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Factory Five Racing 15471, Руководство по установке

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Factory Five Racing, Inc. 

DO NOT DUPLICATE CONFIDENTIAL INFORMATION AND PROTECTED UNDER U.S. COPYRIGHT LAWS 

 2012 FACTORY FIVE RACING, INC.

 

Company/instructions

 

Part Number: 15471 

 

Revision: G 

 

Effective Date: 9/7/12 

 

 

By:  J. INGERSLEV 

Document Type (indicate): 
 

 

 

 Bill of Material      

 

 Drawing (may be attached) 

 Specification 

 

 

 

 Assembly Instructions

    

 Operating Procedure

 

 

 

Other 

Roadster Coyote Engine 

Installation Instructions 

 

 

Parts needed ........................................................................................................................................................................... 2

 

Ford Racing Parts ............................................................................................................................................................... 2

 

Ford Motor Co. Parts.......................................................................................................................................................... 3

 

Summit Racing................................................................................................................................................................... 3

 

Fuel System .................................................................................................................................................................... 3

 

Air Intake System ........................................................................................................................................................... 3

 

Other vendors..................................................................................................................................................................... 3

 

Autozone ........................................................................................................................................................................ 3

 

Supplies ................................................................................................................................................................................. 3

 

Information ............................................................................................................................................................................ 4

 

Accelerator Pedal ................................................................................................................................................................... 4

 

Drivetrain............................................................................................................................................................................. 19

 

Engine prep...................................................................................................................................................................... 19

 

Exhaust ............................................................................................................................................................................ 19

 

Alternator......................................................................................................................................................................... 19

 

Содержание 15471

Страница 1: ...ERSLEV Document Type indicate Bill of Material Drawing may be attached Specification Assembly Instructions Operating Procedure Other Roadster Coyote Engine Installation Instructions Parts needed 2 For...

Страница 2: ...oid 80 Computer mounting 85 Black circuit Board box 92 Power Distribution 97 OBD 2 Port 98 General 99 Exhaust 100 Starting the engine 101 Parts needed Ford Racing Parts M 6007 M50 5 0L Engine M 6017 A...

Страница 3: ...0700 B 4AN Hose Barb 1 needed SUM 220711 B 90 6AN to 6AN Hose Barb 1 needed SUM 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...

Страница 4: ...atest version of the engine controls instructions from the Ford Racing parts website www fordracingparts com Do a parts search for M 6017 A504V and click on the instructions pdf Use the following diag...

Страница 5: ...5 Use a hack saw to cut the right mount off the accelerator Cut right against the flat section of the pedal so it also cuts the top Webbing off...

Страница 6: ...6 On the underside cut the bottom mounts off with a hack saw so that the bottom is flat Cut the accelerator pedal...

Страница 7: ...7 Align the mount holes of the pedal on the pedal mount and mark the pedal through the upper frame mount hole...

Страница 8: ...8 Hold up the mount screw to the pedal at the point marked Mark the pedal where the screw starts stops and the height of the screw...

Страница 9: ...9 Use a grinder hack saw or drill bit to remove material on the pedal for screw clearance Check the fitment of the mount screw by putting the pedal on the pedal mount with the screws...

Страница 10: ...10 Attach the Accelerator pedal mount to the frame accelerator pedal mount using the screws provided and the ones from the standard kit...

Страница 11: ...11 Attach the Coyote accelerator pedal to the new pedal mount Cut the FFR accelerator pedal at the bottom of the existing mount hole using a hack saw...

Страница 12: ...12 Clamp the FFR pedal to the Coyote pedal with a small clamp so that the accelerator pad is 2 back from the brake pedal This is a starting point...

Страница 13: ...as if you were stopping the car You should be able to push the pedal down without hitting the gas pedal but be able to rock your foot heel toe onto the gas pedal Once the correct height is set mark th...

Страница 14: ...lignment of the two pedals with the line you just drew On the backside of the pedal insert one of the locknuts into one of the recesses so that the bolts will be as far apart as possible and still go...

Страница 15: ...15 Using the locknut nylon as a guide drill a 3 16 hole through the plastic pedal Remove the locknut and enlarge the hole using a drill bit...

Страница 16: ...through the metal pedal using the plastic hole as a guide Attach the metal pedal to the plastic pedal using one of the 20 x screws and locknuts included with the kit If your pedal location requires b...

Страница 17: ...17 Use a pair of pliers and a vise to slightly bend the metal pedal to match the plastic Use another lock nut and drill bit to locate the lower hole location and drill a pilot hole...

Страница 18: ...18 Mark and drill the location on the metal pedal Use one of the flanged 20 x screws in the lower hole...

Страница 19: ...13mm 15mm sockets 13mm deep socket ratchet Ford Racing Alternator pipe fittings Shallow oil pan Exhaust Remove the Stock Mustang headers Remove all of the header studs using a 6mm 6 point socket Alte...

Страница 20: ...20 Route and install the serpentine belt Remove the stock oil pan and install a shallow oil pan...

Страница 21: ...lter 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 the relocator does not...

Страница 22: ...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 ba...

Страница 23: ...23 Use Teflon tape on the port plugs Screw the plugs into the spin on adapter...

Страница 24: ...24 Use Teflon tape on the hose fittings Screw the hose fittings into the rear of the spin on adapter...

Страница 25: ...25 Screw hose fittings into the relocator Screw the threaded nipple into the relocator...

Страница 26: ...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...

Страница 27: ...27 Use Teflon tape and install the oil pressure gauge sender From the gauge box screw on the NPT adapter...

Страница 28: ...28 Put Teflon tape on the adapter then screw on the T adapter fitting Put Teflon tape on the 1 50 NPT tube...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...31 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...

Страница 32: ...32 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...

Страница 33: ...33 Screw the adapter into the larger adapter on the block Put Teflon tape on the sending unit...

Страница 34: ...ep Hack 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 6...

Страница 35: ...or just below the pad for the transmission mount Attach the transmission mount plate to the polyurethane transmission mount using the 13 x 1 50 bolts If not already done install the flywheel and clut...

Страница 36: ...g weight from the clutch fork it is not needed Attach the bellhousing and clutch fork to the engine Attach the transmission to the engine Engine Transmission Installation Install the engine and transm...

Страница 37: ...mission mount to the frame mount Fuel System Fuel pressure regulator fittings fuel hose hose clamps high pressure fuel pump The Coyote engine requires a 255 lph high pressure fuel pump such as the Sum...

Страница 38: ...38 Mount a fuel pressure regulator to the firewall and connect the appropriate fittings the return is on the bottom...

Страница 39: ...er 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 h...

Страница 40: ...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...

Страница 41: ...41 Push the vacuum line onto the fuel pressure regulator Push the vacuum line onto the hose adapter...

Страница 42: ...diator hose kit Push the correct size adapters onto to the thermostat housing with a length of the stainless hose Route the stainless hose to the left side lower radiator outlet and mark the hose for...

Страница 43: ...43 Push the Ford supplied hose onto the outlet under the throttle body Decide where you would like to change to the stainless hose and cut the webbing off the hose using wire cutters...

Страница 44: ...44 Cut the hose using a razor knife Push the stainless hose into the end of the rubber hose and run the hose to the right side upper radiator inlet...

Страница 45: ...the left of the throttle body and hose 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...

Страница 46: ...46 Push and hose clamp the small coolant barb behind the coolant tubes Cap and hose clamp the coolant This is the other heater core location if running a heater...

Страница 47: ...47 If running a heater the stock Mustang heater hoses work well The numbers for the hoses are BR3Z 18472 B BR3Z 18472 D...

Страница 48: ...zor knife WD40 Vacuum plugs PCV lines rubber hose T connector There are a couple ways to route the PCV hose depending on your emission requirements tough or relaxed Block off the vacuum ports and fuel...

Страница 49: ...issions If not already done connect the right side stock PCV hose from the valve cover to behind the throttle body Install a barb fitting in the intake tube after the mass air meter but before the thr...

Страница 50: ...50 Carefully cut the 90 PCV fittings out of one of the pcv lines without damaging the barbs Push the heater hose onto the PCV fitting...

Страница 51: ...51 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...

Страница 52: ...52 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...

Страница 53: ...the fitting onto the left valve cover and run the hose the back of the engine Cut the hose at the back of the engine with a razor knife Push the remaining hose onto the other 90 PCV fitting again usi...

Страница 54: ...nto the right valve cover and run the hose around the back 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 the T Push the right...

Страница 55: ...he T and run it down the side of the bellhousing and zip tie it to the transmission tunnel tube Air Intake Filter Mass air meter silicone hoses intake tubes air filter T 20 Torx driver Flat head screw...

Страница 56: ...56 Mass Air Meter 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...

Страница 57: ...nstall 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...

Страница 58: ...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...

Страница 59: ...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...

Страница 60: ...60 Turn the mass air meter over so the Reducer is on the top and let the RTV dry overnight Intake tube Slide the Mass Air Meter tube flat sensor side first Spectre writing into the air filter...

Страница 61: ...61 Adjust the Mass air meter so that the mass air plug is on the far side as the Ford Racing instructions recommend Tighten the hose clamp...

Страница 62: ...to the tube elbow Push the intake tube onto the throttle body and position the air filter under the hood hinge Tighten the hose clamps Wiring Soldering iron solder electrical tape wire cutters wire s...

Страница 63: ...the fuel pump circuit on the chassis harness fuse panel 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...

Страница 64: ...tan and green wires together Make sure the wires and harness are out of the way of the steering shaft Neutral Safety switch If not using the neutral safety switch in the Coyote harness route the wire...

Страница 65: ...65 Cut the wire to length and crimp on a blue ring connector Attach the ring connector to ground...

Страница 66: ...tor fan fuse from the black box Separate the orange and black fan wires The orange wire in the engine harness needs to either be taped back along the harness or a better way is to remove the engine ha...

Страница 67: ...sis harness This would put a second relay and fuse in the circuit The good side of this is that you can easily access the fuse and relay in the fuse panel The fuse in the fuse panel would be the one t...

Страница 68: ...t the top of the footbox area find the chassis harness orange fan wire in the dash harness plugs Cut the wire out of the plug Solder or butt connect the orange fan wires together Skip to the next sect...

Страница 69: ...bypassing the fuse panel Locate the blue wire going into the harness on the opposite side of the cooling fan fuse from the blue wire coming from the fan relay Cut the blue wire and solder it to the or...

Страница 70: ...70 Remove the fan relay from the fuse panel Remove the fan fuse The remaining fan wiring in the black box will be completed later...

Страница 71: ...71 Power start Soldering iron wire cutters strippers electrical tape Locate the EFI crank and coil wires in the chassis harness...

Страница 72: ...72 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 Connect the 12v start run wire red green wire to the orange coil wire...

Страница 73: ...73 Connect the 12v start red blue wire to the blue crank wire Tach Soldering iron wire cutters strippers electrical tape...

Страница 74: ...ach wire in the sending unit plug and cut it so the engine harness can get connected to the purple wire Run the engine harness tach wire to the chassis harness plug and connect it to the purple wire a...

Страница 75: ...Run the chassis harness red alternator wire to the alternator out put post Cut the wire so that a ring terminal can be used on the alternator Crimp on a ring terminal and attach the red wire to the Al...

Страница 76: ...76 Remove the harness wrap and pull the wires back to the first harness branch This will allow them to get routed in the engine bay with enough length...

Страница 77: ...77 Locate the red black power wire junction between the two O2 sensor plugs Cut the wire for the left side O2 sensor a few inches from the junction...

Страница 78: ...Use one of the extra wires pulled out of the harness or chassis harness to extend the wire Start by soldering the wire to the end near the junction Pull the left side O2 sensor wires so they are tigh...

Страница 79: ...79 Pull the wire extension tight and cut to length Solder the other end of the extension wire to the O2 sensor wire...

Страница 80: ...the harness with the original conduit Starter Solenoid The solenoid on the starter is the one being used to start the engine Run the battery cable to the starter solenoid along the transmission from t...

Страница 81: ...81 Attach the battery cable to the starter solenoid Make sure not to push the cable too far over or it may contact the starter post Separate the solenoid and ground wires...

Страница 82: ...82 Tape the ground wire back along the harness to a common frame ground Crimp a ring connector to the ground wire...

Страница 83: ...83 Attach the ring connector to ground Attach the tan green wire to the starting post on the solenoid...

Страница 84: ...84 Cut the chassis harness blue starter solenoid wire back to the harness conduit Use electrical tape to cover the end of the blue wire...

Страница 85: ...85 Computer mounting Silicone Drill Tin snips Measure and find a location for the computer...

Страница 86: ...86 If you are running a heater using the tube over the passenger footbox is a good place to mount a bracket We located it in the firewall on the passenger side...

Страница 87: ...g a heater or wipers you can not do this location This diagram can be scaled on a copier to create a template Measurements are in inches Use weatherstripping or silicone around the flange of the compu...

Страница 88: ...88 Mount the computer to the car using the 10 x 1 screws in the wiring harness mounting hardware or nutserts if you have them...

Страница 89: ...es in the engine harness through the firewall extension hole into the engine bay Drill a hole the size of the harness in the oval block off cover for the firewall extension From the side cut across to...

Страница 90: ...90 Use some grommeting from the misc electrical components to protect the harness Attach the firewall extension to the frame...

Страница 91: ...91 Silicone and rivet the block off cover to the firewall extension Plug the two engine harness plugs into the computer...

Страница 92: ...nside the car find a location that you can mount the black box from the coyote harness We mounted it to the left of the center support Do not mount the box yet Open the black box and remove the nut on...

Страница 93: ...93 Tighten the nut on the fan post then bend the ring connector up so the wire clears the white connector Push the white multipin connector onto the matching connector on the circuit board...

Страница 94: ...94 Run the white plug wires and the orange fan plug out of the box in the slot provided near the plug...

Страница 95: ...95 Connect the green power plug inside the box It gets attached using a large Philips head screwdriver through the bottom of the box...

Страница 96: ...96 Reattach the top of the box Attach the box to the frame...

Страница 97: ...used to start the engine Locate and 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...

Страница 98: ...98 OBD 2 Port Locate the OBD 2 port on the 2 x 2 tube to the right of the steering wheel Use some of the aluminum panel 6 screws to attach the OBD 2 plug to the frame...

Страница 99: ...General Wire cutters strippers electrical tape Cut the white red Intercooler pump wire as far back in the harness as you can It is not needed or used Attach the accelerator plug to the accelerator ped...

Страница 100: ...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 M10 x 1 50 Coarse FFR supplies the course bolts o...

Страница 101: ...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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