ROUSH Front Fascia Kit Installation Instructions

ROUSH Front Fascia Kit Installation Instructions
ROUSH Front Fascia Kit
Installation Instructions
P/N: 421843 • 421844 • 421845 • 421846
421847 • 421848 • 421849 • 421850
421851 • 421852 • 421853
39555 Schoolcraft Rd, Plymouth MI, 48170 | 800.59.ROUSH
ROUSH Front Fascia Kit
ROUSH Front Fascia Kit
Installation Instructions
P/N: 421843 (R1315-17C830) - Primed
421844 (R1315-17C830CY) - Competition Orange
421845 (R1315-17C830H3) – Triple Yellow
421846 (R1315-17C830HN) – Guard Green
421847 (R1315-17C830J4) – Deep Impact Blue
421848 (R1315-17C830J7) – Magnetic
421849 (R1315-17C830PQ) – Race Red
421850 (R1315-17C830RR) – Ruby Red
421851 (R1315-17C830UA) – Black
421852 (R1315-17C830UX) – Ingot Silver
421853 (R1315-17C830YZ) – Oxford White
Application: 2015 Ford Mustang
Important Note:
Before installing the ROUSH Performance Product, please read through the installation procedure and verify that
all items are present. If you are missing hardware or have any questions, please contact ROUSH Performance at
1-800-59-ROUSH, 9:00 AM to 5:00 PM EST.
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TABLE OF CONTENTS
Packing List for ROUSH Front Fascia Kit ..................................................................................................................3
Equipment and Supplies Required............................................................................................................................4
Required Materials for Painting Fascia......................................................................................................................4
Limit of Liability Statement ........................................................................................................................................5
Safety Precautions ....................................................................................................................................................5
Work Safely! ..............................................................................................................................................................5
Paint Preparation .......................................................................................................................................................5
Stock Fascia Removal ...............................................................................................................................................6
OEM Fascia Disassembly..........................................................................................................................................8
Roush Fascia Assembly ............................................................................................................................................9
Fog Lamp Wiring Extension Procedure...................................................................................................................14
Roush Front Fascia Installation ...............................................................................................................................15
Roush Fog Lamp Functional Test............................................................................................................................17
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PACKING LIST FOR ROUSH FRONT FASCIA KIT
Description
Part Number
Quantity
Front Fascia
1315-17C831
1
LH Corner Pocket
1315-17B969
1
RH Corner Pocket
1315-17B968
1
LH Corner Duct
1315-17B971
1
RH Corner Duct
1315-17B970
1
Upper Grille
1315-8202
1
Lower Grille
1315-17K945
1
Impact Attenuator Bracket
1315-17E898
2
Screw – M5 x 19
W715060-S439
12
Screw – M5 x 16
W507043-S437
20
Lower Grille Tape – Top Edge
TAPE-015-12.5x970
1
Lower Grille Tape – Bottom Edge
TAPE-015-12.5x25
5
Foglight Jumper Harness
1315-15A211
2
J-Clip – M4.2
W704823-S439
33
Screw – M4.2 – 1.41 x 20
12742
15
Push Clips
20860
25
Front Splitter
1315-17F775
1
Front Splitter Adapter Kit (GT Perf. Pkg Only)
1315-17F771
1
Front Splitter Closeout
1310R17C831IM
1
J-Clip – M4.2 (Closeout)
W704823-S439
7
Screw – M4.2 x 19 (Front Splitter)
W715060-S439
6
Screw – M4.2 x 16 (closeout)
12741
12
1315-17C830IM
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Roush Front Fascia Install Manual
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EQUIPMENT AND SUPPLIES REQUIRED
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•
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•
•
•
•
•
•
•
•
•
•
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Philips Screwdriver
Flat-head Screwdriver
Push-pin Removal tool – Forked prybar
Ratchet and Extension – 1/4" drive
5.5 mm Socket – 1/4" drive
7 mm Socket – 1/4" drive
8 mm Socket – 1/4" drive
10 mm Socket – 1/4" drive
Pliers
Wire Stripping Tool
1/4" Drill Bit
Wiring De-pinning tool (Pick Tool)
Hole Saw (OEM Options Dependent – Parking Sensors)
Soldering equipment (optional)
REQUIRED MATERIALS FOR PAINTING FASCIA
•
•
•
•
Dupont® 2319 Plastic Prep
Dupont® 2330S or equivalent Adhesion Promoter (for paint)
Sand Paper
Painter’s Tack Cloth
If you are missing any items, please call us toll free at 1-800-59-ROUSH.
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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 Performance Products (RPP) reserves the
right to revise the information presented herein or to discontinue the production of parts described at any time.
SAFETY PRECAUTIONS
STOP
STOP
CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS and WARNINGS BEFORE PROCEEDING
WITH THE INSTALLATION!
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of
the individual performing the kit installation. Improper installation due to the failure to correctly follow these
instructions could cause personal injury or death. Read each step of the installation manual carefully before
starting the installation.
• Always wear safety glasses for eye protection.
• Place 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 with 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.
• Keeps hands and any other objects away from the radiator fan blades.
• Keep yourself and your clothing away from moving parts when the engine is running.
• Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch surface finishes.
• 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.
PAINTED PART PREPARATION
STOP
STOP
Unpainted/primed parts purchased from ROUSH require further preparation prior to being painted. Removal of
any excess plastic flashing and sanding of the primed parts is required prior to paint application. The primed
parts as received should not be painted without further surface preparation.
PAINT PREPARATION
(Pre-painted parts, skip this section)
1. Using sand paper, remove any plastic flash from the part as required.
2. Wipe each part to be painted with plastic prep (Dupont® 2319 or equivalent).
3. Wipe the entire part to be painted with tack cloth.
4. Apply adhesion promoter (Dupont® 2330S or equivalent) prior to color and clear coat applications. This part
is made of TPO (Thermoplastic polyolefin) and requires a promoter for paint adhesion.
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STOCK FASCIA REMOVAL
1. Open the vehicle hood and remove eight (8) pushpin retainers and the black plastic closeout panel
covering the radiator as shown. Set all parts
aside for reinstallation.
3. Remove the front wheel fender liners by removing
the three (3) push pins that hold the liner in place.
They run along the edge where the fender liner
meets the fender panel. SAVE FASTENERS FOR
REINSTALLATION!
NOTE: The push pins are a two (2) part push pin.
Remove the center button first to release the barbs
and then remove the push-pin body.
2. Remove the fasteners on the top of the front
fascia. There are six (6) 8 mm screws running
across the front, as well as two (2) 4.5 mm screws,
one at each side of the fascia near the headlamp.
SAVE THESE FASTENERS!
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4. Once the fender liners have been removed, you
will have access to the two (2) 7 mm fasteners,
one on each side of the vehicle, that hold the
fascia in place where it meets the fender. Remove
these fasteners. They are highlighted below.
SAVE FASTENERS FOR REINSTALLATION!
7. With the underbody aero panel removed,
disconnect the electrical connectors for the fog
lights as well as the turn signals.
8. Remove the fascia by firmly pulling the corner
away from the vehicle, then disengage the clips
holding it in place.
5. For V8 (GT Performance Package) equipped
vehicles only, remove the bottom aero panel
by removing the ten (10) M4.2 screws. Their
locations are shown below.
6. For non-performance package equipped vehicles
(V8/V6/I4), remove the twelve (12) M4.2 screws
along the front edge, as well as the four (4) M4.2
screws near the center recesses of panel.
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9. Pull the fascia forward and lift it off the plastic
dowel pins located along the top (where the
screws were removed in step 2).
3. Remove the turn signal lens from the trim piece
by removing the three (3) 7 mm screws that
fasten them together. SAVE HARDWARE FOR
REINSTALLATION!
This completes the OEM fascia removal process.
OEM FASCIA DISASSEMBLY
1. Remove the three (3) 7 mm screws holding the fog
light into the assembly and remove the fog light.
SAVE HARDWARE FOR REINSTALLATION!
4. Remove the eight (8) 7 mm screws that fasten
to the fascia. KEEP ALL HARDWARE FOR
REINSTALLATION (including J-clips)!
2. Remove the six (6) 7 mm screws that fasten the
pocket trim panel to the fascia. Remove the trim
panel from the fascia. SAVE HARDWARE FOR
REINSTALLATION!
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5. Remove the eight (8) push pins retaining the
splitter to the fascia, as well as the two (2)
corner screws. SAVE ALL HARDWARE FOR
REINSTALLATION!
7. Remove the weatherstrip from the top of the
fascia by pushing up from the bottom of the
retaining clips.
This concludes the OEM fascia disassembly. Please
keep all hardware (screws, J-clips and push pins) for
re-use in the new Roush fascia.
6. Remove the impact attenuator by bending up on
the retaining clips while simultaneously pulling
the attenuator away from the fascia. SAVE THE
IMPACT ATTENUATOR FOR REINSTALLATION!
OEM disassembly hardware to be re-used
(without push pins)
ROUSH FASCIA ASSEMBLY
1. Insert the signal lens assembly into the
appropriate (LH/RH) Roush bracket. Using three
(3) self-tapping take-off screws (M5x16), fasten
the signal assembly to the Roush bracket using a
7 mm socket. Repeat the same procedure for the
opposite side lens.
Close up of the retaining clip engagement
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4. Install two (2) M5 J-clips to the outer sides of the
fascia, one per side. Only install the clip.
2. Using a 7 mm socket, install the fog lamp using
three (3) supplied M5 screws. Repeat the same
procedure for the opposite side fog lamp.
5. Using the six (6) self-tapping M5x16 fasteners
with a 7 mm socket, install the signal assembly
with bracket to the fill panel.
NOTE: The fog lamp locator pins must be on the
bottom-outboard corners.
3. Install the left fill panel to the Roush fascia using
six (6) take-off self-tapping M5x16 screws.
Repeat the same procedure for the opposite side
fill panel.
6. Install six (6) push clips onto the upper grille tabs.
Three (3) are installed per side.
Left (driver) side shown
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7. Install the upper grille to the Roush fascia by
inserting the clips that were previously removed to
their respective holes in the Roush fascia. Make
sure that the guides (shown below) are fed into
their respective slots as on the fascia as well.
10. Push four (4) clips (20860) onto the lower grille,
two (2) per side.
8. Install the park assist sensors. If the fascia is not
equipped with park assist sensors, go to step 12.
PARK ASSIST SENSOR
Right (passenger) side shown
FOG LAMP
BEZEL
11. Apply EX4015 tape across the top of the lower
grille as shown below. Apply strips of tape to the
five (5) marks on the fascia as shown.
9. Drill an 18.8 mm (3/4") hole in the unmarked
area on the top side of the lower grille and push
the sensor through the fascia. The arrow on the
sensor faces upward.
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12. Peel the backing off of the tape and press the
lower grille into place, seating the four (4) clips
that retain the lower grille to the Roush fascia.
Be sure to engage the tabs on the top side of the splitter
to the fascia
13. Use fifteen (15) short J-clips along the bottom of
the fascia, starting at the third position from the
outside, leaving the last two (2) holes free at each
end.
Close up of the outer two (2) J-clips installed (right/
passenger side shown). Notice how they are installed in
the opposite orientation from the rest (upside down)
14. Install the front splitter to the fascia with fifteen
(15) M4.2 screws through the previously installed
J-clips. Then install the sixteen (16) J-clips onto
the splitter, as shown below.
NOTE: For non-V8 GT performance pack-equipped
vehicles, go to step 16.
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15. For GT performance package-equipped vehicles
only, the lower splitter assembly includes a spacer
that fits between the splitter and the underbody
aero panel. Install six (6) J-clips to this spacer,
and fasten to the six (6) J-clips on the splitter.
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16. Push two (2) push clips (20860) onto the
fascia tabs as shown below. Repeat the same
procedure for the opposite side as shown below.
18. Push twelve (12) push clips (20860) onto the
twelve (12) tabs that protrude through the energy
absorber bracket.
19. Push the energy absorber into the energy
absorber bracket. Make sure that the arrow is
pointing up. Snap into position onto both the
metal clips and the fascia tab as shown below.
Fascia tabs highlighted
This concludes the Roush fascia assembly section.
17. Line up and clip the impact attenuator bracket
(1315-17E898) into position as shown below and
press the impact attenuator onto the four (4) clips.
One side (2 clips) shown
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FOG LAMP WIRING EXTENSION
PROCEDURE
1. Begin by cutting the leads to the original
connectors just before the connector. Make note
of which wire belongs to which terminal (black/
ground to B/2 terminal). Do this to both left and
right sides and remove about two (2) inches of the
tape covering the wires.
3. Slide the rubber seal to be flush with the end of
the insulation and place it into the new terminal.
Crimp the terminal onto the seal and then onto the
wire.
ROUSH recommends soldering the terminal to the
wire for improved conductivity and robustness –
however this step may be skipped, if so desired, while
maintaining functionality.
4. Insert the new terminals into the new connectors,
being sure to seat them in the right position as
well as the correct orientation as shown below.
The terminals will click when correctly seated.
2. Slide the purple rubber seals over the insulation
(ribbed end away from cut wire end) and then
strip approximately 1/2" of insulation off the end
of each wire using a pair of wire strippers in the
18-AWG setting.
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ROUSH FRONT FASCIA INSTALLATION
1. Install the ROUSH front fascia. Hook the upper
fascia mounts onto the five (5) dowel pins by the
front of the inner bumper. The fascia should hang
comfortably from the dowel pins.
5. Split the wires apart in order to fit the locking
retainer onto the back of the new connector.
2. Clip the corners of the front fascia into the body,
pressing with your hands to seat all the clips. Do
not hammer the fascia in with a soft fist. Force
isn’t necessary to seat the clips and if they aren’t
aligned, the fascia clips may be damaged.
6. Connect the extension harness to the newly
crafted connector.
This concludes the fog lamp wiring extension harness
section.
3. Install the seven (7) take-off screws that secure
the fascia (reverse operation to step 2) on the
top side of the fascia next to the locating/hang
dowels. Install five (5) 7 mm screws across the
top and two (2) 5.5 mm screws in the corners by
the headlamps.
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4. Line up the bottom corner of the fascia (by the
wheel well) with the wheel well covering and drill
the new hole in the splitter for the push pin with a
1/4" drill bit. Install the take-off push-pin into the
new hole.
6. Non-GT performance (V8/V6/I4) equipped
vehicles ONLY, modify the belly pan to achieve
clearance in the corners to the new front splitter
as shown below.
Right (passenger) side belly pan
7. Reinstall the underbody aero panel reusing the
take-off hardware from the OEM disassembly.
Assembly is the reverse order of operations from
disassembly.
5. Connect the fog lamp extension harness and the
turn signal harnesses. Use a zip tie or equivalent
to fasten the extension harness slack against the
vehicle.
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8. Align the wheel well liner to the holes and reinstall
the retaining clips.
9. Reinstall the top radiator closeout in the reverse
order. Re-use the take-off push pins to secure the
closeout panel.
This concludes the Roush fascia installation
procedure.
ROUSH FOG LAMP FUNCTIONAL TEST
1. Reconnect the negative battery cable.
2. Turn the ignition switch to the ON position.
3. Turn the head lamp switch clockwise so that the
headlamps are ON and make sure the headlamps
are in the low beam setting.
4. Turn the head lamp switch clockwise so that the
headlamps are ON and ensure the headlamps are
in the low beam setting. (NOTE: The fog lamps
will not operate with the headlamps in the highbeam setting.) Toggle the fog lamp switch to the
ON position and check to see if both fog lamps
are illuminated.
5. Toggle the fog lamp switch to the OFF position.
Check to see if the fog lamps are off.
Congratulations!!! You have completed the
installation of the ROUSH Performance Products,
Front Fascia Kit. It is recommended that you save all
parts removed from the vehicle during the installation
of this kit.
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