Coolant Bypass Kit Installation Instructions
2007.5-2018 Dodge Ram 6.7L Cummins Diesel
Spelab Racing
YouTube - SPELAB
service@spelabautoparts.com
https://www.spelabautoparts.com/
Procedure
STEP 1: Disconnect the vehicle batteries.
STEP 2: Drain the coolant.
Remove the cap from the coolant tank. Locate the engine coolant drain, located under the driver's side of the radiator. Drain the coolant into a clean bucket.
NOTE: RAISE THE VEHICLE UP TO ALLOW FOR ACCESS IN FOLLOWING STEP
STEP 3: Remove the rear freeze plug.
Locate the large 58mm (2 ¼") freeze plug at the rear of the engine block. From underneath the truck, using a 36" pry bar and hammer, drive the outer edge of the freeze plug in to rotate it in its bore. Remove the freeze plug from the block.
IMPORTANT: DO NOT HIT THE PLUG IN THE CENTER AND USE CAUTION TO NOT KNICK THE BLOCK AS THIS IS A SEALING SURFACE.
STEP 4: Clean the block surface area.
With the freeze plug removed, use a Scotch-Brite™ pad and a degreasing solution to thoroughly clean the block surface area from the head down to the rear cover, as well as the bore where the freeze plug was previously installed. Be sure to remove all dirt and foreign debris to allow the coolant bypass thermostat housing to fully seat. If the inner bore where the freeze plug was seated is not thoroughly clean, the O-ring on the coolant bypass housing will not properly seal.
STEP 5: Install the coolant bypass hose end.
Using a 1" wrench, thread the coolant bypass hose end with the straight fitting onto the coolant bypass thermostat housing. Tighten the fitting.
STEP 6: Lubricate the sealing O-ring.
With assembly grease or light oil, thoroughly lubricate the sealing O-ring on the coolant bypass thermostat housing and press it into place on the back of the engine block.
STEP 7: Seat the thermostat housing.
Slide the thermostat housing between the firewall and the back of the engine block. Align the thermostat housing with the original freeze plug hole location and press the housing against the engine to seat the housing. The coolant bypass hose should be oriented towards the passenger side of the vehicle.
STEP 8: Secure the thermostat housing.
Ensure that the coolant bypass thermostat housing is firmly seated onto the back of the engine block and fasten it securely into place using the supplied M12 flange head bolts using an 18mm socket.
STEP 9: Remove the engine oil dipstick.
STEP 10: Remove the engine shroud.
Remove the 4, 8 mm bolts that retain the engine shroud and remove the engine shroud.
STEP 11: Disconnect the EGR temperature sensor connector.
Disconnect the EGR temperature sensor connector and retaining clip. There is no need to remove the sensor from the cross over tube.
STEP 12: Remove the EGR cross over tube.
Remove the two V-band clamps at either end of the cross over tube using an 11 mm socket.
STEP 13: Remove the retaining bolt.
Remove the 8 mm bolt that retains the cross over tube at the front of the engine.
STEP 14: Remove the cross over tube and gaskets.
Remove the cross over tube and EGR cross over tube gaskets from each end of the tube. Discard the gaskets, new gaskets are provided in the kit.
STEP 15: Remove the heat shield.
Remove the two, 8mm bolts that retain the heat shield to the top of the cooler elbow. Remove the heat shield.
STEP 16: Loosen the coolant hose clamp.
Using a pair of channel locks, loosen the clamp that retains the coolant hose to the coolant elbow. Slide it down the coolant hose to allow for removal of the hose from elbow.
STEP 17: Remove the cooler elbow.
Remove the three, 8mm bolts that retain the cooler elbow to the cylinder head. Remove the cooler elbow. The three bolts will be reused for installation of the SPELAB coolant bypass elbow.
For MY2007.5-2012 trucks, disconnect the exhaust back pressure sensor and remove it from the original coolant elbow, it will be reinstalled into the new sensor mounting block provided in the kit.
STEP 18: Remove and inspect the thermostat.
Remove the thermostat. Inspect it for wear and proper function. With a Scotch-Brite™ pad and degreasing solution, thoroughly clean the sealing surface of the stock thermostat and thermostat housing. Be sure to remove any foreign debris and reinstall the OE thermostat.
STEP 19: Install the new coolant bypass elbow.
Install the new SPELAB coolant bypass elbow into the same location as the factory coolant elbow. Install the three new M6 bolts included in the kit that retain the coolant elbow to the cylinder head. Reinstall the coolant hose and clamp.
STEP 20: Install the coolant bypass hose.
Install the coolant bypass hose to the coolant bypass elbow.
STEP 21: Reinstall the heat shield.
Reinstall the heat shield over the coolant bypass elbow.
STEP 22: Secure the coolant bypass hose.
Use the double hose clamps provided in the kit to secure the coolant bypass hose to the coolant riser line.
STEP 23: Reinstall the EGR cross over tube.
Reinstall the EGR cross over tube. Ensure the new gaskets included with the kit are utilized. Install the V-band clamps and the bolt that retains the cross over tube to the front of the engine.
For Model Year 2007.5 – 2012 Trucks Only
The SPELAB coolant bypass kit for 2007.5–2012 Dodge Ram 6.7L Cummins includes a new exhaust back pressure sensor mounting block, adapter fitting, and exhaust back pressure line. Install the components as outlined in steps 24-27.
STEP 24: Install the back pressure sensor into the new mounting block.
Remove the exhaust backpressure sensor originally mounted on the factory coolant elbow. Install the back pressure sensor into the new mounting block included in the kit.
STEP 25: Install the new back pressure sensor mounting block.
Remove the upper pivot bolt for the alternator and install the new back pressure sensor mounting block directly against the alternator with the back pressure sensor pointed vertically upwards. Reinstall the original bolt and torque to factory specifications.
STEP 26: Install the adapter fitting.
Install the adapter fitting onto the back side of the sensor block. The O-ring on the adapter fitting will go into the adapter block and the flare side of the fitting will be connected to the back pressure sensor line provided in the kit.
STEP 27: Connect the back pressure sensor line.
Install and connect the back pressure sensor line at both the exhaust manifold and at the sensor block. Reconnect the exhaust back pressure sensor to the chassis harness.
Final Reassembly and Leak Check
STEP 28: Refill the coolant system.
Plug in the EGR temp sensor and install the upper engine shroud. Insert the dipstick. Ensure that the coolant drain plug has been reinstalled in the radiator and proceed to re-fill the coolant system. Re-use or replace coolant as necessary to properly fill the system with clean fluid.
STEP 29: Re-connect the vehicle batteries.
STEP 30: Start the truck and check for leaks.
Start the truck and allow the engine to idle. Inspect all fittings and split-lines for possible leaks. If no leaks are observed, bring the engine to a normal operating temperature and confirm that no leak is present. Repair any observed leaks.