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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
00-9003-C157270 NUT M8 X 1.25 DISTORTED THREAD LOCKNUT ZN PLATED 4 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
00-9003-C157270 NUT M8 X 1.25 DISTORTED THREAD LOCKNUT ZN PLATED 3 EACH
00-9004-C157320 WASHER AN SS 5/16" ALTERNATOR MOUNT 3 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
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-C143790 HOSE, UPPER RAD PASS, 2006 MUSTANG 1 EACH
00-1703-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
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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
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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
00-9003-C157270 NUT M8 X 1.25 DISTORTED THREAD LOCKNUT ZN PLATED 2 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
00-9001-C19336 CAPSCRW HEX FLNG M6x1.0mm 80mm 1 EACH
00-9001-C19335 CAPSCRW HEX FLNG M6x1.0mm 60mm 1 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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TORQUE ITEM OPERATIO
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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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
With a pane
shield in pla
Remove the
ITEM PART NU
TORQUE
NOTES:
20
10
20
10
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
With a pane
shield in pla
Remove the
ITEM PART NU
TORQUE
NOTES:
20
10
20
10
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
With a pane
shield in pla
Remove the
ITEM PART NU
TORQUE
NOTES:
20
10
20
10
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
With a tree
alternator b
Disconnect
They are co
Remove the
It is fastene
ITEM PART NU
TORQUE
NOTES:
20
30
10
20
30
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
Feed the le
molded into
Once in pla
ITEM PART NU
TORQUE
NOTES:
20
10
10
20
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
Set the upp
Once in pla
ITEM PART NU
TORQUE
NOTES:
20
10
10
10
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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TORQUE ITEM OPERATIO
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
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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).
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