Bulletproof Diesel complete oil/EGR cooler install

[2006PSDSD]

Removed front bumper, grill, and plastic flap. After this you remove the condenser


Nevermind the C clamp, I was using that to hold the oil cooler while I tightened the cold weather stat. The clamp is not really necessary


Be sure to install the brass plug. The BPD instructions don't really specify this part.


Oil filter housing moched into place. The fittings are NOT in the correct place at this time


On the 05-07's the 90* fitting is aimed towards the back of the truck. A hole cut through the rubber flap to slide the hose through. I put little bags of the A/C line fittings to keep debris from getting in there. Not good for you A/C! This hose is really easy to route, though this hole, and to the transfer block. Just keep it tiddy and out of the way. I sent mine between the A/C accumulater and A/C line and next to the oil filler tube


You have to cut this small chunk from the headlight frame on the passenger side to allow enough room for the oil thermostat


I forgot to take pics of the new hose. The only thing different is that the new hose is about an inch longer, and I routed it behind the PS lines. Route this hose under the front fender, and above the frame to the oil filter housing


Turbo out and some other things out of the way


A work of art! Beautiful BPD oil transfer block with fittings and sensors installed


Removed the turbo, FICM, intake, and oil oil cooler. The cat litter was to soak up the oil that came out from under the oil cooler. My driveway is at a pretty good angle, and if it were flat you should not have this issue. Be sure to remove the OE filter screen, as the BPD transfer block has a stainless steel one mounted to the bottom permanently. Be sure to fill the HPOP res. before installing the tranfer block!


Out with the old cooler!


Old EGR cooler on the bottom, and BPD on the top. I didn't feel like cleaning the old one to get a pic pic of the OE cooling fins vs the BPD stainless steel pipes


BPD oil transfer block's integral HPOP screen


Bpd transfer block installed in the valley. OE torque is 16 ft lbs on these bolts


Condenser mounted back in place with oil cooler attached. Prime the oil cooler before final installation of hoses. I did it the hard way and primed it before installing, and made a HUGE mess in my driveway! I think you can prime it through the hose or something, but a quick call to BPD may give you a faster way to prime it


Final installation of oil filter housing with hoses attached. Notice the fitting locations. Be sure to prime the oil filter!


Final valley pic with oil tranfer block and EGR cooler installed. The routing of the drivers side hose is a one way design, meaning that you only have enough hose to do it one way. It is routed from the oil filter housing between the fender and above the frame through the rubber flap. Then in between the intercooler and air filter housing snout. The EGR cooler has a certain torque sequence and the torque spec is 8 ft lbs


Post #2 for the intake torque sequence Torque specs for 6.0 - PowerStrokeNation

All in all, I think it took me about 30 hours to complete. The hardest part for me was mounting the oil cooler to the condenser. The rest was prety easy, but time consuming

Bulletproof diesel customer service is TOP NOTCH! They sent me the updated hose from the oil cooler to the filter housing and the tee overnight. Their techs are great too with any kind of advice you may need. Special thanks to Gene, Justin, JC, and John, and everybody else that performs a duty at NEAL Technologies. Thanks for making this install and product second to none

[95dieselsmoke]

Very nice, Good work

[DutchVDub]

Damn, good work man. Thats a lot of work.

[colo_dually]

Thanks for the write-up, Nicholas.

This project is formally on my to-do list now.

[2006PSDSD]

Thanks guys! Its was a LOT of work, but I had a good time doing it... most of the time, LOL. My chest, thighs, and stomach are all bruised from laying on top of the engine for a week. That overhead creeper might actually be worth 200 dollars

[Evil Eye]

Great job in performing the install and decent job on the documentation... Oh and where's the video of your engine running? Yeah, it tears your chest and stomach up to lay on the engine; the topside creeper is a must have if you are going to do more than one of these...

PS. I LOVE the empty Busch can in the box with the old oil cooler! That ALWAYS makes the install much easier...

[2006PSDSD]

Originally Posted by Evil Eye

Great job in performing the install and decent job on the documentation... Oh and where's the video of your engine running? Yeah, it tears your chest and stomach up to lay on the engine; the topside creeper is a must have if you are going to do more than one of these...

PS. I LOVE the empty Busch can in the box with the old oil cooler! That ALWAYS makes the install much easier...

I tried, but my wife was not there like I thought she would be, to take the photos. I was surprised I had as many pics as I did. I'm not totally sure how to post that video, I'll look into it tonight (I can't get on PB from work). I figured the same thing, and I don't plan to have to work on my truck enough to spend that kind of money on the topside creeper

LOL, I had to use that to empty the HPOP reservoir . And yes, it does seem to ease the pain from all the bruising

[Evil Eye]

DUDE, That writeup is MUCH better! Thanks for posting the pics with the descriptions. Were you able to get the drivers side hose figured out?

[2006PSDSD]

Thanks bud! .

Yeah, Andrew said that's the way it was supposed to go. Yours is custom apparently. They are not made to go over the top of the air filter . He did say that he would help me out if I wanted to route it behind the intercooler pipe instead of its current location. Ken has had his that way for 60k, so I'm sure I'll be ok, lol

[Evil Eye]

A one-of-a-kind setup!!! I like that... Glad it wasn't anything to worry about for you. Ken's taken his truck up and down the Baja peninsula several times, so if anyone has put it through it's paces, he has.