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