How To Install: Mishimoto 2003-2007 Ford Powerstroke 6.0L Performance Intercooler

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Mishimoto, the world leader in performance cooling products, is proud to bring you the Mishimoto Performance Aluminum Intercooler for the 2003-2007 Ford F250 w/ 6.0L Powerstroke Diesel!
The engineers at Mishimoto designed this intercooler with cast aluminum end tanks, fully TIG welded to a bar and plate core for added durability and increased cooling capacity. The end tanks have swept inlets and outlets for increased airflow, which compliment this thicker than stock intercooler that is the perfect addition to your F250.
Model Number: MMINT-F2D-03
PARTS LIST
1PC | MISHIMOTO INTERCOOLER
Disclaimer
• Please dispose of any liquids properly.
• Allow vehicle to cool completely prior to attempting installation.
• Mishimoto Performance (MP) is not responsible for any vehicle
damage or personal injury due to installation errors, misuse,
or removal of MP products.
• MP always suggests that a trained professional install all
MP products.
• Do not run the engine or drive the vehicle while overheating.
Serious damage may occur.
• Raise vehicle only on jack stands or on a vehicle lift.
INSTALLATION INSTRUCTIONS
01 | REMOVING THE FACTORY INTERCOOLER
1. Disconnect the negative terminal on both batteries.
2. Remove the air intake box and intake tube. Be sure to disconnect
the mass airflow sensor.
3. Remove the nine pop clips that hold the upper fan shroud to the
grill and radiator support. Once the pop clips have been removed,
the upper shroud can be detached.
4. Remove the four 8mm bolts that secure the upper radiator stays
to the radiator support. Detach the radiator stays from the vehicle.
5. Remove the two 10mm bolts that secure the intercooler to
the upper radiator support.
6. Remove the three pop clips that secure the wiring harness to
the upper radiator support.
7. Remove the two 8mm bolts that secure the AC condenser brackets
to the upper radiator support.
8. Remove the pop clips that secure the air duct flaps to the side of
the radiator support.
9. Loosen the clamps on both the hot- and cold-side intercooler boots.
10. Remove the radiator support beam, which is secured in place
with eight 13mm bolts.
11. Remove the upper radiator support beam. Slide the beam to one
side and lift the opposite end upward to detach it from the lower
radiator support. The hood latch cable will still be attached to this
component, so place the beam carefully on top of the engine and out
of the way.
12. Pull the intercooler away from the radiator, separating the boots
from the cooler. Once this is complete lift the intercooler up and
remove it from the vehicle.
02 | Preparing THE MISHIMOTO INTERCOOLER
1. Transfer the upper mounting grommets from the factory
intercooler to the Mishimoto. First remove the metal bushing and
then pry the rubber grommet from the cooler. Installation on the
Mishimoto will be the reverse of removal.
2. Transfer the lower mounting grommets from the factory
intercooler to the Mishimoto intercooler.
03 | installing THE MISHIMOTO INTERCOOLER
1. Place the Mishimoto intercooler into position in the radiator support.
2. Reconnect the intercooler pipe couplers to the intercooler
and tighten the clamps.
3. Reinstall the upper radiator support beam.
4. Loosely install the eight 13mm bolts for the upper radiator
support beam until the beam is lined up in the factory location.
Make sure the bolt heads line up with the paint marks from the
factory installation. Once everything is lined up, fully tighten the
upper radiator support bolts.
5. Reinstall the two 10mm bolts that hold the intercooler to the
radiator support.
6. Reinstall the AC condenser brackets to the radiator support.
The brackets are secured with two 8mm bolts.
7. Reinstall the three pop clips securing the wire harness to the top
of the radiator support.
8. Reinstall both upper radiator stays, which are each secured by
two 8mm bolts.
9. Reinstall the pop clips that secure the rubber air duct gaskets to
the radiator support.
10. Reinstall the upper radiator shroud, which is secured with eight
pop clips.
11. Reconnect the mass airflow sensor
12. Reinstall the airbox and intake hose.
13. Start the vehicle and check for any leaks in the charge-air system.
14. You have now successfully installed the Mishimoto Ford 6.0L
Powerstroke Intercooler. Enjoy!

[@stradplayer90]

old boy just cares about going fast! Dude needs to do some serious house cleaning on that filter and those terminals.

[@JamesTyreeII]

How does the Mishimoto compare to the Bigg Dogg version?

[@johnhill3706]

I love Mishi Moto parts, they are top-of-the-line, well-built, cost a pretty penny, last forever, guaranteed forever