Active Exhaust Kit

Active Exhaust Kit
ROUSH Active Exhaust
Installation Instructions
P/N: 421926 (R1315-5231AV)
Fastback GT V8 – Convertible GT V8
Fastback EcoBoost I4 – Convertible EcoBoost I4
39555 Schoolcraft Rd, Plymouth MI, 48170 | 800.59.ROUSH
ROUSH Active Exhaust
ROUSH Active Exhaust
Installation Instructions
P/N: 421926 (R1315-5231AV)
Fastback GT V8 – Convertible GT V8
Fastback EcoBoost I4 – Convertible EcoBoost I4
*Vehicle Shown with ROUSH Rear Valance and Quad Tip Exhaust.
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 Active Exhaust ...................................................................................................................3
Equipment and Supplies Required............................................................................................................................3
Limit of Liability Statement ........................................................................................................................................4
Safety Precautions ....................................................................................................................................................4
Work Safely! ..............................................................................................................................................................4
Active Exhaust Installation ........................................................................................................................................5
Template ..................................................................................................................................................................21
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PACKING LIST FOR ROUSH ACTIVE EXHAUST
Description
Part Number
Quantity
Active Exhaust Upgrade Kit
R1315-5231AV
Exhaust Pipe with Valve – LH
1315-6506LH
1
Exhaust Pipe with Valve – RH
1315-6505RH
1
Flashed Controller, Active Exhaust
1315-5E260
1
Vehicle Ready Wiring Harness
1315-9L430
1
OBDII Active Exhaust Programmer
1315-14489
1
Hardware Kit – Active Exhaust
1315-5231AVHK
1
Switch, Mode Selector
1315-13K724
1
Switch Plate, Metal with Engraving
1315-11806
1
Switch Bracket
1315-7Z374
1
Bolt – M4 x 0.7 x 10
90116A207
2
Push Nut – 3/16”
94807A026
2
Washer – M4 Nylon
91755A215
3
Zip Tie with Edge Clip
156-00865
7
Knob, Knurled Style
1315-AVKNOB
1
Set Screw – M3 x 0.5 x 6
93245A100
1
J-Clip – M6
95210A175
1
Bolt – M6 x 31 HEX
R18020009-00
1
Foam Tape 30 mm x 35 mm x 7.9 mm
1315-5E260TP
2
Micro Fuse – 10 AMP
APT-10A
1
Zip Tie – 7”
CTUV740
20
Multipurpose O-Ring, 5.6 mm
9262K215
1
EQUIPMENT AND SUPPLIES REQUIRED
•
•
•
•
•
•
•
•
•
Trim Tool
Tape Measure
Scissors
Masking Tape
Center Punch
Drill
1/4" Drill Bit
Philips Head Screwdriver
Wire Cutters
•
•
•
•
•
•
•
•
•
7 mm Deep Socket
8 mm Socket
10 mm Socket
13 mm Socket
15 mm Socket
Torque Wrench
Small Pick
Flat-head Screwdriver
Razor Blade
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.
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ACTIVE EXHAUST INSTALLATION
1. Refer to the installation manual titled “ROUSH
Quad Tip Exhaust” under part numbers 421920,
421921, 421922 and 421923 for installation of the
Quad Tip Exhaust System. Refer to the installation
manual titled “2015 Mustang Rear Valance” under
part numbers 421894 and 421919 for installation
of the Rear Valance kit. Both the ROUSH Quad
Tip exhaust and Rear Valance are needed for use
with the Active Exhaust Kit.
2. Begin the installation by first opening the hood
and disconnecting the battery (refer to your
owner’s manual for guidance). Next open the
trunk and remove the spare tire cover panel and
rear trunk trim panel. To remove the rear trunk trim
panel, loosen the four (4) plastic nuts by hand,
push the outer ends forward towards the front of
the vehicle and slide the panel upwards to release
the remaining clips that are on the backside of the
panel.
3. Remove two (2) push pins along the driver side
trunk carpet if your vehicle is a fastback. If your
vehicle is a convertible, then you will need to
remove three (3) push pins along the driver side
trunk carpet.
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4. Remove the bottom portion of the rear seat by
pushing in on the latches that are under the front
edge on each side and lifting the seat up.
6. Remove the rear quarter panel trim piece by
first removing the seat belt guide trim ring and
then firmly pulling inwards along the panel to
disconnect the plastic clips along the back.
NOTE: For fastback models, first release the upper
portion of the rear seat and fold it down to gain
access to the seat belt guide trim ring.
5. Remove the door sill trim piece by first lifting up
at the front corner and then disengaging the clips
along the bottom.
NOTE: For convertible models, after removing the
seat belt guide trim ring, remove the top trim piece by
first lifting up at the front and disengaging the clips
along the bottom. Now remove the quarter panel trim
piece as previously instructed.
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NOTE: For convertible models, first remove the trunk
light that is mounted in the driver side trunk carpet by
pressing it out from the back.
8. Locate the M6 J-Clip (P/N: 95210A175) that is in
the Hardware Kit (P/N: 1315-5231AVHK_AA) and
install it on the driver side sheet metal in the trunk
as shown below. Location for fastback models
shown below:
7. Remove the driver side trunk carpet.
NOTE: For fastback models, first remove the push pin
that is located near the driver side rear seat belt.
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Location for convertible models shown below:
Location for convertible models shown below:
9. Apply the two (2) pieces of foam tape (P/N:
1315-5E260TP) to the back of the active exhaust
control module (P/N: 1315-5E260) and locate the
included rubber grommet as shown. Location for
fastback models shown below:
10. Set the active exhaust wiring harness (P/N: 13159L430) in the trunk and locate the large relay. Take
the M6 x 31 bolt (P/N: R18020009-00) and insert
it through the grommet on the control module
followed by the mounting tab on the relay and
then insert it into the M6 J-Clip (P/N: 95210A175)
that was installed in step 5. Torque the bolt to 10
Nm and then plug the module connector from the
wiring harness into the module.
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Location for convertible models shown below:
Location for fastback models shown below:
12. Remove the 8 mm bolt from the factory ground at
the rear of the trunk as well as the push-in retainer
from the factory wiring harness.
11. Remove the rubber cap that is on the passenger
side of the spare tire well. Locate the section of
the active exhaust wiring harness (P/N: 13159L430) that has the grommet and feed the two
(2) connectors through the hole in the spare tire
well that the rubber cap was removed from. Fully
seat the grommet from the active exhaust wiring
harness into the sheet metal of the trunk floor.
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13. Insert the 8 mm bolt into the ring terminal on the
active exhaust wiring harness (P/N: 1315-9L430)
and then reinstall it with the factory ground into
the position it was removed from in step 12
and torque to 2 Nm. Insert the push-in retainer
from the factory wiring harness into the ring clip
from the active exhaust wiring harness and then
reinstall the push-in retainer into the position it
was removed from in step 12.
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14. Route the wiring harness along the driver side of
the trunk into the cabin and secure with both the
standard 7" zip ties (P/N: CTUV740) and the zip
ties with edge clips (P/N: 156-00865) as shown
below. Trim the tails of the zip ties once they are
secure.
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15. Re-install the driver side trunk carpet (and trunk
light, if equipped). Re-install the rear trunk trim
panel by reversing the removal process outlined in
step 2. Re-install the spare tire cover panel.
16. Continue routing the wiring harness along the
driver side of the vehicle and secure with the
standard 7" zip ties (P/N: CTUV740) as shown.
18. Remove the driver side kick panel. Start by prying
out the center cap in the hood release handle
with a small pick and then releasing the inner tabs
with a small flat-head screwdriver to remove the
handle. There are also two (2) clips along the door
jam and one (1) push pin at the front that need to
be released in order to remove the panel.
17. Remove the lower driver side dash trim panel with
a non-marring trim tool. Gently pry the trim piece
out to release the clips on the backside.
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20. Remove the two (2) push pins that secure the
carpet to the wire harness housing along the door
sill and remove the two (2) 10 mm fasteners that
secure the door sill wire harness housing to the
vehicle. Pull the housing back to reveal the factory
sections of tape and carefully remove or cut each
section of tape along the outer edge of the wire
harness housing.
19. Remove the bottom portion of the door seal.
Disconnect the electrical connector for the
illuminated door sill plates. Remove the two (2)
metal clips along the seam in the sheet metal.
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22. Reinstall the two (2) metal clips onto the sheet
metal seam that were removed in step 19.
Reinstall the two (2) 10mm fasteners that secure
the door sill wire harness housing which were
removed in step 19 and torque to 2 Nm. Reinstall
the two (2) push pins that retain the carpet to the
wire harness housing that were removed in step
20.
23. Re-install the rear quarter trim panel and the
bottom portion of the rear seat by reversing the
process outlined in steps 4 and 6.
24. Remove the side trim pieces along the center
console by lifting the front lower corners and
carefully disengage the retaining clips along the
back. Remove two (2) 7 mm fasteners on each
side of the console once the trim pieces are
removed.
21. Route the active exhaust wire harness along the
outside of the factory wiring harness in the wire
harness housing. Close the wire harness housing
and apply new sections of tape to secure it
closed.
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25. Remove the molded rubber tray from in front of
the shifter.
27. With the emergency brake fully engaged, lift the
top portion of the center console up and unplug
the connectors for the key fob detection circuit
and for the cup holder lighting (if equipped).
26. Using a non-marring trim tool, gently lift each
of the rear corners of the center console and
disengage the retaining clips along the bottom
from the rear all the way up to the front.
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28. Release the clips for the shifter trim bezel and
remove the top section of the center console from
the vehicle.
30. Plug the OBDII pass-through connector that is
part of the active exhaust wiring harness (P/N:
1315-9L430) into the OBDII connector that is
under the dash. Secure the connector with two
(2) standard 7" zip ties (P/N: CTUV740) as shown
below.
29. Continue routing the wire harness up through the
driver side kick panel area and secure as shown
below.
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32. Unplug the connector for the 12-volt power outlet
that is in the center console. Using a small pick,
remove the red locking piece that is in the end of
the connector. Carefully lift the tab for the grey
with orange wire in the connector and remove the
terminal from the connector.
31. Continue routing the wiring harness along the
dash structure up through to the center console
and secure with the standard 7" zip ties (P/N:
CTUV740) as shown below.
33. Take the yellow lead from the active exhaust
wiring harness (P/N: 1315-9L430) that has the
same terminal on the end and insert it into the
spot in the 12-volt power outlet connector that
was de-pinned in step 32. Replace the red locking
piece that was in the end of the connector.
34. Remove the rear clip and seal from the new
connector that is bagged and taped to the active
exhaust harness. Insert the clip and then the seal
onto the grey with orange wire that was removed
from the 12-volt power outlet connector and then
insert into the new connector as shown below.
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35. Check to make sure all the connections are fully
seated, slide the seal into place as well as the rear
clip. Plug the connector into the active exhaust
wiring harness (P/N: 1315-9L430) and press the
red lock in the front of the connector to lock it in
place.
36. Plug the factory 12-volt power outlet connector
back into the 12-volt outlet in the center console
and route the active exhaust wiring harness in the
center console as shown.
38. Remove the fuse panel cover in the passenger
kick panel area and remove fuse #23 (10 amp)
from the fuse panel. Plug the 10-amp fuse into
the fuse tap that is located in the active exhaust
wiring harness (P/N: 1315-9L430). Locate the
10-amp fuse (P/N: ATP-10A) that is part of the
hardware kit (P/N: 1315-5231AVHK) and plug that
into the additional spot in the fuse tap. Plug the
fuse tap into slot #23 that the 10-amp fuse was
originally removed from.
37. Locate the lead on the active exhaust wiring
harness with the fuse tap on the end and route it
outside of the console along the dash structure up
to the passenger side kick panel and secure the
harness with standard 7" zip ties (P/N: CTUV740)
as shown.
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39. Reinstall the fuse panel cover.
40. Locate the active exhaust switch (P/N: 131513K724) and install it onto the switch bracket
(P/N: 1315-7Z374) with two (2) M4 screws (P/N:
90116A207), torque to 1 Nm. Install the O-ring
(P/N: 9262K215) onto the switch post.
43. Mark the four (4) holes with a center punch and
drill them with the appropriate sized drill bits as
indicated by the template (1/4").
44. Remove the template and insert the studs on the
active exhaust switch plate (P/N: 1315-11806)
through the holes that were drilled in step 43.
Turn the console over and insert two (2) M4 nylon
washers (P/N: 91755A215) onto the front stud
of the switch plate and (1) nylon washer (P/N:
91755A215) onto the rear stud of the switch plate.
Insert the switch and bracket assembly onto
the switch plate studs and carefully secure with
two (2) 3/16" push nuts. A deep 7 mm socket
works well to drive the push nuts onto the studs.
Check to make sure the entire assembly is fully
seated and that there is no play in any of the
components.
41. Trim out the drill template that is located on the
last page of this installation manual.
42. With the top section of the center console placed
in a safe area, tape the drill template into position
as shown.
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49. Insert the knob onto the active exhaust switch
post. Align the small flat on the switch post to be
perpendicular to the set screw. Seat the knob fully
onto the switch post and torque the set screw to
1 Nm.
50. Locate the active exhaust valve assemblies (P/N’s:
1315-6506LH and 1315-6505RH) and install
them in place of the straight outlet couplers that
are included on the ROUSH Quad Tip Exhaust.
Reuse the existing gaskets, nuts, tips and clamps.
Torque the nuts to 25 Nm and torque the clamps
for the exhaust tips to 47 Nm.
45. Reinstall the top section of the center console
and the side trim pieces by reversing steps 24-28
while being sure to plug the active exhaust switch
(P/N: 1315-13K724) into the mating connector
in the active exhaust wiring harness (P/N: 13159L430). Torque the 7 mm fasteners to 2 Nm.
46. Reinstall the driver side kick panel and the lower
driver side dash trim panel by reversing steps
17-18.
47. Reinstall the door sill trim piece that was removed
in step 5.
48. Locate the active exhaust switch knob (P/N:
1315-AVKNOB) and the M3 set screw (P/N:
93245A100) which can both be found in the
Hardware Kit (P/N: 1315-5231AVHK) and loosely
install the set screw into the threaded hole on the
side of the knob.
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51. Locate the wiring harness that is routed through
the grommet in the trunk floor. Route the short
lead to the passenger side valve and the long lead
to the driver side valve.
52. Secure the wiring to the sheet metal edge under
the vehicle using the edge clips with zip ties
(P/N: 156-00865) as shown below and plug the
respective connectors into each valve.
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53. Reconnect the battery, start the vehicle and test
your new ROUSH active exhaust.
Congratulations, the installation is complete!
4X
0.25"
2"
SWITCH PLATE TEMPLATE
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