M-9000-ZX3 JRSC Focus Big Boost Upgrade Kit INSTALLATION INSTRUCTIONS

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Gavin Evans
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1 Please contact the Tech Hot Line for the most current instruction information (586) !!! PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION!!! INTRODUCTION: These instructions are intended to supplement the original instructions that came with the Jackson Racing Supercharger System for Ford Focus, Ford Racing part # M-6066-ZX3 (Jackson Racing part # ). Please refer to the original instructions that came with your supercharger kit and follow all pre-installation instructions prior to proceeding. If you have any questions regarding the installation of this kit, please call the Ford Racing Tech Hot Line at (586) or visit NOTE: This upgrade kit requires the use of premium unleaded fuel of at least 91 octane. For maximum performance, use the highest octane unleaded fuel available. INSTALLATION: STEP 1: STEP 2: STEP 3: Disconnect the negative battery cable. Remove the gas cap and then retighten it to relieve any residual pressure before moving on. Remove the PowerCard electronics, wiring and vacuum hose. Refer to the original supercharger installation instructions for details. Note that any wires that are exposed after removal of the PowerCard should be covered by wrapping with electrical tape or shrink tube. Remove the Powertrain Control Module (PCM) and ship it to Ford Racing for re-calibration. NOTE 1: You must send the PCM that originally came with the car. NOTE 2: If an aftermarket chip has been installed in the PCM, it must be removed. The PCM cannot be re-calibrated with an aftermarket chip installed and the new calibration will not work with any aftermarket chips STEP 3a: STEP 3b: STEP 3c: STEP 3d: The PCM (ECU, EEC V module) is located on the right side of the passenger side footwell behind the kick panel. Remove the kick panel by removing the two large head plastic screws and pull the kick panel out. The PCM will now be visible; it is the silver box with the large connector. Remove the bolt holding the connector to the PCM using a 10mm socket and undo the connector from the PCM. With the PCM connector undone, the PCM can now be slid down and out. Page 1 of 5

Racing part # 995-000). Please refer to the original instructions that came with your supercharger kit and follow all pre-installation instructions prior to proceeding.

2 STEP 3e: STEP 4: STEP 4a: STEP 4b: STEP 4c: STEP 4d: STEP 4e: STEP 4f: STEP 4g: STEP 5: STEP 5a: STEP 5b: STEP 5c: STEP 5d: STEP 6: STEP 6a: STEP 6b: Fill out the included PCM Return Form (pages 4 & 5 of this Instruction Sheet) and enclose with the PCM in the shipping box. The PCM will be shipped back to you within two business days. Remove the original airbox, mass air flow (MAF) sensor and inlet snorkel. Remove the inlet hose between the MAF sensor on the airbox and the throttle body. Remove the vent hose from the airbox to the valve cover. Unplug the MAF sensor connector. Remove the airbox by lifting it straight up. It is held in place on the bottom with rubber mounts and it may be necessary to gently move it back and forth while pulling up to release it from the rubber mounts. The original MAF sensor stays attached to the original airbox and will not be reused. Remove the two plastic fasteners that hold the front of the inlet snorkel. Do not damage the fasteners, as they will be reused later in the installation procedure. Remove the inlet snorkel by pulling up on the end of the snorkel (towards the rear of the car) to detach the mounting pin, and then pull the snorkel out from the front of the engine compartment. If the snorkel does not come out easily, then consult the factory workshop manual for more detailed instructions on removing the inlet snorkel (air cleaner intake). Install the new airbox and inlet snorkel. Install the new inlet snorkel by pushing it in place from the front of the engine compartment. Push down on the rear of the snorkel to engage the mounting pin. Fasten the front of the new snorkel with the original fasteners. Install the new airbox by pushing it straight down onto the rubber mounts. Note that the new MAF sensor is already installed on the new airbox. Connect the MAF sensor connector to the new MAF sensor. Re-install the vent hose between the valve cover and airbox. Remove the original fuel injectors. Remove the fuel line clip, the two bolts that hold the fuel rail to the intake manifold and pull up on the rail to remove the rail and fuel injectors from the intake manifold. Be careful of fuel still in the fuel line and fuel rail. Remove the clips holding the injectors to the fuel rail and remove the injectors from the fuel rail. Page 2 of 5

Remove the original airbox, mass air flow (MAF) sensor and inlet snorkel. Remove the inlet hose between the MAF sensor on the airbox and the throttle body.

3 STEP 7: STEP 7a: STEP 7b: STEP 8: Install the new high flow fuel injectors. Lubricate the o-rings on the new injectors and install them onto the fuel rail. Install the fuel rail with the new injectors back onto the intake manifold and install the two bolts that hold the fuel rail to the intake manifold and re-install the fuel line clip. Remove the original supercharger pulley and drivebelt. NOTE: This upgrade kit requires the use of the OEM crankshaft pulley. Replace any aftermarket crankshaft pulley with the stock crankshaft pulley before proceeding. STEP 8a: STEP 8b: STEP 9: STEP 9a: STEP 9b: STEP 10: STEP 10a: STEP 11: STEP 11a: STEP 11b: STEP 11c: STEP 11d: Remove the supercharger assembly from the intake manifold. Refer to the original supercharger installation instructions for details. Remove the supercharger pulley nut. The pulley should now be able to be pulled off the supercharger. If the pulley does not come off easily, do not attempt to pry the pulley off. Use a gear puller to pull the original pulley off. Install the new supercharger pulley and drivebelt. Install the new pulley onto the supercharger assembly and torque the pulley nut to 45 ft./lbs. Install the supercharger assembly with the new pulley onto the intake manifold and install the new drivebelt. Refer to the original supercharger instructions for details. Install the re-calibrated PCM. Slide the PCM back into place, reinstall the connector and bolt, and reinstall the kick panel. Finish the installation. Reconnect the negative battery connection. Install the inlet hose between the MAF sensor and throttle body. The upgrade is now complete. Start the engine and let the car idle for a few minutes, then turn the car off and check belt tension and all fasteners for torque. Repeat after driving the car a short distance. Do this periodically to ensure proper operation of all components. DO NOT OPERATE THE CAR AT FULL THROTTLE UNTIL THE FUEL TANK HAS BEEN FILLED WITH PREMIUM UNLEADED FUEL. Page 3 of 5

Remove the original supercharger pulley and drivebelt. NOTE: This upgrade kit requires the use of the OEM crankshaft pulley.

4 PCM Return Form - Part# M-9000-ZX3 You must send the PCM that originally came with your car. The information contained within your PCM will need to match the information on this sheet for the PCM to be properly recalibrated. Since all anti-theft features and vehicle information are retained, only the original PCM that came with your car can be recalibrated. If an aftermarket chip has been installed it must be removed prior to sending in the PCM for recalibration. The new calibration will not work with any aftermarket chip. 1) Please fill in ALL of the following fields so that your PCM will be properly recalibrated. 2) Enclose the completed PCM Return Form with your PCM in the supplied shipping box. 3) Affix the pre-printed UPS shipper to the outside of the box. 4) Please write your name and your return shipping address on the outside of the box, but not over the shipping label. 5) Drop the box off at your local UPS drop-off location. If you have any questions on filling out this form please call the Ford Racing Tech Hot Line at (586) Customer Name and Shipping Address Daytime Contact (phone number or address) Model Year, Bodystyle and Trim Level (ex ZX3 SE) VIN# PCM# (ex. 1M5F-12A650-SA, see picture on page 5 for details) Page 4 of 5

Since all anti-theft features and vehicle information are retained, only the original PCM that came with your car can be recalibrated.

5 Catchword (ex. LFQ0, see picture on page 5 for details) Transmission Type (automatic or manual) Tire Size (ex. 215/45R17) Final Drive Ratio - for manual transmissions only (stock or 4.06) PCM# 1M5F-12A650-SA Catchword: LFQ0 Page 5 of 5

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