10 February L C.A.C. Pipe Installation 1 6.4L C.A.C. PIPE. Ford 6.4L Powerstroke -- Installation Instructions P/N#

Transcription

1 10 February L C.A.C. Pipe Installation 1 6.4L C.A.C. PIPE Ford 6.4L Powerstroke -- Installation Instructions P/N# PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION

2 10 February L C.A.C. Pipe Installation 2 Kit Contents Cast Pipe Bracket Steel Pipe Qty: 1 Qty: 1 Qty: Stepped Boot Straight Ribbed Boot Silicone Step Boot Qty: 1 Qty: 1 Qty: HD Clamps 3.50 HD Clamps 3.75 HD Clamps Qty: 2 Qty: 2 Qty: /4 Lock Washer 1/4 Washer 1/4 Bolt Qty: 2 Qty: 2 Qty: 2

3 10 February L C.A.C. Pipe Installation 3 Tools Required Sockets 8,10,11,13mm Air Ratchet Clip Remover Assembly Steel Pipe Boot Clamp Clamp Boot Clamp Clamp Boot Clamp Clamp Cast Pipe

4 10 February L C.A.C. Pipe Installation 4 Procedure 1. Start by disconnecting the negative terminals (8mm) on both batteries and the passenger side positive battery terminal (8 & 10mm). *IMPORTANT* Always disconnect the negative terminal first. 2. Loosen the boot clamps located at the intake and at the top of the cooler and remove both boots.

5 10 February L C.A.C. Pipe Installation 5 3. Mark the hood latch position with a paint pen or marker then remove mounting hardware for the Charge Air Cooler (C.A.C.), Power Steering Cooler, Horn (10mm) and the Hood latch. 4. Remove the radiator bolts from the rear of the radiator support. 5. Proceed to remove the radiator mount rubber from the passenger side. NOTE: The driver side mount does not need to be removed.

6 10 February L C.A.C. Pipe Installation 6 6. Using the clip remover to pop out the pins holding the hood latch cables in place. 7. Remove the radiator support mounting bolts (13mm) 6 bolts in total. 8. Lift out radiator support by lifting the passenger side up while pushing the radiator towards the engine until the guide pin is clear then proceed to pull the bracket forward to lift out the driver s side.

7 10 February L C.A.C. Pipe Installation 7 9. Remove the factory C.A.C. pipe from the passenger side and set aside. 10. Install the supplied BD stepped boot ( ) onto the 90 end of the cast C.A.C. pipe ( ) utilizing the ( ) 3.5 clamp. 11. Insert the BD steel pipe ( ) with the ( ) 3.75 clamp loose and maneuver the cast C.A.C pipe assembly into position from the engine bay side. NOTE: Adjust the position of the clamps for clearance in the engine compartment.

8 10 February L C.A.C. Pipe Installation Install the 3 straight ribbed boot ( ) to the steel intake pipe with the ( ) 3.25 clamps loose to connect to the intake. 13. On the passenger side of the radiator support there is a lip along the inside radius you will need to grind off this lip from the bottom to halfway through the radius to clear the BD pipe. NOTE: you can now test fit the radiator support in the truck to check clearance. *IMPORTANT* As a safety precaution always use eye protection and wear a mask to prevent inhaling particles. 14. Mount the radiator support leaving the lower passenger side bolt loose (13mm).

9 10 February L C.A.C. Pipe Installation Reinstall the radiator bolts and radiator mount rubber to the rear of the radiator support. 16. Reinstall the Charge Air Cooler, Power Steering Cooler, Horn (10mm) and the Hood latch including the pins holding the hood latch cables in place. 17. Install the step boot ( ) onto the cast C.A.C. pipe leaving the clamps loose to connect to the cooler. The clamp on the cast pipe is the ( ) 3.5 clamp and the cooler clamp is the 3.75 clamp ( ).

10 10 February L C.A.C. Pipe Installation Install mounting bracket ( ) onto the cast pipe by tightening the bolts ( ) with the lock washer ( ) and flat washer ( ) until the bracket can still move on slots. Then adjust the cast C.A.C pipe and tighten all clamps into position so the cast pipe is towards the radiator support and away from the radiator tank. 19. Torque the bolts ( ) on the bracket support to 100 in/lbs securing the cast C.A.C. pipe (6mm) in place. Also tighten the radiator support bolt to 100 in/lbs to secure the bracket to the radiator support. *IMPORTANT* Check clamps do not rub on engine bay components. 20. Reconnect the batteries. Positive lead first then the negative leads (8 & 10mm).