Whipple FRPP SUPERCHARGER 750 HP KITS User manual

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
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Supercharger Installation Manual
Ford Shelby GT500 Mustang 5.4L 32 Valve
Engine: Ford 5.4L 32 Valve
Mustang Model Years: 2007-2011
FRPP SUPERCHARGER 750 HP KITS

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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Symbol Key
Throughout this installation guide you will see the following symbols used:
NOTE
Used to indicate tips and information to aid in installation, maintenance, or use of the
supercharger.
!! CAUTION !!
Used to indicate precautions that must be taken to avoid damage to the
supercharger and associated components.
WARNING!!
Used to indicate precautions that must be taken to avoid bodily injury as
well as damage to the supercharger and associated components.
Table of Contents
Introduction ............................................................................................ 3
Kit Components ..........................................................................................................3
Supercharger Oil .....................................................................................................3
Recommended Tools ..................................................................................................3
Pre-Installation Checklist........................................................................ 4
Supercharger Installation Instructions................................................... 5
Illustrated Installation Guide .....................................................................................6
Maintenance and Service ...................................................................... 31
Maintenance .............................................................................................................31
Servicing Your Supercharger....................................................................................32
Post-Installation Checklist .................................................................... 33
Checklist Review ......................................................................................................33

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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Introduction
This supercharger was created for the 5.4L Ford 32 valve engine, model years of 2007-2011. It has been designed
and tested specifically for this application. Before beginning installation of this supercharger, first read this section
carefully then complete the Pre-Installation Checklist.
Kit Components
Before beginning installation, be sure you have identified all components of your Whipple FRPP Supercharger Kit.
Check the supplied packing slip.
PCM Flash (Complete Kits Only)
Your system includes a FRPP voucher. Follow the voucher instructions to get your flash tool shipped to you. It’s
important to get this before you start your installation.
Supercharger Oil
As described in the Illustrated Installation Guide, the supercharger must be filled with oil prior to use. This
supercharger is shipped without oil inside. The oil is in a separate bottle supplied with your kit and you will be
instructed to add it in the Illustrated Installation Guide.
Warning label attached to Supercharger housing
!! CAUTION !!
Do not attempt to start the engine before adding the supplied Supercharger Oil to the
supercharger!
Recommended Tools and Supplies
The following items are not included in this supercharger kit and it is strongly recommended that they're used for ease
of installation or maximum performance:
Torque Wrench
You will need a quality torque wrench to ensure proper tightening of bolts.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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Tie Straps
These will be useful for securing the wiring harness away from the installation area as directed in the Illustrated
Installation Guide. They are inexpensive and will be very handy during installation.
Sealants
Blue Loctite™#242 or equivalent, Red Loctite™ #271 or equivalent. All bolts that need Loctite™ are marked with:
Loctite™ (#242 blue) threads and Loctite™ (#271 red) threads. Thread sealant such as pipe Teflon
must be used on all pipe threads.
Chemicals and lubricants
You will need some cleaner/degreaser such as carb cleaner.
You’ll be required to fill your intercooler system with approx. 1 gallon of distilled water and Ford approved engine
coolant. Red Line Water Wetter is also a great additive, Whipple recommends using 4 bottles during installation. This
is not supplied in the system, you can find the coolant and Redline at any local auto parts store.
Motor oil will be useful as a lubricant and should be readily available during installation.
Vacuum
A vacuum is necessary to clean up any debris resulting from grinder use.
Clean Shop Towels
Use these to keep the installation area clean.
Pre-Installation Checklist
Before installing your Whipple Ford Racing Supercharger Kit, complete the following checklist.
!! CAUTION !!
Failure to complete the Pre-Installation Checklist may result in severe engine damage
after installation is complete.
1. Verify Condition of Vehicle: Before the supercharger kit is installed, ensure the engine runs smoothly and that
the factory malfunction indicator light (MIL) is off. Only install the supercharger kit if the engine runs smoothly
and the MIL is off.
!! CAUTION !!
This product is intended for use only on stock, unmodified, well-maintained
engines. Installation on a worn-out or modified engine is not recommended
without factory computer and fuel system modifications. Custom engine
configurations could require custom tuning and other supporting modifications.
2. Verify Fuel Octane: Ensure fuel of 91-octane or higher is in the vehicle fuel tank. If the octane grade is not
known, drain the fuel tank completely and fill to 1/8th with fuel of 91-octane or higher.
!! CAUTION !!
Use only 91 octane fuel or higher. If fuel of less than 91-octane is present in the
vehicle fuel tank, the tank must be completely drained and refilled with 91 or
higher octane to 1/8th of a tank.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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3. Verify that your fuel level is below a ¼ full. When changing the fuel pump, this will be very important. If fuel
level is above a 1/4 tank, then you will be required to drain fuel until you reach a ¼ tank or less.
4. Assess Cleanliness of Installation Area: Make sure your work area and the underhood area are free from
debris. This supercharger is a high-quality, close-tolerance compressor and must not be subjected to
contamination by dirt or any type of foreign material. If necessary, vacuum around engine to remove any
foreign material.
!! CAUTION !!
DO NOT remove the protective seal on the supercharger prior to installation.
Foreign material entering the supercharger will automatically void all warranties.
5. Identify Supercharger Kit Components: Before beginning installation, identify all the components of your
Whipple Supercharger Kit and ensure all items are present and undamaged.
6. Read Illustrated Installation Guide: Be sure to read through the Illustrated Installation Guide starting on
page 6 before beginning supercharger installation. Familiarize yourself with the components and tools you will
use and the procedures before you start for faster and easier installation.
Supercharger Installation Instructions
Vehicle: 07-11 Shelby GT500
Engine: 5.4L 32V
Before you begin installing the Whipple Ford Racing 5.4L 32V Supercharger, make sure you have completed the Pre-
Installation Checklist. Be sure you have:
1. □Verified the Condition of the Vehicle
2. □Verified the Fuel Octane
3. □Verified that the fuel level is below a ¼ tank (complete kits only)
4. □Assessed the Cleanliness of the Installation Area
5. □Identified the Supercharger Kit Components
6. □Read and Understood the Illustrated Installation Guide
Have you completed all items in the Pre-Installation Checklist?

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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NOTE
**NOTICE: Installation of Whipple Supercharger products signifies that you have read
this document and have agreed to the terms stated within.
It’s the purchaser’s responsibility to follow all installation instruction guidelines and
safety procedures supplied with the product as it’s received by the purchaser to
determine the compatibility of the product with the vehicle or the device the purchaser
intends to install the product on.
Whipple Superchargers assumes no responsibility for damages occurring from
accident, misuse, abuse, improper installation, improper operation, lack of
reasonable care or all previously stated reasons resulting from incompatibility with
other manufacturer’s products.
There are no warranties expressed or implied for engine failure or damage to the
vehicle in any way, loss of use or inconvenience or labor reimbursement. This
includes merchantability and fitness.
NEVER SMOKE DURING THE INSTALLATION OF THE SC,
THERE WILL BE FLAMMABLE FUMES AND LIQUID AROUND THE
VEHICLE
Be sure you have read and understand the Introduction section and have completed the Pre-Installation
Checklist, then proceed to the Illustrated Installation Guide.
Illustrated Installation Guide
It is strongly recommended that you read through this guide before you begin installing the Whipple Supercharger.
1. Using an air hose, blow off any loose dirt or debris from engine compartment. If really dirty, then steam clean
the engine compartment before proceeding to the next step.
2. Release fuel system pressure.
2011 fuel pump relay 2010 fuel pump relay

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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The fuel pump relay can be found in the bussed electrical center located on the passenger side, front
of engine compartment fuse panel. The fuel pump relay is located in position 21 as shown in the
inside cover of the bussed electrical center. Remove the fuel pump relay. (2011 bused electrical
center has changed see inside cover for fuel pump relay position)
Start the engine and allow it to idle until it stalls. If engine does not start, proceed to net step.
After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection
supply manifold pressure has been released.
Turn the ignition switch to the OFF position.
WARNING!! Batteries normally produce explosive gases. Therefore, do not allow flames, sparks
or lighted substances to come near the battery. When charging or working near a battery, always shield
your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may
result in personal injury.
WARNING!! Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with
skin, eyes or clothing. Also, shield your eyes when working near the battery to protect against possible
splashing of the acid solution. In case of acid contact with the skin or eyes, flush immediately with
water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in personal injury.
3. Disconnect ground cable from battery using an 8mm wrench.
4. Disconnect power cable from battery using an 8mm wrench.
5. Remove battery strap and remove battery from vehicle.
6. Remove battery tray from vehicle.
7. Disconnect the following factory electrical connectors:
Mass Air Flow Sensor element. Carefully pull red tab out, squeeze the connector and then pull the
connector away from connection.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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Electronic Throttle Control motor. Carefully pull red tab out, squeeze the connector and then pull the
connector away from connection.
Throttle Position Sensor. Carefully pull red tab out, squeeze the connector and then pull the connector
away from connection.
8. Disconnect plastic breather hose from passenger side valve cover to factory supercharger inlet. To release, push
green tab on bottom side and then pull.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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9. Disconnect rubber 90deg fitting from air intake tube (Ford #7R3V 9E498 BB). This will not be used later. Will be
removed from bypass nipple when SC is off.
10. Disconnect plastic PCV hose fitting from driver side of intake manifold. To release, push green tab on bottom
side and then pull.
11. Remove the hose clamp securing the rubber inlet hose to throttle body and air box.
12. Remove plastic air inlet between MAF and throttle body.
13. Remove air box from vehicle.
14. Disconnect and remove EGR steel tube from EGR solenoid and exhaust manifold.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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15. Disconnect rubber line from fuel PSI sensor.
16. Disconnect electrical connector from fuel PSI sensor. Carefully pull red tab out, squeeze the connector and then
pull the connector away from connection.
17. Disconnect the 3/8” ID rubber hose from rear/center of supercharger.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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18. Disconnect the rubber line coming from the brake booster to the rear SC intake. To release, squeeze the clear
plastic portion of the connector and pull.
19. Disconnect the rubber line coming from box located on driver side inner fender to the rear/driver side of SC
intake. To release, squeeze the clear plastic portion of the connector and pull.
20. Disconnect the factory fuel line from fuel rail. To release, squeeze the clear plastic portion of the connector and
pull.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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21. Disconnect the IAT2 temp sensor (manifold air temp sensor).
22. Remove the (2) bolts (6mm socket) holding the coolant reservoir on. Let the reservoir hang, this will give better
access to the spring loaded tensioner.
23. Remove the throttle body from SC inlet by removing the (4) bolts (8mm socket).

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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24. Remove the SC inlet from SC by removing the (4) bolts (8mm socket).
25. Remove the fuel rail from manifold by removing the (4) bolts (8mm socket).
26. Remove 10-rib SC belt from motor by using a 3/8” breaker bar or ratchet. Install breaker bar/ratchet into spring
loaded tensioner and rotate in a clockwise rotation, remove belt from SC pulley. Let spring loaded tensioner
return to relaxed position.
27. Remove (1) line from 90deg rubber boot that goes to air bypass nipple. This is the long 1/8” tube with the
90deg on the end that is routed to factory bypass valve.
28. Remove the SC from manifold by removing the (10) bolts (13mm socket).

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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29. Remove the factory ground from driver side firewall and leave loose for now.
30. Install the supplied 3/8” plastic barb to the factory 3/8” hose. Install supplied 3/8” x 4” hose to plastic barb,
route to the driver side by brake booster for later installation. Secure barb with (1) factory clamp and (1)
supplied pinch clamp.
31. (2011 models only) Substitute the harness with the supplied P clip and wrap the wires by the EGR tube with
silver insulation.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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32. DO NOT INSTALL DOW PINS, they are not needed for proper installation.
33. Preinstall (1) of the supplied 8mm x 25mm 6-point bolts so 12-15mm of thread/bolt is exposed in the further
most/driver side bolt hole in intake manifold. You will not be able to install this after this point. All other bolts
can be reached after SC install.
34. (2011 models only) In some applications, the bypass actuator may need to be adjusted, to adjust loosen the
2 button head allen bolts and move away from firewall. Actuator needs a light amount of preload into the
actuator. Re-tighten button head allen bolts torque to 20 ft/lbs.
35. (2011 models only) In some applications , the SC system will hit the firewall. In this case, you will need to
slide the engine forward. Loosen all bolts for the front suspension K-member and transmission. Slide forward,
check the SC clearance. Once install is done the vehicle needs to be aligned.
36. (2011 models only) Remove steel harness wire protector at the rear since it will not clear the motor. Locate
the EGR wiring harness, pull from plastic loom so the wires have more access to the new location of EGR valve.
37. Apply approximately a 3mm bead of Black RTV silicone on top of factory oring (entire oring) to help prevent
leaks between the manifold and the supercharger.
38. Install supercharger assembly by sliding adapter plate and SC assembly on. The rear holes are slotted to help
guide the SC assembly into position. Make sure the rear 3/8” hose does not get pushed down, this needs to be
pushed onto the back of the supercharger inlet.
39. Install the other supplied (1) 8mm x 25mm 6-point bolt (10mm socket) into rear/passenger side bolt hole, do
not tighten yet.
40. Install the other supplied (8) 8mm x 30mm 6-point bolts (10mm socket). Tighten the (8) 8mm x 30mm 6-point
bolts hand tight.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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41. Using a 10mm ratchet wrench, tighten the (1) 8mm x 25mm 6-point bolt you previously installed (under the
inlet system/driver side). Get this snug, but not tight yet.
42. Follow the following torque sequence (3-8-2-7-4-9-1-6-5-10), first pass 18 ft/lbs, second pass 25 ft/lbs.
Improvise for the 1 bolt that you must use the 10mm ratchet wrench. This must be similar to 25 ft/lbs.
1
2
3
4
510
9
8
7
6
43. Install driver side fuel rail. To do this, remove all (4) of the fuel injectors. Apply grease to orings. Carefully place
1 injector in the back cylinder (let it lie in the injector boss, but do not push down yet. Route fuel rail under
inlet. To get fuel injector in, tilt rail counter clockwise and the injector clockwise at the same time until you get
injector oring started in the rail, then rotate the rail back in the clockwise rotation and push the injector into the
rail. Once the rear injector is installed, reinstall the safety clip to secure injector in place. Reinstall the safety clip
to secure injector. Now install the following (3) injectors and safety clips, then press into manifold injector
bosses. Make sure injectors are pressed into rail and manifold all the way.
44. Secure driver side rail with (1) 6mm x 15mm hex head bolt with 6mm AN washer for the back boss, under the
SC inlet. Utilize the supplied 6mm x 20mm socket head cap screw and 6mm allen to front bolt boss. Torque to
110 in/lbs.
45. Install passenger side fuel rail to manifold, secure with the factory 6mm bolts. Torque to 110 in/lbs.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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46. Apply light amount of black RTV silicone to EGR adapter surface. Install EGR billet adapter on SC using supplied
(2) 6mm x 25mm socket head cap screws and torque to 89 in/lbs. (2011)Adjust the orientation of the EGR
adaptor to ensure that the bolt clearance grooves are in the upward position.
47. Install new EGR tube to exhaust manifold and EGR. Leave loose for next instruction.
48. Install EGR to SC inlet using the supplied (2) 8mm x 20mm 6-point bolts. Tighten to 20 ft/lbs.
49. Tighten both ends of the EGR tube (at exhaust manifold and billet adapter).
50. Connect EGR electrical connector to EGR solenoid until it locks in place.
51. Install supplied plastic plug into 90deg rubber boot open hole (line pulled out that use to route to bypass valve).
52. Connect rubber/plastic lines to EGR solenoid and connect rubber 90deg boot to Whipple billet adapter.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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53. Connect EVAP line to quick connect fitting on passenger side intake.
54. Connect all 8 fuel injector connectors until they snap/lock in place.
55. Connect fuel psi sensor connector until it snap/locks in place.
56. Connect fuel PSI pressure hose from intake manifold back to sensor barb.
57. Connect rubber 3/8” line to SC inlet barb fitting you previously installed, secure with pinch clamp.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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58. Locate rubber line coming from brake booster, route back towards driver side so hose makes complete U shape,
then route to SC inlet. Connect the quick connect fitting from the brake booster to SC inlet quick connect male
fitting (bottom). Make sure it snaps/locks in place.
59. BVES valve instructions 2011 only
Remove BVES valve from stock supercharger inlet.
Slip valve into adapter then slip assembly into bracket bolt together with factory bolts.
Torque to 106 in/lbs.

Installation Manual: GT500 FRPP Supercharger System (750HP) (A1R2)
Last Updated: Aug 19th , 2010
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60. Install the bracket for the BVES valve by mounting it on the two bosses on the front of the driver’s side head
with (2) 8x16 low head allen bolts supplied.
61. Lengthen the harness for the BVES valve with provided green & white wire. Cut solder & heatshrink the splices
then cover with conduit.
62. Connect the wiring takeout for the BVES valve. Have the takeout follow the cam sensor wiring loom along
the intake/head mating area.
63. Cut hard line as shown and splice together with billet adapter and clamps.