= SALEEN SPEEDLAB BOOST AND WATER TEMPERATURE GAUGE POD KIT INSTALLATION MANUAL: 2005-09 Mustang 4.6L 3V P/N: 10-8002-C12000B KIT P/N: 10-2903-B11511* Saleen Performance, Inc. 1225 East Maple Rd. Troy, MI 48083 800-888-8945
www.saleen.com IF YOU ARE NOT EXPERIENCED IN THE AREA OF AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT YOU REFER THIS INSTALLATION TO A CERTIFIED INSTALLER OR TECHNICIAN 2
Saleen Speedlab Gauge Pod Kit Installation Guide for '05 to '09 Mustang 4.6L 3V Thank you for buying the Saleen Speedlab Gauge Pod Kit for the '05 to '09 Mustang with the 4.6L 3-valve motor. We appreciate your business, and we hope you enjoy your product. For your benefit, please read the following instructions completely and thoroughly before attempting to install the gauge pod kit. Many questions we have received from customers about the installation of our products could have been easily solved by information listed in the accompanying installation guide. We want you to enjoy the product in its fully functional state, and reading this tutorial is the first step to getting you on your way to a more rare and better performing Mustang. NOTE: Please keep all hardware you remove from your stock Mustang, as much of it will be reused to install the new exhaust kit pieces. Again, thank you for choosing Saleen! 3
Table of Contents I Interior Panel Removal 7 II Gauge Pod Wiring Harness Installation (part 1) 9 III Gauge Pod Wiring Harness Installation (part 2) 11 IV Intercooler Water Temperature Sender Assembly 12 V Intercooler Water Temperature Assembly Installation 14 VI Gauge Pod Wiring Harness Installation (part 3) 16 VII Temperature Sender/Hose Assembly Installation 18 VIII Boost Sender Wire Hookup 20 IX Gauge Pod Hole Drilling 22 X Gauge Pod Wiring Harness Installation (part 4) 23 XI Gauge Pod Attachment to Dashboard 24 4
06-2903-B11158* GAUGE POD ASSY 1 EACH 00-2903-C11150* Gauge 0-10 PSI, boost interim 1 EACH 047-590 BOOST PRESSURE SENDING UNIT 1 EACH 00-2903-C11151* Gauge 100-200 WATER TEMP INTERIM 1 EACH 06-2903-C11201 BRACKET, GAUGES 1 EACH 06-2903-B11157* GAUGE POD HOUSING ASSY 1 EACH 06-2903-C11156 HOUSING, GAUGE POD INTERIM 1 EACH 00-2903-C11159* CLIP, INTERIOR PANEL 2 EACH 00-9006-C11401* TAPE VHB 4956 0.062 THK 1" WIDE 1 INCH 06-3001-B11208 HARNESS, GAUGE POD 1 EACH 00-1704-C09017* TERMINAL, RING 1/4 ID 18 AWG 1 EACH 00-9010-C07071* PVC NON-SHRINK SLEEVING 3/8 BLACK 49.5 INCH 00-1704-C06305* WIRE, 18 AWG YELLOW 131 INCH 00-1704-C06435* WIRE, 18 AWG GREEN 145 INCH 00-1704-C09115* QUICK CONNECT, FEMALE 1/4 4 EACH 00-1704-C6368* WIRE 18 AWG RED 80 INCH 00-1704-C06304* WIRE 18 AWG BLACK 100 INCH 00-1704-C06414* WIRE 18 AWG YELLOW/DK BLUE 86 INCH 00-1704-C09015* PVC NON-SHRINK SLEEVING 1/4 BLACK 60 INCH 00-1704-C09077* HEAT SHRINK, DUAL WALL 3/4 4 INCH 00-1704-C11210* TERMINAL, RING #10 STUD ID 18 AWG 8 EACH 00-1704-C06300* HEAT SHRINK DUAL WALL 1/8 BLACK 46 INCH 06-2003-B11487 MOLDED HOSE S/C TANK TO PUMP MOD 1 EACH 06-2003-C09857 MOLDED HOSE S/C TANK TO PUMP 1 EACH 06-3001-B11164* WATER TEMP. SENDER ASSY 1 EACH 00-3001-C11152* SENDER, WATER TEMPERATURE 1 EACH 00-9010-C11211* UNION TEE, 1/2 NPT 1 EACH 00-9010-C11212* HOSE BARB TO MALE PIPE, 3/4 TO 1/2 NPT 2 EACH 00-9010-C11213* BUSHING, 1/8 FEMALE NPT TO 1/2 MALE NPT 1 EACH 00-9005-C06871* ADEL CLAMP 1" 1 EACH 00-2003-C10068* HOSE CLAMP MOLDED HOSE S/C 2005 MUSTANG 2 EACH 00-1704-C09017* TERMINAL, RING, 1/4" ID 18 AWG 1 EACH 00-1704-C06304* WIRE, 18 AWG BLACK 12 INCH 00-1704-C11621* TERMINAL, RING, 1/2" STUD 16-12AWG 1 EACH 00-9004-C11620* WASHER FLAT 1/2 ID.062" THK AL 1 EACH 5
OBTAIN THE FOLLOWING TOOLS: Drill 1/8 bit Soldering iron Crimp Tool Wire stripper 1/2 Teflon tape 7/8 wrench 12mm wrench 5/16 deep socket wrench 10 mm socket wrench Vice Philips head screwdriver, #2 drive Flat head screwdriver 7 mm nut driver wire dikes Hose Cutter ¼ drive ratchet 10 mm socket, ¼ drive Flashlight Hose clamp pliers 90 degree drill 3/16 bit with drill stop L letter bit with drill stop 5/16 bit with drill stop 1 hole saw ½ wide electrical tape Torque seal 3M Automotive Adhesion Promoter (3M#06396) NON-VOC silicon sealant 6
I Interior Panel Removal Obtain the following tools: Philips head screwdriver Flat head screwdriver 7 mm nut driver Order of Operations: 1. Remove the shifter boot. See FIGURE 1. 2. Remove the two Phillips screws under the center armrest. See FIGURE 2. 3. Remove center console panel by pulling up at the front there are two clips. See FIGURE 3. 4. Remove both side panels by pull them straight back towards the rear of the vehicle. See FIGURE 4. Figure 1 Figure 2 Figure 3 Figure 4 7
5. Remove the 6 bolts that hold the waterfall panel to the instrument panel. (FIGURE 5). 6. Remove the 3 electrically connectors on the top of the panel. Remove the two lower connectors, and remove panel. (FIGURES 6,7,8) 7. Remove the 4 glove box door bolts. 8. Remove the glove box. (FIGURE 9) 9. Remove the 4 radio screws and gently lay the radio down in the center waterfall. Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 8
II Gauge Pod Wiring Harness Installation (part 1) Obtain the following tools: Wire dikes NON-VOC silicon sealant Order of Operations: 1. Remove the passenger wheel well liner. Using a pair of dikes, cut the very end of the rubber nipple on the grommet that is located at the back of the wheel well. Do not remove the entire nipple. (FIGURE 1) 2. With the passenger side kick panel removed, feed only the end of the harness with the two leads through the rubber nipple into the passenger foot well. (FIGURE 2) 3. Stop pulling the harness when you feel the middle section of the harness stop against the nipple. Using NON-VOC silicon, seal the harness and rubber nipple. (FIGURE 3) Figure 1 Figure 2 Figure 3 9
4. Route the harness along the stock Ford harness, have the leads come out where the windshield washer bottle fill neck is. See FIGURES 4, 5, 6, 7. 5. Secure the harness with 3 zip-ties in locations shown in FIGURES 4,5. Figure 4 Figure 5 Figure 6 Figure 7 10
III Gauge Pod Wiring Harness Installation (part 2) Order of Operations: 1. Route the harness that you fed into the foot well along the outside of the foot well, towards the radio and center console, as shown in FIGURES 1-3. 2. Route the harness as shown in FIGURE 4 ensuring that the harness is on the outside of the metal radio bracket. (FIGURE 5 is an overview) 3. Route the end of the harness with the zip-tie leads up and through the two 1 holes in the dashboard. Feed the zip-tied lead that contains the green wire through the left hand side hole. Feed he zip-tied lead that contains the yellow wire through the right hand side hole. (FIGURE 5) Figure 1 Figure 2 Figure 3 Figure 4 Passenger s door Figure 5 Figure 6 11
IV Intercooler Water Temperature Sender Assembly Part Number Description Qty. 00-3001-C11152* Sender, Water Temperature 1 00-1704-C11621* Terminal, Ring, 1/2" Stud 16-12AWG 1 00-9010-C11211* Union Tee, 1/2 NPT 1 00-9010-C11212* Hose Barb To Male Pipe, 3/4 To 1/2 NPT 2 00-9010-C11213* Bushing, 1/8 Female NPT To 1/2 Male NPT 1 00-1704-C09017* Terminal, Ring, 1/4" Id 18 AWG 1 00-1704-C06304* Wire, 18 AWG Black 1 ft. 00-1704-C11620* Washer Flat 1/2 ID.062" Thk Al 1 Obtain the Following Tools: Soldering iron Crimp Tool Wire Stripper 1/2 Teflon tape 7/8 & 12mm wrenches Vice Order of Operations: 1. Wrap Teflon tape on the threads of Part # s 00-9010-C11211*, 00-9010-C11212*, 00-9010- C11213*, 00-3001-C11152*. 2. Solider the 1/2 ID Ring terminal (00-1704-C11621*), to the black ground wire (00-1704-C06304*). Crimp a 1/4" ID ring terminal, (00-1704- C09017*) to the opposite end. (FIGURE 2) 3. Using a vice tighten all the fittings securely, so they do NOT leak fluid. 7/8 wrench is needed. Figure 1 Figure 2 12
4. Place one 1/2" Flat Washer, PN: 00-9004- C11620*, than the 1/2" ID Ring terminal that has been solider to the Black wire, over the Temp. sender, PN: 00-3001-C11152*. Screw the Temp. sender into the assembly and tighten securely, so that it does NOT leak fluid. A12mm wrench is needed. Ensure that the wire is positioned straight back, in-line with the fittings. (FIGURE 3). Figure 3 13
V Intercooler Water Temperature Assembly Installation Part Number Description Qty. 00-2003-C10068* Hose Clamp Molded Hose S/C 2005 Mustang 2 06-2003-C09857C Molded Hose S/C Tank To Pump 1 00-9005-C06871* Adel Clamp 1" 1 Obtain the Following Tools: Hose Cutter Flat head Screwdriver Hose clamp pliers Order of Operations: 1. Cut the hose PN: 06-2003- C09857C, 10.5 from the beginning of the curved section (Figure 1) and 2 from the end of the straight section (Figure 2). Than remove 2 from the end of the newly cut portion. Discard the 2 section. See FIGURES 1, 2. This part is now referenced as 06-2003-B11487. 10.5 Figure 1 2 Figure 2 14
2. Place PN: 00-2003-C10068* HOSE CLAMP MOLDED HOSE S/C 2005 MUSTANG, over each hose piece. Push the hose ends onto the Water Temp. Sender Assy. PN: 06-3001- B11164* (ODS-5096). Slide both hose clamps on. Orientate the Water Temp. Sender Assy as shown in FIGURE. 4. Orientate the hose clamp so that the tabs are pointing up. 3. Slide the Adel clamp PN: 00-9005- C06871* over the hose as shown in FIGURE 4. Figure 3 Figure 4 15
VI Gauge Pod Wiring Harness Installation (part 3) Obtain the Following Tools: ¼ drive ratchet 10 mm socket, ¼ drive Soldering iron Electrical tape Flashlight Order of Operations: 1. Using a 10 mm socket with the ¼ drive ratchet, remove the stock ground bolt as shown in FIGURE 1 the bolt is located behind the glove box, which was removed on page 8. 2. Attach the black ground wire to the bolt and reinstall the bolt. 3. Unplug the small Blue Connector from the SJB box; the SJB box is located behind the passenger side kick panel. (FIGURE 2) 4. On the small Blue Connector find the Yellow / Blue wire*, ensure that the wire is going to PIN # 6. Splice the Orange / Blue Saleen harness wire into the Ford Yellow / Blue wire* using solider, than electrical tape. Plug the connector back in. * The wiring color has changed for 2007 to 2008 Mustangs. The wire is now an Orange w/ blue stripe wire. It will match the Orange w/ Blue stripe wire on the gauge pod wire. Figure 1 Figure 2 16
4. Unplug the large connector from the SJB box. Remove the plastic wiring guard from the back of the connector by squeezing and pulling outward. Locate the pin on the connector that contains TWO Red/Yellow wires. (NOTE: THERE IS ANOTHER PIN LOCATION CONTAINING ONLY ONE RED/YELLOW WIRE, THIS IS NOT THE CORRECT WIRE). See FIGURES. 3, 4. 5. Splice the red Saleen harness wire into one of the two stock Ford Red/Yellow wires at the correct pin location (see step 4) using solder, then electrical tape. Reinstall the plastic wiring guard. 6. Plug the connector back in. Figure 3 Figure 4 17
VII Temperature Sender/Hose Assembly Installation Part Number Description Qty. 06-2003-B11487 Molded Hose S/C Tank To Pump Modified 1 00-2003-C10068* Hose Clamp Molded Hose S/C 2005 Mustang 2 00-9001-C11034* Capscrew PAN HD #8x1/2" PHIL Zn PL 1 Obtain the Following Tools: 5/16 deep socket wrench, ¼ drive 10 mm socket wrench Hose clamp pliers Phillips head screwdriver, #2 drive ¼ drive ratchet Order of Operations: 1. Route the molded hose (S/C Tank To Pump) you modified on page 14 (P/N 00-2003-C10068* becomes 06-2003-B11487A) by first unplugging the 3 PCM connectors (three arrows in FIGURE 3) and the PCM harness connector that is under the top radiator hose (FIGURE 4), and moving to the RH side. Slide the Hose between the PCM and underneath the Fuse box. (FIGURES 1,2,3). 2. Connect the intercooler tank to the hose and use the correct hose clamp (00-2003-C10068*). Connect the pump end of the hose to the pump, using the hose clamp (00-2003-C10068*). 3. Using a ¼ drive ratchet and 5/16 deep socket, attach the ring terminal that is connected to the yellow wire to the temperature sender. See FIGURE 1. 4. Run the ground wire as shown in FIGURE. 2. Run it under the stock Ford harness and up to the radiator support. Unbolt the stock Ford bolt that holds two stock ground terminals using a 10mm socket. Figure 1 Figure 2 18
5. Screw the adel clamp into the sheet metal near the windshield washer bottle using sheet metal screw PN: 00-9001-C11034* with a Phillip #2 drive loaded driver. The adel clamp needs to capture the brass fitting, NOT the hose. See FIGURES. 2, 4. 6. Reconnect the PCM harness and the 3 PCM connectors. See FIGURE. 3. Fuse box PCM connectors PCM Figure 3 Figure 4 Top radiator hose 19
VIII Boost Sender Wire Hookup Obtain the Following Tools: ½ wide electrical tape Order of Operations: 1. With the gauge pod harness routed around the front of the washer bottle neck, route the green boost wire as shown in FIGURES 1, 2. 2. Continue routing the green boost wire along side the PCM (FIGURE 3). Using electrical tape, tape the green boost wire to the stock Ford harness that runs up to the valve covers. (FIGURE 5) 3. Continue routing the green boost wire up the stock Ford harness. Unscrew the nut and washer that is on the Boost sender, and attach the ring terminal that is on the end of the green boost wire. Tighten the nut with the washer on the boost sender. Washer fluid bottle neck Washer fluid bottle neck Figure 1 Figure 2 20
4. Continue routing the green boost wire up the stock Ford harness until you reach the passenger s side front corner of the supercharger. There you will find a threaded plug that needs to be removed with an 11mm socket. 5. Apply Loctite thread sealant #30534 (with PTFE) to the boost sender s threads, then screw the boost sender into the hole where you removed the plug from (passenger front corner of supercharger). Tighten the boost sender with a 13 m wrench. 6. Unscrew the nut and washer that is on the boost sender, and attach the ring terminal that is on the end of the green boost wire. Tighten the nut with the washer on the boost sender, over the green wire ring terminal. (FIGURES 4,5) 7. Using electrical tape, tape the green boost wire to the stock Ford harness. (FIGURES 4, 5) Figure 3 Figure 4 Figure 5 21
IX Gauge Pod Hole Drilling Obtain the Following Tools: 90 degree drill 3/16 bit with drill stop L letter bit with drill stop 5/16 bit with drill stop 1 hole saw L 1in. L 5/16 in. 1 in. Figure 2 Order of Operations: 1. For hole A in FIGURE 1, measure 1 7/8 back from the trailing edge (the edge facing the rear of the car) of the dash. (FIGURE 2) From that line, measure 4 ½ straight across from where the tape measure hits the driver side fold line noted in FIGURE 1 hole A will be 4 ½ to the right of the driver side groove. (FIGURE 2) 2. The two holes on either side of hole A are 1 7/16 away horizontally (straight towards the doors) and 1/8 farther towards the rear of the car (1 ¾ from the trailing edge of the dashboard). (FIGURE 2) 3. The hole in front of hole A is 1 1/8 further forward than hole A. The hole that is farthest forward on the dashboard is 2 ¼ in front of hole A. 4. Using a 3/16 drill bit that has a drill bit stop set for only 1/4 depth, and drill all five pilot holes (FIGURE 2). 5. Using the 5/16 and L drill bits with stops set for ¼ depth, and the 1 hole saw, drill out holes to correct sizes as indicated in FIGURE 2. Don t drill to deep or you will damage the HVAC vents. Deburr all holes. Fold line 1 1/8 A Front of car 1 7/16 1 7/16 1 7/8 1 ¾ 4 ¼ Figure 1 22
X Gauge Pod Wiring Harness Installation (part 4) Part Number Description Qty. 06-2903-B11158* Gauge Pod Assy 1 Obtain the Following Tools: 5/16 wrench Torque seal Order of Operations: 1. With the gauges and bracket already installed in the gauge pod housing, remove the three terminal nuts on each gauge. On the can housing, the nuts are labeled S, I, & G. 2. For the boost gauge & temperature gauge place the black wire over the terminal labeled G, place nut and tighten. Place the red wire on the terminal labeled I, place nut and tighten. 3. For the boost gauge place the green wire over the terminal labeled S, place nut and tighten. 4. For the light place the yellow / blue wire on one of the male spade terminals, and the black wire with female spade terminal on the last male spade terminal. 5. Place torque seal on the nuts and terminals. Boost gauge Temperature gauge Figure 1 23
XI Gauge Pod Attachment to Dashboard Part Number Description Qty. 00-9006-C11401* Tape Vhb 4956 0.062 Thk 1" Wide 1 Obtain the following tools: 3M automotive adhesion promoter (3M# 06396) Order of Operatioms: 1. If there is not tape already on the bottom of the gauge pod, apply 3M automotive adhesion promoter over the crossed section as shown in FIGURE 1. 2. Remove the backing from a 1 x 1 piece of 3M double sided tape (00-9006- C11401*) and press firmly onto the area where you just applied the adhesion promoter. (FIGURE 1) 3. Line the gauge pod up with the dashboard in the orientation shown in FIGUREs 2 and 3, and apply 3M adhesion promoter to the area of the dash where the tape will go. 4. Remove the backing from the tape on the gauge pod, and line up the gauge pod clips with the small holes drilled into the dashboard. (FIGURE 4) 5. Press the gauge pod firmly into place so the clips go into the appropriate holes. 6. Replace the interior trim panel removed on page 7. clips Figure 1 Figure 2 Tape over crossed section clip Figure 3 Figure 4 Hole for clip 24