TS-CCA-VSFD001S/B - Performance Intercooler Upgrade Suit Ford F150 EcoBoostUpdated 7 hours ago

Product Name:	Performance Intercooler Upgrade suit Ford F150 EcoBoost
Product Description:	Air to Air Intercooler
Product Number:	TS-CCA-VSFD001S/VSFD001B

Important notes on your new Intercooler

Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious engine damage or personal injury.
Turbosmart intercoolers is designed for use as a factory replacement for a turbocharged vehicles OEM intercooler.
Ensure the engine is cold prior to installation.

Recommendations

Turbosmart recommends that your intercooler is fitted by an appropriately qualified technician.

Kit Contents

Part	Description	Use
1	Turbosmart Intercooler	Main unit
2	Instruction Card	Instruction Card
3	Turbosmart Sticker	Turbosmart sticker

Tools Required

Allen key set metric

Screwdriver

Basic socket set

Torx bits

Fitting your Intercooler

Identify intercooler location

On the 13^th Generation Ford F Series Truck (P552) the intercooler is located at the front of the vehicle located on the lower portion of the car behind the number plate. It is easily accessible from the bottom of the car.

NOTE!

Allow for the engine to cool down.

Removing the Undertray

Remove the under-tray of the vehicle by removing all the plastic clips holding the tray in place. Once the under-tray is removed, the intercooler assembly can be accessed.

Undo the bolts securing the intercooler cross member to remove the intercooler from the vehicle. The Intercooler undertray is held on with 2 x 15mm bolts.

NOTE!

It may be required to remove auxiliary components to access the diverter valve, ensure you consult your local specialist or a service manual for correct disassembly procedures.

The recirculation hose below needs the grey collar to be rotated in the direction of the arrow. Once rotated the tabs will move up and the part can be separated by pulling apart.

Remove Intercooler Piping

The intercooler piping is held on with a quick release clip. As well as a 7mm hose clamp, once these are removed the pipe can be wiggled free.

The Turbo feed charge pipe also need to be removed. These are also held on with 7mm hose clamps.

Remove Diverter Valve Plug

Removing the plug is done by simply pushing down waiting for the click and removing the plug by pulling backwards.

Remove Diverter Valve Chamber

The chamber is held on at the top of the intercooler with 1 x 8mm self-taping screw. Once removed the chamber is free to be removed.

The chamber pictured below can be removed, the chamber is simply rotated anticlockwise and it will uncouple from the intercooler.

Mounting Turbosmart Diverter Valve

Now we can install the Turbosmart diverter valve now the intercooler is removed from the car. The diverter valve is supplied with a recirculation silicone hose. The longer end of the silicone hose is fitted to the diverter valve and the recirculation hose connector is pre fitted to the shorter end. Use the supplied hose clamps on the silicone hose. It is advised to leave the clamps loose while installing to ensure everything is correctly aligned.

The alignment of the diverter valve is important. The diverter valve can screw in with two directions. The recirculation port must face towards the intercooler as pictured above.

The mount that holds the valve comes in two options. The most suitable one needs to be used. The Smaller right angled one pictured is for the small version intercooler. We must use a M3 Allen key to attach to the diverter valve.

Refitting Diverter Valve/Intercooler to Car

With everything fitted back to the intercooler we can fit the intercooler back into the car. It’s helpful to use the intercooler bracket to assist with the intercooler to remain in place.

The turbo feed pipes as well as charge pipe to the throttle body must be refitted, the charge pipe needs an audible click to sound from the retention clip.

The two 7mm hose clamps must be correctly clamped.

The recirculation pipe must be fitted ensuring the connector clips and locks into place, at this point we should tighten up any loose hose clamp to ensure that we have correct orientation of the recirculation pipe

Refitting Electrical Connector

Plug in Connector ensuring that a positive and audible click is heard with the connector to ensure that it is locked in place.

Refitting Undertray

Refit Undertray with the 2 x 15mm bolts that were moved to originally gain access to the Diverter valve area.

Finalising your Install

It is important to check for leaks and correct operation, ensuring no leaks are present and all hoses are correctly seated.

TROUBLE SHOOTING

Diverter valve not actuating - Confirm electrical signal plug is connected appropriately, as the plugs are new, some force may be required to click the plug into place.

Valve is staying open - Confirm the valve has O-rings as they may have been dropped or lost during installation.

Boost Pressure loss or lower than before - Confirm the valve has O-Rings as they may have been dropped or lost during installation. Intercooler Pipes are correctly seated.

Failing the above, submit a technical request to [email protected] with information of your engine configuration and photos of installation.

As the factory engine control unit controls the valve, the diverter valve is almost silent.

NOTES ON EM SERIES DIVERTER VALVE OPERATION

Due to its construction, your EM series may be much more audible than the OEM valve

During normal operation you may now be able to hear the valve open for a few seconds under the following events: traction control, cruise control management, rapid gear changes and varying throttle position changes. This is standard operation of your diverter valve and is coded as part of the torque management software in the OEM engine control unit; there is no adjustment available over these functions on the Turbosmart EM valve directly. It is normal for a diverter valve to be “very active” as it protects your turbocharger from surge events as well as bypassing air for torque management purposes.

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