10-8002-c11517m install manual sc

8/13/2019 10-8002-C11517M Install Manual SC

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SALEEN SERIES VI.5 SUPERCHARGER KIT

INSTALLATION MANUAL: Saleen S-Series / H-Series / Mustang GT(S281 3V, H281 3V, & Mustang GT )

2005 - 2009 Model YearP/N: 10-8002-C11517M

Saleen Performance Vehic les1-800-888-8945

www.saleen.com

* Please keep this manual with the vehicle.

This manual contains maintenance, service, and parts information important to the operation of the motor and supercharger.


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STOP

IF YOU ARE NOT EXPERIENCED IN THE AREA

OF AUTOMOTIVE MECHANICS, WE

STRONGLY URGE THAT YOU REFER THISINSTALLATION TO A CERTIFIED INSTALLER

OR TECHNICIAN.

ENSURE THE VEHICLE PARKING BRAKE IS

ON AND THE TRANSMISSION IS IN PARK OR

IN GEAR WHEN WORKING ON IT.


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STOP

DO NOT INSTALL ANY AFTERMARKET CHIPS ORPROGRAMMERS, OR HAVE YOUR PCM REPROGRAMMED

ANYWHERE BUT AT SALEEN FOR THIS SUPERCHARGER

KIT. THE 2005 to 2009 MUSTANG USES AN ELECTRONICTHROTTLE CONTROL (ETC), WHICH IS CONTROLLED BYTHE POWERTRAIN CONTROL MODULE (PCM) AND THECALIBRATION INSIDE. AFTERMARKET CHIPS DO NOTPROPERLY RECALIBRATE THE ENGINE MANAGEMENTSYSTEM; THIS CREATES A DANGEROUS SITUATIONTHAT COULD RESULT IN A STUCK THROTTLE AND CANLEAD TO INJURY OR DEATH. SALEEN FULLYREPROGRAMS THE PCM TO FORD STANDARDS, ANDENSURES THAT ALL ENGINE SAFETY CONTROLS AREFULLY FUNCTIONAL.


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STOP

THE SALEEN SERIES VI.5 SUPERCHARGER AND

ACCOMPANYING PROGRAMMING ARE DESIGNED

AROUND THE USE OF 91 OCTANE FUEL OR

HIGHER ONLY. BEFORE YOU RUN YOURMUSTANG WITH THE SERIES VI KIT INSTALLED

EVEN ONCE, YOU MUST EITHER DRAIN THE FUEL

TANK COMPLETELY AND FILL IT UP WITH 91

OCTANE, OR BEGIN USING 91 OCTANE IN YOUR

MUSTANG TWO COMPLETE FILLUPS BEFORE

INSTALLATION.


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Table of ContentsA ( )2005 to 2006 Model C (2009 Model)

B (2007 to 2008 Model)

D (Saleen Naturally Aspirated Pulley Kit - S281 3V & H281 3V)

E ( g )Stock Mustan GT Model G (H - Series Model)F (S - Series Model)

I. Table of Contents Pg. I to II

II. Precautions (PLEASE READ CAREFULLY) Pg. III

III. Introduct ion Pg. IV

IV. Requirements

1. Parts List Pg. V to VIII

2. Tool List Pg. IX

V. Tear-Down Instructions

Battery & Tray Removal Pg. 1PCM Removal Pg. 2

PCM Questionnaire Pg. 3

Hood Removal Pg. 4

E Front Fascia Removal (Stock) Pg. 5E to 7E

F Front Fascia Removal (Saleen S-Series) Pg. 5F to 7F

G Front Fascia Removal (Saleen H-Series) Pg. 5G to 7G

Front Bump Isolator Removal Pg. 8

Air Intake Tube & Air Box Removal Pg. 9

Stock Serpentine Belt Removal Pg. 10

Engine Coolant Removal Pg. 11

Throttle Body Removal Pg. 12

Fuel Rail Removal Pg. 13 to 14

Intake Manifold Removal Pg. 15 to 16Alternator Removal Pg. 17 to 18

A Upper Radiator Hoses Disconnection (2005 to 2006 Model) Pg. 19A

B & C Upper Radiator Hose Removal (2007 to 2009 Model) Pg. 19BC

Water Crossover Removal Pg. 20

Water Tube Assembly Removal Pg. 21

D Pulleys Replacement Process (Saleen N/A Pulley Kit Only) Pg. 22D

Pulleys & Fasteners Removal Pg. 23

A Coolant Hose Assembly Removal (2005 to 2006 Model) Pg. 24A

RH (Passenger) Front Wheel Removal Pg. 25

RH (Passenger) Front Fender Well Removal Pg. 26

VI. Parts Assembly & Modification Instructions

Fuel Rail & Injectors Installation Pg. 27 to 28Water Crossover Assembly Pg. 29

A & B Alternator Pulley Replacement (2005 to 2008 Model) Pg. 30AB to 31AB

C Alternator Pulley Replacement (2009 Model) Pg. 30C to 31C

A & B Alternator Harness Modification (2005 to 2008 Model) Pg. 32AB to 35AB

C Alternator Harness Modification (2009 Model) Pg. 32C to 36C

Air Box Modification & Lid Assembly Pg. 37 to 38

Page I


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Table of ContentsA ( )2005 to 2006 Model C (2009 Model)

B (2007 to 2008 Model)

D (Saleen Naturally Aspirated Pulley Kit - S281 3V & H281 3V)

E ( g )Stock Mustan GT Model G (H - Series Model)F (S - Series Model)

VI. Installation Instructions

Water Pump Harness Installation: Routing Pg. 39 to 40

RH (Passenger) Front Fender Well Installation Pg. 41

RH (Passenger) Front Wheel Installation Pg. 42

Water Pump Harness Installation: Wiring Pg. 43 to 45

Idler Pulley Installation Pg. 46

A Radiator Plumb. Conversion Kit (2005 to 2006 Model) Pg. 47A

B & C I/C Recovery Tank Bracket Installation (2007 to 2009 Model) Pg. 48BC

Lower Heater Core Hose Replacement Pg. 49

B & C Heat Exchanger Installation (2007 to 2009 Model) Pg. 50BC

A Heat Exchanger Installation (2005 to 2006 Model) Pg. 50A

Intercooler Water Pump Installation Pg. 51 to 53

Alternator Idler Pulley & Bracket Installation Pg. 54 to 55

Water Tube Assembly Installation Pg. 56

Engine Compartment Bulkhead Modification Pg. 57

Engine Head Port Inspection Pg. 58

Supercharger Assembly Installation Pg. 59 to 60

Water Crossover Installation Pg. 61 to 62

Alternator Installation Pg. 63

Alternator Harness Installation Pg. 64

Serpentine Belt Installation: Routing Pg. 65

Vacuum Hoses Modification Pg. 66 to 67

ACT Harness Installation Pg. 68

Intercooler Water Pump to Recovery Tank Hose Installation Pg. 69

Recovery Tank Installation Pg. 70

Heat Exchanger Hose Installation Pg. 71

Intercooler to Recovery Tank Hose Installation Pg. 72

Throttle Body Installation Pg. 73

Supercharger Assembly to Engine Connections Pg. 74

Air Box & Intake Snorkel Installation Pg. 75

E Front Fascia Installation (Stock) Pg. 76E to 78E

F Front Fascia Installation (Saleen S-Series) Pg. 76F to 78F

G Front Fascia Installation (Saleen H-Series) Pg. 76G to 78G

Hood Installation Pg. 79

Saleen Programmed PCM Installation Pg. 80

Battery & Tray Installation Pg. 81

Intercooler Coolant Fill Pg. 82

Engine Coolant Fill Pg. 83

Vehicle Decal Installation Pg. 84

VII. Post-Installation

Post Installation Information Pg. 85

Page II


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Pre-Installation Precautions:

To help ensure the proper operation of your vehicle, follow the guidelines below:

IF YOU ARE NOT EXPERIENCEDin the area of automotive mechanics, we strongly

urge that you refer this installation to a certified installer or technician.STOP

PAY ATTENTION TO VEHICLE TYPE NOTATIONbecause there are installationsteps in this manual that differ based on whether your vehicle is a Saleen S-Seriesproduct, Saleen H-Series product, or a factory Mustang GT*. Installation proceduresalso vary depending on the model year. There will be clear markings at the lower RHcorner of the page(A - G designations). Taking the time to read these instructionsalong with following the notes will ensure a smooth, easy, and successfulinstallation**.

*This instruction manual consists of the three most likely vehicle types for this kit (Saleen S-Line, Saleen H-Line, & FactoryStock Mustang). Saleen cannot anticipate what modifications may be done to every vehicle, so there may be an installationconflict with some aftermarket equipment.

**This manual was created during the production process, using the Saleen S281SC as an example. Any form of aftermarketbody kits may require different or additional steps when removing body components (such as the front fascia or hood) may bedifferent then the instructions listed in this manual. If the vehicle does contain other aftermarket body components, contact thataftermarket supplier for disassembly and assembly instructions.

Safety Precautions:

To help guarantee your safety, please follow the guidelines lis ted below:

Page III

NO SMOKING, FLAMES, OR SPARKSaround the battery or fuel system. Batteriescan give off fumes that are flammable and may ignite if there is any form of spark oropen flame near it.

WEAR THE APPROPRIATE SAFTEY GEARsuch as safety glasses and glovesduring the vehicle tear down and installation of new components. Always follow thesafety instructions that come with the tools you are using.

USE CAUTION AROUND VEHICLEwhen working on it. Make sure the vehicle isturned OFF, is properly secured (in park or in gear with the parking brake on), and issitting on a level surface.

If a hoist or floor jack is required, make sure the vehicle is in park or in gear and the

parking brake on. If using a floor jack, make sure the vehicle is on a level surface,the rear tires are chocked, and the vehicle is being supported by jack stands. Follow

ALL safety guidelines & operational instructions spelled out in the hoist or floor jacksowners manual. Failure to do so may result in serious injury.

Avoid wearing loose clothing or jewelry, as these items might get caught in movingparts resulting in injury. When instructed to operate your vehicle, make sure you doso in a well-ventilated area (to prevent carbon monoxide poisoning).

Be safe and use proper care and precautions. Saleen wants you to have a safe and rewardingexperience.


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Installation Guide475 H.P. Series VI.5 Supercharger Kit

2005 to 2009

WELCOME!

Thank you for buying the newly improved Saleen 475HP Series VI.5 Supercharger Kit for your 2005to 2009 Mustang (4.6 Liter, 3-Valve engine).

The new kit contains an improved water crossover design now with an integrated thermostat. The kitalso includes a more efficient supercharger housing for improved flow characteristics. We appreciateyour business, and we hope you enjoy your product.

For your benefit, please read the following instructions completely and thoroughly before attemptingto install the supercharger kit. Many questions we have received from customers about theinstallation of our products could have been easily solved by information listed in this installationguide. We want you to enjoy this product in its fully functional state, and reading this tutorial is agreat first step to getting you on your way to a more unique and powerful Mustang.

Please review the VERY IMPORTANT instructions below before proceeding with the kit installation.

Please note that if you have ANY aftermarket parts already installed on your Mustang, or owna S281 3-Valve or H281 3-Valve (both naturally aspirated) you will need to return the vehicleto Stock Ford Mustang Status. This includes pulley, chips, programmers, etc The vehiclewill not function properly, and kit components may not fit properly if the vehicle is not returned

to stock.

Saleen recommends the use of HTO spark plugs (Saleen Part# 00-1601-C13394*) with thiskit, if your vehicle is produced from 2005 to early model year 2008. The HTO spark plug willnot fit vehicles produced after December 1

st2007. To verify if your vehicle will accept HTO

spark plugs, inspect a spark plug coil. If the coil has a brown plastic sleeve, HTO plugs arenot available. If the coil is all black and does not have a brown sleeve, HTO plugs can beordered through Saleen for your vehicle.

We strongly urge that you have at least one person to help you install the supercharger, asthe supercharger assembly is heavy, and the hood is too awkward to position alone. Withenough help and at least one read of this installation guide, you should be well on your wayto one hot Mustang!

Finally, be sure that you fill out the processor questionnaire and return it to Saleen with yourPCM! We cannot flash the PCM without that questionnaire!

Again, thank you for choosing Saleen!

Installation Manual Created: 2005 Page IVRevised: 03/21/2010 By: AJFRevision# 12 Revision Level M


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PARTS INCLUDED IN SERIES VI.5 S/C KIT ~ 475 HP (2005 to 2006)

Below is a lis t of kit it ems and parts unique to the 2005 to 2006 model year kit. Page V will display all of the kit i tems and parts

universal to all kits (2005 to 2009). If you have ordered a 2005 to 2006 Mustang Series VI Supercharger Kit, the parts below are

included in your kit.

A 10-1607-B138260 SERIES VI.5 SC KIT, 475 HP, 2005-06 MUSTANG 1 EACH

06-2001-B095680 HEAT EXCHANGER KIT 1 EACH

06-2001-C09599 HEAT EXCHANGER S/C S197 MUSTANG 1 EACH

00-9003-C001370 JETNUT M8 x 1.25 4 EACH

06-2001-B095710 RECOVERY TANK KIT 1 EACH

00-2001-C099940 CAP TANK 1 EACH

06-2001-C10212 TANK INTERCOOLER RECOVERY 1 EACH

00-9001-C101410 CAPSCRW HEX FLNG M6x1.0mm 25mm FULL THRD Zn PL 3 EACH

00-9004-C120070 WASHER, M6 ID 18MM OD, 18-8 SS 2 EACH

00-9003-C109360 NUT NYLOC M6 10mm WIDTH 6mm HEIGHT 2 EACH

06-1604-B098630 ALTERNATOR MOUNTING KI 1 EACH

06-1604-C09864 ALTERNATOR MOUNT MACHINED 1 EACH

00-9003-C157270 NUT M8 X 1.25 DISTORTED THREAD LOCKNUT ZN PLATED 3 EACH

00-9004-C157320 WASHER AN SS 5/16" ALTERNATOR MOUNT 3 EACH

00-9002-C110890 STUD ST BLCK OX M8x1.25x110mm UNEQUAL 31mm&12mm THD LGTH 1 EACH

00-9002-C110900 STUD, ST BLACK OXIDE, M8 x 1.25 x 65mm 20mm THRD LNGTH 1 EACH

00-2002-C100910 STUD, ST BLACK OXIDE, M8 x 1.25 x 110mm 1 EACH

00-9001-C106650 CAPSCRW HEX FLNG M8x1.25mm 40mm CL 8.8 FULLY THRD Zn PL 2 EACH

00-1706-C153230 STANDOFF, ALTERNATOR WIRE 1 EACH

00-1703-C070870 DUAL WALL HEAT SHRINK 1/2" RED 1 INCH

06-1604-C09936 ALTERNATOR PULLEY S/C S197 MUSTANG 1 EACH

00-9004-C111460 WASHER 17mm ID 40mm OD 1.6mm THICK Zn PL 1 EACH

00-9003-C102610 NUT HEX JAM M16x1.5x8mm Zn PL 1 EACH

00-3105-C115760 ALT PULLEY TOOL 1 EACH

06-2003-C143820 GASKET, WATER CROSSOVER, DRVR, 2007 MUSTANG 1 EACH

00-2003-C19338 COOLANT HOSE ASSEMBLY 1 EACH

00-2003-C19363 THERMOSTAT 2007 to 2010 1 EACH

06-2003-C143810 O-RING, THERMOSTAT 1 EACH00-1703-C070870 DUAL WALL HEAT SHRINK 1/2" RED 3 INCH

00-1704-C110830 SLEEVING, CONVOLUTED 1/2" BLACK 8.5 INCH

00-1704-C063000 HEAT SHRINK, DUAL WALL 1/8" BLACK 13.5 INCH

00-1703-C070810 WIRE, 4 AWG RED 10 INCH

00-1703-C162470 SPLICE, NON-INSULATED SEAMLESS 6 AWG BUTT 1 EACH

00-1703-C070900 TERMINAL, RING 4 AWG FOR 1/4" STUD 1 EACH

00-1704-C093820 WIRE, 20 AWG YELLOW 12.25 INCH

00-1704-C129750 WIRE, 20 AWG YELLOW/BLUE 12.25 INCH

00-1704-C157540 WIRE, 20 AWG ORANGE/BLUE 12.25 INCH

00-1704-C092600 SPLICE, NON-INSULATED SEAMLESS 18-20 AWG BUTT 9 EACH

Page V


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PARTS INCLUDED IN SERIES VI.5 S/C KIT ~ 475 HP (2007 to 2008)

Below is a lis t of kit it ems and parts unique to the 2007 to 2008 model year kit. Page V will display all of the kit i tems and parts

universal to all kits (2005 to 2009). If you have ordered a 2007 to 2008 Mustang Series VI Supercharger Kit, the parts below are

included in your kit.

B 10-1607-B150580 SERIES VI.5 SC KIT, 475 HP, 2007-08 MUSTANG, A/M 1 EACH

06-2001-B150880 HEAT EXCHANGER KIT 1 EACH

06-2001-C09599 HEAT EXCHANGER S/C S197 MUSTANG 1 EACH


00-9004-C001740 WASHER FLAT M8 ST 4 EACH

00-9001-C135810 BOLT M8x1.25mm 30mm CL 8.8 Zn PL FLANGE 2 EACH

00-9004-C114890 WASHER FLAT M8 24mm OD 2mm THK Zn PL 2 EACH

06-2001-B095710 RECOVERY TANK KIT 1 EACH

00-2001-C099940 CAP TANK 1 EACH

06-2001-C10212 TANK INTERCOOLER RECOVERY 1 EACH

00-9001-C101410 CAPSCRW HEX FLNG M6x1.0mm 25mm FULL THRD Zn PL 3 EACH

06-1604-B098630 ALTERNATOR MOUNTING KI 1 EACH

06-1604-C09864 ALTERNATOR MOUNT MACHINED 1 EACH


00-9004-C157320 WASHER AN SS 5/16" ALTERNATOR MOUNT 3 EACH00-9002-C110890 STUD ST BLCK OX M8x1.25x110mm UNEQUAL 31mm&12mm THD LGTH 1 EACH

00-9002-C110900 STUD, ST BLACK OXIDE, M8 x 1.25 x 65mm 20mm THRD LNGTH 1 EACH

00-2002-C100910 STUD, ST BLACK OXIDE, M8 x 1.25 x 110mm 1 EACH

00-9001-C106650 CAPSCRW HEX FLNG M8x1.25mm 40mm CL 8.8 FULLY THRD Zn PL 2 EACH

00-1706-C153230 STANDOFF, ALTERNATOR WIRE 1 EACH


06-1604-C09936 ALTERNATOR PULLEY S/C S197 MUSTANG 1 EACH

00-9004-C111460 WASHER 17mm ID 40mm OD 1.6mm THICK Zn PL 1 EACH

00-9003-C102610 NUT HEX JAM M16x1.5x8mm Zn PL 1 EACH

00-3105-C115760 ALT PULLEY TOOL 1 EACH

06-2003-C143790 HOSE, UPPER RAD PASS, 2006 MUSTANG 1 EACH


00-1704-C110830 SLEEVING, CONVOLUTED 1/2" BLACK 8.5 INCH

00-1704-C063000 HEAT SHRINK, DUAL WALL 1/8" BLACK 13.5 INCH

00-1703-C070810 WIRE, 4 AWG RED 10 INCH

00-1703-C162470 SPLICE, NON-INSULATED SEAMLESS 6 AWG BUTT 1 EACH

00-1703-C070900 TERMINAL, RING 4 AWG FOR 1/4" STUD 1 EACH

00-1704-C093820 WIRE, 20 AWG YELLOW 12.25 INCH

00-1704-C129750 WIRE, 20 AWG YELLOW/BLUE 12.25 INCH

00-1704-C157540 WIRE, 20 AWG ORANGE/BLUE 12.25 INCH

00-1704-C092600 SPLICE, NON-INSULATED SEAMLESS 18-20 AWG BUTT 9 EACH

Page VI


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PARTS INCLUDED IN SERIES VI.5 S/C SUPPLEMENTAL KIT ~ 2009

Below is a list of kit it ems and parts unique to the 2009 model year. Page V will display all of the kit items and parts universal

to all kits (2005 to 2009). If you are installing a Saleen Series VI.5 Supercharger Kit on a 2009 Mustang, the parts below are

inclu ded in the suppl emental kit. Otherwise, the kit is the same as a 2007-2008 kit.

C 06-1604-B19222 2009 SUPPLEMENTAL KIT, SUPERCHARGER 1 EACH

06-1604-C18921 ALTERNATOR PULLEY S/C S197 2009 1 EACH

00-9004-C18923 WASHER, M14 FLAT 1 EACH

00-9003-C18922 NUT, HEX M14x1.50 1 EACH

00-1607-C146160 GASKET, INTAKE MANIFOLD TO HEAD, MUSTANG 8 EACH

Page VII


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PARTS INCLUDED IN SERIES VI.5 S/C KIT ~ 475 HP (UNIVERSAL)

Below is a list of kit it ems and parts that are universal to all model year kits (2005 to 2009)

06-2002-B095960 WATER PUMP KIT 1 EACH

00-2002-C099910 INTERCOOLER WATER PUMP, '05 S281 1 EACH

06-2002-C09888 BRACKET WATER PUMP 05 S281 1 EACH

00-9001-C100640 CAPSCRW HEX FLNG M8x1.25mm 20mm CL 8.8 FULL THRD Zn PL 1 EACH


00-9004-C001740 WASHER FLAT M8 ST 2 EACH

00-9001-C114650 CAPSCRW HEX HD M8x1.25x50 FULL THRD Cl 10.9 Zn PL 2 EACH

00-9004-C114890 WASHER FLAT M8 24mm OD 2mm THK Zn PL 2 EACH

06-2002-C11237 SPACER WATER PUMP BRACKET 2 EACH

06-1704-B16574 HARNESS, '05-'09 MUSTANG (S281 SC & S281 E) WATER PUMP 1 EACH

06-2003-B098560 HOSE KIT S/C 4.6 3V 1 EACH

06-2003-C09857 MOLDED HOSE S/C TANK TO PUMP 1 EACH

069-950 3/4" HEATER HOSE 7.5 INCH

06-2003-C09860 MOLDED HOSE S/C INTERCOOLER TO TANK 1 EACH

06-2003-C09861 MOLDED HOSE S/C H.E TO INTERCOOLER 1 EACH

00-2003-C100680 HOSE CLAMP MOLDED HOSE S/C 2005 MUSTANG 8 EACH

06-2003-B19367 WATER CROSSOVER KIT - SERIES VI.5 1 EACH

00-9001-C101410 CAPSCRW HEX FLNG M6x1.0mm 25mm 4 EACH



00-9004-C19337 M6 WASHER 2 EACH

069-950 HEATER HOSE 6 INCH

00-2003-C100680 HOSE CLAMP 2 EACH

00-2003-C19335 WATER NECK, WATER CROSSOVER 1 EACH

00-2003-C19336 WATER CROSSOVER SERIES VI.5 1 EACH

00-1607-B19330 SUPERCHARGER SERIES VI.5 ASSEMBLY, 475 H.P., S197 MUSTANG 1 EACH

06-1704-B12563 HARNESS, 05-09 MUSTANG (S281 SC & S281 E) ACT CONNECTOR 1 EACH

06-1602-C15559 AIR INLET DUCT 1 EACH

06-1602-C13093 AIR BOX COVER 2006 S281 1 EACH

00-1701-C120760 FUEL INJECTOR 8 EACH00-9001-C101410 CAPSCRW HEX FLNG M6x1.0mm 25mm FULL THRD Zn PL 12 EACH

00-9005-C18840 SPRING CLAMP, 7/16IN SS 1 EACH

00-1604-C111700 GOODYEAR GATERBACK 109.0" 6 RIB BELT 1 EACH

06-2003-C09925 WATER TUBE MUSTANG 1 EACH

178-428 ALTERNATOR IDLER PULLEY, 76MM 1 EACH

00-1604-C099580 IDLER PULLEY, 76MM, GUIDED 1 EACH

10-8003-C12466 STICKER NEON ORANGE 3"x11.5" PCM BOX 1 EACH

10-8003-C12239 (BOX) PCM 2005 MUSTANG 1 EACH

06-9101-C11353 LABEL BELT DIAGRAM SC 1 EACH

069-703 14" ZIP TIE 1 EACH

00-9007-C10122* 7" ZIP TIE 4 EACH

Page VIII


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TOOLS REQUIRED FOR KIT INSTALLATION:

3/8" Drive - Torque Wrench 90 Degree Pick

3/8" Drive - Ratchet Panel Puller

3/8" Drive - 6" Extension Short Phillips Head Screwdriver

5mm Socket Flat Blade Screwdriver

12mm Deep Socket Wire Stripper / Crimper

13mm Deep Socket Heat Gun (For Heat Shrink)

15mm Socket Air Saw or Hack Saw

3/8" Deep Socket Coolant System Pressure Tool

13mm Ratcheting wrench 2 Gallon Bucket

1/4" Drive - Torque Wrench Hose Clamp Pliers

1/4" Drive - Ratchet Pliers1/4" Drive - 8" Extension Fiber Stick

5.5mm Socket (1/4" Drive) 1/2" Drive Impact

8mm Socket (1/4" Drive) 1/2" Drive Breaker Bar

8mm Deep Socket (3/8" Drive) 1/2" Drive 17mm Impact Socket

10mm Socket (1/4" Drive) Deep Socket 1/2" Drive 24mm Impact Socket

10mm Socket (1/4" Drive) Shallow Swivel Socket 1/2" Drive 22mm Impact Socket

3/8" Drive 5/16" Allen Tool Fuel Line Disconnect Tool

3/8" Drive 5mm Allen Tool Blue Loctite

3/8" Drive 6mm Allen Tool Red Loctite

1/4" Drive 3/16" Allen Tool Pen Light

1/4" Drive 4mm Allen Tool Mechanics Magnet

T15 Torx Bit

NOTE:If you do not have any of the tools listed above, you may be able to obtain them from your local tool

lending service

Page IX


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TORQUE ITEM OPERATIO

NOTICE: N

Batteries c

there is an

Disconnect

the clamp w

Disconnect

socket.

Remove the

Remove the

battery.

Using the p

harness to t

Remove the

tray.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

50

60

THE BATTERY, BATTERY TRAY, HEAT SHIELD, HOLD-

DOWN, AND FASTENERS WILL BE SET ASIDE TO BE

INSTALLED LATER

50

60

30

40

60

60

10

20


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The PCM is

the battery.

Pull back on

disconnect

With a 10m

mounting b

Pull the PC

Fill out the P

including th

it to the follo

S

33

T

If you have

ITEM PART NU

10-8003-C

10-8003-C

TORQUE

NOTES:

20

30

10

40

50

20

40

30

A

B


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>

>

S281 SCBLACK INJ. 435HP

S281 SCBLUE INJ. 465HP

S281 SC

DAN GURNEY

S281 SC

SLEEPER

S281 EXTREME

600 HP

S302 SC

EXTREME

TECH SUPPORT

SALEEN REPORT#:

(IF ONE WAS GIVEN)

S281 SC

AMERICAN FLAG

S281 SC

RED FLAG

SHIP PCM TO

H281

3V

SUPERCHARGE

KIT 475 HP

H302

3V

H302

SC

e.g. HEADERS, INTAKES, AIR OR FUEL MANAGEMENT, EXHAUST, OTHER CAL. 'TUNERS'

SALEEN - PCM PROGRAMMIG

33603 Dequindre Rd.

Troy MI, 48083

TAGSHIP (N) (G)

SL (Y) (N)

REC

SENT

OLD

NEW

SALEEN USE ONLY

SELECT THE SALEEN PERFORMANCE LEVEL THAT IS INSTALLED ON YOUR VEHICLE

REAR GEAR RATIO:

(please look at vehicle)

ENGINE

SIZE:

6 SPEED

AUTOTRANSMISSION>

** PLEASE INCLUDE THIS WITH THE PCM YOU ARE SHIPPING **

OTHER MODIFICATION / AFTERMARKET PARTS INSTALLED - NON SALEEN

PLEASE LIST

ALL ITEMS:

REASON FOR PROGRAMMING --- DO NOT LEAVE BLANK

"SEND PCM"

"OVERNIGHT"

CONTACT NUMBERS: DIRECT: 1.800.888.8945 ext 2101 FAX: 1.248.499.5333

10/21/2009

TODAYS DATE: / /

SHIP TO ADDRESS FOR PCM (PLEASE NO P.O. BOXES)

CONTACTNAME: DEALERNAME:

PROCESSOR QUESTIONNAIRE2005 - 2009 MUSTANG

CUSTOMERS

NAME:

PHONE NUMBER:

CITY: STATE: ZIP:

SHIPPING

ADDRESS:

EMAIL:

OTHER

NOT LISTED

S302 SC

25TH STERLING

5 SPEED

MANUAL

TIREMANUFACTURER:

REARTIRE SIZE:

VEHICLE

YEAR:

S302 3V

PARNELLI JONES

SHAPE OF INTAKE TUBE AT A IRBOX: ROUND

S2813V

PLEASE

EXPLAIN:

OVAL

SALEEN AIR INTAKE MODIFICATION INFORMATION

S281 EXTREME

550 HP

S281 EXTREME

575 HP

VEHICLE

MODEL:

VEHICLE

BUMPER#:

VEHICLE

MILEAGE:

VIN:

Page 3


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Locate the w

hood liner)

T-fitting on

(driver). Th

Remove the

hood with a

(passengerfrom the ho

While anoth

10mm bolts

hood is free

get damage

NOTICE: T

the spraye

ITEM PART NU

TORQUE

NOTES:

20

30

1010 10

30

20


18/118


With a pane

shield in pla

Remove the

ITEM PART NU

TORQUE

NOTES:

20

10

20

10


19/118


Both wheel

removed. T

the necess

Once the sc

front wheel

front fascia

Undernea

are four 5.

bottom of

Remove the

to the car.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

20

20

10

30

40


20/118


Once all of

placing the

down until t

order to dis

Press in the

side). Once

from the lam

Disconnect

connectors

disconnect

Remove fro

damaged.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10

30

30

20

DO NOT WEAR WATCHES, RINGS, BRACLETS, OR OTHER

JEWELERY THAT MAY SCRATCH PAINTED PARTS

DURRING DISASSEMBLY OR ASSEMBLY


21/118


With a pane

shield in pla

Remove the

ITEM PART NU

TORQUE

NOTES:

20

10

20

10


22/118


Both wheel

removed. T

the necess

Once the sc

front wheel

front fascia

Undernea

are two 5.5

bottom of

Remove the

to the car.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

20

20

40

10

30


23/118


24/118


With a pane

shield in pla

Remove the

ITEM PART NU

TORQUE

NOTES:

20

10

20

10


25/118


Both wheel

removed. T

the necess

Once the sc

front wheel

front fascia

Undernea

are four 5.

bottom of

Remove the

to the car.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

20

20

10

30

40


26/118


Retrieve so

headlamp b

while pullin

each headl

Remove the

of the front

sit on the fr

Press in the

side). Once

from the lam

Disconnect

connectors

disconnect

Remove fr

damaged.

NOTICE: Uheadlamp

clean any t

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10

40LH SHOWN

30

10

50

DO NOT WEAR WATCHES, RINGS, BRACLETS, OR OTHER

JEWELERY THAT MAY SCRATCH PAINTED PARTS

DURRING DISASSEMBLY OR ASSEMBLY


27/118


28/118


29/118


Insert a 1/2

remove the

Pull the bre

tension on t

While the te

removed.

ITEM PART NU

TORQUE

NOTES:

20

10

10

20

30


30/118


Release the

relief cap an

Once press

Find a suita

bottom pas

coolant.

NOTICE: I

to extract t

and then v

Once the co

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

30

40

10

20


31/118


Disconnect

red shield o

the now exp

vehicle to re

Disconnect

the red lock

Remove the

the 2 nuts a

Once the th

intake man

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10

20

30

30

40


32/118


NOTICE: N

The fuel lin

may ignite

Detach the

bolts and p

Disconnect

mounting s

Disconnec

electrical c

Disconnect

injectors.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10

2030

30

40

40

40


33/118


NOTICE: N

The fuel lin

may ignite

Remove the

Place a rag

and vapors

Place the fu

Slide the fu

tool locks in

Remove the

used later).

Lift the fuel

Remove ea

tip of the sc

injector conthe screwd

the injector

out of the fu

NOTICE: T

them with a

go flying.

to wear saf

used.

TORQUE

NOTES:

20

30

10

40

50

60

10

30

40

50 60 60


34/118


Disconnect

ventilation t

Disconnect

at the rear o

Using hose

rear driver'sthe other sid

Disconnect

driver's side

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10

20

30

40

REAR OF INTAKE MANIFOLD SHOWN


35/118


Remove the

from the cy

Remove the

side fire wa

Remove the

Remove the

with the new

NOTICE: I

that new in

NOTICE: 2

gaskets tha

2009 modeto 2008 gas

your vehic

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

PASSENGER SIDE DRIVER SIDE10 10

REMOVE 5 BOLTS RETAINING THE INTAKE MANIFOLD TO

THE DRIVER (LH) CYLINDER HEAD. THE CENTER BOLT IS

LOCATED TO THE INSIDE OF THE INTAKE RUNNERS.

REMOVE 5 BOLTS RETAINING THE INTAKE MANIFOLD TO

THE PASSENGER (RH) CYLINDER HEAD. THE CENTER

BOLT IS LOCATED TO THE INSIDE OF THE INTAKE

RUNNERS.

20

40

C


36/118


With a tree

alternator b

Disconnect

They are co

Remove the

It is fastene

ITEM PART NU

TORQUE

NOTES:

20

30

10

20

30


37/118


Remove the

bolts and tw

used later.

Remove the

alternator to

wire off of th

Remove the

NOTICE: 2

one pictu re

way.

ITEM PART NU

TORQUE

NOTES:

20

30

1010

10

REMOVE THE 2 STUDS FROM THE ENGINE BLOCK

20

30


38/118


Use tension

(LH) side u

is released,

Use tension

passenger

the clamp is

crossover.

Tuck the dis

clamps on t

ITEM PART NU

TORQUE

NOTES:

20

30

10

10

20


39/118


Remove the

crossover.

Release the

cover.

Remove the

NOTICE: S

into the ne

Release the

radiator. P

Once the up

tension clam

later.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

50

10

30

40

20 50

50


40/118


Before rem

the engine

easier clean

Disengage

disconnect

Remove the

the engine

Remove the

Save the ro

crossover.

NOTICE: F

After the wa

masking tap

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

50

10

20

30

40

50

2007 to 2009 WATER CROSSOVER SHOWN -

2005 to 2006 CROSSOVERS ARE SIMILAR


41/118


42/118


43/118


Remove the

capacitor.

the 18mm h

NOTICE: T

support br

will need to

Remove the

driver side

Remove the

removing th

Remove the

by removin

NOTICE: S

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

30

10

40

2010

2005 to 2006 MODELS: REMOVE THE

WATER HOSE UPPER SUPPORT BRACKET

2007 to 2009 MODELS

10


44/118


Using tensi

lower therm

Remove the

outlet.

Remove the

coolant rese

Remove co

NOTICE: R

hose. Theclamps mig

heat.

ITEM PART NU

TORQUE

NOTES:

20

30

1020

30

10

40


45/118


NOTICE: F

need to be

lifted shou

sure the ve

front cor ne

wheels are

park or in g

be with a h

equipment

Break loos

bar and a

Elevate th

tires no lon

Remove the

Make sure t

nuts are rem

Remove thdamaged.

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10 30

40


46/118


NOTE: The

With a Phili

loose the h

holding eac

Remove e

ITEM PART NU

TORQUE

NOTES:

20

10

6 of 7 RETAINERS SHOWN FENDER LINER

RETAINER PIN

10

20


47/118


NOTICE: N

The fuel lin

may ignite

Retrieve the

passenger

facing upwa

Retrieve th

the fuel rail

Slide the R

side.

Once the R

previous po

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

10

20

30 40


48/118


NOTICE: N

The fuel lin

may ignite

Retrieve the

fuel injector

injector o-ri

Install the f

into the chaneed to fac

Once there

rail. Make

and that bo

When all 8

supercharg

tabs for eac

supercharg

Fasten the

Two of the

used to moare from the

2). Those b

Tighten the

91 Lb-in +/-

NOTICE: I

four fuel ra

used for ap

ITEM PART NU

00-1701-C

TORQUE

NOTES:

91 +/- 13

20

30

10

40

50

A

60

1

PASSENGER (RH) SIDE SHOWN -

THE 2 STUD BOLTS ARE FROM THE FUEL

RAIL MOUNTING TO THE OLD MANIFOLD

DRIVER (LH) SIDE SHOWN -

THE 2 BOLTS ARE FROM THE STOCK

ALTERNATOR MOUNTING BRACKET

601

160

50

50

40

1020

30


49/118


Retrieve the

threads.

Thread the

snug.

Use a 21mm

is positione

2005 to 200

and re-insta

water cross

2007 to 200

Page 20), a

thermostat

shown.

Set the ther

and line up

applying firm

(F)and tigh

ITEM PART NU

00-2003-C

00-2003-C

00-2003-C

06-2003-C

00-2003-C

00-9001-C

TORQUE

NOTES:

91 +/- 13

20

30

10

40

50

10

30

30

40

50

1

A

B

C

D

1

E

F


50/118


Retrieve the

Disconnect

that needs

the connect

Remove the

alternator.

With a flat b

alternator p

Retrieve the

Insert the to

remove the

Saleen Un

aspirated p

Page 22Da

an impact a

Slip the new

the original

pulley is fac

ITEM PART NU

06-1604-C

TORQUE

NOTES:

20

30

10

40

5020

30

70

40

50

SALEEN NATURALLY ASPIRATED UNDERDRIVE

PULLEY KIT PULLEY SHOWN

STOCK PULLEY SHOWN

60

60

70

A


51/118


Retrieve the

of red Loctit

Slide the wa

Then thread

pulley, run t

Obtain 1 alt

Slide the he

shrink to the

Thread the

the harness

the stock 10

ITEM PART NU

00-9004-C

00-9003-C

00-1706-C

00-1703-C

TORQUE

NOTES:

20

30

10

40

10

20

30

40

A

B

C

D


52/118


Retrieve the

Disconnect

that needs

the connect

Remove the

alternator.

Retrieve the

the tool into

the pulley.

NOTICE: A

remove the

Slip the new

the original

pulley is fac

ITEM PART NU

06-1602-C

TORQUE

NOTES:

20

30

10

40

50

20

3010

40 50

A


53/118


Retrieve the

a dab of red

Slide the wa

Thread the

the pulley, r

ITEM PART NU

00-9004-C

00-9003-C

TORQUE

NOTES:

20

30

102010

2030

A

B


54/118


Retrieve a s

end of the h

together. P

harness wit

Remove the

With large w

power wire.

Once the rin

Retrieve the

terminal (B)

ITEM PART NU

00-1703-C

00-1703-C

00-1703-C

TORQUE

NOTES:

20

30

10

40

10

40

20

30 THE POWER WIRE EXTENSION WILL COME PACKAGED

WITH THE RING TERMINAL AND SPLICE ATTACHED

A

B

C


55/118


Take the po

the alternat

section to th

Clamp the n

in the crimp

soldier. Kee

crimp.

Reposition

upward. W

exposed co

wire and rin

Allow both

1.5" section

cover the sp

the ring term

seated to th

ITEM PART NU

00-1703-C

TORQUE

NOTES:

20

30

10

40

20

POSITION THE HEAT SHRINK

AS SHOWN

10

3040

A


56/118


Retrieve the

harness on

Start by cut

the remaini

each cut so

After cutting

heat shrink

shrink total

Obtain the t

wire w/ blue

extension w

Attach each

harness (ex

to crimp eac

Once all thr

piece of hea

heat shrink

ITEM PART NU

00-1704-C

00-1704-C

00-1704-C

00-1704-C

00-1704-C

TORQUE

NOTES:

20

30

10

40

50

30

40

30

EACH WIRE EXTENSION WILL COME PACKAGED WITH A

SPLICE ATTACHED TO EACH END

50

50

A

B

C

D

E


57/118


Wrap the si

With electri

Make sure t

reaches the

Once the al

wire, slide tentire lengt

Make sure t

the alternat

convoluted

ITEM PART NU

00-1704-C

TORQUE

NOTES:

20

30

10

40

6.25"

10 20

30

3040

A


58/118


Retrieve th

bench (stre

for the fuel

battery ring

NOTICE: R

3 clips on t

To move th

towards the

with a mark

Start with th

orientation

attached to

harness, an

Line up the

sure the ori

removed. R

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

EACH CLIP NEEDS TO BE MOVED TOWARDS THE

BATTERY RING TERMINAL - 9.5"10

BATTERY RING

TERMINAL

30

9.5" 9.5" 9.5"

LINE UP CENTER OF EACH

CLIP WITH EACH PAINT

MARK ( OPERATION 20 )

40


59/118


Proceed to

the small zi

zip tie is loc

Carefully re

electric tap

electric tap

With a razo

convoluted

the red pos

tape holdin

harness.

Line up the

the ring ter

position, ele

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

REMOVE

20

30 SIGNAL HARNESS

POSITIVE CABLE

POSITION THE SIGNAL

HARNESS CONNECTOR

EVEN WITH THE BOTTOM

OF THE RING TERMINAL

40

10


60/118


Once the s

tuck the wir

to protrude

harness wit

The engine

be protrudi

tape around

With a razo

the harness

tubing to re

Use cutters

Make the c

Once the ri

the end of t

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

50

THE ALTERNATOR CONNECTOR

PORTION OF THE SIGNAL HARNESS

SHOULD PROTRUDE FROM THE

CONVOLUTE WHERE SHOWN

6"

20

APPLY ELECTRIC TAPE

AROUND WIRES

30

40

50

10


61/118


Retrieve the

ring termina

Take the po

over the str

orientating

terminal is f

the operato

Once the e

insert the h

the extensio

Clamp the n

in the crimp

soldier. Kee

crimp.

Reposition

upward. W

exposed co

wire and rin

ITEM PART NU

00-1703-C

00-1703-C

00-1703-C

TORQUE

NOTES:

20

30

10

40

50

3010

40 50

THE ALTERNATOR POWER WIRE WILL BE PACKAGED

WITH THE RING TERMINAL AND SPLICE ATTACHED

A

B

C


62/118


Allow both t

1.5" section

will cover th

of the ring t

Apply heat

positive cab

positioned

Retrieve the

convoluted

Once the n

convolute w

3". Once to

tubing to th

itself).

ITEM PART NU

00-1703-C

00-1704-C

TORQUE

NOTES:

20

30

10

40

10

POSITION THE HEAT

SHRINK AS SHOWN

20

30

40

A

B


63/118


Retrieve the

sensor from

two fastene

Re-install th

lid (A)with t

sure the air

and motor.

With a recip

box (flat po

air box to cr

NOTICE: 2

Refer to the

Smooth out

necessary,

ITEM PART NU

06-1602-C

00-9001-C

TORQUE

NOTES:

18 +/- 2

20

30

10

50

10

FLOW

120

2009 MODEL A IR BOX 2005 to 2008 MODEL AIR BOX

30

A

B

1


64/118


Set the new

Obtain the a

tabs protrud

lower the lid

into place.

Prep the su

alcohol wip

facing forwa

ITEM PART NU

00-1602-C

06-9101-B

TORQUE

NOTES:

20

30

10

40FLOW

20

30

40

A

B


65/118


Locate the

Locate the

cutters.

Retrieve the

water pumpand mark th

NOTICE: W

side of the

end). Do n

Feed the en

white w/ ye

the harness

(OPERATIO

edge of the

ITEM PART NU

06-1704-B

TORQUE

NOTES:

20

30

10

50

A

INSIDE VEHICLE

WHEEL

WELL

10

20

30

40


66/118


Feed the wa

(RH) wheel

Feed the wa

and bottom

Continue ro

front of the later step.

Once it has

correctly, tu

ties (A)to fa

passenger

ITEM PART NU

00-9007-C

TORQUE

NOTES:

20

30

10

50

A

20

10

MAIN HARNESS

30

40

ZIP TIE

ZIP TIEZIP TIE

WATER PUMP

HARNESS


67/118


Set the fron

Line up the

of the 7 reta

Set the rea

behind the the fender w

Line up the

of the 7 reta

NOTICE: T

pass throu

ITEM PART NU

TORQUE

NOTES:

20

30

10

50

6 of 7 RETAINERS SHOWN FENDER LINER

RETAINER PIN

10

40

20


68/118


Slide the fro

lug nut to h

Seat each l

torque the l

the hub.

Verify all lug

lower the fro

NOTE: Wh

elevated ve

elevated of

potential to

manual for

Make sure t

rolling) Wit

on each wh

each lug nu

and secure

ITEM PART NU

TORQUE

NOTES:

100 +/-

20

30

10

50

1

1

2

34

5

40

1

10


69/118


With a fiber

there is eno

trim until it u

by 4 clips.

Remove the

once the do

up on the w

Disconnect

panel by rot

Once the lo

ITEM PART NU

TORQUE

NOTES:

20

30

1010

20 COVER LAYING

OVER THE SJB

REMOVE THE PASSENGER

SIDE DOOR SILL TRIM

30

PASSENGER SIDE

KICK PANEL TRIM


70/118


While lightly

pop the 4 ta

careful.

Unwrap the

pump harne

Locate pin #

connector o

stripe.

Cut and stri

Splice the w

yellow strip

butt splice (

(B)is added

Once the sp

shrink over

ITEM PART NU

00-1704-C

00-1704-C

TORQUE

NOTES:

20

30

10

40

A

B

UNRAVEL THE

ELECTRIC TAPE AND

LOCATE THE WATER

PUMP HARNESS

2010

30

HEAT

SHRINK

1/8"

VEHICLE WHITE W/ YELLOW STRIPE (PIN 36)

-WIRING DIAGRAM-

WATER PUMP

WHITE W/ YELLOW

STRIPE - TO PLUG

WHITE W/ YELLOWSTRIPE - TO

VEHICLE HARNESS

40

BUTT SPLICE

18-20 AWG

WATER PUMP POWER

WIRE

60

50

50

60


71/118


Wrap conne

secure them

Plug the co

panel by en

pushing the

Re-cover th

panel by sli

Make sure t

lines up wit

pins (one o

existing trim

Once the cl

the door sill

Press the o

rocker sill to

ITEM PART NU

TORQUE

NOTES:

20

30

10

50

50

30 COVER OVER

THE SJB

INSTALL THE PASSENGER

SIDE DOOR SILL TRIM

20

60

PASSENGER

SIDE KICK

PANEL TRIM

30

60

70


72/118


Apply red lo

was remove

Retrieve the

side (LH) pu

Thread the

Tighten the

ITEM PART NU

00-1604-C

TORQUE

NOTES:

18 +/- 2

20

30

10

40

A

1

20

40

1


73/118


Using tensi

coolant hos

(Page 24A)

Lower the c

Install the h

steering puproperly to

retaining br

Install the h

position and

Install the re

Make sure t

leaks.

ITEM PART NU

00-2003-C

TORQUE

NOTES:

20

30

10

40

A

10

30

40

50

50


74/118


Remove the

(inboard).

Once the 2

Orientate th

2 inboard st

Apply blue

OPERATIO

26 Lb-ft +/-

ITEM PART NU

06-2001-C

TORQUE

NOTES:

26 +/- 3

20

30

10

A

1

10

10

20

130


75/118


Locate the

the bulkhea

the bulkhea

two clips in

Once the st

white lockin

Retrieve the

from inside

locking clip

Install the h

the hose fitt

fitting).

ITEM PART NU

06-2003-C

TORQUE

NOTES:

20

30

10

40

A

40

10

20

30


76/118


Install two 1

into the ope

Tighten eac

Slide the he

bolts just in

below it.

Slide four w

HAND TIGHin the heat

between th

The nuts w

Page 53.

ITEM PART NU

00-9001-C

00-9004-C

06-2001-C

00-9004-C

00-9003-C

TORQUE

NOTES:

18 +/- 2

20

30

10

A

1

10

LH SHOWN

RH SHOWN

20

RH SHOWN

1

30

THIS SIDE UP, THIS SIDE FORWARD

B

C

D

E


77/118


Slide the he

factory bolt

Thread on,

Leave the n

installing th

water pump

intercooler

ITEM PART NU

06-2001-C

00-9003-C

TORQUE

NOTES:

20

10

A

THIS SIDE UP, THIS SIDE FORWARD

RH SHOWN

10

10

20

20

B


78/118


Retrieve the

intercooler

Orientate th

Once positi

one 12mm

18 Lb-ft +/-

Remove the

Attach the 7

attach with

ITEM PART NU

00-2002-C

06-2002-C

00-9001-C

069-9

00-2003-C

TORQUE

NOTES:

18 +/- 2

20

30

10

40

1

50

20

40

30

1

50

C

D

E

A

B


79/118


Remove the

RH bumper

Slide the wa

into the bum

OPERATIO

torque wren

Retrieve the

attach the o

exchanger

Slide two sp

20. Slide th

bolt as show

pump brack

Slide the in

washers (E

Tighten the

ITEM PART NU

00-9004-C

00-9001-C

00-2003-C

06-2002-C

00-9004-C

00-9003-C

TORQUE

NOTES:

18 +/- 2

20

30

10

40

1

50

1

50

BOTTOM BOLT SHOWN

20

1

40

10

30

C

D

E

A

B

F


80/118


Now tighten

bumper mo

18 Lb-ft +/-

Re-install th

isolator is re

beam. The

locks into th

ITEM PART NU

TORQUE

NOTES:

18 +/- 2

20

10

1

20

110

110


81/118


Apply a dab

right idler p

Apply a dab

thread the s

left of the to

NOTICE: T

cannot excthe stud st

stud th at e

Repeat OP

Apply a dab

thread into

idler pulley

the engine b

Slip the new

ITEM PART NU

00-9002-C

00-9002-C

00-2002-C

178-4

TORQUE

NOTES:

20

30

10

40

10

30

30

40

THE STUD CANNOT

STICK OUT FROM THE

FRONT COVER MORE

THAN 63mm

20

A

B

C

D


82/118


Retrieve the

belt around

Slide the alt

installed on

Retrieve 3 w

bracket is inred Loctite

applying the

Tighten eac

ITEM PART NU

06-1604-C

00-1604-C

00-9004-C

00-9003-C

TORQUE

NOTES:

18 +/- 2

20

30

10

40

1

10

20

30

401 A

B

C

D


83/118


Retrieve the

the top of th

the coolant

Re-install th

mounting ta

passenger

torque wren

Attach the 2

Re-install th

each hose

hose).

Retrieve a 3

turned end

Make sure

ITEM PART NU

06-2003-C

069-9

00-2003-C

TORQUE

NOTES:

91 +/- 13

20

30

10

40

1

50

10 30

40

50

A

B

C


84/118


Use a plast

After the su

between th

TO

M

Measure th

and the lip

cowl trim).

TO

M

NOTICE: O

supercharg

represent h

supercharg

ITEM PART NU

TORQUE

NOTES:

20

30

10

10

20 30


85/118


Remove the

Look down

plastic caps

insert a mec

that might b

Clean the to

cleaner and

head.

ITEM PART NU

TORQUE

NOTES:

20

30

10LH SIDE SHOWN - RH SIDE TYPICAL10

20

LH SIDE SHOWN - RH SIDE TYPICAL


86/118


Retrieve the

With a large

bypass valv

2005 to 200

the stock in

supercharg

NOTICE: If

will need to

2009 MOD

(due to the

the superch

Remove the

NOTICE: D

screw. It is

Do a last m

correct inje

and proper

Slowly lowe

up on the fr

assembly fr

Re-install th

contacts th

ITEM PART NU

00-1607-B

069-7

00-1607-C

TORQUE

NOTES:

20

30

10

40

50

20

40

60

70

30

60

70

A

B

C


87/118


Retrieve the

the motor.

completed,

started bolt

Tighten eac

91 Lb-in +/-

SC assemb

ITEM PART NU

00-9001-C

TORQUE

NOTES:

91 +/- 13

20

10

1

A

1

2

3

4

5

6

7

8

201


88/118


Install a ten

water tube.

2005 to 200

new gasket

the gasket

2007 to 200

take-off gasis fully seat

Then retriev

install it on

gasket is fu

Set the cro

sure the bra

3" hose sec

NOTICE: T

page. The

OPERATIO

ITEM PART NU

00-2003-C

06-2003-C

TORQUE

NOTES:

20

30

10

40

10

40

ORIENTATE THE

GASKET SO THE

NUB SETS INSIDE

THE MACHINED

NOTCH

20

30A

B


89/118


Make sure

crossover.

Install the c

Apply blue

bolt (A), on

Slide a M6

the bolt into

crossover.

hole on the

in +/- 13.6 L

Slide the re

and installi

crossover.

hole on the

91 Lb-in +/-

Retrieve th

Slide the on

other end oscrewdriver

engaged.

ITEM PART NU

00-9001-C

00-9001-C

00-9004-C

00-9001-C

06-2003-C

TORQUE

NOTES:

91 +/- 13

20

30

10

40

1

10

20

30 1

60mm BOLT (B)

WITH WASHER (C)25mm BOLT (D)

A

B

C

D

E

401

80mm BOLT (A)

WITH WASHER(C)

50

25mm BOLT (D)

50


90/118


NOTICE: T

left. The 2

2009 mode

Apply red L

each bolt in

top bolt thro

the alternat

Retrieve the

31AB or 30

protruding f

capacitor st

Once the al

mounting b

2005 to 200

alternator w

2009 Mode

set aside.

ITEM PART NU

00-9001-C

TORQUE

NOTES:

18 +/- 2

20

30

10

40

A

1

10

20

30

40

ALTERNATOR HARNESS

STAND-OFF - 2005 to 2008 MODELS

1

2005 to 2008 MODEL ALTERNATOR SHOWN

RADIO

INTERFERENCE

CAPACITOR


91/118


NOTICE: T

of the mod

attention to

year vehic

Retrieve the

2005 to 200

of the altern

alternator h

stand-off. R

71 Lb-in +/-

2009 Mode

alternator s

(that is cove

install the 1

with a torqu

Place the g

plug in the

engaged.

Clip the res

retaining cli

retainer (tre

bulkhead.

Connect the

engine harn

NOTICE: F

harness wi

reach the a

Connect the

clamp. Rem

clamp, and

71 Lb-in +/-

TORQUE

NOTES:

71 +/- 10

20

30

10

40

1

50

30

40

60

1

201

20

2005 to 2008 MODELS 2009 MODELS20

1

30

2005 to 2008 MODEL HARNESS SHOWN -

2009 MODEL HARNESS TYPICAL

60


92/118


Route the b

off of the w

Use a d

pulling on t

Slide the se

Once the b

tensioner a

pulleys, and

ITEM PART NU

00-1604-C

TORQUE

NOTES:

20

30

10

40

A

10

20


93/118


Locate the

1/4" hose fr

rail on Page

Cut two inc

Connect on

other end osupercharg

place with 1

Connect the

of the back

line (where

ITEM PART NU

00-9005-C

TORQUE

NOTES:

20

30

10

40

A

10

T-FITTING

2"

CAREFULLY

REMOVE THE

CLIP

20

BYPASS

ACTUATOR

VACUUM LINE

REMOVE 2"

FROM THE END

OF THE HOSE

30

30


94/118


Remove the

and remove

Once the 4

3/8" vacuum

Take the pi

OPERATIOT-fitting to t

Slide the 3/

supercharg

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

4 - 1/4"

10

4030

20


95/118


Locate the

about 6 be

Locate both

4.5 behind

connector.

Strip of

slide a 1 s

shrink is on

wires of the

and crimp w

each crimp

Slide each

splices and

Replace the

10, and sec

the ACT se

Secure the

(not include

ITEM PART NU

06-1704-B

00-1704-C

00-1704-C

00-9007-C

TORQUE

NOTES:

20

30

10

40

50

ACT SENSOR

GAUGE POD

HARNESS

CONNECTOR

(NOT USED)

ZIP TIE

20

50

30

10

A

B

C

D


96/118


Starting at t

hose (A)un

over the fra

Continue ro

hose should

With 1 tens

pump. The

ITEM PART NU

06-2003-C

00-2003-C

TORQUE

NOTES:

20

30

10FUSE BOX A/C LINE

TOWERFASCIA

SUPPORT

BRACKET

10

30

A

B


97/118


Install the in

hose onto t

with a tensi

2005 to 200

the top of th

holding the

Just remove

2005 to 200

tower flange

line up the

ring termina

71 Lb-in +/-

NOTICE: B

nuts on t he

and 2 Nylo

missing, sl

washers a

the same a

2007 to 200

tank brackethree 10mm

torque wren

ITEM PART NU

00-2003-C

06-2001-C

00-9001-C

READ NOTICE BELO

00-9004-C

00-9003-C

TORQUE

NOTES:

71 +/- 10

20

30

10

40

1

10

2005 to 2006 MODEL VEHICLES ONLY

20

BATTERY HARNESS RING

TERMINAL BETWEEN THE

RC TANK AND THE FLANGE1

401

2005 to 2006 MODEL VEHICLES ONLY 2007 to 2009 MODEL VEHICLES ONLY

10

30 A

B

C

D

E


98/118


Route the h

pack (towar

between the

Route the h

canister, an

The hose w

exiting the r

thermostat

Connect the

at the heat

Connect the

at the interc

fitting protru

sure the tab

NOTICE: M

fittings, an

engaging t

ITEM PART NU

06-2003-C

00-2003-C

TORQUE

NOTES:

20

30

10

40

A

50

10

A/C SENSOR

FITTING

A/C LINE TO

DRYER CANISTER

POWER STEERING

LINES

THERMOSTAT HOSE

10

40

50

30

20

B


99/118


Retrieve the

clamps (B).

the hose.

Install the re

sliding the l

the hose so

tension clam

Slide the ot

the superch

and make s

NOTICE: Mfittings, an

engaging t

ITEM PART NU

06-2003-C

00-2003-C

TORQUE

NOTES:

20

30

10

A

20 THE SALEEN LETTERINGWILL BE FACING UPWARD

20

30

30

HEAT EXCHANGER

HOSE INSTALLED

ON PAGE 55

B


100/118


Remove the

Insert the ta

the groove

seated into

Using the fo

inlet assem

torque wren

ITEM PART NU

00-9001-C

TORQUE

NOTES:

91 +/- 13

20

30

10

A

1

20

11

30

30


101/118


Plug in the

side of the

until it is ful

throttle bod

Connect the

throttle bod

fully seated

to lock the

Connect the

assembly li

tube onto th

Connect the

supercharg

tube. Press

Connect the

on the drive

connector i

Connect theach grey c

Press the fu

Press the lo

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

501 OF 8 FUEL INJECTORS SHOWN

10

20

30 40

50

60

70

70

60

70


102/118


Set the mod

two studs w

Line up the

fender well

tighten the

Slip the air

8mm clamp

torque wren

Slip the oth

assembly.

27 Lb-in +/

Reconnect

duct, just in

until it locks

ITEM PART NU

06-1602-C

TORQUE

NOTES:

71 +/- 10

27 +/-

20

30

10

40

1

50

302

5040

2

10

1

20

2

A


103/118


Retrieve the

set the fron

connections

Connect the

connector (

they are ful

Connect bo

connector o

seated.

Set the fron

side of the

lamp.

Once the fr

maneuver e

protruding f

each side o

NOTE: To

connector

doesn't slip

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

50

20

30

50

LH SIDE SHOWN - RH TYPICAL RH SIDE SHOWN - LH TYPICAL

RH SIDE SHOWN - LH TYPICAL RH SIDE SHOWN - LH TYPICAL

40


104/118


Once the e

enough to s

per side). W

44 Lb-in +/

Tuck the ea

screws per

Re- install t

fascia to th

Re-install th

the upper s

to44 Lb-in

ITEM PART NU

TORQUE

NOTES:

44 +/- 6

20

30

10

40

1

10

20

30

1

RH SIDE SHOWN - LH TYPICAL LH SIDE SHOWN - RH TYPICAL

LH SIDE SHOWN - RH TYPICAL

140


105/118


Feed the le

molded into

Once in pla

ITEM PART NU

TORQUE

NOTES:

20

10

10

20


106/118


107/118


Once the e

enough to s

per side). W

44 Lb-in +/

Tuck the ea

screws per

Re- install t

fascia to th

Re-install th

the upper s

to 44 Lb-in

ITEM PART NU

TORQUE

NOTES:

44 +/- 6

20

30

10

40

1

RH SIDE SHOWN - LH TYPICAL LH SIDE SHOWN - RH TYPICAL

RH SIDE SHOWN - LH TYPICAL

101

20

30

140


108/118


Set the upp

Once in pla

ITEM PART NU

TORQUE

NOTES:

20

10

10

10


109/118


110/118


Set the fron

side of the

lamp.

Align/instal

the fender o

stud) onto t

tighten eac

Adjust the f

inboard ver

Make sure

rectangular

Install the tw

the upper s

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

30

20

40

1

50

10

1

50


111/118


Install and t

fascia and w

Clean each

continuing

Position ea

even all thedifferent po

place, remo

bar to each

Re-fasten t

5.5mm scre

the screws

with a torqu

Feed the le

molded into

Once in pla

ITEM PART NU

TORQUE

NOTES:

44 +/- 6

20

30

10

40

1

50

10

1

MEASURE THE DISTANCE BETWEEN THE BUMPER

AND THE HEADLAMP BAR. MAKE SURE IT IS EVEN

ACROSS THE HEADLAMP.

30

20

40

6050

60


112/118


NOTICE: W

person to h

start the hi

to the hood

Lift each ho

hood match

line up the

have been s

held up by t

Tighten the

with a torqu

Take the wi

holes in the

Press the w

sprayer noz

NOTICE: I

position th

ITEM PART NU

TORQUE

NOTES:

14 +/-

20

30

10

40

1

10

4030

201


113/118


Retrieve the

PCM brack

Install the tw

with a torqu

Plug the thr

pushing the

PCM. This

WARNING

ITEM PART NU

TORQUE

NOTES:

62 +/- 9

20

30

10

1

30

10

201


114/118


NOTICE: N

Batteries c

there is an

Insert the b

three 10mm

8 Lb-ft +/- 1

Connect the

Lower the b

compartme

(make sure

71 Lb-in +/-

Set the batt

the bulkhea

Connect the

nearest the

clamp to71

Connect the

remaining p

71 Lb-in +/-

ITEM PART NU

TORQUE

NOTES:

8 +/- 1

71 +/- 10

20

30

10

40

1

50

20

1

1010

10

30

2

40

2

502

60

2

60


115/118


NOTICE: F

straight an

Remove the

into a drain

Cap off the

piece of 3/

Fill the rese

NOTICE: S

Attach the c

recovery ta

Actuate the

drain pan. M

Remove the

installing th

Remove theThen re-ins

ITEM PART NU

TORQUE

NOTES:

20

30

10

40

50

10

20

10

FILL 1"

FROM TOP

30 70

60

40

60

70


116/118


Make sure t

NOTICE: A

coolant sys

vehicle coo

be used to

Refill the co

the radiatorholds stead

Once the ta

radiator rec

remaining a

this step, th

recovery ta

Fill the reco

Close the re

NOTICE: T

Start the vetemperature

Turn the ign

level will dro

Open the re

the cold fill

NOTICE: R

drops belo

monitor t h

once the a

steady.

TORQUE

WARNING! ---- PLEASE READ NOTICE BELOWhile the engine is r unning and right after the engine has been stopped, the coolant w ill be EXTREMELY

HOT!. DO NOT remove the recovery tank cap and / or radiator cap whil e the engine is running and / or

right after the vehicle has been running. Doing so will cause a sudden release of scoldi ng hot coolant and

/ or steam which can cause serious burns and injuries. Always make sure the engine coolant has fully

cooled before accessing any portion of the coolant system.

20

30

10

40

50

60

70

80

10

20

30

40

50


117/118


NOTICE: C

be attache

Open the fu

side of the f

meets the r

Open the h

side cam co

cap making

Apply the b

passenger

the hood st

Apply the C

passenger

ITEM PART NU

06-9101-C

06-9101-C

06-9101-C

10-9101-C

TORQUE

NOTES:

20

30

10

40

50

40TWO HOLES

30

30

HOOD STOP

PAD

40

A

B

C

D


118/118

Post-Installation Review

Listed below is important information about your supercharger kit. Please take the time to read theinformation provided. If you are installing this kit, and not the vehicle owner, please keep this pagewith the vehicle for the vehicle owner to review.

Post-Installation Review:

Make sure that all electrical connections have been made

Check the vehicle for any coolant or fuel leaks

Verify that the intercooler water pump is running when the engine is running.

Verify that all hazard lights (turn signals, parking lights, fog lights, etc) are working properly.

Engine Maintenance & Care:

Use 91 Octane fuelor higher when re-fueling the vehicle.

Use 5w-30weight motor oil (of the highest SAE rating) in the engine instead of the stockrecommended weight. As long as the engine is past the manufacturer recommended break-in, Saleen recommends synthetic motor oil.

Change the motor oil & filter every 3,000 miles. Oil capacity with filter change is 6 quarts.

Change the spark plugs* every 50,000 miles.

Clean and re-oil the air filter every 50,000 miles.

Change the supercharger oil every 50,000 miles. Saleen recommends the use ofNYE Synthetic Oil #605 for the supercharger.

Fill the intercooler system with a 50/50 mixture(anti-freeze / water).

10-8002-c11517m install manual sc

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