Ford 6.0 7.3 Instructions
Contents
1. INTERCODLERS Je ES Intercooler Upgrade Kit 04 06 Ford 6 0L P N 70057 99 03 Ford 7 3L P N 70058 TUR BONE TIC amp S Turbonetics Inc 14399 Princeton Avenue Moorpark CA 805 581 0333 TurboneticsInc com 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 staff The information conta2. 31317 325 31364 PARTS LIST P N 70057 Ford 6 0L Part Number 70056 21472 21525 Silicone Hump Hose 3 0 w internal bead 22174 30315 31317 300 60205 HARDWARE KIT P N 11568 only included with 70058 Ford 7 3L Part Number 22084 22085 22086 30576 40 30591 30593 30596 30807 31067 31312 31313 31314 INSTRUCTION PACKET P N 60205 included with both Ford 7 3L and 6 0L Part Number Quantity 21415 Badge Polydome O 22035 Spacer Block Rubber 60204 Install Instructions Ford 7 3L 6 0L I C Kit 60204_revA doc Page 3 of 21 INSTALLATION 1 Disconnect negative terminals from both batteries by loosening the 8mm bolts on the battery terminals SEE FIGURES 1 amp 2 FIGURE 1 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 60204 revA doc Page 4 of 21 INTERCOOLERSE same 4 For 7 3L Remove the wing nut that secures the emergency jack and tools in the engine bay SEE FIGURE 5 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 _ FIGURE 7 60204 revA doc Page 5 of 21 6 Fo
3. 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 60204 revA doc Page 21 of 21
4. of when working around the A C lines the lines are soft and can be bent slightly out of the way easily FIGURE 43 20 For the 7 3L remove the rubber flap on the bottom of the bumper The flap is secured to the bumper with plastic snap in clips This will allow you to gain access to install the lower support brackets on the new Spearco intercooler SEE FIGURES 44 amp 45 FIGURE 44 _____ FIGURE 45 60204 revA doc Page 13 of 21 21 Carefully remove the small section of rubber flap on each side of the vehicle to gain access to the bolts on the oil cooler The rubber flap is secured to the vehicle using plastic snap in clips SEE FIGURES 46 amp 47 FIGURE 46 FIGURE 47 mea tn 1 DIEU i NN re D 22 For 7 3L unbolt the two M6 screws that secure the oil cooler to the lower core support SEE FIGURES 48 amp 49 FIGURE 48 FIGURE 49 LE ae 23 For 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 Adhere the factory rubber isolator to the intercooler with silicone to make installation easier 60204 revA doc Page 14 of 21 ac 24 For the 7 3L install the new supplied rubber isolator PN 22035 to the lower mounting brackets of the Spearco intercooler Making sure the rubber isolator is flush to th
5. RE 60 SSS NN Ni FIGURE 61 e FIGURE 62 60204_revA doc Page 17 of 21 28 For 7 3L adjust the bottom L brackets as necessary until they are lined up with the mounting holes of the factory oil cooler Line up the machined notch on the L bracket with the factory threaded clip The notch will allow the L bracket to sit flush against the factory core support Re install the oil cooler to the core support using the supplied M6 serrated flange hex bolt PN 31314 SEE FIGURES 64 amp 65 FIGURE 64 FIGURE 65 29 Carefully pry the rubber flap away from the core support which will allow you to gain access to the hex nut that is securing the L bracket to the rubber isolator on the bottom of the intercooler Using a long extension and a socket tighten nuts on both brackets SEE FIGURE 66 FIGURE 66 30 Using the supplied M8 1 25 hex bolt PN 30576 40 M8 fender washer PN 30807 and 4 supplied rubber spacers PN 22084 with one on each side of the top intercooler bracket Secure the new intercooler to the vehicle 31 For 7 3L install the factory boost tube on the passenger side of the vehicle to the intercooler using the supplied silicone transition hose PN 22172 and supplied 3 0 t bolt clamps PN 31317 300 3 25 t bolt clamps PN 31317 325 Make sure the side with a hose bead inside the silicone hose faces toward the boost tube SEE FIGURE 67 32 For 7 3L install the factory boost
6. e edge of the new intercooler lower mount SEE FIGURE 50 amp 51 NOTE Adhere the factory rubber isolator to the intercooler with silicone to make installation easier FIGURE 50 FIGURE 51 25 For 7 3L install the supplied lower support L brackets to the threaded boss on the bottom of the new intercooler using the supplied M6 rubber isolators PN 31067 and M6 serrated flange hex nut PN 31312 Apply threadlocker to both sides of the thread on the supplied rubber isolator Hand tighten the serrated flange hex nut to the rubber isolator SEE FIGURES 52 57 NOTE Notice the orientation of the L brackets to the hose connectors on the intercooler SEE FIGURE 56 amp 57 FIGURE 52 FIGURE 53 L Bracket PN 22086 60204 revA doc Page 15 of 21 FIGURE 54 lt h Pin the Se FIGURE 56 FIGURE 57 HOSE CONNECTORS FACING DOWNWARDS L BRACKETS FACING UPWARDS 26 For 7 3L carefully slide the new intercooler into the vehicle The two bottom L brackets should line up with the mounting holes of the factory oil cooler SEE FIGURE 58 FIGURE 58 60204 revA doc Page 16 of 21 27 For the 7 3L insert the 2 supplied cardboard spacers PN 31364 between the intercooler and the radiator Insert the spacers diagonally where the bottom edge of the spacers would rest on the ledge of the radiator core and the top side resting on the hose connector of the intercooler SEE FIGURES 59 63 FIGURE 59 FIGU
7. ecure using supplied M6 1 0x30mm bolts PN 31313 and M6 washers PN 30591 SEE FIGURES 72 73 FIGURE 72 _ FIGURE 73 37 Re install the remaining factory pieces rubber flaps and plastic trims 38 Complete 60204 revA doc Page 20 of 21 RACING INTERCOOlLERS 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 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 device 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 sub sequential 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 dama
8. ges 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 Returned 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
9. he cover and depressing the tab from inside the box on each side of the tube SEE FIGURES 24 27 FIGURE 24 FIGURE 25 TS A4 LAS FIGURE 27 13 For 7 3L and 6 0L remove two 10mm bolt that secures the factory intercooler to the core support SEE FIGURES 28 29 6 0L and 30 31 7 3L FIGURE 28 FIGURE 29 60204 revA doc Page 9 of 21 FIGURE 30 14 For 7 3L and 6 0L using a 12mm open wrench or socket remove the eight bolts that secure the core support to the chassis SEE FIGURES 32 35 FIGURE 32 __ FIGURE 33 __ 60204 revA doc Page 10 of 21 FN pe PY OCS 15 Ford 7 3L and 6 0L carefully pry the top core support out with a pry bar without scratching it SEE FIGURES 36 amp 37 FIGURE 36 16 For 6 0L remove the drivers side boost tube some years may come with a plastic boost tube while others may come with a steel tube SEE FIGURES 38 amp 39 FIGURE 38 FIGURE 39 60204 revA doc Page 11 of 21 OCS 17 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 40 FIGURE 40 18 For 7 3L loosen the hose clamps on both driver and passenger side boost tube SEE FIGURES 41 amp 42 FIGURE 41 7 FIGURE 4 60204 revA doc Page 12 of 21 19 For 7 3L amp 6 0L slowly remove the factory intercooler out of the vehicle by lifting upwards SEE FIGURE 43 NOTE Be careful
10. ined 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 Re It is recommended to have the following items before beginning installation Ford factory service manual for your model year large table or bench and plenty of adjacent available workspace Standard selection of automotive tools primarily metric sizes Medium strength threadlocker Loctite or equiv Std silicone sealer adhesive TOOLS REQUIRED 8 11 amp 12mm Deep socket Socket Extension Ratchet 10mm 12mm Wrench Pry bar Pliers EST INSTALL TIME 2 Hr 60204 revA doc Page 2 of 21 PARTS LIST P N 70058 Ford 7 3L Part Number 70065 11568 22172 22173 30315 31317 300
11. r 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 B FIGURE 12 FIGURE 13 i eE P d 60204_revA doc Page 6 of 21 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 latch alignment during re assembly SEE FIGURES 15 amp 16 FIGURE 15 FIGURE 16 Swen eS a a a L a a ae FIGURE 17 9 For 7 3L and 6 0L carefully unclip the plastic fastener that secures the hood latch cable to the core support SEE FIGURE 18 FIGURE 18 60204 revA doc Page 7 of 21 10 For 7 3L and 6 0L unbolt the two 8mm bolts for the upper A C condenser brackets SEE FIGURES 19 20 6 0L and 21 22 7 3L FIGURE 19 o _ FIGURE 20 FIGURE 22 FN Wen wn abs Li Rog 11 22 Hil sei Ay Wi me i 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 23 FIGURE 23 60204 revA doc Page 8 of 21 ET EE HAT RUHL aa 12 For the 7 3L remove the plastic intake tube that goes from the intake box to the front of the truck by lifting t
12. tube on the drivers side of the vehicle to the intercooler using the supplied silicone hump hose PN 22173 and 3 0 t bolt clamps PN 31317 300 Make sure the side with a hose bead inside the silicone hose faces toward the boost tube SEE FIGURE 68 60204 revA doc Page 18 of 21 Se FIGURE 67 FIGURE 68 33 For 6 0L install the new supplied stainless boost tube PN 21472 that connects the intercooler to the engine using the supplied 3 0 t bolts clamps P N 31317 300 silicone hump connector PN 22174 and silicone hose adapter PN 21525 SEE FIGURE 69 FIGURE 69 se ch 4E INTERCOOLER SIDE mE 60204_revA doc Page 19 of 21 INTERCOOLE 34 Install the boost tube PN 21472 in between the intercooler and the intake manifold using the supplied silicone hump hose PN 22174 and two 3 0 t bolt clamp P N 31317 300 on the intercooler side and the silicone hose adapter PN 21525 and two 3 0 t bolt clamp PN 31317 300 on the intake manifold side SEE FIGURES 70 amp 71 FIGURE 70 FIGURE 71 35 For 6 0L when installing the new supplied silicone hose adapter PN 21525 the side with the bead on the inside of the hose goes on the engine side Re install the factory hood latch making sure the latch lines up with the lines marked on the core support earlier 36 For 7 3L re install the factory hood latch with supplied spacers PN 22085 in between the hood latch and the core support and s
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