HS MOTORSPORTS 122004 Intercooler Pipe Upgrade Kit Installation Guide
- June 13, 2024
- HS MOTORSPORTS
Table of Contents
HS MOTORSPORTS 122004 Intercooler Pipe Upgrade Kit
Product Information
The Intercooler Pipe Upgrade Kit is designed as an OEM replacement for the 2011-2016 6.7L Ford Power Stroke engine. It is manufactured by H&S Motorsports and is intended to improve the performance and reliability of the intercooler system.
The kit includes the following parts:
- 1 HSM Throttle Body Adapter Assembly
- 1 Stainless Steel Tubing
- 1 90 Deg. Silicone Boot
- 1 Straight Silicone Boot
- 1 Pack of Installation Hardware
If you have any questions or need assistance during the installation process, please contact H&S Motorsports support at tech@hs- motorsports.com or 855-623-4450.
Product Usage Instructions
Step 1: Disconnect Batteries and Remove Intake Air Temperature Sensor
- Disconnect the batteries.
- Remove the intake air temperature sensor connector and clip from the back side of the factory intercooler pipe.
- Remove the clip holding the intake air temperature sensor wiring to the fan shroud.
Step 2: Remove the Power Steering Reservoir and Loosen the T-Bolt Clamp
- Remove the factory power steering reservoir bolt at the fan shroud and set it aside.
- Lift the power steering reservoir out of the retainer guide on the fan shroud and set it to the side.
- Loosen the t-bolt clamp at the factory intercooler connection.
Step 3: Remove the Factory Cold-Side Intercooler Pipe Assembly
- Remove the large locking C-Ring from the factory cold-side intercooler pipe at the throttle body assembly. Be careful not to damage the ring as it will be re-used later.
- Carefully remove the entire cold-side intercooler pipe assembly from the vehicle.
Step 4: Install the Intake Air Temperature Sensor into the HSM Throttle Adapter
- Gently pry up on the factory intake air temperature sensor locking tab to release it while twisting the sensor counter-clockwise to remove it from the factory intercooler pipe.
- Install the sensor into the supplied HSM throttle adapter by pressing the sensor into the hole and twisting it clockwise until fully locked.
Step 5: Install the O-Ring onto the HSM Throttle Adapter
- Carefully remove the O-Ring from the inside of the factory intercooler pipe using a small flat-head screwdriver or other small tool.
- Clean the O-Ring of any oil or debris and apply a small amount of Vaseline or Assembly Lube/Grease to the O-Ring.
- Install the O-Ring to the groove inside the HSM throttle adapter by starting on one side and working all the way around, ensuring it is fully seated in the groove.
Step 6: Reinstall Large Locking C-Ring and Connect Intake Air Temperature Sensor Wiring
- Install the previously removed large locking C-Ring onto the HSM throttle adapter.
- Find the previously unplugged harness belonging to the intake air temperature sensor and route the wiring behind the power steering reservoir.
- Plug the connector back into the intake air temperature sensor.
Step 7: Clean the Intercooler Boot Sealing Surface
Using brake cleaner or another similar cleaning media, clean the factory
intercooler boot sealing surface on the intercooler to remove any oil residue
or contaminants.
Step 8: Install Clamps on Intercooler Boots
When installing the clamp on the intercooler end of all boots, make sure the
clamp is pushed up close against the intercooler outlet to prevent the boot
from being cut if the clamp is tightened too far out.
For more detailed installation instructions and troubleshooting, please refer to the complete user manual available at https://hs-motorsports.com/manuals /intercooler-pipe-upgrade-kit-manual.pdf.
INTERCOOLER PIPE UPGRADE KIT
2011-2016 6.7L FORD POWER STROKE
TROUBLESHOOTING
Please read and understand all installation instructions before proceeding with the installation. If you have questions during the installation of this product, please contact H&S Motorsports support at tech@hs- motorsports.com or 855-623-4450.
INCLUDED PARTS
- 1 – HSM Throttle Body Adapter Assembly
- 1 – Stainless Steel Tubing
- 1 – 90 Deg. Silicone Boot
- 1 – Straight Silicone Boot
- 1 – Pack of Installation Hardware
Installation Instruction
-
STEP 1
Disconnect Batteries. Remove the intake air temperature sensor connector and clip it from the back side of the factory intercooler pipe. Remove the clip holding the intake air temperature sensor wiring to the fan shroud.
-
STEP 2
Remove the factory power steering reservoir bolt at the fan shroud and set it aside. Lift the power steering reservoir out of the retainer guide on the fan shroud and set it to the side. Loosen the t-bolt clamp at the factory intercooler connection.
-
STEP 3
Remove the large locking C-Ring from the factory cold side intercooler pipe at the throttle body assembly. Be careful not to damage the ring as it will be re-used later. With everything disconnected, carefully remove the entire cold- side intercooler pipe assembly from the vehicle. -
STEP 4
Using a small flat-head screwdriver or other small tool, gently pry up on the factory intake air temperature sensor locking tab to release it while twisting the sensor counter-clockwise to remove it from the factory intercooler pipe. Install the sensor into the supplied HSM throttle adapter by pressing the sensor into the hole and twisting clockwise until fully locked as shown. -
STEP 5
With a pick or other small-ended tool, carefully remove the O-Ring from the inside of the factory intercooler pipe. Clean the O-Ring of any oil or debris and apply a small amount of Vaseline or Assembly Lube/Grease to the O-Ring. Install the O-Ring to the groove inside the HSM throttle adapter by starting on one side and working all the way around, ensuring it is fully seated in the groove. -
STEP 6
Install the previously removed large locking C-Ring onto the HSM throttle adapter. Find the previously unplugged harness belonging to the intake air temperature sensor and route the wiring behind the power-steering reservoir as shown. Plug the connector back into the intake air temperature sensor.
-
STEP 7
With the HSM logo on top and the intake air temperature sensor facing the front of the vehicle, carefully install the HSM throttle adapter to the factory throttle body assembly by applying pressure while slightly twisting the HSM throttle adapter back and forth until the C-Ring is locked into place. Keep in mind that these parts are a tight fit to ensure proper sealing, so some force may be required for installation. Be careful not to damage the sealing O-Ring, intake air temperature sensor, or harness during this step! -
STEP 8
Using brake cleaner or another similar cleaning media, clean the factory intercooler boot sealing surface on the intercooler (failure to clean the intercooler may result in the boot blowing off due to oil residue or other contaminants on the sealing surface). -
STEP 9
Fully loosen (without removing nuts) and slide the two supplied T-Bolt clamps onto the supplied 90-degree silicone coupler as shown. Slide the supplied 90-degree silicone coupler onto the longer leg of the supplied intercooler pipe as shown (applying a small amount of glass cleaner to the outside of the pipe and/or inside of the couplers may help with adjustments during installation). Install the supplied straight coupler onto the shorter leg of the supplied intercooler pipe. Clamps for the straight coupler will be installed at a later time.
Note: Make sure when installing the clamp on the intercooler end of all boots to be sure the clamp is pushed up close against the intercooler outlet as shown, so the intercooler outlet does not cut the boot if the clamp is tightened too far out. -
STEP 10
Install the new intercooler pipe assembly to the vehicle by sliding the 90-degree silicone coupler onto the intercooler and then working the straight coupler onto the HSM throttle adapter. Adjust the pipe and couplers to ensure that everything is lined up properly and that there is adequate room for clamps on all clamp locations. Work the long leg of the intercooler pipe up out of the 90-degree boot so there is approximately 1/2 of clearance between the coupler and pipe as shown. Slide straight 3×3” boot into place, and adjust so it is even on the HSM coupler and the pipe. -
STEP 11
While holding the lower 90-degree coupler and T-Bolt clamp tight against the intercooler, tighten the clamp. Make any necessary adjustments and then tighten the other T-Bolt clamp on the 90-degree coupler. Tighten all clamps to 90-inch lbs. -
STEP 12
Locate the supplied T-Bolt clamps and completely remove the nuts. Open clamps and install them around clamp locations on the straight coupler. After ensuring proper fit and alignment, tighten these clamps to 90-inch lbs. -
STEP 13
Using the supplied HSM power-steering reservoir relocation bracket and ¼” hardware, loosely install the bracket to the reservoir. Using the factory reservoir bolt, install the other end of the bracket to the factory location. Adjust the reservoir so it is not binding or contacting other components and tighten all hardware. -
STEP 14
Zip-tie the intake air temperature wiring to the nearby coolant line. Reconnect batteries and double-check all installed items for proper fitment. Test drive the vehicle to ensure all parts were installed correctly. -
STEP 15
- Please make sure to check the level of the coolant in the secondary cooling system.
- Failure to do so may cause overheating of the intercooler system and premature boot failure.
-
STEP 16
Kit installed.
C.A.R.B. E.O. NOTICE
E.O. identification label is required to pass the Smog Check inspection.
The E.O. identification label must be placed on or near the device in the
engine compartment so that smog check technicians can verify the E.O. number
.
Contact Us
- 1222 S. HILLCREST DR. WASHINGTON, UT 84780.
- HS-MOTORSPORTS.COM.