If you have any questions please don’t hesitate to contact us.
Thank you for your purchase of this fine Billy Boat Performance Exhaust product. With proper installation your new Billy Boat Performance Exhaust system will last a lifetime. While installation of this product is very simple and straight forward, there are a couple areas that need some attention. Customer assumes all responsibility. Billy Boat Performance Exhaust is not liable for any damages that might occur during installation.
#1- Secure vehicle to wheel lift. Figure 1 shows the kit as it comes from Billy Boat Performance Exhaust. Before beginning open kit inspect all components.
#2- With the hood opened, remove the coil packs from the passenger side of the engine by removing the nuts marked “A” and disconnecting plug “B” shown in figure 2 and lay coil packs on the intake manifold.
#3- Locate the vacuum ports on the rear of the intake manifold, see figure 3. The large port towards the driver side is for the brake booster. Towards the passenger side there is a smaller port with a plastic T shaped cap, this cap (figure 4) must be removed. The best way to do this is with a twisting motion. Once the cap is removed install the vacuum hose to the port and run it down between the firewall and bell housing.
#4- Raise the vehicle and locate vacuum hose and route thru the center tunnel under the automobile, down the passenger side of the tunnel. (Note: Using some type of a steel wire such as a coat hanger may make this easier to run). After exiting the tunnel run the vacuum line up over the rear end following the parking brake cable (Figure 5) through the aluminum cross member brace and along frame towards rear of car (figure 6). Using the supplied zip ties secure the vacuum line to the transmission cooler lines up by the engine and the parking brake line at the rear of the car.
#5- Lower the vehicle to begin the installation of the Fusion control box. Open passenger side door and remove floor mat. Pull down on passenger side floorboard to access fuse block. Remove 10 amp fuse located in the bottom right and insert fuse adapter into fuse block (figure 7). Locate the grounding screw on the bottom left and remove. Insert screw through ground wire connector and reinstall (figure 7). Place Fusion control box under fuse block and route blue antenna wire as shown (figure 7). Making sure all wires are tucked in, fold back floorboard and re-install mat.
#6- Take remaining wire loom and route it towards the rear of the car on the passenger side tucking it under the interior trim working towards the rear. Continue tucking wires under interior trim in rear cargo area and down into the passenger side storage well. (Figures 8,9,10)
#7- Drill 3/8” hole in back rear corner of the storage well (figure 11). Route wire loom through hole and insert grommet.
#8- Using the supplied template drill (4) 3/16” mounting holes into the passenger side rear splash guard (note: If you do not have a 90 degree angle drill you will have to remove the passenger rear tire). Mount the vacuum reservoir and solenoid assembly to the inside of the rear splash guard with the supplied bolts and nuts (figure 12). Install rear tire if it was removed.
#9- Plug electrical connections together. Plug vacuum line coming from front of car into open side of vacuum reservoir. Route vacuum line coming from solenoid and connect to both Fusion actuators’ using supplied “T’s” and vacuum line (figure 13). - Check to make sure that the vacuum hose or electrical does not rub on anything. Check to make sure that all vacuum hose and electrical connections are tight.
#10- Reinstall the coil packs and start the engine and check for vacuum leaks.
Fusion Exhaust switch operation. Now that your install is complete you are ready to test the system. With the engine running the exhaust valves will be closed. Press the “off” button and the valves will open unleashing the beast within. Press “on” and the valves will again close.
Thanks again for choosing Billy Boat Performance Exhaust. If you have any questions please don’t hesitate to call our toll-free line at 888-228-7435.
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