Turbo Upgrade Kit Installation for Ford Mustang Ecoboost PN *

Transcription

1 Turbo Upgrade Kit Installation for Ford Mustang Ecoboost PN * BORLA PERFORMANCE INDUSTRIES ***** Please compare the parts in the box with the bill of materials provided ***** to assure that you have all the parts necessary for this installation. These instructions have been written to help you with the installation of your Borla Performance Turbo Upgrade Kit. Please read this document completely before beginning the installation of your system. To ensure this part number fits your specific model year, please visit our website for the latest model year listings at Borla Performance Turbo Upgrade Kit Systems (PN ) is designed for the Ford Mustang equipped with a 2.3L Ecoboost 4-cylinder engine, automatic or manual transmissions. *LEGAL ONLY FOR RACING VEHICLES THAT MAY NEVER BE USED, OR REGISTERED, OR LICENSED FOR USE, UPON A HIGHWAY. Borla Performance Industries recommends that an turbo shop or professional after market parts installer, who has all the necessary equipment, tools and experienced personnel needed for proper installation, should perform the installation of this system. However, if you decide to perform the installation, we recommend someone should help you. Ensure the installer uses all under car safety precautions including eye protection. Please take time to read and understand the following By installing your Borla Performance Turbo Upgrade Kit, you indicate that you have read this document and you agree with the terms stated below. It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Borla Performance Turbo System. Borla Performance Industries assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer s products and/or systems. Included with your Borla Performance Turbo System is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Borla Performance Turbo System, please give us a call at the number provided on the warranty card. 1 of 22

2 Minimum Required Tool List: TOOLS: 1. Vehicle Lift 2. 2 Exhaust jacks, to support system weight 3. Complete 3/8 Drive Ratchet Set with metric sockets, 7mm thru 19mm, assortment of extensions 4. Complete 1/4 Drive Ratchet Set with metric sockets, 7mm thru 19mm, assortment of extensions 5. Set of Torx 10, thru 40, in ¼ drive, wobbly ratchet 6. Air ratchet, or electric ratchet 7. Full set of metric wrenches, 7mm thru 19mm 8. Portable undercar / under-hood work light 9. Pry Bar SHOP SUPPLIES: 1 Safety goggles / glasses to protect your eyes 2 Spray Lubricant 2 of 22

3 WARNING: Use extreme caution during installation. Torque all fasteners according to manufacturer s torque values and tightening sequence. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the down pipe. DO NOT use air impact tools to tighten fasteners on Borla Performance Turbo Upgrade / Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks. NOTE: When you first start your vehicle after the installation of your new Borla Performance Down Pipe, there may be some smoke and fumes coming from exhaust. This is a protective oil based coating used in the manufacturing of mandrel bent performance exhaust tubing. This is not a problem and will disappear within a very short period of time after the exhaust has reached normal operating temperatures. Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all turbo fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble. Turbo Upgrade Kit Installation for Ford Mustang Ecoboost PN Borla s EFR Turbocharger Upgrade Kit for the Mustang Ecoboost is a true plug-and-play product. Featuring a 7163 EFR Ballbearing Turbocharger from BorgWarner, this kit has great power and excellent drivability; it makes your Mustang perform like the thoroughbred it was meant to be. The Upgrade kit includes a highly efficient Intercooler. This Intercooler is engineered to provide maximum charge air temperature reduction in the OEM location, this location was chosen based on careful consideration of the Mustang s front-end aero dynamics. Testing has shown the Intercooler to provide significant efficiency gain over the OEM unit, we have found that it has improvements over several front mounted units that partially block air-flow to the radiator assembly. A high-flow 3 downpipe fitted with a free flowing catalytic converter is part of the kit, the kit is not certified for street use, but many enthusiasts appreciate the function of the catalytic converter in an off-road only kit. The downpipe is compatible with the OEM exhaust or with the Borla Catback system (not included) for the Mustang Ecoboost. We do recommend a Borla CAtback system be used with this kit to achieve max power. The Upgrade Kit also comes with a Cobb Accessport and a tune for 91 Octane. This tune produced 24psi on our R&D dyno, however, results will vary depending on vehicle specific conditions (We need you to send a few data-logs after installation of the kit to verify compatibility of the tune to the vehicle, local fuel octane, etc.) Supporting hardware such as the cast stainless steel adapter between the cylinder head and turbo is included as well as water lines, oil lines, silicone hose connectors, vacuum hose, fittings, clamps, nuts and bolts. 3 of 22

4 BORLA PERFORMANCE INDUSTRIES 1. Remove fasteners from the bottom engine tray and bumper cover. You will now have access to the wire-harnesses and connectors to the lights in the bumper cover. Disconnect the harness from each of the lights. (See Fig. 1) 1 2. Remove fasteners holding the top trim cover in place, then remove trim cover (trim cover not shown), then remove fasteners along the trailing edge of the bumper cover. (See Fig. 2) 2 3. Remove clips / fasteners from inner fender to access and remove fasteners holding the front bumper cover to the front fenders. There are differences in how the fender to front bumper cover is attached from year to year, we therefore recommend that you refer to Ford Service Manual for specifics. (See Fig. 3) 3 4 of 22

5 4. Gently remove the bumper cover from the vehicle, take care not to scratch the paint while removing it. (See Fig. 4) After removal of the bumper cover, the OEM air management system is visible in the front of the radiator. If desired, the air shutter components can be removed by first removing the front crash-beam. Removal or modification to the air channeling components in the intercooler area is needed for best fit You can now access the intercooler hose connectors from the bottom. Loosen the hose clamps on the intercooler side and slide the hose connectors rearward. Un-clip the intercooler on the driver side and gently remove the OEM intercooler from the vehicle. (See Fig. 5) 5 6. Loosen the hose clamp that holds the compressor discharge tube and remove the tube assembly. Remove the reinforced rubber hose connector that attaches the compressor discharge tube to the intercooler; this connector is reutilized in combination with the new stainless steel compressor discharge tube that comes with the kit (See Figs. 6A & 6B). 6A 5 of 22

6 6. See 6A for details. 6B 7. The rubber grommets are installed into the front lower frame extension in the large hole toward the front edge, next to where the grommet is shown. (See Fig.7) 7 8. Brackets and hardware for the new intercooler. (See Fig.8) Due to space constraints it is helpful to attach the brackets to the intercooler while the intercooler is in position on the vehicle. It is also helpful to have a second person assisting with this task. The short pieces of weather-strip are installed on the brackets as shown; see arrow. 8 6 of 22

7 BORLA PERFORMANCE INDUSTRIES 9. Grommets shown installed. (See Fig.10) There is now room for the new upgraded intercooler. (See Fig. 7) The upgraded intercooler can now be positioned in this location. Slide intercooler into the cavity and carefully position the brackets with the piece of weatherstrip (acting as a locator) in the upper intercooler receiver channel in the radiator support. Then place the fastener in the lower bracket, through the grommet and fasten with the washer and nut. 11. Slide intercooler into the cavity and carefully position the brackets with the piece of weatherstrip (acting as a locator) in the upper intercooler receiver channel in the radiator support. Then place the fastener in the lower bracket, through the grommet and fasten with the washer and nut. (See Fig.11) Note: this image show the intercooler installed with brackets and TIP sensor of 22

8 BORLA PERFORMANCE INDUSTRIES 12. Attach the TIP (Throttle Inlet Pressure) sensor to the new intercooler. (See Fig. 12) Slide the intercooler outlet hose over the intercooler outlet nipple and torque the hose clamp. (See Fig. 13) Place the stainless steel compressor discharge tube with the reinforced rubber hose connector attached onto the intercooler inlet nipple, but do not torque the hose clamp yet. Torque the clamp after you have positioned the compressor discharge tube to the discharge nipple of the turbocharger. (See Fig. 14) 14 8 of 22

9 15. Lubricate all hangers and rubber isolators, bolts, and nuts. Loosen and remove the flange hardware in front of OE front pipe. (See Fig.15) 16. Loosen and remove hardware using a 13mm socket. (See Fig.17) Loosen (2) bolts on Bracket for more clearance, and disconnect 02 Sensors. (See Fig.17) of 22

10 18. Disconnect and remove both 02 Sensors. (See Fig.18) Use a muffler stand to support exhaust mid pipe. Remove the down pipe assembly from the vehicle. (See Fig.19) Before starting step 20 below, refer to Ford Service Manual to drain coolant from the radiator. 20. Loosen the banjo bolt securing the coolant line to the block. Loosen the hose clamp holding the other coolant line and carefully remove the hose from the hard-line it is attached to. Coolant will now flow out. (See Fig.20) of 22

11 21. Loosen the two fasteners holding the turbo oildrain flange to the block. Loosen the turbo oil-inlet fitting at the block. (See Fig.21) The new black anodized aluminum 2-bolt flange /fitting will be attached in this location Loosen the nuts holding the turbocharger to the cylinder head, if you have not yet done so, disconnect the Oil-drain line at the block, the Oil-inlet fitting at the block and both water lines at the block. (See Fig.22) Once everything is disconnected, unscrew the nuts holding the turbocharger and carefully remove the turbocharger from the engine bay. The turbo is now able to be lifted out of the vehicle as an assembly. (See Fig.23) of 22

12 24. It is recommended that you seal the ends of the lines from the turbo such that dirt / debris do not enter into the line while it is in storage. Placing the assembly in a plastic bag and sealing the bag will work well also. (See Fig.24) The gasket can now be removed. Clean the surface and install the new gasket supplied in the kit. (See Fig.25) Make sure you put an o-ring in the o-ring grove of the oildrain flanges. (See Fig.26) This flange fitting is then installed on the block on the oil-drain boss where the factory tube / flange was installed before of 22

13 BORLA PERFORMANCE INDUSTRIES 27. Install the 8mm studs into the manifold adapter casting. Note: one of the studs is installed upside down (not with the shorter threaded portion into the casting, but rather the longer threaded portion) to accommodate the tight fit in one hole in the turbine housing. This stud gets installed 2mm deeper into the casting (See Fig.27) It may be helpful to install the adapter on the turbo (don t forget the gasket) and torque the nuts before installing on the engine It is helpful to install manifold adapter, the coolant lines and oil lines on the EFR turbocharger prior to placing the assembly on the engine. (See Fig. 28 & 29) Place the -6AN to M14 fittings in the turbo coolant ports (side), then tighten. The 90 degree -6AN fittings on the coolant hoses attaches to the -6AN to M14 fittings on the turbo, the 90 degree fittings / hose in a downward position, then tighten. The 90 degree -4AN fitting on the oil-inlet hose attaches to the -4AN to M12 fitting on the turbo (top) with the hose / fitting leading toward the engine, then tighten. The 45 degree -10AN fitting on the oil-drain hose attaches to the 2-bolt flange / fitting combination on the turbo (bottom), it is helpful to leave this loose until the 90 degree fitting is connected to the oil-drain fitting on the block; then tighten both fittings. (See Fig. 28 & 29) Place turbo assembly onto the mounting studs on the cylinder head and secure with nuts. It is helpful to install the turbo / adapter in such a way that the compressor inlet (front) of the turbo is at the highest elevation possible before tightening the nuts - this is to make the downpipe clearance to the body underneath the vehicle optimal of 22

14 BORLA PERFORMANCE INDUSTRIES 30. Install M14 / -6AN fitting and torque. (See Fig.30) Install the -4AN Male to M12 Male fitting into the oilsupply location in the block, tighten, then fit the oil-inlet line fitting onto the fitting on the block and tighten. (See Fig.30) Slide the hose clamp over the coolant hose end and then slide the coolant hose onto the hose barb on the block. Secure it in place by sliding the hose clamp into position and tighten. Connect the second coolant hose / fitting onto the fitting you installed in the block earlier. 32. Slide the OEM 2 inch diameter hose clamp / hose assembly over the compressor discharge tube end and then slide the intercooler connecting hose clamp / hose assembly hose onto the opposite side. Secure it in place by sliding the assembly into position on the intercooler and compressor discharge nipple and tighten. (See Fig.32, 33) of 22

15 BORLA PERFORMANCE INDUSTRIES 33. After the tube is in place and attached to both the turbo and intercooler, tighten all hose clamps. (See Fig.33) Tube shown in position with clamps tightened Install the inlet pipe and silicone hose connectors between the turbo and the OEM airfilter box. (See Fig.34) Tighten the hose clamps. Install the high-flow panel air filter in the airfilter box. (See Fig.35) of 22

16 36. Install the Borla Performance Down Pipe from the bottom of the vehicle by carefully sliding the tube up toward the turbo. (See Fig.36) It is helpful to loosely install the two fasteners for the engine bracket, using the original hardware, secure the flange. DO NOT TIGHTEN THE ISO- LATOR HARDWARE YET. (See Fig.37) It is helpful to loosely install the v-band clamp to secure the joint between the turbo and the downpipe. Do not tighten the v-band clamp yet, the remaining components of the down pipe will need to be installed and positioned before tightening any of the joints of 22

17 39. If you have not loosened the bracket for the downpipe isolator, it is helpful to do this now as it facilitates positioning of the downpipe. Don t forget to tighten the fasteners holding the engine bracket to the engine block after the downpipe and exhaust has been aligned and all the joints have been tightened Place a clamp over the expanded end at the front of the Flex Pipe Assembly and insert end into Down Pipe Assembly inserting hangar into rubber isolator. Using the original hardware, secure the hangar support. DO NOT TIGHTEN HARDWARE. (See Fig.40) Place a clamp over the expanded end at the front of the Y-Pipe Assembly or Nipple (depending on exhaust used, refer to page 2) and insert end into Flex Pipe Assembly. Do not tighten the clamp. Install remaining exhaust system per manufacturer recommendations. Check newly installed assembly for proper clearance under the vehicle. (See Fig.41) of 22

18 42. Once all the exhaust components are connected and adjusted to hang in the appropriate location, start tightening clamps. Begin with the v-band clamp at the turbo, and work your way toward the rear of the vehicle. Tighten the Accuseal clamps to ft. lbs. Tighten the flange hardware to ft. lbs. (See Fig.42) Install and torque the two O2 sensors. (See Fig.43) 44. Locate the vacuum tube at the back of the intake manifold, cut the line and place the supplied T in that line, the bottom of the T (the 6mm port) attaches to the supplied vacuum hose which in turn attaches to the bypass valve port on the turbo. See Fig.44) turbo (i) (iii) 43 (ii) actuator of 22

19 BORLA PERFORMANCE INDUSTRIES WARNING: You are about to reprogram your vehicle s ECU. Make sure the vehicle has a fully charged battery before starting this procedure. WE HIGHLY RECOMMEND THAT A BATTERY CHARGER IS ATTACHED WHILE REPROGRAMMING THE ECU. IF BATTERY VOLTAGE DROPs TO LOW DURING REPROGRAMMING, YOU WILL NEED TO CONTACT THE FORD DEALER TO PURCHASE A NEW ECU. If you have any doubts about your ability to perform the reprogramming task, please contact a professional who can assist you with this task. The following procedure outlines how to reprogram the vehicle ECU. 1 2 Plug the Accessport into the OBD2 port and follow the screen prompts. The following sequence is typical for an installation process. 4 3 Depending on which vehicle you own, there may be a difference in the firmware in your ECU. This particular vehicle is a USDM (USA Domestic Market) 2015 Mustang. Choose the Borla Turbo Mustang file. 19 of 22

20 BORLA PERFORMANCE INDUSTRIES 5 6 WE HIGHLY RECOMMEND THAT A BATTERY CHARGER IS ATTACHED WHILE REPROGRAMMING THE ECU. IF BATTERY VOLTAGE DROPs TO LOW DURING REPROGRAMMING, YOU WILL NEED TO CONTACT THE FORD DEALER TO PURCHASE A 7 8 This can take 5-10 minutes 20 of 22

21 9 10 If you get this screen, you have successfully installed a new tune in the ECU. 11 You are not completely done yet. Make sure you wait the full 15 seconds the Accessport is instructing you to. Before you start the vehicle, make sure you have appropriate oil level in the engine. Also make sure you have coolant in the radiator and expansion tank. Make sure all fastener and joints are tight, and after you start the vehicle, be prepared to check for leaks. If there are any leaks, shut the engine down immediately and correct the issue. If everything is OK, allow the vehicle to warm up to operating temperature, shut down the engine, then check oil level. You will be able to check coolant level visually: DO NOT OPEN THE CAP ON THE EXPANSION TANK WHILE THE NOTE: THE NEXT SHOWS HOW TO SET UP THE DATA-LOGGING FEATURE IN THE ACCESSPORT. IMPORTANT: DATALOG 1-3 RUNS AS PER INSTRUCTIONS, THEN EXTRACT THE FILE AND TO BORLA. 21 of 22

22 DATALOGGING PROCEDURE 1 2 With the accessport connected to the vehicle, navigate to the Gauges screen. Navigate to the Green arrow button. 3 Navigate to the Configure Datalogging option. 4 Navigate to the each of the following datalogging channels and turn them on. They will have a green indicator button (C) WGDC Base (%) (C) WGDC Comp Mode (Enum) (C) WGDC Final (%) (C) WGDC Pre-Final (%) Accel. Pedal Pos. (%) Boost Pressure (PSI) Charge Air Temp. ( F) ETC Angle Actual ( ) Engine RPM (RPM) FRP Actual (PSI) Gear Current (Gear) Ign Corr. Cyl1 ( ) Ign Corr. Cyl2 ( ) Ign Corr. Cyl3 ( ) Ign Corr. Cyl4 ( ) Ign Timing Cyl1 ( ) Intake Air Temp. ( F) Load Actual (%) Oct Adj Ratio Lrn (Mult) TIP Actual Abs (PSI) 5 With the accessport connected to the vehicle, navigate to the Gauges, then to Datalogging screen. Start the vehicle, drive gently until coolant is at operating temperature and then 30 minutes to allow the computer to start adapting. Press the center button to start logging, then accelerate up thru the gears while logging. The logging drive should include at least three full throttle, full boost segments. Stop data logging by pressing the center button. After the drive, connect the Accessport CONGRATULATIONS ON THE INSTALLATION OF YOUR NEW BORLA TURBO UPGRADE! 22 of 22