OIL COOLER KIT INSTALLATION INSTRUCTIONS D Application: , E89 Z4 sdrive 35i without stock oil cooler* PARTS LIST

Transcription

1 OIL COOLER KIT INSTALLATION INSTRUCTIONS D Application: , E89 Z4 sdrive 35i without stock oil cooler* PARTS LIST Qty Part No. Description 1 D Oil Cooler + Frame Assy 1 D Oil Line Mount with O-rings 1 D Oil Cooler Hose Inner 1 D Oil Cooler Hose Outer 1 D Shroud Assy 1 D Open Grill Wheel Well Liner 1 D Hardware Kit 1 M8x25 allen M8x25x1.25p allen bolt 1 M8 Schnorr M8 ribbed washer Open Grid right Oil Filter Housing* Thermostat Housing* M8 x 25 Torx head bolts* seal ring* O-ring* Tools needed: Die grinder Fiberglass cutting disc for die grinder Important Note: All Cars This kit is designed for cars with a standard bumper. This kit may not fit cars equipped with alternate bumpers, including the BMW M-Technic bumper. INS Page 1 of 9 Rev. 10/20/10

2 1. Raise the car and remove the front wheels. Remove the Front Bumper Skin 2. Remove the doors for the headlight cleaning system if your car is equipped with them. Pull out spray nozzle (1) by cover (2). Hold spray nozzle and carefully unclip cover sideways and remove. Grip spray nozzle firmly. See figure below. This step is best done with two people. 3. Remove the large splash pan that mounts under the engine. When reinstalling these small screws later, be sure to use hand tools no power tools! 4. Remove the right side (passenger side) front wheel well liner. This part will not be reused. Be sure to save the brake duct block-off panel that attaches to the bottom of this liner. 5. Remove the four screws that connect the left side wheel well liner to the front bumper skin. 6. Disconnect the headlight squirter hose coupler (if so equipped) in preparation for bumper skin removal. 7. Prepare a safe storage spot such as a body panel stand for the bumper skin. 8. Remove the seven Torx head screws that secure the bumper skin to the top front of the car. These screws are under the rubber seal. Carefully remove the bumper skin and store in a safe location. Install Oil Filter Housing and Oil Thermostat Housing 9. Locate the Oil Filter Housing, Thermostat Housing, and the three M8 x 25 Torx head bolts. You can use the TIS # procedure to install the Oil Filter Housing then simply bolt on the Thermostat Housing using the three M8 x 25 bolts, torqued to 16Nm. But first read the hints below to make things easier and prevent getting oil in the cooling system. 10. Place rags over the two turbo inlet tubes after removing the air filter box. 11. Remove the oil pressure sender from the stock oil filter housing before removing the Housing. INS Page 2 of 9 Rev. 10/20/10

3 12. Remove the used oil filter and use a suction tool to remove any pooled up oil. 13. Place drip pan under engine and disconnect the upper radiator hose from the stock oil filter housing to drain the housing. 14. Disconnect the smaller water hose with flange from the front of engine just under the oil filter housing to drain the housing. After you have installed the new Oil Filter Housing you can reinstall this water hose using a new O-ring. 15. Leave the large plastic intake scoop off of the car until the Oil Lines are completely installed. Install the Oil Line Mount 16. Install the O-Rings onto the Oil Line Mount with a little motor oil on the O-rings. Put the 8mm x 25mm Allen head bolt and lock washer in place. Your Line Mount may differ from photo. 17. Install the Oil Line Mount onto the oil filter thermostat housing. Make sure the O-Rings don t get pinched as you install the block. Hold the Mount up against the thermostat housing firmly as you tighten the screw. Torque the bolt to 20Nm (15ft-lbs.). INS Page 3 of 9 Rev. 10/20/10

4 18. Reinstall the oil pressure sender with the new seal ring. Trim The Support Hanger 19. Use the photo to mark and trim the support hanger that should already be on your car. You can use a hacksaw blade held in vise-grips or a fiberglass cutting disc to make the cuts with the part still on the car. 2-3/8 3/8 INS Page 4 of 9 Rev. 10/20/10

5 Install the Oil Cooler 20. Locate the Oil Cooler + Frame Assy and the Hardware Kit. 21. The Dinan Oil Cooler will mount to the same support frame as the stock oil cooler. Locate the three rubber mounts with M6 studs ( ). Screw these into the three threaded holes in the support frame as shown below. Loop Clamp INS Page 5 of 9 Rev. 10/20/10

6 22. Locate the three small pieces of rubber edge trim and the tube of super glue. Wear some gloves for this operation. Use the photo below to position the pieces of edge trim that will protect the Oil Hoses. Put two or three drops of glue evenly spaced in the grooves of the edge trim then attach them to the edges as shown. When attaching the 2 piece, be sure to have the trim overlap the sharp corner a little. 23. Mount the Oil Cooler + Frame Assy to the three rubber mounts using the three M6 wave washers and three M6 nuts. Install The Oil Cooler Hoses 24. The Oil Hoses must be installed before the Shroud Assy can be installed. When tightening the Oil Cooler Hoses it is important to hold the fitting adaptor with one wrench while you tighten the hose end. It is easy to loosen the adaptors at the Cooler when attaching the Hoses so be sure to check the tightness of these after installing the Hoses. To help keep the Cooler from rotating during the hose install process we have installed two retaining straps across the cooler. Observe the following several photos to familiarize yourself with the routing of the Oil Cooler Hoses before connecting any hoses. Note: Your hoses/hose ends may appear different than the ones in the photos. INS Page 6 of 9 Rev. 10/20/10

7 90 end of Outer Hose 45 end of Inner Hose Outer Hose Inner Hose INS Page 7 of 9 Rev. 10/20/10

8 25. You must first install the Inner Oil Cooler Hose between the driver s side fitting on Oil Line Mount and the inner fitting on the Oil Cooler. I prefer to connect the 45 hose end to the Oil Line Mount finger tight first then connect the remaining hose end to the inner fitting on the Cooler. Route both hoses on the forward side of the tubular brace that mounts to the frame rail. Always apply a little anti-seize compound or engine oil to the threads and mating surfaces of these compression type fittings before assembly to avoid damage to them. Also make it a habit to always start the fitting threads several turns by hand and only use the wrench to do the tightening, as these threads are very easy to cross-thread! If they do not turn easily by hand then they are not properly engaged! The Connection of the 120 hose end at the Cooler is the most critical. Finger tighten the 120 hose end for now then install the Loop Clamp from the Hardware Kit to secure the Hose to the frame rail as shown in two of the previous photos. 26. Now you can carefully tighten the 120 hose end at the Cooler so the hose just barely touches the edge trim on the Cooler Frame. Leave the hose end at the Line Mount loose for now. 27. Install the Outer Oil Cooler Hose by first connecting the 90 hose end to the Line Mount (you will need to back off the 45 hose end first). Tighten this hose end with about a 1/16 gap between the Oil Hose and the water hose at the closest point. 28. Tighten the 45 hose end now with about a 1/16 gap between the Oil Hose and the water hose at the closest point. 29. Tighten the 120 hose end of the Outer Hose at the Cooler again with the Hose just barely touching the edge trim on the Cooler Frame. Notice how the Hoses are to be bundled by observing the previous photo of the installed Oil Cooler on page By now you should have the Oil Cooler Hoses in place and all hose ends tight. If not, tighten them now. 31. Use three tie straps to secure the Hoses together at the Oil Cooler as shown on page 5. The top tie strap must run through the oil cooler support to keep them in towards the Oil Cooler. 32. Use a tie strap to connect the two Hoses together at the Loop Clamp. Loosely install another at the support tube that connects to the frame rail. This tie strap at the support tube can be used to pull the Hose bundle closer to the engine and away from the fan housing. 33. Use a tie strap to connect the two Hoses together about 2 from the end of the 90 hose end then another every 3-1/2 or so to keep the hoses neat and vertically stacked. Do not over tighten these tie straps or they will pop when the pressure builds up. The Hoses should be secured in a manner that does not let them rub on anything. 34. Add 1/2 to 1 quart of engine oil depending on where the oil level was initially. 35. Fill the cooling system and purge using the bleeder screw next to the filler opening. INS Page 8 of 9 Rev. 10/20/10

9 36. I prefer to start the car and run it for several minutes so I can check for even the tiniest oil leak. Start the engine and run it at about 2,000 RPM s for a few minutes or until the oil thermostat opens if you have the time (preferred). When the Cooler gets hot the thermostat is opened. Closely look over the hose ends and Oil Line Mount for possible leaks. Retighten as needed. Install the Oil Cooler Shroud Assy 37. Locate the Shroud Assy. Mount the Shroud using the four M5 x 10 bolts that secured the retaining straps and two from the Hardware Kit. Use the six M5 wave washers from Hardware Kit as well. 38. Install the new Open Grid right in the bumper skin after breaking off the two hole tab. 39. You can now reinstall the front bumper skin and the Open Grill Wheel Well Liner. Remove the outlet grill before installing. 40. Make sure that the opening we cut out for the Inner Oil Cooler hose end is appropriate for the position of your hose end. Use a diegrinding bit with fine teeth to trim if necessary. Do not do the cutting with the part still on the car! 41. Install the outlet grill on the wheel well liner while checking for sufficient clearance. There should be at least ¼ of clearance between the grill and the oil Cooler Hoses. Trim grill if necessary. 42. Don t forget to install the two screws for the plastic support hanger you trimmed in a previous step. 43. If you are satisfied with the fit of the Open Grill Wheel Well Liner you can install the brake duct block-off panel. 44. Reinstall the large plastic intake scoop. 45. Reinstall the large plastic splash pan. 46. Reinstall the wheels and torque them. 47. Congratulations you have completed the installation of the Dinan Oil Cooler! INS Page 9 of 9 Rev. 10/20/10