S B FILTERS 83-1001 S Charge Air Cooler Pipe Kit Instruction Manual

: June 13, 2024
: S B Filters

Table of Contents

S B FILTERS 83-1001 S Charge Air Cooler Pipe Kit
Product Information
Introduction
Tools Required
Maintenance
Before You Start
EXPLODED VIEW
INSTALLATION STEPS
More Information
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

S B FILTERS 83-1001 S Charge Air Cooler Pipe Kit

S_B-FILTERS-83-1001-S-Charge-Air-Cooler-Pipe-Kit-
product

Product Information

This product is an Charge Air Cooler Pipe Kit designed for the 2017-2021 Ford F-250/F-350 with a 6.7L Powerstroke engine. It is compatible with the specified vehicle model and engine. Please note that this Charge Air Cooler Pipe Kit may not fit if you have aftermarket parts installed, such as an aftermarket intercooler, radiator and/or coolant hoses, fan or fan shroud, power steering fluid reservoir, or hood. Ensure compatibility before installation.

The installation of this kit requires various tools including 7mm and 10mm sockets and wrenches, 11mm deep socket, 10 socket extension or 4 + 6 socket extensions, panel popper, pick, small flat blade screwdriver, wire cutters, and a torque wrench with a 75 in-lb setting. Before installation, it is important to check and clean all components prior to assembly. When removing any turbocharger air intake system components, make sure to cover any open ports to prevent debris from entering the system.

Introduction

Vehicle Application

YEAR: 2017-2021
MAKE: Ford
MODEL: F-250/F-350
ENGINE: 6.7L Powerstroke

Note: This Charge Air Cooler Pipe Kit may not fi t with the following aftermarket parts installed:

Aftermarket Intercooler
Aftermarket Radiator and/or Coolant Hoses
Aftermarket Fan or Fan Shroud
Aftermarket Power Steering Fluid Reservoir
Aftermarket Hood

Tools Required

7mm, 10mm, Socket and Wrench
11mm Deep Socket
10” Socket Extension or 4” + 6” Socket Extensions
Panel Popper
Pick
Small Flat Blade Screwdriver
Wire Cutters
Torque Wrench, 75 in-lb setting

Note: Approximate Install Time: 1 Hr 00 Mins for Kit Installation.

Notice: When removing any turbocharger air intake system components, make sure to cover any openports to prevent any debris from entering the system. All components need to be inspected andcleaned (if necessary) prior to assembly and installation.

Maintenance

Maintenance: Periodically Check the Following

Charge air cooler T-Bolt Hose Clamps making sure they are tight and secure.
All electrical connections and wire harnesses moved during the installation of the charge aircooler pipe/hose and making sure they are secure and away from any hot or moving components.
Check for any signs of abrasion or wear and tear on the charge air cooler hose, coolant hoses,power steering reservoir, power steering hoses, and electrical harnesses near the charge air coolerpipe/hose and repair/replace as necessary.

Before You Start

Please read the entire product installation guide before proceeding.
Ensure all parts are present.
If you are missing any of the components, call Customer Support at 909-947-0015.
Do not work on your vehicle while the engine is hot.
Make sure the engine is turned off and the vehicle is safely in Park and the Parking Brake is.

Performance Testing

After your installation is complete, engage the parking brake and start your engine. Listen forabnormal noises. If an air leak is detected, re-inspect hoses and connections as they may need to berepositioned and tightened.
S&B FILTERS recommends that you keep your OE charge air cooler hoses and clamps in theevent it is required in the future.
In order to maintain your warranty, all connections and components must be checkedperiodically for alignment and for proper tension on all connections. Failure to do so may void your warranty.

CARB Status-Pending

Emission Standard

The California Air Resource Board (CARB) requires that an E.O. Identifi cation label be applied tothe vehicle in order to pass a smog check inspection when a Charge Air Cooler Pipe/Hose Kit hasbeen installed. You must place the E.O. Label provided on or near the kit after installation so thata smog check technician can easily verify the E.O. Number. Check the status of the exemptionprocess by looking up a specifi c part number at www.sbfi lters.com. The CARB Exemption numberand/or status is listed under the Product Details section for each part number.

If the status showsas “Pending,” CARB has yet to issue an exemption but the product has been submitted. Productsthat have not been issued an E.O. number are street legal in most states, but may not be used onemission controlled vehicles in the state of California and are for off -road use only. If youpurchased your kit from S&B Filters directly, we will automatically mail you your ExemptionSticker when it is issued to us. If you purchased your kit from an authorized S&B Filters Dealer, logonto our website and register to receive your Exemption Sticker.

EXPLODED VIEW

S B-FILTERS-83-1001-S-Charge-Air-Cooler-Pipe-Kit-fig-1

S B-FILTERS-83-1001-S-Charge-Air-Cooler-Pipe-Kit-fig-2

INSTALLATION STEPS

STEP 1
- Loosen the upper hose clamp of the Charge Air Cooler (CAC) outlet hose.
- Tools Required: 7mm Socket/Wrench
STEP 2
- Loosen the lower hose clamp of the CAC outlet hose.
- Tools Required: 7mm Socket/Wrench, 10” Socket Extension or 4” + 6” Socket Extension
STEP 3
- Slide the hose off the upper hose barb and the intercooler outlet and remove from the vehicle.
STEP 4
- Depress the locking clip and remove the electrical connector from the air temperature sensor.
STEP 5
- Remove the temp sensor harness retainer from the upper hose barb.
- Tools Required: Panel Popper
STEP 6
- Using a Pick, carefully remove the Spring Clip from the plastic upper hose barb and set it behind the hosebarb on the throttle assembly.
- Tools Required: Pick
STEP 7
- Remove the Spring Clip from the throttle assembly being careful not to over stretch or bend it. Save the Spring Clip for use in Step 12.
STEP 8
- Remove the upper hose barb from the throttle assembly
STEP 9
- Using a Small Flat Blade Screwdriver, gently lift the Temp Sensor tab above the locking ramp, then twist (counter clockwise) and pull out the Temp Sensor.
STEP 10
- Insert the Temp Sensor into the CAC Hard Pipe (A) with the Temp Sensor tab resting on top of the boss and in front of the locking ramp as shown below
STEP 11
- Twist the Temp Sensor clockwise until the tab goes over and is locked by the locking ramp.
STEP 12
- Install the Spring Clip from Step 7 into the clip groove on the CAC Hard Pipe (A).
- (IMAGE 2)
STEP 13
- Remove the screw holding the power steering reservoir and set the screw aside.
- Tools Required: 10mm Socket/Wrench
STEP 14
- Lift the power steering reservoir from the support slot and carefully leave it off to the side while keepingit upright. This will give you more room when you install the CAC Silicone Hose (C).
STEP 15
- Install the smaller T-Bolt Hose Clamp ( E) onto the smaller end of the CAC Silicone Hose ( C) with the spring and nut pointed up towards you as shown below. Install the larger T-bolt Hose Clamp ( D) on the other end (where the S&B Logo is located) of the CAC Silicone Hose with the spring and nut underneath and pointed towards you as shown below. Leave both T-Bolt Hose Clamps loose for now.
STEP 16
- Clean and remove any residual oil on the Intercooler outlet and install the CAC Silicone Hose (C) with the T-Bolt Hose Clamps into the vehicle with the small end attaching to the Intercooler outlet. Leave the T-Bolt Hose Clamps loose at this time.
STEP 17
- The lower T-Bolt Hose Clamp (E) should be positioned so that the spring and nut are pointed towards you and accessible from above as shown below.
STEP 18
- The upper T-Bolt Hose Clamp ( D), should be positioned so that the spring and nut are underneath the CAC Silicone Hose, and pointed towards the front of the vehicle as shown below.
STEP 19
- Stretch the O-Ring ( B ) by hand while adding a thin coat of clean diesel engine oil to the O-Ring. Workyour way around the entire O-Ring, gently stretching and oiling it as you go. After stretching, verify thatthe outside diameter of the O-Ring touches all around the inside of the o ring groove of the CAC HardPipe ( A ) as shown below. If the outside diameter of the O-Ring feels loose in the o-ring groove, gentlystretch the O-Ring by hand again.
- IMAGE 2
STEP 20
- Add a thin coat of clean diesel engine oil all around the outside diameter of the throttle assembly
STEP 21
- Install the CAC Hard Pipe ( A) onto the throttle assembly until the Spring Clip snaps into place on the throttle assembly. Rotate the CAC Outlet Hard Pipe so that the hose end is pointed upwards as shown
STEP 22
- Rotate the CAC Hard Pipe ( A ) and pull the CAC Silicone Hose ( C ) onto the end of the Hard Pipe. As you continue to rotate the Hard Pipe, the Silicone Hose will slip over the Hard Pipe into position as shown. nap into the grommet.
- (IMAGE 2)
- (IMAGE 3)
STEP 23
- Reconnect the electrical harness to the Temp Sensor.
STEP 24
- Temporarily put the power steering reservoir back in its support slot and check for clearances all around the CAC Hard Pipe ( A ) and CAC Silicone Hose ( C ). Rotate the CAC Hard Pipe to adjust the clearances making sure the CAC Hard Pipe and Silicone Hose are far enough away from the power steering reservoir and other surrounding lines and hoses
- (IMAGE 2)
STEP 25
- Rotate the power steering reservoir spring band hose clamp so that the prongs are pointing away from the Silicone Hose (C).
STEP 26
- Verify that the CAC Silicone Hose ( C ) is up against the intercooler, with the intercooler outlet fully inserted, and the T-Bolt Hose Clamp (E) about 1/ 8” from the end of the Silicone Hose as shown below.
STEP 27
- Once you have everything positioned properly, tighten and torque the T-Bolt Hose Clamp to 75 in-lb.
- Tools Required: 10” Socket Extension or 4” + 6” Socket Extension, 11mm Deep Socket/Wrench, TorqueWrench
STEP 28
- Verify that the CAC Hard Pipe ( A ) is fully inserted into CAC Silicone Hose ( C ) and the T-Bolt Hose Clamp( D) about 1/ 8” from the end of the Silicone Hose as shown below
STEP 29
- Make sure that the T-Bolt Hose Clamp ( D) is positioned so that the T-Bolt, spring, and nut are away fromtouching anything. Tighten and torque the T-Bolt Hose Clamp to 75 in-lb.
- Tools Required: 11mm Deep Socket/Wrench, Torque Wrench.
STEP 30
- Place the power steering reservoir back in the support slot and tighten the screw.
- Tools Required: 10mm Socket/Wrench
STEP 31
- Secure the loose Temp Sensor harness with Cable Ties ( F) to the plastic vacuum line as shown below. Cutoff the excess cable tie with a Wire Cutter. Make sure to keep the plastic vacuum line and rubber coolantlines separated as it was from the factory to prevent them from rubbing on each other.
- Tools Required: Wire Cutter
STEP 32
- Inspect your installation, make sure the kit is properly positioned with clearances around all the parts toprevent wear or damage to any parts during vehicle operation, movement, and vibration. Verify both T-Bolt Hose Clamps are tight and secured. Keep all stock parts in case you ever need to reinstall the stockintake assembly. Affi x the ID label somewhere visible and near the CAC Outlet Kit. If you are an installer,give the owner the QR code for the Installation Instructions so that he/she is aware of the Maintenanceand Operation procedures given in the beginning of the Instructions. Clean a fl at visible surface under thehood and affi x the enclosed CARB EO sticker for SMOG purposes. The installation is now complete.