DINAN D780-0003 High Performance Heat Exchanger Installation Guide

Installation Instructions
D780-0003
HIGH PERFORMANCE
HEAT EXCHANGER
Document Revision: A
Release Date: 12/11/2023

D780-0003 High Performance Heat Exchanger

Thank you for being selective enough to choose a Dinan Performance Heat Exchanger. The Dinan Engineering Team has spent many hours developing this product to assure that you will receive increased performance and durability that you as a customer will be able to enjoy for many years. Ease of installation and maintenance is important to us and has been highly considered throughout the design process.
Prior to performing the installation, familiarize yourself with these instructions as it should help you with the process. If you feel that you do not have the required skills or tools, please arrange for a qualified technician to perform the installation.
If you have any difficulties during the installation, or if these instructions are not clear to you, please call Dinan’s Technical Support Staff at 800-341-5480.
Again, thank you for choosing Dinan. Enjoy.

PARTS LIST

• [ D780-0003 ] HEAT EXCHANGER

TOOLS REQUIRED

Basic hand tools such as screwdrivers (including bits such as Torx), pliers, and picks are required; no specialty tools are required.
Panel clip pliers may improve the installation experience.

INSTALLATION

• All spatial references are relative to the location/orientation of a seated driver.
  STEP 1:
  Open the engine compartment and complete a visual inspection. Repair and validate existing failures before progressing with the installation of your Dinan high performance heat exchanger.

STEP 2:
Remove the fasteners securing the front of both chassis (strut) braces; the fasteners feature a 13 [mm] hex interface.

STEP 3:
Remove the fasteners securing the back of both chassis (strut) braces; the fasteners feature a 13 [mm] hex interface.
The fender liner must be removed to access the nut which secures the bolt from below; it is located near the top of the suspension strut chassis interface.
Remove both chassis (strut) braces.

STEP 5:
Remove the front engine compartment hood seal.
Starting from one side, pull the seal up and away from its mounting interface.

STEP 6:
Remove the panel clips securing the upper bumper cover.
Using panel clip pliers, or your preferred alternative, pull the panel clips up and away from the upper bumper cover.

STEP 8:
Disengage the retaining clips securing the upper bumper cover.
Using a screwdriver, pick, or your preferred alternative, push the retaining clip away from the locking interface on the upper bumper cover.
Remove the upper bumper cover.

STEP 9:
Pull the engine compartment hood latch cable out and away from its retaining tabs.
Remove the core support brace plate.
It is secured by fasteners with the following interfaces:
– (8x) 13 [mm] hex
– (2x) retaining clip
– (2x) T30 Torx

STEP 14:
Remove the fasteners securing the engine compartment hood latch mechanisms to the central crossmember, and the crossmember to the chassis; the fasteners feature Torx T30 and E-Torx E18 interfaces respectively.
Disconnect all electronics wiring from the central crossmember.
Remove the central crossmember.

STEP 17:
Remove the fasteners securing the lower bumper cover / skid plate to the chassis; it is secured by panel clips and fasteners with Torx T30 interfaces around its perimeter.
Remove the lower bumper cover / skip plate.

STEP 18:
Disconnect the lower coolant line fitting.
Using a pick, screwdriver, or your preferred alternative, pull the retaining clip away from the locking interface. Drain the coolant; the flow rate may be increased by removing the low-temperature cooling circuit overflow tank cap.

STEP 19:
Remove the four fasteners securing the heat exchanger stack top shroud; the fasteners feature a Torx T30 interface.
Remove the heat exchanger stack top shroud. Disengage the retention clips and lift the fan assembly up and away from the heat exchanger stack.

STEP 20:
Disconnect the upper coolant line fitting.
Using a pick, screwdriver, or your preferred alternative, pull the retaining clip away from the locking interface.

STEP 21:
Remove the OEM low-temperature heat exchanger by lifting it up and away from the vehicle.
Install the Dinan high performance low-temperature heat exchanger; ensure the alignment/mounting tabs on the sides are aligned correctly.

STEP 19:
Complete the inverse of steps 1-20 in reverse order (reassemble the vehicle and fill the cooling system).

Installation Instructions: D780-0003
Dinan Engineering
4800 US Hwy 280 West
Opelika, AL 36801
Phone: 800.341.5480

Documents / Resources

| DINAN D780-0003 High Performance Heat Exchanger [pdf] Installation Guide
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