Includes: 1. High Flow Turbo Up-Pipe 1. J-Hook Block Off / Coolant Reroute 1. Coolant Hose 1. EGR Valve Block Off Plate 2. Hose Clamps 4. Bolts & Nuts
WARNING: This product is not legal for sale or use on pollution controlled vehicles and is sold ONLY for off-road competition race use only. It is not for sale or use in CARRB regulated areas. This product cannot be used on highway registered vehicles. By purchasing this product, you agree to use it in conform to local, state, and federal laws. The purchaser of this product is responsible for misuse of the product. CAUTION: Never work on a hot vehicle. The hot exhaust system or hot engine can cause serious injury in the form of burns. If the vehicle has been in use or the engine was running and the exhaust system or engine is hot, allow the engine to cool for a minimum of one hour prior to starting the job. Always wear eye protection when working on or under the vehicle. Before removing any of the original parts from your vehicle, please compare the parts you have received with the picture and parts list of the kit you ordered. This assures that you have all the parts necessary for the installation. Prior to disassembly, we suggest applying penetrating fluid, such as PB-Blaster or JB-80 to all exhaust fasteners. Before working on the vehicle, be sure it is parked on a level surface and is chocked to prevent the vehicle from rolling. Please also be sure the keys are removed from the vehicle for your safety. 1: Disconnect the batteries. 2: Drain the coolant below the level of the oil cooler. (No need to drain all the coolant) 3: Remove the clips for plastic wire way located above turbo. Fold onto windshield of truck. 4: Remove the upper fan shroud by prying away from radiator through the slots. 5: Loosen hose clamps and remove the intake tube. Then remove the turbo inlet tube and PCV Valve.
6: Loosen the T bolt clamps and remove the intercooler charge pipe. Then unbolt the alternator and disconnect its wires. 7: Disconnect the downpipe by loosening the v-band clamp from back of turbo and remove the 2 bolts holding the catalytic converter to the downpipe. 8: Remove the turbo by removing the two oil feed line bolts, actuator connector, Y-pipe V-band clamp and the three mounting bolts. The turbo will roll forward toward the passenger side of the truck and off the pedestal. 9: Remove the turbo mounting pedestal and then remove the oil drain tube from the HPOP cover. 10: Remove the exhaust manifold to passenger side up-pipe bolts. The bolts can be discarded. This is easiest to do from underneath the truck. 11: Loosen the driver side Y-pipe to exhaust manifold bolts. You do not need to remove the Y-pipe however it will make install easier if you do. 12: Remove the bolts holding the factory up pipe to the Y-pipe. Loosen the v-band clamp holding the EGR cooler to the passenger side up pipe. Remove the Y-pipe, then remove the factory up pipe which has the V band EGR port. 14: Loosen the intake manifold bolts on the driver s side. Then completely remove the intake manifold bolts from the passenger side and note their location. Then remove the two bolts that go through the inner fan stator which are located under the shroud. Note: If the intake manifold gaskets are deteriorated or if you would like to be on the safe side, now is a good time to remove the intake manifold completely and replace the intake manifold gaskets.
15: Remove the bolt that is used to support the heater tube to the manifold which is located under the alternator. Bend the support tab upward. 16: Remove the three EGR cooler mounting bolts. 17: Push down on the EGR cooler and pull up on the intake manifold to remove the EGR cooler from the intake manifold. 18: Gently hold the manifold up with a pry bar or screw driver. Then move the cooler toward the back of the engine. Holding the manifold up, remove the cooler through the front of the engine. Make sure all the gaskets and O-rings are removed with the EGR cooler. 19: Install the silicone hose onto the new J-hook coolant reroute/ intake block off. Keep the hose clamp rings loose on the hose. 20: Lightly grease the J-hook block off O-ring. Then install it onto the intake manifold. Finger tighten the two long factory cooler mounting bolts. The third smaller bolt can be set aside. 21: Tighten the J-hook block off / reroute bolts to 120 in lbs. Make sure the O-ring stays in place and the alignment is correct. Do not over torque the bolts. Then slide the silicone hose over the oil cooler nipple. Replace intake manifold bolts and torque to 120 in lbs. Then tighten both hose clamps on the silicone hose. 22: Remove the EGR valve from the intake manifold and install the block off plate. Torque bolts to 120 in lbs. If the vehicle throws a code or the check engine light turns on (normally on 2005+), try leaving the factory EGR valve in place or install a programmer. 23: Install the new high flow turbo up pipe using the new hardware and the new replacement gasket.
24: Reinstall the turbo, all intake and exhaust tubes including the down pipe, alternator, shroud, wires etc. in reverse order. Be sure everything is tight and secure. 25: Using manufacturer recommended coolant, refill the coolant. 26: Start the engine and inspect for leaks. If no leaks are present, run the engine until the coolant circulates. Top off the coolant as needed. Do not open the cooling system when hot! Congratulations on your installation! Check out our other Powerstroke parts! KBDieselPerformance.com