Ford FR SuperPack 600 Supercharger Installation Instructions

Installation Instructions - FR SuperPack 600
P/Ns: M-6066-SGT (Black)
M-6066-SGTP (Polished)
Application: 2007 Ford SVT Mustang
EO# D-418-7
Licensed by:
Roush Performance Products
28156 Plymouth Road
Livonia, MI 48150
Important Notes:
•
BEFORE INSTALLING the FR SuperPack 600, please register this product by following the
steps listed on the yellow voucher card included with the kit. PRODUCT REGISTRATION
IS REQUIRED to receive the ProCal flash tool used to recalibrate the vehicle PCM.
Operating the engine without the PCM recalibration will result in engine damage or failure
and will VOID THE WARRANTY.
•
Please read the installation manual carefully and verify that all items are present. If you are
missing hardware or have any questions, please contact the Ford Racing Call Center at 1(800)
367-3788.
•
Premium fuel (91 octane or higher) is required to prevent “spark-knock” or detonation under
certain operating conditions. The use of fuel additives (ie. octane boosters) is not recommended.
There is a possibility that these chemicals can damage your engine and cause drivability issues
with your vehicle.
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PACKAGING LIST FOR COMPLETE KIT
1
2
4
Item
5
Description
3
6
7
Part Number
Qty
1
Clean Air Tube
R07060101
1
2
Air Box Assembly
R07060106
1
3
High Flow Conical Air Filter w/ Worm Clamp
R07060131
1
4
Clean Air Tube Support Bracket
R07060104
1
5
Bolt - Bracket to Tube & Airbox (M6 x 13)
N605771
3
6
Bolt - Airbox to ABS Bracket (M8 x 33)
N808920
1
7
EO Label
R07040042
1
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*Optional Polished
1
4
2
Item
3
Description
Part Number
Qty
1
TVS2300 Supercharger (Black Finish)
TVS2300 Supercharger (Polished)
R07050050
*R07050053
1
2
Registration/Warranty Voucher
R07140004
1
3
Installation Instructions
R07050051
1
4
ProCal Flash Tool
NPN
0**
**The ProCal flash tool is NOT included in the kit. Once you register the
product with Ford Racing, this tool will be shipped to you.
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EQUIPMENT AND SUPPLIES REQUIRED
•
•
•
•
•
•
•
•
•
•
•
1/4” and 3/8” Drive Ratchets with Extensions
Metric and Standard Socket Sets (short and deep recommended)
3/8” Drive Ratchet or Breaker Bar
Metric and Standard Wrench Sets
Torque Wrenches
Short Phillips-head Screwdriver
Hex Key Set
T-20 Torx Bit Screwdriver or Socket
Thread Sealing Compound
Medium Strength Thread Locker – Loctite 242 (blue) or equivalent
Ford Service Manual
GLOSSARY OF TERMS
ACT
ETC
IPTS
MAFS
PCM
PCV
TPS
VMV
Air Charge Temperature Sensor
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
Throttle Position Sensor
Vapor Management Valve (Located on driver side strut tower)
INFORMATION ABOUT THE SUPERCHARGER BYPASS OPERATION
There is a great deal of misinformation about the function of supercharger bypass systems. The
supercharger is a positive-displacement pump; that is, so long as it is rotating, it is always pumping air.
During low demand or high vacuum operation (i.e. idle, deceleration, and light 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.
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SAFETY PRECAUTIONS
STOP! CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS AND
WARNINGS BEFORE PROCEEDING WITH THE INSTALLATION!
Appropriate disassembly, assembly methods and procedures are essential to ensure the
personal safety of the individual performing the kit installation. Improper installation due to the
failure to correctly follow these instructions could cause personal injury or death. Read each
step of the installation manual carefully before starting the installation.
Always wear safety glasses for eye protection.
Place the ignition switch in the OFF position.
Always apply the parking brake when working on the vehicle.
Block the front and rear tire surfaces to prevent unexpected vehicle movement.
Operate the engine only in well-ventilated areas to avoid exposure to carbon
monoxide.
Do not smoke or use flammable items near or around the fuel system.
Use chemicals and cleaners only in well-ventilated areas.
Batteries can produce explosive hydrogen gas, which can cause personal injury.
Therefore do not allow flames, sparks or flammable sources to come near the
battery.
Keep hands and any other objects away from the radiator fan blades.
Keep yourself and your clothing away from moving parts when the engine is
running.
Do not wear loose clothing or jewelry which can be caught in rotating or moving
parts.
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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).
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.
WARNING: Do not smoke or carry lighted tobacco or open flame of
any type when working on or near any fuel-related components. Highly
flammable mixtures are always present and can be ignited, resulting in
personal injury.
a. Remove the fuel pump module fuse.
NOTE: The fuel pump module fuse is located in the bussed electrical center, location F41.
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b. Start the engine and allow it to idle until it stalls.
c. After the engine stalls, crank the engine for approximately 5 seconds to make sure the
fuel injector supply manifold pressure has been released.
d. Turn the ignition switch to the OFF position.
3. Disconnect the (-) negative & (+) positive connections to the battery. Cover the (+) positive
battery terminal to prevent any contact.
4. Remove the factory strut tower brace.
Strut tower bolts
5. Carefully label each port before removing the vacuum harness from the vehicle (ie. supercharger
housing, ESM and supercharger bypass actuator).
NOTE: A separate
vacuum line connects
the bypass actuator to
the clean air tube. This
will be disconnected
from the supercharger
later.
S/C
ESM
Bypass
Actuator
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6. Disconnect the electrical connector from the MAF sensor. Disconnect the vacuum harness and
PCV hose from the clean air tube. Remove the clean air tube from the airbox and throttle body.
Disconnect
vacuum tube
Clean air tube
clamps
PCV hose
MAF wiring
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7. Remove the airbox retainer bolt and assembly from the vehicle.
Airbox
retainer
bolt
8. Remove the three grommets, MAF and MAF bolts from the factory airbox. These will be reused
later.
MAF sensor
& bolts
Rubber grommets
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9. Disconnect the throttle body wiring in two places (ETC & TPS connections). Disconnect the
brake booster and VMV hoses from the throttle body spacer. Remove the throttle body spacer
(including throttle body) from the supercharger.
Disconnect brake
booster hose here
VMV hose
ETC & TPS wiring
connections
Throttle body
spacer bolts
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10. Remove the ESM (EGR System Module) electrical connector. Remove the EGR tube nut from
the ESM. Remove the ESM bolts and assembly from the supercharger. NOTE: The ESM
gasket will be reused. It is important that it does not become damaged or lost.
Electrical harness
ESM
EGR tube
ESM bolts
11. Disconnect the PCV and PCV bubbler hoses from the supercharger.
PCV bubbler
PCV
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12. Remove the two degas bottle fasteners. Make sure the cap is tightly secured. Rotate the degas
bottle out of the way to gain additional access to the FEAD belt tensioner.
Degas bottle
fasteners
13. Use a 3/8” breaker bar to release the first sheave tensioner and remove the FEAD belt from the
supercharger pulley.
S/C
First sheave
tensioner
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14. Disconnect the wiring harness and vacuum tube from the fuel rail pressure sensor (IPTS).
Disconnect the wiring harness from the ACT sensor.
IPTS vacuum
harness
IPTS wiring
connector
ACT sensor connector
15. Disconnect all eight fuel injector wiring connectors.
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16. Remove the fuel rail mounting bolts. Pull up on the fuel rail and all eight injectors to gain access
to the supercharger. Rotate the fuel rail around the fuel rail supply line and set aside on the
driver side strut tower.
WARNING: Do not smoke or carry lighted tobacco or open flame of any typed
when working on or near any fuel-related components. Highly flammable mixtures are
always present and can be ignited, resulting in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the
engine is not running. Before working on or disconnecting any of the fuel lines or fuel
system components, the fuel system pressure must be relieved. Failure to do so can
result in personal injury.
NOTE: Be careful not to get any contaminants in the injectors or into the boss on the intake
manifold. Be careful not to damage the O-rings on the injectors.
Injector wiring
connections
Fuel rail
bolts
Injector wiring
connections
17. Remove the supercharger mounting fasteners and carefully remove the supercharger from the
vehicle. If the dowel pins did not remain in the intake manifold, remove them from the
supercharger and re-install into the intake. Transfer the vacuum line (attached to the
supercharger bypass valve) to the new supercharger. NOTE: Attempt to maintain the stock
orientation and connect to the lower port.
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SECTION B- INSTALLATION
The following section will guide you through the final installation of this kit. If you need to stop during any
part of the installation, make sure you cover any open ports in the cylinder heads or intake manifold to
prevent foreign material from contaminating your engine.
1. Install the new supercharger to the intake manifold using the stock fasteners. Torque the
fasteners to 5 Nm using the inside-out pattern shown below. Repeat this procedure and torque
each fastener to 25 Nm.
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2. Re-install the injectors and fuel rail onto the intake manifold. Torque fuel rail bolts to 10 Nm.
Fuel rail
bolts
3. Connect fuel injector wiring harnesses, fuel pressure regulator (IPTS) electrical harness,
vacuum harness and ACT wiring connector.
Injector wiring connections
IPTS
Vacuum
harness
ACT sensor
Injector wiring
connections
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4. Re-install the FEAD belt over the supercharger pulley by using a breaker bar to release the
tensioner.
Supercharger
pulley
First sheave
tensioner
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5. Rotate the degas bottle back into place. Re-install the two fasteners used to secure the degas
bottle in place and torque to 10 Nm.
Install degas
bottle fasteners.
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6. Re-install the PCV and PCV bubbler lines to the supercharger housing.
PCV bubbler
PCV
7. Apply a thread sealing compound to the stock EGR bolts. Install the ESM and torque the
bolts to 25 Nm. Connect ESM electrical harness and the EGR tube. Torque the EGR tube to
35 Nm.
ESM harness
ESM
EGR tube
ESM bolts
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8. Re-install the vacuum harness to the ESM, supercharger, and supercharger bypass actuator.
NOTE: Ensure the harness is properly routed and all connections are fully seated.
Vacuum harness
connections
9. Re-install the stock throttle body spacer assembly to the supercharger using the stock bolts and
torque to 10 Nm.
Throttle body
spacer bolts
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10. Re-install the brake booster hose and VMV to the throttle spacer. Re-connect the electrical
harness to the ETC and TPS mounted on the throttle body.
Attach brake booster
hose here
VMV
ETC & TPS wiring
connections
11. Re-install the stock clean air tube onto the throttle body. Do not tighten the clamp at this point.
Stock clean
air tube
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12. Install the MAF sensor and bolts from the stock airbox into the new clean air tube (R07060101).
Torque the bolts to 4 Nm.
Clean air tube
Factory MAF
Sensor
Factory
MAF bolts
13. Install the clean air tube support bracket (R07060104) to the clean air tube and position using
the alignment marks on both the bracket and the tube. Secure the bracket to the tube using the
bolt (N605771) supplied in the kit. NOTE: Apply medium strength thread locking compound to
the bolt threads prior to installation and torque this bolt to 10 Nm.
Alignment marks
Airbox bracket & bolt
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14. Install the air filter (R07060131) to the clean air tube and torque the worm drive clamp to 3 Nm.
NOTE: Align the metal strip on the air filter with the alignment mark on the clean air tube.
Clamp
Alignment marks
15. Install the rubber grommet from the factory airbox into the new airbox housing (R07060106).
NOTE: Remove the metal sleeve to ease grommet insertion into the airbox. Once the rubber
grommet is firmly seated in position, re-install the metal sleeve into the grommet.
Rubber grommet
Sleeve
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16. Assemble the air tube and filter onto the airbox housing using two bolts (N605771) and torque
to 10 Nm.
17. Locate the ABS module bracket and remove the bolt shown below.
ABS module
Remove bolt
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18. Install the rubber grommets (previously removed from the factory airbox) into the holes located
beneath the airbox, rearward of the ABS module.
Installed rubber
grommets
19. Lower the complete airbox assembly into the vehicle using the two pegs as guides into the
rubber grommets. Use the take-off airbox bolt and newly supplied ABS bracket bolt (N808920)
to secure the airbox in the vehicle. Torque the M6 bolt to 10 Nm, and the M8 bolt to 25 Nm.
ABS bracket bolt
Take-off
airbox bolt
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20. Install the stock rubber clean air tube onto the new clean air tube/airbox assembly. Tighten
both ends using worm drive clamps and torque to 3 Nm.
21. Re-install the PCV line and vacuum harness onto the clean air tube.
electrical connector onto the MAF sensor.
Re-install the MAF
Attach PCV
tube
Attach MAF
sensor wiring
Secure clean air
tube clamps
Attach supercharger
bypass vacuum
harness
22. Re-install the strut tower brace and torque nuts to 35 Nm.
23. Reinstall the battery connections. Connect the positive cable first then the negative cable to the
battery. Check to ensure that the battery if fully charged (12.0V to 14.5V).
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24. VERY IMPORTANT!!! THE FOLLOWING STEPS CAN ONLY BE COMPLETED ONCE YOU
RECEIVE YOUR FORD RACING PROCAL FLASH TOOL. PLEASE READ THE FOLLOWING
INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION!!!
ProCal Calibration Flash Tool Instructions
Please follow the directions below in order to make sure that your vehicle’s powertrain control module
(PCM) is successfully programmed (flashed) with the correct calibration. Do not drive the vehicle until
the programming operation has completed successfully. Please read these instructions in their
entirety prior to beginning the flash procedure. If you have any questions or concerns, please call the
Ford Racing Techline at 1-800-FORD788 if they are not addressed in this document.
This ProCal tool has been designed to deliver a performance calibration to your vehicle and keep a copy
of your vehicle’s stock calibration, should you decide to remove the performance pack for any reason.
The tool will be locked to your vehicle until the stock calibration has been restored. Once the original
calibration has been restored to your vehicle, the performance calibration and corresponding hardware
can be installed on another vehicle of the same year, make, model, PCM part number, tire size and axle
ratio.
Recalibration Procedure
Before You Begin:
1
2
Check to see that the battery is fully charged (at least 12.0 volts) and all
accessories (radio, interior fan, headlights, etc.) are switched off. It is strongly
recommended that the vehicle be connected to a battery charger during the
flashing process to avoid potential low-voltage issues.
Locate the on-board diagnostic (OBD-II) diagnostic link connector (DLC)
located beneath the dashboard on the driver’s side of the vehicle. The exact
location will vary with the model and year of the vehicle but will always be on
the driver’s side.
Flashing Your PCM:
1
2
3
4
5
Ensure the ignition key is in the OFF position.
Hold the ProCal tool so that the side with the instructions on it is facing up and
the LEDs and switch are facing you. Slide the function switch to the LEFT
(toward center of unit) to select the performance calibration, or to the RIGHT
(toward edge of unit) to select the stock calibration.
Connect tool to the vehicle diagnostic connector and wait another 5 seconds.
A blinking yellow light should appear which means the tool is ready to begin
flashing the vehicle’s PCM.
Turn key to ON position but do not start the engine. The yellow light should
stop blinking and stay on during the PCM flashing process, which can take
anywhere between 5 minutes and 40 minutes depending on the type of PCM.
Please be patient and do not touch the key or turn on any accessories (such
as the radio) while flashing is in process.
When the tool is finished flashing the PCM, the solid yellow light will turn off
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and either a solid green or solid red with blinking yellow will result. If the green
light is on, turn the ignition key to the OFF position, remove the tool from the
DLC and continue to STEP 6. If the red light is on, an error has occurred and
the PCM has not successfully been flashed. Refer to the “Light Status” section
below for diagnosis.
Congratulations! You have now successfully flashed the PCM. Start the
engine and enjoy.
6
Light Status:
Solid GREEN only
Flashing YELLOW only
Solid YELLOW only
Solid RED, blinking YELLOW
Flashing process successfully completed.
Ready to begin flashing process and waiting for key
to be turned to ON position.
Flashing in process. Please be patient.
Error encountered. Count yellow blink sequence and
refer to the following table for error code. If the error
code is not shown below, call the Techline for further
instructions at 1-800-FORD788.
Error Code Diagnosis:
# of
Blinks
Error
1
Vehicle mismatch
2
Switch position error
General software upload
error
General software download
error
Voltage read error
The battery voltage is too
low
The battery voltage is too
high
The ProCal reprogramming
voltage is not working
properly
3
4
6
7
8
9
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Description
Attempting to program second vehicle before
first vehicle has been returned to the stock
calibration.
Try again with the switch in the other position.
Call Techline at 1-800-FORD788.
Call Techline at 1-800-FORD788.
Try again with battery charger connected.
Try again with battery charger connected.
Check that correct battery is installed in vehicle.
Check vehicle DLC wiring.
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25. Inspect all underhood wiring harnesses for potential interference issues. Use zip ties to safely
position the harness away from any areas of concern.
26. Pressurize the fuel system.
Note: This procedure was taken directly from the Ford service manual; section 310-00.
a. Install the fuel pump module fuse. Its location can be seen on pg 7 of this manual.
b. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks
before starting the engine.
c. Start the vehicle and check the fuel system for leaks.
27. Check for unusual noises, dash service lights, and unusual operation. If problems are
detected, immediately stop the engine or vehicle, diagnose and repair the problem.
28. Affix the E.O. Decal (R07040042) on driver side strut tower adjacent to the air filter assembly.
FORD RACING LIMITED WARRANTY
A Limited Warranty is valid only when proof of purchase is registered by the installing dealer by
contacting the Ford Racing Call Center at 1(800) 367-3788. For warranty details please visit the website:
WWW.FORDRACINGPARTS.COM
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