！Before installation, confirm that：
This high-performance component does not comply with the laws and regulations for highway driving and cannot be used on any vehicle that has been registered or certified for use on highways. This means that the component may only be suitable for racing cars or other off-road vehicles. If it is installed on vehicles driving on the highway, legal issues will be borne by oneself.
This is the installation process for the ER-0077: 2003-2007 5.9L & 2007.5-2018 6.7L Dodge Ram Cummins Diesel Engines Coolant Bypass Kit,provided for your reference during installation.
Step1:
Step 2:
Step 3:
Locate the large 58mm (2 ¼") freeze plug at the rear of the engine block.From underneath the truck, using a 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.(Note: Do not tap the center of the plug,be careful not to scratch the plug, as it is a sealing surface.)
Step 4:
After removing the freeze plug, thoroughly clean the surface area of the cylinder block from the cylinder head to the rear cover, as well as the holes where the freeze plug was previously installed, using sandpaper and degreasing solution. Ensure that all dirt and foreign objects are removed to fully position the coolant around the constant current device housing. If the inner hole where the freeze plug is located is not thoroughly cleaned, the O-ring on the coolant bypass housing will not seal properly.
Step 5:
Using a 1” wrench, screw the end of the coolant bypass hose with a straight connector onto the coolant bypass thermostat housing. Tighten the connector.
Step 6:
Use assembly grease or light oil,Thoroughly lubricate the seals O-ring on coolant bypass thermostat shell and press down Position on the backEngine cylinder.
Step 7:
Slide the thermostat housing between the firewall and the rear of the engine block. Align the thermostat housing with the original freeze plug hole position, and then press the housing onto the engine to position it. The coolant bypass hose should face the passenger side of the vehicleand be located above the exhaust manifold.
Step 8:
Ensure that the coolant bypass thermostat housing is securely installed on the back of the engine block and firmly secured in place using the provided M12 flange head bolts and 18mm sleeves.
Step 9:
1.Remove the engine oil dipstick.
2.Remove the 4 and 8mm bolts that secure the engine cover, and then remove the engine cover.
Step 10:
Disconnect the EGR temperature sensor connector and fixing clip. No need to remove the sensor from the cross pipe.
Step 11:
Loosen the two V-clamps using an 11mm socket. Remove the 10mm bolt from the center of the tube and disconnect the sensor plug. The EGR crossover pipe cannow be removed.
Step 12:
Remove the two 8mm bolts that secure the heat shield to the top of the cooler elbow. Remove the heat shield.
Step 13:
Fix the O-ring onto the radiator and re secure the radiator ventilation pipe with the screws provided in the kit.
Step 14:
1.Connect the coolant bypass hose at one end of the thermostat housing to the ventilation pipe.
2.Secure the coolant bypass hose with the buckle of the kit.
This high-performance component does not comply with the laws and regulations for highway driving and cannot be used on any vehicle that has been registered or certified for use on highways. This means that the component may only be suitable for racing cars or other off-road vehicles. If it is installed on vehicles driving on the highway, legal issues will be borne by oneself.
This is the installation process for the ER-0077: 2003-2007 5.9L & 2007.5-2018 6.7L Dodge Ram Cummins Diesel Engines Coolant Bypass Kit,provided for your reference during installation.
Step1:
Disconnect the vehicle batteries.
Step 2:
Remove the cover from the coolant tank.Find the engine coolant discharge port Under the driver's side of the radiator.Drain the coolant into a clean bucket.(Note: Raise the vehicle to enter in the following steps.)
Step 3:
Locate the large 58mm (2 ¼") freeze plug at the rear of the engine block.From underneath the truck, using a 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.(Note: Do not tap the center of the plug,be careful not to scratch the plug, as it is a sealing surface.)
After removing the freeze plug, thoroughly clean the surface area of the cylinder block from the cylinder head to the rear cover, as well as the holes where the freeze plug was previously installed, using sandpaper and degreasing solution. Ensure that all dirt and foreign objects are removed to fully position the coolant around the constant current device housing. If the inner hole where the freeze plug is located is not thoroughly cleaned, the O-ring on the coolant bypass housing will not seal properly.
Using a 1” wrench, screw the end of the coolant bypass hose with a straight connector onto the coolant bypass thermostat housing. Tighten the connector.
Step 6:
Use assembly grease or light oil,Thoroughly lubricate the seals O-ring on coolant bypass thermostat shell and press down Position on the backEngine cylinder.
Slide the thermostat housing between the firewall and the rear of the engine block. Align the thermostat housing with the original freeze plug hole position, and then press the housing onto the engine to position it. The coolant bypass hose should face the passenger side of the vehicleand be located above the exhaust manifold.
Ensure that the coolant bypass thermostat housing is securely installed on the back of the engine block and firmly secured in place using the provided M12 flange head bolts and 18mm sleeves.
1.Remove the engine oil dipstick.
2.Remove the 4 and 8mm bolts that secure the engine cover, and then remove the engine cover.
Disconnect the EGR temperature sensor connector and fixing clip. No need to remove the sensor from the cross pipe.
Loosen the two V-clamps using an 11mm socket. Remove the 10mm bolt from the center of the tube and disconnect the sensor plug. The EGR crossover pipe cannow be removed.
Remove the two 8mm bolts that secure the heat shield to the top of the cooler elbow. Remove the heat shield.
Fix the O-ring onto the radiator and re secure the radiator ventilation pipe with the screws provided in the kit.
1.Connect the coolant bypass hose at one end of the thermostat housing to the ventilation pipe.
2.Secure the coolant bypass hose with the buckle of the kit.
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