2006-04 Ford E350, E450 Van 1784 6.0 LITER DIESEL ENGINE W/SINGLE OE ALTERNATOR TYPE B Uses TM-16, 4-3/4 Poly Groove Rear Port Compressor PARTS LIST 1 6m-1.0 x 15 Bolt 1 6m-1.0 x 45 Bolt 3 6m Flat Washer 3 6m Lock Washer 2 6m-1.0 Nut 2 8m-1.25 x 35 Bolt 2 8m Flat Washer 2 8m Lock Washer 4 10m-1.25 x 40 Bolt JIS Flange Head 3 10m-1.5 x 40 Bolt Grd 10.9 5 10m-1.5 x 50 Bolt ANSI Head Grd 10.9 1 10m-1.5 x 75 Bolt Grd 10.9 1 10m-1.25 x 90 Bolt 2 10m-1.5 x 110 Bolt Grd 10.9 1 10m-1.5 x 120 Bolt 9 10m Flat Washer 15 10m Lock Washer 1 10m-1.25 Nut 2 10m-1.5 Nut 6 12 Black Zip Tie 1 1 x 3-1/2 Heater Hose 1 #16 Worm Gear Clamp 1 1 Barbed Splice 2 89062 Backside Idler Pulley 4 10m Bearing Bushing 2 C-11238 Clamp 1 3/4 x 7/16 x 3-13/32 Mount Spacer 1 70-89279 Tensioner Assembly 1 810K-6 Dayco Belt 1 1240K-8 Dayco Belt 2 1 x 6 Wire Loom 1 1-1/2 x 3 Wire Loom 1 1784-1 Rear Mount 1 1784-2 Front Mount 1 1784-3 Special Spacer 1 1784-4 O-Ring 1 1784-5 Worm Gear Clamp 1 1784-6 P/S Hose Bracket 1 1784-7 Coolant Hose Bracket 1 1683-1 Crankshaft Pulley 1 1683-3 Cast Tensioner Bracket 1 1684-5 Tab 1 1684-6 Tensioner Plate Brackets in kit may vary in physical appearance from those in photographs. All kits designed by BSI are designed on an engine and in most cases will fit your application without any modification. However, in some cases, your application may have slight differences in the hoses, wire harnesses, turbo tubes, etc. It is the responsibility of the installer to modify, manuever or change position of such items that may be in the way during installation. BSI will not be responsible to make a change to kits for modifications such as these. All photographs in this installation guide are representative to show installation location only. The physical appearance of your vehicle may vary. In some cases, the bracket design changed slightly after the photo s were taken and the vehicle was no longer available for new photo s. If the actual part looks different from the photo, follow the written instructions for proper installation. BSI will not be responsible to make changes to artwork in such cases. 1 BSI 9-14-2005 Revised 6-14-2007
2006-04 Ford E350, E450 Van 1784 6.0 LITER DIESEL ENGINE W/SINGLE OE ALTERNATOR TYPE B Uses TM-16, 4-3/4 Poly Groove Rear Port Compressor INSTALLATION INSTRUCTIONS 3. 1. Disconnect batteries. 2. Drain radiator and coolant reservoir. Catch fluid. 3. Remove plastic shield. Retain hardware. 4. 4. Remove and retain radiator supports. Retain hardware. 2 BSI 2005
5. Remove power steering reservoir bracket. Retain hardware. 5. & 6. 6. Remove and retain air duct. 7. Remove and retain turbo tube. 7. 8. Take loose upper radiator hose at radiator and move to the side. 9. Remove and retain turbo tube and bracket. Retain hardware. 9. 3
10. 10. Remove body cross member. Retain hardware. 11. 11. Remove and retain rubber evaporator cover. 12. Remove fan shroud. Retain hardware. 13. 13. Remove intercooler. Retain hardware 4
14. Remove fan and stator. Retain hardware. 14.. 15. Mark position of OE tensioner. Remove and discard OE belt. 15. 16. Remove vacuum pump and bracket. Discard bracket and bolts. Retain pump and bolts. 16. - 18. 17. Remove and retain OE 8 groove idler pulley. Discard spacer and bolt. 18. Disconnect heater hose from engine and move to side. Discard plastic clamp. 19. Remove and retain electronics box bolt. 19. 5
20. 20. Remove electronics box and clock 180 o counterclockwise. Attach to existing rear hole using OE bolt with one (1) 6m FW-LW and nut. NOTE: Do not disconnect wire harness from electronics box. 21. 21. Install 1684-5 tab to original electronics box bolt location using one (1) 6m-1.0 x 15 W/LW. Use one (1) 6m-1.0 x 45 W/(2) FW-LW and nut to connect to electronics box. 22. 22. Install 1683-1 crankshaft pulley using three (3) 10m-1.5 x 40 Grd 10.9 W/LW. 23. Install one (1) 1784-6 power steering hose bracket to upper, inner steering box bolt hole using OE bolt. Attach power steering hose to bracket with one (1) C-11238 clamp and one (1) 10m-1.5 nut W/FW-LW. 1784-6 23. 6
24. Install 1784-1 rear mount to compressor at upper and lower rear inboard ears using two (2) 10m- 1.25 x 40 JIS flange. 24. 25. Loosely install rear mount to cylinder head at previous vacuum pump bracket location using two (2) 10m-1.5 x 50 ANSI Grd 10.9 W/FW-LW. 26. Double fold shop rag and use to protect fuel lines from prybar. Insert prybar between fuel lines,use cylinder head next to head bolt as prybar anchor point. Carefully bend upper fuel line approximately 1/4. Then with rag still on prybar pry lower fuel line at same point on cylinder head enough to achieve clearance at compressor body. 26. 25. & 26. Note clearence 27. Install one (1) 1 x 3-1/2 heater hose to engine using one (1) 1784-5 worm gear clamp. Insert one (1) 1 barbed hose splice into heater hose using one (1) #16 worm gear clamp. Insert other end of splice into OE heater hose using OE clamp. Note: position clamps as in photo. Head of 1784-5 worm gear clamp is under engine boss. Head portion of 1784-5 worm gear clamp must be as shown. When tight, the belt portion of the worm gear clamp must not protrude forward of the hose so that it does not touch the idler pulley. Cover with one (1) 1-1/2 x 3 wire loom. 27. 27. 29. & 30. 28. If OE wire loom covering the power steering hose is not long enough, one (1) 1 x 6 wire loom is provided. 1784-7 29. Before installing 1784-2 front engine mount to the engine, install vacuum pump to front engine mount using OE bolts. 30. Loosely install 1784-7 coolant hose bracket at the upper bolt. 7
31. 31. Install (1) 10m -1.5 x 75 Grd 10.9 W/FW-LW through front side of 1784-2 front mount. Install OE grooved idler pulley onto bearing pilot with one (1) 1784-3 special spacer and one (1) 1784-4 o-ring. O-ring fits into recess of spacer. NOTE: Open side of pulley goes toward engine. 32. Slip 1240K-8 Dayco belt over engine pulleys, then slip belt over OE grooved idler pulley and start bolt, finger tighten bolt. 35. 32. 32. - 35. 33. Loosely install front mount to front inboard compressor ears using two (2) 10m-1.25 x 40 JIS flange. 34. 33. 33. 34. Loosely install one (1) 89062 backside idler pulley and two (2) 10m bearing bushings using one (1) 10m-1.5 x 110 Grd 10.9 W/LW at lower boss. 35. Loosely install one (1) 89062 backside idler pulley, two (2) 10m bearing bushings to front mount using one (1) 10m-1.5 x 110 Grd 10.9 W/LW at upper boss. 36. 36. Run all bolts in evenly, then tighten. NOTE: Rear mount bolts are accessable through front mount window. 8 1.
37. Attach coolant hose to coolant hose bracket with one (1) C-11238 clamp and one (1) 10m-1.5 nut W/FW-LW. 37. 38. Bend electronics box bracket tab so it doesn t touch vacuum pump. 38. 39. Remove OE tensioner assembly. Install 1683-3 cast tensioner bracket using three (3) 10m-1.5 x 50 ANSI Grd 10.9 W/FW-LW. Reinstall OE tensioner assembly. 39. 1683-3 40. Install 1684-6 tensioner plate to idler bracket using two (2) 8m-1.25 x 35 W/FW-LW and one (1) 10m-1.5 x 120 W/LW and one (1) 3/4 x 7/16 x 3-13/32 mount spacer at engine boss. 40. 1684-6 9
41. 41. Install 70-89279 tensioner assembly to tensioner plate using one (1) 10m-1.25 x 90 W/FW-LW and nut. 42. 42. 42. Wrap and tension inner belt. (Note: Tensioner range should be at or to tight side of OE posi tion.) Install 810K-6 Dayco belt. Belt runs in cen ter six (6) groovesof tensioner pulley, compressor clutch and vacuum pump. Check position of 70-89279 tensioner to ensure proper tension. Upper two stops of tensioner should be approxi mately 1 apart. Belt 1240K-8 Alt Clutch Face Ten Idl Idl Idl V/P 810K-6 Center Six (6) Grooves Idl Ten W/P Idl Comp P/S Comp C/S 43. Make sure all mount and compressor nuts and bolts are tight. 10
44. Modify stator as shown in photographs. Modify by removing white area. Remove insulation before beginning modification. 44. 45. Check clearances at all pinch points and other areas such as belts, hoses, wire harnesses, compressor clutch, etc. Six (6) 12 black zip ties have been provided if needed to tie back hoses or wire harnesses. 46. Reinstall fan and modified stator using OE hardware. 47. Reinstall intercooler using OE hardware. 48. Reinstall fan shroud using OE hardware. 49. Reinstall rubber evaporator cover. 50. Reinstall body cross member using OE hardware. Remove Fins Top 44. 51. Reinstall turbo tubes and bracket using OE hardware. 52. Reinstall upper radiator hose at radiator using OE clamp. 53. Reinstall power steering reservoir bracket using OE hardware. Cover power steering hose with (1) 1 x 6 wire loom. Then tie off 3/8 P/S line with 12 zip tie provided. Remove Fins 54. Reinstall air duct using OE hardware. 55. Reinstall radiator supports using OE hardware. 56. Reinstall plastic shield using OE hardware. 57. Check all clearances. 58. Refill coolant. 59. Connect batteries. Wire loom goes here. Tie off these three lines together 53. 11