vortech tahoe supercharger
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P/N: 4LGL020-010 v5.0, 2011-06 2011 Lys
All Rigts Reserved, Intl. Cpr. Secu
1650 Pacific Avenue, Channel Islands CA 93033-9901 Phone: 805 247-0226Fax: 805 247-0669 www.lysholm.us M-F 8:00AM - 4:30PM (PST)
GMTruck/SUV
WithCathedralPortCylinderHeads
LysholmTwin-ScrewSuperchargerSystem
InstallationInstructions2007-2011ModelYear5.3L
2005-2007ModelYear"Classic"6.0L
50StateSmogLegalperCARBEO#D-213-28
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P/N: 4LGL020-010 v5.0, 2011-06-01 2011 Lysl
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FOREWORD
Tae note of the following before proceeding:
1. Proper installation of this supercharger kit requires general auto-motive mechanic knowledge and experience. Please browse througheach step of this instruction manual prior to beginning the installationto determine if you should refer the job to a professional installer/technician. Please contact your dealer or Lysholm for possible
installers in your area.2. This prodct was designed for se on stoc (un-modified, OEM) vehicles.
The PCM (computer), engine, transmission, drive axle ratios and tire O.D. mustbe stock. If the vehicle or engine has been modified in any way, check withLysholm prior to installation and use of this product.
3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).
4. Always listen for any sign of detonation (knocking/pinging) and discontinue harduse (no boost) until the problem is resolved.
5. Lysholm is not responsible for any clutch, transmission, drive-line or enginedamage.
Exclusions from Lysholm warranty coverage considerationsinclude, but not limited to:
1. Neglect, abuse, lack of maintenance, abnormal operation or improper installa-tion.
2. Continued operation with an impaired vehicle or sub-system.
3. The combined use of Lysholm components with other modifications such as,but not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, thirdparty PCM programming or other such changes.
2011 LysholmAll rigts reserved. N part f tis publicatin ay be reprduced, transitted, transcribed, r translated
int anter language in any fr, by any eans witut written perissin f Lysl.
This manual provides information on the installation, maintenance and serviceof the Lysholm supercharger kit expressly designed for this vehicle. All infor-mation, illustrations and specifications contained herein are based on the lat-
est product information available at the time of this publication. Changes to themanual may be made at any time without notice. Contact Lysholm for any addi-tional information regarding this kit and any of these modifications at (805) 247-0226 8:00am-4:30pm PST.
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TABLE OF CONTENTSFOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
COPYRIGHT NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
AuTOmATIC TRANSmISSION DISCLAImER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Gm TRuCk/SuV INSTALLATION INSTRuCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
PARTS LIST, PN 2310040 ('05 - '07 Gm 6.0L TRuCk (Classic)) . . . . . . . . . . . . . . . . . . . . . vi
PARTS LIST, PN 2310070 ('07 - '11 Gm 5.3L SuV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
PARTS LIST, PN 2310100 ('07 - '11 Gm 5.3L Trc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
1. BASIC COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. INTAKE MANIFOLD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. SUPERCHARGER PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. IDLER AND DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6. SURGE TANK AND COOLANT RESERVOIR INSTALLATION ('05 - '07 Classic) . . . . 22
6.1 SURGE TANK AND COOLANT RESERVOIR INSTALLATION ('07 NEW BODY - '11) . 246.2 SURGE TANK AND COOLANT RESERVOIR INSTALLATION ('07 - '11 SUV) . . . . . . . 26
7. WATER COOLER INSTALLATION ('05 - '07 Classic) . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 WATER COOLER INSTALLATION ('07 NEW BODY - '11, TRUCK) . . . . . . . . . . . . . . . 32
7.2 WATER COOLER INSTALLATION ('07 - '11 SUV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8. WATER PUMP WIRING ('05 - '07 Classic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1 WATER PUMP WIRING ('07 NEW BODY - '11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9. AIR INLET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10. MISCELLANEOUS REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11. REFLASH COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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COPYRIGHT NOTICE
This product is protected by state common law, copyright and/or patent. All legal rights
therein are reserved. The design, layout, dimensions, geometry and engineering features
shown in this product are the exclusive property of Lysholm. This product may not
be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or
fortuitously, nor shall any design, dimension, or other information be incorporated into
any product or apparatus without prior written consent of Lysholm.
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The transission shift strategies bilt into the Lyshol ECu calibration
spplied with this it have been designed and tested to wor properly with
the Lyshol Spercharger nder noral driving conditions at the Lyshol
spplied power levels. Towing, racing, perforance driving, hard accelerations
and other heavy/severe dty driving activities place extra deands on the
vehicle's atoatic transission and its cooling syste. If yo se or plan to
se yor newly spercharged vehicle nder any of these deanding driving
conditions, Lyshol sggests that yo evalate yor atoatic transission
syste. Several copanies ae prodcts to increase yor transission's
sefl life.
Shift Iprover kit: These products are designed to improve the performance
and durability of your vehicle's transmission by enhancing the internal hydraulic
system. This results in a positive shift with reduced slippage and heat generation
under extreme conditions.
Oil Cooler: Transmission oil coolers keep the transmission's vital hydraulic uid
temperature under control. Excessive uid temperature will cause transmission
failure. If your vehicle was not equipped with an external air/oil transmission
cooler (typically mounted in front of the radiator, directly behind the grille), you
need to consider adding one for improved durability. If your vehicle was equippedwith a factory transmission oil cooler and you plan on heavy duty towing or
severe driving, Lysholm suggests upgrading to a larger unit.
Oil Pan: Aftermarket deep sump pans allow the use of extra uid to further
stabilize uid temperature in your transmission.
AUTOMATIC TRANSMISSIONDISCLAIMER
NOTE: This listing is provided solely for informational purposes.Lysholm has made no evaluation of the quality or function-ality of any specific brands of these products. Please con-tact product companies should you wish to obtain moreinformation.
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Before beginning this installation, please read throgh this entire instrction boolet and the StreetSpercharger Syste Owners manal which incldes the Atootive Liited Warranties Prograand the Warranty Registration for.
Lysholm supercharger systems are performance improving devices. In most cases, increases in torque of3035% and horsepower of 3545% can be expected with the boost levels specied by Lysholm. This prod-uct is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engineis not recommended and may result in failure of the engine as well as the supercharger. Lyshol is notresponsible for engine daage.
Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-inprocedures are followed.
For best perforance and contined drability, please tae note of the following eypoints:
1. Use only premium grade fuel 91 octane or higher (R+M/2).
DO NOT uSE E85 OR OTHER ALTERNATIVE /FLEX FuELS.
2. The engine must have stock compression ratio.
3. If the engine has been modied in any way, check with Lysholm prior to using this product.
4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problemis resolved.
5. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles withoriginal heat range plugs as specied by the manufacturer and resettiming to factory specications (follow the procedures indicated withinthe factory repair manual and/or as indicated on the factory under-hood emissions tag). Do not se platin spar plgs nlessthey are original eqipent. Change spark plugs every at least15,000 miles and spark plug wires at least every 50,000 miles.
TOOL & SUPPLY REQUIREMENTS: Factory Repair Manual 3/8 Socket and Drive Set: SAE & Metric 1/2 Socket and Drive Set: SAE & Metric Adjustable Wrench Open End Wrenches: 3/8, 7/16, 1/2, 9/16
Flat #2 Screwdriver Phillips #2 Screwdriver Drill Motor 1/8, 3/16, 1/4, 27/64 Drill Bits 3/16 Allen Wrench Wire Strippers and Crimpers Utility Knife
If your vehicle has in excess of 15,000 miles since its last spark plug change, then youwill also need:
Spark Plug Socket NEW Spark Plugs
GM TRUCk/SUV
INSTALLATION INSTRUCTIONS
Congratlations on selecting the best perforing and best baced atootivespercharger available today... the LysholSpercharger!
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P/N: 4LGL020-010 v5.0, 2011-06 2011 Lys
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008119 VINYL DECAL 2
008448 1 YR S/C STRT INFO PkG ASY 1
009028 S/C LUBE, LYSHOLM 2300 5.4Oz 1
2L218-040 S/C ASY, 2300 LYSHOLM, 07 CLSC 6.0 12L118-010 UNIV S/C ASY, LYShoLm 2300AX, Gm CATh. PoRT V8 12L036-325-01 PULLEY, 6-RIB, 3.25, Gm TRK LYShoLm 14LGL010-010 BRKT, hoLD DN mAP SENS.LYShoLm 14LGL010-050 BRKT, FUEL hoSE, LYShoLm GmT 17C060-013 m6 X 1.0 X 12mm FLG hD CL10.9+ ZINC 14LGL145-010 FUEL LINE ASSY A, LYSh Gm 5.3 17R003-008 ADEL CLAmP, 1/2" ID 17C060-008 m6 X 1.0 X 8mm, ShCS PLATED 17C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ ZINC 4
4LGL020-010 INSTR MAN., GM TRk, LYSHOLM 1
4LGL112-010AIR INLET ASSY, GM TRk, LYSHOLM 14LGL010-011 ADAPTER, T-BoDY Gm TRK,LYShoLm 14LGL012-010 DUCT, INLET Gm TRK, LYShoLm 14LGL040-010 GASKET, ThRTL BoDY, Gm TRK 15W001-007 3/16" hEAT-ShRINK TUBING 0.5FT5W001-012 18-22 GA BUTT CoNN RED INSUL 25W001-032 1/4" PLASTIC WIRE Loom 18IN5W001-076 hARNESS, IAT SENSoR Gm TRK 17C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ Z 27C060-025 m6 X 1.0 X 25mm hX 17C060-040 m6 X 1.0 X 40 hXhD CL8.8 47J006-093 6mm WAShER, PLATED 57P250-045 1/4 mALE NPT X 3/8 mALE BARB 17PS350-303 BUmP hoSE, 3.50D X 3.00L 17PS400-300 SLEEVE, BLACK 4.0D X 3.0 17R002-056 #56 SAE TYPE F SS hoSE CLAmP 2
7R002-064 #64 SAE TYPE F SS hoSE CLAmP 27U030-053 3/8 X 90 moLDED RUBBER hoSE 18h040-165 FILTER, Gm TRK 99-08 PNL. 1
4LGL116-030SUPPORT ASSY, GM TRk, 07 CLASS 12A017-750-03 SPACER, .750 oD X .130 LoNG 12A046-120 BELT, GATES K061203 12C017-002 PILoT, 6203/5 BRG, 7/16 SCREW 14Fh016-150 IDLER PULY, SmooTh 6RIB 3" FLA 14LGL017-011 SPACER,IDLER, .88 X 1.220 14TX016-150 IDLER, 2.75 DIA, SmooTh, 7 RIB 15W001-030 1 1/2" hEAT ShRINK 0.67FT5W001-077 INJ ADAPTER, mULTEC II m To EV 85W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.17FT5W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.17FT7C010-151 m10 X 1.5 X 150 hXhD CL10.9 17C080-027 m8 X 1.25 X 25mm BhCS 107P125-032 1/8NPT-STR,5/16 BARB 1
7R003-027 ADEL CLAmP,1-11/16" 17R004-003 STEPLESS CLAmP, 14.5-70 27R007-001 NYLoN RATChET CLAmP 1-1/8" 57U030-016 1/4" EFI hP FUEL LINE 1.5FT7U031-016 5/16" PCV/VAC RUBBER hoSE 3FT7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
5A003-060 TUNER, SCT, GM 1
8N105-200 WATER TANk ASSY, 07+ GM TRUCk 1
2A017-875-08 SPACER, .875 oD X .290 LoNG 27A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 47J250-001 1/4 WAShER, SAE, PLTD 47P375-075 3/4" hoSE BARB UNIoN, BRASS 37P500-026 1/2NPT X 3/4 BARB 90 BRASS 27P500-034 1/2NPT X 3/4 BARB 90, NICKEL 17P500-075 1/2NPT X 3/4 hoSE FIT STRT NIC 17R007-001 NYLoN RATChET CLAmP 1-1/8" 147U030-065 hoSE, 3/4 X 90 RUBBER, ShoRT 17U038-000 3/4" hEATER hoSE 14FT7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 17U038-150 hoSE, 3/4 D X150 moLDED hoSE 17U100-055 TIE WRAP, 7.5" NYLoN 68N010-250 BRKT, SURGE TANK, 07 Gm TRK 18N010-260 BRKT, CooLANT RES 07 Gm TRK 18N010-370 BRKT, CooLANT RES 07-09 Gm TRK 18N055-030 TANK, WATER, TRIANGLE ShAPE 18N055-050 PLASTIC CAP, SURGE TANK 18N056-060 SURGE TANK, PLASTIC 1
8N106-140 WATR COOLR ASY, 07 ESCAL 17A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 47E010-075 #12 X 3/4" ShT mETL SCRW hEX 47J250-001 1/4 WAShER, SAE, PLTD 87P375-075 3/4" hoSE BARB UNIoN, BRASS 17R003-016 ADEL CLAmP, 1.0" 17R007-001 NYLoN RATChET CLAmP 1-1/8" 47U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 38N006-020 WATER CooLR, FLDYN DUAL PASS 18N010-320 FLDYN BKT, 07 ESCALADE DRVR 18N010-330 FLDYN BKT, 07 ESCALADE PASS 1
8N107-050 WATER PMP ASSY, GMT LS1 H.O. 1
5W001-002 FUSE TAP 15W001-005 3/8" PLASTIC WIRE Loom 5FT5W001-013 14-16 GA BUTT CoNN BLU INSUL 45W001-015 FUSE, BLADE TYPE 20 AmP 15W001-017 12-10GA X 3/8" RING TERmINAL 15W001-019 10-12 GA BUTT CoNN INSULATED 25W001-022 T-TAP CoNN,14-16 AWG 15W001-024 mINI ATC FUSE TAP 15W001-041 12-10GA mALE SLIDE INSULATED 15W001-043 12-10GA X 1/4" RING TERmINAL 15W001-071 FUSE hoLDER,16GA WIRE 17A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 27E010-048 #10 X 3/4" ShT mETL SCRW PhILLIPS 27E010-075 #12 X 3/4" ShT mETL SCRW hEX 27F008-020 NUT, m8 X 1.25 17F250-021 1/4-20 NYLoCK NUT ZINC PLATED 17R003-027 ADEL CLAmP,1-11/16" 17U100-044 TIE WRAP, 4" NYLoN 4
7U100-055 TIE WRAP, 7.5" NYLoN 68F001-402 PUmP, WATER, PIERBURG 18F101-320 FUEL PUmP RELAY ASSY, LS1 TRK 1
5W001-010 16-14GA FEmALE SLIDE INSULATED 25W001-016 RELAY,BoSCh 15W001-040 12-10GA FEmALE SLIDE INSULATED 25W001-042 12-10GA X 3/16" RING TERmINAL 25W012-000 12 GA,STRD WIRE, RED 9.5FT5W012-000 12 GA,STRD WIRE, RED 1.5FT5W012-010 12 GA WIRE BLACK 0.5FT5W014-030 14GA STRD WIRE BLACK 0.5FT5W016-010 16GA STRD WIRE YELLoW 2.5FT
PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY
IMPORTANT: Befre beginning installatin, verify tat all parts are included in te kit. Reprt any srtages r
daaged parts iediately.
'05 - '07 GM 6.0L TRUCk (Classic)Part No. 2310040
PARTS LIST
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P/N: 4LGL020-010 v5.0, 2011-06-01 2011 Lysl
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IMPORTANT: Befre beginning installatin, verify tat all parts are included in te kit. Reprt any srtages r
daaged parts iediately.
008119 VINYL DECAL 2
008448 1 YR S/C STRT INFO PkG ASY 1
009028 S/C LUBE, LYSHOLM 2300 5.4Oz 1
2L218-010 S/C ASSY, 2300 LYSHOLM, GM TRk 12L118-010 UNIV S/C ASY, LYShoLm 2300AX, Gm CATh. PoRT V8 12L036-380-01 PULLEY 3.80, LYShoLm GmT 5.3 14LGL010-010 BRKT, hoLD DN mAP SENS.LYShoLm 14LGL010-040 BRKT, EVAP SoLENoID LYShoLm GmT 14LGL010-050 BRKT, FUEL hoSE, LYShoLm GmT 17C060-013 m6 X 1.0 X 12mm FLG hD CL10.9+ ZINC 14LGL145-010 FUEL LINE ASSY A, LYSh Gm 5.3 17R003-008 ADEL CLAmP, 1/2" ID 1
7C060-008 m6 X 1.0 X 8mm, ShCS PLATED 17C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ ZINC 4
4LGL020-010 INSTR MAN., GM TRk, LYSHOLM 1
4LGL112-010AIR INLET ASSY, GM TRk, LYSHOLM 14LGL012-010 DUCT, INLET Gm TRK, LYShoLm 14LGL040-010 GASKET, ThRTL BoDY, Gm TRK 15W001-007 3/16" hEAT-ShRINK TUBING 0.5FT5W001-012 18-22 GA BUTT CoNN RED INSUL 25W001-032 1/4" PLASTIC WIRE Loom 18IN5W001-076 hARNESS, IAT SENSoR Gm TRK 17C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ Z 27C060-025 m6 X 1.0 X 25mm hX 17C060-040 m6 X 1.0 X 40 hXhD CL8.8 47J006-093 6mm WAShER, PLATED 57P250-045 1/4 mALE NPT X 3/8 mALE BARB 17PS350-303 BUmP hoSE, 3.50D X 3.00L 17PS400-300 SLEEVE, BLACK 4.0D X 3.0 1
7R002-056 #56 SAE TYPE F SS hoSE CLAmP 27R002-064 #64 SAE TYPE F SS hoSE CLAmP 27U030-053 3/8 X 90 moLDED RUBBER hoSE 18h040-165 FILTER, Gm TRK 99-08 PNL. 1
4LGL116-010SUPPORT ASSY, GM TRk, LYSHOLM 12A046-124 BELT, GATES K061247 12C017-002 PILoT, 6203/5 BRG, 7/16 SCREW 14Fh016-150 IDLER PULY, SmooTh 6RIB 3" FLA 14LGL010-011 ADAPTER, T-BoDY Gm TRK,LYShoLm 14LGL010-071 ADAPTER, mAP SENSoR, 09 Gm TRK LYShoLm 14LGL016-150 IDLER, 6 RIB, 4.2", ComPoSITE 14LGL017-011 SPACER, IDLER, .88 X 1.220 15W001-030 1 1/2" hEAT ShRINK 0.666FT5W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.166FT5W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.166FT7C010-151 m10 X 1.5 X 150 hXhD CL10.9 17C060-022 m6-1.0 X 22mm ShCS LYSh SC 27C080-027 m8 X 1.25 X 25mm BhCS 10
7J640-032 WAShER, .640" ID X .032" ThK X 1.188" 17R003-027 ADEL CLAmP,1-11/16" 17R007-001 NYLoN RATChET CLAmP 1-1/8" 57U012-111 o-RING, .630oD X .424ID X .103W 17U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 17U100-028 FILLER NECK, oIL, 09 Gm TRK LYShoLm 1
4LGL117-021 SPACER kIT, BODY LIFT, 07+ GMT 1
5A003-060 TUNER, SCT, GM 1
8N105-200 WATER TANk ASSY, 07+ GM TRUCk 1
2A017-875-08 SPACER, .875 oD X .290 LoNG 27A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 47J250-001 1/4 WAShER, SAE, PLTD 47P375-075 3/4" hoSE BARB UNIoN, BRASS 37P500-026 1/2NPT X 3/4 BARB 90 BRASS 27P500-034 1/2NPT X 3/4 BARB 90, NICKEL 17P500-075 1/2NPT X 3/4 hoSE FIT STRT NIC 17R007-001 NYLoN RATChET CLAmP 1-1/8" 147U030-065 hoSE, 3/4 X 90 RUBBER, ShoRT 17U038-000 3/4" hEATER hoSE 14FT7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 17U038-150 hoSE, 3/4 D X150 moLDED hoSE 17U100-055 TIE WRAP, 7.5" NYLoN 6
8N010-250 BRKT, SURGE TANK, 07 Gm TRK 18N010-260 BRKT, CooLANT RES 07 Gm TRK 18N010-370 BRKT, CooLANT RES 07-09 Gm TRK 18N055-030 TANK, WATER, TRIANGLE ShAPE 18N055-050 PLASTIC CAP, SURGE TANK 18N056-060 SURGE TANK, PLASTIC 1
8N106-140 WATR COOLR ASY, 07 ESCAL 17A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 47E010-075 #12 X 3/4" ShT mETL SCRW hEX 47J250-001 1/4 WAShER, SAE, PLTD 87P375-075 3/4" hoSE BARB UNIoN, BRASS 17R003-016 ADEL CLAmP, 1.0" 17R007-001 NYLoN RATChET CLAmP 1-1/8" 47U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 38N006-020 WATER CooLR, FLDYN DUAL PASS 18N010-320 FLDYN BKT, 07 ESCALADE DRVR 18N010-330 FLDYN BKT, 07 ESCALADE PASS 1
8N107-050 WATER PMP ASSY, GMT LS1 H.O. 15W001-002 FUSE TAP 15W001-005 3/8" PLASTIC WIRE Loom 5FT5W001-013 14-16 GA BUTT CoNN BLU INSUL 45W001-015 FUSE, BLADE TYPE 20 AmP 15W001-017 12-10GA X 3/8" RING TERmINAL 15W001-019 10-12 GA BUTT CoNN INSULATED 25W001-022 T-TAP CoNN,14-16 AWG 15W001-024 mINI ATC FUSE TAP 15W001-041 12-10GA mALE SLIDE INSULATED 15W001-043 12-10GA X 1/4" RING TERmINAL 15W001-071 FUSE hoLDER,16GA WIRE 17A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 27E010-048 #10 X 3/4" ShT mETL SCRW PhILLIPS 27E010-075 #12 X 3/4" ShT mETL SCRW hEX 27F008-020 NUT, m8 X 1.25 17F250-021 1/4-20 NYLoCK NUT ZINC PLATED 17R003-027 ADEL CLAmP,1-11/16" 17U100-044 TIE WRAP, 4" NYLoN 47U100-055 TIE WRAP, 7.5" NYLoN 68F001-402 PUmP, WATER, PIERBURG 18F101-320 FUEL PUmP RELAY ASSY, LS1 TRK 1
5W001-010 16-14GA FEmALE SLIDE INSULATED 25W001-016 RELAY,BoSCh 15W001-040 12-10GA FEmALE SLIDE INSULATED 25W001-042 12-10GA X 3/16" RING TERmINAL 25W012-000 12 GA,STRD WIRE, RED 9.5FT5W012-000 12 GA,STRD WIRE, RED 1.5FT5W012-010 12 GA WIRE BLACK 0.5FT5W014-030 14GA STRD WIRE BLACK 0.5FT5W016-010 16GA STRD WIRE YELLoW 2.5FT
PART NO. DESCRIPTION QTYPART NO. DESCRIPTION QTY
'07 - '11 GM 5.3L SUVPart No. 2310070
PARTS LIST
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IMPORTANT: Befre beginning installatin, verify tat all parts are included in te kit. Reprt any srtages rdaaged parts iediately.
008119 VINYL DECAL 2
008448 1 YR S/C STRT INFO PkG ASY 1
009028 S/C LUBE, LYSHOLM 2300 5.4Oz 1
2L218-010 S/C ASY, 2300 LYSHOLM, GM TRk 12L118-010 UNIV S/C ASY, LYShoLm 2300AX, Gm CATh. PoRT V8 12L036-380-01 PULLEY 3.80, LYShoLm GmT 5.3 14LGL010-010 BRKT, hoLD DN mAP SENS.LYShoLm 14LGL010-040 BRKT, EVAP SoLENoID LYShoLm GmT 14LGL010-050 BRKT, FUEL hoSE, LYShoLm GmT 17C060-013 m6 X 1.0 X 12mm FLG hD CL10.9+ ZINC 14LGL145-010 FUEL LINE ASSY A, LYSh Gm 5.3 1
7R003-008 ADEL CLAmP, 1/2" ID 17C060-008 m6 X 1.0 X 8mm, ShCS PLATED 17C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ ZINC 4
4LGL020-010 INSTR MAN., GM TRk, LYSHOLM 1
4LGL112-010AIR INLET ASSY, GM TRk, LYSHOLM 14LGL012-010 DUCT, INLET Gm TRK, LYShoLm 14LGL040-010 GASKET, ThRTL BoDY, Gm TRK 15W001-007 3/16" hEAT-ShRINK TUBING 0.5FT5W001-012 18-22 GA BUTT CoNN RED INSUL 25W001-032 1/4" PLASTIC WIRE Loom 18IN5W001-076 hARNESS, IAT SENSoR Gm TRK 17C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ Z 27C060-025 m6 X 1.0 X 25mm hX 17C060-040 m6 X 1.0 X 40 hXhD CL8.8 47J006-093 6mm WAShER, PLATED 57P250-045 1/4 mALE NPT X 3/8 mALE BARB 17PS350-303 BUmP hoSE, 3.50D X 3.00L 1
7PS400-300 SLEEVE, BLACK 4.0D X 3.0 17R002-056 #56 SAE TYPE F SS hoSE CLAmP 27R002-064 #64 SAE TYPE F SS hoSE CLAmP 27U030-053 3/8 X 90 moLDED RUBBER hoSE 18h040-165 FILTER, Gm TRK 99-08 PNL. 1
4LGL116-010SUPPORT ASSY, GM TRk, LYSHOLM 12A046-124 BELT, GATES K061247 12C017-002 PILoT, 6203/5 BRG, 7/16 SCREW 14Fh016-150 IDLER PULY, SmooTh 6RIB 3" FLA 14LGL010-011 ADAPTER, T-BoDY Gm TRK,LYShoLm 14LGL010-071 ADAPTER, mAP SENSoR, 09 Gm TRK LYShoLm 14LGL016-150 IDLER, 6 RIB, 4.2", ComPoSITE 14LGL017-011 SPACER, IDLER, .88 X 1.220 15W001-030 1 1/2" hEAT ShRINK 0.666FT5W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.166FT5W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.166FT7C010-151 m10 X 1.5 X 150 hXhD CL10.9 17C060-022 m6-1.0 X 22mm ShCS LYSh SC 27C080-027 m8 X 1.25 X 25mm BhCS 107J640-032 WAShER, .640" ID X .032" ThK X 1.188" 17R003-027 ADEL CLAmP,1-11/16" 17R007-001 NYLoN RATChET CLAmP 1-1/8" 57U012-111 o-RING, .630oD X .424ID X .103W 17U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 17U100-028 FILLER NECK, oIL, 09 Gm TRK LYShoLm 1
5A003-060 TUNER, SCT, GM 1
8N105-200 WATER TANk ASSY, 07+ GM TRUCk 12A017-875-08 SPACER, .875 oD X .290 LoNG 2
7A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 47J250-001 1/4 WAShER, SAE, PLTD 47P375-075 3/4" hoSE BARB UNIoN, BRASS 37P500-026 1/2NPT X 3/4 BARB 90 BRASS 27P500-034 1/2NPT X 3/4 BARB 90, NICKEL 17P500-075 1/2NPT X 3/4 hoSE FIT STRT NIC 17R007-001 NYLoN RATChET CLAmP 1-1/8" 147U030-065 hoSE, 3/4 X 90 RUBBER, ShoRT 17U038-000 3/4" hEATER hoSE 14FT7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 17U038-150 hoSE, 3/4 D X150 moLDED hoSE 17U100-055 TIE WRAP, 7.5" NYLoN 6
8N010-250 BRKT, SURGE TANK, 07 Gm TRK 18N010-260 BRKT, CooLANT RES 07 Gm TRK 18N010-370 BRKT, CooLANT RES 07-09 Gm TRK 18N055-030 TANK, WATER, TRIANGLE ShAPE 18N055-050 PLASTIC CAP, SURGE TANK 18N056-060 SURGE TANK, PLASTIC 1
8N106-160 WATER COOLER ASY, 07+ GM TRk 17A250-075 1/4-20 X .75 ShCS PLTD 87F250-021 1/4-20 NYLoCK NUT ZINC PLATED 87J250-001 1/4 WAShER, SAE, PLTD 167P500-026 1/2NPT X 3/4 BARB 90 BRASS 27R003-016 ADEL CLAmP, 1.0" 17U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 18N006-010 WATER CooLR, SETRAB SINGLE PAS 18N010-270 BRKT "A", hEAT EXChGR 07 GmT 18N010-280 BRKT "B", hEAT EXChGR 07 GmT 1
8N107-050 WATER PMP ASSY, GMT LS1 H.O. 1
5W001-002 FUSE TAP 15W001-005 3/8" PLASTIC WIRE Loom 5FT5W001-013 14-16 GA BUTT CoNN BLU INSUL 45W001-015 FUSE, BLADE TYPE 20 AmP 15W001-017 12-10GA X 3/8" RING TERmINAL 15W001-019 10-12 GA BUTT CoNN INSULATED 25W001-022 T-TAP CoNN,14-16 AWG 15W001-024 mINI ATC FUSE TAP 15W001-041 12-10GA mALE SLIDE INSULATED 15W001-043 12-10GA X 1/4" RING TERmINAL 15W001-071 FUSE hoLDER,16GA WIRE 17A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 27E010-048 #10 X 3/4" ShT mETL SCRW PhILLIPS 27E010-075 #12 X 3/4" ShT mETL SCRW hEX 27F008-020 NUT, m8 X 1.25 17F250-021 1/4-20 NYLoCK NUT ZINC PLATED 17R003-027 ADEL CLAmP,1-11/16" 17U100-044 TIE WRAP, 4" NYLoN 4
7U100-055 TIE WRAP, 7.5" NYLoN 68F001-402 PUmP, WATER, PIERBURG 18F101-320 FUEL PUmP RELAY ASSY, LS1 TRK 1
5W001-010 16-14GA FEmALE SLIDE INSULATED 25W001-016 RELAY,BoSCh 15W001-040 12-10GA FEmALE SLIDE INSULATED 25W001-042 12-10GA X 3/16" RING TERmINAL 25W012-000 12 GA,STRD WIRE, RED 9.5FT5W012-000 12 GA,STRD WIRE, RED 1.5FT5W012-010 12 GA WIRE BLACK 0.5FT5W014-030 14GA STRD WIRE BLACK 0.5FT5W016-010 16GA STRD WIRE YELLoW 2.5FT
PART NO. DESCRIPTION QTYPART NO. DESCRIPTION QTY
'07 NEW BODY- '11 GM 5.3L TrucPart No. 2310100
PARTS LIST
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A. Temporarily disconnect the negative battery
cable.
B. Remove the plastic engine/intake manifoldcover (if equipped), item will not be resuable.
C. Remove all air inlet ducting between the
Mass Air Flow (MAF) sensor (connected to
airbox lid) and the throttle body as it will not
be reused. The ducting is attached with a
large hose clamp at each end as well as a
number of plastic clips and rubber grommets.
Remove the crankcase breather hose from
the passenger side valve cover. Do not
remove the MAF itself. See Fig 1A
D. Unplug the electrical connector from the
MAF.
E. Temporarily remove the airbox/MAF assem-
bly from the vehicle. The airbox is secured
to the vehicle at three (3) points on the bot-
tom and simply snaps into and out of place.
See Fig 1B
F. Remove the accessory drive belt by releas-
ing the tensioner with a 15mm wrench. The
OEM belt will not be reused.
1. BASIC COMPONENT REMOVAL
Fig. 1A
Fig. 1B
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G. Remove the oil filler neck and cap from the
passenger side valve cover. The neck is
removed in a similar fashion to the cap, but
has a locking tab preventing inadvertent
removal. Twist the neck counter-clockwise
while gently working it back and forth and itwill loosen and eventually slide out. Take
care not to break any pieces off of the neck
that may drop into the valve cover. See Fig
1C
'05 - '08 All: Reinstall the cap directly into
the valve cover, filler neck is no longer
used.
'09 - '10: Install the included short oil filler
neck and reinstall the cap. See Fig. 1D
H. Remove the plastic panel covering the area
between the grille and the radiator core
support. Carefully disengage the eight (8)
clips (seven on 05 - 07 Classic; six on
SUV) holding it in place with a flat-tip
screwdriver or similar tool and retain them
for reassembly. See Fig. 1E
I. Remove the grille by removing the four (4)
10mm-headed fasteners (six on SUV) onthe top surface ('07 NEW BODY - '09 only)
and then disengaging the six (6) retaining
clips (number may vary) that secure it to
the radiator core support. GMC Sierra mod-
els have additional tabs securing the bum-
per cover to the grille. These tabs need to
be depressed and the bumper cover
pushed out (forward) to release the grille.
Fig. 1C
Fig. 1D
Fig. 1E ('05 - '07 Classic Only)
PLASTIC PANELCoVER CLIPS
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Fig. 1F
Fig. 1G
FENDER LINERFASTENERS
REmoVE
SCREWS
Fig. 1H
PULL oUTThEN FoRWARD
J. '07 - '10 New Body SuV ONLY (All others
proceed to Section 2, Intae manifold
Reoval): Remove four (4) fasteners on
each side connecting the front inner splash
guards to the bumper cover. See Fig 1F
K. Remove fasteners that attach the underside
of the bumper cover on each side just in front
the tires. See Fig 1G
L. Release the sides of the bumper cover by
first pulling outward then forward. See Fig 1H
M. Slowly remove the bumper cover and grille
assembly, being sure to unplug the wiring
harness on each side located just above the
front bumper. See Fig 1I
Fig. 1I
DISCoNNECTELECTRICAL
CoNNECToRSoN EACh SIDE
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A. '05 - '07 Classic: Locate the small coolant
hose running from the radiator to a fitting on
the throttle body. Clamp the hose shut near
the end closest to the throttle body and then
disconnect it from the throttle body. Directly
across from the throttle body connection a
similar hose runs from the throttle body to a
fitting in the front of the driver side cylinder
head behind the alternator. Remove this
hose and set it aside.
'07 NEW BODY - '10: Locate the small cool-
ant hose running from the radiator to a fitting
directly beneath the throttle body (location
may vary by application). Clamp the hose
shut near the end closest to the engine and
then disconnect the hose from the engine.
See Fig 2A
B. Remove the steel cover support bracket from
the top of the intake manifold (if equipped).
This item will not be reused.
C. Remove the hardware and brackets securing
the large electrical harness to the engine.
These items will not be reused. See Fig 2B
D. Disconnect the electrical connectors from
each of the eight (8) injectors. Label them
with their original location to avoid later con-
fusion as the harnesses will be moved
around during supercharger installation.
Fig. 2A
Fig. 2B
2. INTAkE MANIFOLD REMOVAL
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E. Disconnect the Electronic Throttle Control
(ETC) connector from the throttle body. See
Fig 2C
F. Disconnect the Manifold Absolute Pressure
(MAP) sensor electrical connector on top ofthe intake manifold. The specific location
may vary depending on your application.
G. Confirm that the negative battery cable is
disconnected and disconnect the charge wire
and the electrical connector from the alterna-
tor.
H. Remove and save the bolts fastening the
large cast alternator/power steering pump
bracket to the engine. There are three (3)bolts under the alternator and one (1) enter-
ing the engine block from the driver side
behind the power steering pump. Then locate
and loosen the bottom bolt (below the power
steering pulley) to allow the bracket assem-
bly to rotate away from the engine, towards
the driver side until it rests out of the way.
NOTE: Te blt lcated directly belw te alternatr (at 6'clck psitin) will nt be reused. Tis blt willbe replaced wit an idler and new ardware in a
later step.
Fig. 2C
Cation: on newer bdy style veicles ('07-'10), use cau-tin wen setting te alternatr/pwer steeringbracket aside. Te ca psitin sensr cnnectris lcated just belw te bracket n te frnt tiingcver and can be accidentally discnnected if tebracket rests n te arness r cnnectr.
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I. 05 - 07 Classic: Disconnect the
Evaporative Emission Control (EVAP) electri-
cal connector from the EVAP solenoid locat-
ed on the top of the intake manifold directly
behind the throttle body. Disconnect the
EVAP vent tube that runs to the driver sideand then rearward from the solenoid.
'07 NEW BODY - '10: Disconnect the
Evaporative Emission Control (EVAP) electri-
cal connector from the EVAP solenoid locat-
ed above the driver side fuel rail. Disconnect
the EVAP vent tube that runs rearward from
the solenoid. See Fig 2D
J. Lift the large electrical harness from the top
of the intake manifold and push it off to theside to the furthest extent possible.
Separate the harness from the previously-
disconnected plastic harness brackets. Set
the brackets aside, as they will no longer be
used.
K. Relieve any residual pressure in the fuel sys-
tem using the capped fitting on the passen-
ger side fuel rail. Remove the cap, cover the
fitting and surrounding area with a rag and
depress the valve. Use caution as a smallamount of fuel may squirt out. See Fig 2E
L. Remove the safety clip around the fuel line
connection to the fuel rail and retain for later
use. Using the proper fuel line disconnect
tool, disconnect the fuel supply line from the
fuel rail. See Fig 2F
Fig. 2D
Fig. 2E
Fig. 2F
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M. Disconnect the crankcase breather hose
from the back of the driver side valve cover,
this hose will not be reused. See Fig 2G
N. Disconnect the power brake booster vacuum
hose (if equipped) from the fitting on thebrake booster. Leave any valve or electrical
sensor in place on the booster.
O. Remove the ten (10) 6mm (8mm-headed)
intake manifold mounting screws and their
sleeves. One or more of them may remain
captured by other hardware, but the more of
them you can remove the easier intake mani-
fold removal will be. These screws will not be
reused.
P. Carefully remove the intake manifold and set
aside, taking care not to damage the intake
manifold gaskets, the wiring harness, or any
other nearby components. Avoid letting dirt
and debris fall into the cylinder head intake
ports. See Fig 2H
Q. Use a vacuum cleaner to remove any dirt
from the intake ports and surrounding area.
Temporarily cover the intake ports with tape
or rags prior to completing the remaining
steps.
Fig. 2G
Fig. 2H
NOTE: Bt oEm intake anifld gaskets will be re-usedduring supercarger installatin. Carefully inspectte reved gaskets. Ensure tat bt gaskets
are in gd cnditin wit n cuts r daage tte sealing surfaces. If teres any dubt, replacete wit te apprpriate oEm replaceent parts(Gm part nuber 89060413)
CRANKCASEBREAThER hoSE
BRAKE BooSTERhoSE
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A. 05 - 07 Classic: Locate the thin coolant
vent tube assembly running along the top
front of the engine between the cylinder
heads (the one from which the small coolant
hose was previously removed). Using a
small deep-well socket that closely fits the
hose nipple, carefully and gradually bend the
nipple to lean forward and point to the pas-
senger side as shown in Figure 3A.
'07 NEW BODY - '10: Locate the thin cool-
ant vent tube assembly running along the top
front of the engine between the cylinder
heads (the one from which the small coolant
hose was previously removed). Using a
small deep-well socket that closely fits the
hose nipple, carefully and gradually bend the
nipple forward and to the passenger side as
shown in Figure 3A-2. Adjust the position of
the socket as you bend so the entire bend
isnt at the same spot on the nipple. The
total bend needed is only 15-20 from verti-
cal and it takes very little force to do. See
Figure 3B for approximate final position.
B. Remove the coolant vent tube assembly by
removing the two 10mm-headed screws and
lifting upward. Ensure that the two (2)
O-rings sealing the fittings to the cylinder
heads are retained. This assembly is being
temporarily removed to create clearance and
will be reinstalled in a later step.
Fig. 3B
Fig. 3A
Fig. 3A-2
CooLANT VENTTUBE
CooLANT VENTTUBE
3. SUPERCHARGER PREPARATION
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C. Remove the OEM MAP sensor from the
OEM intake manifold by removing the retain-
ing clip and pulling the sensor straight out.
Ensure that the MAP sensor seal is not dam-
aged. Replace the seal if it appears to bedamaged. See Fig 3C
D. 05 - 08 All: Apply a small amount of clean
engine oil or similar lubricant onto the rubber
MAP sensor seal (taking care not to get any
grease in or near the sensor opening) and
carefully install the MAP sensor into the
Lysholm manifold as shown. Secure the
MAP sensor to the Lysholm manifold using
the pre-installed retainer clip and fastener.
Depending on application, the retainer clipmay have to be bent to fit. See Fig 3D
'09 and newer: Remove the MAP sensor
retaining clip and fastener from the Lysholm
manifold and set aside. These parts are not
used with the 09-style MAP sensor. Locate
the included MAP sensor adapter and its
O-ring seal. Place the O-ring around the
snout, using a small amount of clean engine
oil or similar lubricant to hold it place. Use
the included M6 X 22mm socket head capscrew to fasten the MAP sensor adapter to
the Lysholm manifold in the threaded hole
previously occupied by the retaining clip fas-
tener. Pass the snout through the MAP sen-
sor hole in the manifold, ensuring that the
O-ring stays in position. Apply a small
amount of clean engine oil to the MAP sen-
sor seal and insert the MAP sensor into the
bore on the adapter. Secure the MAP sen-
sor to the adapter with another M6 X 22mm
socket head cap screw. The reinstalled MAPsensor should appear as shown in Figure
3D-2.
Fig. 3C
Fig. 3D ('05-'07 Classic, '07-'08)
Fig. 3D-2 (2009 Models)
oEm mAPSensr
oEm mAPSensr
EVAP hse
CrankcaseBreater hse
Pwer BrakeBster hse
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E. Remove the OEM power brake booster hose
from the back of the intake manifold and
install it onto the large hose barb on the rear
of the Lysholm inlet duct. See Figure 3D on
previous page.
F. Install the supplied Intake Air Temperature
(IAT) connector and pigtail to the IAT sensor
located on the top back surface of the
Lysholm manifold. The loose ends of the
wires will be connected in a later step.
G. 05 - 07 Classic: Remove the long EVAP
vent tube (See Fig. 3E-3) previously con-
nected to the EVAP solenoid from the engine
by disconnecting its fitting behind the driver
side cylinder head. Use a sharp blade to slitthe tube where it connects to each end fitting
so the tube can split and be removed from
the fittings as shown in Fig. 3E-4. Insert the
end fittings into the ends of the included
3-foot length of 5/16 hose as shown in Fig.
3E-5.
'07 NEW BODY - '10: Remove the EVAP
vent tube that runs from the forward fitting of
the EVAP solenoid to the top front of the
intake manifold. Use a sharp blade to slit thetube where it connects to the lower 90
quick-connect fitting so the tube can split and
be removed from the fitting. Insert the 90
fitting into the end of the long 5/16 hose
coming from the back of the supercharger
inlet duct.
H. 05 - 07 Classic: Remove the EVAP sole-
noid from the OEM intake manifold by
removing its retaining screw. Remove the
rubber gasket from the solenoid.
'07 NEW BODY - '10: Remove the EVAP
solenoid from the OEM intake manifold by
gently depressing the vertical tab on the
metal bracket until the solenoid slides up and
off.
Fig. 3E-5 ('05-'07 Classic Only)
Fig. 3E-3 ('05-'07 Classic Only)
Fig. 3E-4 ('05-'07 Classic Only)
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I. 05 - 07 Classic: Apply a small amount of
white grease or similar lubricant to the O-ring
on the end of the EVAP solenoid. Insert the
solenoid into the bore of the protrusion on
the front of the Lysholm supercharger intake
manifold from the top. Secure it using theexisting fastener at the base of the protru-
sion, placing the included .130 spacer
between the solenoid and the manifold if
needed to make the EVAP solenoid sit flat.
Thread the NPT x 5/16 barb fitting into
the bottom of the protrusion, using an appro-
priate pipe thread sealant.
'07 NEW BODY - '10: Slide the EVAP sole-
noid down into position on the bracket on the
driver side of the Lysholm manifold similar inshape and location to the EVAP bracket on
the OEM intake manifold.
J. Remove the OEM intake manifold gaskets
from the intake manifold and thoroughly
inspect them. If the sealing surfaces appear
to be damaged replace the gaskets with the
appropriate OEM replacement parts.
K. Modify the OEM intake manifold gaskets as
shown in Figure 3F and Figure 3G, carefullytrimming off the indicated protrusions for
clearance with the Lysholm intake. Trim the
center shark fin down in height to fit into the
relief on the intake, and remove one of the
end clips completely. The center clip and
one end clip need to remain intact test fit
each gaset to the intae to clarify which
clip needs to be reoved. Reduce the
height of the dome-shaped protrusions by
about 2/3 as shown in Figure 3H (this is to
improve installation clearance to the cowland may not be necessary on the Classic
HD models or other trucks with a body lift).
Take care to only remove as much material
as necessary without damaging the sealing
surfaces of the gasket.
Fig. 3G
Fig. 3H
Fig. 3F
TRIm
TRIm
CENTER ShARK FINTo BE TRImmED
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L. Install the gaskets onto the Lysholm super-
charger/manifold as shown in Figure 3I.
Ensure that the gaskets are properly aligned
and that the remaining mounting tabs snap
into place. Use a piece of tape to temporarily
secure the unsupported rear portion of thepassenger side gasket in such a way that the
tape can be removed after supercharger
installation.
M. Remove the fuel rail protection plate from the
rear face of the driver side cylinder head
using a 15mm wrench. Reinstall the plate
with the aluminum spacers (included in the
water tank assembly) between the plate and
cylinder head over the screw and dowel as
shown in Figure 3J. It may be helpful toapply a dab of RTV to the spacers to hold
them to the plate during reinstallation.
N. Replace the ten (10) bolts securing the valley
cover directly beneath the intake manifold
with the included M8-1.25 X 25mm low-pro-
file button head screws, reusing the small
plastic collar that may come out with the
OEM bolts. Tighten in a crisscross pattern
similar to the intake manifold. See Fig. 3K
Fig. 3I
Fig. 3J
Fig. 3K
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O. '07 NEW BODY - '10 only ('05 - '07 Classic
proceed to Section 4, Spercharger
Installation): Cut away the section of the
firewall insulation blanket above the intake
manifold area all the way back to the vertical
portion of the firewall. See Fig 3L
P. '08 and newer odels only: The oil pres-
sure sensor connector may interfere with the
supercharger if it is clocked toward the front
of the vehicle. While looking down at the
connector, if the protruding square portion
lines up with the OEM valley cover screw as
shown in Figure 3M or faces forward, it will
interfere. If this is the case, remove the sen-
sor and install the supplied copper shim
between the sensor and its mating surface.This will clock the connector rearward and
away from the manifold so interference will
not occur. Apply sealant to the threads of
the sensor and RTV to the shim to prevent
leaks. Reinstall and reconnect electrical con-
nection. See Fig. 3N
Fig. 3M
Fig. 3L
Fig. 3N
OEM screw
PtentialInterference
Zne
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Fig. 3Q
(Mid-frame mounts, 1/4" stack)
Fig. 3R
(Mounts behind rear door, 1/8" stack)
Q. '07 - '10 SuV ONLY (All others proceed to
Section 4, Spercharger Installation): The
following steps will achieve a sublte body lift
to allow adequate supercharger clearance.
Locate the 10 body to frame mounts on the
vehicle: 2 rearward of front bumper (See Fig.
3O), 2 next to catalytic converters (See Fig.3P), 2 mid frame (See Fig. 3Q), 2 forward of
rear axle (See Fig. 3R), and 2 forward of rear
bumper/tow hitch (See Fig. 3S).
R. The front mount screws will need a 15mm
boxed wrench on top (adjacent to the radiator
end tanks) with an 18mm socket from below.
All other mounts will need a 21mm socket to
remove.
Fig. 3S
(Rear most mounts, no spacers)
Fig. 3O
(Front most mounts, 1/2" stack)
Fig. 3P
(Mounts forward of front door, 3/8" stack)
FRoNT
FRoNT
FRoNT
FRoNT
FRoNT
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Fig. 3T
Fig. 3U
S. Remove the two (2) nuts on the front and
loosen the eight (8) screws securing the body
to the frame at the locations previously speci-
fied. Remove all the hardware except for the
front and rear most points. See Fig. 3T
T. Lift vehicle using secure points on the frame.
Place jack stands that extend at least 24 tallunder the body of the vehicle. The jack
stands need to be placed underneath body
cross supports located just behind the trans-
mission cross member, next to the ABS mod-
ule just inboard of the frame on the driver
side and outboard of the frame on the pas-
senger side. See Fig. 3U and Fig. 3V
U. Carefully lower the frame away from the body
until the wheels come to rest on the floor.
Verify that there is a minimum 4" of body sep-aration at the mounts just forward of the front
doors. Chock the tires to prevent the frame
from rolling and becoming misaligned with the
body.
Fig. 3V
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Fig. 3W (mount rotated for clarity)
Fig. 3X
W. Locate the body lift spacer kit. You will need
to arrange the spacers in a staggered height
as follows: front most one (1) 3/8 and one
(1) 1/8 spacer (1/2" total stack), forward of
front door one (1) 3/8 spacer, Mid-frame
two (2) 1/8 spacers (1/4" total stack), behind
rear doors one (1) 1/8 spacer, rear most
no spacer. See Fig. 3O thru Fig. 3S on previ-ous page for locations.
X. You will be able to simply slide the spacers in
to place in all positions except by the front
doors. When inserting the spacers between
the body and the mount, be sure the plastic
alignment guide for the screw is seated under
the spacer. See Fig. 3W and Fig. 3X
Y. After inserting the spacers, go ahead and
start the screws and hand tighten hardware at
this time.
Z. Ensure all the factory hardware is installed on
all the body mounts. You can now go ahead
and lift the vehicle by the frame, as the body
seats to the frame look for binding of the
mounts. Also ensure that any electrical,
cables, fuel or brake lines do not become
pinched during this process.
AA. Once the body is seated to the frame (See
Fig. 3Q), remove the jack stands and lowerthe vehicle back on to the ground. Apply a
dab of red loctite to the hardware and torque
down the ten (10) body mount hardware, start
from the middle and work your way to the
outer mounts. Torque to 44lb-ft.
Fig. 3Q
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A. With an assistant, carefully install the super-
charger assembly. Pay special attention to
the intake manifold gasket alignment and
position. It may be necessary to rotate the
upper radiator hose clamp where it attaches
to the engine for clearance. See Fig. 4A
B. Following the torque sequence shown in Fig.
4C, torque the ten (10) screws securing the
supercharger assembly to the engine first to
44 in-lb, then to a final torque of 89 in-lb.
Note that these torqe vales are in inch-
ponds, not foot-ponds.
C. Attach the OEM fuel line to the Lysholm fuel
fitting. Ensure that the connection is secure.
Attach the OEM safety clip around the con-nection. See Fig. 4B
D. Connect the short hose coming from the
back of the supercharger inlet duct to the
crankcase breather fitting at the rear of the
driver side valve cover.
E. Reconnect the power brake booster vacuum
hose (if equipped) to the fitting on the brake
booster.
1 5 8
93267
10 4
FRONT OF ENGINE
Fig. 4A
Fig. 4B
Fig. 4C
hse Clap
4. SUPERCHARGER INSTALLATION
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F. '07 NEW BODY - '10: Reinstall the modified
coolant vent tube assembly and confirm that
the nipple points away from any obstructions.
Reinstall the OEM small coolant hose to the
bent fitting. Reinstall the OEM hose clamp
and remove the clamping tool used to sealthe hose prior to removal. See Fig. 4D
G. Rotate and secure the alternator/power
steering assembly back to it's factory location
on the engine with the factory hardware pre-
viously removed. Do not install the factory
bolt directly below the alternator, this bolt will
be replaced in a later step.
H. 05 - 07 Classic: Locate the eight (8) includ-
ed fuel injector adapter pigtails and use themto connect the OEM injector harness to the
new fuel injectors as shown in Fig. 4D-2.
Attach the OEM electrical connectors to the
MAP sensor (behind the supercharger inlet
duct) and the EVAP solenoid (on the protru-
sion on the front of the supercharger assem-
bly).
'07 NEW BODY - '10: Attach the OEM elec-
trical connectors for the fuel injectors, MAP
sensor (behind the supercharger inlet duct),and EVAP solenoid (above the driver side
fuel rail).
Fig. 4D
Fig. 4D-2 ('05-'07 Classic Only)
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Fig. 4H
I. 05 - 07 Classic: Install the throttle body
onto the supercharger inlet duct with the sup-
plied metal gasket and M6 hardware.
Connect a length of the included hose
between the driver side bottom nipple on the
throttle body and the previously-bent nippleon the OEM coolant tube assembly and
secure with the included 14.5 stepless
clamps. Reconnect the OEM small coolant
hose to the passenger side bottom nipple on
the throttle body. Reinstall the OEM hose
clamp and remove the clamping tool used to
seal the hose prior to removal.
'07 NEW BODY - '10: Attach the included
throttle body adapter plate to the supercharg-
er inlet duct with the supplied metal gasketand M6 hardware. The socket-head cap
screws fit into the counter-bored holes and
the hex-headed screw is used in the upper
hole. Transplant the rubber seal from the
OEM intake manifold into the adapter plate.
Install the throttle body using the included
M6 hardware. See Fig. 4E, Fig. 4F, Fig. 4G
J. Attach the OEM electrical connector to the
ETC on the throttle body. See Fig 4H
K. Reconnect the charge wire and electrical
connector to the alternator.
Fig. 4E
Fig. 4F
Fig. 4G
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L. 05 - 07 Classic: Locate the 3-foot hose
created in a previous step with the OEM
EVAP quick-connect fittings inserted into the
ends. Connect the straight fitting to its origi-
nal location behind the driver side cylinder
head. Connect the 90 fitting to its originallocation on the top of the EVAP solenoid.
'07 NEW BODY - '10: Connect the OEM
EVAP vent tube running from the rear of the
engine to the rearward-facing port on the
EVAP solenoid. Ensure that the fitting snaps
securely into place.
M. 05 - 07 Classic: Connect the long 5/16
hose running from the back of the super-
charger inlet duct to the NPT x 5/16 barbfitting underneath the EVAP solenoid. See
Fig. 4I-2
'07 NEW BODY - '10: Connect the long
5/16 hose running from the back of the
supercharger inlet duct to the front of the
EVAP solenoid with the previously-installed
OEM 90 fitting. See Fig. 4I
N. Locate the bypass actuator assembly located
on the driver side of the superchargerassembly near the rear. Route and secure
the OEM wiring harness for proper clearance
to the bypass actuator assembly. Note that
the bypass arm will move during normal
operation and proper clearance of the har-
ness to the moving arm must be maintained.
Use supplied Adel clamp(s) and one or more
of the various screw locations on the driver
side valve cover or any similar suitable fas-
tening points. See Fig. 4J
Fig. 4I ('07-'10 New Body Only)
Fig. 4I-2 ('05-'07 Classic Only)
Fig. 4J
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A. Install the supplied 3 smooth idler in the
location of the previously-removed bolt below
the alternator. Place the tall bushing to the
inside, the small pilot bushing to the outside,
and secure the assembly with the M10 X
150mm bolt. See Fig. 5A
B. 5.3L ALL: Remove the OEM ribbed tension-
er idler and replace it with the supplied 4.3
ribbed idler. Secure with the OEM screw and
check for free operation. It may be necessary
to file a small amount of material off of the
protrusion on the tensioner body near the
bottom if it rubs on the pulley. It may also be
necessary to remove the dust shield that fits
under the head of the OEM screw. See Fig.
5B
6.0L ALL: Remove the OEM smooth idler
located beneath the supercharger drive
(above the water pump). Replace it with the
supplied 2.75 smooth idler using the OEM
hardware. See Fig 5B-2
C. Install the supplied drive belt onto the pulleys
as shown in Fig. 5C ('07-'10 New Body Style
shown, '05-'07 Classic similar).
Fig. 5A
Fig. 5B-2 ('05-'07 Classic)
Fig. 5B ('07 NEW BODY - '10)
5. IDLER AND DRIVE INSTALLATION
Fig. 5C
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6. SURGE TANk AND RESERVOIR
INSTALLATION, '05 - '07 CLASSIC
NOTE: See te diagra at te end f Sectin 7 fr reference.
A. Locate the supplied surge tank, P/N 8N056-
060, and the supplied mounting bracket.
Attach the bracket to the surge tank with the
supplied -20 X .50 screws and washers.
B. Install one straight NPT X barbed fit-
ting into the bottom and one 90 NPT X
barbed fitting into the side, angled down
and forward. See Fig. 6A.
C. Locate the cowl brace at the passenger side
rear corner of the engine compartment.
Remove the two 13mm-headed bolts secur-
ing it to the cowl area.
D. Place the surge tank bracket between the
brace and the cowl and reinstall the OEMbolts. See Fig. 6B
E. Locate the supplied triangle-shaped coolant
reservoir and install a 90 NPT X
barbed fitting into each of the two threaded
openings. Orient as shown in Fig. 6C and
Fig. 6D.
F. Install the mounting bracket to the reservoir
with the supplied -20 hardware. See Fig.
6C
G. Attach the water pump to the reservoir using
the supplied Adel clamp and -20 screw with
washer. See Fig. 6C
Fig. 6A
Fig. 6B
NOTE: Lysl suggests using pipe paste/sealant/tape n allNPT treads fr te cling syste.
Fig. 6C
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H. Install the short 90 hose between the water
pump and the barbed fitting on the bottom of
the reservoir and secure with two nylon
ratchet clamps. See Fig. 6D
I. Place the reservoir assembly into the loca-tion shown, on the inside face of the passen-
ger side frame rail just forward of the tubular
cross brace, and mark the location of its
mounting holes on the frame rail. See Fig.
6E
J. Drill an 11/64 pilot hole in each of the two
reservoir mounting hole locations on the
frame rail. Place the reservoir into position
and secure with the supplied self-tapping
screws with washers.
K. Attach the short end of the 90 formed hose
to the water pump outlet and route the long
end upward, forward of the radiator. Some
trimming of the splash shield may be
required. Leave the clamp loose until orienta-
tion is finalized in a later step.
L. Attach a length of hose to the fitting on
top of the reservoir. Route it through the radi-
ator core support and rearward to the bottomfitting of the surge tank previously installed.
Ensure that the hose is free of kinks and
away from heat, sharp edges, and moving
parts. Secure each end of the hose with a
nylon ratchet clamp.
Fig. 6D
Fig. 6E
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A. Locate the supplied surge tank, P/N 8N056-
060, and the supplied mounting bracket.
Attach the bracket to the surge tank with the
supplied -20 X .50 screws and washers.
B. Install one straight NPT X barbed fit-
ting into the bottom and one 90 NPT X
barbed fitting into the side, angled down
and forward as shown in Fig. 6.1A.
C. Locate the battery tray brace and adjacent
hood hinge brace on the passenger side of
the engine compartment. Remove the two
13mm-headed bolts securing them to the
cowl area.
D. Place the surge tank bracket between the
braces and the cowl and reinstall the OEM
bolts. See Fig 6.1B
E. Locate the supplied triangle-shaped coolant
reservoir and install a 90 NPT X
barbed fitting into each of the two threaded
openings. Orient as shown in Fig. 6.1C.
F. Install the 90 mounting bracket to the reser-
voir with the supplied -20 hardware as
shown in Fig. 6.1C.
G. Attach the water pump to the reservoir usingthe supplied Adel clamp and -20 screw with
washer.
Fig. 6.1B
Fig. 6.1ANOTE: Lysl suggests using pipe paste/sealant/tapen all NPT treads fr te cling syste.
6.1 SURGE TANk AND RESERVOIR
INSTALLATION, '07 NEW BODY - '11
NOTE: See te diagra at te end f Sectin 7.1 fr reference.
Fig. 6.1C
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H. Install the short 90 hose between the water
pump and the nearby barbed fitting and
secure with two nylon ratchet clamps. See
Fig 6.1C on previous page.
I. Place the reservoir assembly into the loca-tion shown, on the inside face of the passen-
ger side frame rail just forward of the tubular
cross brace, and mark the location of its
mounting holes on the frame rail. See Fig
6.1D
J. Drill an 11/64 pilot hole in each of the two
reservoir mounting hole locations on the
frame rail. Place the reservoir into position
and secure with the supplied self-tapping
screws with washers.
K. Partially remove the rubber splash shield
behind the bumper to grant access to the
reservoir assembly from above.
L. Locate the nylon retaining clips securing the
flexible plastic shield to the upper radiator
core support. Remove the clips and move
the shield to the side. See Fig 6.1E
M. Attach the short end of the 90 formed hose
to the water pump outlet and route the long
end upward, forward of the radiator. Leave
the clamp loose until orientation is finalized
in a later step.
N. Attach a length of hose to the fitting on
top of the reservoir. Route it through the
radiator core support and rearward to the
bottom fitting of the surge tank previously
installed. Ensure that the hose is free of
kinks and away from heat, sharp edges, and
moving parts. Secure each end of the hose
with a nylon ratchet clamp.
Fig. 6.1D
Fig. 6.1E
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A. Locate the supplied surge tank, P/N 8N056-
060, and the supplied mounting bracket.
Attach the bracket to the surge tank with the
supplied -20 X .50 screws and washers.
B. Install one straight NPT X barbed fit-
ting into the bottom and one 90 NPT X
barbed fitting into the side, angled down
and forward as shown in Fig. 6.2A.
C. Locate the battery tray brace and adjacent
hood hinge brace on the passenger side of
the engine compartment. Remove the two
13mm-headed bolts securing them to the
cowl area.
D. Place the surge tank bracket between the
braces and the cowl and reinstall the OEM
bolts. See Fig. 6.2B
E. Locate the supplied triangle-shaped coolant
reservoir and install a 90 NPT X
barbed fitting into each of the two threaded
openings. Orient as shown in Fig. 6.2C.
F. Install the 45 mounting bracket to the reser-
voir with the supplied -20 hardware as
shown in Fig. 6.2C.
G. Attach the water pump to the back of thereservoir using the supplied Adel clamp and
-20 screw with washer as shown in Fig.
6.2C.
Fig. 6.2B
Fig. 6.2ANOTE: Lysl suggests using pipe paste/sealant/tapen all NPT treads fr te cling syste.
6.2 SURGE TANk AND RESERVOIR
INSTALLATION, '07 - '10 SUV
NOTE: See te diagra at te end f Sectin 7.2 fr reference.
Fig. 6.2C
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H. Install the short 90 hose between the water
pump and the bottom barbed fitting and
secure with two nylon ratchet clamps. See
Fig 6.2C
I. Attach the short leg of one (1) of the supplied90 formed hose from water pump outlet.
Leave the clamp loose until orientation is
finalized in a later step. See Fig 6.2C
J. Place the reservoir assembly into the loca-
tion shown, on the inside face of the passen-
ger side frame rail just forward of the tubular
cross brace, and mark the location of its
mounting holes on the frame rail. (See Fig
6.2D) Drill an 11/64 pilot hole in each of the
two reservoir mounting hole locations on theframe rail.
M. Using a hose union fitting and two nylon
ratchet clamps, attach the long leg of another
90 formed hose to the hose previously
attached to the water pump outlet. Trim the
long legs as need to configuration shown on
Fig. 6.2E.
N. Feed the hoses attached to the water pump
outlet thru the opening on the bumper sup-port. This will attach to the Charge Air
Cooler's bottom fitting in a later step. See
Fig. 6.2E
O. Place the reservoir into position and secure
with the supplied self-tapping screws with
washers.
P. Attach a length of hose to the fitting on
top of the reservoir. Route it through the
radiator core support and rearward to the
bottom fitting of the surge tank previously
installed. Ensure that the hose is free of
kinks and away from heat, sharp edges, and
moving parts. Secure each end of the hose
with a nylon ratchet clamp.
Fig. 6.2E
Fig. 6.2D
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7. WATER COOLER INSTALLATION
'05 - '07 CLASSIC
NOTE: See te diagra at te end f tis sectin fr reference.
A. Locate the water cooler assembly P/N
8N106-140.
B. Attach the two supplied brackets to the water
heat exchanger as shown using the included
-20 hardware. Do not fully tighten, allowing
for adjustment. See Fig. 7A
C. Place the heat exchanger and bracket
assembly in place so the angled portions of
the mounting brackets rest on the diagonal
radiator support members as shown in Fig.
7B. Mark the mounting hole locations on the
diagonal support members.
D. Using an angle drill and extreme caution asto not damage radiator, drill 11/64 holes in
the mounting locations previously marked
(See Fig. 7C). The diagonal members may
be removed to facilitate drilling.
E. Mount the water cooler to the vehicle using
the included #12 sheet metal screws. Align
the cooler and tighten all mounting hardware.
See Fig. 7D.
Fig. 7A
Fig. 7D
Fig. 7C
NOTE: Teprarily place a piece f seet etal r ter barrieraterial between te A/C cndenser and te radiatrcre supprt braces befre drilling te les in te fllw-ing step t avid puncturing te cndenser.
Fig. 7B
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F. Using a 1" holesaw, drill through the plastic
core support in the location shown in Fig. 7E
being EXTREMELY careful not to drill into or
damage the A/C hard lines or radiator end
tank. Carefully inspect the surrounding areas
before drilling. It may be necessary toremove the headlight assembly by removing
the two headlight retaining pins to grant
access and additional clearance.
G. Trim the short leg of one of the 4 X 12 90
formed hoses as needed and connect it tothe heat exchangers lower fitting, oriented to
run straight down (See Fig. 7F). Secure it
with an included nylon ratchet clamp. Use a
hose union to connect the long leg to the
90 formed hose coming up from output fit-
ting of the water pump previously mounted to
the coolant reservoir. Secure with a nylon
ratchet clamp.
H. Run a length of hose from the bottom fit-
ting of the surge tank previously mounted tothe cowl to the fitting on top of the coolant
reservoir. Ensure that the hose runs downhill
the entire way to minimize potential trapped
air pockets, and secure each end with a
nylon ratchet clamp.
I. Locate the two remaining 4 X 12 90
formed hoses. These will connect to the fit-
tings on the front of the supercharger assem-
bly and need to be trimmed to nest together
routed toward the passenger side while stillproviding adequate clearance to the EVAP
solenoid. See Fig. 7G and Fig. 7H).
Fig. 7E
Fig. 7F
NOTE: At tis pint it is recended tat yu teprarily placete oEm airbx int psitin t aid in deterining prpercarge cler se ruting.
Fig. 7G
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Fig. 7H
J. After trimming the 4 X 12 90 formed hoses,
cover the long legs with the included abra-
sion sleeve and secure the ends of the
sleeve with the included heat-shrink tubing as
shown. Insert a barbed union fitting into the
end of each long leg and secure each con-nection with a nylon ratchet clamp. See Fig.
7I
K. Connect the two 4 X 12 90 formed hoses
to the front of the supercharger assembly in
the orientation shown (pointing toward the
passenger side) and secure each connection
with a nylon ratchet clamp.
L. Connect a length of hose from the 90 fit-
ting on the side of the surge tank to the 4 X12 90 formed hose coming from the pas-
senger side of the supercharger assembly.
Trim the hose to length such that it travels in
a smooth arc free of kinks and away from hot
parts and sharp edges. Secure with a nylon
ratchet clamp. See Fig. 7I
M. Connect a length of hose to the 4 X 12
90 formed hose coming from the driver side
of the supercharger assembly and secure
with a nylon ratchet clamp. Route this hosein as direct a manner as possible to the
upper fitting of the heat exchanger. Pass it
through the hole previously drilled on the
plastic core support through the opening in
between the headlight and radiator near the
passenger side bottom of the radiator as
shown in Fig. 7J. Secure the hose connec-
tion to the heat exchanger with a nylon
ratchet clamp.
N. Fill the charge cooler system with a 75/25
water/antifreeze mixture through the cap on
the surge tank.
Fig. 7I
Fig. 7J
NOTE: This hose routing creates a high point
at the heat exchanger, potentially making
it difficult to purge air from the system.
Pre-fill the hose with water to the extent
possible before finalizing the connections
to minimize this difficulty.
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HOSE ROUTING DIAGRAM, '05 - '07 CLASSIC
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A. Locate the water cooler assembly, P/N
8N106-160.
B. Install a 90 NPT X barbed fitting into
each of the openings. With the cooler orient-
ed vertically and the openings to the right,
orient the fittings such that the upper one
faces directly away from you and the lower
one faces down and forward.
C. Install the upper and lower cooler mounting
brackets to the cooler as shown in figure 6A.
Secure with the included bolts, washers, and
nylock nuts. See Fig 7.1A
D. Trim the radiator core support as shown in
Fig. 7.1B.
Fig. 7.1A
Fig. 7.1B
7.1 WATER COOLER INSTALLATION
'07 NEW BODY - '11 TRUCk
NOTE: See te diagra at te end f tis sectin fr reference.
TRIm oEm
BRACKET
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E. Attach the upper cooler mounting bracket to
the A/C condenser mount with the OEM fas-
teners, sandwiching the bracket between the
condenser mount and its mounting surface.
See Fig 7.1C
F. Attach the lower cooler mounting bracket to
the two (2) OEM 10mm-headed bolts on the
passenger side of the radiator core support.
See Fig 7.1C
G. Attach the long end of the 90 formed hose
previously connected to the water pump out-let to the coolers lower fitting. Secure each
end with a nylon ratchet clamp.
H. Locate one of the 4 x 12 90 formed hoses
and trim approximately 5 from the long end.
Trim approximately 1.5 from the short end to
provide adequate clearance to the A/C con-
denser when the hose is assembled to the
coolers upper fitting and is oriented to run
behind the cooler toward the passenger side.
Do not install at this time.
I. Install a barbed union fitting into the long end
of the 90 formed hose from the previous
step. Attach a length of hose to the other
end of the union and secure each joint with a
nylon ratchet clamp. Feed the length of
hose in a smooth radius rearward through
the radiator core support and install the short
end of the 90 formed hose onto the coolers
upper fitting. Secure with a nylon ratchet
clamp. See Fig 7.1D
Fig. 7.1C
NOTE: At tis pint it is recended tat yu teprari-ly place te oEm airbx int psitin t aid indeterining prper carge cler se ruting.
Fig. 7.1D
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J. Locate the two remaining 4 x 12 90 formed
hoses. These will connect to the fittings on
the front of the supercharger assembly and
need to be trimmed to nest together in
close proximity to the assembly. See Fig.
7.1E
K. After trimming the two 4 x 12 90 formed
hoses, cover the long legs with the included
abrasion sleeve and secure the ends of the
sleeve with the included heat-shrink tubing
as shown. Insert a barbed union fitting into
the end of each long leg and secure each
connection with a nylon ratchet clamp. See
Fig. 7.1F
L. Connect the two 4 x 12 90 formed hoses
to the front of the supercharger assembly in
the orientation shown (pointing toward the
passenger side) and secure each connection
with a nylon ratchet clamp.
M. Connect the hose running from the top of
the cooler to the 4 x 12 90 formed hoseleading to the driver side of the supercharger
assembly. Trim the hose to length such that
it travels in a smooth arc free of kinks and
away from hot parts and sharp edges.
Secure with a nylon ratchet clamp. See Fig.
7.1F
N. Connect a length of hose from the 90 fit-
ting on the side of the surge tank to the other
4 x 12 90 formed hose coming from the
passenger side of the supercharger assem-bly. Trim the hose to length such that it trav-
els in a smooth arc free of kinks and away
from hot parts and sharp edges. Secure with
a nylon ratchet clamp. See Fig. 7.1F
Fig. 7.1F
Fig. 7.1E
NOTE: "Upill" ruting f te fllwing se sectins willaid in purging air fr te cling syste at initialstartup.
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O. Return the flexible plastic shield previously
moved aside to its original position and
secure with the OEM clips. It will be neces-
sary to trim the shield to clear the cooler
hose. Take care to leave adequate clear-
ance between the shield and the hose toprevent hose damage during use. See Fig.
7.1G
P. Return the rubber splash shield previously
moved aside to its original position and
secure with the OEM clips. It will be neces-
sary to trim the shield to clear the cooler
assembly. See Fig. 7.1G
Q. Fill the charge cooler system with a 75/25
water/antifreeze mixture through the cap onthe surge tank.
Fig. 7.1G
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HOSE ROUTING DIAGRAM, '07 NEW BODY - '11 TRUCk
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A. Locate the water cooler assembly P/N
8N106-140.
B. Temporarily attach the two supplied brackets
to the water heat exchanger as shown using
the included -20 hardware. Do not tighten,
allowing for adjustment. See Fig 7.2A
C. Place the heat exchanger and bracket
assembly in place so the angled portions of
the mounting brackets rest on the diagonalradiator support members as shown in Fig.
7.2B. Mark the mounting hole locations on
the diagonal support members.
D. Using an angle drill and extreme caution as
to not damage radiator, drill 11/64 holes in
the mounting locations previously marked.(See Fig. 7.2C) The diagonal members may
be removed to facilitate drilling.
E. Mount the water cooler to the vehicle using
the included #12 sheet metal screws. Align
the cooler and tighten all mounting hardware.
See Fig. 7.2D
7.2 WATER COOLER INSTALLATION
'07 - '11 SUV
Fig. 7.2A
Fig. 7.2B
Fig. 7.2D
('07 Classic shown, '07-'10 SUV similar)
Fig. 7.2C
NOTE: Teprarily place a piece f seet etal r ter barrieraterial between te A/C cndenser and te radiatrcre supprt braces befre drilling te les in te fllw-ing step t avid puncturing te cndenser.
NOTE: See te diagra at te end f tis sectin fr reference.
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F. Located the formed 150 hose and connect
the short end to the CAC as shown. Trim the
hose as necessary and use hose union fit-
ting and two nylon ratchet clamps to secure.
G. Locate the two remaining 4 X 12 90 formedhoses. These will connect to the fittings on
the front of the supercharger assembly and
need to be trimmed to nest together routed
toward the passenger side in close proximity
to the assembly. See Fig. 7.2F and Fig. 7.2G
H. After trimming the two 4 x 12 90 formed
hoses, cover the long legs with the included
abrasion sleeve and secure the ends of the
sleeve with the included heat-shrink tubing as
shown. Insert a barbed union fitting into theend of each long leg and secure each con-
nection with a nylon ratchet clamp. See Fig
7.2G
I. Connect the two 4 x 12 90 formed hoses to
the front of the supercharger assembly in the
orientation shown in Fig. 7.2G (pointing
toward the passenger side) and secure each
connection with a nylon ratchet clamp.
Fig. 7.2E
Fig. 7.2F
Fig. 7.2G
NOTE: "Upill" ruting f te fllwing se sectins willaid in purging air fr te cling syste at initial
startup.
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J. Connect the hose running from the top of
the cooler to the 4 x 12 90 formed hose
leading to the driver side of the supercharg-
er assembly. Trim the hose to length such
that it travels in a smooth arc free of kinks
and away from hot parts and sharp edges.Secure with a nylon ratchet clamp. See Fig
7.2G
K. Connect a length of hose from the 90
fitting on the side of the surge tank to the
other 4 x 12 90 formed hose coming from
the passenger side of the supercharger
assembly. Trim the hose to length such that
it travels in a smooth arc free of kinks and
away from hot parts and sharp edges.
Secure with a nylon ratchet clamp. See Fig7.2G
L. Fill the charge cooler system with a 75/25
water/antifreeze mixture through the cap on
the surge tank.
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HOSE ROUTING DIAGRAM, '07 - '11 SUV
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A. Mount the supplied water pump relay in the
approximate location shown on the firewall orany other nearby suitable location (See Fig.
8A). It may be necessary to enlarge the
relay mounting hole.
B. Remove the four (4) 13mm-headed bolts
attaching the driver side cowl brace and set
the brace aside. Remove the power distribu-
tion box lid and plastic shroud and set them
aside.
C. Connect the short red wire from relay termi-nal #30 to the positive terminal post located
at the inboard rear corner of the power distri-
bution box as shown in Fig. 8B. Protect the
wire with split loom and route it such that it
will pass under the plastic shroud away from
sharp edges.
D. Connect the black wire from relay terminal
#86 to a good chassis ground. The stud
shown in Fig. 8A used to mount the relay is
suitable for this purpose.
Fig. 8A
Fig. 8B
8. WATER PUMP WIRING
'05 - '07 CLASSIC
WATER PUmP
RELAY
PoSITIVE
TERmINAL
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E. Feed the yellow wire from relay terminal #85
to the 20A fuse in the power distribution box
as shown in Fig. 8C. Connect using the sup-
plied fuse tap.
F. Run the long red wire from relay terminal #87down and across to the water pump. Place
the included fuse holder inline (install the
included fuse) and connect to the positive
(blue/green) wire on the water pump.
Secure the wire away from heat, sharp
edges, and moving parts.
G. Run the negative (brown) wire from the water
pump to a suitable chassis ground.
H. Reinstall the plastic fuse panel shroud andthe driver side cowl brace.
I. Reconnect the negative battery cable and
turn the key to the ON position (DO NOT
ATTEMPT TO START THE ENGINE). Make
sure that the water pump is operating and
that coolant is flowing through the surge
tank. Add coolant as needed. If the coolant
is not flowing, remove the charge cooler sup-
ply hose and lower until coolant flows out of
the hose. If necessary, provide light suctionto the hose to help prime the pump. Verify
coolant flow. Do not let the pump run dry for
more than 30 seconds without coolant flow.
Continue to check and fill the system until
the level stabilizes.
Fig. 8C
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A. Mount the supplied water pump relay in the
approximate location shown on the forwardface of the power distribution box such that
the cover will fit over it. The cover may
require a small amount of trimming to the
internal rib. See Fig 8.1A
B. Connect the short red wire from relay termi-
nal #30 to the positive terminal on the front
of the power distribution box using the sup-
plied ring terminal. See Fig 8.1A
C. Connect the black wire from relay terminal#86 to a suitable ground. See Fig 8.1A
Fig. 8.1A
8.1 WATER PUMP WIRING
'07 NEW BODY - '11, ALL
WATER PUmP
RELAY
PoSITIVE
TERmINAL
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D. Feed the yellow wire from relay terminal #85
to fuse #4 in the power distribution box as
shown and connect with the supplied fuse
tap. Any key on +12V source will work for
this connection. See Fig 8.1B
E. Run the long red wire from relay terminal #87
down and across to the water pump. Place
the included fuse holder inline (install the
included fuse) and connect to the positive
(blue/green) wire on the water pump.
Secure the wire away from heat, sharp
edges, and moving parts.
F. Run the negative (brown) wire from the water
pump to a suitable ground.
G. Reconnect the negative battery cable and
turn the key to the ON position (DO NOT
ATTEMPT TO START THE ENGINE). Make
sure that the water pump is operating and
that coolant is flowing through the surge
tank. Add coolant as needed. If the coolant
is not flowing, remove the charge cooler sup-
ply hose and lower until coolant flows out of
the hose. If necessary, provide light suction
to the hose to help prime the pump. Verify
coolant flow. Do not let the pump run formore than 30 seconds without coolant flow.
Continue to check and fill the system until
the level stabilizes.
Fig. 8.1B
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