Injen SES9004ICP Intercooler Piping System Instruction Manual

Injen SES9004ICP Intercooler Piping System

Product Information

This product is an intercooler piping system designed for Ford F-250, F-350, F-450, and F-550 Super Duty models manufactured between 2017 and 2022. It is compatible with V8 6.7L Turbo Diesel engines.

• Part Number: SES9004ICP
• Parts Included:
  • A – 1 Quantity
  • B – 1 Quantity
  • C – 1 Quantity
  • D – 1 Quantity
  • E – 2 Quantity
  • F – 2 Quantity
  • G – 4 Quantity
  • H – 1 Quantity
• Tools Required:
  • Ratcheting wrench
  • 10mm socket
  • Flat head screwdriver
  • 8mm socket
  • Needle nose pliers
  • 7mm socket

Product Usage Instructions

Before You Begin
Ensure that the engine bay is in stock condition.

Installation Steps:

Page 2:

1. Loosen the clamp connecting the OEM hot side intercooler pipe to the turbo inlet.
2. Loosen the clamp holding the hot side intercooler pipe to the intercooler and remove the hot side charge pipe.
3. Remove the plastic retaining clip from the hot side turbo outlet coupler by prying on both ends and then lifting up.
4. Install the OEM retaining clip onto the Injen secondary hot side intercooler pipe.
5. Install the provided O-Ring onto the Injen secondary hot side intercooler pipe.
6. Install the secondary hot side intercooler pipe onto the turbo outlet. Ensure that the retaining clip engages.
7. Install the 3.00 hump hose onto the secondary hot side intercooler pipe and secure it using the provided clamps.
8. Install the 3.00 hump hose onto the intercooler and secure it using the provided clamps.
9. Install the Injen primary hot side intercooler pipe and secure all clamps.

Page 3:

10. Disconnect the IAT sensor harness located on the OEM cold side intercooler pipe.
11. Lift the tab on the IAT sensor and twist it a quarter turn to remove it from the cold side intercooler pipe.
12. Loosen both clamps from the cold side intercooler pipe.
13. Remove the cold side intercooler pipe from the engine bay.
14. Disengage the retaining clip from the IAT sensor adapter and remove the adapter from the engine bay.
15. Install the OEM O-Ring onto the Injen cold side intercooler pipe in the same direction it was removed.
16. Install the retaining clip onto the cold side intercooler pipe.
17. Install the elbow hose onto the cold side intercooler pipe and secure it using the provided clamps.
18. Remove the bolt securing the power steering reservoir and move the reservoir to give clearance for installing the intercooler pipe.
19. Once the intercooler pipe is in place, secure the clamps and then secure the power steering reservoir to its factory location.

Page 4:

21. Install the IAT sensor onto the cold side intercooler pipe. Once fully seated, rotate the sensor to secure the tab in place.
22. Reconnect the IAT sensor harness.

Ensure that all connections are tight and secure before starting the engine.

PARTS INCLUDED

TOOLS REQUIRED

BEFORE YOU BEGIN

• Please check the list of parts included and report any defective or missing parts to the authorized Injen dealer you purchased this product from. Before installing any parts of this system, please read the instructions thoroughly. If you have any questions regarding installation, please contact your Injen Technology dealer. Installation DOES require some mechanical skills. A qualified mechanic is always recommended.
• This product includes a Limited Lifetime Warranty to the original purchaser against defects in material and workmanship on all Injen intercooler piping systems. Any and all warranty coverage is limited to the repair or replacement of the defective part only, at Injen Technology’s discretion. The warranty does not cover incidental or consequential damages, nor does it cover the cost of installation or removal of the defective part or its replacement. Proof of purchase is required.
• Do not attempt to install the intercooler piping system while the engine is hot. Severe burn could result from touching hot engine components.
• WARNING: Failure to follow installation instructions and not using the provided hardware may damage the intercooler piping system, engine, or components of either.
• CARB Note: Injen intercooler piping systems are street legal in most states unless the state is adopting to California Emissions standards. States that have adopted California emission standards include: Arizona, California, Connecticut, District of Columbia, Maine, Maryland, Massachusetts, New Jersey, New Mexico, New York, Oregon, Pennsylvania,
• Rhode Island, Vermont, and Washington. These states will require a California Air Resource Board Executive Order Number (CARB E.O.) for the legal use of an Injen intake system in your vehicle for use on public roads or highways. Otherwise, the vehicle will be considered “Legal in California only for racing vehicles competition use only, which may never be used upon a public street or highway.” Please keep your factory intercooler piping system for any future on-road use.
• Note: It is always recommended to disconnect your battery before disconnecting any sensors.

Installation Instructions

1. Stock engine bay.
2. Loosen the clamp connecting the OEM hot side intercooler pipe to the turbo inlet.
3. Loosen the clamp holding the hot side intercooler pipe to the intercooler then remove the hot side charge pipe.
4. Disengage the retaining clip attached to the turbo outlet by prying up on the retaining clip then remove the hot side turbo outlet coupler.
5. Remove the plastic retaining clip from the hot side turbo outlet coupler by carefully prying on both ends and then lifting up.
6. Remove the retaining clip from the hot side turbo outlet coupler.
7. Install the OEM retaining clip onto the Injen secondary hot side intercooler pipe.
8. Install the provided O-Ring onto the secondary hot side intercooler pipe.
9. Install the secondary hot side intercooler pipe onto the turbo outlet. You should hear the retaining clip engage.
10. Install the 3.00” hump hose onto the secondary hot side intercooler pipe. Secure using the provided clamps.
11. Install the 3.00” hump hose onto the intercooler. Secure using the provided clamps.
12.  Install the Injen primary hot side intercooler pipe. Secure all clamps.
13. Disconnect the IAT sensor harness located on the OEM cold side intercooler pipe.
14. Lift the tab on the IAT sensor then twist the sensor a 1/4 turn to remove it from the cold side intercooler pipe.
15. Loosen both clamps from the cold side intercooler pipe.
16. Remove the cold side intercooler pipe from the engine bay.
17. Disengage the retaining clip from the IAT sensor adapter then remove the adapter from the engine bay.
18. Remove the O-Ring from the IAT sensor adpater. Note the direction it was removed in.
19. Install the OEM O-Ring onto the Injen cold side intercooler pipe in the same direction it was removed.
20. Remove the OEM retaing clip from the IAT sensor adapter.
21. Install the retaining clip onto the cold side intercooler pipe.
22. Install the elbow hose onto the cold side intercooler pipe. Secure using the provided clamps.
23. Remove the bolt securing the power steering reservoir then move the reservoir to give clearance for installing the intercooler pipe.
24. Once the intercooler pipe is in place. Secure the clampsthen secure the power steering reservoir to its factory location.
25. Install the IAT sensor onto the cold side
26. Reconnect the IAT sensor harness. intercooler pipe. Once fully seated, rotate the sensor to secure the tab in place.
27. Ensure all bolts and clamps are properly secured. Ensure all retaining clips have properly engaged.

CONGRATULATIONS! You have just completed the installation of this intercooler piping system. Periodically, check the alignment of the intercooler piping, normal wear and tear can cause nuts and bolts to come loose. Note: Check clearance and adjust if needed! Failure to check the alignment and adjust the intercooler piping can cause damage that will void the warranty. Injen Technology is not responsible for any damages caused by/from improper installation. INTERCOOLER PIPING SYSTEM
Part Number: SES9004ICP

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