Install Sheet - Xtreme Diesel Performance
Contents
1. Upgrade Intercooler Kit 99 03 Ford 7 3L P N 2 478 04 06 Ford 6 0L P N 2 483 ct UR e On EF Tile S Turbonetics Inc 2255 Agate Court Simi Valley CA 805 581 0333 Turboneticsinc com SZAR HACING INTERCO0LERS R EE diilim READ THIS FIRST Study these instructions completely before proceeding Engine and or turbocharger damage may occur if any component within these instructions is improperly installed Turbonetics Inc or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation This complete turbocharger system can be installed using common tools and automotive procedures but installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle If in doubt contact Turbonetics technical support staff at 805 581 0333 between the hours of 8 00AM and 5 00PM PST Monday through Friday Remove the heat exchanger from its carton and inspect for any obvious physical damage All kit components are thoroughly inspected and carefully packaged prior to shipment from the factory If any shipping damage is evident contact your supplier and request that they process a claim with the shipper involved Be sure to review the parts list on page 2 to verify that you have all necessary system components to proceed If any components in the parts list are missing contact Turbonetics customer service staff2. 34 anil yal 60139revB Page 9 of 13 16 For 6 0L loosen the hose clamp that secures the boost tube from the turbo to the intercooler on the passenger s side SEE FIGURE 35 FIGURE 35 17 For 7 3L loosen the hose clamps on both driver and passenger side boost tube SEE FIGURES 36 amp 37 FIGURE 3 a o o FIGURE37 18 For 7 3L amp 6 0L slowly remove the factory intercooler out of the vehicle by lifting uowards SEE FIGURE 38 NOTE Be careful of when working around the A C lines the lines are soft and can be bent slightly out of the way easily 60139revB Page 10 of 13 NTERCODLERS FIGURE 38 gt 19 For 7 3L remove the two rubber grommet one of each side on the top mounting brackets of the factory intercooler and re install it onto the top of the new Spearco intercooler 20 For 7 3L amp 6 0L remove the rubber isolator from the lower mounting brackets of the factory intercooler and re install it onto the new Spearco intercooler Making sure the rubber isolator is flush to the edge of the new intercooler lower mount NOTE Glue the factory rubber isolator to the Spearco intercooler with silicone to make installation easier 21 Install your new intercooler into vehicle in reverse order 22 For 6 0L install the new supplied stainless boost tube P N 21472 that connects the intercooler to the engine using the supplied t bolts clamps P N 30275 300 silicone hump connector
3. P N 30435 4 and silicone hose adapter P N 21525 SEE FIGURE 39 INTERCOOLER SIDE 23 Install the boost tube P N 21472 in between the intercooler and the intake manifold using the supplied silicone hump hose P N 30435 4 and two 3 0 t bolt clamp P N 30275 300 on the intercooler side and 60139revB Page 11 of 13 the silicone hose adapter P N 21525 and two 3 0 t bolt clamp P N 30275 300 on the intake manifold side SEE FIGURES 40 amp 41 FIGURE 40 FIGURE 41 a uit cae 24 When installing the new supplied silicone hose adapter P N 21525 the shorter side with the ring on the inside of the hose goes on the engine side FINAL CHECKLIST e Review these instructions to make sure that all fasteners clamps connections have been installed correctly e Check that all hose routings are free of any kinks or near any hot or abrasive surfaces which may cause wear over time Adjust or reroute as necessary to provide adequate slack for engine movement 60139revB Page 12 of 13 SZAR HACING INTERCO0LERS R EE diilim NO FAULT NO HASSLE WARRANTY PROGRAM TURBONETICS will repair or replace at our expense any new TURBONETICS Spearco products that fail including products used in racing or competition applications for a period of one year from the original date of purchase All turbocharger and cartridge assemblies have a factory installed inline oil filtration device This filter de
4. The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability Turbonetics reserves the right to revise the information presented herein or to discontinue the production of parts described at any time SAFETY REQUIREMENTS It is recommended to follow these precautions Always wear safety glasses amp gloves Turn the ignition switch to the OFF position amp disconnect the batteries Always use properly rated jack stands when working under the vehicle Prevent unexpected vehicle movement by using wheel chocks and or parking brake Operate the vehicle only in well ventilated areas Do not smoke or use flammable items near or around the vehicle s fuel system Keep hands clothing and other objects away from moving parts when engine is running SUPPLIES It is recommended to have the following items before beginning installation e Ford factory service manual for your model year e A large table or bench and plenty of adjacent available workspace e Standard selection of automotive tools primarily metric sizes EST INSTALL TIME 1 Hr PARTS LIST 5 380 SC Heat Exchanger Assembly 6 0L 1 21472 C Bost OY M S O 30275 300 Clamp T Bolt 3 0 6 0L 30435 4 Silicone Hump Connector 3 0 6 0L 21525 Silicone Hose Adapter 6 0L TOOLS REQUIRED 1 8 11 amp 12mm Deep socket 2 Socket Extension 3 Rat
5. chet 4 10mm 12mm Wrench 5 Pry bar 6 Pliers 60139revB Page 2 of 13 INSTALLATION 1 Disconnect negative terminals from both batteries by loosening the 8mm bolts on the battery terminals SEE FIGURES 1 amp 2 FIGURE 1 FIGURE 2 2 For 6 0L remove both battery terminals on the drivers side battery and remove the battery cover by pulling upwards and remove the battery out of the vehicle by unbolting the 8mm bolt SEE FIGURE 1 3 For 6 0L Remove upper radiator mounts by unbolting the two 8mm bolts on each mount SEE FIGURES 3 amp 4 FIGURE 3 FIGURE 4 4 For 7 3L Remove the wing nut that secures the emergency jack and tools in the engine bay SEE FIGURE 5 60139revB Page 3 of 13 FIGURE 5 5 For 7 3L Remove the five 8mm bolts that secure the upper radiator mount to the core support SEE FIGURES 6 to 8 FIGURE 6 o FIGURE7 60139revB Page 4 of 13 6 For 7 3L Remove three 8mm bolts securing radiator overflow tank to the truck SEE FIGURES 9 amp 10 NOTE Do not remove the coolant tank completely out of the vehicle FIGURE 9 FIGURE 10 7 For 7 3L and 6 0L remove the four plastic snap in fasteners that secures the plastic trim to the core support SEE FIGURES 11 12 13 amp 14 6 0L FIGURE 11 o o FIGURE12 FIGURE 14 60139revB Page 5 of 13 8 For 7 3L and 6 0L use a marker and mark the location of the hood latch in relative to the core support this will help
6. d Goods Authorization tracking number No returns will be accepted without an RGA tracking number No returns will be accepted after ninety 90 days from the original shipping date from TURBONETICS unless approved All approved returns are subject to a 15 restocking charge NO EXCEPTIONS The original invoice must accompany the return Accepted warehouse distributor and open account returns will be issued credit only RETURNED GOODS AUTHORIZATION TRACKING NUMBER TURBONETICS will only accept product returns repair orders upgrades and warranty requests that have been approved and are returned with a corresponding RGA Returned Goods Authorization tracking number Contact TURBONETICS for approval and the RGA number Write the RGA number clearly on the outside of the package and include it inside the package This is very important in allowing us to properly identify and process your request Failure to comply with this requirement will result in the delay of processing or the product being returned to you 60139revB Page 13 of 13
7. latch alignment during re assembly SEE FIGURES 15 amp 16 FIGURE 15 FIGURE 16 9 For 7 3L and 6 0L carefully unclip the plastic fastener that secures the hood latch cable to the core support SEE FIGURE 17 FIGURE 17 10 For 7 3L and 6 0L unbolt the two 8mm bolts for the upper A C condenser brackets SEE FIGURES 18 19 6 0L and 20 21 7 3L 60139revB Page 6 of 13 FIGURE 18 m hey A T A Nai h I C IR i eT es 7 ge y AS Sew Rees ina k bs im e Brees De FIGURE 21 l D ai 11 For 6 0L remove the air filter and then the plastic intake tube that goes from the front of the truck to the filter SEE FIGURE 22 FIGURE 22 60139revB Page 7 of 13 12 For 7 3L and 6 0L remove two 10mm bolt that secures the factory intercooler to the core support SEE FIGURE 23 24 6 0L amp 25 26 7 3L FIGURE 23 _ FIGURE 24 FIGURE 25 ii FIGURE 26 13 For 7 3L and 6 0L using a 12mm open wrench or socket remove the eight bolts that secures the core support the chassis SEE FIGURES 27 to 30 FIGURE 27 _ 60139revB Page 8 of 13 FIGURE 29 f 14 Ford 7 3L and 6 0L carefully pry the top core support out with a pry bar without scratching it SEE FIGURES 31 amp 32 4 il 7 FIGURE 31 FIGURE 32 15 For 6 0L remove the driver s side boost tube some years may come with a plastic boost tube while others may come with a steel tube SEE FIGURE 33 amp 34 FIGURE 33 FIGURE
8. vice must remain in place if any warranty is to be considered under the No Fault No Hassle program Electrical components that fail due to misuse are not covered under the No Fault No Hassle Warranty Program Warranty is limited to TURBONETICS products and does not include progressive or subsequential damage and does not cover removal or installation labor or associated parts No warranty is made for any other claims for special indirect or consequential damages including but not limited to component removal or installation equipment downtime prospective profits or other economic loss Warranty will not be granted for recurring damage malfunction or failure due to improper installation misuse unauthorized repair or alterations or externally induced physical damage Warranty is non transferable and must be processed via the original purchaser from TURBONETICS Remanufactured units performance upgraded units and O E M replacement units are covered by a 90 day warranty or the O E warranty period TURBONETICS highly recommends that the installation of mechanical or electrical parts be performed by trained professionals Improperly installed products may lead to unsafe and unreliable conditions RETURN POLICY Only unused and complete merchandise may be accepted for return subject to inspection and acceptance by TURBONETICS No goods will be accepted without prior return authorization from TURBONETICS Call for approval and RGA Returne
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