Kit contents [oilcooler01.jpg]

Loosely assembled: Cooler assembly

90’ Adapter

Engine Block-to-Banjo Bolt Fitting

Banjo Bolt

Cooler-90’ Fitting

90-to-block O-ring (look in oil filter box)
Banjo-to-90 O-ring (look in oil filter box)
Motorcraft 820S Oil Filter
Motorcraft KM3051 hose
Motorcraft KM3065 hose
(3) Hose clamps

Tools & Supplies needed

12mm hex wrench
1-1/4” and 3/4” sockets and wrench
Pliers
Screwdriver or hex driver for hose clamps
Paint pen or grease pencil
SHARP (new) razor blade or utility knife
Coolant
Oil

Before you Start

Disassemble the cooler/adapter/fittings.
Check over the kit contents, and make sure you have everything and it is all in good condition.
You may wish to port the 90’ elbow oil ports. I simply radiused the openings on both ends, to allow smoother transition for oil flow. [oilcooler04.jpg]
These coolers were take-offs from new Explorer engines. I have degreased and flushed them, but it is your responsibility to make sure they are completely clean before installation. I highly recommend that the coolant portion be thoroughly flushed with water, and the oil portions (especially the cooler) be thoroughly cleaned with brake cleaner before installation.

Installation

1. Make sure engine is cool and the radiator is not under pressure and remove the radiator cap. Put a catch pan (a mortar tub works well) under the car and drain the radiator. Move the catch pan under the lower radiator hose and remove.

2. Remove the oil filter.

3. Remove the filter-to-block adapter. [oilcooler06.jpg] Some cars may have an internal or external hex for removal, but most do not. Chances are you will have to use pliers directly on the threads to get it off. I had to remove the oil “log” to get at the fitting correctly. BIG channel locks do the job. [oilcooler07.jpg]

4. Install the Block-to-Banjo fitting, torque to 20-30 ft-lb.

5. Lightly oil the 90-to-block o-ring (large) and install it in the groove in the 90 adapter.

6. Lightly oil the Banjo-to-90 o-ring (small) and install it in the groove in the 90 adapter

7. Hold the 90 adapter against the block with the alignment tab at 6 O’clock (below the oil pan rail). Install the banjo bolt finger tight.

8. Lightly oil the Cooler-90 adapter O-ring (captured in the cooler); hold the cooler up against the adapter with the outlet pointing towards the water pump; install the cooler-90 fitting finger tight.

9. The next step is to properly “clock” the 90 adapter to the block and the cooler to the 90 adapter. It is important to get these parts aligned properly so that the hoses are not kinked when they are assembled. The radiator-cooler hose (KM3065) is used without modification. {My install photos are for a Griffin radiator, so I did not use the KM3065 hose at all}. First install this hose without clamps. Then rotate the cooler and adapter to match the orientation in the pictures. Notice the difference between the 12:00-position [oilcooler10.jpg] and the 10:00-position [oilcooler11.jpg] final setting. Fine tune the orientation so that the lower hose is not excessively “puckered” or “ovaled” where it attaches to the cooler, and the cooler outlet and water pump inlet are in the same plane—this means that a line extended straight out from each port will intersect. Once everything is aligned properly, mark the orientation with a paint pen or grease pencil by marking a line where the cooler and 90 adapter meet, and where the adapter and block meet.

10. With the cooler and adapter properly clocked, measure the length of each leg of the cooler-to-pump hose. Both the cooler and pump have stops for the hose; make sure you measure all the way to the stops.

11. Cut the cooler-to-pump hose out of the angle of the KM3051 hose. The final length is approximately 4” long [oilcooler09.jpg] To cut the hose, use a hose clamp as a guide. Slide the hose clamp onto the hose where you wish to make the cut and tighten until it barely holds the hose; use the edge of the clamp as a guide to make a score mark all the way around; then carefully cut all the way around. You may want to initially make each leg 1-2” longer than needed, then hold it up to the cooler and pump for final marking.

12. Loosen the adapter and/or cooler and rotate them out of the way so the cooler-to-pump hose can be installed. Slip the hose and two clamps on to the cooler and pump, and rotate back into position. [oilcooler10.jpg] and [oilcooler11.jpg]

13. Remove the radiator-to-cooler hose and install a screw clamp on the cooler side and the original “spring” clamp on the radiator side.

14. Realign the cooler and 90 adapter using your marks; tighten the banjo bolt and the cooler-to-90 fitting 20-30 ft-lb.

15. Tighten all hose clamps.

16. Install 820S Oil filter

17. Refill radiator

18. Start engine and check for leaks

19. Top off coolant and oil as needed.

20. See ya at the track! J