Factory Five Racing Hot Rod Coyote Installation Instructions Manual Download

Page: 104 / 119

104

Check the angle of the pedal pad then clamp the pedal pad to the mount brackets.

Drill through the back of the pedal pad into the recess.

Summary of Contents for Hot Rod Coyote

Page 1: ...ill of Material Drawing may be attached Specification Assembly Instructions Operating Procedure Other Hot Rod Coyote Engine Installation Instructions Parts needed 2 Ford Racing Parts 2 Ford Motor Co P...

Page 2: ...lternator 79 Wiring 84 Accelerator Pedal 89 Air Intake 108 Mass Air Meter 108 Intake tube 113 Exhaust 117 Starting the engine 119 Parts needed Ford Racing Parts M 6007 M50 5 0L Engine M 6017 A504V 5 0...

Page 3: ...800199 0 100 EFI fuel pressure gauge SUM G3138 Fuel Pump Air Intake System SPE 9741 4 to 3 50 Reducer adapter SPE 9771 4 hose coupling SPE 9799 4 90 intake tube SPE 9705 Mass Air Sensor filter adapter...

Page 4: ...ons Engine prep Oil filter relocator Hex key 8mm socket ratchet Teflon tape ratchet extensions wrench vise grips Pipe fittings oil filter relocator The filter on the engine has a metric thread while t...

Page 5: ...Put the o ring in the relocator groove and screw the spin on adapter onto the block Use one of the hose adapters to turn the relocator if necessary so that the spin on adapter is oriented front to bac...

Page 6: ...6 Use Teflon tape on the port plugs Screw the plugs into the rear of the spin on adapter...

Page 7: ...7 Use Teflon tape on the hose fittings Screw the hose fittings into the front of the spin on adapter Screw hose fittings into the relocator...

Page 8: ...e on a location for the relocator We located it under the steering rack in the center of the frame X so that the filter is accessible from under the car but is high enough to allow clearance This did...

Page 9: ...ipe fittings Gauge assembly H14 Hex key 12mm deep 13 16 11 16 sockets ratchet Teflon tape ratchet extensions 2 9 16 11 16 wrenches vise grips Remove the stock oil pressure sender from the block locate...

Page 10: ...10 Use Teflon tape and install the oil pressure gauge sender From the gauge box screw on the NPT adapter...

Page 11: ...11 Put Teflon tape on the adapter then screw on the T adapter fitting Put Teflon tape on the 1 50 NPT tube...

Page 12: ...Use vise grip pliers to attach the 1 50 tube to the sender assembly Use Teflon tape and install the pipe fitting assembly in the oil pressure location on the engine so that the side port faces up for...

Page 13: ...flon tape and install the OEM oil pressure sender in the side of the T fitting Water Temp Sender H14 Hex key or socket 11 16 socket 12mm deep socket extension ratchet Teflon tape Water temp gauge send...

Page 14: ...14 Remove the NPT plug from the side of the block using a H14 Hex key or socket Put Teflon tape on the NPT to NPT adapter...

Page 15: ...15 Screw the adapter into the block using a 1 1 16 socket Use Teflon tape on the NPT to NPT adapter included with the gauge...

Page 16: ...16 Screw the adapter into the larger adapter on the block Put Teflon tape on the sending unit...

Page 17: ...17 Use a 12mm deep socket to screw the sender into the adapters Engine Bolts The engine ends up extremely close to the firewall Cut any extra length off the bolts to prevent damaging the firewall...

Page 18: ...or jig saw Use a hack saw or sawzall with a course wood blade a fine metal blade will get gummed up with the aluminum Use a Marker to mark the top stock alternator boss on the driver side as shown It...

Page 19: ...saw or Reciprocating saw socket ratchet Transmission Polyurethane engine transmission mount kit The two aluminum spacers provides are not used If you are using a Tremec 3550 TKO 500 or a TKO 600 you...

Page 20: ...ransmission mount If not already done install the flywheel and clutch on the engine Remove the vibration damping weight from the clutch fork it is not needed Attach the bellhousing and clutch fork to...

Page 21: ...21 Engine Transmission Installation If electric steering is installed undo the mounting bolts and rotate the motor down out of the way Install the engine and transmission per the assembly manual...

Page 22: ...frame mount and transmission using the 1 09 and 0 32 spacers provided If using electric steering reattach the motor mounting bolts Make sure there is some clearance between the oil pan and motor Redri...

Page 23: ...The Coyote engine requires a 255 lph high pressure fuel pump such as the Summit Racing SUM G3138 Fuel Pump Either an inline pump or intank pump can be used depending on preference Mount a fuel pressu...

Page 24: ...over to the engine fuel rail Push the white fuel line connector onto the fuel rail Hold the fuel line up to the connector and cut it to length with a razor knife Remove the fuel line connector Slide a...

Page 25: ...d Assemble the to 5 32 90 degree adapter Push the side into the short section of hose and fasten with a hose clamp Slide a second hose clamp onto the hose Push the hose onto the vacuum manifold port o...

Page 26: ...26 Push the vacuum line onto the fuel pressure regulator Push the vacuum line onto the hose adapter...

Page 27: ...Cooling system Razor knife flat head screwdriver wire cutters hack saw marker Stainless radiator hose kit Push the correct size adapters onto to the thermostat housing with a length of the stainless h...

Page 28: ...ess hose around towards the center of the frame down then straight forward to the lower radiator outlet and mark the hose for cutting Remove the stainless hose and cut it where marked with a hack saw...

Page 29: ...29 Cut the plastic clamp off the stock upper hose Cut and remove the rubber hose from the plastic adapter...

Page 30: ...30 Attach one of the kit hose adapters to the plastic adapter Push the adapter onto the engine...

Page 31: ...31 Attach another hose adapter to the radiator Route and cut the radiator hose so that the hose curls towards the right side of the car not the left the air filter goes there...

Page 32: ...e clamp the lower one For air bleeding later remove the top cap until coolant starts going up the tube then recap and hose clamp This top one is one of the heater core hose locations if running a heat...

Page 33: ...33 Cap and hose clamp the coolant This is the other heater core location if running a heater and A C If running a heater and A C the stock Mustang heater hoses work well The numbers for the hoses are...

Page 34: ...8472 D Vacuum ports and PCV vent Flat head screwdriver razor knife WD40 Vacuum plugs PCV lines rubber hose T connector There are a couple ways to route the PCV hose depending on your emission requirem...

Page 35: ...k off the vacuum ports and fuel evaporator intake tube just behind the throttle body Tough emissions If not already done connect the right side stock PCV hose from the valve cover to behind the thrott...

Page 36: ...rb fitting in the intake tube after the mass air meter but before the throttle body Carefully cut the 90 PCV fittings out of one of the pcv lines without damaging the barbs Push the heater hose onto t...

Page 37: ...37 Attach the fitting to the left side valve cover Run the hose over to the intake barb and cut the hose to length Use a hose clamp to attach the hose to the intake tube...

Page 38: ...38 Relaxed Emissions Carefully cut the 90 PCV fittings off the pcv lines without damaging the barbs Spray some WD40 into the end of the hose and push the heater hose onto one of the PCV fittings...

Page 39: ...ting onto the left valve cover and run the hose forward just left of the throttle body Cut the hose at the back of the engine with a razor knife Push the remaining hose onto the other 90 PCV fitting a...

Page 40: ...Push the fitting onto the right valve cover and run the hose around the front of the engine to the left side Insert the T fitting into left side hose Cut the Right side hose so that it will go onto th...

Page 41: ...41 Push the right side hose onto the T Push the remainder of the hose onto the third leg of the T and run it down behind the coolant inlet...

Page 42: ...ng in the engine bay Cut the shaft into two sections 8 for the lower shaft and 4 25 for the upper shaft Assemble the two shaft pieces with the included steering joint with the short half of joint on t...

Page 43: ...osely attach the pillow block to the tube clamps the screws will not tighten because of the tube Locate the tube clamps on the tube so that the shaft is as straight as possible and then tighten the cl...

Page 44: ...from turning or moving if they loosen for some reason Reassemble the tube clamps and pillow block on the tubes using the pillow block mounting screws in the drilled holes to locate them Tighten the se...

Page 45: ...wiring harness will exit the cockpit towards the right side of the transmission tunnel Black circuit board box Small and Large Philips head screwdriver Open the black box and remove the nut on the pos...

Page 46: ...46 Put the orange wire ring connector onto the post Tighten the nut on the fan post then bend the ring connector up so the wire clears the white connector...

Page 47: ...47 Push the white multipin connector onto the matching connector on the circuit board Run the white plug wires and the orange fan plug out of the box in the slot provided near the plug...

Page 48: ...48 Connect the green power plug inside the box It gets attached using a large Philips head screwdriver through the bottom of the box...

Page 49: ...t of the center of the car on the tubes behind the firewall If using an A C unit there is enough room behind the dash to mount the box to the A C unit In the following picture an aluminum piece was us...

Page 50: ...ck box to the frame or mount using some of the self tapping aluminum screws used to hold the aluminum to the frame during shipping Fuel Pump Remove the fuse from the fuel pump circuit on the chassis h...

Page 51: ...51 On the back of the fuse panel cut the tan wire going from the relay to the fuse area Route the Coyote harness fuel pump green wire to the back of the chassis harness fuel panel...

Page 52: ...Cut the wire to length and solder the tan and green wires together Neutral Safety switch If not using the neutral safety switch in the Coyote harness route the wire blue yellow to a ground on the chas...

Page 53: ...53 Cut the wire to length and crimp on a blue ring connector Attach the ring connector to ground...

Page 54: ...ounting Ratchet 10mm deep socket 5 32 Hex key pliers Place the computer mounting bracket onto the front oil pan stud on the right side of the engine as shown and the side mount stud on the left side o...

Page 55: ...et and 6mm locknuts to mount the bracket If using electric steering hold the computer up to the front side of the bracket with the plastic side of the computer on top and check for clearance with the...

Page 56: ...6 If necessary use a pair of channel lock pliers to bend the computer bracket up slightly so there will be clearance for the computer Test fit the computer again then attach the computer to the bracke...

Page 57: ...57 Run the computer plugs on the right side of the oil pan...

Page 58: ...58 Plug the two engine harness plugs into the computer...

Page 59: ...59 Pull the harness tight along the oil pan and zip tie the harness to the mounting eyes on the oil pan Starter Solenoid The solenoid on the starter is the one being used to start the engine...

Page 60: ...e battery cable to the starter solenoid along the transmission from the battery Attach the battery cable to the starter solenoid Make sure not to push the cable too far over or it may contact the star...

Page 61: ...1 Attach the tan green wire to the starting post on the solenoid Run the ground wire that exits the harness with the tan green starter wire over to your engine ground strap ground or some frame ground...

Page 62: ...62 Crimp a ring connector to the ground wire Attach the wire to ground Attach the battery cable starter wire and ground wire to the oil pan with the wiring harness...

Page 63: ...63 Cut the chassis harness blue starter solenoid wire back to the harness conduit Use electrical tape to cover the end of the blue wire...

Page 64: ...gine control the radiator fan If you do not want to do this do not use the wires and remove the correct radiator fan fuse from the black box and skip this section Pull the blue fan wire out of the cha...

Page 65: ...65 Cut the blue fan wire Remove the fan relay from the fuse panel...

Page 66: ...66 Remove the fan fuse Run the orange and black Coyote harness fan wires over to the front chassis harness...

Page 67: ...67 Run the fan wires forward to the front of the frame with the chassis harness Power start Soldering iron wire cutters strippers electrical tape...

Page 68: ...68 Locate the EFI crank and coil wires in the chassis harness Route the Coyote 12v start run wire red green and 12v start red blue wires to the chassis harness EFI wires and cut to length...

Page 69: ...69 Connect the 12v start run wire red green wire to the orange coil wire Connect the 12v start red blue wire to the blue crank wire...

Page 70: ...70 Gauges Tach Find the purple tach wire in the sending unit plug and cut it so the engine harness can get connected to the purple wire...

Page 71: ...71 Run the engine harness tan yellow tach wire over to the purple wire and solder them together Water Temp Sender Wire cutter wire crimper wrench...

Page 72: ...72 Run the blue water temp chassis harness wire to the sending unit and cut to length Crimp a ring terminal to the sending unit wire...

Page 73: ...73 Attach the ring terminal to the water temp sending unit Oil Temp sender 11 16 wrenches Wire cutter wire crimper...

Page 74: ...74 Push the Engine computer harness plug onto the stock sending unit Run the chassis harness gray oil pressure wire to sending unit and cut to length Crimp on a blue ring terminal connector...

Page 75: ...75 Rotate the sending unit so the computer sending unit is facing the rear of the engine Attach the sending unit wire ring terminal to the sending unit...

Page 76: ...O2 Harness Soldering iron wire cutters strippers electrical tape Locate the right side O2 wires in the Coyote harness near the bellhousing Zip tie the harness forward to the harness going to the compu...

Page 77: ...left side O2 wires between the oil pan and bellhousing over to the left side of the engine Intercooler wire Cut the white red Intercooler pump wire as far back in the harness as you can It is not need...

Page 78: ...attach the power distribution post to the 2 x 2 tube Shorten and attach the red wire from the black box to the power distribution post using one of the yellow ring connectors Attach a ring connector t...

Page 79: ...ive kit The stock Alternator is designed to run counter clockwise and the frame goes through the stock location so it can not be used With the internal fan curve direction of the stock Alternator ther...

Page 80: ...80 Put the large long bolt through the alternator and place the spacer on the bolt Attach the alternator to the mounting bracket leaving the nut so that the alternator can rotate...

Page 81: ...81 Pass the short bolt through the other bracket mounting hole and place the small ID spacer on the bolt Thread the bolt into the Alternator...

Page 82: ...82 Tighten the alternator mounting bolts Run the bracket mounting bolts through the bracket and put the spacers on the bolts...

Page 83: ...83 Remove the timing cover screws at the points shown in the picture above Attach the mounting bracket to the engine keeping the engine control harness behind the bracket...

Page 84: ...h the belt tensioner to the timing chain cover and tighten to 18 lbft 25Nm then route the belt as shown Wiring Run the red chassis harness alternator wire under the firewall up to the right side of th...

Page 85: ...Run the alternator wire to the front of the engine next to the engine harness Run the alternator wire down to the alternator output post Cut the wire to length and attach a yellow ring terminal connec...

Page 86: ...86 Put the ring terminal on the alternator output post Tighten the locknut on the output post so that the nut is snug Do not over tighten or the post might break...

Page 87: ...light that is grounded on the other side of the light Locate the Coyote harness yellow alternator wire VBAT Monitor and run it to the Alternator plug Cut the wire to length Test fit the small connecto...

Page 88: ...88 Crimp the small blue connector onto the yellow wire Connect the wire to the Ignition connector on the Alternator...

Page 89: ...89 Accelerator Pedal 5 32 Hex key 7 16 wrench Marker 3 16 drill bits drill hack saw masking tape clamp Use a hack saw to remove the extra part of the right pedal mount...

Page 90: ...90 Mark where the bend is in the pedal Cut the pedal at the point marked On the pad part if desired trim the stalk down to the top of the pad...

Page 91: ...nt part of the pedal and hold the pedal up in place in the pedal box Readjust the location of the pad up and down as desired The higher the pad is located the harder the pedal will be to press due to...

Page 92: ...te on the pedal so that the short side is on the solid side of the stalk and the longer side is under the pedal pad Make the bracket flush with the bottom side of the pad Holding the aluminum in place...

Page 93: ...bracket by putting two lock nuts in the hollow part of the stalk so that the nuts are spread away from each other but still within the mount plate area Remove the mount plate and drill through the nu...

Page 94: ...using the pedal pad and mark the bracket through the holes in the stalk Drill through the bracket at the points marked using a 3 16 drill bit Stack the two mount brackets so that the sides are even an...

Page 95: ...95 Clamp the brackets together so that the holes in the large bracket can be used as a guide for drilling the small bracket With the brackets clamped together still open the bracket holes up to...

Page 96: ...96 Enlarge one of the holes in the stalk to Put a bolt through one of the brackets and the stalk align the other hole then clamp the two together...

Page 97: ...97 Drill the second hole out in the stalk to Bolt the two brackets to the stalk...

Page 98: ...ootbox attach the plug to the pedal Hold the pedal up in the footbox area so that the pedal is as far over to the right as possible and as high as possible with the plug going up next to the steering...

Page 99: ...99 Drill through the top left pedal mount hole and the front of the footbox Insert one of the mount bolts through the pedal and hole just drilled...

Page 100: ...100 Check the alignment of the pedal and the plug then drill the bottom left mount hole Insert another mount bolt...

Page 101: ...101 Drill the top right pedal mount hole with a drill bit Locate and tape the pedal pad to the mount plates on the stalk Un plug and remove the pedal from the footbox...

Page 102: ...102 Mark the back mount plate in the vertical location of the center of the recess in the pedal pad so that the lock nuts will not hit the supports in the plastic...

Page 103: ...ddle of the mount plates at the heights marked so that there is enough room for the locknuts If you would like the pedal mount brackets to disappear tape off and paint the brackets and mount bolts usi...

Page 104: ...104 Check the angle of the pedal pad then clamp the pedal pad to the mount brackets Drill through the back of the pedal pad into the recess...

Page 105: ...105 Attach the pedal pad to the mount brackets Finished Accelerator pedal assembly...

Page 106: ...106 Connect the harness plug to the pedal From the engine bay side insert the mounting screws through the firewall into the cockpit...

Page 107: ...107 Put the pedal on the mounting bolts Put washers on the pedal mount bolts...

Page 108: ...hten the mounting bolts using a 7 16 socket ratchet and 5 32 Hex key Air Intake Mass Air Meter T 20 Torx driver Philips head screwdriver Sensor safe RTV Mass air meter silicone hoses intake tubes air...

Page 109: ...109 Unscrew the mass air sensor from the Ford intake using a T 20 Torx driver Remove the sensor and note the direction of the curved part of the sensor...

Page 110: ...Install the rubber ring into the intake mount Insert the sensor into the mount to determine which way around it needs to go so the sensor mount holes will line up and the sensor will mount the correct...

Page 111: ...o the intake tube using the long screws so that the flat side of the sensor will face the Spectre writing Install the sensor on the mount using the short screws so the flat side of the sensor will fac...

Page 112: ...ead of Sensor safe RTV silicone around the flange of the large plastic reducer Slide the Mass Air Meter tube flat sensor side first Spectre writing down onto the plastic reducer Wipe any excess RTV of...

Page 113: ...113 Turn the mass air meter over so the Reducer is on the top and let the RTV dry overnight Intake tube...

Page 114: ...Slide the Mass Air Meter tube flat sensor side first Spectre writing into the air filter Adjust the Mass air meter so that the mass air plug is on the far side as the Ford Racing instructions recomme...

Page 115: ...115 Tighten the hose clamp Connect the elbow tube to the mass air meter using the silicone connector only tighten one of the hose clamps right now Attach the silicone reducer to the tube elbow...

Page 116: ...116 Push the intake tube onto the throttle body and position the air filter so that it clears the upper control arm and engine covers if used Tighten the hose clamps...

Page 117: ...removing the headers studs compare the thread to the new header bolts Production header bolt change dates From 3 22 10 to 9 8 10 M10 x 1 50 Coarse From 9 8 10 to 1 18 11 M10 x 1 25 Fine From 1 18 11...

Page 118: ...118 Attach the headers to the engine by inserting and tighten all of the bolts by hand before tightening any with a wrench Attach the connector pipes to the headers and kit exhaust system...

Page 119: ...the correct pressure as described in the Ford Racing engine control instructions Start the engine and allow the engine to get up to 195 F 200 F then allow to cool completely it will suck coolant from...

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