Step 1
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Make sure the front wheels are straight.
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Step 2
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Disconnect both batteries.
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Step 3
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Drain the coolant using the coolant drain plug located on the bottom of the radiator on the driver side.
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Step 4
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Remove the 3/8” hose that runs to the degas bottle (coolant overflow tank). Keep this hose as it will be re-used during installation.
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Step 5
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Remove the upper radiator hose by popping the wire clip out and pulling the hose straight out.
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Step 6
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Remove the driver side battery.
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Step 7
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Remove the upper radiator hose by popping the wire clip out and pulling the hose straight out.
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Step 8
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Remove the battery tray and degas bottle. This is held on by four bolts. Image four shows parts removed.
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Step 9
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Loosen the clamp on driver side intercooler tube and separate the intercooler tube from the rubber boot. It is not necessary to remove the tube.
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Step 10
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Disconnect the electrical connector on top of the vertical EGR cooler.
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Step 11
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Disconnect the coolant lines on the vertical EGR cooler. Remove the nuts and bolts securing the coolers together. Release the mounting clamps and separate the two coolers by prying on the flanges.
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Step 12
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Hold the intercooler tube back while pulling the vertical EGR cooler up and out. You may have to rotate the cooler to release it from its mount.
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Step 13
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Remove the plastic coolant tube. Be careful to not break the coolant tube as it will be re-used during installation.
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Step 14
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Remove the upper radiator hose from the thermostat housing. If your radiator hose has a single O-ring it is a good idea to replace it with a new double O-ring version.
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Step 15
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Remove the upper radiator hose from the thermostat housing. If your radiator hose has a single O-ring it is a good idea to replace it with a new double O-ring version.
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Step 16
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Remove the steering shaft bolt and slide the stem up and out of the steering box shaft. Note: Be sure to not turn the steering wheel or tires.
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Step 17
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Remove the nut that secures the dipstick tube in place.
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Step 18
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Release the mounting clamps on the lower EGR cooler. It may be easier to access the clamps though the wheel well.
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Step 19
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Remove the coolant line on the EGR Cooler. It may be easier to cut the line. Note: The line will not be reused.
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Step 20
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Remove the bolts on the rear flange of the EGR cooler. It is easier to access the bottom bolt from underneath the truck and the top bolt from above.
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Step 21
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With the dipstick moved out of the way, remove the EGR cooler by pulling forward and rotating it out of its mount.
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Step 22
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Remove the bolt securing the coolant line to the timing cover. This line is attached to the lower EGR cooler mount and will be removed as one piece.
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Step 23
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Use a 10mm wrench to remove the four bolts on the lower EGR cooler mount.
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Step 24
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Install the four replacement bolts (M10-1.25 x 40) in the exhaust manifold and torque to factory specifications.
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Step 25
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Install the exhaust block off using M10-1.125 x 20 bolts and gasket.
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Step 26
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Remount the dipstick tube with the factory bolt.
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Step 27
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Remove the coolant tube that was connected from the vertical EGR cooler to the engine. Replace it with the coolant plug supplied in the kit to block off the hole.
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Step 28
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Install the coolant plug included in the GDP Cooler Upgrade kit. Use the factory bolts that secured the lines in place.
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Step 29
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Use a 13mm wrench to re-install the stud using the spacer provided in the GDP Cooler Upgrade kit. Then secure the power steering line to the stud.
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Step 30
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Re-install the plastic coolant tube. Be careful not to crack or break it.
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Step 31
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Re-connect the steering shaft and torque to the factory specifications.
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Step 32
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Re-install the battery box and degas bottle.
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Step 33
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Re-connect the coolant lines to the degas bottle. Also re-connect the vent line to the battery box.
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Step 34
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Clean the end of the silicone boot and intercooler tube with glass cleaner. Reconnect the intercooler tube.
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Step 35
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Re-connect the upper radiator hose and make sure the metal clips are securely in place.
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Step 36
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Disconnect the wire connectors to the EGR valve.
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Step 37
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Remove four bolts and loosen hose clamp on the intercooler plumbing to remove the EGR valve.
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Step 38
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Install the intake elbow by sliding the tube into the boot. Using supplied M6-1.25 x 25 bolts secure the flange to the intake manifold.
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Step 39
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Use the 3/8” hose that was saved from step four and barbed hose connection from the kit to re-connect the coolant line running over the radiator to the degas bottle. The line will have to be cut to appropriate length. Re-use factory hose clamps on the connections.
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Step 40
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Secure the coolant line over the radiator with the plastic hose routing clips.
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Step 41
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Refill the coolant according to factory specifications.
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Step 42
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Run engine and check for leaks.
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