GM Truck/SUV With Cathedral Port Cylinder Heads

Transcription

1 GM Truck/SUV With Cathedral Port Cylinder Heads Lysholm Twin-Screw Supercharger System Installation Instructions Model Year 5.3L Model Year "Classic" 6.0L 50 State Smog Legal per CARB EO# D Pacific Avenue, Channel Islands CA Phone: Fax: M-F 8:00AM - 4:30PM (PST)

2 FOREWORD This manual provides information on the installation, maintenance and service of the Lysholm supercharger kit expressly designed for this vehicle. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Lysholm for any additional information regarding this kit and any of these modifications at (805) :00am-4:30pm PST. Take note of the following before proceeding: 1. Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to 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 product was designed for use on stock (un-modified, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Lysholm 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 hard use (no boost) until the problem is resolved. 5. Lysholm is not responsible for any clutch, transmission, drive-line or engine damage. Exclusions from Lysholm warranty coverage considerations include, but not limited to: 1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation. 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, third party PCM programming or other such changes Lysholm All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into another language in any form, by any means without written permission of Lysholm. i

3 TABLE OF CONTENTS FOREWORD...i TABLE OF CONTENTS ii COPYRIGHT NOTICE iii automatic transmission disclaimer... iv GM Truck/SUV Installation Instructions...v PARTS LIST, PN ('05 - '07 GM 6.0L TRUCK (Classic))... vi PARTS LIST, PN ('07 - '11 GM 5.3L SUV)... vii PARTS LIST, PN ('07 - '11 GM 5.3L Truck)...viii 1. BASIC COMPONENT REMOVAL INTAKE MANIFOLD REMOVAL SUPERCHARGER PREPARATION SUPERCHARGER INSTALLATION IDLER AND DRIVE INSTALLATION SURGE TANK AND COOLANT RESERVOIR INSTALLATION ('05 - '07 Classic) SURGE TANK AND COOLANT RESERVOIR INSTALLATION ('07 NEW BODY - '11) SURGE TANK AND COOLANT RESERVOIR INSTALLATION ('07 - '11 SUV) WATER COOLER INSTALLATION ('05 - '07 Classic) WATER COOLER INSTALLATION ('07 NEW BODY - '11, TRUCK) WATER COOLER INSTALLATION ('07 - '11 SUV) WATER PUMP WIRING ('05 - '07 Classic) WATER PUMP WIRING ('07 NEW BODY - '11) AIR INLET INSTALLATION MISCELLANEOUS REASSEMBLY REFLASH COMPUTER FINAL ASSEMBLY AND CHECK ii

4 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. iii

5 automatic transmission disclaimer The transmission shift strategies built into the Lysholm ECU calibration supplied with this kit have been designed and tested to work properly with the Lysholm Supercharger under normal driving conditions at the Lysholm supplied power levels. Towing, racing, performance driving, hard accelerations and other heavy/severe duty driving activities place extra demands on the vehicle's automatic transmission and its cooling system. If you use or plan to use your newly supercharged vehicle under any of these demanding driving conditions, Lysholm suggests that you evaluate your automatic transmission system. Several companies make products to increase your transmission's useful life. Shift Improver 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 fluid temperature under control. Excessive fluid 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 equipped with 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 fluid to further stabilize fluid temperature in your transmission. NOTE: This listing is provided solely for informational purposes. Lysholm has made no evaluation of the quality or functionality of any specific brands of these products. Please contact product companies should you wish to obtain more information. iv

6 GM Truck/SUV Installation Instructions Congratulations on selecting the best performing and best backed automotive supercharger available today... the Lysholm Supercharger! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner s Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form. Lysholm supercharger systems are performance improving devices. In most cases, increases in torque of 30 35% and horsepower of 35-45% can be expected with the boost levels specified by Lysholm. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Lysholm is not responsible for engine damage. Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed. For best performance and continued durability, please take note of the following key points: 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 modified 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 problem is resolved. 5. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every at least 15,000 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 you will also need: Spark Plug Socket NEW Spark Plugs v

7 '05 - '07 GM 6.0L TRUCK (Classic) Part No parts list IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY VINYL DECAL YR S/C STRT INFO PKG ASY S/C LUBE, Lysholm oz 1 2L S/C ASY, 2300 Lysholm, 07 CLSC L UNIV S/C ASY, Lysholm 2300AX, GM CATH. PORT V8 1 2L PULLEY, 6-RIB, 3.25, GM TRK Lysholm 1 4LGL BRKT, HOLD DN MAP SENS.Lysholm 1 4LGL BRKT, FUEL HOSE, Lysholm GMT 1 7C M6 X 1.0 X 12MM FLG HD CL10.9+ ZINC 1 4LGL FUEL LINE ASSY A, LYSH GM R ADEL CLAMP, 1/2" ID 1 7C m6 X 1.0 X 8MM, SHCS PLATED 1 7C M6 X 1.0 X 16MM SHCS CL10.9+ ZINC 4 4LGL INSTR MAN., GM TRK, Lysholm 1 4LGL AIR INLET ASSY, GM TRK, Lysholm 1 4LGL ADAPTER, T-BODY GM TRK,Lysholm 1 4LGL DUCT, INLET GM TRK, Lysholm 1 4LGL GASKET, THRTL BODY, GM TRK 1 5W /16" HEAT-SHRINK TUBING 0.5FT 5W GA BUTT CONN RED INSUL 2 5W /4" PLASTIC WIRE LOOM 18IN 5W HARNESS, IAT SENSOR GM TRK 1 7C M6 X 1.0 X 16MM SHCS CL10.9+ Z 2 7C m6 X 1.0 X 25MM HX 1 7C m6 X 1.0 X 40 HXHD CL J MM WASHER, PLATED 5 7P /4 MALE NPT X 3/8 MALE BARB 1 7PS BUMP HOSE, 3.50D X 3.00L 1 7PS SLEEVE, BLACK 4.0D X R #56 SAE TYPE F SS HOSE CLAMP 2 7R #64 SAE TYPE F SS HOSE CLAMP 2 7U /8 X 90º MOLDED RUBBER HOSE 1 8H FILTER, GM TRK PNL. 1 4LGL SUPPORT ASSY, GM TRK, 07 CLASS 1 2A SPACER,.750 OD X.130 LONG 1 2A BELT, GATES K C PILOT, 6203/5 BRG, 7/16 SCREW 1 4FH IDLER PULY, SMOOTH 6RIB 3" FLA 1 4LGL SPACER,IDLER, Ø.88 X TX IDLER, 2.75 DIA, SMOOTH, 7 RIB 1 5W /2" HEAT SHRINK 0.67FT 5W INJ ADAPTER, MULTEC II M TO EV 8 5W SLEEVE, FLEX BRAID Ø.75" NOM. 1.17FT 5W SLEEVE, FLEX BRAID Ø.75" NOM. 1.17FT 7C m10 X 1.5 X 150 HXHD CL C m8 X 1.25 X 25MM BHCS 10 7P /8NPT-STR,5/16 BARB 1 7R ADEL CLAMP,1-11/16" 1 7R STEPLESS CLAMP, R NYLON RATCHET CLAMP 1-1/8" 5 7U /4" EFI HP FUEL LINE 1.5FT 7U /16" PCV/VAC RUBBER HOSE 3FT 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 5A TUNER, SCT, GM 1 8N WATER TANK ASSY, 07+ GM TRUCK 1 2A SPACER,.875 OD X.290 LONG 2 7A /4-20 X.50 SHCS GR8 ZINC PLT 4 7J /4 WASHER, SAE, PLTD 4 7P /4" HOSE BARB UNION, BRASS 3 7P /2NPT X 3/4 BARB 90 BRASS 2 7P /2NPT X 3/4 BARB 90, NICKEL 1 7P /2NPT X 3/4 HOSE FIT STRT NIC 1 7R NYLON RATCHET CLAMP 1-1/8" 14 7U HOSE, 3/4 X 90 RUBBER, SHORT 1 7U /4" HEATER HOSE 14ft 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 7U HOSE, 3/4 D X150 MOLDED HOSE 1 7U TIE WRAP, 7.5" NYLON 6 8N BRKT, SURGE TANK, 07 GM TRK 1 8N BRKT, COOLANT RES 07 GM TRK 1 8N BRKT, COOLANT RES GM TRK 1 8N TANK, WATER, TRIANGLE SHAPE 1 8N PLASTIC CAP, SURGE TANK 1 8N SURGE TANK, PLASTIC 1 8N WATR COOLR ASY, 07 ESCAL 1 7A /4-20 X.50 SHCS GR8 ZINC PLT 4 7E #12 X 3/4" SHT METL SCRW HEX 4 7J /4 WASHER, SAE, PLTD 8 7P /4" HOSE BARB UNION, BRASS 1 7R ADEL CLAMP, 1.0" 1 7R NYLON RATCHET CLAMP 1-1/8" 4 7U hose, 3/4 DIA 90, 4 X 12 LEGS 3 8N WATER COOLR, FLDYN DUAL PASS 1 8N FLDYN BKT, 07 ESCALADE DRVR 1 8N FLDYN BKT, 07 ESCALADE PASS 1 8N WATER PMP ASSY, GMT LS1 H.O. 1 5W FUSE TAP 1 5W /8" PLASTIC WIRE LOOM 5ft 5W GA BUTT CONN BLU INSUL 4 5W FUSE, BLADE TYPE 20 AMP 1 5W GA X 3/8" RING TERMINAL 1 5W GA BUTT CONN INSULATED 2 5W T-TAP CONN,14-16 AWG 1 5W mini ATC FUSE TAP 1 5W GA MALE SLIDE INSULATED 1 5W GA X 1/4" RING TERMINAL 1 5W FUSE HOLDER,16GA WIRE 1 7A /4-20 X.50 SHCS GR8 ZINC PLT 2 7E #10 X 3/4" SHT METL SCRW phillips 2 7E #12 X 3/4" SHT METL SCRW HEX 2 7F NUT, M8 X F /4-20 NYLOCK NUT ZINC PLATED 1 7R ADEL CLAMP,1-11/16" 1 7U TIE WRAP, 4" NYLON 4 7U TIE WRAP, 7.5" NYLON 6 8F PUMP, WATER, PIERBURG 1 8F FUEL PUMP RELAY ASSY, LS1 TRK 1 5W GA FEMALE SLIDE INSULATED 2 5W RELAY,BOSCH 1 5W GA FEMALE SLIDE INSULATED 2 5W GA X 3/16" RING TERMINAL 2 5W GA,STRD WIRE, RED 9.5ft 5W GA,STRD WIRE, RED 1.5ft 5W GA WIRE BLACK 0.5ft 5W GA STRD WIRE BLACK 0.5ft 5W GA STRD WIRE YELLOW 2.5ft vi

8 '07 - '11 GM 5.3L SUV Part No parts list IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO. DESCRIPTION QTY VINYL DECAL YR S/C STRT INFO PKG ASY S/C LUBE, Lysholm oz 1 2L S/C ASSY, 2300 Lysholm, GM TRK 1 2L UNIV S/C ASY, Lysholm 2300AX, GM CATH. PORT V8 1 2L PULLEY Ø3.80, Lysholm GMT LGL BRKT, HOLD DN MAP SENS.Lysholm 1 4LGL BRKT, EVAP SOLENOID Lysholm GMT 1 4LGL BRKT, FUEL HOSE, Lysholm GMT 1 7C M6 X 1.0 X 12MM FLG HD CL10.9+ ZINC 1 4LGL FUEL LINE ASSY A, LYSH GM R ADEL CLAMP, 1/2" ID 1 7C m6 X 1.0 X 8MM, SHCS PLATED 1 7C M6 X 1.0 X 16MM SHCS CL10.9+ ZINC 4 4LGL INSTR MAN., GM TRK, LyshOLM 1 4LGL AIR INLET ASSY, GM TRK, LyshOLM 1 4LGL DUCT, INLET GM TRK, Lysholm 1 4LGL GASKET, THRTL BODY, GM TRK 1 5W /16" HEAT-SHRINK TUBING 0.5ft 5W GA BUTT CONN RED INSUL 2 5W /4" PLASTIC WIRE LOOM 18in 5W HARNESS, IAT SENSOR GM TRK 1 7C M6 X 1.0 X 16MM SHCS CL10.9+ Z 2 7C m6 X 1.0 X 25MM HX 1 7C m6 X 1.0 X 40 HXHD CL J MM WASHER, PLATED 5 7P /4 MALE NPT X 3/8 MALE BARB 1 7PS BUMP HOSE, 3.50D X 3.00L 1 7PS SLEEVE, BLACK 4.0D X R #56 SAE TYPE F SS HOSE CLAMP 2 7R #64 SAE TYPE F SS HOSE CLAMP 2 7U /8 X 90 MOLDED RUBBER HOSE 1 8H FILTER, GM TRK PNL. 1 4LGL SUPPORT ASSY, GM TRK, LyshOLM 1 2A BELT, GATES K C PILOT, 6203/5 BRG, 7/16 SCREW 1 4FH IDLER PULY, SMOOTH 6RIB 3" FLA 1 4LGL ADAPTER, T-BODY GM TRK,Lysholm 1 4LGL ADAPTER, MAP SENSOR, 09 GM TRK Lysholm 1 4LGL IDLER, 6 RIB, 4.2", COMPOSITE 1 4LGL SPACER, IDLER, Ø.88 X W /2" HEAT SHRINK 0.666ft 5W SLEEVE, FLEX BRAID Ø.75" NOM ft 5W SLEEVE, FLEX BRAID Ø.75" NOM ft 7C m10 X 1.5 X 150 HXHD CL C m6-1.0 X 22MM SHCS LYSH SC 2 7C m8 X 1.25 X 25MM BHCS 10 7J WASHER, Ø.640" ID X.032" THK X Ø1.188" 1 7R ADEL CLAMP,1-11/16" 1 7R NYLON RATCHET CLAMP 1-1/8" 5 7U o-ring,.630od X.424ID X.103W 1 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 7U FILLER NECK, OIL, 09 GM TRK Lysholm 1 4lgl SPACER KIT, BODY LIFT, 07+ GMT 1 5A TUNER, SCT, GM 1 8N WATER TANK ASSY, 07+ GM TRUCK 1 PART NO. DESCRIPTION QTY 2A SPACER,.875 OD X.290 LONG 2 7A /4-20 X.50 SHCS GR8 ZINC PLT 4 7J /4 WASHER, SAE, PLTD 4 7P /4" HOSE BARB UNION, BRASS 3 7P /2NPT X 3/4 BARB 90 BRASS 2 7P /2NPT X 3/4 BARB 90, NICKEL 1 7P /2NPT X 3/4 HOSE FIT STRT NIC 1 7R NYLON RATCHET CLAMP 1-1/8" 14 7U HOSE, 3/4 X 90 RUBBER, SHORT 1 7U /4" HEATER HOSE 14ft 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 7U HOSE, 3/4 D X150 MOLDED HOSE 1 7U TIE WRAP, 7.5" NYLON 6 8N BRKT, SURGE TANK, 07 GM TRK 1 8N BRKT, COOLANT RES 07 GM TRK 1 8N BRKT, COOLANT RES GM TRK 1 8N TANK, WATER, TRIANGLE SHAPE 1 8N PLASTIC CAP, SURGE TANK 1 8N SURGE TANK, PLASTIC 1 8N WATR COOLR ASY, 07 ESCAL 1 7A /4-20 X.50 SHCS GR8 ZINC PLT 4 7E #12 X 3/4" SHT METL SCRW HEX 4 7J /4 WASHER, SAE, PLTD 8 7P /4" HOSE BARB UNION, BRASS 1 7R ADEL CLAMP, 1.0" 1 7R NYLON RATCHET CLAMP 1-1/8" 4 7U hose, 3/4 DIA 90, 4 X 12 LEGS 3 8N WATER COOLR, FLDYN DUAL PASS 1 8N FLDYN BKT, 07 ESCALADE DRVR 1 8N FLDYN BKT, 07 ESCALADE PASS 1 8N WATER PMP ASSY, GMT LS1 H.O. 1 5W FUSE TAP 1 5W /8" PLASTIC WIRE LOOM 5ft 5W GA BUTT CONN BLU INSUL 4 5W FUSE, BLADE TYPE 20 AMP 1 5W GA X 3/8" RING TERMINAL 1 5W GA BUTT CONN INSULATED 2 5W T-TAP CONN,14-16 AWG 1 5W mini ATC FUSE TAP 1 5W GA MALE SLIDE INSULATED 1 5W GA X 1/4" RING TERMINAL 1 5W FUSE HOLDER,16GA WIRE 1 7A /4-20 X.50 SHCS GR8 ZINC PLT 2 7E #10 X 3/4" SHT METL SCRW phillips 2 7E #12 X 3/4" SHT METL SCRW HEX 2 7F NUT, M8 X F /4-20 NYLOCK NUT ZINC PLATED 1 7R ADEL CLAMP,1-11/16" 1 7U TIE WRAP, 4" NYLON 4 7U TIE WRAP, 7.5" NYLON 6 8F PUMP, WATER, PIERBURG 1 8F FUEL PUMP RELAY ASSY, LS1 TRK 1 5W GA FEMALE SLIDE INSULATED 2 5W RELAY,BOSCH 1 5W GA FEMALE SLIDE INSULATED 2 5W GA X 3/16" RING TERMINAL 2 5W GA,STRD WIRE, RED 9.5ft 5W GA,STRD WIRE, RED 1.5ft 5W GA WIRE BLACK 0.5ft 5W GA STRD WIRE BLACK 0.5ft 5W GA STRD WIRE YELLOW 2.5ft vii

9 '07 NEW BODY- '11 GM 5.3L Truck Part No parts list IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO. DESCRIPTION QTY VINYL DECAL YR S/C STRT INFO PKG ASY S/C LUBE, Lysholm oz 1 2L S/C ASY, 2300 Lysholm, GM TRK 1 2L UNIV S/C ASY, Lysholm 2300AX, GM CATH. PORT V8 1 2L PULLEY Ø3.80, Lysholm GMT LGL BRKT, HOLD DN MAP SENS.Lysholm 1 4LGL BRKT, EVAP SOLENOID Lysholm GMT 1 4LGL BRKT, FUEL HOSE, Lysholm GMT 1 7C M6 X 1.0 X 12MM FLG HD CL10.9+ ZINC 1 4LGL FUEL LINE ASSY A, LYSH GM R ADEL CLAMP, 1/2" ID 1 7C m6 X 1.0 X 8MM, SHCS PLATED 1 7C M6 X 1.0 X 16MM SHCS CL10.9+ ZINC 4 4LGL INSTR MAN., GM TRK, LyshOLM 1 4LGL AIR INLET ASSY, GM TRK, LyshOLM 1 4LGL DUCT, INLET GM TRK, Lysholm 1 4LGL GASKET, THRTL BODY, GM TRK 1 5W /16" HEAT-SHRINK TUBING 0.5ft 5W GA BUTT CONN RED INSUL 2 5W /4" PLASTIC WIRE LOOM 18in 5W HARNESS, IAT SENSOR GM TRK 1 7C M6 X 1.0 X 16MM SHCS CL10.9+ Z 2 7C m6 X 1.0 X 25MM HX 1 7C m6 X 1.0 X 40 HXHD CL J MM WASHER, PLATED 5 7P /4 MALE NPT X 3/8 MALE BARB 1 7PS BUMP HOSE, 3.50D X 3.00L 1 7PS SLEEVE, BLACK 4.0D X R #56 SAE TYPE F SS HOSE CLAMP 2 7R #64 SAE TYPE F SS HOSE CLAMP 2 7U /8 X 90 MOLDED RUBBER HOSE 1 8H FILTER, GM TRK PNL. 1 4LGL SUPPORT ASSY, GM TRK, Lysholm 1 2A BELT, GATES K C PILOT, 6203/5 BRG, 7/16 SCREW 1 4FH IDLER PULY, SMOOTH 6RIB 3" FLA 1 4LGL ADAPTER, T-BODY GM TRK,Lysholm 1 4LGL ADAPTER, MAP SENSOR, 09 GM TRK Lysholm 1 4LGL IDLER, 6 RIB, 4.2", COMPOSITE 1 4LGL SPACER, IDLER, Ø.88 X W /2" HEAT SHRINK 0.666ft 5W SLEEVE, FLEX BRAID Ø.75" NOM ft 5W SLEEVE, FLEX BRAID Ø.75" NOM ft 7C m10 X 1.5 X 150 HXHD CL C m6-1.0 X 22MM SHCS LYSH SC 2 7C m8 X 1.25 X 25MM BHCS 10 7J WASHER, Ø.640" ID X.032" THK X Ø1.188" 1 7R ADEL CLAMP,1-11/16" 1 7R NYLON RATCHET CLAMP 1-1/8" 5 7U o-ring,.630od X.424ID X.103W 1 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 7U FILLER NECK, OIL, 09 GM TRK Lysholm 1 5A TUNER, SCT, GM 1 8N WATER TANK ASSY, 07+ GM TRUCK 1 2A SPACER,.875 OD X.290 LONG 2 PART NO. DESCRIPTION QTY 7A /4-20 X.50 SHCS GR8 ZINC PLT 4 7J /4 WASHER, SAE, PLTD 4 7P /4" HOSE BARB UNION, BRASS 3 7P /2NPT X 3/4 BARB 90 BRASS 2 7P /2NPT X 3/4 BARB 90, NICKEL 1 7P /2NPT X 3/4 HOSE FIT STRT NIC 1 7R NYLON RATCHET CLAMP 1-1/8" 14 7U HOSE, 3/4 X 90 RUBBER, SHORT 1 7U /4" HEATER HOSE 14ft 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 7U HOSE, 3/4 D X150 MOLDED HOSE 1 7U TIE WRAP, 7.5" NYLON 6 8N BRKT, SURGE TANK, 07 GM TRK 1 8N BRKT, COOLANT RES 07 GM TRK 1 8N BRKT, COOLANT RES GM TRK 1 8N TANK, WATER, TRIANGLE SHAPE 1 8N PLASTIC CAP, SURGE TANK 1 8N SURGE TANK, PLASTIC 1 8N WATER COOLER ASY, 07+ GM TRK 1 7A /4-20 X.75 SHCS PLTD 8 7F /4-20 NYLOCK NUT ZINC PLATED 8 7J /4 WASHER, SAE, PLTD 16 7P /2NPT X 3/4 BARB 90 BRASS 2 7R ADEL CLAMP, 1.0" 1 7U hose, 3/4 DIA 90, 4 X 12 LEGS 1 8N WATER COOLR, SETRAB SINGLE PAS 1 8N BRKT "A", HEAT EXCHGR 07 GMT 1 8N BRKT "B", HEAT EXCHGR 07 GMT 1 8N WATER PMP ASSY, GMT LS1 H.O. 1 5W FUSE TAP 1 5W /8" PLASTIC WIRE LOOM 5ft 5W GA BUTT CONN BLU INSUL 4 5W FUSE, BLADE TYPE 20 AMP 1 5W GA X 3/8" RING TERMINAL 1 5W GA BUTT CONN INSULATED 2 5W T-TAP CONN,14-16 AWG 1 5W mini ATC FUSE TAP 1 5W GA MALE SLIDE INSULATED 1 5W GA X 1/4" RING TERMINAL 1 5W FUSE HOLDER,16GA WIRE 1 7A /4-20 X.50 SHCS GR8 ZINC PLT 2 7E #10 X 3/4" SHT METL SCRW phillips 2 7E #12 X 3/4" SHT METL SCRW HEX 2 7F NUT, M8 X F /4-20 NYLOCK NUT ZINC PLATED 1 7R ADEL CLAMP,1-11/16" 1 7U TIE WRAP, 4" NYLON 4 7U TIE WRAP, 7.5" NYLON 6 8F PUMP, WATER, PIERBURG 1 8F FUEL PUMP RELAY ASSY, LS1 TRK 1 5W GA FEMALE SLIDE INSULATED 2 5W RELAY,BOSCH 1 5W GA FEMALE SLIDE INSULATED 2 5W GA X 3/16" RING TERMINAL 2 5W GA,STRD WIRE, RED 9.5ft 5W GA,STRD WIRE, RED 1.5ft 5W GA WIRE BLACK 0.5ft 5W GA STRD WIRE BLACK 0.5ft 5W GA STRD WIRE YELLOW 2.5ft viii

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11 1. Basic Component Removal A. Temporarily disconnect the negative battery cable. B. Remove the plastic engine/intake manifold cover (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 Fig. 1A D. Unplug the electrical connector from the MAF. E. Temporarily remove the airbox/maf assembly from the vehicle. The airbox is secured to the vehicle at three (3) points on the bottom and simply snaps into and out of place. See Fig 1B F. Remove the accessory drive belt by releasing the tensioner with a 15mm wrench. The OEM belt will not be reused. Fig. 1B 1

12 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 it will 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. Fig. 1C '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 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) on the 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 models have additional tabs securing the bumper cover to the grille. These tabs need to be depressed and the bumper cover pushed out (forward) to release the grille. PLASTIC PANEL COVER CLIPS Fig. 1D Fig. 1E ('05 - '07 Classic Only) 2

13 J. '07 - '10 New Body SUV ONLY (All others proceed to Section 2, Intake Manifold Removal): Remove four (4) fasteners on each side connecting the front inner splash guards to the bumper cover. See Fig 1F FENDER LINER FASTENERS 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 Fig. 1F 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 REMOVE SCREWS Fig. 1G DISCONNECT ELECTRICAL CONNECTORS ON EACH SIDE PULL OUT THEN FORWARD Fig. 1I Fig. 1H 3

14 2. Intake Manifold Removal 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 coolant 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 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 confusion as the harnesses will be moved around during supercharger installation. Fig. 2B 4

15 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 of the 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 alternator. 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) entering 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 assembly to rotate away from the engine, towards the driver side until it rests out of the way. Fig. 2C NOTE: The bolt located directly below the alternator (at 6 o'clock position) will not be reused. This bolt will be replaced with an idler and new hardware in a later step. Caution: On newer body style vehicles ('07-'10), use caution when setting the alternator/power steering bracket aside. The cam position sensor connector is located just below the bracket on the front timing cover and can be accidentally disconnected if the bracket rests on the harness or connector. 5

16 I Classic: Disconnect the Evaporative Emission Control (EVAP) electrical connector from the EVAP solenoid located on the top of the intake manifold directly behind the throttle body. Disconnect the EVAP vent tube that runs to the driver side and then rearward from the solenoid. '07 NEW BODY - '10: Disconnect the Evaporative Emission Control (EVAP) electrical connector from the EVAP solenoid located above the driver side fuel rail. Disconnect the EVAP vent tube that runs rearward from the solenoid. See Fig 2D Fig. 2D J. Lift the large electrical harness from the top of the intake manifold and push it off to the side to the furthest extent possible. Separate the harness from the previouslydisconnected plastic harness brackets. Set the brackets aside, as they will no longer be used. K. Relieve any residual pressure in the fuel system using the capped fitting on the passenger side fuel rail. Remove the cap, cover the fitting and surrounding area with a rag and depress the valve. Use caution as a small amount of fuel may squirt out. See Fig 2E 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. 2F 6

17 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 the brake 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 manifold removal will be. These screws will not be reused. CRANKCASE BREATHER HOSE BRAKE BOOSTER HOSE Fig. 2G 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 NOTE: Both OEM intake manifold gaskets will be re-used during supercharger installation. Carefully inspect the removed gaskets. Ensure that both gaskets are in good condition with no cuts or damage to the sealing surfaces. If there s any doubt, replace them with the appropriate OEM replacement parts (GM part number ) 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. 7

18 3. Supercharger Preparation A 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 passenger side as shown in Figure 3A. '07 NEW BODY - '10: 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 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 isn t at the same spot on the nipple. The total bend needed is only from vertical 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. COOLANT VENT TUBE COOLANT VENT TUBE Fig. 3A Fig. 3A-2 Fig. 3B 8

19 C. Remove the OEM MAP sensor from the OEM intake manifold by removing the retaining clip and pulling the sensor straight out. Ensure that the MAP sensor seal is not damaged. Replace the seal if it appears to be damaged. See Fig 3C D 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 clip may 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 cap screw to fasten the MAP sensor adapter to the Lysholm manifold in the threaded hole previously occupied by the retaining clip fastener. Pass the snout through the MAP sensor hole in the manifold, ensuring that the O-ring stays in position. Apply a small amount of clean engine oil to the MAP sensor seal and insert the MAP sensor into the bore on the adapter. Secure the MAP sensor to the adapter with another M6 X 22mm socket head cap screw. The reinstalled MAP sensor should appear as shown in Figure 3D-2. OEM MAP Sensor OEM MAP Sensor Fig. 3C EVAP Hose Crankcase Breather Hose Power Brake Booster Hose Fig. 3D ('05-'07 Classic, '07-'08) Fig. 3D-2 (2009 Models) 9

20 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 Classic: Remove the long EVAP vent tube (See Fig. 3E-3) previously connected to the EVAP solenoid from the engine by disconnecting its fitting behind the driver side cylinder head. Use a sharp blade to slit the 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 the tube 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. Fig. 3E-3 ('05-'07 Classic Only) Fig. 3E-4 ('05-'07 Classic Only) H Classic: Remove the EVAP solenoid 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) 10

21 I 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 the existing fastener at the base of the protrusion, placing the included.130 spacer between the solenoid and the manifold if needed to make the EVAP solenoid sit flat. Thread the ¼ NPT x 5/16 barb fitting into the bottom of the protrusion, using an appropriate pipe thread sealant. '07 NEW BODY - '10: Slide the EVAP solenoid down into position on the bracket on the driver side of the Lysholm manifold similar in shape and location to the EVAP bracket on the OEM intake manifold. CENTER SHARK FIN TO BE TRIMMED TRIM TRIM Fig. 3F 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, carefully trimming 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 gasket to the intake to clarify which clip needs to be removed. 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 cowl and 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 11

22 L. Install the gaskets onto the Lysholm supercharger/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 the passenger 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 to apply 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 M X 25mm low-profile 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 12

23 O. '07 NEW BODY - '10 only ('05 - '07 Classic proceed to Section 4, Supercharger 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 models only: The oil pressure 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 sensor 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 connection. See Fig. 3N Potential Interference Zone Fig. 3L OEM screw Fig. 3M Fig. 3N 13

24 Q. '07 - '10 SUV ONLY (All others proceed to Section 4, Supercharger 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. FRONT Fig. 3Q (Mid-frame mounts, 1/4" stack) FRONT FRONT Fig. 3O (Front most mounts, 1/2" stack) Fig. 3R (Mounts behind rear door, 1/8" stack) FRONT FRONT Fig. 3P (Mounts forward of front door, 3/8" stack) Fig. 3S (Rear most mounts, no spacers) 14

25 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 specified. 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 tall under the body of the vehicle. The jack stands need to be placed underneath body cross supports located just behind the transmission cross member, next to the ABS module just inboard of the frame on the driver side and outboard of the frame on the passenger side. See Fig. 3U and Fig. 3V Fig. 3T 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 separation 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. 3U Fig. 3V 15

26 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 previous 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 Fig. 3W (mount rotated for clarity) 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. Fig. 3X AA. Once the body is seated to the frame (See Fig. 3Q), remove the jack stands and lower the 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 16

27 4. Supercharger INSTALLAtion A. With an assistant, carefully install the supercharger 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 torque values are in inchpounds, not foot-pounds. C. Attach the OEM fuel line to the Lysholm fuel fitting. Ensure that the connection is secure. Attach the OEM safety clip around the connection. 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. Hose Clamp Fig. 4A Fig. 4B FRONT OF ENGINE Fig. 4C 17

28 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 seal the 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 previously removed. Do not install the factory bolt directly below the alternator, this bolt will be replaced in a later step. Fig. 4D H Classic: Locate the eight (8) included fuel injector adapter pigtails and use them to 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 protrusion on the front of the supercharger assembly). '07 NEW BODY - '10: Attach the OEM electrical connectors for the fuel injectors, MAP sensor (behind the supercharger inlet duct), and EVAP solenoid (above the driver side fuel rail). Fig. 4D-2 ('05-'07 Classic Only) 18

29 I Classic: Install the throttle body onto the supercharger inlet duct with the supplied metal gasket and M6 hardware. Connect a length of the included ¼ hose between the driver side bottom nipple on the throttle body and the previously-bent nipple on 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. Fig. 4F '07 NEW BODY - '10: Attach the included throttle body adapter plate to the supercharger inlet duct with the supplied metal gasket and 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. 4G Fig. 4E Fig. 4H 19

30 L 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 original location behind the driver side cylinder head. Connect the 90 fitting to its original location 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. Fig. 4I ('07-'10 New Body Only) M Classic: Connect the long 5/16 hose running from the back of the supercharger inlet duct to the ¼ NPT x 5/16 barb fitting 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 supercharger assembly 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 harness 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 fastening points. See Fig. 4J Fig. 4I-2 ('05-'07 Classic Only) Fig. 4J 20

31 5. Idler and Drive Installation 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 tensioner 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 Fig. 5B ('07 NEW BODY - '10) 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. 5B-2 ('05-'07 Classic) Fig. 5A Fig. 5C 21

32 6. Surge Tank and Reservoir Installation, '05 - '07 Classic NOTE: See the diagram at the end of Section 7 for reference. A. Locate the supplied surge tank, P/N 8N , and the supplied mounting bracket. Attach the bracket to the surge tank with the supplied ¼-20 X.50 screws and washers. B. Install one straight ½ NPT X ¾ barbed fitting into the bottom and one 90 ½ NPT X ¾ barbed fitting into the side, angled down and forward. See Fig. 6A. Fig. 6A NOTE: Lysholm suggests using pipe paste/sealant/tape on all NPT threads for the cooling system. C. Locate the cowl brace at the passenger side rear corner of the engine compartment. Remove the two 13mm-headed bolts securing it to the cowl area. D. Place the surge tank bracket between the brace and the cowl and reinstall the OEM bolts. See Fig. 6B E. Locate the supplied triangle-shaped coolant reservoir and install a 90 ½ NPT X ¾ barbed fitting into each of the two threaded openings. Orient as shown in Fig. 6C and Fig. 6D. Fig. 6B F. Install the mounting bracket to the reservoir with the supplied ¼-20 hardware. See Fig. 6C G. Attach the water pump to the reservoir using the supplied Adel clamp and ¼-20 screw with washer. See Fig. 6C Fig. 6C 22

33 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 location shown, on the inside face of the passenger 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. Fig. 6D 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 orientation is finalized in a later step. L. Attach a length of ¾ 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. 6E 23

34 6.1 Surge Tank and Reservoir Installation, '07 NEW BODY - '11 NOTE: See the diagram at the end of Section 7.1 for reference. A. Locate the supplied surge tank, P/N 8N , and the supplied mounting bracket. Attach the bracket to the surge tank with the supplied ¼-20 X.50 screws and washers. B. Install one straight ½ NPT X ¾ barbed fitting into the bottom and one 90 ½ NPT X ¾ barbed fitting into the side, angled down and forward as shown in Fig. 6.1A. NOTE: Lysholm suggests using pipe paste/sealant/tape on all NPT threads for the cooling system. 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 ½ NPT X ¾ barbed fitting into each of the two threaded openings. Orient as shown in Fig. 6.1C. Fig. 6.1B F. Install the 90º mounting bracket to the reservoir with the supplied ¼-20 hardware as shown in Fig. 6.1C. G. Attach the water pump to the reservoir using the supplied Adel clamp and ¼-20 screw with washer. Fig. 6.1C 24

35 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 location shown, on the inside face of the passenger 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. Fig. 6.1D 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. Fig. 6.1E N. Attach a length of ¾ 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. 25

36 6.2 Surge Tank and Reservoir Installation, '07 - '10 SUV NOTE: See the diagram at the end of Section 7.2 for reference. A. Locate the supplied surge tank, P/N 8N , and the supplied mounting bracket. Attach the bracket to the surge tank with the supplied ¼-20 X.50 screws and washers. B. Install one straight ½ NPT X ¾ barbed fitting into the bottom and one 90 ½ NPT X ¾ barbed fitting into the side, angled down and forward as shown in Fig. 6.2A. NOTE: Lysholm suggests using pipe paste/sealant/tape on all NPT threads for the cooling system. 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 ½ NPT X ¾ barbed fitting into each of the two threaded openings. Orient as shown in Fig. 6.2C. Fig. 6.2B F. Install the 45º mounting bracket to the reservoir with the supplied ¼-20 hardware as shown in Fig. 6.2C. G. Attach the water pump to the back of the reservoir using the supplied Adel clamp and ¼-20 screw with washer as shown in Fig. 6.2C. Fig. 6.2C 26

37 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 supplied 90 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 location shown, on the inside face of the passenger 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 the frame rail. Fig. 6.2D M. Using a ¾ hose union fitting and two nylon ratchet clamps, attach the long leg of another 90º 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 support. This will attach to the Charge Air Cooler's bottom fitting in a later step. See Fig. 6.2E Fig. 6.2E O. Place the reservoir into position and secure with the supplied self-tapping screws with washers. P. Attach a length of ¾ 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. 27

38 7. Water Cooler Installation '05 - '07 Classic NOTE: See the diagram at the end of this section for reference. A. Locate the water cooler assembly P/N 8N B. Attach the two supplied brackets to the water heat exchanger as shown using the included ¼ -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. Fig. 7B NOTE: Temporarily place a piece of sheet metal or other barrier material between the A/C condenser and the radiator core support braces before drilling the holes in the following step to avoid puncturing the condenser. 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. 7C). The diagonal members may be removed to facilitate drilling. Fig. 7C 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 28

39 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 to remove the headlight assembly by removing the two headlight retaining pins to grant access and additional clearance. NOTE: At this point it is recommended that you temporarily place the OEM airbox into position to aid in determining proper charge cooler hose routing. Fig. 7E G. Trim the short leg of one of the 4 X formed hoses as needed and connect it to the heat exchanger s lower fitting, oriented to run straight down (See Fig. 7F). Secure it with an included nylon ratchet clamp. Use a ¾ hose union to connect the long leg to the 90 formed hose coming up from output fitting of the water pump previously mounted to the coolant reservoir. Secure with a nylon ratchet clamp. H. Run a length of ¾ hose from the bottom fitting of the surge tank previously mounted to the 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. Fig. 7F I. Locate the two remaining 4 X formed hoses. 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 while still providing adequate clearance to the EVAP solenoid. See Fig. 7G and Fig. 7H). Fig. 7G 29

40 J. After trimming the 4 X 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. 7I K. Connect the two 4 X 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. Fig. 7H L. Connect a length of ¾ hose from the 90 fitting on the side of the surge tank to the 4 X 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 Fig. 7I M. Connect a length of ¾ hose to the 4 X formed hose coming from the driver side of the supercharger assembly and secure with a nylon ratchet clamp. Route this hose in 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 connection to the heat exchanger with a nylon ratchet clamp. 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. Fig. 7I Fig. 7J N. Fill the charge cooler system with a 75/25 water/antifreeze mixture through the cap on the surge tank. 30

41 HOSE ROUTING DIAGRAM, '05 - '07 Classic 31

42 7.1 Water Cooler Installation '07 NEW BODY - '11 truck NOTE: See the diagram at the end of this section for reference. A. Locate the water cooler assembly, P/N 8N B. Install a 90 ½ NPT X ¾ barbed fitting into each of the openings. With the cooler oriented 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 Fig. 7.1A D. Trim the radiator core support as shown in Fig. 7.1B. TRIM OEM BRACKET Fig. 7.1B 32

43 E. Attach the upper cooler mounting bracket to the A/C condenser mount with the OEM fasteners, 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 NOTE: At this point it is recommended that you temporarily place the OEM airbox into position to aid in determining proper charge cooler hose routing. Fig. 7.1C G. Attach the long end of the 90 formed hose previously connected to the water pump outlet to the cooler s lower fitting. Secure each end with a nylon ratchet clamp. H. Locate one of the 4 x 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 condenser when the hose is assembled to the cooler s 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 ¾ hose to the other end of the union and secure each joint with a nylon ratchet clamp. Feed the length of ¾ hose in a smooth radius rearward through the radiator core support and install the short end of the 90 formed hose onto the cooler s upper fitting. Secure with a nylon ratchet clamp. See Fig 7.1D Fig. 7.1D 33

44 J. Locate the two remaining 4 x 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 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 Fig. 7.1E NOTE: "Uphill" routing of the following hose sections will aid in purging air from the cooling system at initial startup. L. Connect the two 4 x 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 ¾ hose running from the top of the cooler to the 4 x formed hose leading 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 Fig. 7.1F N. Connect a length of ¾ hose from the 90 fitting on the side of the surge tank to the other 4 x 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 Fig. 7.1F 34

45 O. Return the flexible plastic shield previously moved aside to its original position and secure with the OEM clips. It will be necessary to trim the shield to clear the cooler hose. Take care to leave adequate clearance between the shield and the hose to prevent 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 necessary to trim the shield to clear the cooler assembly. See Fig. 7.1G Fig. 7.1G Q. Fill the charge cooler system with a 75/25 water/antifreeze mixture through the cap on the surge tank. 35

46 HOSE ROUTING DIAGRAM, '07 NEW BODY - '11 TRUCK 36

47 7.2 WATER COOLER INSTALLATION '07 - '11 SUV NOTE: See the diagram at the end of this section for reference. A. Locate the water cooler assembly P/N 8N B. Temporarily attach the two supplied brackets to the water heat exchanger as shown using the included ¼ -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 diagonal radiator support members as shown in Fig. 7.2B. Mark the mounting hole locations on the diagonal support members. Fig. 7.2B NOTE: Temporarily place a piece of sheet metal or other barrier material between the A/C condenser and the radiator core support braces before drilling the holes in the following step to avoid puncturing the condenser. 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. Fig. 7.2C 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 Fig. 7.2A Fig. 7.2D ('07 Classic shown, '07-'10 SUV similar) 37

48 F. Located the formed 150º hose and connect the short end to the CAC as shown. Trim the hose as necessary and use ¾ hose union fitting and two nylon ratchet clamps to secure. G. Locate the two remaining 4 X formed hoses. 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 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 7.2G Fig. 7.2E I. Connect the two 4 x 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. NOTE: "Uphill" routing of the following hose sections will aid in purging air from the cooling system at initial startup. Fig. 7.2F Fig. 7.2G 38

49 J. Connect the ¾ hose running from the top of the cooler to the 4 x formed hose leading 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 7.2G K. Connect a length of ¾ hose from the 90 fitting on the side of the surge tank to the other 4 x 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 Fig 7.2G L. Fill the charge cooler system with a 75/25 water/antifreeze mixture through the cap on the surge tank. 39

50 HOSE ROUTING DIAGRAM, '07 - '11 suv 40

51 8. Water PUMP Wiring '05 - '07 Classic A. Mount the supplied water pump relay in the approximate location shown on the firewall or any 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 distribution box lid and plastic shroud and set them aside. WATER PUMP RELAY C. Connect the short red wire from relay terminal #30 to the positive terminal post located at the inboard rear corner of the power distribution 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. Fig. 8A 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. POSITIVE TERMINAL Fig. 8B 41

52 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 supplied fuse tap. F. 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. G. Run the negative (brown) wire from the water pump to a suitable chassis ground. Fig. 8C H. Reinstall the plastic fuse panel shroud and the 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 supply 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 dry for more than 30 seconds without coolant flow. Continue to check and fill the system until the level stabilizes. 42

53 8.1 Water PUMP Wiring '07 New body - '11, all A. Mount the supplied water pump relay in the approximate location shown on the forward face 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 POSITIVE TERMINAL B. Connect the short red wire from relay terminal #30 to the positive terminal on the front of the power distribution box using the supplied ring terminal. See Fig 8.1A WATER PUMP RELAY C. Connect the black wire from relay terminal #86 to a suitable ground. See Fig 8.1A Fig. 8.1A 43

54 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. Fig. 8.1B 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 supply 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 for more than 30 seconds without coolant flow. Continue to check and fill the system until the level stabilizes. 44

55 9. Air Inlet Installation A. Separate the OEM airbox cover from the airbox and remove the OEM filter. Install the supplied high-flow replacement filter and reassemble the airbox. B. Install the airbox assembly into the vehicle and press into place in the OEM fashion. C. Attach the supplied 3.5 bump hose to the airbox outlet using one of the #56 clamps. Make sure it is fully seated against the locating features on the airbox. Slide the remaining #56 clamp over the open end. Fig. 9A D. Attach the supplied 4.0 sleeve to the throttle body using one of the #64 clamps. Make sure it is fully seated against the locating features on the throttle body. Slide the remaining #64 clamp over the open end. 90º MOLDED HOSE E. Install the supplied hose barb fitting into the supplied molded plastic inlet duct. F. Install the molded plastic inlet duct between the throttle body and the airbox. Ensure that the duct is properly positioned within the bump hoses and tighten the clamps. See Fig 9A Fig. 9B G. Connect the supplied 90 molded hose between the hose barb fitting on the plastic inlet duct and the passenger side crankcase breather tube as shown. Trim the hose as necessary. See Fig 9B H. Locate the MAF harness and pull back the protective covering approximately 8-10 inches. Separate the tan and tan w/black stripe intake air temperature sensor wires from the harness. 45

56 I Classic: Cut the solid tan and black wires approximately 2 from the MAF connector (See Fig. 9C). Be careful not to cut the black w/white stripe wire for the MAF sensor. '07 NEW BODY - '11: Cut the tan and tan w/ black stripe wires approximately 2 from the MAF connector. See Fig 9C J. Locate the supplied Intake Air Temperature (IAT) harness that was plugged in into the IAT sensor located at the rear of the supercharger assembly from a previous step. Slide a piece of supplied heat shrink tubing over each of the IAT wires. Solder the ends of the MAF wires coming from the main harness to the new harness (the color of the wires does not matter). Insulate the connections by shrinking the sleeve with the proper amount of heat. Protect the wires with split loom or another suitable means and route them away from heat, sharp edges, and other hazards. Butt connectors have been supplied for temporary connection if a solder joint cannot be completed at installation time. The remaining wires with cut ends that are still attached to the MAF will no longer be used. See Fig 9D IAT SENSOR HARNESS Fig. 9C Fig. 9D 46

57 10. Miscellaneous Reassembly A. ALL EXCEPT SUV: Reinstall the grille. Secure with the four (4) OEM 10mm-headed screws (if equipped) and ensure that the OEM retaining clips snap securely into place. B. SUV ONLY: Reinstall the grille/bumper cover assembly, reversing the removal sequence from Section 1. Remember to reconnect the electrical connector on each side (2 total). NOTE: It will be necessary to trim away a small portion of the foam bumper material to provide clearance for the new coolant reservoir mounted on the inside frame rail. C. Reinstall the plastic panel covering the area between the grille and the radiator core support. Secure with the OEM plastic expansion plugs. 47

58 11. Reflash Computer IMPORTANT! To ensure trouble-free programming of your vehicle s computer: Make sure the vehicle's battery is sufficiently charged. Turn off all accessories and close doors to prevent unnecessary drain on the battery. Locate the instrument panel fuse block on the vehicle. Temporarily remove the following fuses: #4 (Driver Door Module); #5 (Dome Lamps, Driver Side Turn Signal); #15 (Body Control Module); #17 (Interior Lamps); #19 (Rear Seat Entertainment); #20 (Ultrasonic Rear Parking Assist, Power Liftgate); #22 (Driver Information Center); #25 (Driver Seat Module, Remote Keyless Entry System). Do not attempt to program your vehicle while a battery charger is connected. Improper battery voltage will result in failure of the programming process. Do not disconnect the cable or turn off the ignition during programming. NOTES: All vehicles equipped with On-star that have aftermarket stereos will experience problems with the ability to re-program the vehicle s ECM. It is necessary to disconnect the aftermarket stereo from the factory wiring harness before continuing with the programming procedure. Do not disturb the cable or turn the ignition off during this time. If the programming is disrupted, the computer will not start or run your vehicle! ARROW KEYS OBD-II CONNECTOR CANCEL SELECT Fig. 11B-1 ('07 NBS - '10 Shown) Fig. 11A A. Reconnect the battery if previously disconnected. OBD-II CONNECTOR B. Locate the vehicle s OBD2 connector located under the dash on the driver side of the vehicle. See Fig. 11B C. Attach the OBD2 connector from the reflash tool that is provided in the kit to the vehicle s OBD2 port. Make sure this connector is seated all the way in the vehicle s OBD2 port. Do not allow this connector to become disconnected during programming or damage may occur to the vehicle s ECM. Fig. 11B-2 ('05 - '07 Classic Shown) 48

59 NOTE: If you have any questions throughout this procedure, please contact our service department for further assistance. D. The reflash tool should power up and display PROGRAM VEHICLE at the top of the screen. Press the SELECT button. See Fig. 11D Fig. 11D E. PREPROGRAMED TUNE will be displayed at the top of the screen. Press the SELECT button. See Fig. 11E F. Read the disclaimer entirely, then press the SELECT button if you agree with the terms of the disclaimer. See Fig. 11F G. At this point you will need to turn the ignition to the ON position (do not start the vehicle). Set the parking brake and press the SELECT button to continue. See Fig. 11G Fig. 11E Fig. 11F Fig. 11G 49

60 H. The reflash tool will proceed to check the Operating System (OS) part number of the vehicles ECU. See Fig. 11H I. PROGRAM VEHICLE will be displayed at the top of the screen. At this time make sure you have turned off any additional accessories that may cause unnecessary draw on the vehicles battery (headlights, radio, etc.).press the SELECT button to proceed with BEGIN PROGRAM. See Fig. 11J Fig. 11H NOTE: Once the programming sequence has been started use care NOT to disturb the cable, or turn the ignition or any accessories on or off during this time. Throughout the programming sequence it is normal for the Reflash tool to AUTOMATICALLY cycle the vehicles power on and off. If the programming is disrupted, permanent damage to the vehicles computer may result! Fig. 11I Fig. 11J Fig. 11K 50

61 L. The reflash tool will then automatically proceed through the following screens during the programming process. See Fig. 11K thru Fig. 11P i. Unlock ECU ii. Upload ECU iii. Setup Device Fig. 11L iv. Make Adjustments v. Calculate Checksums vi. Unlock ECU vii. Download tune Fig. 11M Fig. 11N Fig. 11O Fig. 11P 51

62 M. Once the reflash tool has completed the DOWNLOAD TUNE process the screen should read "Turn Key Off And Remove key." At this time remove the key and press the SELECT button to continue. See Fig. 11Q N. Once the tool has successfully completed the POWER DOWN ECU sequence you will see "Download Complete" displayed on the screen. Press the SELECT BUTTON. See Fig. 11R and Fig. 11S O. CONGRATULATIONS! You have successfuly completed reflashing the vehicle's ECU with the Lysholm Supercharger Calibration. You may now unplug the reflash tool from the vehicle's OBD2 port. Fig. 11Q Fig. 11R Fig. 11S 52

63 12. Final ASsembly and Check A. Re-install all OEM ruses that were temporarily removed in step 11. B. If your vehicle has gone over 10,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle. C. Check all fittings, nuts, bolts and clamps for tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie-wraps. D. Check all fluid levels, making sure that your tank(s) is/are filled with 91 octane or higher fuel before commencing test drive. E. Start engine and allow to idle a few minutes. F. Recheck to be sure no hoses, wires, etc. are near exhaust headers or moving parts and check for any sign of fluid leakage. Recheck all fluid levels. G. PLEASE TAKE SPECIAL NOTE: Operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS. H. Test drive the vehicle. J. Read the Street Supercharger System Owner's Manual and RETURN The Warranty REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify for the 3 year limited warranty. 53