BulletProofDiesel.com Installation Manual

BulletProofDiesel.com
Bullet Proof Oil Cooler Kit
Neal Technologies, Inc.
(Patent pending)
Updated 9/2/2011
Installation Manual
2003-2007
F-Series
1
Installation Manual | BulletProofDiesel.com
These are the parts included in your kit. Please locate and identify each part prior to starting the
installation process. There are some drawings in the back of this manual that can aid you in identifying
the proper pieces.
Part Number
90100013
6502039
6000015
6000013
6200002
6200004
6200005
6200011
6200015
6200013
6200014
6200076
6200016
6400004
6400008
6400038
6400007
6400002
Misc.
6502031
Description
EGR Cooler Gasket Set and Turbo Hardware
Bullet Proof Diesel Oil Filter Mount
High Capacity Engine Oil Cooler
Diesel Oil Filter, 85832
Constant Tension Spring Clamp
Allen Head, Black, Metric 35mm
Allen Head, Black, Metric 40mm
¼-20 Lock Nut
¼” Flat Washer
5/16-18 Lock Nut
5/16-18 x 1 ¼ Hex Head Bolt
5/16-18 x ¾” Hex Head Bolt
6/16” Flat Washer
Silicone Hose,(6 inches)
#12 90° Elbow Fitting
#12 JIC Straight Fitting
#12 O-Ring Hex Plug
¼” Counter Sunk Hex Plug
Hoses with Fittings Attached (per Hose Routing
Diagram)
6.0L Adapter Manifold Block, Assembled
6502032
6502028
Unique Parts for 2003-2004 Installation:
03-04 Oil Filter Bracket, Driver’s Side
03-04 Rock Panel, Driver’s Side
1
1
6502033
6502034
Unique Parts for 2005-2007 Installation:
05-07 Oil Filter Bracket, Driver’s Side
05-07 Rock Panel, Driver’s Side
1
1
6502044
6200083
6200084
90201009
2
With Condenser Bracket Mounting:
Condenser Mounting Bracket
Hex Head Sheet Metal Screw
Aluminum Spacer
Transmission Cooler Lowering Brackets, Rivets and
Washers
Parts List | BulletProofDiesel.com
Quantity
1
1
1
1
2
2
2
4
4
1
1
2
4
1
2
2
2
1
3
1
1
4
4
1
Installation Overview
Installing the Bullet Proof Diesel Oil Cooler Kit is no more difficult than replacing the OEM oil cooler.
That being said, it is important to remember that this is major surgery. Cleanliness and taking the time
to do the job correctly are essential for a perfect installation.
There are two major stages to the installation:
1. Replacement of the OE EGR cooler and oil cooler with the Bullet Proof Diesel (BPD) Oil and EGR
coolers. This is performed the same as OE repair procedures with only a few deviations and
includes removal of the turbo and intake manifold.
2. Installation of the air cooled engine oil cooler and oil lines. This stage will also entail the
removal of the air conditioning condenser. Please make sure that you have the equipment to do
that according to the established EPA regulations.
Please Note: There are some slight differences between different model years you should check on and
be aware of. Please see the pages 14-17 regarding transmission coolers, turbo oil supply lines and power
steering coolers.
Extra Help: Step-By-Step Instructions for Removal of the Intake
Manifold
Detailed installation and removal instructions for the EGR Cooler and Engine Oil Cooler can be
purchased online. Please go to BulletProofDiesel.com. Click on “Questions? We have answers”. Click
on “Do-It-Yourself” and find the link 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 REMOVAL AND REPLACEMENT
INSTRUCTIONS FOR THE INTAKE MANIFOLD.
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Installation Overview | BulletProofDiesel.com
Installation Stage 1: The Oil Transfer Block
1. Follow the OE oil cooler replacement procedures (which include removal of the intake manifold
and turbo).
2. Install the OE oil cooler gasket into the Bullet Proof Diesel (BPD) Oil Transfer Block.
3. Remove the oil pressure sender and oil temperature sensor from the OE oil cooler housing.
4. Gently clean and install the oil temperature sensor and the oil pressure sender into the oil
transfer block.
5. When the OE oil cooler is completely removed, remove all of the oil and debris from the HPOP
reservoir.
6. Remove and discard the HPOP filter. The BPD Oil Transfer Block has an integral HPOP screen,
made from stainless steel, which operates in place of the OE HPOP filter.
7. Use the OE bolts and torque specifications to install the BPD Oil Transfer Block.
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Installation Stage 1| BulletProofDiesel.com
8. Discard the OE silicone coolant hose. This is replaced by the silicone 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 silicone rubber relaxes.
9. Continue following the OE installation procedure. Once the intake manifold is installed, but
prior to the turbo being installed, the “in” oil hose (hose #3) 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 the bolts 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.
NOTE: THERE ARE NUMEROUS UPGRADES AND UPDATES THAT CAN AND SHOULD BE INSTALLED
DURING THIS PHASE. YOU CAN PURCHASE THE APPROPRIATE UPDATE KIT FROM
BULLETPROOFDIESEL.COM SEARCH KEYWORD: “PROFESSIONAL”
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Installation Stage 1| BulletProofDiesel.com
Installation Stage 2: The Oil Cooler, Oil Filter, and Condenser Mount
Remove the Condenser:
1.
Mark hood latch position with a Sharpie
marker or other.
2. Remove plastic condenser
cover/upper radiator air
deflector.
3. Remove hood latch mechanism.
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Installation Stage 2 | BulletProofDiesel.com
4. Recover A/C refrigerant per EPA regulations.
NOTE: IF YOU ARE INSTALLING A COLD WEATHER PACKAGE PLEASE REFER TO PAGE 32 FOR
FURTHER INSTRUCTION.
5. Remove “L” brackets that hold the condenser in place.
6. Disconnect the A/C lines from condenser AFTER the refrigerant is properly recovered.
Mounting the Oil Cooler to the Bracket:
NOTE: PLEASE SEE COLD WEATHER KIT SECTION ON PAGE 31 IF APPLICABLE PRIOR TO THIS STEP.
7. Use the mounting studs on the condenser bracket along with the supplied hardware to secure
the air cooler in place.
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 WILL NOT BECOME TRAPPED WITHIN THE COOLER.
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Installation Stage 2 | BulletProofDiesel.com
On the BPD oil cooler, there are three ports. The two large ports are for oil in and oil out. The small
port can be used for any of the following:



Supply line for a by-pass oil filtration system.
Port for engine oil temperature or engine oil pressure gauge.
Other uses such as oil supply for a secondary turbo, etc.
This port should be blocked off if you do not intend to use it for any of the above.
To block this port off properly, follow these steps PRIOR to installation of the air cooler:
8. Identify the ¼ pipe-plug brass insert that fits this
port (provided with kit).
9. Wrap the brass plug with Teflon pipe-sealing tape
and install into the cooler. DO NOT OVER
TIGHTEN.
10. After installation of the oil cooler system, check
for oil leaks with the engine running.
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Installation Stage 2 | BulletProofDiesel.com
NOTE: 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).
Mounting the Bracket to the Condenser:
11. Place condenser on working surface (see picture)
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Installation Stage 2 | BulletProofDiesel.com
12. Identify the holes in the condenser.
NOTE: IF YOUR CONDENSER IS DIFFERENT THAN WHAT IS SHOWN, YOU PROBABLY HAVE AN
AFTERMARKET CONDENSER (NON-FORD PART).
13. Position the oil cooler and bracket on the condenser.
Supplied mounting hardware.
14. 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.
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Installation Stage 2 | BulletProofDiesel.com
15. 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.
NOTE: MAKE SURE YOU USE THE 4 ALUMINUM SPACERS AS SHOWN IN THE NEXT PICTURE. THIS
CREATES AN IMPORTANT AIR GAP BETWEEN THE OIL COOLER AND THE A/C CONDENSER.
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Installation Stage 2 | BulletProofDiesel.com
16. Mount the bracket to the condenser using the hardware provided. Drill only if necessary.
17. 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.
Be sure that the cooler
bracket crowns are aligned
with the condenser crowns.
18. Mount the oil hoses, (#2 and #3) provided on the condenser at this time – be sure to tighten the
hoses now, as this is the easiest time to do so.
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Installation Stage 2 | BulletProofDiesel.com
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Installation Stage 2 | BulletProofDiesel.com
Note on Transmission Coolers:
Most F-Series trucks are equipped with a transmission cooler. This cooler is located behind the
condenser, underneath the hood latch. While most of these coolers are 14 inches tall, some heavy-duty
transmission coolers are 17 inches tall. The 17 inch transmission coolers will need to be lowered to
allow for enough room to clear the Bullet Proof Engine Oil Cooler.
If you have the 17 inch tall cooler, you will need the transmission cooler lowering brackets, included
with the kit.
The picture above shows the transmission cooler before modifications.
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Installation Stage 2 | BulletProofDiesel.com
This shows the necessary modification to the mounting stems at the bottom of the transmission
cooler, it should lower it by 2.5 inches. Some drilling and cutting will be necessary.
NOTE: VERIFY THAT YOUR TRANSMISSION FLUID LINES ARE NOT KINKED OR PINCHED
AFTER LOWERING THE TRANSMISSION COOLER .
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Installation Stage 2 | BulletProofDiesel.com
Note on Power Steering Coolers:
In Mid 2006 Ford made a mounting location change to the power steering cooler. The power steering
cooler on 2003- early 2006 models is in the lower position, at/near the bottom of the radiator. In the
late 2006-2007 models, the power steering cooler has been located up near the hood latch, near the top
of the radiator.
Here you can see the power steering cooler in the lower position, near the bottom of the radiator.
If you have the high-mounted power steering cooler, the condenser mounted BPD Engine Oil Cooler will
require you to relocate your power steering cooler to the lower position.
To do this you will need a new power steering cooler (the 2003-2005 version) as well as the hoses from
the same model years. These parts are listed on BulletProofDiesel.com and are shown here:
Power Steering Cooler: 2003-2005,
P/N 6000039
Power Steering Hose Assembly, P/N 6000038
for F250 and F350
Power Steering Hose Assembly, P/N 6000072
For F450 and F550
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Installation Stage 2 | BulletProofDiesel.com
Note on Turbo Oil Feed Lines:
On a few, very early 2003 6.0L diesel trucks, Ford used a thread-in style turbo oil feed tube. This
threaded turbo feed tube is extremely rare and is only present on some 2003 models. The threaded
style of oil feed tube applies to all Ford 6.0L’s with the production date of 3/18/2003 and earlier.
This threaded oil feed tube is not compatible with the oil transfer block from Bullet Proof Diesel. The
Bullet Proof Diesel block requires the slip-fit O-ring style connection.
If you find that your turbo oil feed tube is the threaded style, you will need to purchase a new turbo oil
feed tube from Bullet Proof Diesel or Ford.
Ford Part Number is: 3C3Z-9T516-BA
Bullet Proof Diesel Part number: 6000082
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Installation Stage 2 | BulletProofDiesel.com
Installing the Condenser with the Oil Cooler Attached:
19. Install the condenser loosely in the truck. Check to make sure that the orientation of the cooler
is as shown and that nothing is going to hit, rub or interfere with it. Two people definitely make
this part of the installation much easier.
20. 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!
21. Install the A/C hoses.
22. Recharge the A/C system as a last step just in case you have an oil leak.
23. Reinstall the hood latch (using the marks as a guide) and the condenser cover/upper radiator air
deflector.
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Installation Stage 2 | BulletProofDiesel.com
24. Bolt the oil filter adapter to the oil filter mounting bracket using the supplied 5/16” hardware
25 Install the hose fittings into the oil filter housing exactly as shown above.
NOTE: SEE APPROPRIATE HOSE ROUTING DIAGRAM FOR FITTING PLACEMENT AND ORIENTATION
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The Oil Filter Adapter | BulletProofDiesel.com
NOTE: VERIFY THAT THE HOSE FITTINGS ARE IN THE PROPER PORTS. ONE OIL IN AND ONE OIL
OUT MUST BE USED IN ORDER TO PREVENT ENGINE DAMAGE. MAKE SURE THAT HOSE #1 FROM
THE ENGINE TO THE OIL FILTER IS ATTACHED TO AN “OIL IN” PORT, AND THAT HOSE #2 EXITING
THE OIL FILTER TO THE COOLER IS “OIL OUT”
26. Mount the oil filter bracket to the backside of the bumper frame rail on the drivers’ side using
the OE bumper mounting bolts and hardware to secure the oil filter bracket. It is generally
easier to connect both hoses to the oil filter adapter before mounting the oil filter assembly to
the vehicle frame.
NOTE: ON SOME MODELS, THE FRONT LEAF SPRING BOLT MAY NEED TO BE TRIMMED FOR
CLEARANCE OF THE OIL FILTER.
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The Oil Filter Adapter | BulletProofDiesel.com
Oil Hose Routing
1. Route oil hose #1 (Oil Out from Engine on Driver’s Side) from transfer block down and under the
air cleaner. In this picture, the air cleaner has been removed.
2. This view shows the hose
running from under the air
cleaner element along the
intercooler line and
towards the front of the
truck. Make sure to secure
the oil hose away from the
intercooler.
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Hose Routing | BulletProofDiesel.com
3. Hose #1 is routed out
and down towards the
engine oil filter
assembly.
4. Route hose #1 down and under the engine oil assembly as shown. Secure the hose to prevent
rubbing or chaffing.
NOTE: THE 56” HOSE MAY SEEM SHORT BUT HAS BEEN THOROUGHLY TESTED AND PROVES TO
WORK BEST IN THIS PATH.
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Hose Routing | BulletProofDiesel.com
5. To make installation of the #2 hose easier, make sure the oil filter assembly is firmly mocked up
in place. Once the hose #1 from the engine is connected to the oil filter assembly, install hose #2
6. Install hose #3 to the cooler if you haven’t already done so. Route the hose through the core
support where the A/C hoses and intercooler come through.
NOTE: TAKE CARE TO INSURE THE OIL HOSE AND A/C HOSES DO NOT RUB. THIS COULD LEAD
TO THE EVENTUAL FAILURE OF THE A/C HOSES.
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Hose Routing | BulletProofDiesel.com
Bumper Re-Installation
1. Adjust oil filter assembly placement to clearance the bumper support brackets and tighten
hardware. Install the previously removed bumper support brackets and install the rock panel
bracket. If there is interference with the oil filter assembly, re-adjust the oil filter bracket until
the oil filter assembly has proper clearance.
2. 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.
3. Finish the OE oil cooler installation procedure. Make sure all connections are tight.
ON THE 2005-2007 INSTALLATION: INSTALL THE ROCK PANEL AS SHOWN IN PLACE OF THE BUMPER BRACKET.
THE 2003-2004 VERSION HAS A ROCK PANEL, TOO. IT SERVES A SIMILAR PURPOSE BUT LOOKS AND FITS A BIT DIFFERENTLY.
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Bumper Installation | BulletProofDiesel.com
Hose Routing Diagrams
25
Hose Routing | BulletProofDiesel.com
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Hose Routing | BulletProofDiesel.com
Hose Routing Diagram: 2003-2004 F-Series, Condenser Mounted
NOTE: HOSE LENGTH IS MEASURED BY THE CUT LENGTH OF THE HOSE NOT INCLUDING FITTINGS.
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Hose Routing | BulletProofDiesel.com
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Hose Routing | BulletProofDiesel.com
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Hose Routing | BulletProofDiesel.com
Hose Routing Diagram: 2005-2007 F-Series, Condenser Mounted
NOTE: HOSE LENGTH IS MEASURED BY THE CUT LENGTH OF THE HOSE NOT INCLUDING FITTINGS.
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Hose Routing | BulletProofDiesel.com
BulletProofDiesel.com
Bullet Proof Cold Weather Kit
Neal Technologies, Inc.
(Patent pending)
Updated 9/2/2011
31
Cold Weather Kit | BulletProofDiesel.com
The purpose of the cold weather kit is allow operation of 6.0L Powerstroke diesel engines in cold
climates where ambient air temperatures are low enough to cause concern when using an air-to-liquid
cooler.
The kit consists of an oil thermostat and the necessary hardware and hoses to install the thermostat.
The thermostat kit is fully reverse compatible with all Bullet Proof Condenser mounted oil system kits.
THE COLD WEATHER KIT FUNCTIONS AS FOLLOWS:
Oil from the engine is pumped into the Bullet Proof oil cooler system by the OEM low pressure oil pump.
After being filtered the oil then heads to the cooler. If the oil has not reached the desired operating
temperature, it is allowed to bypass the engine oil cooler and return to the engine. Once the desired
engine oil temperature has been reached, the thermostat closes and eliminates the path by which oil
can circumvent the oil cooler. Oil will follow the path of least resistance. When cold, the oil cooler
offers greater resistance to flow than the oil cooler thermostatic bypass circuit. At no time is the oil
cooler blocked or made to be static. A path of less resistance is opened or blocked depending oil
temperature.
A pressure bypass valve is also incorporated into the thermostat assembly. This will allow a portion of
the oil to bypass the oil cooler in the event a pressure differential greater than 18PSI exists between the
inlet and outlet of the engine oil cooler. This ensures a constant flow of oil to the engine under extreme
operating conditions such as racing or subfreezing climates.
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Cold Weather Kit | BulletProofDiesel.com
TO INSTALL THE COLD WEATHER KIT :
1. Make sure all components are CLEAN.
2. Remove the A/C condenser. Be sure to follow the Factory guidelines for this procedure.
3. If you are retro fitting the cold weather kit to an existing installation of the Bullet Proof oil cooler
kit, you will need to remove the oil cooler from the condenser mount and remove the oil cooler
mount from the condenser.
4. Attach the thermostat assembly to the “oil out” side of the oil cooler. Make sure to seat the Oring all the way into the oil cooler. Be careful not to seat the O-ring on the threads of the fitting.
This could cause an oil leak.
5. Position the oil cooler and thermostat as shown
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Cold Weather Kit | BulletProofDiesel.com
6. If you are retro fitting the thermostat to an existing installation, mark where the thermostat
support bracket touches the oil cooler mount. Remove the oil cooler assembly from the oil cooler
mounting bracket and drill a ¼” hole where the bracket was marked. Remember to remove the
oil cooler bracket from the condenser prior to drilling the hole. Condensers are expensive.
NOTE: CONDENSER SUPPORT BRACKET COMES WITH THE STUD ALREADY ATTACHED IN
CURRENT KITS.
7. Attach the oil cooler bracket to the condenser per the instructions in the Bullet Proof oil cooler
installation manual. On retro installs, make sure to install the ¼”- 20x1” bolt through the drilled
¼” hole so that the hex head is between the oil cooler mount and the A/C condenser. Ensure
you have a wrench that will fit between the oil cooler mount and the A/C condenser.
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Cold Weather Kit | BulletProofDiesel.com
8. Install the oil cooler assembly as shown. Tighten the oil cooler to the condenser bracket with oil
cooler mounting hardware.
9. Tighten the thermostat to cooler coupler as shown below.
10. Install the bypass manifold.
11. Install the oil filter to oil cooler hose #2 on the bypass manifold.
12. Lower the condenser back into place and mark the areas on the headlight support bracket
where the thermostat will interfere.
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Cold Weather Kit | BulletProofDiesel.com
13. Remove the condenser and cut out the marked area with a hack saw or other suitable tool.
14. Re-install the condenser and ensure adequate clearance of both the transmission cooler and the
headlamp support bracket.
15. Refer back the Bullet Proof Diesel Engine Oil Cooler installation manual for additional
instructions if you need to continue installing the Oil Cooler Kit.
NOTE: REMEMBER TO PRIME TO OIL SYSTEM BEFORE
STARTING THE ENGINE. FAILURE TO DO SO CAN RESULT IN
SEVERE ENGINE DAMAGE .
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Cold Weather Kit | BulletProofDiesel.com
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Cold Weather Kit | BulletProofDiesel.com
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Cold Weather Kit | BulletProofDiesel.com
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Cold Weather Kit | BulletProofDiesel.com
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Cold Weather Kit | BulletProofDiesel.com
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