Owners manual

INSTALLATION INSTRUCTIONS
MAKE: FORD
MODEL: F-250/F-350
YEAR: 2003-2007
ENGINE: V8-6.0L (td)
Oil Cooler
46-80001
1. Disconnect vehicle batteries before installation.
2. Release the 4 airbox clips and remove the airbox and air filter.
3. Use a 7/16” deep socket to loosen the clamps on both the driver and passenger side intercooler pipes.
4. Disconnect the plastic wiring shroud from the firewall for easier access to the top of the engine (move
the shroud out of the way by temporarily attaching it to the windshield wiper arm).
5. Use a flat screwdriver and an 8mm wrench to remove the turbo inlet tube from the turbo.
6. Disconnect the wire harness from the turbo.
7. Use a 13mm and 10mm socket to remove the alternator from the engine.
8. Use a flat screwdriver to remove the fan shroud screws and to release the plastic clips.
9. Remove the fan shroud.
10. Use a 10mm socket and 10mm wrench to remove the three turbo mounting bolts (one is located under
the turbo and not visible).
11. Use a 7/16” deep socket to loosen the v-band clamp connecting the turbo to the exhaust downpipe.
12. Remove the turbo from the engine.
13. Use a 7/16” deep socket to loosen the v-band clamp connecting the EGR cooler to the exhaust up-pipe.
14. Use a 10mm socket to remove the 4 turbo pedestal mounting bolts.
15. Remove the turbo pedestal from the engine.
16. Use a 15mm socket to remove the 2 fan shroud bolts from the intake manifold.
17. Use a 10mm socket to loosen 8 intake manifold mounting bolts (do not remove).
18. Remove the intake manifold and EGR cooler.
19. Remove the EGR cooler coolant supply port cover, Oil filter base and the oil cooler assembly. Discard all
gaskets.
20. Clean and inspect all sealing surfaces.
21. Replace oil pump inlet strainer with strainer provided
22. Install new oil cooler, oil filter base, and EGR cooler coolant supply port cover with new gaskets supplied
in kit.
23. Install the intake manifold on the engine using new gaskets.
24. Connect the EGR cooler to the exhaust up-pipe and seal with a new gasket.
25. Repeat the steps above in the reverse order to re-assemble the engine components.
26. Your installation is now complete, Enjoy!
Note: Retighten all connections after approximately 100-200 miles.
.
Tools Needed:
• 8mm Socket
• 10mm Socket
• 13mm Socket
• 15mm Socket
• 7/16" Deep Socket
• 3/8" Driver Ratchet
• 3/8" Driver Extension
• Flathead Screwdriver
Parts Included:
• Oil Cooler (1)
• Gasket Kit (1)
CAUTION: Allow time for your vehicle to cool down prior to installation. When working on or under your vehicle proceed with caution. Engine bays reach
high temperatures and may cause serious burns. Wear protective safety equipment; eye goggles and gloves to ensure a safe installation. aFe recom-
mends professional installation of this product as it involves removal of the turbocharger, intake manifold as well as opening the cooling and oil systems.
06-80799
Updated: Febuary, 2016