Step 1
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Disconnect Batteries
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Step 2
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Drain coolant
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Step 3
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Remove clips for plastic wire way located above turbo. Fold to windshield of truck.
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Step 4
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Remove upper fan shroud by prying away from radiator through slots figure 2.0/2.1
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Step 5
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Loosen hose clamps and remove intake tube figure 3.0. Then unscrew bolts and remove turbo inlet tube and PCV Valve figure 3.1
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Step 6
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Loosen clamps and remove charge pipe figure 4.0. Unbolt alternator and disconnect wires figure 4.1, then tilt towards front of vehicle.
Note: it is not necessary to loosen belt tensioner.
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Step 7
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Disconnect downpipe by removing v-clamp from back of turbo figure 5.0 and remove the 2 bolts from the catalytic converter figure 5.1.
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Step 8
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Remove turbo charger. This is done by removing the two oil feed line bolts, VGT actuator wire, Up-pipe v band clamp, and the three turbo mounting bolts. It is strongly recommended to use penetrating oil on all turbo bolts, exhaust up pipe bolts, and pedestal bolts. Once these parts are removed the turbo will roll toward the passenger side of the truck and out of the pedestal.
Figure 6.0
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Step 9
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Remove the turbo mounting pedestal, Remove the oil drain tube from the H.P.O.P cover figure 6.1
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Step 10
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Loosen do not remove the intake manifold bolts on the drivers side. Completely remove the intake manifold bolts from the passenger side and note their location using a piece of cardboard figure 7.0 Remove the two bolts that go through the inner fan stator (located under the shroud) 7.1
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Step 11
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Remove the bolt that is used to stiffen the heater tube to the manifold (located below alternator). Bend this tab upward figure 8.0
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Step 12
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Remove EGR cooler mounting bolts (3 total) figure 8.1
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Step 13
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Lightly push down on the EGR cooler while pulling up on the intake manifold to disengage from the manifold figure 9.0
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Step 14
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While holding the manifold up with a small pry bar move the cooler toward the back of the engine. Continuing to hold the manifold up, lift and remove the cooler through the front of the engine. Be sure that all gaskets and o-rings are removed with the cooler figure 9.1
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Step 15
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Install supplied EGR cooler block off disk to up-pipe using existing v-clamp.
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Step 16
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Replace intake manifold bolts and torque to 120inlbs
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Step 17
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Install the 3/4” silicone hose, 3/4” 180 degree Stainless steel coolant tube provided, and the worm drive hose clamp rings loose on the hose
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Step 18
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Grease the Sinister billet adapter o-ring. Place into intake manifold bore. Finger tighten the two longer factory cooler mounting bolts. The third smaller bolt can be discarded figure 10.0
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Step 19
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Tighten billet adapter bolts to 120inlbs, while tightening make sure the o-ring stays in place and alignment is correct. Be sure not to over torque the bolts. Slide hose over the oil cooler nipple and tighten both hose clamps figure 10.1
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Step 20
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Reinstall turbo, all intake and exhaust tubes including down pipe, alternator, shroud, wires etc.in reverse order from steps 3 to 17
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Step 21
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Refill with new coolant, use manufacturer recommended and mix according to label
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Step 22
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You are ready to test the Sinister delete kit. Start engine and run till coolant circulates. Top off coolant system if needed. Make a close inspection for any coolant leaks or oil leaks.
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