Billet Plenum Install Instructions for Ford Powerstroke

27. July, 2012

Ford Mod Installations

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

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Recommended Tools:

‐SAE and Metric Sockets and Wrenches
‐90o Die Grinder with cutoff wheel.
‐RPD HPOP Hose Quick Disconnect Tool

Recommended Parts:

‐Billet Plenums
‐Billet Plenum Hardware Kit
‐Turbo O‐Ring Kit (1) GZ‐9‐003
‐Fuel Line Sleeves: (2) GX‐7‐004, (1) GZ‐7‐005, (1) GZ‐7‐006

 

Installation Instructions:

1) Disconnect the negative cable from both batteries.

2) Remove the Powerstroke Engine Cover (If installed)

3) Remove the air cleaner intake tube from the valve cover bracket and the turbo assy. Remove the (2) bolts at the bracket and the clamps on the intake tube. Pull the intake/CCV adapter out of the CCV hose by pulling straight up. The crimped clamp will remain on the CCV hose.

4) Drain the fuel bowl by placing a 3/8” hose over the fuel drain tube. Open the fuel bowl drain and allow the fuel to drain.

5) Remove the (4) fuel lines from the fuel bowl. Remove the (2) ¼” lines on the passenger side with a 9/16” wrench. The return line and feed line are on the drivers side. The return line is removed with a 5/8” wrench and the feed line is removed with a ¾” wrench. Slide the fuel drain tube hose adapter off the drain valve. (Fig 1 & 2)

6) Remove the heater connector off of the rear of the fuel bowl.

7) Remove the (2) bolts for the fuel bowl located on the forward side of the HPOP Reservoir. (Fig 3) If you have an FRx installed, disconnect the hoses from the heads.

8) Remove the fuel bowl from the engine.

9) Remove the turbo from the engine using ’99‐’03 7.3L Turbo Removal and Reinstall Instructions.

10) Remove the turbo pedestal by removing the EBP Solenoid Connector (if installed), then remove the (4) bolts using a 10mm socket. Lift the pedestal out of the valley and set aside.

 

11) Disconnect the two HPOP hoses from the head connections using the RDP HPOP Hose Quick Disconnect Tool. (Not required but gives more room to work with)

12) Remove the (3) nuts common to the GPR/AIH bracket (if installed). Remove bracket assy off of the studs and tie back away from the plenum. (Fig 8)

13) Remove the nut from the passenger side fuel line clamp.

14) Remove the nut for the AIH ground wire from the drivers side plenum. Remove the wire and place to the side.

15) Remove the plenum (10) bolts/studs from each plenum. Note: The passenger side plenum forward lower bolt cannot be fully removed. The plenum is slotted for this fastener and can be slid aft to remove without removing the bolt fully.

16) The plenums are sealed in place with RTV. Use a thin scraper or putty knife to break the bond between the plenum and head.

17) Remove both plenums and use rags in the heads to keep debris from entering the intake tract.

18) Clean the remaining RTV off of the heads using a non‐metallic scraper or Scotch‐Brite ® and solvent. This will prepare the surface for the O‐ring seals on the billet plenums. (Fig 4)

19) On the passenger head forward lower bolt, turn it out until it contacts the front cover. This will hold it in place during the cut. (Fig 5)

20) Using a 90o die grinder with a cut‐off wheel, carefully cut the head of the bolt off. You can use a hacksaw blade if you desire, it just takes longer. Once the head has been removed, you will be able to remove the threaded portion of the bolt. (This bolt location is not utilized on the billet plenums). (Fig 6)

21) Clean the head to plenum surface and remove the protective rags. Install the plenums on each head using the 8 mm x 1.25 hardware. Use the 30mm long bolts in the thick portion and the 25mm long bolts in the reduced area. (Fig 7) If you have a GPR/AIH Relay bracket, insert (3) 50mm studs at the location shown (Fig 8). If you utilize the fuel line clamp on the passenger head, insert a stud in that location. On the drivers side, insert a stud in the forward lower location for the AIH ground wire.

22) Torque the bolts to 89 In‐Lb.

23) At the stud locations, install the supplied countersink spacers.

24) Install the GPR/AIH Relay bracket, fuel line clamp, and AIH ground wire using the OEM nuts removed previously. Tighten to 89 In‐Lb.

 

25) Reconnect the HPOP hoses to the heads making sure they engage firmly into the fittings and cannot be pulled free. (Fig 9)

26) Using new O‐rings, install the turbo pedestal. Torque the (4) bolts to 18 ft‐lb. (Fig 10)

27) Remove the plenum boots off of the old plenums and install onto the billet plenums. Tighten the lower clamps to 60 In‐Lb. (Fig 11)

28) Reinstall the turbo onto the pedestal using ’99‐’03 7.3L Turbo Removal and Reinstall Instructions.

29) Reinstall the fuel bowl by loosely installing the (2) bolts through the HPOP Reservoir. Once the threads engage into the fuel bowl start each of the four lines (using Fuel Line Sleeves: (2) GX‐7‐004, (1) GZ‐7‐005, (1) GZ‐7‐006) making sure they are started straight and have a few threads engaged. Fully tighten the fuel bowl bolts to 23 Ft‐Lb.

30) Tighten the fuel lines to the fittings. Make sure the tube nut contacts the fitting and there is no gap. (Fig 12)

31) Connect the fuel bowl heater/water in fuel connector to the fuel bowl.

32) Reinstall the air cleaner intake tube from the valve cover bracket and the turbo assy. Install the (2) bolts at the bracket and the clamps on the intake tube. Insert the intake/CCV adapter into the CCV hose by pushing straight down.

33) Reconnect the ground cables to the batteries.
34) Cycle the key 3‐4 times for 20‐30 seconds each cycle. This will recharge the fuel bowl. Inspect the fuel bowl for leaks as you do this.

35) Start the truck and look for leaks. If you disconnected the HPOP hoses, you may experience a slow to start or rough idle. This will clear out after driving roughly 50 miles.

 

Special thanks to Ken (Woodnthings on FTE) for pictures and instructions.

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Riffraff Diesel disclaims any responsibility/ liability for improper, incorrect, or inexperienced installation of products by the consumer or paid installer resulting in damage or loss. Buyer affirms by purchase of this product that it is fit for intended use and accepts all liability.

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