Support Center

Before you start

Tune-file delivery: Monday–Friday, 9 AM–5 PM Central.

Link your truck during these hours if you still need files. Flashing after hours? Make sure the correct files are already downloaded on the phone you will use.

Linking your truck does not mean the files are ready immediately. Wait until the correct file is available before you start the installation.

Make sure you know when to install the parts and when to flash the truck. Follow the instructions in your Ironline order. Contact us first if anything is unclear.

1. Connect to your truck

• Install the Auto Agent app and sign in. Finish account setup and any device updates before flashing.
• With the engine off, turn the ignition to RUN and plug the AutoAgent into the truck's diagnostic port.
• Open your phone's Wi-Fi settings and join the network that starts with EZLYNK_. Open the app and check that it shows your truck.

A “No Internet” message on this Wi-Fi is normal. It connects your phone to the truck. Use mobile data or regular internet Wi-Fi when linking and downloading files.

2. Link your truck

In the app, open Vehicle → Your truck → Technicians.

• If the correct technician from your order is already listed, move to the next step.
• Otherwise, tap Lynk and enter the technician email in your Ironline order instructions. Follow the prompts and include your truck's current modifications.
• If you do not have the email or are unsure which technician to use, contact Ironline before continuing.

3. Download your tune

Open Vehicle → Your truck → ECU Profiles.

• Connect your phone to the internet. Choose the file that matches your truck and the instructions from Ironline.
• Tap the cloud or download button. Wait until the download finishes and Install is available.
• If the file list is empty or the file name is unclear, contact us before flashing.

If you are waiting for files, turn the ignition off to avoid draining the batteries. Only do this when no update or flash is running.

4. Get ready to flash

• Park securely and leave the engine off. Make sure the truck's batteries are charged, then connect battery support that is suitable for vehicle programming.
• Reconnect your phone to the EZLYNK_ Wi-Fi network. Open the app and turn the ignition to RUN.
• Open ECU Profiles and check the file name one more time.

5. Install the tune

Tap Install and follow the app's instructions.

Keep the app open and everything connected. Do not unplug the AutoAgent, start the engine or turn the ignition off unless the app tells you to.

Stay in the truck until the process finishes so you can follow each prompt. Do not switch to another app while the tune is loading.

Finish every ignition prompt and wait for the app to confirm that installation was successful. Complete any required hardware work before starting the engine.

Changing to another tune file

Download the other approved file, then repeat steps 4 and 5. Changing files uses the same flashing process.

A switch-on-the-fly dial works differently: it changes between levels already included in your installed SOTF tune. Turning the dial does not install another file.

If a flash fails

Keep power connected. Write down the exact error or take a screenshot. Follow the app's recovery instructions and contact Ironline before trying anything else.

Trouble connecting before you start?

• No EZLYNK_ Wi-Fi network? Check the AutoAgent lights. Green means it has power; blue means it is broadcasting Wi-Fi. Contact Ironline if the network still does not appear.
• App cannot see the truck? Check that the ignition is in RUN with the engine off and your phone is connected to EZLYNK_ Wi-Fi.
• No tune files? Check the Technicians screen to confirm the link, then contact Ironline with your order number.

These checks are for setup. If a flash or device update is already running, follow its on-screen instructions and keep everything connected.

Before you start

Your truck needs a tune that supports this switch. A switch will not add power levels to a single-level tune.

2011–2014 and 2015–2016 use different plugs. Make sure the switch plug matches your truck.

Before assembling a loose plug: these steps use a separate rubber seal on each wire. If yours has one shared seal, get the matching assembly instructions first. A five-position plug also needs three sealing plugs for the unused openings; contact Ironline if those are missing.

Check your kit: these steps cover a rotary switch with two wires and one supplied plug. If yours has extra wires, two plugs or different hardware, contact Ironline before connecting it.

If the plug is already assembled, leave its terminals in place and follow the connection checks.

Tune-file delivery: Monday–Friday, 9 AM–5 PM Central. Link during these hours if you still need files. For an after-hours flash, download the correct files beforehand.

1. Choose a place for the dial

Park securely, turn the ignition off and let the engine cool.

Choose a spot you can reach easily. Check behind the panel before drilling. Keep the dial and wires clear of the pedals, steering parts and airbags.

Use the mounting template that came with your switch. Keep the small stop washer in place so the dial has five positions.

2. Run the wires

Use a protected opening through the firewall. Protect the wires with the supplied covering and secure them away from hot parts, sharp edges and anything that moves.

Keep the rubber seal around the opening in place, and reseal around the wire if needed to keep water out.

Leave enough slack so the wires are not pulled tight. Check that they cannot catch a pedal or steering part.

3. Find the plug and fit the wires

This switch uses the truck's fuel-temperature connection.

Find the fuel-temperature electrical connector near the upper fuel filter on the driver's side of the engine. With the ignition off, release its lock and unplug it by holding the housing. Do not remove the sensor or disconnect a fuel line.

2011–2014: two-position plug. Insert one switch terminal into each opening at the wire-entry end. Either wire can go in either opening.

2015–2016: five-position plug. Only two positions are used. Follow the circuit-matching steps below.

For the five-position plug: find the green wire and the green wire with a white stripe on the truck's side. Line up the two plug housings as they will connect. Fit the two switch terminals into the positions that will meet those two factory wires. Either switch wire can meet either of those circuits. Close the other three openings with the supplied sealing plugs.

If the factory wires are a different color, have been repaired or cannot be identified, contact Ironline before inserting terminals. The front and back views are reversed; do not guess left and right.

Insert each terminal from the wire-entry end until it locks. Seat its individual rubber seal fully, then lightly pull the wire to check that it stays in place. Do not force it.

Check both plugs for dirt, damage or bent contacts. Connect the assembled switch to the truck's harness that you unplugged. Check that the housing lock engages.

The switch supplies the temperature signal used by your SOTF tune. The sensor's electrical socket stays disconnected; protect it from moisture and dirt with a suitable connector cover.

4. Fit the knob

Install the mounting hardware and numbered label. Loosen the knob's small set screw, slide the knob onto the shaft and line up the pointer with the label. Tighten the set screw gently.

Check that the knob has five positions, with four clicks between its ends. The wiring must stay in place. If the dial turns farther, follow the supplied stop-washer instructions before use.

5. Load the tune and check the switch

Use the EZ Lynk guide to install your approved SOTF tune. Follow the power-level list and driving instructions sent with your files. The numbers on the dial do not have the same horsepower meaning on every tune.

After all installation work is complete, make the first switch check with the truck parked and idling. Select one level at a time. Do not turn the dial while accelerating or pulling hard.

If you cannot tell whether the switch is working, contact Ironline. We can tell you which reading to check in the app for your tune.

Send your truck year, tune file name and a clear photo of the connection. Include any warning or fault message.

Switching levels or changing files

The dial selects a level inside your current SOTF tune. To load a different tune file, use the EZ Lynk flashing steps again.

Before you start

Your truck needs a tune that supports this switch. A switch will not add power levels to a single-level tune.

Before assembling a loose plug: these steps use a separate rubber seal on each wire. If yours has one shared seal, get the matching assembly instructions first. A five-position plug also needs three sealing plugs for the unused openings; contact Ironline if those are missing.

Check your kit: these steps cover a rotary switch with two wires and one supplied plug. If yours has extra wires, two plugs or different hardware, contact Ironline before connecting it.

If the plug is already assembled, leave its terminals in place and follow the connection checks.

Tune-file delivery: Monday–Friday, 9 AM–5 PM Central. Link during these hours if you still need files. For an after-hours flash, download the correct files beforehand.

1. Choose a place for the dial

Park securely, turn the ignition off and let the engine cool.

Choose a spot you can reach easily. Check behind the panel before drilling. Keep the dial and wires clear of the pedals, steering parts and airbags.

Use the mounting template that came with your switch. Keep the small stop washer in place so the dial has five positions.

2. Run the wires

Use a protected opening through the firewall. Protect the wires with the supplied covering and secure them away from hot parts, sharp edges and anything that moves.

Keep the rubber seal around the opening in place, and reseal around the wire if needed to keep water out.

Leave enough slack so the wires are not pulled tight. Check that they cannot catch a pedal or steering part.

3. Find the plug and fit the wires

This switch uses the truck's fuel-temperature connection.

Find the fuel-temperature electrical connector near the upper fuel filter on the driver's side of the engine. With the ignition off, release its lock and unplug it by holding the housing. Do not remove the sensor or disconnect a fuel line.

2017–2019: five-position plug. Only two positions are used.

For the five-position plug: find the green wire and the green wire with a white stripe on the truck's side. Line up the two plug housings as they will connect. Fit the two switch terminals into the positions that will meet those two factory wires. Either switch wire can meet either of those circuits. Close the other three openings with the supplied sealing plugs.

If the factory wires are a different color, have been repaired or cannot be identified, contact Ironline before inserting terminals. The front and back views are reversed; do not guess left and right.

Insert each terminal from the wire-entry end until it locks. Seat its individual rubber seal fully, then lightly pull the wire to check that it stays in place. Do not force it.

Check both plugs for dirt, damage or bent contacts. Connect the assembled switch to the truck's harness that you unplugged. Check that the housing lock engages.

The switch supplies the temperature signal used by your SOTF tune. The sensor's electrical socket stays disconnected; protect it from moisture and dirt with a suitable connector cover.

4. Fit the knob

Install the mounting hardware and numbered label. Loosen the knob's small set screw, slide the knob onto the shaft and line up the pointer with the label. Tighten the set screw gently.

Check that the knob has five positions, with four clicks between its ends. The wiring must stay in place. If the dial turns farther, follow the supplied stop-washer instructions before use.

5. Load the tune and check the switch

Use the EZ Lynk guide to install your approved SOTF tune. Follow the power-level list and driving instructions sent with your files. The numbers on the dial do not have the same horsepower meaning on every tune.

After all installation work is complete, make the first switch check with the truck parked and idling. Select one level at a time. Do not turn the dial while accelerating or pulling hard.

If you cannot tell whether the switch is working, contact Ironline. We can tell you which reading to check in the app for your tune.

Send your truck year, tune file name and a clear photo of the connection. Include any warning or fault message.

Switching levels or changing files

The dial selects a level inside your current SOTF tune. To load a different tune file, use the EZ Lynk flashing steps again.

Before you start

Your truck needs a tune that supports this switch. A switch will not add power levels to a single-level tune.

2023 and newer: Contact Ironline to confirm the switch plug and tune for your truck before connecting it.

Check your kit: these steps cover a rotary switch with two wires and one supplied plug. If yours has extra wires, two plugs or different hardware, contact Ironline before connecting it.

If the plug is already assembled, leave its terminals in place and follow the connection checks.

Tune-file delivery: Monday–Friday, 9 AM–5 PM Central. Link during these hours if you still need files. For an after-hours flash, download the correct files beforehand.

1. Choose a place for the dial

Park securely, turn the ignition off and let the engine cool.

Choose a spot you can reach easily. Check behind the panel before drilling. Keep the dial and wires clear of the pedals, steering parts and airbags.

Use the mounting template that came with your switch. Keep the small stop washer in place so the dial has five positions.

2. Run the wires

Use a protected opening through the firewall. Protect the wires with the supplied covering and secure them away from hot parts, sharp edges and anything that moves.

Keep the rubber seal around the opening in place, and reseal around the wire if needed to keep water out.

Leave enough slack so the wires are not pulled tight. Check that they cannot catch a pedal or steering part.

3. Find the plug and fit the wires

This switch uses the truck's charge-air cooler (CAC) temperature connection.

Find the two-wire temperature sensor on the cold-side charge-air pipe—the pipe carrying cooled air toward the engine. Release its electrical plug by the locking tab. The sensor stays in the pipe.

Use the two-position plug supplied with the switch. Insert one terminal into each opening at the wire-entry end. Either switch wire can go in either opening.

Push each terminal in until it locks and its rubber seal is seated. A light pull on the wire should not release the terminal. Do not force a terminal that will not seat.

Connect the assembled switch plug to the truck's electrical harness you just disconnected. Leave the sensor's socket disconnected and protect it from dirt and moisture with a suitable connector cover.

If you find more than two positions, a different plug shape or a connection that will not fit, stop and send Ironline a photo.

4. Fit the knob

Install the mounting hardware and numbered label. Loosen the knob's small set screw, slide the knob onto the shaft and line up the pointer with the label. Tighten the set screw gently.

Check that the knob has five positions, with four clicks between its ends. The wiring must stay in place. If the dial turns farther, follow the supplied stop-washer instructions before use.

5. Load the tune and check the switch

Use the EZ Lynk guide to install your approved SOTF tune. Follow the power-level list and driving instructions sent with your files. The numbers on the dial do not have the same horsepower meaning on every tune.

After all installation work is complete, make the first switch check with the truck parked and idling. Select one level at a time. Do not turn the dial while accelerating or pulling hard.

If you cannot tell whether the switch is working, contact Ironline. We can tell you which reading to check in the app for your tune.

Send your truck year, tune file name and a clear photo of the connection. Include any warning or fault message.

Switching levels or changing files

The dial selects a level inside your current SOTF tune. To load a different tune file, use the EZ Lynk flashing steps again.

This guide covers replacing the center exhaust section while keeping the rear exhaust on the truck.

These are general assembly steps. Before removing the old exhaust, get the fitting instructions for your truck, including how to handle any attached sensors or lines, any cutting measurements and the tightening values. Contact Ironline if those instructions were not included.

Before you start

Have your tune files ready. We deliver tune files Monday–Friday, 9 AM–5 PM Central. Link your truck during these hours if you still need files. Working after hours? Download the correct files first. Make sure you know when to flash the truck and when to install the hardware before you begin.

Check the truck and kit. Make sure your order matches your truck year, cab and bed length. Compare both ends of the new pipe with the exhaust connections on your truck. For 2023 and newer trucks, contact Ironline to confirm the downpipe connection before removing anything.

Let the exhaust cool completely. Park on level ground and secure the truck. If you raise it, use a suitable lift or properly rated stands. Never work under a truck supported only by a jack. Wear gloves and eye protection.

1. Lay out the new pipe

Place the pieces in order from the front of the truck to the rear. Identify the clamps, end connections and hanger. Check for missing or damaged pieces before taking the old exhaust apart.

Take photos of the old exhaust, its hangers and any attached wires or lines. If you are unsure how to handle a sensor or line, contact Ironline before disconnecting it.

2. Remove the center section

Support the exhaust before loosening its connections or removing its hangers. Keep the rear exhaust supported while you remove the center section. Do not let the weight of the exhaust pull on wires or lines.

Release electrical plugs by their locking tabs, never by pulling the wires. Secure loose wiring clear of the exhaust, driveshaft and suspension.

3. Install the new pipe loosely

Fit the front section first. Place the middle clamp on the pipe before joining the pieces. Fit the rear section, seat its hanger in the rubber mount and connect it to the rear exhaust you are keeping.

Install the clamp and end hardware, but leave everything loose enough to move by hand.

4. Line everything up

Adjust the pipe so the connections sit straight and the hanger is not pulled to one side. Make sure the pipe clears the body, frame, suspension, wiring and hoses.

Do not force a connection or cut a pipe to make the wrong kit fit. If a section needs trimming, contact Ironline first to confirm which section to cut and how far the joined pipes must overlap.

5. Tighten and check

Tighten the connections from front to rear, checking the pipe position as you go. Use the tightening values for the clamps and bolts in your kit. Contact Ironline if those values were not included.

Before starting the engine, make sure all hangers and connections are secure and the required tune is installed. Check for leaks and rattles. If something leaks or touches the truck, shut the engine off and let the exhaust cool before adjusting it. Fix the problem before driving.

Need help? Send Ironline your order number, truck year, cab and bed length, and a clear photo of the connection you need help with.

This guide covers installing the exhaust from the downpipe connection to the tailpipe.

These are general assembly steps. Before removing the old exhaust, get the fitting instructions for your truck, including how to handle any attached sensors or lines, any cutting measurements and the tightening values. Contact Ironline if those instructions were not included.

Before you start

Have your tune files ready. We deliver tune files Monday–Friday, 9 AM–5 PM Central. Link your truck during these hours if you still need files. Working after hours? Download the correct files first. Make sure you know when to flash the truck and when to install the hardware before you begin.

Check the truck and kit. Make sure your order matches your truck year, cab and bed length. Check the front connection before removing the old exhaust. For 2023 and newer trucks, contact Ironline to confirm the downpipe needed for your setup.

Let the exhaust cool completely. Park on level ground and secure the truck. If you raise it, use a suitable lift or properly rated stands. Never work under a truck supported only by a jack. Wear gloves and eye protection.

1. Lay out the new exhaust

Arrange the pieces from front to rear: front pipe, straight sections, pipe over the rear axle and tailpipe. Identify the clamps and hangers. Check for missing or damaged pieces before removing the old system.

Take photos of the old exhaust and any attached wires or lines. If you are unsure how to handle a sensor or line, contact Ironline before disconnecting it.

2. Remove the old exhaust

Support each section before loosening its connections or removing its hangers. Do not let the exhaust pull on wires or lines.

Release electrical plugs by their locking tabs, never by pulling the wires. Secure loose wiring clear of the exhaust, driveshaft and suspension.

Check how the pipe over the rear axle will come out before you begin. Do not change the truck's supports while working underneath it.

3. Hang the new sections loosely

Place each clamp on the pipe before joining the pieces. Start the front pipe at the downpipe connection. Then position the pipe over the rear axle and the tailpipe. Put their hangers into the rubber mounts.

Add the straight sections between the front and rear pieces. Install the clamps, but leave them loose enough to adjust the pipe positions.

4. Check the length and clearances

Set the tailpipe where it belongs, then check that every section lines up. Keep the exhaust clear of the body, frame, suspension, spare tire, hitch, wiring and hoses. The hangers should sit without being stretched or pulled sideways.

Cut lengths vary by truck. Before trimming a pipe, contact Ironline to confirm which section can be shortened and how far the joined pipes must overlap. Test the full system in place before marking a cut.

Allow for the pipe that slides inside each joint. Measuring only the open gap can leave a section too short.

5. Tighten and check

Tighten the connections from front to rear, checking the pipe position as you go. Use the tightening values for the clamps and bolts in your kit. Contact Ironline if those values were not included.

Before starting the engine, make sure all hangers and connections are secure and the required tune is installed. Check for leaks and rattles. If something leaks or touches the truck, shut the engine off and let the exhaust cool before adjusting it. Fix the problem before driving.

Need help? Send Ironline your order number, truck year, cab and bed length, and a clear photo of the area you need help with.

Check your kit first

These steps cover a long solid coolant cover, a small intake cover with an O-ring, an exhaust cover and a bracket that supports the pressure line. Your kit must match this layout.

Have the tightening values and coolant refill instructions for your truck ready before draining it. Confirm the sealing instructions for the long coolant cover; do not add sealant or reuse seals unless those instructions call for it.

Tune-file delivery: Monday–Friday, 9 AM–5 PM Central. Link during these hours if you still need files. Working after hours? Download the correct files first. Follow the hardware and flashing order in your Ironline order instructions.

1. Let the truck cool

Park on level ground and secure the truck. Let the engine cool completely. Never open a hot or pressurized cooling system.

Disconnect the negative cable from both batteries. Drain both cooling circuits into suitable containers using the procedure for your truck. Keep coolant away from children and pets.

2. Remove the air intake

Take photos of the hoses and wiring before moving them. Unplug the airflow sensor, remove the airbox fasteners and loosen the intake clamps. Lift the airbox out of its rubber mounts.

Release the coolant lines from the intake-tube clips, then remove the intake tube. Keep dirt out of the open intake.

3. Fit the coolant hose

Check this route before disconnecting any hoses. If your hoses or connections do not match, stop and contact Ironline.

For the kit with a curved reservoir hose, remove the two large coolant hoses connected to the cooler. Replace the small coolant-hose tee with the supplied straight connector.

Connect the short end of the new curved hose to the coolant reservoir. Route it beneath the airbox and connect the other end to the lower radiator connection left open by the removed hose. Secure both ends and keep the hose clear of sharp edges and rubbing points.

4. Disconnect the cooler connections

Release the quick-connect coolant hose beside the cooler. Unplug the EGR temperature sensor and the electrical connectors on the cooler.

Release the locks on the passenger-side engine-computer plugs and move the plugs clear. Pull on the housings, never the wires. Disconnect the separate valve connector near the fan shroud.

Release the EGR vacuum line and fit the supplied cap to the hard vacuum line. If you cannot identify a connection, send Ironline a photo before unplugging it.

5. Remove the cooler and pipes

Release the wiring brackets and heat-shield clips. Remove the short and long EGR pipes. Keep their fasteners and gaskets organized.

Remove the cooler mounting bolts and the nut holding the pressure line behind the cooler. Support the pressure line so it does not bend.

Ease the cooler toward the front of the truck. Check for any clips, hoses or wiring still attached before lifting it out. Do not force it past another part.

6. Install the three covers

• Exhaust cover: fit it with the original exhaust gasket and the correct mounting hardware. Replace a damaged gasket. Follow your order instructions for any sensor or threaded opening in this cover.
• Long coolant cover: prepare the sealing surface as directed for your kit, then fit the solid cover with its supplied fasteners.
• Intake cover: seat the supplied O-ring in its groove and fit the cover. Do not put the old intake gasket underneath this O-ring style of cover.

Use the specified tightening values for each connection. Do not guess a value or use the same value for every bolt.

7. Reconnect and support the lines

Reconnect the engine-computer plugs and lock them in place. Reconnect the quick-connect coolant hose and check that it locks securely.

Use the supplied bracket to support the pressure line at the rear passenger-side intake mounting point. Secure unused plugs and the capped vacuum line clear of heat, sharp edges and moving parts.

8. Reassemble and check

Reinstall the airbox and intake tube. Secure their clamps, reconnect the airflow sensor and check that all tools and loose hardware are out of the engine bay. Reconnect the batteries.

Refill and bleed both cooling circuits using the procedure for your truck year. Complete the required tune installation before starting the engine.

Before starting, make sure any threaded opening in the exhaust cover has the required sensor or plug installed.

Check for coolant, exhaust and intake leaks. Shut the engine off if there is a leak, a warning or an unusual temperature reading. Let the engine cool completely before opening the cooling system or rechecking the coolant level.

Check the extra hoses before you start

The hose arrangement covered here includes a separate formed heater hose and its support bracket. Have Ironline confirm which arrangement your kit uses before draining the truck.

A single curved reservoir hose does not identify the heater-hose setup. Send a photo of your hoses and bracket before you begin.

What is different on these trucks?

The matching setup replaces the two larger cooler hoses and changes the small hose tee to a straight connector. A replacement coolant hose connects the reservoir to the lower passenger-side radiator port.

The separate heater hose uses a support bracket and has a 90-degree end at the firewall. Have a diagram showing both ends of that hose before disconnecting it. This page does not show the full hose installation.

Have your files and instructions ready

Tune-file delivery is Monday–Friday, 9 AM–5 PM Central. Link during these hours if you still need files. Download the correct files before an after-hours installation.

Before taking the truck apart, have the matching hose diagram, cover-sealing instructions, tightening values and coolant refill procedure ready. Follow the hardware and flashing order in your Ironline order instructions.

Get the right hose instructions

Send Ironline your truck year, order number and a photo of every hose and bracket in the kit. We need to match the heater hose before you begin.

Check your kit first

These steps cover a long solid coolant cover, a small intake cover with an O-ring, an exhaust cover and a bracket that supports the pressure line. Your kit must match this layout.

Have the tightening values and coolant refill instructions for your truck ready before draining it. Confirm the sealing instructions for the long coolant cover; do not add sealant or reuse seals unless those instructions call for it.

Tune-file delivery: Monday–Friday, 9 AM–5 PM Central. Link during these hours if you still need files. Working after hours? Download the correct files first. Follow the hardware and flashing order in your Ironline order instructions.

1. Let the truck cool

Park on level ground and secure the truck. Let the engine cool completely. Never open a hot or pressurized cooling system.

Disconnect the negative cable from both batteries. Drain both cooling circuits into suitable containers using the procedure for your truck. Keep coolant away from children and pets.

2. Remove the air intake

Take photos of the hoses and wiring before moving them. Unplug the airflow sensor, remove the airbox fasteners and loosen the intake clamps. Lift the airbox out of its rubber mounts.

Release the coolant lines from the intake-tube clips, then remove the intake tube. Keep dirt out of the open intake.

3. Disconnect the cooler connections

Release the quick-connect coolant hose beside the cooler. Unplug the EGR temperature sensor and the electrical connectors on the cooler.

Release the locks on the passenger-side engine-computer plugs and move the plugs clear. Pull on the housings, never the wires. Disconnect the separate valve connector near the fan shroud.

Release the EGR vacuum line and fit the supplied cap to the hard vacuum line. If you cannot identify a connection, send Ironline a photo before unplugging it.

4. Remove the cooler and pipes

Release the wiring brackets and heat-shield clips. Remove the short and long EGR pipes. Keep their fasteners and gaskets organized.

Remove the cooler mounting bolts and the nut holding the pressure line behind the cooler. Support the pressure line so it does not bend.

Ease the cooler toward the front of the truck. Check for any clips, hoses or wiring still attached before lifting it out. Do not force it past another part.

5. Install the three covers

• Exhaust cover: fit it with the original exhaust gasket and the correct mounting hardware. Replace a damaged gasket. Follow your order instructions for any sensor or threaded opening in this cover.
• Long coolant cover: prepare the sealing surface as directed for your kit, then fit the solid cover with its supplied fasteners.
• Intake cover: seat the supplied O-ring in its groove and fit the cover. Do not put the old intake gasket underneath this O-ring style of cover.

Use the specified tightening values for each connection. Do not guess a value or use the same value for every bolt.

6. Reconnect and support the lines

Reconnect the engine-computer plugs and lock them in place. Reconnect the quick-connect coolant hose and check that it locks securely.

Use the supplied bracket to support the pressure line at the rear passenger-side intake mounting point. Secure unused plugs and the capped vacuum line clear of heat, sharp edges and moving parts.

7. Reassemble and check

Reinstall the airbox and intake tube. Secure their clamps, reconnect the airflow sensor and check that all tools and loose hardware are out of the engine bay. Reconnect the batteries.

Refill and bleed both cooling circuits using the procedure for your truck year. Complete the required tune installation before starting the engine.

Before starting, make sure any threaded opening in the exhaust cover has the required sensor or plug installed.

Check for coolant, exhaust and intake leaks. Shut the engine off if there is a leak, a warning or an unusual temperature reading. Let the engine cool completely before opening the cooling system or rechecking the coolant level.

This page helps you check the kit and get ready; it does not show the full EGR installation. Get the hose instructions for your truck from Ironline before disconnecting or cutting any coolant hoses. Have the correct hose layout ready before taking the cooler out.

1. Check your truck year

Have your order number and truck year ready. Send Ironline a clear photo of your engine bay and kit. The earlier-year hose steps do not establish the correct route for a 2020 or newer truck.

2. Check the kit

The kit covered here has a long, solid plate with three mounting holes and no large cutouts. Lay out the covers, hose, clamps, seals, bracket and bolts before starting.

If your plate looks different, stop and send Ironline a photo so we can point you to the correct instructions. Do not take the truck apart if pieces are missing or damaged.

3. Have your tune files ready

We deliver tune files Monday–Friday, 9 AM–5 PM Central. Link your truck during these hours if you still need files.

For an after-hours installation, download the correct files beforehand. Make sure you know when to flash the truck and when to install the hardware before you begin. Linking the truck does not mean the files are ready immediately.

4. Get ready to work

Park securely and let the engine cool completely. Never open the coolant cap while the system is hot or under pressure. Wear gloves and eye protection.

Have a clean drain container, hose-clamp tools, a torque wrench and the correct coolant ready. Before starting, make sure you have the hose diagram, tightening values and coolant refill instructions for your truck.

Take clear photos of the hose, wiring and bracket connections. Keep removed bolts and clips in labeled groups. Keep coolant and dirt out of open pipes and electrical connectors.

5. Before you start the engine

After following the installation instructions for your truck, check that every hose, cover, clamp and electrical connection is secure. Make sure hoses and wires cannot rub against sharp edges or touch hot or moving parts.

Refill the cooling system and remove trapped air using the procedure for your truck year. A simple top-up may leave air in the system. Complete the required tune installation before starting the engine.

If you find a coolant leak, an exhaust leak or an unusually high engine temperature, shut the engine off. Let it cool completely before checking the coolant level or opening the system.

Get the right instructions: Send Ironline your order number, truck year and clear photos of your kit and engine bay before you begin.