Riffraff Diesel Performance Parts: Ford Diesel HP Crossover (HPX) Kit Installation Instructions

HP Crossover (HPX) Kit

Installation Instructions

Page 1 of 5

IMPORTANT: Before starting installation, please be sure that all items which were supplied with the kit are accounted for.

1 – HPX line

5 pages of installation instructions

Recommended Tools:

-5/8” deep well socket

-5/8” open end wrench

-Large flat-blade screw driver

-8mm socket

-Standard pliers

AIH removed.

spider

e d c

AIH intact.

f	g

Installation:

1.Disconnect and/or remove the following components (refer to pictures for locations):

a)Air Intake Heater wire (unless AIH is already removed).

b)8mm bolt underneath the wastegate controller solenoid valve (put bolt back into intake manifold “spider” to prevent losing it).

c)Disconnect the red line’s elbow from the spider

d)Unplug the manifold air temp sensor (between the pressure/vacuum nipples)

e)Move the clamp and disconnect the manifold air pressure tube

f)Unclip the red vacuum line from the turbo intake tube

g)Disconnect the red vacuum line from the waste gate actuator

h)Loosen both clamps on each rubber boot connected to the spider and slide out of the way

Toll Free Sales & Customer Service: (866) 446-3360

HP Crossover (HPX) Kit

Installation Instructions

Page 2 of 5

i)Loosen only the lower screw clamp of each of the red rubber boots at the bottom of the spider (leave the top ones in position for easier and simpler removal of spider)

2.Remove the large rubber boots from the top spider nozzles. Over time, these boots may have become somewhat stuck to the nozzles, so you may need to carefully wedge the flat blade tip of the screwdriver under the edge of the boot and slide it around to help loosen the boot for removal. Be careful to not use excessive force and tear the boot. Once the boots are completely loose, it is helpful to squeeze one side of the boot inwards to remove them. Remove

the boots and clamps from the IC tubes for cleaning (if they are very dirty).

3.Remove the Air intake tube from the truck to allow for more lateral movement of the driver side IC pipe while removing the spider.

4.Remove the spider from the truck by wiggling it free from the boots on the top nozzles and the air intake plenums underneath. You will see the two 5/8” hex oil port plugs which you will need to remove.

Clean up any oil which may have leaked and accumulated in the engine valley beneath the spider (not uncommon to find some oily residue from years of use).

Toll Free Sales & Customer Service: (866) 446-3360

HP Crossover (HPX) Kit

Installation Instructions

Page 3 of 5

NOTE: If you are either working on an Excursion or have performed the Ranger heater

Valve mod for improved air conditioner performance, you may find it helpful to disconnect the vacuum tubing which connects to the heater valve on the passenger side to allow for a wider range of movement with your wrench while tightening the oil port fittings in the following steps.

5.Insert a clean rag into each IC pipe opening and the turbo discharge opening to prevent the small parts, debris, etc. from getting into the engine components.

6.Prepare the HPX line for installation by first removing the two JIC brass fittings from the HPX line, lube the o-rings with oil, and place the fittings on the cowl behind the turbo so they are handy for rapid installation.

7.Using a 5/8” socket, loosen both oil port plugs on the engine, but do not yet remove them. Have TWO fairly clean rags handy for the plug removal and fitting installation steps.

NOTE: Be prepared to perform steps 6-9 as quickly as possible to minimize oil seepage into your engine valley.

8.Remove one of the oil port plugs and quickly place the rag around the port, followed by immediately installing the brass JIC fitting into that open port. Snug the JIC fitting down as much as possible with your hand, and then tighten it completely until the fitting bottoms out on top of the engine head as pictured.

If this fitting is not tightened all the way down, you will have a leak upon startup.

9.Use a rag to catch oozing oil while you complete the other side.

10.Repeat steps 7 and 8 for the other head (remove the oil port plug and install the associated JIC fitting).

11.Quickly place the HPX line into position and finger-tighten each compression fitting onto the companion JIC fittings you inserted into the oil ports.

Sometimes, the hard tubing HPX lines need to be “coaxed” into position at the second fitting once the first side is finger-tight, and it may be helpful to slightly loosen the first side’s compression fitting to allow more movement while aligning the second side’s fittings together. Tighten compression fittings with the 5/8” wrench. See Tips on next page.

Tip for tightening the Soft HPX line: You must properly position the line to avoid direct contact with the turbo housing before tightening the compression fittings. Do this by pulling the hose forward as much as possible and then first tightening the

Toll Free Sales & Customer Service: (866) 446-3360

HP Crossover (HPX) Kit

Installation Instructions

Page 4 of 5

driver side compression fitting. The torque of tightening the fitting will cause it to shift towards the turbo housing unless held firmly away during tightening (use caution to avoid stripping the threads).

Tip for tightening the Hard Tubing: It is best to progressively tighten the two sides in an alternating pattern, especially if force was necessary to align the fittings.

12.Your newly installed HPX line should look like one of these two pictures (soft HPX line on the left, and Hard Tube HPX on the right). Once more, wipe up any spilled oil from the engine valley.

Now you can reinstall the spider by reversing steps 1-4, but there are a few tips which you may find helpful. We also recommend that you take advantage of having the spider out of the truck to thoroughly clean both the spider and all four associated boots and all eight clamps. Simple Green, scrub brush, and low pressure water works well. Just be very careful to avoid damaging the temperature sensor with either the brush or water.

13.Make sure the EBPV sensor indicated in the above right picture is still connected (it is easy for this sensor to become disconnected while working in the valley).

14.Install the bottom red boots on the truck individually. It is a lot easier to re-install the spider with those boots already in place. Tighten the lower screw clamp on each of these two boots firmly.

15.Place the second screw clamp on each of the red plenum boots you just installed, but leave them very loose for freedom of movement while manipulating the spider into position. If you are installing a soft HPX line, you may want to consider positioning the driver

side top screw clamp opposite the way it was originally to avoid having the clamp contacting the HPX fire-guard lining as pictured.

16.Install the two IC pipe boots and clamps, but do not yet tighten either boot.

Toll Free Sales & Customer Service: (866) 446-3360

HP Crossover (HPX) Kit

Installation Instructions

Page 5 of 5

17.Manipulate the spider into position. This may take some serious wrangling with the boots, and you may your flat-bladed screwdriver very useful in shoe-horning the boots over the spider nozzles. It is probably best to get the upper and lower spider nozzles from one side into position first, then the bottom nozzle on the opposite side, and then followed by the final connection with the final top IC boot.

18.Position and tighten all clamps to securely hold the boots onto the spider nozzles.

19.Re-install the air intake tube (if removed).

20.Re-connect the heater valve’s vacuum line (if removed).

21.Re-connect the red tubing at the waste gate actuator, in the clip on top of the turbo intake tube, and on the driver side nipple on front of the spider.

22.Re-connect the manifold air temp sensor between the two nipples.

23.Re-connect the manifold air pressure tube (passenger side 90° vacuum nipple).

24.Re-attach the wastegate controller solenoid (front of the spider with the 8mm bolt).

25.Re-attach the Air Intake Heater wire (if removed).

26.Re-check all boot clamps to ensure they are properly tightened.

27.Start the engine and observe the port fittings for potential leaks. If there are no leaks, take the truck for a quick run so the HPOP can establish higher operating pressures and return to your “shop” for a final leak inspection. Re-tighten fitting connections if necessary (though it is possible to strip the fitting threads, these are steel fittings which can take much more tightening forces than more typical brass fittings – just make sure to exercise adequate caution and you may need to re- tighten several times if you’re overly cautious).

Credit for pictures and information to big poppa pump, F250_, and the whole FTE crew. Thanks!

If you are interested in performing the Air Intake Heater delete mod, Riffraff Diesel has a hard-anodized plug kit specifically for that modification which is available both plain and with a boost gauge port, and these plugs are available in red, blue, black, and clear.

Disclaimer of Warranties and Liabilities

Riffraff Diesel disclaims any implied warranties of merchantability and fitness for a particular purpose.

Riffraff Diesel also disclaims any liability or consequential damages including, but not limited to, repair labor, rental vehicles, hotel cost, or any other inconvenience costs.

This warranty is in lieu of all other warranties or guarantees, either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser.

Toll Free Sales & Customer Service: (866) 446-3360