Installation Manual

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40. Using six 13mm bolts, reattach the upper radiator support

to the truck.

41. Reinstall the single 10mm bolt that holds the horns to the

upper radiator support.

42. Reinstall the intercooler in the truck. Make sure that

mounting pegs seat properly when installing.

43. Reattach the cold-side pipe boot to the intercooler.

44. Using two 10mm bolts, reinstall the top of the intercooler

to the upper radiator support.

45. Reattach the lower hot-side pipe boot to the intercooler.

46. Reﬁ ll the cooling system with a 50/50 mix of coolant and

distilled water.

47. Reconnect the negative battery terminals on both batteries.

48. Start the vehicle and set the heat to high to purge any air

from the cooling system. Allow the vehicle to reach operating

temperature and check for any leaks in the system.

49. Fill the cooling system with premixed, Ford-approved coolant,

start the engine, and allow it to idle with the expansion tank

cap off. Turn the heat to full hot, and put the fan on low.

Monitor the engine temperature and coolant level in the

reservoir. Add coolant as needed to maintain a proper level

in the reservoir, and check your connections for leaks. If the

vehicle begins to overheat or coolant starts to overﬂ ow from

the reservoir, shut the engine off and allow it to cool before

continuing. Once the vehicle is fully warmed up and the

coolant level has stabilized, allow the vehicle to cool off

completely, and then top off the coolant level. Coolant level

should be checked once more after putting in some miles.

Congrats! You just ﬁ nished installing

the '08

—

'10 Ford 6.4L Powerstroke

Aluminum Radiator.

'08

—

'10 FORD 6.4L POWERSTROKE

ALUMINUM RADIATOR

INSTALLATION GUIDE