1 Page 81 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES REVISIONS TO SECTION D INSTALLATION 2009 Vehicles Only The following steps replace steps 1 2 11 15 and 18 20 of the Charge Harness and Wiring Installation in
8. a Remove the fuel pump module fuse NOTE The fuel pump module fuse is located in the bussed electrical center location F41 Tm J F jj z EE des Mil LH 1305SS TVSIM BA 2013091 1 Page 8 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 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 3 Using an 8mm wrench disconnect the negative amp positive connections to the battery Remove the battery hold down bolt using an 8mm socket wrench Remove the hold down amp battery With an 8mm socket wrench remove the 3 bolts holding the battery tray to the vehicle Remove the battery tray ol 2 Batterv Trav Bolts rh i ri j Ry j j l i I 1305SS TVSIM BA 20130911 Page 9 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Before continuin refer to the CALKIT included with your ROUSHcharger kit Determine the PCM flash method you will be using If performing the PCM flash ourself or at a preferred ROUSH dealer proceed to step 5 If sending the PCM to ROUSH for a ROUSH performed PCM flash co
9. in IL a7 QS 7 rs E wy T i r zu s wi i P L7 Hs i i Bo z i og n a i j i Toe P d Lr 1 ime E a 2 en T SJ BL Hag IPES MAF C H Ium onnecto F ka og gl ie E i a E pa m n n r i 56S Man s e Mr E Pea m am PR zs np um Pe Po Sam ak i J r 2 F Hifo 1 oe i j j F T 5 ys Hold down bolt 1 LN a T E 8 Disconnect ETC electronic throttle control amp TPS throttle position sensor connectors from the throttle body Pull the red locking tab back press the black release tab to disengage the lock 9 Remove the PCV line from the intake manifold and left hand cam cover Remove the VMV line from the intake manifold and position out of the way Remove the vacuum line and electrical connector from the IPTS on the fuel rail and save for reuse Remove the black safety clip from the fuel line connection Place rags under the fuel rail using a 5 8 fuel line tool wrap additional rags around the tool disconnect the fuel line from the fuel rail V HL fs Em ERES C a m dil 4 PCV Line 1305SS TVSIM BA 20130911 Page 13 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 10 Disconnect the alternator harness from the positive battery terminal and remove the harness clips from the fuel rail studs 11 Disconnect the wiring connectors from the fuel inject
10. 20 30 Nm then finally torque the top M8 bolt to 20 30 Nm 977 etd NS t a T A ax 9 Ti l EHT N i J is Ae ea m am i XL S QU PE TEL eres EAR le x mm 3 emet HS ie y 12 Install the 2 FEAD Pulleys R07020049 to the alternator bracket using the 2 M8x1 25x32 Idler Bolts R18020060 Torque bolts to 20 30Nm R18020060 M8X1 25X28mm TORQUE 20 30 Nm 1305SS TVSIM BA 2013091 1 Page 53 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 13 Lubricate the fuel injector o rings with 5W 20 engine oil Apply a small amount of engine oil to the injector pockets in the intake manifold and install the fuel rail and injector assembly Be sure each injector is properly seated into the intake manifold Secure the fuel rail using 2 take out studs on the driver s side and 2 M6 x 1 0 x 22mm bolts R18020057 on the passenger side Torque bolts to 8 12 Nm e WN CEE F RAN V S 14 Install the 7 32 vacuum hose R18140001 from the IPTS on the fuel rail to the fitting in the upper intake manifold MSN N IN PRAY A j V R18140001 rga SS Das D y 7 ei 1305SS TVSIM BA 20130911 Page 54 of 87 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Charge Harness and Wiring Installation 1 2005 08 VEHICLES ONLY Sli
11. 5 16 Mark and drill to 5 16 3 Clean the mating surfaces of the degas bottle and fan shroud with brake cleaner or rubbing alcohol Peel and stick one side of the Double Sided Tape R07030002 provided in Cooling oystem Hardware Kit to the underside of the degas bottle 1305SS TVSIM BA 2013091 1 Page 35 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES This page is intentionally left blank 1305SS TVSIM BA 2013091 1 Page 36 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 4 Remove the upper fan shroud bolts and force the shroud toward the rear of the vehicle Install the 2 J Clips N623332 from the Hardware Kit Peel the second side of the double sided tape and set the bottle on the fan shroud Secure the intercooler degas bottle using 2 M6 x 1 0 x 33 bolts N808429 and the M6 x 1 0 x 8 cap screw R18020010 with washer R18030002 from Hardware Kit and torque to 8 12Nm Reinstall the upper fan shroud bolts and torque to 8 12Nm Intercooler Radiator Assembly Mountin 1 Remove the 6 push pin retainers highlighted below by pulling the center pin and remove the radiator trim cover 1305SS TVSIM BA 201530911 Page 37 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR US
12. OO A s m 7 y fA btipb itla v JALILILITITITTTS he IN A h i fyd Hiii LIITETTY r ih te tere au TTD 772 8 err m 1305SS TVSIM BA 20130911 Page 58 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 10 Connect the IPTS 11 2005 08 VEHICLES ONLY Route the B cable R07080032 under the main harness in between the VCT solenoid and coil 5 2009 Vehicles please refer to Section E on Page 79 1305SS TVSIM BA 2013091 1 Page 59 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 12 2005 08 VEHICLES ONLY Push the B cable retainers onto the fuel rail studs 2009 ase refer to Section E on Page 79 Vehicles ple 13 2005 08 VEHICLES ONLY Remove the 2 plastic fasteners that hold the cowl grill in place Lift the cowl grill for easier access to replace the factory screw that secures the grounding strap to the cowl with 1 M6 x 1 0 x 18 5mm bolt N605891 at the arrow shown Torque bolt to 8 ase refer to Section E on Page 79 12Nm and replace plastic fasteners 2009 Vehicles ple Mer m j Hn m fasteners Bi t SEE JDUDSUUL Lii 1 800 59 ROUSH Page 60 of 87 1305SS TVSIM BA 20130911 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH P
13. Radiator Assembly Lower Radiator Hose RPP Part Qt Description Number y Intercooler Hose amp Steel Tibe Kit R07070074 1 Tube Assembly Heater Water Inlet R0707008 1 Tube Assemby CACLins R0707005 1 Ya Hose Degas Inlet R0707006 1 Ya Hose Degas Outlet RO7070008 1 Es L3 NEN it L4 i Qty 3 4 Hose LTR Inlet 34 Hose LTR Outlet 74 Hose Heater Tube Inlet Upper Radiator Hose R0707022 1 Clamp 34 Hose Worm Drive ee Clamp 4 Hose Constant Tension boo o 0400 Hose with Clamps PCV Bubbler R070600175 1 RPP Part Qt Description Number y Intercooler Hardware Kit R07070075 Degas Bottle Cap XL3Z 8100 A J clip Degas Bottle amp Pump Bracket Mounting M6 Short N623332 EN NN Double sided Tape Degas Bottle Mounting R07030002 1 zz EE 3 4 1 1 1 1 1 1 1 1 1 1 0 1 Washer M6 x 18mm OD R18030002 1 Bolt Pump Bracket amp I C Tube Assembly Mounting M6 x 1 x 18 N605891 Bolt Degas Bottle Mounting M6 x 1 0 x 33 N808429 2 1 1 Cap Screw Degas Bottle Mounting M6 x 1 0 x 8 R18020010 1 2 Bolt Long Bumper Bolts M8 x 1 25 x 35 R18020007 Bolt 9N491 Tube Assembly Mounting M16 x 40 R18020006 1 Nut Heater Tube Mounting to S C M6 W520412 Nut LTR Mounting amp Pump Bracket M8 W520413 1305SS TVSIM BA 20130911 Page 4 of 8
14. SECTION D INSTALLATION section of the 05 08 instruction manual 1 Push the Alternator Charge Harness R07080034 retainers onto the driver side fuel rail studs as shown below a 5 LE 2 Insert 2 M8 x 55mm Bolts N808130 and 2 M8 Nuts W520413 through the alternator bracket Be sure to leave enough room to insert the alternator Loosely secure the alternator charge harness eyelet to the alternator using the take off M8 nut Slide the alternator onto the bolts and route the charge harness under the rear alternator bracket refer to picture in step 3 on next page Torque M8 bolts to 25 Nm 18 Ib ft 1305SS TVSIM BA 20130911 Page 82 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 3 Secure the alternator to the intake using 1 M8x25mm Bolt W500224 Torque to 20 Nm Torque the nut securing the charge harness to the alternator to 15 20 Nm Plug in smart Take special care to make sure the charge harness is not charge connector to alternator pinched anywhere NX 7M CX OM 7X 00 XX Amm Route charge harness under the bracket in this ES 4 Remove the 2 plastic fasteners that hold the cowl grill in place Lift the cowl grill for easier access to replace the factory screw that secures the grounding strap to the cowl with 1 M6 x 1 0 x 18 5mm bolt N605891 at the arrow shown Torque bolt to 8 12Nm and replace plasti
15. and connecting it to the steel heater inlet tube using the original constant tension clamp 39 Connect the LTR Outlet hose routed from behind the passenger side headlamp to the lower Intercooler tube using 1 constant tension clamp Install the 17 72 Degas Inlet hose R07070006 from the upper intercooler tube using 1 constant tension clamp 81 B to the upper degas bottle fitting using 1 74 worm clamp 34 Install the upper radiator hose R07070022 using the take off constant tension clamps 1305SS TVSIM BA 2013091 1 Page 69 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 35 Locate the ABS module bracket and remove the bolt shown below MAU I r MF X od ABS module I T Ir x A LIII I a Ni IS l B Ri M ij Te In 36 Install the rubber grommets from the bottom of the factory air box into the holes located beneath the air box rearward of the ABS module A AN Sw Nes f 7 e IA Sy ct Li A 2 ef j eg Io dou Installed rubber grommets 1305SS TVSIM BA 20130911 Page 70 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 3 Lower the air box assembly into the vehicle using the t
16. depining tool can be made and used to pull the blue terminal locking device from the connector and to release the terminal from the connector See below Depining Tool Straiten a large paper clip Using needle nose pliers bend 1 8 90 Using a hammer and the anvil of a vice tap the other end of the paper clip to form a slight wedge na Male terminal shown female terminal similar e Secure the excess wire in the trunk with wire ties e Cover the entire length of the red power wire with 1 4 convolute e Cut the fuse holder from the red wire Cut the end off of the wire nipple and pass the red wire and convolute through the opening Wrap with tape as shown to seal the grommet e At the fuse box cut the excess red wire for best fit and reattach the fuse holder to the red wire using the same technique used on the engine harness for the TPS and ACT wiring Cover the wire with 1 4 convolute as shown d A cci miu Rr xt T e Secure the overlay harness to the vehicle main harness with wire ties placed every 10 to 12 and in the right front wheel well every 6
17. harness to intake manifold stud clip and re tape it to the harness 210mm from the left valve cover rear retainer 8 Locate the TPS Throttle position sensor connector and harness at the front of the passenger side Remove the split loom convolute and tape from this harness until the main bundle 9 Stagger cut the 4 TPS wires 60 90 120 and 150mm from the TPS connector Use the supplied TPS extension harness R07080031 13 AA to lengthen the TPS wires using the same technique outlined in step 4 Cover the extend harness with the supplied convolute and run it along with the main harness securing it to the main harness with tape every 150mm to a position 30mm before the rear intake manifold wire retainer New Location Steps 8 9 New Location Step 5 ETC Hi 155mm New Orientation New Location On Top Step 7 Step 7 Wiring Modification Summary 1305SS TVSIM BA 20130911 Page 28 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Fuel System Modification This section only to be completed by Phase 2 Customers 1 Using the Ford Racing installation manual M 9407 GTO5 which is located at the end of this manual in Appendix A install the Ford Racing GT500 Fuel System Upgrade Kit R14020001 These instructions can also be found on the internet at www fordracingparts com download instructionsheets FordInstShtM 9407 GTO05 pdf 2 Use
18. into the fuel rail injector cups Fuel Charging 1 Install the PCV Bubbler Hose R07060175 onto the Fuel Charging Assembly RO7060135 and secure it using 1 of the supplied PCV Bubbler clamps R07060175 BUBBLER HOSE R07060135 MANIFOLD ASY FUEL CHARGING 1305SS TVSIM BA 2013091 1 Page 33 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES SECTION D ASSEMBLY 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 intake manifold to prevent foreign material from contaminating your engine Intercooler Reservoir Mounting 1 Using the Intercooler Degas Bottle R07070007 with Degas Bottle Cap XL3Z 8100 AA as a template place the bottle on the flat part of the electric fan shroud between the power steering reservoir and the engine coolant degas bottle With the edge of the bottle at the edge of the electric fan shroud mark the 2 mounting holes with a paint pen and drill two 5 16 holes through the fan shroud 1305SS TVSIM BA 20130911 Page 34 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 2 Cutout the following template and use it to mark the third mounting hole and drill to
19. into the fuel tank Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 7 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIINIG s s INSTRUCTION SHEET Pe Fe SEA EO ae T NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS STEP 17 Connect the cross over fuel tube quick connect coupling to the fuel pump CAUTION Make sure the fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube STEP 18 Make sure the alignment arrows on the dual fuel pump and the fuel tank meet before tightening the dual fuel pump lock ring Using the special tool or brass punch install the dual fuel pump with the new lock ring 18A Tighten the lock ring until it meets the stops on the fuel tank NOTE The fuel pump is spring loaded into the tank and may require slight pressure to install lock ring STEP 19 Connect the quick connect coupling on top of the dual fuel pump CAUTION Make sure the fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube STEP 20 Remove black cover from inside trunk to access fuel pump driver module see Fig 12 STEP 21 Disconnect fuel pump driver module located in spare tire well on driver side see Fig 13 Techline 800 FORD788 Fac
20. manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 14 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIINIG s INSTRUCTION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 27 STEP 37 Connect FUSE POWER 1 to FUSE POWER 2 STEP 38 Connect POWER to hot side of bussed electrical center see Fig 29 Fig 29 STEP 39 Reinstall relay in position 21 of bussed electrical center STEP 40 Connect negative terminal of battery STEP 41 Check for leaks before starting the engine 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 STEP 42 Start the engine and check for leaks Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 15 of 15 Dual Fuel Pump Kit M 9407 GT05 Amendments To avoid spilled fuel onto the carpet to aid in the installation of the Wheel Hop Kit to protect the power wire from abrasions and to allow for a better seal on the grommet in the passenger foot well please adhere to the fallowing amendments to the Ford Racing Installation Instructions e Remove the fuel tank from the vehicle when changing the pump assemblies e Install the Wheel Hop Kit with the fuel tank removed e A
21. of insulation off the end of the intercooler wire and connect to the red wire using the provided splice connector from the Intercooler Pump Wiring Harness Kit and crimp using a W type crimping tool Using a clean hot soldering iron heat the wires not the solder in the splice connector until they are hot enough to melt the solder touched to them Slide the heat shrink tubing over the solder joint and heat to shrink with a heat gun Reinstall the convoluted tubing and tape removed from the factory harness Heat Shrink Tubing Intercooler Pump ire 1305SS TVSIM BA 20130911 Page 46 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 11 Plug the connector back together Route the remainder of the Intercooler Pump Wiring Harness over the radiator following the existing harness behind the headlamp on the driver side and into the inner fender area where the water pump bracket is mounted Remove the top water pump bracket mounting bolt and install the wiring harness ground eyelet and re torque the fastener Connect the wiring harness to the electric water pump he zal a i Jj WEE a Ground the pump wiring harness to the body in this location 1305SS TVSIM BA 20130911 Page 47 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION C
22. striped end of the Gray IAT wire into one side of the provided splice connector From the Electrical Jumper ACT slide the ACT SIGNAL wire into the other side of the splice connector and crimp using a W type crimping tool Using a clean hot soldering iron heat the wires not the solder in the splice connector until they are hot enough to melt the solder touched to them Repeat the above for the IATRTN ACT GROUND Slide the heat shrink tubing over the solder joints and heat to shrink with a heat gun Position the ACT harness so that the base of the connector is 180mm from the main bundle Wrap ACT and MAF harness with tape Provided ACT Connector E e ACT Signal Heat Shrink Tubing uu Gray fred 1305SS TVSIM BA 20130911 Page 27 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 Pull the 2 wire ETC electronic throttle control wiring loose from the main harness and drag it back to 20mm past the 8 coil break out point Position the ETC connector so that the base of the connector is 165mm from the main bundle 6 Slide the driver side of the harness back into its convoluted tubing and re tape Wrap the ECT wiring with tape 7 Move the front 2 harness retainers on driver s side coil harness from the bottom side to the top side of the harness leaving the rear retainer on the bottom side Remove the
23. to the ground screw directly above the relay Remove the ground screw and install the I C Pump ground wire with all the factory grounds that were already in place with the bolt Torque the bolt to 8 12Nm 8 Locate the square 16 pin connector on the driver side of the PCM bracket Unplug the connector and remove the short section of convoluted tubing and electrical tape from the harness immediately behind the engine side rearward half as mounted of the connector Locate the red w yellow stripe wire in pin location 16 Cut this red wire about 1 inch back from the connector Red vellow stripe 16 HFA Y i i 2 4 T E AT f t l ligi J i y a ee Y A j 7 l N A 4l N 1 Ziv is S a Ww CN V NYA N QA Y 1305SS TVSIM BA 20130911 Page 45 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 Seal the connector end of the red wire using one piece of heat shrink provided with the Intercooler Pump Wiring Harness Kit R07080016 1 wire and tubing c7 i 3 heating M 4 sealedifinished Sealing cut wire ends with Heat Shrink tubing 10 Strip approximately 3 8 of insulation off the harness side of the red w yellow wire Place a piece of supplied heat shrink tubing over the remaining non terminated end of the Intercooler Pump Wiring Harness Strip approximately 3 8
24. using 4 M6 x 1 0 x 32 5 screws R18020009 Torque to 8 12 Nm 1305SS TVSIM BA 2013091 1 Page 66 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 2 Connect TPS and ETC M MR S elias Lun ae nad a 1305SS TVSIM BA 20130911 Page 67 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 29 Install the Intercooler Tube Assembly R07070005 onto the passenger side cylinder head using the M16 x 40mm Tube Mounting Bolt R18020006 for the rear and 1 M6 x 1 0 x 18 I C Tube Mounting Bolt N605891 Torque the M16 bolt to 43 47Nm and the M6 bolt to 8 12Nm 30 Reconnect the stock 5 8 heater hose from the firewall to the modified heater tube located on the rear of the passenger side cylinder head using the original constant tension clamp 31 Install the 34 x 190 9mm Intercooler Inlet hose R07060173 from A to A using 2 4 constant tension clamps Install the 277 x 286 2mm Intercooler Outlet hose R07060174 from B to B using 2 4 constant tension clamps 1305SS TVSIM BA 2013091 1 Page 68 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 32 Reconnect the stock 3 4 heater hose from the firewall by routing it under the intercooler hoses
25. 7 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES RPP Part Description Number Supplemental Hardware 1305 TVSHK1 1 Alternator Charge Harness 2009 Only Rear Alternator Support Bracket 2005 08 Only Bolt Rear Alt Supt Brkt M8 x 20mm Description RPP PartNumber Qty Unique Phase 1 Hardware Pulley S C Bolt On 6K x 105mm 6K105 6V066 FEAD Belt R07020041 CALKIT 130RPICALKT 1 ROUSH Diagnostic Tool Flash Manual P1305 P1 Description RPP Part Number Qty Unique Phase 2 Hardware Nut M6 2 FPDM Retention CALKIT 130 amp P2CALKT 1 P1305 P2 1305SS TVSIM BA 2013091 1 Page 5 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES ACT CMCV ETC IPTS MAFS PCM PCV RDT SCBP TPS VMV VCT Breakout Point 1305SS TVSIM BA 20130911 EQUIPMENT AND SUPPLIES REQUIRED 1 4 and 3 8 Drive Ratchets with Extensions Metric and Standard Socket Sets short and deep recommended 1 2 Drive Ratchet or Breaker Bar Metric and Standard Wrench Sets 3 8 Drive Torque Wrench 7 35 ft lb range Short Phillips head Screwdriver Hex Key Set Teflon pipe sealing tape or equivalent 5 8 Fuel Line Removal Tool T 20 Torx Bit Screwdriver or Socket Soldering Iron and Solder Wire Stripp
26. 8020007 from the Hardware kit in place of the 4 which were just removed Insert the Intercooler Radiator Assembly R07070047 behind the bumper and between the frame rails aligning the holes in the bracket with the weld nuts for the inner bumper bolts Snug the inner bumper bolts threading them through the bracket holes and torque to 20 30 Nm Install the 4 LTR Mounting Nuts W520413 from the Hardware Kit on the exposed end of the long bumper bolts and torque to 20 30 Nm E i s zw 4 _____ A w i ra 7 hl y i Intercooler Radiator Assembly Mibi a FS m i i l k n m ie E 8 Reinstall the impact absorber onto the front bumper beam using the take out pushpins 9 Install the 12 77 LTR Inlet Hose on the driver side of LTR with one 34 Hose Clamp and leave hanging Install the 33 LTR Outlet Hose on the passenger side of the LTR with one 24 Hose Clamp and route up through the fender and into the engine compartment as illustrated below 1305SS TVSIM BA 20130911 Page 40 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Electric Water Pump Bracket Mountin 1 Cut out the following template Line up the template with the tie down bracket inside the driver side wheel well Center punch the X s marked on the template into the frame rail of the vehicle Drill two 4 holes through the frame rail and de
27. AL INJURY WARNING THIS PROCEDURE INVOLVES FUEL HANDLING BE PREPARED FOR SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY 1 WARNING FUEL LEVEL MUST BE AT 4 OF A TANK OR LOWER OR FUEL SPILLAGE WILL OCCUR WHEN FUEL MODULE IS REMOVED STEP 1 Release fuel system pressure 1A The fuel pump relay can be found in the bussed electrical center The fuel pump relay is located in position 21 as shown in the inside cover of the bussed electrical center Remove the fuel pump relay see Fig 1 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 1 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIINIG s INSTRUCTION SHEET Pe Fe PE a EO aN NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 1 1B Start the engine and allow it to idle until it stalls If engine does not start proceed to STEP 1D 1C After the engine stalls crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released 1D Turn the ignition switch to the OFF position 1 WARNING BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES THEREFORE DO NOT ALLOW FLAMES SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY WHEN CHARGING OR WORKING
28. E WITH POLLUTION CONTROLLED VEHICLES 2 Raise the vehicle and remove both front tires 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 3 Remove the 3 lower close out to radiator support screws 7mm Remove the 2 upper bumper cover screws near the headlights 10mm Remove the 4 front fender to bumper cover nuts inside the forward wheel well 10mm Upper Bumper Cover Screws Fender to Bumper Close out screws Cover Nuts 1305SS TVSIM BA 2013091 1 Page 38 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 4 Reach inside the front wheel wells and unplug the front turn signals there are four connectors total Lift the front bumper cover slightly and pull partially off of the vehicle Unplug the fog lights and set the front bumper cover aside 9 Remove the four push pins that retain the impact absorber to the front bumper beam and set the absorber aside i Hl lia Pi Ny 5 LI 1 OOT n a TE a al le G z E a 1305SS TVSIM BA 20130911 Page 39 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 7 Loosely install the 4 Long Bumper Bolts R1
29. F FORD RACING PERFORMANCE PARTS STEP 11 Using a fuel tank lock ring wrench or a brass punch remove the fuel pump retaining lock ring see Figs 7 8 Fig 7 Fig 8 CAUTION The fuel pump must be handled carefully to avoid damage to the float arm filter and convolute hoses STEP 12 Carefully lift the fuel pump out of the fuel tank enough to access and release the fuel cross over tube quick connect coupling from the fuel pump see Fig 9 Fig 9 STEP 13 Completely remove the fuel pump from the fuel tank see Fig 10 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 6 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIINIG s INSTRUCTION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 10 CAUTION Inspect the surfaces of the fuel pump mounting flange and fuel tank O ring seal contact surfaces Do not polish or adjust the O ring seal contact area of the fuel tank flange or the fuel tank Install a new fuel tank if the O ring seal contact area is bent scratched or corroded CAUTION Make sure to install a new fuel pump O ring seal and lock ring STEP 14 To install apply clean engine oil to the O ring seal STEP 15 Install new fuel pump O ring seal see Fig 11 Fig 11 STEP 16 Position the dual fuel pump
30. M6 bolt to 8 12Nm and torque the M8 bolt to 22 26Nm 41 Check induction system to make sure everything is secured and at the required torque specification 42 Connect the MAF sensor 1305SS TVSIM BA 20130911 Page 72 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 43 Install the PCV Fresh Air tube R07050083 by connecting the 90 deg fitting to the passenger side cam cover and running the tube over the supercharger and connecting the straight fitting to the rubber clean air tube 1305SS TVSIM BA 20130911 Page 73 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Battery and Tray 1 Install the battery tray by reversing the removal instructions Torque the battery tray bolts to 8 12 Nm 2 Place the battery in the tray and secure with battery hold down Torque the battery hold down bolt to 8 12 Nm Reinstall the heat protecting battery wrap over the battery 3 Connect the B Alternator Harness to the positive battery terminal Torque nut to 8 12Nm 4 Reinstall the battery connections by connecting the positive cable first then connecting the negative cable 1305SS TVSIM BA 20130911 Page 74 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES
31. NEAR A BATTERY ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES ALWAYS PROVIDE VENTILATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY WARNING KEEP OUT OF THE REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH THE SKIN OR EYES FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION IF ACID IS SWALLOWED CALL A PHYSICIAN IMMEDIATELY FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY STEP 2 Disconnect battery ground terminal see Fig 2 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 2 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIINIG s s INSTRUCTION SHEET NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 2 STEP 3 The fuel level in the tank should be 34 of a tank or less before proceeding If fuel exceeds more than 34 of a tank then follow STEPS 4 6 If fuel level is 34 of a tank or less then proceed to STEP 7 STEP 4 Remove the fuel tank filler cap STEP 5 Insert a suitable drain hose into the fuel tank filler pipe until it reaches the fuel tank inlet tube CAUTION The fuel pump
32. NLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 Install the modified heater tube assembly using the take out stud bolt Be sure to lube the O rings with assembly lube before installing the heater tube to the water pump fitting in the block Torque the stud to 8 12 Nm Fr ey he P i pe RP uL 6 Carefully place the intake manifold assembly with gaskets down onto the cylinder heads Be carefully not to damage your sealing surfaces or gaskets during this step Take special care to ensure that the CHT wiring harness does not get pinched or trapped during manifold installation Insert 2 M6 x 1 0 x 40 bolts R18020004 in holes A and B as shown and start threads by hand Do NOT tighten these fasteners The intake must remain free to move along the cylinder head surfaces 1305SS TVSIM BA 2013091 1 Page 50 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 7 Install the Alternator Bracket R07020035 onto the studs previously used to mount the alternator to the cylinder block and temporarily secure the bracket using the stock nuts Use the FEAD bracket rear mounting bosses to properly align the intake manifold on the cylinder head surfaces by shifting the manifold from front to back and side to side When you are finished these features should be aligned in both the for aft and side to side directions 8 Once aligned fasten the
33. OLLUTION CONTROLLED VEHICLES 14 2005 08 VEHICLES ONLY Route the B cable through the grounding strap and secure it to the dash using 1 Stud Mount Zip Tie R18080003 Push the Zip Tie onto the M6 Bolt from the previous step then wrap the zip tie around the cable 2009 Vehicles please refer to Section E on Page 79 15 2005 08 VEHICLES ONLY Secure the B cable to the dash by pushing the retainer Christmas tree to the factory dash panel tab 2009 Vehicles please refer to Section E on Page 79 ol i t QU BA J N 1305SS TVSIM BA 20130911 Page 61 of 87 1 800 59 ROUSH Y i ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 16 Using the take off M8 nut fasten the driver side radio suppressor to the driver side front cover stud Before tightening ensure there is sufficient clearance to all FEAD components Torque to 23 2 Nm Use a screwdriver to bend the tab around the back of the stud 17 Using the take off M8 nut fasten the passenger side radio suppressor to the passenger side front cover stud Before tightening ensure there is sufficient clearance to all FEAD components Torque nut to 23 27 Nm Bend the tab around the back of the stud 1305SS TVSIM BA 20130911 Page 62 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 18 2005
34. ONTROLLED VEHICLES Lower Radiator Hose Installation 1 2005 06 VEHICLES ONLY Install the Lower Radiator Hose 7R33 8B273 AA by sliding the hose onto the outlet at the bottom corner of the radiator Then push the hose on to the fitting on the oil filter adapter Connect the smaller hose to the bottom of the degas bottle Secure each point with the clamps that are glued onto the hose 1305SS TVSIM BA 20130911 Page 48 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Engine Hardware and ROUSHCharger Installation 1 Using the take off bolts install the FEAD tensioner R07020043 Torque bolts to 20 30 Nm 2 Remove the factory spark plugs and coils from the engine NOTE Customers with 2005 07 vehicles and 2008 vehicles with AA level engines only use the supplied 14mm plugs HTO 032 Customers with 2008 vehicles with AB level engines and customers with 2009 vehicles with 12mm plugs Ford P N 8LSE 12405 BB must gap their factory spark plugs to 0 032 0 002 3 Install either the newly supplied HTO 032 plugs 14mm plugs or regapped 12mm plugs depending on your engine configuration Torque 14mm plugs to 30 38 Nm Torque 12mm plugs to 10 15 Nm 4 Reinstall the coils and torque coil bolts to 4 6 Nm 1305SS TVSIM BA 20130911 Page 49 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE O
35. RESULTING FROM THE INSTALLATION OR USE OF ANY PRODUCT SOLD THROUGH THIS CATALOG OR ARISING OUT OF ANY BREACH OF WARRANTY EXCEPT AS MAY BE STATED IN THIS CATALOG ROUSH DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL ROUSH S LIABILITY EXCEED THE PRICE PAID BY CUSTOMER DEALER FOR PRODUCTS SOLD REGARDLESS IF ROUSH HAS BEEN ADVISED IN ADVANCE OF ANY POTENTIAL PROBLEM OR IF A CLAIM IS BASED ON CONTRACT TORT STRICT LIABILITY PRODUCT LIABILITY OR OTHERWISE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF IMPLIED WARRANTIES OR THEIR DURATION OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY This ROUSH Supercharger kit is designed and tested to function properly only on vehicles as they are equipped from the factory completely stock powertrain The use of aftermarket parts and equipment such as cams headers nitrous oxide systems other bolt on performance parts or any other performance parts not sold by manufactured by or approved of in writing by ROUSH will result in powertrain and supercharger kit damage and will not be the responsibility of ROUSH in any way 1305SS TVSIM BA 2013091 1 Page 86 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES APPENDIX A FORD RACING MUSTANG GT DUAL FUEL PUMP KIT
36. ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 2005 09 R2300 Phase 1 amp 2 ROUSHCharger Kits Single Sheave P Ns 130558 TVSP1 1305SS TVSP2 NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Installation Instructions Applications 2005 09 Ford Mustang GT with 4 6L 3V engine w Manual Transmissions ONLY Important Notes T Vv M Before installing your Mustang ROUSHCharger Kit please read the installation manual and verify that all items are present Contact ROUSH Customer Service at 1 800 59 ROUSH 9 00 AM to 5 00 PM weekdays for any questions regarding fit or instructions that are unclear to you 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 These chemicals can damage your engine and cause drivability issues with your vehicle Operating your engine without the Roush PCM recalibration will result in engine damage or failure Customers with 2005 07 and 2008 with AA level engines vehicles have high thread HT 14mm spark plugs These customers will receive colder replacement 14mm plugs from Roush when their PCM is returned to them Customers with 2008 with AB level engines and 2009 vehicles have 12mm spark plugs Ford P N 8L3E 12405 BB These customers MUST gap their plugs to 0 032 0 002
37. SH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Warranty All retail parts carry a 90 day warranty from the date of purchase This warranty covers defects in materials or workmanship and does not include i normal wear and tear environmental conditions improper installation ii road hazards misuse abuse neglect accidents collision fire theft freezing vandalism riot explosion or objects striking the vehicle iii misusing the vehicle such as driving over curbs overloading racing or using the vehicle as a stationary power source iv altering disassembling or modifying the parts v defects caused or induced by failures breakdowns or damage by other parts components or the vehicle vi subjecting the parts to excessive moisture or water or any motor vehicle fluids e g oil anti freeze battery acid brake fluid etc vii acts of God natural disasters and other similar causes beyond the reasonable control of ROUSH or viii application of chemicals that affect the parts This Limited Warranty does not cover surface deterioration of paint trim and appearance items that result from use and or exposure to the elements such as stone chips scratches bird droppings lightning hail windstorm dings dents earthquake road salt tree sap water or flood ROUSH SHALL NOT BE LIABLE TO REIMBURSE CUSTOMER DEALER FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES
38. TION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 5 CAUTION If the liquid or vapor tube is damaged torn holes or delaminated the effected tube assembly must be replaced with a new tube assembly Do not use aftermarket sleeving Do not re adhere loose sleeving material CAUTION When reusing liquid or vapor tube connectors make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube Apply clean engine oil to the end of the tube before inserting the tube into the connector CAUTION Fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness be observed when working with these components Always install blanking plugs to any open orifices or tubes STEP 10 Disconnect the fuel tube quick connect coupling on the fuel pump 10A Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect see Fig 6 Fig 6 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 5 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIING s INSTRUCTION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION O
39. Vacuum System Connections 1 Install the modified VMV hose such that the 90 deg fitting is connected to throttle body spacer and the straight fitting is connected to the VMV s upper port 1305SS TVSIM BA 20130911 Page 75 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 2 Connect the modified brake booster hose assembly onto the throttle body spacer Peeeeeaaanr 3 Connect the 7 32 vacuum hose from the T fitting to the UPPER fitting on the supercharger bypass valve this will be the fitting closest to the dash panel The bottom lower fitting MUST remain open to atmosphere for the supercharger bypass system to function properly 1305SS TVSIM BA 20130911 Page 76 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Coolant Fill and Final Assembl 1 2 Fill 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 trap
40. able at the fuse box Note The bolt will remain retained by the cable s terminal end 2 Locate the fuse holder branch of the Intercooler Pump Harness R07080016 Run the short lead with the eyelet from the fuse holder to the Fuse box battery terminal 1305SS TVSIM BA 20130911 Page 43 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 3 Reinstall the battery cable bolt through the I C fuse lead and the main battery cable Torque the bolt to 8 12Nm 4 Secure the fuse holder to the strut tower using a M6 x 1 0 x 14 bolt N605771 from Hardware kit threaded into the tapped hole in the strut tower across from the fuse box s main battery terminal Torque bolt to 8 12 Nm 9 Route the remaining I C pump harness with the vehicle harness around the driver side of the PCM bracket to the space ahead of the PCM connectors 6 Locate the M6 bolt threads protruding from the core support into the engine compartment ahead of the PCM brackets Slide the I C pump relay s bracket over this stud and secure with a M6 nut W520412 Torque the nut to 8 12Nm Nee 6mm Bolt threads SS M p DAK D P Vehicle N IN Ao 1305SS TVSIM BA 20130911 Page 44 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Route the ground wire branch of the harness up
41. all the FEAD belt as shown Using a 77 drive breaker bar or ratchet rotate the belt tensioner clockwise to install the supplied belt 22 Connect the rubber heater tube inlet hose R07070067 to the steel heater water inlet tube R07070063 using 1 74 constant tension clamp Install this assembly onto the engine by connecting the rubber hose to the 90 deg fitting on the intake using 1 constant tension clamp and fasten the steel tube to the supercharger studs using 2 M6 nuts W520412 JA E CN a AUD LU ra m 1 i l h Ts A k 2 T ne _ _ _ _ h E SE Fy OS oe 4 sam Sane i T Ba Ios T IU T TOC T 1305SS TVSIM BA 20130911 Page 64 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 23 Connect the fuel inlet line to the fuel rail and secure it using the safety clip 24 Install the throttle body spacer gasket R07060152 and the throttle body gasket R07060153 in the throttle body spacer R07060147 1305SS TVSIM BA 2013091 1 Page 65 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 25 Fasten the throttle body spacer to the supercharger using 4 M6 x 1 0 x 32 5 screws R18020009 and torque to 8 12 Nm c fe re AEN 26 Install throttle body onto the throttle body spacer
42. and fuel level sensor will be below the fuel level in the tank when the tank is full Make sure to drain of the fuel capacity through the filler pipe prior to removing the pumps or fuel spillage will occur STEP 6 Attach the fuel storage tanker to the fuel drain hose and remove as much fuel as possible from the fuel tank filler pipe The fuel tank has a 16 gallon capacity The removal of 4 gallons would lower the fuel level of a tank STEP 7 Remove the rear seat bottom and any insulation padding covering the fuel pump access cover 7A From under the front of the rear cushion assembly push in the seat cushion release tab located on the left and right of the seat lift and remove the rear cushion assembly see Fig 3 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 3 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLATIUNE s INSTRUCTION SHEET Plat Hae aa CL AFET SS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 3 STEP 8 Remove the fuel pump access cover see Fig 4 Fig 4 STEP 9 Disconnect the fuel pump electrical connector see Fig 5 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 4 of 15 M 9407 GTO5 Mustang GT Dual Fuel Pump Kit TLACIING s INSTRUC
43. block i AT T y Ul I M iL 6 16 2005 06 VEHICLES ONLY Locate the coolant hose hanger on the front of the engine and remove 1305SS TVSIM BA 20130911 Page 17 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 17 Remove the tensioner and retain the bolts for reuse later 1305SS TVSIM BA 20130911 Page 18 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 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 intercooler pump bracket mounting all of this work can be performed away from the vehicle Alternator Modification In order for the alternator to be installed in its new location two of the original mounting ears must be removed Using a band saw or similar cutting tool remove the mounting ears shown Be careful to avoid getting debris inside of the alternator when removing these features 2005 08 Alternators should look similar to the pictures below EN ae e Ps Before SS SS fj SS 1305SS TVSIM BA 20130911 Page 19 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES VMV Modificati
44. burr the holes Cut this out and use as a template to locate holes 2 Install 2 J Clips N623332 from Hardware Kit and mount the Intercooler Pump Mounting Bracket R07070015 using Bolts N605891 onto the body Torque bolts to 8 12Nm Slide the Intercooler Pump F8YZ 8501 AA into the bracket and secure using the bumper bolt removed earlier and a M8 Nut W520413 from Hardware Kit Torque the nut and bolt to 8 12Nm l mr A l in aa EE M Use take off bumper bolt in this location 1305SS TVSIM BA 20130911 Page 41 or 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES This page is intentionally left blank 1305SS TVSIM BA 20130911 Page 42 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 3 Connect the 12 772 LTR Inlet Hose previously installed to LTR to the outlet of the pump with a 4 Hose Clamp Install the 31 Degas Bottle Outlet Hose onto the pump inlet with a 34 Hose Clamp Route the Degas Bottle Outlet Hose up through the fender to the Degas Bottle as ee TIO a Note Route all intercooler hoses very carefully It is critical to the intercooler performance that these hoses are not kinked once installed into the vehicle Electric Water Pump Harness 1 Disconnect the positive battery leads from the main positive battery c
45. c fasteners Insert new XA m Ait Re bolt here Hmm Remove plastic EMI LT AUTE TE fasteners ull nity p MET rii JOU JUser JUUUUUUUUUUUUBPUIN E Hi H lt K j Pull io mmu m 1305SS TVSIM BA 2013091 1 Page 83 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 Route the alternator charge harness through the grounding strap and secure it to the dash using 1 Stud Mount Zip Tie R18080003 Push the Zip Tie onto the M6 Bolt from the previous step then wrap the zip tie around the cable 6 Secure the alternator charge harness to the dash by pushing the retainer Christmas tree to the factory dash panel tab 1305SS TVSIM BA 20130911 Page 84 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 7 Run the remaining smart charge section of the charge harness with the battery harness that runs along passenger side strut tower and secure it using the zip ties that have been pre installed on the charge harness Route wires under the main wiring harness bundle and plug into the connector T x Satis ts d d be 3 Ww wd At X M e Ne SR An A WARE ros A Ta Route wires WN ie under main Y av YS nM wf p A V S X w a i PO S 1305SS TVSIM BA 2013091 1 Page 85 of 87 1 800 59 ROU
46. cluster bezel on the flat area below the small center gauges 10 The Premium Fuel white decal with black lettering R07110003 is to be placed on the lower half of the inside of the fuel filler door 11 If performing the PCM Flash procedure proceed to the PCM Flashing section If the PCM was sent to ROUSH for the Optional ROUSH Performed Flash and it has been reinstalled start the engine and check for unusual noise dash service lights and or unusual operation If problems are detected immediately stop the engine or vehicle diagnose and repair the problem 1305SS TVSIM BA 20130911 Page 78 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES PCM FLASHING 1 If equipped with a SAE J2534 pass through device refer to the RDT CALIM manual included in the CALKIT for PCM flashing The RDT CALIM manual will guide you through the ROUSH Diagnostic Tool RDT software installation process and the ROUSH POM flashing procedure OPERATING THE ENGINE WITHOUT THE RECALIBRATED PCM WILL RESULT IN ENGINE DAMAGE OR FAILURE AND WILL VOID THE WARRANTY 2 Once the PCM has been successfully re calibrated 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 1305SS TVSIM BA 20130911 Page 79 of 87 1 800 59 ROUSH ROUSH
47. de the smart charge harness R07080033 underneath the front cover of the supercharger behind the FEAD bracket so that the round connector is on the passenger side of the engine 2009 Vehicles please refer to Section E on Page 79 2 2005 08 VEHICLES ONLY Connect the alternator smart charge harness by routing the harness as shown 2009 Vehicles please refer to Section E on Page 79 1305SS TVSIM BA 2013091 1 Page 55 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 3 Connect injector 41 4 and coil 1 3 4 Move the main harness on top of coil 4 and plug in coil 4 around it ZEN M Um De SA ZEE PP Ah A CALAMI IJ LEM j M ax fE 3 gt ne tw v e s 1305SS TVSIM BA 20130911 Page 56 of 87 1 800 59 ROUSH ROUSH OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 6 Drape the TPS harness breakout in between the driver side fuel rail and the supercharger 7 Install the rear harness retaining clip on the stud in the back of the intake manifold 1305SS TVSIM BA 20130911 Page 57 of 87 1 800 59 ROUSH THE OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 8 Push the two retaining clips onto the studs on the LH cam cover Connect injectors 45 8 and coils 5 8 h DEDE NEO
48. e Products RPP reserves the right to revise the information presented herein or to discontinue the production of parts described at any time SAFETY REQUIREMENTS STOP READ IMPORTANT SAFETY CAUTIONS AND WARNINGS BEFORE PROCEEDING IMPORTANT SAFETY NOTICE 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 actual installation Always wear safety glasses for eye protection Place ignition switch in the OFF position Always apply the parking brake when working on a vehicle Block the front and rear tire surface to prevent unexpected vehicle movement If working without a lift always consult vehicle manual for correct lifting specifications 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 in well ventilated areas Batteries produce explosive gases which can cause personal injury Therefore do not allow flames sparks or flammable substances to come near the battery 10 Keeps hands and any other objects away from the radiator fan blades 11 Keep yourself and your clothing away from moving parts when the engine is runn
49. ent Page 6 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 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 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 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 ROUSH Performanc
50. ers Wire Crimpers W type for OEM style wiring connectors 1 8 9 64 and Drill Bits and Drill motor Coolant meeting G 05 specification 6 Scale Tape Measure or Other Measuring Device Brake Parts Cleaner Assembly Lubricant White Lithium Grease or Petroleum Jelly Electrical Tape Sharp Knife or Razor Blade Tie Straps Zip Ties Trim Pad Tool for pushpin removal Fender Cover 2 Medium Strength Thread Locker Loctite 242 blue or equivalent GLOSSARY OF TERMS 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 Charge Motion Control Valve Located on the back of the base intake manifold This feature is not used with the ROUSHCharger Electronic Throttle Control Injection Pressure and Temperature Sensor Mass Air Flow Sensor Powertrain Control Module a k a ECM ECU PCU EEC Positive Crankcase Ventilation ROUSH Diagnostic Tool Supercharger Control Bypass Solenoid A 3 way electronic vacuum control solenoid that allows the PCM to control the ROUSHCharger bypass to reduce heat buildup and noise during low throttle operation Throttle Position Sensor Vapor Management Valve Located on driver side strut tower Variable Camshaft Timing 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 compon
51. factory retainers wherever possible Expose all of the internal wiring from the MAF ETC split all the way around to the rear of the driver side cam cover 2 Locate the 6 wire MAF sensor connector Looking into the face of the connector with the release tab positioned up the first two wires in the connector IAT from the right are grey and grey w red tracer Cut both of these wires approximately 5 to 6 inches from the back of the connector MAF IAT Sensor SDI Slot In Gry wi Red Tracer 1305SS TVSIM BA 20130911 Page 26 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 3 Seal the connector side of both cut IAT wires with pieces of heat shrink provided in the ACT electrical jumper 1104 12B637 BA Place two pieces of heat shrink tubing halfway onto the ends of the wires to be sealed and heat with a heat gun until it stops shrinking and sealant flows out from the open end of the tubing 1 wire and tubing a fae 3 heating 4 sealedifinished Sealing cut wire ends with Heat Shrink tubing 4 Drag the 2 IAT wires out of the harness back from the MAF connector so that they break out 60mm past the 6 Coil Connector Strip a inch of insulation from the end of each wire Slide a short length of heat shrink tubing over both wires Now using the Electrical Jumper ACT from the kit 1104 12B637 BA lay the
52. ing 12 Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch surface finishes 13 Allow the engine cooling system brakes and exhaust to cool before working on a vehicle WORK SAFELY Perform this installation on a good clean level surface for maximum safety and with the engine turned off o DD CO pras eu 1305SS TVSIM BA 20130911 Page 7 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 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 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 Z h 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
53. intake manifold using 11 M6 x 1 0 x 40 supplied bolts R18020004 and the stock driver side rear stud in hole 10 used to retain the wiring harness Tighten these fasteners in the sequence shown below and torque all to 8 12 Nm Remove the alternator bracket from the engine as it will be installed in a later step 1305SS TVSIM BA 20130911 Page 51 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 Fasten the supercharger to the intake manifold using 8 M8 x 1 25 x 56 bolts N808130 and 2 M6 x 15 M8 x 53 studs R18040007 in holes 1 and 5 Torque fasteners in three steps 10Nm 20Nm and 30Nm in the sequence shown A Y p x AN d 10 Connect the PCV bubbler hose to the 90 deg fitting on the back of the supercharger using 1 of the supplied 3 8 constant tension clamps JEEZY 1305SS TVSIM BA 20130911 Page 52 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 11 Re install the FEAD bracket using 2 take off M8 nuts for mounting to old alternator studs 2 M8 x 1 25 x 38 bolts W705128 for fastening to the upper intake manifold and 1 M8 x 1 25 x 110 bolt R18020058 with 1 spacer R18030017 to fasten to the supercharger First hand tighten every bolt then torque the M8 nuts to 20 30 Nm then torque the middle M8 bolts to
54. llation and torque to 8 12 Nm 3 Install the air filter R07060131 to the clean air tube and align the metal strip on the air filter with the alignment mark on the clean air tube Torque the worm drive clamp to 3 Nm 1305SS TVSIM BA 20130911 Page 31 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 4 Install rubber Grommet and Sleeve Assembly R07130013 by first installing the rubber grommet into the Shelby Air Box Assembly R07130039 Once the grommet is firmly seated in position re install the metal sleeve into the grommet 5 Assemble the air tube and filter onto the air box housing using 2 bolts N605771 and torque to 8 12 Nm 1305SS TVSIM BA 20130911 Page 32 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES S C Pulley Install 1 Install the S C Pulley onto the Supercharger P51AGH 6F066 using the six 6 N605771 bolts M6 x 14 provided Ensure the pulley is properly seated on the hub before tightening any bolts Torque bolts to 8 12 Nm Fuel Rail Assembly 1 Install the new injector clips 13109C995 onto the new Fuel Injectors R07110007 from Hardware Kit B Apply assembly lube to the injector O rings and install the injectors into the new Fuel Rail R07110006 Verify that the injector clips are properly seated and fully engaged
55. lt FEAD Bracket to Intake M8 x 38 Bolt Alternator Bracket to S C M8 x 110 Nut Alternator M8 1305SS TVSIM BA 20130911 Page 2 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Spacer Alternator Bracket To S C 3 8 ID x 3 4 OD x 3 8 RPP Part Description Number Induction System T ai Clean Air Tube Assembly Shelby Clean Air Tube Air Filter High Flow Conical Shelby Air Box Assembly Qty RPP Part Qt Description Number y Induction System Hardware Kit R07130040 1 RPP Part Description Number PCV Fresh Air Inlet R07050083 PCV Purge Hose R07050084 7 32 Vacuum Hose IPTS to Upper Intake Manifold R18140001 Qty RPP Part Qt Description Number y Hardware Kit Wiring R0708005 1 Zip Tie Stud Mount Ground Strap Bolt Nut I C Relay Mounting M6 1305SS TVSIM BA 2013091 1 Page 3 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Description RPP Part Number Qty Hardware Kit Single Sheave Decals SS TVSHK2 AA 1 Decal Single Sheave Belt Routing Diagram Decal Premium Fuel Only IP Cluster Decal Premium Fuel Only Fuel Door RPP Part Description Number Intercooler System i NX Degas Bottle I C Electric Water Pump Bracket I C Pump Mounting Intercooler
56. n properly with the new components Please complete the Optional Roush PCM Flash request document and include it along with the PCM and the Voucher Card Once we receive your POM we will reprogram and 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 Using bubble wrap or another appropriate packing material wrap and package the PCM to help prevent it from being damaged during shipping e Place the wrapped PCM in an appropriate shipping box e Complete the Optional ROUSH PCM Flash request document PCM FLASHDOC and attach the flash Voucher Card P1305 P1CALKIT P1305 P2CALKIT to the document e Include the Optional ROUSH PCM Flash document and the Voucher Card in the shipping box along with the PCM e Ship the PCM and contents to ATTN PCM FLASH 39555 Schoolcraft Rd Plymouth MI 48170 Upon receipt of the PCM a customer service representative will contact you to arrange payment Once you receive your ROUSH flashed PCM reverse step 4 fo
57. ntinue with step 4 4 Disconnect the 3 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 Ll i JH Ti fs Y d are l 5 p BLUE d a or gg gg i i fi I E i z pug Fa j LS 6C I if 3 j P ou Lh Jo A PF ih fa s i z Fi i Ld I LRL in 7 i at eu n i i i i i fou I i 1 I _ i i ia i La a E f nr m m h ti fe fey BIEN L1 J I Tia A j FL 5 I Tg jl l i 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 1305SS TVSIM BA 20130911 Page 10 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 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 ru
58. on 1 Remove split loom convolute from stock VMV hose assembly 2 Mark hose at 130mm 5 25in from end of straight connector 3 Using a knife cut the hose at the applied mark 1305SS TVSIM BA 20130911 Page 20 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 4 Using a knife cut the hose as shown to remove the straight connector from the cut off piece of VMV hose 9 Re install straight connector into shortened VMV hose 6 Using a knife cut off 100mm 4 in of split loom convolute to fit the shortened VMV line Re install the split loom convolute onto the modified VMV hose 1305SS TVSIM BA 20130911 Page 21 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Brake Booster Hose Modification Note This modification does not require removal of the hose from the booster Removing the hose from the booster could damage the booster fitting 1 Remove the split loom convolute from brake booster hose Remove the T fitting with the 7 32 vacuum hose and the short hose from the brake booster hose assembly 2 Remove and keep T fitting with the 7 32 vacuum hose and hose clamp from the take off brake booster hose Discard short section of the brake booster hose Discard 3 Remove and discard the 7 32 vacuum hose retaining clip Measu
59. ors 8 Remove the four 8mm stud bolts holding the fuel rail to the intake manifold and remove the fuel rail assembly with injectors There may be some additional fuel leakage around the injectors Clean all excess fuel before proceeding 1305SS TVSIM BA 20130911 Page 14 of 87 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 12 Disconnect the CMCV connector located in the center rear of the intake manifold Remove the brake booster vacuum line from the intake manifold Pull the wiring harness off of the stud bolt on the driver side rear of intake manifold Remove the ten fasteners which used to bolt the intake manifold to the cylinder heads Save the rear stud for reuse Remove the intake manifold Use tape or equivalent to cover the cylinder head ports to prevent engine contamination Brake Booster Hose if ft i d Ax A Y WA A j Y Intake Manifold Bolts A J W pu X A L l old down wr ID 2 13 Release the accessory drive belt by rotating the tensioner clockwise with a 2 breaker bar or ratchet and slip the belt off the water pump pulley and remove the belt Disconnect the regulator connector and the battery cable from the alternator Using a 10mm socket wrench remove the four upper support bracket bolts Remove the two 15mm alternator nuts and remove the alternator ZA NX mU VE p a hn A fi a 1 ra Pi ie ae is E i
60. ped 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 issues Use zip ties to safely position the harness away from any areas of concern If the PCM was removed and shipped to ROUSH for a ROUSH performed flash reinstall it once the PCM is returned from ROUSH and apply PCM decal R07100008 If you are equipped with a SAE J2534 pass through device refer to the PCM Flashing section when installation is complete DO NOT ATTEMPT TO REINSTALL THE PCM AND START THE VEHICLE IF THE PCM IS NOT EQUIPPED WITH A ROUSH CALIBRATION OPERATING THE ENGINE WITHOUT THE RECALIBRATED PCM WILL RESULT IN ENGINE DAMAGE OR FAILURE AND WILL VOID THE WARRANTY Reinstall the battery connections by connecting the positive cable first then connecting the negative cable The Belt Routing Diagram 13106E072 is to be placed on the underside of the hood on the driver side opposite of the factory Vehicle Emission Control Information decal 1305SS TVSIM BA 20130911 Page 77 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 The Premium Fuel clear decal with white lettering R07110004 is to be installed on the instrument
61. r PCM installation 1305SS TVSIM BA 20130911 Page 11 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 9 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 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 6 Disconnect the PCV vent tube from the right hand cam cover and clean air tube Using an 8mm nut driver loosen the 2 clamps at either end of the clean air tube Remove the clean air tube from the throttle body and airbox res 2 ys A Lf RA m ae Eo dizi LE ry ot Ni T NNI OCA PCV Vent Tube 1305SS TVSIM BA 20130911 Page 12 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Remove the MAF mass air flow connector by pulling the red locking tab back and pressing the black release tab With a 10mm socket wrench remove the airbox hold down bolt Firmly grasp the airbox and pull up to remove it from the vehicle H L F M r m e F j m i UA AL T m dd i L n i 1 i Ur Lr r Hs En a i y TE Jl I a EU Mi n i P k r 1 i s
62. re and mark 45mm from the end of the 7 32 vacuum hose Use a knife to cut the vacuum hose at mark 1305SS TVSIM BA 20130911 Page 22 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 4 Mark the brake booster hose 80mm from end Using a knife cut the brake booster hose at the applied mark 6 Install the 80mm piece of hose which was cut off in step 3 on the open end of T fitting TE LUI TT 1305SS TVSIM BA 20130911 Page 23 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 7 Install the hose clamp onto the end of the 80mm hose Heater Tube Assembly Modification 1 The upper tube and hose on the heater tube assembly is not used a new tube is supplied in the kit Using a die grinder or air saw cut the forward bracket that connect the two tubes together and cut along side of the rear bracket through the upper tube De burr all sharp edges Retain the lower tube which connects to the water pump and the mounting bracket for reinstallation Discard this tube 1305SS TVSIM BA 20130911 Page 24 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES Wiring Harness Modifications The following details the modifications to the factory engine harness which are necessary
63. tang GT and beyond a second hole with a 11 diameter will need to be cut into the access cover The hole should be 7 away from existing hole to allow clearance for the new grommet to seal Once the hole is cut out pull DUAL PUMP CONNECTOR and SENDER CONNECTOR 1 through hole and seal hole with grommet Do not take the existing harness out of the existing hole in the access cover Unlock the existing 4 pin female connector connector on the end of the existing harness going through access cover previously connected into the stock fuel pump Unlock the connector by pulling the blue center piece forward see fig 19 29C Release terminals for the LB YE wire and the LG VT wire from the connector housing Do not remove terminal from wire These are the fuel sender wires STEP 30 Insert fuel sender wires into the connector labeled SENDER CONNECTOR 2 with the LB YE wire going into the left side and the LG VT wire going into the right see Fig 20 STEP 31 Connect SENDER CONNECTOR 1 into SENDER CONNECTOR 2 Once connection is made the LG VT wire should line up with the RD YE wire and the LB YE with the BK wire STEP 32 Connect the DUAL PUMP CONNECTOR to the newly installed dual pump STEP 33 Install access cover see Fig 21 2005 Mustang GT view Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 12 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit
64. to complete the installation of this kit These modifications should be done without removing the harness from the engine as it will be easier to verify final locations of the break out points Extreme care must be taken to insure that wiring and or its insulation is not accidentally damaged while removing the convoluted tubing All of the convoluted tubing and various clips that are removed while making these changes are intended to be reinstalled in the same place unless otherwise noted EE Di m F i i ae i i E E r J Ar on i r T Mi p 5 E 1 P F O L z 5 Pru i E n d fal me VN Es Ty Pi J in Le ot i RU d ia r us ho mal i i Nera T es A a A E E Connectors for Wiring Circuits that will need to be modified Hi 1305SS TVSIM BA 20130911 Page 25 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 1 Make a note of the locations of the harness retaining clips and breakout points With the harness still fastened to the engine with the factory retainers carefully cut the tape off of the convoluted tubing and wiring harness on the drivers side of the engine where the ETC branches out of the main harness using a razor or utility knife The area is highlighted in the following diagram The convoluted tubing is split from the factory so follow the split Lift the wiring out of the convoluted tubing without disturbing the
65. to stock ground for audio amp on passenger side see Fig 17 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 10 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit FC HSME INSTRUCTION SHEET Pe Fe SEA EO ae T NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 17 STEP 29 Run connectors labeled DUAL PUMP CONNECTOR and SENDER CONNECTOR along the wall of the driver side of trunk under rear seat and into rear seat area where the dual pump is located 29A For 2005 Mustang GT a 1 7 diameter hole will need to be cut out in the center of the access cover for the fuel pump see Fig 18 Once hole is cut out pull DUAL PUMP CONNECTOR and SENDER CONNECTOR 1 through hole and seal hole with grommet Unlock existing 4 pin female connector on the harness previously connected into the stock fuel pump Unlock the connector by pulling the blue center piece forward see Fig 19 Proceed to STEP 29C Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 11 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit TLACIING s INSTRUCTION SHEET Pe Fe PE a EO aN NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS 29B For 2006 Mus
66. tory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 8 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit FC IUNE r INSTRUCTION SHEET Pe Fe SEA EO ae T NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 13 STEP 22 Mount additional fuel pump driver module in spare tire well on opposite side of existing fuel pump driver see Fig 14 Fig 14 STEP 23 Mount RELAY from harness on inside of tire well to the left of the stock fuel pump driver module see Fig 15 Techline 800 FORD788 Factory Ford shop manuals are available from Helm Publications 1 800 782 4356 IS 1850 0129 Page 9 of 15 M 9407 GT05 Mustang GT Dual Fuel Pump Kit Fc HN INSTRUCTION SHEET NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR AGREEMENT AND WRITTEN PERMISSION OF FORD RACING PERFORMANCE PARTS Fig 15 STEP 24 Connect connector labeled FPDM BODY SIDE CONNECTOR into the harness where the existing fuel pump driver module was connected STEP 25 Connect connector labeled FPDM NO 1 to stock fuel pump driver module STEP 26 Mount wires labeled RELAY GROUND and FPDM NO 1 GROUND in hole next to stock ground using ground screw see Fig 16 Fig 16 STEP 27 Connect connector labeled FPDM NO 2 to newly mounted fuel pump driver module on passenger side STEP 28 Mount wire labeled FPDM NO 2 GROUND
67. wo pegs as guides into the rubber grommets Loosely secure the air box to the vehicle using the take off air box bolt and the supplied ABS bracket bolt N808920 Note Do not torque bolts l le FA l A TNI i ES 1 ed ERIS gt Tre E Uam i o IN OO Take off air 50 N box bolt u po XA LB 38 Install the 3 16 4440 and 3 8 P2333A fittings into their respective holes on the clean air tube 1305 9B659 Foaming glass cleaner can be used to aid in this step Place a vacuum cap over each of these fittings 383004 amp CS2575 found in Hardware kit R07130040 7 1305SS TVSIM BA 20130911 Page 71 of 87 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING OFF ROAD USE ONLY NOT FOR USE WITH POLLUTION CONTROLLED VEHICLES 39 Loosely install the 120 140mm clamp R07130014 onto the oval end of the clean air tube and the 110 130mm clamp onto the round end of the clean air tube R07130015 Orient the clamps so both screw heads are facing the same direction of the PCV fitting Install the clean air tube in the vehicle by first sliding the round end onto the MAF tube then pushing the oval end onto the throttle body Tighten the throttle body clamp so the screw is close to the ETC motor on the topside of the throttle body Tighten the MAF tube clamp so the screw is on the bottom side of the tube Torque both clamps to 3 Nm 40 Tighten the 2 bolts in the air box Torque the

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