Installation Instructions

Transcription

1 VMP 2.3L TVS Supercharger Kit GT/Boss 5.0 Installation Instructions Application: Ford Mustang GT and Boss 302 with 5.0L 4-Valve Engine w/ Manual or Automatic 2015 Ford Mustang GT with some changes, a different lower intake, CAI, and degas bottle is used Important Notes: Before installing, please read the instructions and verify all items from the packing list are present. If you have any questions with this kit call or Sales@VMPTuning.com TABLE OF CONTENTS Packing & Parts lists by box... Page 2-4 Dis-assembly of engine and bumper before SC install Page 5-13 Front Cover Modifications Page Misc. Preparations and Assembly Page Lower intake, supercharger, and CAI installation Page Intercooler system degas bottle, heat exchanger and hoses Page Installation of FEAD bracketry and belt installation Page Wiring requirements Page VMP TVS Installation Manual download Page 1 of 42

2 VMP TVS KIT COMPONENTRY LIST BY BOX (4 BOXES TOTAL) Part Ref Description Part Number Qty Box JLT Air Induction Kit box components inside 15lbs JLT 123MM Plastic CAI or optional JLT Carbon Fiber CAI CAIBA-FMG-11 1 kit Throttle Body Assembly Dual 60 mm (optional 67mm, std on Stg 3) R Serpentine FEAD Belt 6-rib (2015 uses shorter K060806) K VMP S/C Pulley, 82mm standard, smaller optional RSC5L82MM6 1 VMP Gen2 5.0L TVS hardware kit (with 90* brass nipple) GEN2-50L-HDWK 1 bag Stg 2 & 3 SCT X4 Tuner with VMP Tune Auto only Brake booster check valve (automatic only) XW4Z-2365-AA 1 Stg 3 only VMP Booster with PNP wiring harness VMPAMPPNP11 1 kit All kits VMP 5.0L plug and play wiring harnesses kit (4 pieces) VMP50L-PNP 1 bag One of the following: Stg 1 & 2 Ford Racing 47lb injectors (Stage 1 and 2) M-9593-LU47 1 box 15 Stg 2 Ford 56lb injectors (2015 only) Set 8 Stg 3 Injector Dynamics ID1000 Injectors with Purple Hats (Stage 3) box One of the following: Stg 1 VMP Intercooler pump PNP harness (non-fan HE) bag Stg 2 & 3 VMP Intercooler pump & dual fan PNP harness (triple pass) bag Part Ref Description Part Number Qty Box Main SC kit box with lower intake VMP50L-6006-DA 62lbs Fuel Charging Assembly (lower intake manifold, assembled) 13119H487 1 Fuel Rail 13119F792 1 Upper FEAD Bracket 13118B653U 1 FEAD Tensioner Spider Bracket Assembly 13118B603 1 Intercooler Degas Bottle/Reservoir 13108D080 1 Intercooler Electric Water Pump with Bracket /4" Z Hose Degas Bottle Inlet Top of lower intk to Degas 13118D031-AA 1 3/4" U Hose Intercooler Pump Inlet bottom of degas to pump 13108D /4" Long Hose Intercooler LTR Outlet Bottom lower intk to HE 13118D /8" Hose engine degas bottle to engine AA 1 PCV Fresh Air Inlet - hard molded U-tube AA 1 PCV Purge Hose - hard molded with rubber bubbler hose 13116K817-AA 1 Evaporative Emission Canister Hard Purge Valve Line (EVAP) BR3V-9G271-CF 1 Vacuum line molded SC Bypass Vent ref top of BPV to side of CAI 7R3V-9E498-BB 1 Hardware Kit B Fuel Charging (inside main box) 1311-TVSHK-BB 1 bag Hardware Kit C FEAD idlers and hardware (inside main box) FRTHKC 1 bag Hardware Kit E VMP I/C system (inside main box) VMP50L-HWKE-AA 1 bag Misc baggy hose, sleeve, sticker, grommet (inside main box) N/A 1 bag VMP TVS Installation Manual download Page 2 of 42

3 Part Ref Description Part Number Qty Box Supercharger box VMP15-6F066-A 40lbs VMP Gen2 5.0L Supercharger Assembly tested and filled with oil VMP15-6F066-A 1-5/8 PCV connection on left side Installed 1-3/8 90* quick connect on back of blower Installed 1 -VMP SS HUB VMP B-SST-TVS23 Installed 1 Part Ref Description Part Number Qty Box VMP Heat Exchanger Box (both bags included inside) 20lbs Heat exchanger Triple or non-pro 1 Bag HE Mounting hardware bolts, snappys, sleeves, nuts, washers AFCO 1 Bag Z-bracket Baggy Z-BRACKET 1 Aluminum bracket for IC pump mounting Z-BRACKET 1 M8 serrated nut for mounting to bumper support 2 ¼ carriage bolt (pump to bracket) 2 ¼ -20 serrated nut (pump to bracket) 2 Hose 3/4" Hose Intercooler Pump to HE straight hose, cut as needed Gates ¾ 5 BAGGED SUB-KITS WITHIN JLT BOX (2 bags) Part Ref Description Part Number Qty 9-14JS VMP Gen2 5.0L Head Unit HARDWARE KIT (inside JLT box) GEN2-50L-HDWK 1/8 NPT x 90* brass nipple for BPV vacuum (upper port) 53525K11 1 BEVIS/EVAP Valve mounting bolts M6x45mm 2 BEVIS/EVAP Valve aluminum mounting spacers AS Heat Exchanger aluminum spacer AS use these spacers on and to mount the HE farther back Part Ref Description Part Number Qty 9-14JS Engine control system wiring harnesses (inside JLT box) VMP50L-PNP IAT Harness with shrink tube, crimp (11-14 only) RF-PH-50 1 EVAP valve extension harness 38 (2-wire) (not used on Boss) CSP Throttle Body Y harness to TB motor and TPS (6-wire into 2/4) CSP MAF extension harness 12 (6-wire) (combined on 2015+) CSP *2015 kits will use a combined IAT and MAF extension harness, no PCM re-pinning is required, the supplied brass air temp sensor must be installed in the lower intake in leu of the black plastic one. VMP TVS Installation Manual download Page 3 of 42

4 BAGGED SUB-KITS WITHIN MAIN BOX (4 bags) Part Ref Description Part Number Qty 9-14JS Hardware Kit B Fuel Charging (inside main box) 1311-TVSHK-BB Gasket Red Throttle Body To Gen2 Blower R Gasket Black Throttle Body Spacer to Supercharger (not used) R Bolt Throttle Body to Spacer & Supercharger (M6 x 32.5)(4 used) R /8 Bolt Intake to Cylinder Heads (M6 x 40) R Bolt Supercharger to Intake (M8 x 53) (one not used with gen2) N /10 Bolt Evaporative Emission Valve to Elbow (M6 x 35.5) (not used) N /2 Bolt S/C Pulley (M6 x 16) (Black flanged) W Part Ref Description Part Number Qty 9-14JS Hardware Kit C FEAD (inside main box) FRTHKC-CA Pulley - Idler B/S 76mm (for 6-rib only, 8-rib gets upgraded) Bolt Idler (M8 x 28 large washer) R Bolt Upper FEAD to Engine and Intake (M8 x 84) W Bolt Lower Bracket to Upper Bracket (M8 x 41) W Bolt Lower Bracket to Engine (M8 x 120) N Bolt M8 X 60MM for new style upper FEAD bracket JS-LM 3 Part Ref Description Part Number Qty 9-14JS Hardware Kit E VMP I/C system (inside main box) VMP50L-HWKE-AA Degas Bottle Cap 9C3Z-8101-B 1 Clamps ¾ Hoses (Constant Tension) CT19x12-BO 8 Bolt Degas Bottle Mounting R J-Clip Degas Bottle 2 nd mounting point (use M6 bolt) N Part Ref Description Part Number Qty 9-14JS Misc Parts Baggy (inside main box) None Grommet Induction Resonance Tube Delete W Decal Belt Routing Diagram 1 3/16 ID Vacuum Hose - 6 /150mm 1 3/4 Hose Sleeve 424mm Heater Hoses (optional) K579SLV 2 DOWNLOAD FULL COLOR INSTRUCTIONS: (CASE SENSITIVE) VMP TVS Installation Manual download Page 4 of 42

5 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. Fender covers are recommended. Fuel System De-pressurization 1. Release fuel system pressure (NOTE: The following is taken directly from the Ford Service Manual). 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. Disconnect the Fuel Pump Control Module electrical connector. NOTE: The Fuel Pump Control Module is located in the spare tire stowage compartment. 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. 2. Using an 8mm wrench, disconnect the (-) negative & (+) positive connections to the battery. Front bumper cover removal VMP TVS Installation Manual download Page 5 of 42

6 (for heat exchanger installation, may be done later) 1. Remove the (8) push pin retainers by pulling the center pin and remove the radiator trim cover. 2. Raise the front of the vehicle using the Ford recommended lifting points and place onto safety stands (optional). With the tires lifted off of the ground, remove the front wheels (optional). Remove the (3) forward Phillips-head screws from each front wheel liner. Using a Phillipshead screwdriver, turn the (5) inner fender push pins ¼ turn to release the centers (optional). Remove the pushpins and then remove the forward inner fenders (optional). 3. Remove the (3) lower close-out shield to radiator support screws (7mm socket), on the lower radiator support. Remove the (2) upper bumper cover screws near the headlights (10mm socket). Reach inside the front wheel wells and unplug the front turn signals. Lift the front bumper cover slightly and pull partially off of the vehicle. The bumper cover comes off by unsnapping it where it meets the fenders behind the headlights. The bumper cover is clipped to the fenders, it comes off by pulling hard. Unplug the fog lights and set the front bumper cover aside. 4. Remove the (4) push pins that retain the impact absorber to the front bumper beam and set the absorber aside. Tip: Removing the front wheels and inner wheel-well liners is optional; it may make the bumper removal easier, but is not required. If your vehicle is not lowered it is possible to remove the bumper cover with the car completely on the ground, or slightly raised on ramps. There is no other work that needs to be done under the car. Bumper cover removal in preparation for heat exchanger installation may be saved for later. VMP TVS Installation Manual download Page 6 of 42

7 Engine bay preparations 1. If equipped, remove the (4) 13mm nuts and the strut tower cross brace. Reinstall the (4) nuts and torque to 25 FT/lb. The strut tower cross brace cannot be reused after the supercharger has been installed. Aftermarket STB that clear are available but not required. 2. Remove the engine appearance cover. The cover cannot be reused after the supercharger has been installed. VMP TVS Installation Manual download Page 7 of 42

8 3. Remove the M6 bolt that secures the induction resonance tube to the driver side fender near the cowl. Remove the tube from the cowl. It is no longer used. Remove 4. Disconnect the PCV Fresh Air Inlet tube from the left-hand cam cover and clean air tube. Remove the clean air tube from the throttle body and airbox. Remove the clean air tube and the induction resonance tube from the vehicle. Neither of these components will be reused. 5. Remove the MAF (mass air flow) sensor connector by pulling the red locking tab back and pressing the black release tab. Release the locking tabs securing the upper airbox lid to the lower airbox. Disconnect the MAF wiring harness retainer from the front edge of the upper airbox lid and remove the lid from the vehicle. Remove the sensor with a T-25 Torx bit, it will be reused. The airbox lid will not be reused. Release Tabs Harness Retainer Location Disconnect MAF Connector 6. Disconnect the throttle body electrical connector. (Pull the red locking tab back; press the black release tab to disengage the lock). Refer to #15 in figure shown below. VMP TVS Installation Manual download Page 8 of 42

9 7. Disconnect the VMV (evaporative emission canister purge valve) tube and electrical connector. Remove the VMV tube retainer from the front left hand cam cover. Disconnect the remainder of the tube at the fitting located behind the inner fender below the brake booster (use a long flathead screwdriver to dis-engage the green locking tab). This tube will not be reused. Refer to #16 in figure shown below. 8. Remove the PCV Purge line from the intake manifold and right-hand cam cover. This line will not be reused. Refer to #17 in figure shown below. Procedures # Disconnect the fuel supply hose from the fuel rail. Refer to #18 in figure shown below. 10. Disconnect the brake booster vacuum hose from the intake manifold. This port is located directly behind the throttle body. Refer to #19 in figure shown below. 11. OPTIONAL Disconnect the heater feed and return hoses located at the front of both the LH and RH cylinder head intake flanges. Position these hoses aside by tucking them up underneath the edge of the hood near the windshield wipers. This is so a braided sleaving may be installed later for appearance. Refer to #20 in figure shown below. 12. Remove the (2) nuts and support bracket that retained the RH heater hose above the RH fuel rail. This hardware will not be reused. Refer to #21 in figure shown below. 13. Remove the steel section of the brake booster vacuum line from the rubber hose at the joint found at the rear of the intake manifold. Discard the steel and forward rubber section of this assembly as it will not be reused. Refer to #22 in figure shown below. VMP TVS Installation Manual download Page 9 of 42

10 14. Remove the (2) nuts and support bracket that retained the LH heater hose above the LH fuel rail. This hardware will not be reused. Refer to #23 in figure shown below. Procedures # Remove the 3/8 engine coolant degas hose, it will be replaced with a new hose. You may temporarily cap the degas bottle, unbolt it, and position it out of the way. 16. Carefully detach the (4) wiring harness retainers from the rear of the intake manifold. The two outer clips will be reused once the new manifold is installed to retain the harness. Long bentend needle nose pliers work good to work them loose. VMP TVS Installation Manual download Page 10 of 42

11 17. Remove and discard the LH and RH fuel rail insulators. Disconnect the (8) fuel injector electrical connectors. 18. Remove the (4) fuel rail bolts. These bolts will be reused. NOTE: It is not necessary to remove the fuel rail from the intake manifold assembly. The injectors may be left installed in the rail and manifold to prevent fuel leakage. The rail feed may be capped. The kit includes a new rail. 19. Remove the (6) intake manifold mounting bolts and remove the intake manifold and fuel rail assembly from the vehicle. This hardware will not be reused. Procedures # Clean the intake mounting surfaces and apply tape over the open intake ports to prevent engine contamination. VMP TVS Installation Manual download Page 11 of 42

12 21. Place the engine coolant degas bottle to the side, it may be left connected. 22. Remove the (4) 10mm bolts securing the Water Pump Pulley to the engine, you should loosen them while the belt is still on. 23. Remove the Front End Accessory Drive (FEAD) belt. Rotate the FEAD Tensioner counterclockwise with a 15mm box wrench to release the belt tension and remove the belt. 24. Cut and remove the A/C compressor belt. Discard belt, SC belt now drives AC. 25. OPTIONAL Remove the upper radiator hose. 26. OPTIONAL Remove the electric fan and shroud assembly from the vehicle. 27. Unclip the engine electrical harness retention clips that retain the engine harness to the top corners of the right hand (passenger side) front cover. Induction Resonance Tube Delete Grommet (drivers side firewall) 1. Install the Induction Resonance Tube Delete Grommet (W651016) found in Hardware Kit A (1311-TVSHKA) in the hole that was exposed when the boom tube was removed. VMP TVS Installation Manual download Page 12 of 42

13 Airbox Modification 1. Remove the MAF sensor from the stock airbox lid with a T-25 torx bit and install into the JLT CAI using the supplied gasket and phillips-head mounting screws, make sure the airflow arrow is pointing toward the oval TB end. Set aside for later. Brake Booster Vacuum Connection 1. Disconnect the factory brake booster hose where it connects to the metal hard line. It will be connected to the back of the supercharger later on. *If you have an automatic car swap out the brake booster 90* fitting (circled below) with the supplied combination 90* and check valve. 40 ** WARNING: ** 30 Automatic transmission vehicles require the installation of a check valve on the brake vacuum booster to retain power break function when the engine is off. VMP TVS Installation Manual download Page 13 of 42

14 11-14 Front Cover Modification This modification can be done several different ways. Depending on the year of the vehicle the front cover design will be slightly different. The first half of 2011 have diagonal ribs (shown below dark shaded) that must be removed along with the bosses. Second half of 2011 through 2012 have no ribs and only need bosses removed. In vertical ribs were added around the left side boss (A) and must be reduced in height to ¼ max (see color picture on next page). A 4.5 or 4 electric angle grinder is very effective for making this modification, a small cutoff tool or air jigsaw are another option. The bosses will break off after having been cut about halfway through. The 2011 style ribs may be scored along the top and bottom, then cut every 1-2 linearly, then snapped off with pliers. Boss G (present on all years) may be cut at an angle to save time. 1. Using a grinder or cut off wheel, modify the front cover in the areas shown. The two bosses located at A & B need to be reduced in height such that they are ¼ max height or lower than the height of the nearby rib structure. The portions of the rib structure (2011 only) C, D, E & F need to be removed completely (cut just above flush to the surface of the front cover). Be careful not to remove too much material in these areas as permanent damage to the front cover could occur. The boss located at G needs to be reduced in height and cut in half (or at an angle). Make sure G is reduced enough not to interfere with the Upper FEAD Bracket (installed on page 32) style: B A G C D CROSS HATCHED SURFACES A & B, MUST BE LOWER THAN OR EQUAL TO THIS RIB HEIGHT E F *Optional 8-rib belt drive conversion kit requires that Boss A, B, and ribs (if present) be ground down within 1/16 of flush with front cover. VMP TVS Installation Manual download Page 14 of 42

15 Boss G is present on all years and needs to be stepped as pictured or may be cut at an angle in one pass. Test fit the upper FEAD bracket in place and make sure it clears this boss. REMOVE MATERIAL OFF OF BOSS G UNTIL THE 20mm HEIGHT IS ACHIEVED. B G front cover design and modifications VMP TVS Installation Manual download Page 15 of 42

16 2011 style ribbed front cover modifications. Notice some ribs that need to be flush vs ¼ high. C REMOVE MATERIAL IN THESE AREAS UNTIL THEY ARE FLUSH WITH THE FRONT COVER SURFACE. D F E VMP TVS Installation Manual download Page 16 of 42

17 Knock Sensor Orientation Adjustment 1. Loosen the two bolts which retain the knock sensors to the engine block and rotate the RH and LH knock sensor toward the RH and LH cylinder heads respectively. In order to do so, first remove the 90 degree plastic wiring retainer clipped to the connector and taped to the wiring convolute. Torque the knock sensor bolts to 25Nm. Remove Clips Here Re-Gapping the Factory Spark Plugs for Optimum Performance 1. Disconnect the electrical connectors for each ignition coil (8 places) and remove the fastener holding the coil on plug in place. Remove the ignition coil on plug. A slight twisting motion will break the seal and ease removal. Remove the spark plugs and re-gap them to inches (8 places) as shown. Anywhere from.028 to.035 is acceptable. 2. Install the re-gapped spark plugs. Torque to 14 Nm (124 lb-in). Install the ignition coil on plugs. Torque the bolts to 6 Nm (53 lb-in). Re-install the coil on plug covers. 3. Optionally, you may install aftermarket plugs such as NGK TR7IX-11(PN 6510). An iridium plug is recommended over a copper or platinum plug for longevity. Much colder plugs should be used at 16psi and above depending on the fuel used and the racing conditions. VMP TVS Installation Manual download Page 17 of 42

18 Intake Manifold Build Up 1. Remove Fuel Charging Assembly (13119H487) from the packaging. 2. Attach the rubber hose from the PCV Purge Hose (13116K817) to the bubbler fitting (3/8 barb) on the bottom of the fuel charging assembly and secure it with the supplied clamp. Install clamp in this location VMP TVS Installation Manual download Page 18 of 42

19 VMP Gen2 Blower Assembly 1. Remove the Evaporative Emission Canister Purge Valve from the stock intake manifold. GT Style 90* angle style valve shown below (Boss valve is straight) 2. The GT style valve bolts down directly to the VMP elbow using the supplied aluminum spacers and 45mm SS allen head bolts. For Boss Mustangs we recommend obtaining a GT style valve from Ford or the parts store Motorcraft: CX-2409 or Ford: AU5Z-9C915-B. The cost is ~$ Connect the supercharger boost bypass valve upper line to the small port on the VMP Gen2 TVS with the supplied 6 x 3/16 hose. The barbed 90* brass nipple fitting will need to be set into the blower with Loctite or a sealant. 4. When you install the blower, you will need to trim the brake booster hose and connect it to the silver tube on the Gen2 s integrated elbow, use one of the factory clamps. 5. Install the red moulded o-ring into the groove of the TB body mounting flange on the Gen2. Fuel Rail Assembly Install the (8) 47lb FRPP, 56lb Ford, ID725, or ID1000 Injector Dynamics injectors into the fuel rail, use a slight amount of lubricant on the o-rings. The purple height extenders should be kept on the ID injectors. The 56s use purple or silver height extenders. The 47s do not need extenders. The electrical connectors should be pointing at ~90* angle to the outside of the rail (or sides of the car). Alignment clips are not used. The injectors are retained by the downward force from the fuel rail. VMP TVS Installation Manual download Page 19 of 42

20 Intake Manifold and Supercharger Installation 1. Remove the tape from the cylinder heads and clean the cylinder head to intake manifold mating surfaces. 2. Install the intake manifold using six (6) M6 x 1.0 x 40 mm bolts (R ) found in Hardware Kit B (1311-TVSHKB). Install these fasteners in the positions shown and tighten the sequence in two stages. Stage 1; torque bolts to 10 Nm. Stage 2; tighten bolts an additional 45 degrees. Reinstall the engine wiring harness retention clips at the rear of the intake manifold Wiring Retainers Here Lube the fuel injector o-rings with assembly lube. Install the fuel rail and injectors into the intake manifold using the take off bolts (very long). Be sure each injector is properly seated into the intake manifold. Tighten the bolt pattern in two stages while pushing the intake manifold rearward as much as possible. Stage 1; torque bolts to 10 Nm. Stage 2; tighten bolts an additional 90 degrees. The lower intake should be biased rearward as much as possible on the heads Connect the eight fuel injector connectors. VMP TVS Installation Manual download Page 20 of 42

21 5. Remove the supercharger assembly from the protective packaging and carefully place on top of the intake manifold. Make sure NOTHING is inside the SC inlet. The supercharger is leak tested, spin tested, and filed with oil at the time of manufacture. For optimal belt alignment we recommend the alignment dowels be discarded and the blower placed as far back on the lower intake manifold as possible, push it rearward while tightening the bolts. 6. Install the VMP supercharger pulley onto the hub of the supercharger using the six (6) M6 x 16 supercharger mounting bolts (W500013) found in Hardware Kit B (1311-TVSHKB). A 1/4in cordless impact with a 5/16 magnetic bit will quickly install or remove these bolts. Go around the pulley in a star pattern 3-times to make sure they are tight, they should be snug, approx ft/lbs, DO NOT OVERTIGHTEN. 7. Install the ten (9) M8 x 53 fasteners (N808130) provided found in Hardware Kit B (1311-TVSHKB) into the mounting holes. Torque fasteners in three steps; 10Nm, 20Nm and 30Nm in the sequence shown. Hole #6 under the integral inlet elbow on Gen2 is not used. Push the blower rearward while tightening the bolts for optimum belt alignment Connect the supercharger bypass reference vacuum line (7R3V-9E498-BB) to the bottom fitting on the supercharger bypass actuator, the other end should be connected to the vent line on the side of the CAI. Route this underneath the heater hose & fuel line. 9. Connect the small black 3/16 vacuum line boost bypass hose from the elbow of the blower to the top port of the supercharger bypass actuator. You will need to thread the 1/8 NPT x 90* barb fitting into the threaded hole on the back of the blower with a small amount of sealant. VMP TVS Installation Manual download Page 21 of 42

22 10. Connect the brake booster vacuum line to the silver tube on the back of the blower. 11. Connect the new Evaporative Emission Canister Purge Valve electrical connector (long 2-wire extension, except Boss, which already has connector nearby). 12. Install the new Evaporative Emission Canister Purge Valve Line (BR3V-9G271-CB) from the fitting below the brake booster to the relocated Purge Valve coming off the Throttle Body Spacer. If not already done, use a long flat head screwdriver to dis-engage the green clip to remove the stock one. 13. Connect the fuel inlet line to the fuel rail. VMP TVS Installation Manual download Page 22 of 42

23 16. Connect the PCV Purge Line (13116K817) to the PCV Valve on the passenger side cam cover and the port on the supercharger. 17. The Red-Orange Moulded Throttle Body Gasket (R ) should have already been installed in the TB opening on the Gen2 blower. Use (4) M6 x 1.0 x 32.5 mm bolts (R ) to secure the Dual 60mm Throttle Body Assembly (R ) OR VMP Twinjet 67mm to the Spacer. Torque bolts to 10 Nm. These can be found in Hardware Kit B (1311-TVSHKB). VMP TVS Installation Manual download Page 23 of 42

24 18. Connect the TPS and ETC Throttle Body electrical connectors from the long Y harness. This harness should be routed along the back of the blower and up the passenger side of the engine, use zip ties so it does not fall. JLT Intake Installation Install the JLT intake according to the directions from JLT. The throttle body coupler should be installed loose, and then tightened after final adjustments are made. The filter should be carefully installed so the internal stop mates up with the end of the tube. The tube will be installed on the TB at a slight angle to accommodate placement of the filter in the shield. The couplers, filter, and tube may be wiped with denatured alcohol or another solvent to prevent them from slipping off. The clamps on the TB end should be installed on the side, not the top, to put equal force on the plastic tube. Avoid over-tightening the clamps on the plastic tube on the TB or filter end. When properly adjusted the JLT CAI will fit and perform well, make sure there are no air leaks and the filter is not pushed on too far as this will cause idle problems. VMP TVS Installation Manual download Page 24 of 42

25 INTERCOOLER SYSTEM INSTALLATION Intercooler Reservoir Mounting 1. Install the Intercooler Degas Bottle (13108D080) with Degas Bottle Cap (9C3Z-8101-B) onto the fan shroud using (1) M6 x 1.0 x 22 mm bolt (R ) from I/C System Hardware Kit E. Use the bottle as a template to mark the second mounting hole with a paint pen. Remove the bottle and drill a 5/16 hole through the fan shroud. Mark Hole Here 2. Install (1) M6 J-Clip (N623332) from I/C System Hardware Kit E onto the fan shroud, if you have left the shroud on the vehicle you can loosen the bolts and slip the J-clip onto the edge. VMP TVS Installation Manual download Page 25 of 42

26 Intercooler Heat Exchanger/Low-Temp Radiator Assembly Mounting The VMP and Afco heat exchangers mount in the same way. Longer bolts through the four inner bumper bolts hold the HE to the frame (see red arrows on right) 1. Start by removing the four inside 13mm bolts (two on each side) that run through the bumper into the frame rails. They are threaded into the frame rails and have a nut on the back, loosen the nut ¼ turn and then thread the bolts out from the front while holding the nut. 2. The heat exchanger will be a tight fit, it will be easier if you only start the long M8x60mm bolts through the bumper about ½ to ¾ of the way and then put them in the rest of the way once the heat exchanger and blue snappy grommets are in place. Use a washer. 3. Assemble the blue snappy grommets in the heat exchanger mounting brackets. There is a cylindrical insert that goes through the middle to provide support, there should be a washer on each side. 4. Once the HE is in place, you may tighten the bolts all of the way down until snug. Once that is done, place M8 nylock nuts on the back to secure the unit. They will eventually bottom out (due to the insert in the snappy) and become snug bumpers require trimming to clear the heat changer, detailed on the next page. It is possible to angle the HE back with washers on the bottom mounts to reduce the amount of trimming required bumpers require no modification. Hose routing and wiring are detailed on the following pages. Use the (4) supplied aluminum spacers to mount the HE farther reward on models and models with the collision warning sensor. These spacers are not needed on models and models without the collision warning system. VMP TVS Installation Manual download Page 26 of 42

27 HE Clearance modifications required on lower valance for ONLY Intercooler Pump/Dual-Fan wiring harness installation VMP Stage 2 and 3 kits use a dual-relay harness to power the intercooler pump and dual fans. Stage 1 kits only have one relay. The relays mount under the headlights, power comes from the rear of the fusebox. The turn-on signal comes from the back of the passenger side head. It is easiest to route the wires under the HE and zip tie them to the fan shrouds. The harness should be grounded just above the headlight. Details may be found on Page 34. VMP TVS Installation Manual download Page 27 of 42

28 Electric Water Pump, Mounting Bracket and Hose Routing 1. Mount the Bosch intercooler pump using the supplied Z-bracket. Assembly breakdown listed below. 2. The side of the Z bracket with round and slotted hole mounts to the bumper bolts on the outside of the frame rail. Attach it using the two supplied M8 serrated nuts. 3. Mount the intercooler pump to the Z bracket with the supplied ¼ carriage bolts and nuts, the inlet should be pointing down (picture on right) and electrical connector pointing up. 4. Install the Intercooler Pump Inlet Hose (13108D029 second longest molded U hose). Connect to the degas bottle outlet port (on bottom, see picture) to the IC pump inlet (pointing down, see pic). It should be routed under the frame rail. Secure the hose on both ends using ¾ constant tension clamps. Sometimes trimming the straight end of the hose by 2-4 will improve fitment. If you have brake cooling ducts leave yourself some extra room. 5. The pump outlet is on the side, it should be pointed towards the front of the vehicle. Connect the 1 of straight ¾ hose to the outlet on the pump and then connect the hose to the inlet on the side of the VMP triple-pass heat exchanger. The intercooler fluid flows into the reservoir tank, then out the bottom of the reservoir tank, into the pump, out of the pump and into the intercooler (VMP Tripple-pass inlet is on drivers side bottom), then out of the intercooler (VMP Tripple-pass outlet is on the top passenger side) and into the bottom port on the lower intake. *If using an Afco 80280PRO (dual-fan) or an Afco 80280NDP (non-fan) it is a dual-pass design and both inlet and outlet are on the passenger side. The Z bracket is not used to mount the pump. Instead, the pump is mounted to the top of the HE. The Afco supplied 90* hose is used for the pump oulet and the medium-length IC pump inlet hose is ran slightly differently to match up with the pump inlet now on top of the HE. VMP TVS Installation Manual download Page 28 of 42

29 Installation of FEAD Belt Drive Assembly 1. Remove the (4) bolts and (1) stud from the front cover as shown. These two bolts will be reused 2. Install the smaller Upper FEAD Bracket (13118B653U) using (2) M8 x 1.25 x 57mm bolts that were removed in the previous step and (2) M8 x 1.25 x 84mm bolts (W704752) from Hardware Kit C ( FRTHKC). Torque bolts to 25 Nm. Make sure there is no interference with the part removed during front cover modification. There is a ground that will need to go on the upper left bolt, you will need to change the round eyelet to a fork by cutting out a section of it, it is currently too small for the bolt to fit through it. Make sure it is installed on the outside of the bracket and not between the bracket and head, which could cause a belt alignment issue. Make sure the boss you trimmed down is not interfering with the bracket. Newer FEAD brackets attach using two extra mounting points on the waterpump/block. Additional bolts (black) are included for this. Shorter 57mm bolts here VMP TVS Installation Manual download Page 29 of 42

30 3. Install (2) Idler Pulleys (900873) onto the machined posts of the Upper FEAD Bracket. Secure the pulleys using (2) M8 x 1.25 x 28mm idler bolts (R ) found in Hardware Kit C. Torque bolts to 25 Nm. The optional 8-rib conversion uses wider idlers in these two positions. 4. Loosely install the FEAD Tensioner Bracket Assembly (13118B603) onto the front cover using (2) M8 x 1.25 x 120mm (N811329) bolts found in Hardware Kit C, leaving at least a 10mm gap between the two new FEAD brackets. Leave a 10mm gap between these bosses to allow for the FEAD belt to be installed. VMP TVS Installation Manual download Page 30 of 42

31 5. Route the FEAD belt. Do not route the belt onto the supercharger pulley yet. 6. Install (1) M8 x 1.25 x 41mm bolt (W705128) found in Hardware Kit C, to fasten the Tensioner Bracket to the Upper FEAD Bracket. Torque all three Tensioner Bracket bolts to 25 Nm. VMP TVS Installation Manual download Page 31 of 42

32 7. Using a 17mm socket, rotate the new tensioner clockwise to install the belt on to the supercharger pulley. Inspect each pulley to ensure the belt is properly seated. Use this nut to rotate the tensioner and enough slack to install the FEAD belt. 8. Re-install the Coolant Pump Pulley using the (4) take off bolts. Torque bolts to 25 Nm. VMP TVS Installation Manual download Page 32 of 42

33 9. Re-install the stock FEAD Belt by rotating the tensioner counter-clockwise and routing the belt as per the stock Ford belt routing. VMP TVS Installation Manual download Page 33 of 42

34 Electrical wiring and extensions (this may be done after the blower is in place to make routing easier) TPS/ETC Extension 1. Locate the Throttle Position Sensor (TPS) connector and harness at the front of the passenger side cylinder head. Connect the VMP Plug and Play Y harness. Route the harness along the main wiring harness around the back of the blower to the rear of the driver side valve cover. Use tape or zip ties to secure the extension harness to the main harness. Once the blower and fuel rail is installed it may be tucked under the existing harness. Canister Purge Valve Extension 1. Locate the Canister Purge Valve electrical connector (2-wire) at the front of the passenger side cylinder head. Connect the VMP Plug and Play extension harness. Run the harness along the drivers side cylinder head back to the firewall, it will connect to the valve on the side of the supercharger elbow. *12-13 Boss 302 does not require an extension as the connector is already located near the firewall. Intercooler Pump and Dual Fan Wiring 1. The harness is supplied with relays and fuses installed. 2. Start by mounting the two relays to the two bolts under the passenger side headlight. 3. Run the power wires with the two fuse holders up behind the headlight and to the large +12v power lug on the back side of the fuse box (remove cover to find it). 4. Run the ground wire behind the headlight and to one of the ground studs above the headlight. A good ground is very important. To ensure a good connection, only use an existing ground. 5. Run the single orange wire in-line connectors behind the headlight the same way, past the PCM, to the top of the cylinder head (to avoid heat from the headers), along the fuel rail and coolant lines, and to the back of the passenger side head. There is a radio capacitor connector on the back of the head that can be disconnected, and this harness plugged in-line with. This will provide a 12v signal to trigger the intercooler pump and fans whenever the key is on. There are several connectors back there, feel around until you find the right ones (pictured on right) 6. We recommend running the two fan connectors and one pump connector along the underside of the heat exchanger and securing it to the fan shroud with zip ties. The harness was designed to run this way for the cleanest install. The single pump connector should find itself under the drivers side headlight, ready for the pump installation. VMP TVS Installation Manual download Page 34 of 42

35 Air Charge Temperature (ACT) Wiring ( only) 1. Unplug the 3 PCM connectors by pushing the gray connector lock arms towards the front of the vehicle. You will be working with the bottom 70 pin or "cowl" connector only. 2. a) Remove the pin locking device as shown in figures 2 and 3. Also remove the wire support on the back of the connector (figure 5) by removing the tape and using a small screwdriver to lift the locking tabs. Figure 2 Figure 3 The ACT sensor harness (VMP) will have the ACT sensor connector at one end. On the other end will be 2 wires, one with a blunt end and the other with a pin already crimped on. The blunt wire will be spliced into the wire located in pin C-56 of the cowl connector. The wire with the pin will be inserted into location C-36 of the cowl connector. There are small numbers on the back of the connector noting location. Figure 4 below will also help to identify the pin locations. Figure 4: PCM Pin Locations for Cowl Connector Front View (side that connects to PCM) VMP TVS Installation Manual download Page 35 of 42

36 b) Remove pin C-56 from the connector by gently moving the locking tab away from the pin on the front of the connector and pulling the wire out of the back of the connector. Remove the insulation from a 1/2" section of the pin C-56 wire and 1/2" of the end of the blunt wire on the ACT loom. Solder the two wires together and seal them with the supplied shrink wrap. Reinsert the spliced wire into the C-56 location. Note the orientation of the pins on the front of the connector and reinstall the pin in the same way. If the pin is turned it will not lock. The finished/inserted splice is shown in figures 5 and 6 (green wire with black shrink wrap). c) Insert the ACT loom wire with the pin into the empty C-36 location of the connector. The back of the connector may have a blank cover at the C-36 location. Carefully push this blank cover in with a small screw driver or punch to allow you to insert the pin. Note the orientation of the pins on the front of the connector and install the new pin in the same way. If the new pin does not go in easily be careful not to break it off, the cover may not have come out cleanly causing resistance. If that happens make sure the hole is clean. Figure 5 Figure 6 3. a) Reinstall the pin locking device by snapping it into place. Reinstall the wire support on the back of the connector and wrap with tape as before. b) Reconnect the PCM connectors and route the ACT loom wire along the top of the cylinder head as shown in figure 7. Connect the 2-pin IAT harness to the IAT sensor next to the blower. Figure uses an integrated maf extension harness and IAT harness, no re-pinning is required. VMP TVS Installation Manual download Page 36 of 42

37 Mass Air Flow (MAF) Wiring 1. Locate the MAF wire harness connector and plug in the VMP Plug and Play MAF extension harness. After the CAI is installed you may route the harness to the side of it and connect it to the MAF sensor. For 2015 the extension harness also includes a breakout for the IAT sensor. Intercooler Hoses 1. Install the Intercooler LTR Outlet hose (13118D030 longest molded hose). Route the hose from the LTR, behind the passenger side headlamp to the lower intercooler turret on the front of the intake manifold. Secure the hose using ¾ constant tension clamps. You may need to hole-saw a ~1 ½ hole through the RH Rad shield. RH Rad. Side Shield Rad. Drain Petcock View from underneath front passenger side 2. Install the Degas Bottle Inlet Hose (13118D031) from the upper intercooler turret to the upper degas bottle fitting using (2) ¾ constant tension clamps. Orient the clamps so the I on the hose is in the center of the clamp tangs. VMP TVS Installation Manual download Page 37 of 42

38 3. Reinstall the upper radiator hose (removal was optional) 4. Reinstall the factory coolant degas bottle onto the fan shroud and torque the bolt to 10Nm. 5. Before reinstalling the factory heater feed and return hoses you must first install the protective sleeve material supplied with this kit in the areas shown below. (OPTIONAL). a) Install one length of protective sleeve ( K579SLV) onto the passenger side heater hose. Slide it over the quick connect fitting and along the heater hose. Apply electrical tape over either end of the protective sleeve to secure its position on the hose. VMP TVS Installation Manual download Page 38 of 42

39 b) Install the other length of protective sleeve ( K579SLV) over the quick connect fitting and along the heater hose on the drivers side. Apply electrical tape over either end of the protective sleeve to secure its position on the hose. 6. Install the 3/8 Engine Bottle Degas Hose ( ) from the engine degas bottle to the fitting on the driver side cylinder head. Secure with the constant tension clamps removed from the factory hose. Ensure both ¾ intercooler hoses, the degas hose and all clamps and wiring have been installed to provide maximum clearance to the supercharger belt. VMP TVS Installation Manual download Page 39 of 42

40 Air Induction System 1. Install the JLT CAI according to the supplied directions. We recommend installing the clamps loose and aligning everything before tightening them down. Do not tighten the clamps too much on the plastic tube or it will deform. The inside of the filter and the outside of the JLT tube should be wiped with alcohol to remove any oil on the rubber and plastic, this will help keep the filter on. A bead of superglue or other adhesive may also be used to keep the filter from coming off. 2. Connect the open end of the supercharger bypass reference line (7R3V-9E498-BB) to the fitting on the side of the JLT intake. 3. Install the supplied PCV Fresh Air Inlet tube ( ) by connecting the 90 deg fitting to the driver side cam cover and angled fitting to the PCV fitting in the clean air tube. VMP TVS Installation Manual download Page 40 of 42

41 Final Assembly 1. Fill the engine cooling system (using a proper coolant mixture) to the marked level on the radiator degas bottle (if the system was opened). 2. Using the same coolant mixture, fill the intercooler system. The coolant should be approximately one inch below the top of the cap. Be careful not to overfill as this will make it difficult to prime the system. If you live in an area that does not freeze you may fill the system with water only and a small amount of coolant or water wetter. 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. You may vacuum fill the system to properly evacuate the trapped air. 3. Reinstall front bumper cover, lower close-out panel and inner fenders by reversing the removal procedures. 4. Reinstall the front wheels/tires. Torque wheel lugs to the factory Ford specifications. 5. Inspect all underhood wiring harnesses for potential interference issues. Use zip ties to safely position the harness away from any areas of concern. Of particular concern is the upper FEAD bracket idler and engine harness. 6. Reinstall the radiator trim cover by reversing the removal instructions. 7. Reinstall the battery connections by connecting the positive cable first then connecting the negative cable. 8. Reconnect the fuel pump control module electrical connector located in the spare tire stowage compartment. 9. DO NOT DRIVE THE VEHICLE UNTIL THE PCM PROGRAMING OPERATION HAS BEEN COMPLETED SUCCESSFULLY. OPERATING THE ENGINE WITHOUT THE PCM RECALIBRATION WILL RESULT IN ENGINE DAMAGE OR FAILURE. 10. Once the re-flash procedure has been successfully completed, 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. VMP TVS Installation Manual download Page 41 of 42

42 11. The Belt Routing Diagram (13116E072) is to be placed on the underside of the hood, on the driver side, opposite of the factory Vehicle Emission Control Information decal. Place Decal in This Area Final Notes: The intercooler system must be circulating and working properly or engine damage may result. You should see water flowing through the reservoir. The heat exchanger fans (stage 2 and 3) should suck air in through the lower grill and blow towards the rear of the vehicle. The VMP custom tune (Stage 2 and 3 kits) is very easy to install with the SCT X4 tuner. Plug in the tuner, go to program vehicle, make sure you select a custom VMP tune from the bottom. The vehicle is now ready to run and drive. You may take datalogs and send them to VMP for review to make sure everything is performing 100%. Intercooler flow diagram for reference: VMP TVS Installation Manual download Page 42 of 42