Installation Instructions 2005-2007 Mustang GT Single 76mm Turbo
Contents
1. 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 22 Remove the pressed in tube from the thermostat housing This can be done 2 ways 1 By heating the area around the pressed in fitting while moving it back and forth as the sealant get soft the fitting will pull out or 2 By placing the pressed in fitting in a vice and gently twisting it back and forth Once the pressed in fitting has been removed clean out the excess sealant and use a 1 2 npt tap to thread the hole Once tapped and clean apply thread sealer and install the supplied 1 2 npt x 5 8 barbed hose fitting Step 23 Remount the power steering reservoir to the left side strut tower using the supplied bracket and hardware use the existing tapped hole in the shock tower Step 24 Once the reservoir is mounted locate and install the 3 8 by 20 long the hose is routed from the reservoir to the rack and pinion The larger of the two hoses needs to be cut so you are able to rotate it to line up properly Use the supplied 3 4 brass hose coupler and clamps manual71 doc 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 abba eee zan E wa ipie M a TL it ee ae a oye Sea ttt earls ee is ar T 3 T ar P es vf er ls SALELE Sadri LO a prea ee oe E EET TTET FF ee r i Fa hed fe as lt pa Step 25 Locate the lower r2. of any defective part of the product determined to be necessary by Granatelli Motor Sports This only applies if written Granatelli Motor Sports received notice of the claimed defect prior to expiration of the warranty period All warranties of merchantability and fitness for a particular purpose are expressly excluded The duration of any and all implied warranties is limited to the duration of this express warranty All incidental and consequential damages including but not limited to loss profits even if it has been advised of the possibility of such damages are hereby excluded Regardless of the form of the claim Granatelli Motor Sports liability for any damages to the customer for such product is limited to the guidelines herein This stated expressed warranty is in lieu of all liabilities or obligations of Granatelli Motor Sports for damages arising out of or in connection with delivery use or performance of the product This warranty cannot be amended or changed by any Granatelli Motor Sports representative employee or agent and any promises inconsistent with this warranty are void and unenforceable against Granatelli Motor Sports Some states do not allow limitations of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may have other rights that vary from state to state Your sole remedy for the above warranties is the repair or replacement of the de
3. first pipe goes between radiator fan and frame Step 73 Install couplers onto turbo discharge and then slide pipe in from bottom and into the coupler on turbo Step 74 The second pipe the horseshoe shaped intercooler inlet tube goes from intercooler to first pipe See photo manual71 doc 17 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Once both pipes are installed tighten all clamps making sure pipes do not come in contact with brake lines or A C hoses Step 75 Locate oil drain hose and two 10 clamps Install onto turbo drain and oil pan Be sure to make sure hose does not come in contact with any moving parts or exhaust pipes ae an a i ri a K a r 7 fr ee r h ot aA i EAS P r gt a d ero e 3 AO ae me Jobe G 7 t f a Pi a r DAE i 4 z fi i rE E A 4 l j A f j p d gs E ME ee S me i Toe a i Yi F Ah n alee 3 i a C E pe i e ine 7 E Eea a Step 76 Locate air filter 4 coupler two 2 64 clamps and air filter pipe Install coupler onto turbo Install air filter onto pipe and install onto turbo Position filter so it has clearance and tighten manual71 doc 18 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 77 Locate stainless water pipe and two 1 14 couplers and four 24 clamps Install couplers onto motor and ther
4. place by 15mm nut on drivers side cylinder head This support bracket is not reused manual71 doc 2 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 13 Remove 2 upper Radiator support bracket held in place by 2 10mm bolts These parts are modified by drilling 2 3 8 7 93mm holes in the brackets to pull the upper portion of the radiator forward of an inch J Step 14 Drill 2 two 3 8 holes per bracket 3 4 closer to the rubber grommet Reinstall brackets using newly drilled holes We do this to tilt the top of the radiator fan assembly forward for more clearance for the turbo Step 15 Remove the power steering reservoir held in place with 1 8mm bolt at fan shroud Drain all fluid Step 16 Remove factory power steering cooling tube The tube is fastened in front of the a c condenser running from the rack and pinion and is returned back to the power steering fluid reservoir This is a simple single pass tube It will no longer be needed Step 17 Remove the lower radiator hose Step 18 Remove the hose from the thermostat housing assembly to the expansion reservoir Step 19 Remove the top upper hose from the thermostat housing to the engine Step 20 Remove the side hose from the thermostat housing leave the other end attached to the engine Step 21 Remove the thermostat housing as an assembly to be modified manual71 doc
5. All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Tr Note the airflow arrow on the electronics and confirm the arrow points in the path of the throttle body and not towards the intercooler see photo below step 39 Step 37 With the MAF electronic securely fastened into the tube connect the MAF tube to the intercooler using the supplied 3 to 4 adapter sleeve with 64 clamp Step 38 Using the 3 x 4 long coupler sleeve attach the transition elbow with 44 clamps Step 39 Using the 3 x 45 angle coupler sleeve install the throttle body tube in at one side and using the 6 x 4 long coupler sleeve in the oval configuration fasten to the throttle body See photo 3 gt anA 4 E Skai d n 5 ipia m a amp ay ee AT MOET ny a a nn A Erer LE ath Step 40 Locate supplied MAF extension harness and install from factory wire to new MAF sensor Step 41 Reinstall the windshield washer fluid tank back to the factory position and location Step 42 Remove catalytic converter H pipe Y in shape section from exhaust manifolds and save nuts and band clamps Step 43 Measure 2 in front of hanger brackets and cut both pipes See photo manual71 doc 10 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 44 The starter wires will need to be rotated up to clear the new exhaust pipes Simply loos
6. C 7 Granatelli Motor Sports Inc e 1000 Yarnell Place e Oxnard CA 93033 2454 805 486 6644 Phone 805 486 6684 Fax Hours M F 8AM 5PM PST www GranatelliMotorSports com techsupport htm TechSupport GranatelliMotorSports com Installation Instructions 2005 2007 Mustang GT Single 76mm Turbo System Proper Installation of the Granatelli Turbocharger Kit requires a general understanding of automotive mechanics Please read the entire installation manual completely and decided whether you feel qualified to attempt the installation before you begin A major portion of this installation is to be done from the bottom 4 Four sturdy jack stands with a minimum of 18 inches of height is highly recommended Always use premium grade fuel 91 octane or higher and maintain regular oil changes every 3000 miles Step 1 Find a place where you will be able to work on the car without having to move it for at least 10 hours Elevate car and place jack stands as wide as possible in all four corners to support the car A hoist is also very helpful Step 2 Disconnect Positive and Negative cables from battery using 5 16 or 8mm wrench located at passenger side firewall Step 3 Remove the entire factory air intake system This includes the factory air box Note Air Box is held in place by 2 10mm bolts Step 4 Remove the plastic belly pan under the nose Note Held in place by 7 5 5mm screws Keep this in a safe place as this part w
7. V band clamp this pipe has a V band inlet and a 3 slip outlet Install onto down pipe using the V band clamp This pipe should be pointed straight back Do not tighten yet Step 66 Locate Y pipe and two 3 V band clamps Install Y pipe next Step 67 Locate converters and install onto previous mounted exhaust piping See photos Step 68 Install V band clamps position all pipes as to clear frame power steering hoses and floorboard tighten all clamps now from steps 63 to 68 Double check for clearance Step 69 Install three O2 sensors one in crossover and one in each converter Step 70 Reinstall previously cut factory rear H pipe Y in shape manual71 doc 16 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 71 Locate wastegate and wastegate pipe install wastegate now using supplied V band clamps Install wastegate discharge pipe position pipe to clear sway bar and oil filter and steering rack tighten both clamps Install wastegate pressure hose from turbo compressor outlet to the side of wastegate Your kit came preset at 7lbs of boost which will support 450 hp and 470 ft lbs of torque to the rear wheels Do not use top wastegate port unless you are using a boost controller not supplied Installing Discharge Tubing 2 1 2 Hot Side Step 72 Install 90 2 1 elbow on to driver side of intercooler with 90 elbow facing straight down The
8. adiator hose removed in step 17 cut and remove a 90 degree section from it Step 26 Install the 90 degree section of hose just modified onto the lower radiator outlet pointing up at the 12 o clock position Step 27 Install the thermostat housing modified in step 22 onto the lower radiator hose as show in picture below i T i aa lt E iia ahr r Po i i at F k ay a et i P sr a F 2 a i pii s 7 2 E Step 28 Install the aluminum extension pipe 1 1 2 x 4 into the 1 2 x 3 long silicone hose then install in between the radiator hose from the block Tighten all clamps manual71 doc 5 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 29 Lengthening the lower coolant Expansion Tank tube Since we moved the thermostat housing now we need to extend the expansion tank hose that runs from the thermostat housing to the tank Locate 3 4 x 5 metal extension tube supplied in your kit This needs to be installed in the middle of the lower reservoir hose to lengthen it See photo Once lengthened reconnect to newly installed barbed fitting on housing aa i Fuel System Upgrades lf you purchased a Granatelli Turbo kit that included injectors now is the perfect time to install them Consult the factory service manual for detailed installation instructions However this is really a simple a
9. e 2 1 2 pipe and to the lower front A C stud See photo leave loose for positioning manual71 doc 14 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 59 Install exhaust turb V band flange on the other side This pipe goes from the turbo inlet to the 2 1 2 pipe installed above Locate 2 1 2 V band clamp turbo inlet gasket and four 3 8 x 1 1 4 bolts and locknuts Install pipe onto bottom of turbo using gasket bolts nuts and V band clamp Do not tighten yet Step 60 Locate four 4 3 8 x 1 exhaust discharge bolts Install the first bolt into the upper rear exhaust turbine house through the support bracket Finger Tight Step 61 Locate exhaust discharge pipe install this pipe onto turbo and under oil filter using the four 3 8 x 1 bolts and gaskets do not tighten See photo A i a d lt p r T a ee Pa t NK a haust Discharg ty X aPipg 2 i Foo y Step 62 Once all these pipes have been installed position pipes for clearance from frame radiator fan AC compressor sway bars mounts tighten all bolts on turbo mount from steps 55 to 62 Double check for clearance Step 63 Attach oil feed hose to turbo and tighten manual71 doc 15 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 64 Install heat shield on turbo Step 65 Locate exhaust pipe and
10. en wires to starter and flip them 180 so that they are facing up See photo a ae Before ES After Sway Bar Drop Brackets In order to add clearance for the down pipe from the turbo the sway bar must be dropped one bolt hole The sway bar will have to be relocated by dropping it down 3 inches Step 45 Remove the 4 15mm sway bar mounting nuts holding the sway bar to the radiator omega brackets and remove sway bar from the studs You will need to cut 3 8 of an inch off the top of the studs Step 46 Locate the sway bar relocation brackets and 2 3 8 x 1 bolts locknuts and washers These brackets relocate the sway bar 3 lower Install slotted sway bar drop brackets over factory studs protruding from Omega brackets The top factory sway bar retainer hole now mounts the supplied brackets and the bottom stud from the factory omega bracket now becomes the top mounting hole for the sway bar clamps Step 47 Reinstall sway bar onto brackets See photo manual71 doc 11 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 48 Drain Engine Oil Step 49 Locate 23 12 oil pressure hose 4 tee and 4x 3 90 Step 50 Remove oil pressure sending unit from oil filter adapter and install 1 4 pipe tee and x 3 90 fitting see photo for clocking Install 3 braided steel oil feed hose and tighten reinstall sending unit io i r ii tee Step 51 L
11. fective product only at Granatelli Motor Sports sole discretion RETURN POLICY Before you return a product for a warranty claim contact our service department M F 8AM 5PM PST at 805 486 6644 or techsupport GranatelliMotorSports com for an RGA number No returns are accepted without a pre approved RGA return goods authorization No returns on special orders electrical items or after 90 days from date of original shipment All returns must be safety packaged in original packaging if available and clearly marked with your RGA number on the top and two sides of the box Please insure your shipment for full replacement value as lost stolen or items damaged in shipment are not covered by our limited warranty We recommend using FedEx www FedEx com or UPS www UPS com for shipping Lost stolen or damaged items claims must be made by the customer and resolved by the freight company and not Granatelli Motor Sports All returns may be subject to a restocking fee of up to 25 The balance will be returned in the form of a company check or may be applied as credit towards another purchase PERFORMANCE CONSUMER S BILL OF RIGHTS Legally a vehicle manufacturer cannot void the warranty on a vehicle due to an aftermarket part unless they can prove that the aftermarket part caused or contributed to the failure in the vehicle per the Magnuson Moss Warranty Act www GranatelliMotorSports com magnusonmoss him 15 U S C 2302 C For best results consider
12. ill be re installed manual71 doc 1 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 5 Remove plastic radiator cover Note Held in place by 6 push in clips Step 6 Remove front nose assembly held in place by 3 per side Phillips head screws at lower front fender well Note It is also a good idea to remove the front tires to gain even more access however turning steering wheel lock to lock allows for all screws to be removed At front fender belt line remove 1 per side 10mm bolts at the top of the engine compartment just to the side of each headlight Before removing nose disconnect wiring harnesses to fog lights turn signals and running lights Step 7 Remove Passenger side headlight 3 10mm bolts Step 8 Remove windshield washer tank 2 10mm bolts and 1 10mm nut off stud Note this will be reinstalled Step 9 Drain engine coolant Petcock is on passenger side bottom of radiator Step 10 Remove coolant tank 2 8mm screws Save to be reinstalled Note Once bolts are removed hold the tank up as high as possible so coolant in the tank drains back to the engine then pull 1 hose off bottom of the tank and drain excess coolant Step 11 Remove upper radiator hose off drivers side and at top of thermostat housing Disconnect lower radiator hose from drivers side of radiator Step 12 Remove bracket on block that supports radiator hose held in
13. ine tolerances vehicle modifications chassis and engine dyno calibration chassis and engine dyno brand etc manual71 doc 21 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0
14. mostat Install pipe be sure pipe clears brake lines and turbo housing See photo i Step 78 The breather system needs to be modified the1 2 hose that goes from drivers side valve cover needs to be cut and check valve needs to be installed Remove tube from engine and cut 1 3 4 section out of straight section install check valve with arrow pointing towards engine and tighten clamps reinstall now See photo Step 79 The crank case vent needs to be modified also this tube is on the passenger side valve cover remove tube and strip plastic tube off of valve cover fitting locate 3 8 breather hose and install from passenger side valve cover to air filter pipe manual71 doc 19 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 80 The plastic radiator cover needs to be notched to clear bypass pipe See photo B Fi Step 81 Lower plastic air deflector needs to be modified see photo reinstall washer reservoir fill cooling system install oil fill power steering reservoir install injectors and hook battery up i a ae A merirrrti ttt i TTT oo ee manual71 doc 20 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 LIMITED WARRANTY Granatelli Motor Sports warrants that all products shall be free from defects in materials and or workmanship for ni
15. nd straight forward procedure a The fuel rails are held in place by two 2 7mm bolts per side Starting from either side remove the two bolts b Remove the wiring harnesses that snap into each injector c Wiggle the fuel rails in an upward motion Doing so will gently pull the injectors from their socket in the manifold d Once the rails are away from the engine it will be easy to remove the factory injectors and directly replace them with injectors supplied in the kit manual71 doc 6 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Fuel Pump Upgrade Your factory fuel pump is more then adequate to supply enough fuel to support 525 hp at the crank When coupled with the Granatelli Turbo kit at less then 8psi no fuel pump modifications are required Granatelli Motor Sports also offers a high flow high pressure fuel pump upgrade kit part GMFS0507 for those of you looking to exceed 480 rear wheel hp Caution internal engine modifications are highly recommended before you proceed to increase boost past 10 psi Installing the Turbo Head Unit Mounting Brackets Step 380 Your kit came with 5 spacers 3 coupling nuts with 7 16 bolts and washers and 2 with 7 16 studs The 2 shorts spacers with studs are used to mount the intercooler so we are not ready for them see Intercooler Installation section Locate the three coupling nuts marked 1 2 amp 3 The 1 nut goes onto the lo
16. nety days from the date of purchase except in tank and in line fuel pumps purchased at dealer or wd prices as these items have no warranty and roller rocker arms which have a 12 month limited warranty The following requirements and exclusions apply 1 You must be the original purchaser and must complete the warranty registration form located at www GranatelliMotorSports com warranty asp and return the defective product within 10 days after the expiration of the product warranty Failure to do so voids all warranty either express or implied set forth herein 2 You must reside in the United States or Canada and use the product as described in the warranty registration 3 The product must not have been altered disassembled modified or converted for any other use than intended by Granatelli Motor Sports 4 The product or any part thereof is not used in accordance with the operating parameters specified by Granatelli Motor Sports 5 The product or any part thereof is damaged or rendered unserviceable due to negligence vandalism theft fire debris flood Act of God or other peril malfunction of equipment or by any cause within the Customer s control 6 The serial number if applicable must not have been altered or removed The extent of Granatelli Motor Sports liability under this warranty shall be limited to the prompt correction or replacement at Granatelli Motor Sports option and at no cost to the customer other than return shipment
17. ocate 3 8 oil drain tee and 3 8 x hose barb Step 52 Remove oil level sensor on passenger side of oil pan manual71 doc 12 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 53 Install 3 8 tee and hose barb and reinstall oil level sensor see photo for clocking tte Step 54 There are some power steering tubes that will need to be bent to clear the exhaust discharge pipe see photo to see which way they need to be bent be careful not to kink or break them KY e EE O AAL DMY Installing Turbocharger Head Unit Step 55 Locate turbocharger oil drain gasket and two 8mm oil drain bolts Using gasket sealer glue gasket on to support bracket Do not use silicone Install turbocharger onto support bracket using the two 8mm bolts and finger tighten only manual71 doc 13 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Step 56 Locate all exhaust pipes and two rolls of heat wrap you will need to heat wrap all exhaust pipes except the 3 Y pipe and the two converters See photo maid cen OR Pa rl Step 57 The crossover pipe is next we have pre assembled this pipe it will go in assembled install it now leave the bolts loose for positioning eS eS ae a i 9pm ARNE A a ie nl ae 7 ma a p Y 7 IN Step 58 Locate small support bracket This bracket bolts to th
18. ve a 1 4 x20 stud sticking out of one end Once spacers are fastened mount intercooler and tighten in place using 1 2 wrench When facing the front of your car the discharge side of intercooler should be pointing towards passenger side of car on the bottom and the inlet side is pointing towards the drivers side top Discharge side of intercooler is 3 and inlet side is 2 5 See photo manual71 doc 8 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Installing Discharge Tubing 3 Cold Side Your discharge tubing consists of 3 sections MAF mass airflow sensor tube transition tube and throttle body tube Additionally you were supplied a BA 2800 MAF and MAF wiring harness extension Step 34 Install the blue GMS supplied blow off valve into the discharge transition tube using the O ring and snap ring supplied Note Vacuum nipple needs to point straight down Step 35 A small portion of the passenger side head light support must be removed to allow the discharge tubing to properly follow the path of least resistance Using tin snips small air saw or narrow hacksaw cut the section out as needed See photo eee e a Step 36 Install BA 2400 BA 2800 MAF electronics into the appropriate section of discharge piping Be careful not to damage the electronics as you insert them into the tube manual71 doc 9 2000 06 Granatelli Motor Sports Inc
19. wer alternator stud on the drivers side 2 nut goes on the stud right under the water outlet neck on the driver side of engine Note In some cases this stud will need to be shortened by cutting 3 8 of an inch off the end of the stud If required simply remove the stud make required modification and reinstall bolt now you can install 2 nut onto stud 3 nut goes on the stud right above power steering pulley Note this stud may require similar modifications as well Install 3 nut onto cut stud tighten 1 2 3 nuts Step 31 Install the 2 turbo support backs the straight bracket goes between 1 and 2 support Nuts first See photo manual71 doc 7 2000 06 Granatelli Motor Sports Inc All Rights Reserved Intl Copr Secured 18Jul2006 V 1 0 Phone ag hbo Y 3 a a Step 32 The curved bracket goes between 2 and 3 nuts second See photo These brackets will go in several different ways see photo to make sure they are installed correctly Note The curved bracket stacks on top of the short bracket n pm welded to it to prevent any chance for a leak Put the oil drain hose on the bracket and clamp tightly Step 50 to 60 address getting the oil into the pan Installing Front Mount Intercooler Step 33 The Intercooler is supported by the two 2 8mm lower studs of the inter side of the bumper mount Start by threading the supplied intercooler spacers to the factory studs These are the spacers that ha
20. working with performance oriented dealerships with a proven history of working with customers If your vehicle manufacturer fails to honor emission warranty claims contact EPA at 202 260 2080 or www epa gov If federal warranty protection is denied contact the FTC at 202 326 3128 or www ftc gov For additional information check out www GranatelliMotorSports com TechSupport htm Disclaimer Actual products may vary from photographs shown For latest information please call 805 486 6644 first You can also check out our web site at www GranatelliMotorSports com However it may have not been updated at the time you actually view it Therefore we cannot guarantee the accuracy of the information on our web site Granatelli Motor Sports is not responsible for any unintentional omissions or typographical errors and reserves the right to make changes to packages services operating procedures colors materials features specifications part numbers pricing and to discontinue any products and or components at any time without prior notice Some items shown are sold for off road use only and or racing use not street legal and not intended for use on public highways customer assumes costs and liability for installation and use Performance figures shown can vary considerably due to a variety of factors including but not limited to altitude humidity barometric pressure outside temperature vehicle age state of vehicle tune vehicle manufacturer eng
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