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Message: [QUOTE="Snake, post: 461078, member: 97"] 31. Connect the following electrical connectors: [INDENT]a. Injector Pressure Regulator (IPR) sensor b. Injector Control Pressure (ICP) sensor c. Engine Oil Temperature (EOT) sensor d. Engine Oil Pressure (EOP) sensor e. Exhaust Gas Recirculation (EGR) valve sensor f. EGR throttle position sensor g. Engine Coolant Temperature (ECT) sensor h. Intake Air Temperature (IAT2) sensor i. Exhaust Backpressure (EBP) sensor j. Glow Plug Module (GPM) connector[/INDENT] 32. Install the FICM. Plug in the three FICM connectors (X1, X2, and X3) and position the FICM on top of the driver side valve cover. Secure the rear of the FICM to the valve cover with two 8mm bolts and torque them to 10 ft/lbs. Also see picture for Step 11. 33. Connect the heater hose tube (passenger side). If you removed the heater hose tube from the front cover, replace the o-ring for that mounting plate (where the end of the heater hose tube meets the front cover) and secure the heater hose tube to the front cover using the plate and corresponding 8mm bolt. Connect the heater tube to the side of the intake manifold with the OEM bracket and 8mm bolt. If you chose to bend the bracket (Option 1 from Step 17), gently bend the bracket back into position and torque both 8mm bolts to 10 ft/lbs. 34. Connect the Manifold Absolute Pressure (MAP) sensor hose. Slide the MAP sensor hose over the fitting on top of the passenger side of the intake manifold and slide the spring clamp over the hose and fitting. [B][SIZE="3"]Now for the fun stuff. [/SIZE][/B] **NOTE** My truck has the 14” transmission cooler and the power steering cooler is located near the bottom of the radiator. If your truck has a 17” transmission cooler and/or a power steering cooler that is located near the hood latch, additional steps are necessary and covered in the Bulletproof Diesel Installation manual. 35. Remove the Air Conditioning Condenser. Remove the nine retaining pins that hold the sight shield (cover) in place, and gently pull the sight shield up and off the front of the truck. Use a 13mm open end wrench to disconnect the A/C condenser core inlet and outlet lines located on the passenger side of the A/C condenser (each line is held in place with a 13mm nut). Mark the location of the hood latch (we could see where the mechanism would need to be positioned when installed and skipped this step). Remove the two 8mm screws holding the hood latch in place and position the hood latch out of the way. Remove the 8mm screw that holds the “L” shaped AC condenser bracket to the core support and repeat on the other bracket. Lift the A/C condenser out through the space normally covered by the sight shield. [ATTACH=full]95415[/ATTACH] [ATTACH=full]95416[/ATTACH] 36. Mount the Bulletproof Diesel heat exchanger (also referred to as the air cooler and/or oil cooler) to the Bulletproof Diesel condenser mounting bracket. **NOTE** Ensure the heat exchanger is positioned on the mounting bracket correctly. The oil inlet and oil outlet ports are positioned at different heights on the heat exchanger to prevent air from being trapped in the system. Place the mounting bracket onto a working surface with the flat side down (the large “lip” should be at the top). This is how the bracket would be viewed if you were sitting directly behind it after it’s mounted to the AC condenser (the flat side mounts to the back of the AC condenser). With the “Bulletproof Diesel” logo facing the back (the side facing up, in this case) of the condenser mounting bracket, align the two holes on the top of the heat exchanger with the two studs at the top of the mounting bracket and do the same with the two holes and studs at the bottom of the components. Slide a 1/4” washer over each stud and then secure the heat exchanger to the mounting bracket with a 1/4” nut on each stud. Tighten the 1/4” nuts securely. [ATTACH=full]95417[/ATTACH] [ATTACH=full]95418[/ATTACH] [ATTACH=full]95419[/ATTACH] 37. Install JIC fittings into heat exchanger. **NOTE** The JIC fittings do not require Teflon tape or thread sealer. With the condenser mount and heat exchanger still face down, thread a #12 JIC 90° elbow fitting into the port on the left side of the heat exchanger. This is the “oil in” side of the heat exchanger and the port is centered from top to bottom on the side of the heat exchanger. Ensure the opening of the JIC fitting is pointing directly towards the bottom of the heat exchanger and tighten the fitting into the port using a 1 1/4” open end wrench. Thread a #12 JIC straight fitting into the port closest to the top of the right side of the heat exchanger. This is the “oil out” port. **NOTE** There are two threaded ports on the right side of the heat exchanger, and they’re dummy proof: the hole closest in the center of the side of the heat exchanger is smaller and won’t accommodate a #12 JIC fitting. Use a 1 1/4” open end wrench to tighten the straight fitting into the port. The center port on the right side can be used to tie in a supply line for a by-pass oil filtration system or a sender for an engine oil temperature or engine oil pressure gauge. This may be the one time I didn’t add something “extra” to a part being installed on my truck and I used the 1/4” pipe-plug brass insert included in the Bulletproof Diesel kit to block off this port. To install this pipe-plug, wrap the threads of the pipe-plug with Teflon tape and thread the pipe-plug into the port. **TIP** Hold the pipe plug with the bottom (the end going into the port) facing you and wrap the Teflon tape in a clockwise direction. Tighten the plug in the port using a 1/4” hex head socket (or hex key wrench). DO NOT OVER TIGHTEN. 38. Mount the Bulletproof Diesel heat exchanger and condenser mounting bracket to the A/C condenser. For simplicity, I’ll collectively refer to the heat exchanger and condenser mounting bracket as the mounting bracket. Place the front of the A/C condenser on a working surface in the same manner as the previous step: the front of the condenser should be flat on the working surface, the back of the condenser should be facing up, and the top of the condenser should be facing away from you. Lay the front of the mounting bracket (the side with the Bulletproof Diesel logo on the heat exchanger) on the back of the A/C condenser while aligning the tops of the mounting bracket and the A/C condenser. In other words, the top of the mounting bracket should sit level (flush) with the top of the A/C condenser. Determine which four holes on the left and right sides of the mounting bracket line up most closely with holes on the A/C condenser and insert one aluminum spacer (included in the Bulletproof kit) in between the mounting bracket and the A/C condenser for each hole you identified. Use one self tapping screw (included) for each hole and secure the condenser mount to the back of the A/C condenser using a flat-head screwdriver to tighten the screws. **TIP** It may be easier to insert one spacer, loosely screw in one of the self tapping screws, and repeat for the remaining three. This will help keep the spacers in place. [ATTACH=full]95420[/ATTACH] [ATTACH=full]95421[/ATTACH] 39. Mount oil hoses to the heat exchanger. Locate the black, 16” long oil hose with a straight fitting on either end. This hose will connect the heat exchanger to the Bulletproof Diesel oil filter adapter (oil filter mount). Screw one of the oil hose’s straight fittings onto the JIC 90° elbow fitting located on the left side of the heat exchanger (the “oil in” port). Tighten securely using a 1 1/4” open end wrench. Next, locate the black, 56” long oil hose with a straight fitting on either end (the other 56” long oil hose has a straight fitting on one end and a 90° elbow fitting on the other). This hose returns oil from the heat exchanger to the Oil Transfer Block. Screw one of the oil hose’s straight fittings to the JIC straight fitting on the right side of the heat exchanger (the “oil out” port). Tighten securely using a 1 1/4” open end wrench. 40. Install the A/C condenser with the heat exchanger attached. **TIP 1** A second set of hands is almost a necessity for this step. I found it was easiest to have a person on the left side and a person on the right side of the condenser. **TIP 2** Use duct tape to cover the open ends of the unsecured fittings (the fittings not connected to the heat exchanger). This will prevent debris from entering the hoses. Start by positioning the A/C condenser close to where the sight cover / hood latch is located and route the unsecured ends of the two oil hoses into the space where the A/C condenser will eventually go. While lowering the A/C condenser into its mounting location, route the unsecured end of 56” oil hose (passenger side) through the hole in the core support where the A/C lines pass through. In the engine bay, this hose will route under the passenger side battery tray and along the inside of the fender well before turning up and over the Glow Plug Module (GPM) on its way to the Oil Transfer Block. **TIP 3*** Ensure the oil hose and the A/C hoses do not rub or the A/C hoses can eventually fail. **TIP 4** Do not connect this hose to the Oil Transfer Block yet. There are other parts that need to be installed and the passenger side oil hose will be used to prime the heat exchanger. Route the unsecured end of the 16” oil hose towards the front driver side tire. Ensure this hose is behind the tow hook bucket / bumper mount bracket. Verify the A/C condenser is fully seated in it’s mounting location, secure the “L” shaped A/C condenser mounting brackets to the core support using the 8mm screws, and torque to 89 in/lbs. Next, mount the hood latch back in it’s original location on the core support with the 8mm screws. Torque the screws to 9 ft/lbs. Finally, connect the A/C condenser inlet and outlet lines to the fittings on the passenger side of the A/C condenser. Lubricate two new o-rings in mineral oil, place one on each fitting of the A/C condenser, and connect each line using a 13mm nut. Torque to 71 in/lbs. **TIP 5** Do not install the sight shield at this time. After all components have been installed and fluids have been replaced, start the truck and visually inspect for leaks. It will be easier to look for and fix any leaks that are found if some of the larger vehicle parts have not been installed yet. [ATTACH=full]95422[/ATTACH] [ATTACH=full]95423[/ATTACH] [/QUOTE]