Whipple 2.9L Install Write-Up

[S197 GT]

What's up guys. I've been here since '05 but this is my very first post.

I've owned a few S197's over the years including my first, a 2005 Black with porno red leather GT. I bought it in November of 2004. I put a Kenne Bell 2.6L on it back in 2007.

Now I've got a 2011 5.0, and I love this car! Done a few things to it. It runs great and handles like a dream now, but I want more power!

So a few weeks ago I ordered the following:

Whipple 2.9L Crusher Supercharger
Whipple 4.00" (8 psi) and 3.75" (10 psi) pulleys
JLT Carbon Fiber 127mm Cold Air Intake
Ford Racing 65mm Throttle Body
Ford Racing 47 lbs Injectors
Ford Racing One Step Cooler Spark Plugs (.030")
Jon Lund Tune

I got the package sans the JLT on last Monday, and I started the install on last Tuesday.

I only work an hour or so at a time during the week, so I get most accomplished over the weekends.

Here is my install write-up:

First thing I did was raise the front end of the car.

I went back to the trunk and unplugged the Fuel Pump Control Module connector.

Then I turned on the car to let it idle until it had died. I then cranked the engine for a few seconds to release the fuel injector supply manifold pressure.

Disconnected the battery.

Removed the radiator cover.

Removed the front bumper.

Removed the impact absorber and the radiator side shields.

Then I loosened the petcock on the radiator to drain the fluid. Taking off the cap first.

This is where I leave it for the night.

I'll start right back off taking off the JLT and the Boss Mani tomorrow night.

Until then...

 

[S197 GT]

Tonight was great! Got exactly where I wanted to be by Saturday.

Took about 2 hours to get to the timing cover grinding.

First thing I did was remove the JLT Carbon Fiber (shameless plug) intake.

I removed the throttle body electrical connector, purge valve and complete tube connecting below the brake booster (you wanna lift up on this clip), and both PCV lines.

I disconnected the supply line to the fuel rail, and both heater hoses. I used the windshield wipers to hold the heater hoses out of the way.

I removed the support brackets for the heater hoses and then I removed the steel section of the brake booster vacuum line from the joint near the rear of the intake manifold.

I removed the 3/8" coolant hose from the tank to the engine.

(to be continued)

 

[S197 GT]

I removed the (2) harness retainers on the back of my Boss Manifold. The stock intake manifold uses (4).

I removed both fuel rail insulators and disconnected all (8) fuel injector connectors. I removed the (4) bolts that run through the fuel rails, and the (6) bolts through the intake manifold (these do not come all the way out).

The intake manifold is ready to be removed.

I lifted the intake manifold off of the engine and placed it to the side with injectors and fuel rail intact.

I cleaned the exposed surfaces of the intake ports and used painters tape to keep debris out.

Notice the knock sensors in the valley. These will be rotated later in the install.

I removed the coolant tank and then used a 16mm socket to rotate the Front End Accessory Drive Tensioner counter-clockwise in order to release enough tension to remove the belt.

I removed the (4) bolts securing the water pump pulley to the engine.

I cut the AC belt and removed the upper radiator hose.

I removed the (2) bolts securing the electric fan and shroud and then unclipped the harness from the fan.

I removed the electric fan and shroud.

(to be continued)

 

[S197 GT]

I unclipped the electrical harness clips along the top of the passenger side of the front timing cover to make room for the surgery I'll be performing tomorrow!

I made some rough markings for where I'll be cutting and grinding tomorrow.

Here's how the car sits until tomorrow.

Tomorrow night I need to go buy a few tools, and I'll be right back at it. Ready to conduct surgery on my timing cover.

 

[S197 GT]

Today started off by drinking several beers standing over the engine compartment bullshitting for a while.

I had stopped at the thrift store and bought a bunch of sheets to cover the engine.

I used a Dremel to take care of the grinding.

This is a very slow process, but it is easy work. I think a Dremel will ultimately be the cleanest way to take care of the timing cover grinding.

I got all of the complete bosses grinder down, along with all of the ribs. The ribs were very easy to do. All I have left is the half cut boss to finish.

We went through about 30 cutting wheels, so plan accordingly if you are going to do this yourself.

Unfortunately, the timing cover was all I got done between last night and today.

I went out and partied last night until 5AM, so I was dragging my feet a bit this morning.

Here's how the grinding looks now. I still wanna clean it up a bit more.

I'm heading out to a comedy show here in a few minutes. Katt Williams, Dave Chappelle, Chris Tucker, Jo Koy, and a few more comics will be there. It should be a hell of a time. So I'm done for the day.

I'll pick up tomorrow where I left off, and I'll see if I can finish the grinding and clean it up a bit.

My intake is on backorder, and my tuner is out on vacation, so I'm in no rush right now.

I'll likely push the estimated completion date to next weekend.

 

[Tob]

As a fellow Whipple 2.9 owner I'm looking forward to the rest of your write up. Good luck with it!

Tob

 

[SID297]

Email me the full size pics of this and I'll put this write up on the front page for you.

[email protected]

 

[TBuick87]

DAM Good and TIMELY Write up, Just Bought my Roush Today!! Install Begins Next Week...I SERIOUSLY Owe You a BEER!!! BIG PROPS!!

 

[grnenvy]

Lookin good!
Try using an air angle grinder with cut off wheels and also a cookie attachment with 3M sanding disks it would be alot easier. It took me 2hrs to cut and grind my cover. (TVS)
I should have taken pics of it. When I was finished it looked like it was machined that way.

 

[Fast Willy]

Damn the whipple is no longer just a bolt on kit?

 

[grnenvy]

Hmm

If u want the best all around pwr a PDB is the way to go but yes it's a little more work.

Damn the whipple is no longer just a bolt on kit?

 

[FastRedPonyCar]

can't wait for the final results!

Selling the boss intake?

 

[S197 GT]

More grinding tonight...

Had to remove (2) water pump bolts to get more room.

Went back and smoothed out the bosses.

 

[FastRedPonyCar]

why not just buy a grinder from sears, use it then take it back for a refund? LOL.

 

[S197 GT]

why not just buy a grinder from sears, use it then take it back for a refund? LOL.

I'd like to prove you can do the entire project with a Dremel.

 

[Fast Willy]

Lookin good so far. Can't wait to see the results

 

[grnenvy]

Hmm

Sorry bro
I should have told u that I used a mini hacksaw on the top boss it worked great.
Only took two cuts one down the middle and one from the side.

More grinding tonight...

Had to remove (2) water pump bolts to get more room.

Went back and smoothed out the bosses.

 

[S197 GT]

Really, a hacksaw?

I may try that tonight!

Thanks bro!

 

[z28th1s]

Nice write-up.

 

[S197 GT]

Finally got through the last boss!

Still cleaning up the cuts a bit.