Ford Performance M-6017-504V 5.0L Controls Pack Installation Manual

Introduction

This kit is developed by Ford Performance to enable performance enthusiasts to install the 5.0L 4V TiVCT NA Crate Engine (Ford Performance P/N: M-6007-M50A) into their chosen application. The system is designed for manual transmission use only. Cruise control is not available with this system.

Please read all instructions carefully before installation. For questions, contact Ford Performance Technical Support at 1-800-367-3788.

Overview

This booklet provides a step-by-step guide for the preparation and installation of the controls pack.

Included Components

3.1 Powertrain Control Module (PCM) – FR3Z-12A650-EGC

The PCM is the central processing unit for engine operation. It receives input data from engine sensors and uses this data to perform calculations that adjust fuel quantity and spark timing based on driver demand (e.g., accelerator pedal input). The PCM in this Controls Pack features custom software and calibration developed by Ford Performance engineers for peak performance and reliability with the 5.0L 4V TiVCT NA Crate Engine.

PCM Calibration Notes:

• The PCM calibration will NOT work with the factory 'Returnless' fuel system. A return-style fuel system is required.
• The included Air Filter Assembly with Integral Mass Air Flow Sensor must be used for acceptable engine performance. Changes to the air inlet system may require PCM calibration.
• Requires Premium Fuel (91 Octane or higher).

Note: Installing this PCM in a production Mustang vehicle with the described fuel system requirement will result in a no-start condition.

3.2 Accelerator Pedal Position Sensor (APPS) – CR3Z-9F836-C

This assembly includes integrated pedal position sensors (APPS1/APPS2) and is designed for correct interface with the PCM (FR3Z-12A650-EGC) for proper engine operation.

3.3 Clutch Pedal Position Switches

Bottom Travel (CBT) - 6G9Z-11A152-A (Gray Plunger)

Top Travel (CTT) - 4M5Z-11A152-A (Black Plunger)

These switches translate clutch pedal position to the PCM. The bottom travel switch also acts as a starter safety interlock, preventing the starter from engaging until the clutch is fully depressed.

• CBT switch: Normally Open (Clutch Pedal NOT fully depressed); Closed (Clutch Pedal fully depressed).
• CTT switch: Normally Open (With foot off Clutch Pedal); Closed (Otherwise).

WARNING: DO NOT BYPASS THE STARTER INTERLOCK. Doing so creates a hazard as the starter can operate with the transmission in gear and the clutch pedal engaged.

3.4 Universal Exhaust Gas Oxygen Sensor (UEGO) – FL3Z-96444-A

Two UEGO sensors provide wide-range feedback to the PCM for closed-loop air-fuel ratio control by measuring oxygen in the exhaust. Use caution during installation to prevent lubricant from contacting the sensor element. Tighten to 48 Nm (35 lb-ft). Do not splice or modify UEGO wiring, as this will adversely affect signal performance and reliability.

Sensor Location Tips:

• The engine harness and controls package is designed for 2015 Mustang GT stock UEGO sensor locations. Moving sensors may require PCM recalibration.
• Best option: Locate sensor to sample from all 4 cylinders without harness modification.
• If modification is needed, sample from a single cylinder. Preferred cylinders are #4 (Bank 1) and #7 (Bank 2). Alternatives are #3 (Bank 1) and #8 (Bank 2). Calibration required.

Firing Order: 1-5-4-8-6-3-7-2

3.5 B + to FPPDB Cable Assembly

Provides B+ from the battery positive post to the in-line fuse and then to the Ford Performance Power Distribution Box (FPPDB). Ensure the ground eyelet is attached to a solid grounding location.

3.6 Plastic Bag of Assorted Items

• Zip-ties
• 4 AWG Jumper Cable
• Buss 250A In-line Fuse
• Malfunction Indicator Light
• Small diameter heat shrink (red)
• Large diameter heat shrink (black)
• Large diameter eyelet terminal
• Small diameter eyelet terminal

3.7 Air Cleaner Assembly with Integral Mass Air Flow Sensor

IMPORTANT NOTE: The PCM calibration requires the use of this specific air box/MAF sensor system. Any changes to the air inlet system will necessitate PCM calibration adjustments.

Air Inlet System Design Guidelines:

• Flow Profile: Locate MAF sensor in a straight section of zip tube for uniform flow. If not possible, place on the outside radius in a high-velocity area.
• Flow Area: Keep the MAF sensor tube's cross-sectional area close to the original induction system.
• Flow Quality: Minimize flow direction changes and maintain smooth tubing to reduce turbulence.
• Flow Pulsation: Install sensor 6-8 inches upstream of the throttle body.
• Transient Performance: Installing the sensor too far upstream (>24 inches) can cause lean/rich spikes.
• MAF Sensor Contamination: Install sensor in the upper half of the cross-sectional area to minimize condensation contact. Avoid locations near the crankcase ventilation inlet; ideally, position 3 diameters upstream of it.

3.8 Controls Pack Wiring Assembly - CM-14A006-A504VA

Connects to the vehicle battery and inline connectors. Includes FPPDB, 250A fuse, and wiring for APPS, Clutch Switches, Ignition Switch & Starter. Features a Data Link Connector for DTCs and a Check Engine/Malfunction Indicator Lamp (MIL). The MIL will illuminate when ignition is ON and the engine is NOT running. Only the included MIL will illuminate if a fault exists; the stock instrument panel MIL will not function.

Pre-Installation of Harness and Parts

4.1 Planning

• PCM Mounting Location: Limited by the length of the leads connecting to the PCM.
• Inline Fuse Holder: Must be mounted within 12" of the vehicle battery positive post.
• Harness Layout: Lay out the harness and components to ensure all leads reach their intended locations before drilling or mounting.
• Grounding: Ford Performance Power Distribution Box must be mounted within 60" of the vehicle battery.

4.2 Connector ID

Refer to Table 1 for a summary of Controls Pack Connectors and their descriptions.

Table 1 - Summary of ControlsPack Connectors

Figure 1 - Controls Pack Wiring Harness Components

4.3 Tools Required

• Wire Cutter/Stripping Tool
• Crimper
• Digital Volt/Ohm Meter
• Solder Gun / Solder
• Center Punch
• Cordless Drill / Drill bits / Hole saw / Screwdriver bits

4.4 Cap off the Unused Supercharger Intercooler Connector

If your vehicle is not supercharged, cut the wires leading to the 2-way ICP (Item P, Connector C400) and individually tape or heat shrink each wire to prevent shorting.

4.5 Engine Harness Routing

Refer to Figure 2 (Rear View of Engine) and Figure 3 (Front View of Engine) for engine harness routing. Note: The blue harness shown is the ENGINE harness (FU5Z-12A581-E), not the Controls Pack wiring harness.

Controls Pack Harness Installation Instructions

NOTE: Disconnect the vehicle's Negative Battery Terminal before starting. Reconnect only at the final step.

1. Identify mounting locations for the PCM, Power Distribution Box (Item C), and Inline Fuse Holder (Item W). Use templates to drill holes and attach components.
2. Locate the PCM connector (C175E) on the engine harness. If a stock PCM is present, unplug and store it.
3. Plug C175E (engine harness) and C175B (controls pack harness) into the PCM. Use zip-ties to secure the wire bundles.
4. Follow the harness routing, using zip-ties to secure the controls pack harness to the engine harness approximately every 200 mm.
5. Identify and connect various takeouts (AA, BB, CC, DD, EE, FF, GG, HH) to their respective components (Alternator, MAF Sensor, Intercooler Connector, PCM Power/Ground, FPPDB, Ground eyelet, Instrument Panel Pigtail, APPS, Clutch Switches, Data Link Connector).
6. Route the harness through the firewall using a grommet to protect the wires.
7. Mount the Bracket with OBDII connector.
8. Connect the ground eyelet (Item V) to a reliable chassis ground.
9. Connect the Instrument Panel Pigtail connector (C160A).
10. Route C160A to the steering wheel area.
11. Connect APPS (C2040) to the accelerator pedal module.
12. Connect components in Takeout HH (Clutch Switches, Data Link Connector) to their locations.
13. Connect the 16-way I/P Pigtail connector (Item S) to C160A.

Removal Procedures for Unused Connectors: If a connector is not needed, cut the wire leading to it, and individually heat shrink and tape each wire for protection.

16-way I/P Pigtail Connection Details

The 16-way pigtail connects according to the chart below. Setup A uses toggle switches; Setup B uses an ignition cylinder.

Table 2 - 16-way I/P Pigtail Connections

Required Blunt Lead Connections:

• Blunt Lead 1 (Dark Green): Connect to Fuel Pump positive.
• Blunt Lead 3 (Light Blue): Connect to starter momentary switch or ignition cylinder 'Start' output.
• Blunt Lead 4 (Blue): Connect to the negative (black) lead on the MIL. Provide 12V for the positive (red) lead.
• Blunt Lead 5 (Light Green): Connect to the ignition toggle switch output or ignition cylinder 'Start/Run' output.
• Blunt Lead 8 (Red): Connect to the input node of the A/C toggle switch, Starter momentary switch, or Ignition toggle switch (Setup A); or A/C toggle switch and ignition cylinder (Setup B).
• Blunt Lead 9 (Black): Connect to the negative (black) lead on the MIL.
• Blunt Lead 16 (Yellow): Connect to the ignition cylinder 'Accessory/Run' output (Setup B). Not needed for Setup A.

Optional Blunt Lead Connections:

• Blunt Lead 2 – AUX 1 (Brown): Optional 12V power supply. Requires additional fuse in FPPDB.
• Blunt Lead 6 – A/C Request (Violet): Connect to A/C toggle switch output to energize A/C Clutch Solenoid.
• Blunt Lead 7 – AUX 2 (Orange): Optional 12V power supply. Requires additional fuse in FPPDB.
• Blunt Lead 10 - AUX 3 (Pink): Optional 12V power supply. Requires additional fuse in FPPDB.
• Blunt Lead 12 – HS CAN (-) (White): Optional CAN line.
• Blunt Lead 13 – HS CAN (+) (White-Blue): Optional CAN line.

Once blunt lead connections are soldered, insert the 16-way I/P Pigtail connector into C160A.

Fuses & Relays

The Power Distribution Box (PDB) contains various fuses and relays. Refer to the diagram for component IDs, types, values, and names. Do not replace fuses with a higher value than specified.

Power Distribution Box (PDB) Diagram:

[Diagram showing J-Case fuses, Minifuses, and Power Mini Relays with their respective positions and functions]

Connector Faces

Diagrams illustrating the connector faces for the Alternator, MAF/IAT Sensor, APPS, and I/P Pigtail are provided for reference.

Alternator Connector:

[Diagram of Alternator Connector]

MAF/IAT Sensor Connector:

[Diagram of MAF/IAT Sensor Connector]

APPS Connector:

[Diagram of APPS Connector]

I/P Pigtail Connector (C160B):

[Diagram of I/P Pigtail Connector]

Additional Connector Diagrams

Diagrams for the UEGO Sensor, Clutch Pedal Switches, Diagnostic/Data Link Connector, and IC Pump are also provided.

UEGO Universal Exhaust Gas Oxygen Sensor:

[Diagram of UEGO Sensor Connector]

Clutch Pedal Top Travel Switch:

[Diagram of Clutch Pedal Top Travel Switch Connector]

Clutch Pedal Bottom Travel Switch:

[Diagram of Clutch Pedal Bottom Travel Switch Connector]

Diagnostic / Data Link Connector:

[Diagram of Diagnostic/Data Link Connector]

Mass Airflow (MAF/IAT) C128:

[Diagram of MAF/IAT C128 Connector]

IC PUMP C400:

[Diagram of IC PUMP C400 Connector]

I/P Pigtail C160B:

[Diagram of I/P Pigtail C160B Connector]