The term "bolt ons" is deceiving. Technically, you could say building a car from a pile of parts is a "bolt ons" job; you bolt the suspension to the frame, bolt the engine and transmission together. But we've come to understand the term "bolt ons" to mean a simple remove-and-replace, with little effort required to make things fit. Very often this isn't the case, as anyone reading this magazine can attest. Fortunately, this bolt ons install was an exception. It was easy to do, required only a heat gun for special tools, and took about five hours of steady, but not frantic, work. Even better, we were rewarded with 30 extra horsepower at the wheels of this '05 Mustang GT, making the experience that much more rewarding. The setting for this install was GTR High Performance in Rancho Cucamonga, California, where Ricardo Topete, who co-owns the shop with his brother, did the work on a customer's car, installing Ford Racing's mufflers, intake manifold, throttle-body, and cold-air kit. These "bolt ons" fit all '05 to '09 Mustang GTs. Topete started at the back of the car, replacing the car’s stock mufflers with the smaller Ford Racing versions. They fit the stock tailpipes, and with a straight-through design, they offer greater flow and a more aggressive exhaust note. Topete started at the back of the car, replacing the car’s stock mufflers with the smaller The new mufflers fit the stock hangers perfectly. Topete loosened the tailpipes to aim the mufflers, making sure they fit evenly with each other and were centered in their cutouts in the bumper cover. The new mufflers fit the stock hangers perfectly. Topete loosened the tailpipes to aim the Moving to the front of the car, Topete removed the stock airbox and intake tube after he relieved the pressure in the fuel rails by running the engine with the fuel pump fuse removed, then he loosened the bolts holding the fuel rail to the intake. You’ll need the proper spring coupling disconnect tool to separate the fuel rail from the fuel line. Moving to the front of the car, Topete removed the stock airbox and intake tube after he r With the fuel rail and injectors removed, Topete disconnected the remaining wiring and hoses and removed the manifold with the throttle-body still attached. No coolant runs through the intake, so this is a spill-free job. With the fuel rail and injectors removed, Topete disconnected the remaining wiring and hos Anyone familiar with the modular engine is acquainted with what’s come to be known as valley crud, the smorgasbord of stuff that collects in the V of the engine block. Here we were treated with the crusty remains of gastropods and rat poo. “I’ve seen this before. Rats like to grab the snails and take them to a sheltered area to eat them,” Topete tells us of the shell fragments and rat leavings that clogged his shop vac. Anyone familiar with the modular engine is acquainted with what’s come to be known as vall Per the very thorough Ford Racing instructions, the bracket that holds the alternator wiring must be modified. An extra hole needs to be drilled, and part of the bracket needs to be bent about 90 degrees toward the front of the car to clear the new intake and throttle-body. Per the very thorough Ford Racing instructions, the bracket that holds the alternator wiri Note that the Ford Racing manifold (left) has slightly less plenum area but longer runners. It also eliminates the inlet butterflies in the factory manifold. Known as charge motion control valves from the factory, they are an emissions-control device designed to increase air speed at low rpm. While customers will experience no driveability problems with eliminating this system, the car’s ECM Will need to be reprogrammed to compensate. The computer will notice the missing CMCVs, trigger a “Check Engine” light, and alter the ignition timing to compensate. Note that the Ford Racing manifold (left) has slightly less plenum area but longer runners After cleaning the sealing surface of the cylinder heads, Topete dropped the new manifold in place. As with most modern engines, each runner is sealed with its own O-ring, rather than a dedicated intake manifold gasket. After cleaning the sealing surface of the cylinder heads, Topete dropped the new manifold The Ford Racing manifold is taller than stock, so the fuel rail crossover tube has to be routed underneath. The Ford Racing manifold is taller than stock, so the fuel rail crossover tube has to be r There are three intake manifold bolts of different lengths, but their locations are clearly marked in the instructions. The bolts are torqued to 89 in-lb. There are three intake manifold bolts of different lengths, but their locations are clearl Though you could reuse the factory throttle-body, we’d recommend upgrading to a larger Ford Racing piece. The dual 62mm butterflies offer a potential increase in airflow over the stock dual, 55mm throttle-body, giving you room to grow as you continue to modify your car. Though you could reuse the factory throttle-body, we’d recommend upgrading to a larger For The only bit of custom work we encountered was the need to shorten one of the PCV tubes. The instruction book includes detailed instructions on how to do this, but it basically involves cutting the tube away from the plastic quick-disconnect fitting and then cutting the tube to the correct length. Next, heat the tube with a heat gun (don’t melt it!) to soften it enough to slip the quick- disconnect coupler back in. As the tube cools, it forms a tight seal around the base of the coupler. This sounds more difficult than it actually is. The only bit of custom work we encountered was the need to shorten one of the PCV tubes. T The remainder of the job was simple. Topete reconnected all the sensors and vacuum lines and installed the new cold-air intake tube and airbox assembly. The remainder of the job was simple. Topete reconnected all the sensors and vacuum lines a Five hours later. Topete cycled the key to activate the fuel pump. After verifying that there were no fuel leaks, he fired the engine and checked for vacuum leaks by spraying carb cleaner around the intake runners and near the vacuum and PCV hoses. Though the engine did start and run, the addition of a larger mass airflow sensor and throttle-body required reprogramming the ECM to accommodate the greater amount of air entering the engine. Topete reflashed the ECM before running the car on his chassis dyno. The result was 313 hp and 314 lb-ft, an increase of 29 hp and 5 lb-ft of peak power and torque. Five hours later. Topete cycled the key to activate the fuel pump. After verifying that th The results were better than we expected. Because the Ford Racing intake parts are designed to flow more air at high rpm, we expected to see a slight drop in power at low rpm. Instead, we were pleasantly surprised to see a slight increase in both power and torque between 3,000 and 3,400 rpm. The package really works above 4,000 rpm, and that 30 extra horsepower at the wheels is something you will definitely feel. What’s more, these parts offer a good foundation for further modifications if plans for a cam change or power-adder are in your future. The results were better than we expected. Because the Ford Racing intake parts are designe Parts List DescriptionPart NumberPriceSource High-flow throttle-bodyM-9926-3V579.95Ford Racing Performance intake manifoldM-9424-463V549.95Ford Racing Cold-air kit with ProCalM-9603-GTB655.99Ford Racing SVT muffler kitM-5230-S589.95Ford Racing Performance Tool fuel and transmission line disconnect tools WMR-W89330$39.95 Summit Racing SOURCES Ford Racing Performance Parts 15021 Commerce Drive S Suite 200 Dearborn MI 48120 800-FOR-D788 http://www.fordracingparts.com GTR High Performance 8678 Utica Ave. Rancho Cucamonga CA 91730 909-987-4352 http://www.gtrhipo.com « | 1 | 2 | View Full Article By John McGann Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!