Bullet Proof Oil Cooler Kit Neal Technologies, Inc. (patent pending) Updated 12/23/09 Installation Manual 1 Installation Overview
These are the parts included in your kit. Please locate and identify each part prior to starting the installation process. Part Number Description Quantity 6000001 EGR Cooler Gasket Set, Ford 1 6000002 Oil Filter Mount 1 6000003 High Capacity Engine Oil Cooler 1 6000004 Diesel Oil Filter 1 6200002 Constant Tension Spring Clamp 2 6200004 SHCS, Black, Metric 35mm 2 6200005 SHCS, Black, Metric 40mm 2 6200011 ¼-20 Lock Nut 4 6200012 ¼-20 x ¾ Hex Head Bolt 4 6200013 5/16-18 Lock Nut 3 6200014 5/16-18 x 1 ¼ Hex Head Bolt 3 6200015 ¼ Flat Washer 4 6200016 5/16 Flat Washer 6 6400004 Silicon Hose, in 6 Misc Hoses with Fittings Attached 3 6502031 6.0L Adapter Manifold Block, Assembled 1 Unique Parts for 2003-2004 Installation: 6502032 03-04 Oil Filter Bracket, Driver s Side 1 Unique Parts for 2005-2007 Installation: 6502033 05-07 Oil Filter Bracket, DS 1 6502034 05-07 Rock Panel, DS 1 With Bumper Bracket Mounting: 6502030 Front Mounting Bumper Bracket Cooler 1 With Condenser Bracket Mounting: 6502044 Condenser Mounting Bracket 1 2 Installation Overview
Installation Overview Installing the Neal Technologies Oil Cooler Kit is no more difficult than replacing the OE oil cooler. That being said, it is important to remember that this is major surgery. Cleanliness and taking time to do the job correctly are essential for a perfect installation. There are three major stages to the installation. The first stage is replacement of the OE EGR cooler and oil cooler with the Neal Technologies Oil and EGR coolers. This is performed the same as OE repair procedures with only a few deviations and includes removal of the intake manifold. The second stage of the installation involves installation of the air cooled engine oil cooler. If you have the front bumper mounted version (less popular) then installation of the cooler involves the removal of the front bumper and the front left turn signal assembly to install the new engine oil cooler, oil filter assembly and the oil hoses. If you have the condenser mounted version (more popular) then removal of your AC condenser is on your list for today. If (and only if) you have the bumper mounted version then the third stage of the installation process involves modifying the Air Conditioning (AC) system. Since a portion of the engine heat load is dumped in front of the AC condenser, the heat transfer dynamic of the AC system must be modified to compensate. Step-By-Step Instructions for Removal of Intake Manifold Detailed installation and removal instructions for the EGR Cooler and Engine Oil Cooler can be purchased online. Please go to bulletproofdiesel.com/installations and find the information to purchase the information from eautorepair.net for your particular make and model. Once purchased, please proceed to the section: REPAIR> GO TO THE SEARCH BOX AND TYPE IN INTAKE MANIFOLD AND CLICK ON SEARCH> UNDER ENGINE CLICK ON MECHANICAL > CLICK ON ENGINE 6.0 DIESEL F250-F550 PICKUPS > CLICK ON HEADINGS SEARCH FOR THE IN-VEHICLE REPAIR CATEGORY, WHICH INCLUDES REMOVE AND REPLACE INSTRUCTIONS FOR THE INTAKE MANIFOLD. 3 Installation Overview
Installation Stage 1: The Oil Transfer Block 1) Follow the OE oil cooler replacement procedure (which includes removal of the intake manifold). 2) Remove the oil pressure sender and oil temperature sensor from the OE oil cooler. 3) Gently clean and install the oil temperature sender and the oil pressure sender into the oil transfer block. 4) When the OE oil cooler is completely removed, remove all of the oil and debris from the HPOP reservoir. 5) Remove and discard the HPOP filter. The Neal Technologies (NT) Oil Transfer Block has an integral HPOP screen, made from stainless steel, which operates in place of the OE HPOP filter. 6) Install the OE oil cooler gasket into the NT Oil Transfer Block. 7) Use the OE bolts and torque specifications to install the NT Oil Transfer Block. 8) Discard the OE silicon coolant hose. This is replaced by the silicon hose and spring clamps supplied in the kit. We recommend using the spring clamps over regular hose clamps due to the location and the difficulty involved with tightening regular hose clamps after the installation is complete. Spring clamps, by design, will tighten as the silicon rubber relaxes. 9) Continue following the OE installation procedure. Once the intake manifold is installed, but prior to the turbo being installed, the out oil hose should be installed. 10) Install the oil/fuel filter housing using the bolts supplied in the kit. There are two long and two short bolts. Install into the corresponding long and short holes on the oil filter housing. Use OE torque specifications to tighten the bolts. 11) Discard the OE oil filter element, but retain the element cover as this will still be used to cover the void in the non-functional OE oil filter housing. 12) Complete the installation procedures except for installing the air filter assembly and intercooler air hoses. 4 Installation Stage 1: The Oil Transfer Block
Installation Stage 2: The Oil Cooler and Oil Filter, Front Bumper Version 1) Remove the front bumper assembly. This normally is a total of 6 bolts. Four on the front and one on each side where the support bracket attaches to the frame. 5 Installation Stage 2: The Oil Cooler and Oil Filter, Front Bumper Version
2) Install the supplied oil cooler on the cooler mounting bracket using the supplied hardware. Orient the oil cooler such that the is facing forward on the bracket and is right side up. NOTE: MAKE SURE THE COOLER IS CENTERED ON THE MOUNTING BRACKET BEFORE DRILLING ANY HOLES. 3) Bolt the oil filter adapter to the oil filter mounting bracket using the supplied 5/16 hardware. 6 Installation Stage 2: The Oil Cooler and Oil Filter, Front Bumper Version
4) The supplied oil cooler s mounting flanges can be mounted on either side of the mounting bracket. Situations where the vehicle is used in harsh environments, the installation of a protective shield might be prudent. 5) The oil cooler and oil filter brackets are connected to the vehicle using the OE bumper hardware. Hang the cooler bracket on the vehicle s bumper mounts. Prior to reinstalling the bumper, mock install the oil filter bracket, and hoses to insure proper fit. NOTE: NOW IS THE TIME TO MAKE ANY NECESSARY ADJUSTMENTS. ONCE THE BUMPER IS RE-INSTALLED, IT WILL BE ALMOST IMPOSSIBLE TO CHANGE THE FIT WITHOUT REMOVING THE BUMPER AGAIN. HANDY TIP USE THE BUMPER BOLTS TO HOLD THE OIL FILTER MOUNT IN PLACE. RUN THE HOSES TO AND FROM THE OIL FILTER. WHEN REINSTALLING THE BUMPER, SIMPLY ALLOW THE HOSES TO HOLD THE OIL FILTER IN PLACE, AIDING IN BUMPER INSTALLATION! 7 Installation Stage 2: The Oil Cooler and Oil Filter, Front Bumper Version
Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount Remove the Condenser: 1. Mark Hood Latch position with a Sharpie marker. 2. Remove plastic condenser cover/upper radiator air deflector. 3. Remove hood latch mechanism. 8 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
4. Discharge/recover AC refrigerant. 5. Remove L brackets that hold condenser in place. 6. Remove condenser. Mounting the Oil Cooler to the Bracket: 7. Align, mark, and drill holes in the oil cooler using the bracket as a template. Make sure that the oil cooler is oriented correctly and centered on the bracket. NOTE: THE INLET INTO THE OIL COOLER SHOULD BE ON THE DRIVER S SIDE OF THE BRACKET. THE INLET IS POSITIONED IN THE MIDDLE OF THE COOLER, WHILE THE OUTLET IS NEAR THE TOP OF THE COOLER. THIS IS IMPORTANT SO THAT AIR CANNOT BECOME TRAPPED WITHIN THE COOLER. ALSO MOUNT THE COOLER ON THE ENGINE SIDE OF THE BRACKET TO PREVENT COOLER ON CONDENSER INTERFERENCE. 8. Drill the marked holes in the oil cooler. 9 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
9. Mount the cooler to the condenser bracket. NOTE: ORIENT THE BOLTS IN THE MATTER SHOWN SO AS TO NOT DAMAGE YOUR CONDENSER. ORIENT THE OIL COOLER AS SHOWN, CAREFUL TO NOTE INLET AND OUTLET POSITIONS (OUTLET IS HIGHER THAN INLET TO AVOID TRAPPING AIR IN THE COOLER). 10 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
11 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
Mounting the Bracket to the Condenser: 10. Place condenser on working surface (see picture) 11. Identify the holes in the condenser. Please make sure that it is oriented as shown. 12. Position the oil cooler and bracket on the condenser. 12 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
13. Align the square slots/holes in the bracket with the holes in the condenser. Be sure to allow for the condenser bracket to align with the top of the condenser when finished. 14. IF NO HOLE IS AVAILABLE for the mounting hardware (this is a rare occurrence) you can drill a hole through the edge of the condenser. NOTE: USE A 1/8 (.125) DIAMETER DRILL BIT AND CAREFULLY ALIGN THE HOLE POSITION SO THAT IT AND THE INSTALLED SCREW WILL NOT DAMAGE THE TUBES AT THE END OF THE CONDENSER. 13 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
15. Mount the bracket to the condenser using the hardware provided. Drill only if necessary. 16. Secure the bracket to the condenser with all four screws, making final adjustments such that the top level of the bracket aligns with the top level of the condenser. 14 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
17. Mount the oil hoses provided on the condenser at this time be sure to tighten the hoses as this is the easiest time to do so. Verify that the hoses are mounted tightly. 15 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
Installing the Condenser with the Oil Cooler Attached: 18. Install the condenser loosely in the truck, checking to make sure that the orientation of the cooler is as shown and that nothing is going to hit/rub/interfere. 19. Install the condenser L brackets on the newly installed cooler bracket crowns. NOTE: PRE-FILLING THE ENGINE OIL COOLER WITH OIL IS BOTH NECESSARY AND PARAMOUNT! DOING SO WITH HOSES ATTACHED TIGHTLY TO THE COOLER MAY BE THE MOST SUITABLE TIME. 20. Install the A/C lines. 21. Recharge the A/C system. 22. Reinstall the hood latch (using the marks as a guide) and the condenser cover/upper radiator air deflector. 16 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
23. Bolt the oil filter adapter to the oil filter mounting bracket using the supplied 5/16 hardware. 24. Mount the oil filter bracket to the backside of the bumper, driver s side using the same two mounting bolts and hardware to secure the oil filter bracket. 17 Installation Stage 2: The Oil Cooler and Oil Filter, Condenser Mount
Oil Hose Routing on the 2003-2004 Models On the 2003 and 2004 models: Behind the driver side left front turn signal assembly is an elongated hole. This hole generally has several wires routed through it. Thesee wires need to be removed from this elongated hole and rerouted through the hole behind the left headlight. The elongated hole is where the lower section of the out hose will be routed. Hose Routing on 2003-2004 behind driver side turn signal lamp housing 18 Oil Hose Routing on the 2003-2004 Models
19 Oil Hose Routing on the 2003-2004 Models
Oil Hose Routing on the 2005-2007 Models Remove the grill. Remove the front driver side headlamp. Loosen the four screws that hold in the headlamp retainer bracket. 20 Oil Hose Routing on the 2005-2007 Models
21 Oil Hose Routing on the 2005-2007 Models
Route the hose as shown: 22 Oil Hose Routing on the 2005-2007 Models
CONTINUE INSTALLATION FOR BOTH 2003-2004 AND 2005-2007 1) To make installation of the oil out hose easier, make sure the oil filter assembly is firmly mocked up in place. Once the hose from the engine is connected to the oil filter assembly, install the filter-to-cooler hose. NOTE: THIS HOSE CAN BE THE MOST DIFFICULT PART OF THE INSTALLATION. PLEASE USE PATIENCE. SOME OIL COOLERS AND FILTER ADAPTERS HAVE ALUMINUM HOSE FITTINGS. IT IS VERY EASY TO CROSS THREAD THESE CONNECTIONS. 2) The length of the filter-to-cooler hose is critical. Make sure the hose does not bind or put undue stress on the cooler or filter assemblies. 3) Install the oil return hose to the cooler. Route the hose through the core support where the AC hoses and intercooler come through. NOTE: TAKE CARE TO INSURE THE OIL HOSE AND AC HOSES DO NOT RUB. THIS COULD LEAD TO THE EVENTUAL FAILURE OF THE AC HOSES. 4) Remove the left (drivers side) support bracket from the bumper. 5) Remove any lights from the bumper (bumper mounted version only). 6) Re-install the bumper using the OE hardware. 23 CONTINUE INSTALLATION FOR BOTH 2003-2004 AND 2005-2007
7) Adjust oil filter assembly placement to clearance the bumper support brackets and tighten hardware. Install the previously removed bumper support bracket. If there is interference with the oil filter assembly, re-adjust the oil filter bracket until the oil filter assembly has proper clearance. 8) Once the above steps are complete, prime the oil cooler and filter with oil. This can be accomplished by pumping oil from a bulk oil dispenser through the oil supply hose or by filling the oil cooler and filter with oil at the time of installation. 9) Finish the OE Oil cooler installation procedure. Make sure all connections are tight. Installation Stage 3: Air-conditioning Adjustment - Bumper Installation Version Only NOTE IN SOME HOTTER CLIMATES, A SMALL ADJUSTMENT TO THE AIR- CONDITIONING SYSTEM MAY BE REQUIRED. THIS MAY BE NECESSARY BECAUSE OF ALL THE HEAT FROM THE ENGINE OIL COOLER THAT IS NOW BEING DUMPED IN FRONT OF THE CONDENSER. A SMALL ADJUSTMENT OUTLINED BELOW WILL ADJUST FOR THIS CHANGE. 1) Reclaim the refrigerant from the AC system in accordance with local and EPA regulations. 2) Remove the OE orifice tube and replace with a GM white orifice tube (Four Seasons Part# 38623). 3) Evacuate and recharge the AC system with an additional 6oz of refrigerant more than the OE specified amount. Test drive at highway speeds and add up to an additional 12oz of refrigerant as needed. 24 Installation Stage 3: Air-conditioning Adjustment - Bumper Installation Version Only