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 DSG 6.5TD Engine Oil Cooling Kit Anyone who has owned a 6.5 for any length of time has had to deal with leaking engine oil cooling lines. Because of age-hardening and countless temperature cycles, all factory oil cooling lines eventually begin leaking at the hose joints. The braided stainless-steel flexible lines and leak-proof hydraulic fittings included in the DSG kit should offer a permanent solution to this age-old problem, and the new high-efficiency engine oil cooler should help to reduce oil and engine temperatures. Except for hand tools and a tube of pipe thread sealant, literally everything you'll need to install the kit is included. DSG produces this kit for all 6.5 engines, whether they're in a 2-wheel drive or 4-wheel drive vehicle, and whether you have an early 6.5 or the very latest 6.5. In addition to all of the kit hardware components, you'll find two sets of 90° block fittings and two sets of oil filter adapter o-rings/gaskets - that'll allow installation in any 6.5. I was impressed with the quality and completeness of the kit as well as the full-color printed instructions and installation video. 
Features:
DSG's high-capacity 48-plate cooler, while using the same design, is considerably larger than the factory 36-plate cooler, and is said to offer a 50% improvement in overall engine oil cooler efficiency. Arguments for lower engine oil temperatures include improved engine durability, reduced thermal breakdown of the oil, and lower overall engine temperatures. 
The 9 minute video DSG included on CD is the first product installation video we've seen here at The Diesel Page. The audio was a bit muffled, but I was very impressed that DSG went to such effort to provide this level of instructional materials. If you're like me, after watching the video a couple of times, you'll agree that all aftermarket products should come with an installation video. This is an absolutely great idea!
There is a complete tool list provided in the DSG instructions. You'll need two open-end wrenches and pipe thread sealant to install the fittings in the cooler - one to hold the cooler side and one to turn the fitting.
The most tedious portion of the oil cooler line installation was threading in the rear most 90° fitting in the engine block. Interference with the exhaust manifold requires that you use a die grinder or angle-grinder to remove a small amount off the exhaust manifold flange, or loosen the eight the exhaust manifold bolts to provide more clearance. We chose to grind a small amount off the exhaust manifold, in the area pointed to in this photo. We had taped over all of the exposed fittings and oil filter mount to prevent grinding material from contaminating the engine. Though the DSG instructions indicate that you can leave the exhaust crossover pipe and front driveshaft in place, this portion of the kit installation was made much easier after first removing those components.
The larger oil cooler fit the available space quite well. The included brackets fit perfectly, but can be massaged to increase clearance if necessary. DSG includes all of the hardware necessary to mount the cooler.
We pulled the Turbo Technology intercooler to ease installation of the engine oil cooling lines, and to bolt the included DSG oil cooling line mounting bracket to the motor mount. This would be difficult to impossible to complete without first removing the intercooler. The stainless-steel braided lines were tied back against the frame to ensure they didn't rub on the intercooler, and were positioned away from truck parts that could damage the lines over time.
Though this truck is a 1989 model, the radiator core support, grille and bumper represent the 1994 & newer style. In this installation, we needed to relieve a small area to allow the lower grille filler to clear the fittings on the new oil cooler. This does not harm the structural integrity of the grille filler, and the modified area can't be seen once the upper grille has been installed.
 
This photo shows that the odometer had accumulated 291,010 miles by the time we installed the DSG oil cooler/line kit in early February 2005. The 6.5 Project engine was installed in this truck with an odometer reading of 135,000 miles, meaning the engine had been running for more than six years and 156,000 miles. During this time, Chris has replaced an alternator, A/C compressor, crank pulley, belt tensioner and had the 4L80-E automatic transmission rebuilt, but not a single bolt on the engine has been turned and the original Peninsular marine DB2 fuel injection system continues to provide normal power and normal hot/cold starts. Due to the DSG gear-drive timing set, the fuel injection timing has not required adjustment during the past six years. Current fuel economy averages about 17-mpg in the winter and 17-20 during the summer months. A brand new set of factory engine oil cooling lines were installed along with the engine back in January of 1999, and which had begun leaking by mid 2004. We expect the installation of the DSG engine oil cooler and line kit will be the last time we need to deal with these components. Do it once - do it right. TDP Oil Cooler/Line Kit Sources:
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