Ford Trucks 6.0L 2003-2007 Sub Zero Intercooler PDF Installation Instruction Manual v1.1

Prior to installation, visually inspect the ATS Sub Zero Intercooler for cracks, holes or damage. All intercoolers are carefully pressure tested, inspected and packaged but damage can occur during shipping. If intercooler arrives damaged, please contact ATS customer service. Visually inspect the interior of the inlet and outlet tanks for debris. ATS Sub Zero Intercoolers are packaged to prevent anything from entering the tanks during shipping but ATS suggests double checking prior to installation.

If debris of any kind is present, position the intercooler so the inlet and outlet tubes are vertical. Shake the intercooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Rinse thoroughly with clean water.

1. Park vehicle on level ground. Set parking brake.
2. Disconnect the negative (-) battery cables and secure them away from the negative battery terminals.
3. Remove the air deflectors on each side of the A/C Condenser.
4. Remove the upper A/C condenser support brackets.
5. Remove the hood latch. NOTE: It is helpful to mark the outlined location of the latch with a pen or marker to ensure proper latch alignment when reassembled.
6. Remove the battery cable retainers to be able to move the battery cable back and out of the way.
7. Remove the intercooler support bolts and bushings. Set them aside as they will be reused later.
8. Remove the upper radiator support. The support is held in by eight bolts, four on the back and four on the front. Remove the support by shifting it to one side inside the uprights and pull the opposite side up and out (a prybar can be helpful in this process).
9. Remove the factory plastic driver side charge tube and replace it with the steel charge tube supplied in the kit. Use the 3.5” long black boot
supplied with the kit to connect the charge tube to the intake manifold. Reuse the factory clamp in this location and the one 3.25” clamp provided.
10. Remove the stock intercooler boot clamps using a deep 11mm socket.
11. Discard the factory intercooler boots and clamps.
12. Pull the A/C condenser back slightly and swing it up and over the engine being careful not to bend the A/C lines. Be very careful when
performing this step. Do NOT disconnect the lines from the condenser.
13. Remove the factory intercooler. Be sure not to damage the radiator when lifting the intercooler upwards.
14. With the factory intercooler out of the truck, remove the rubber grommets from the factory intercooler lower mounts and install them into the Sub Zero intercooler.
15. Remove the grommets from the factory intercooler top mounting brackets and install them into the Sub Zero intercooler top mounting brackets.
16. To install the ATS Sub Zero Intercooler, follow the removal procedure in reverse order noting the torque specs shown.
17. Connect the charge tubes to the intercooler using the 3 to 3.5” reducer boots provided in the kit. The reducer boots provided have an internal rib that will seat into the factory passenger side charge tube. Make sure the clamp is centered over the internal rib connection.