GM Truck/SUV: Lysholm Twin-Scr Ew Superchar Ger System Installa Tion Instr Uctions

P/N: 4LGL020-010 v5.
0, 2011-06-01
2011 Lysholm
All Rights Reserved, Intl. Copr. Secured
1650 Pacific Avenue, Channel Islands CA 93033-9901 Phone: 805 247-0226
Fax: 805 247-0669 www.lysholm.us M-F 8:00AM - 4:30PM (PST)
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P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
i
FOREWORD
Take note of the following before proceeding:
1. Proper installation of this supercharger kit requires general auto-
motive 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 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, third
party PCM programming or other such changes.
2011 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.
T
his manual provides information on the installation, maintenance and service
of 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 the
manual 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.
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
ii
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 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 Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . 24
6.2 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
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
iii
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.
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
iv
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 fuid
temperature under control. Excessive fuid 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 fuid to further
stabilize fuid temperature in your transmission.
AUTOMATIC TRANSMISSION
DISCLAIMER
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 more
information.
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
v
Before beginning this installation, please read through this entire instruction booklet and the Street
Supercharger System Owners 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
3035% and horsepower of 3545% can be expected with the boost levels specifed by Lysholm. This prod-
uct 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 modifed 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 specifed by the manufacturer and reset
timing to factory specifcations (follow the procedures indicated within
the factory repair manual and/or as indicated on the factory under-
hood 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
GM TRUCk/SUV
INSTALLATION INSTRUCTIONS
Congratulations on selecting the best performing and best backed automotive
supercharger available today... the Lysholm
Supercharger!
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
vi
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 1
2L118-010 UNIV S/C ASY, LYShoLm 2300AX, Gm CATh. PoRT V8 1
2L036-325-01 PULLEY, 6-RIB, 3.25, Gm TRK LYShoLm 1
4LGL010-010 BRKT, hoLD DN mAP SENS.LYShoLm 1
4LGL010-050 BRKT, FUEL hoSE, LYShoLm GmT 1
7C060-013 m6 X 1.0 X 12mm FLG hD CL10.9+ ZINC 1
4LGL145-010 FUEL LINE ASSY A, LYSh Gm 5.3 1
7R003-008 ADEL CLAmP, 1/2" ID 1
7C060-008 m6 X 1.0 X 8mm, ShCS PLATED 1
7C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ ZINC 4
4LGL020-010 INSTR MAN., GM TRk, LYSHOLM 1
4LGL112-010 AIR INLET ASSY, GM TRk, LYSHOLM 1
4LGL010-011 ADAPTER, T-BoDY Gm TRK,LYShoLm 1
4LGL012-010 DUCT, INLET Gm TRK, LYShoLm 1
4LGL040-010 GASKET, ThRTL BoDY, Gm TRK 1
5W001-007 3/16" hEAT-ShRINK TUBING 0.5FT
5W001-012 18-22 GA BUTT CoNN RED INSUL 2
5W001-032 1/4" PLASTIC WIRE Loom 18IN
5W001-076 hARNESS, IAT SENSoR Gm TRK 1
7C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ Z 2
7C060-025 m6 X 1.0 X 25mm hX 1
7C060-040 m6 X 1.0 X 40 hXhD CL8.8 4
7J006-093 6mm WAShER, PLATED 5
7P250-045 1/4 mALE NPT X 3/8 mALE BARB 1
7PS350-303 BUmP hoSE, 3.50D X 3.00L 1
7PS400-300 SLEEVE, BLACK 4.0D X 3.0 1
7R002-056 #56 SAE TYPE F SS hoSE CLAmP 2
7U030-053 3/8 X 90 moLDED RUBBER hoSE 1
8h040-165 FILTER, Gm TRK 99-08 PNL. 1
4LGL116-030 SUPPORT ASSY, GM TRk, 07 CLASS 1
2A017-750-03 SPACER, .750 oD X .130 LoNG 1
2A046-120 BELT, GATES K061203 1
2C017-002 PILoT, 6203/5 BRG, 7/16 SCREW 1
4Fh016-150 IDLER PULY, SmooTh 6RIB 3" FLA 1
4LGL017-011 SPACER,IDLER, .88 X 1.220 1
4TX016-150 IDLER, 2.75 DIA, SmooTh, 7 RIB 1
5W001-030 1 1/2" hEAT ShRINK 0.67FT
5W001-077 INJ ADAPTER, mULTEC II m To EV 8
5W001-082 SLEEVE, FLEX BRAID .75" Nom. 1.17FT
7C010-151 m10 X 1.5 X 150 hXhD CL10.9 1
7C080-027 m8 X 1.25 X 25mm BhCS 10
7P125-032 1/8NPT-STR,5/16 BARB 1
7R003-027 ADEL CLAmP,1-11/16" 1
7R004-003 STEPLESS CLAmP, 14.5-70 2
7R007-001 NYLoN RATChET CLAmP 1-1/8" 5
7U030-016 1/4" EFI hP FUEL LINE 1.5FT
7U031-016 5/16" PCV/VAC RUBBER hoSE 3FT
7U038-012 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 2
7A250-050 1/4-20 X .50 ShCS GR8 ZINC PLT 4
7J250-001 1/4 WAShER, SAE, PLTD 4
7P375-075 3/4" hoSE BARB UNIoN, BRASS 3
7P500-026 1/2NPT X 3/4 BARB 90 BRASS 2
7P500-034 1/2NPT X 3/4 BARB 90, NICKEL 1
7P500-075 1/2NPT X 3/4 hoSE FIT STRT NIC 1
7U030-065 hoSE, 3/4 X 90 RUBBER, ShoRT 1
7U038-000 3/4" hEATER hoSE 14FT
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
7U038-150 hoSE, 3/4 D X150 moLDED hoSE 1
7U100-055 TIE WRAP, 7.5" NYLoN 6
8N010-250 BRKT, SURGE TANK, 07 Gm TRK 1
8N010-260 BRKT, CooLANT RES 07 Gm TRK 1
8N010-370 BRKT, CooLANT RES 07-09 Gm TRK 1
8N055-030 TANK, WATER, TRIANGLE ShAPE 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N056-060 SURGE TANK, PLASTIC 1
8N106-140 WATR COOLR ASY, 07 ESCAL 1
7E010-075 #12 X 3/4" ShT mETL SCRW hEX 4
7R003-016 ADEL CLAmP, 1.0" 1
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 3
8N006-020 WATER CooLR, FLDYN DUAL PASS 1
8N010-320 FLDYN BKT, 07 ESCALADE DRVR 1
8N010-330 FLDYN BKT, 07 ESCALADE PASS 1
8N107-050 WATER PMP ASSY, GMT LS1 H.O. 1
5W001-002 FUSE TAP 1
5W001-005 3/8" PLASTIC WIRE Loom 5FT
5W001-013 14-16 GA BUTT CoNN BLU INSUL 4
5W001-015 FUSE, BLADE TYPE 20 AmP 1
5W001-017 12-10GA X 3/8" RING TERmINAL 1
5W001-019 10-12 GA BUTT CoNN INSULATED 2
5W001-022 T-TAP CoNN,14-16 AWG 1
5W001-024 mINI ATC FUSE TAP 1
5W001-041 12-10GA mALE SLIDE INSULATED 1
5W001-071 FUSE hoLDER,16GA WIRE 1
7E010-048 #10 X 3/4" ShT mETL SCRW PhILLIPS 2
7F008-020 NUT, m8 X 1.25 1
7F250-021 1/4-20 NYLoCK NUT ZINC PLATED 1
7R003-027 ADEL CLAmP,1-11/16" 1
7U100-044 TIE WRAP, 4" NYLoN 4
8F001-402 PUmP, WATER, PIERBURG 1
8F101-320 FUEL PUmP RELAY ASSY, LS1 TRK 1
5W001-010 16-14GA FEmALE SLIDE INSULATED 2
5W001-016 RELAY,BoSCh 1
5W012-000 12 GA,STRD WIRE, RED 9.5FT
5W012-010 12 GA WIRE BLACK 0.5FT
5W014-030 14GA STRD WIRE BLACK 0.5FT
5W016-010 16GA STRD WIRE YELLoW 2.5FT
PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or
damaged parts immediately.
'05 - '07 GM 6.0L TRUCk (Classic)
Part No. 2310040
PARTS LIST
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
vii
2L218-010 S/C ASSY, 2300 LYSHOLM, GM TRk 1
2L036-380-01 PULLEY 3.80, LYShoLm GmT 5.3 1
4LGL010-040 BRKT, EVAP SoLENoID LYShoLm GmT 1
7R003-008 ADEL CLAmP, 1/2" ID 1
7C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ Z 2
7C060-025 m6 X 1.0 X 25mm hX 1
7C060-040 m6 X 1.0 X 40 hXhD CL8.8 4
7PS350-303 BUmP hoSE, 3.50D X 3.00L 1
4LGL116-010 SUPPORT ASSY, GM TRk, LYSHOLM 1
2A046-124 BELT, GATES K061247 1
2C017-002 PILoT, 6203/5 BRG, 7/16 SCREW 1
4LGL010-071 ADAPTER, mAP SENSoR, 09 Gm TRK LYShoLm 1
4LGL016-150 IDLER, 6 RIB, 4.2", ComPoSITE 1
4LGL017-011 SPACER, IDLER, .88 X 1.220 1
5W001-030 1 1/2" hEAT ShRINK 0.666FT
7C010-151 m10 X 1.5 X 150 hXhD CL10.9 1
7C060-022 m6-1.0 X 22mm ShCS LYSh SC 2
7C080-027 m8 X 1.25 X 25mm BhCS 10
7J640-032 WAShER, .640" ID X .032" ThK X 1.188" 1
7R003-027 ADEL CLAmP,1-11/16" 1
7U012-111 o-RING, .630oD X .424ID X .103W 1
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
7U100-028 FILLER NECK, oIL, 09 Gm TRK LYShoLm 1
4LGL117-021 SPACER kIT, BODY LIFT, 07+ GMT 1
2A017-875-08 SPACER, .875 oD X .290 LoNG 2
7P500-026 1/2NPT X 3/4 BARB 90 BRASS 2
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
8N106-140 WATR COOLR ASY, 07 ESCAL 1
7R003-016 ADEL CLAmP, 1.0" 1
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 3
8N006-020 WATER CooLR, FLDYN DUAL PASS 1
8N010-320 FLDYN BKT, 07 ESCALADE DRVR 1
8N010-330 FLDYN BKT, 07 ESCALADE PASS 1
5W001-022 T-TAP CoNN,14-16 AWG 1
7F008-020 NUT, m8 X 1.25 1
7R003-027 ADEL CLAmP,1-11/16" 1
'07 - '11 GM 5.3L SUV
Part No. 2310070
PARTS LIST
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
viii
2L218-010 S/C ASY, 2300 LYSHOLM, GM TRk 1
2L036-380-01 PULLEY 3.80, LYShoLm GmT 5.3 1
4LGL010-040 BRKT, EVAP SoLENoID LYShoLm GmT 1
7R003-008 ADEL CLAmP, 1/2" ID 1
7C060-015 m6 X 1.0 X 16mm ShCS CL10.9+ Z 2
7C060-025 m6 X 1.0 X 25mm hX 1
7C060-040 m6 X 1.0 X 40 hXhD CL8.8 4
7PS350-303 BUmP hoSE, 3.50D X 3.00L 1
4LGL116-010 SUPPORT ASSY, GM TRk, LYSHOLM 1
2A046-124 BELT, GATES K061247 1
2C017-002 PILoT, 6203/5 BRG, 7/16 SCREW 1
4LGL010-071 ADAPTER, mAP SENSoR, 09 Gm TRK LYShoLm 1
4LGL016-150 IDLER, 6 RIB, 4.2", ComPoSITE 1
4LGL017-011 SPACER, IDLER, .88 X 1.220 1
5W001-030 1 1/2" hEAT ShRINK 0.666FT
7C010-151 m10 X 1.5 X 150 hXhD CL10.9 1
7C060-022 m6-1.0 X 22mm ShCS LYSh SC 2
7C080-027 m8 X 1.25 X 25mm BhCS 10
7J640-032 WAShER, .640" ID X .032" ThK X 1.188" 1
7R003-027 ADEL CLAmP,1-11/16" 1
7U012-111 o-RING, .630oD X .424ID X .103W 1
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
7U100-028 FILLER NECK, oIL, 09 Gm TRK LYShoLm 1
2A017-875-08 SPACER, .875 oD X .290 LoNG 2
7P500-026 1/2NPT X 3/4 BARB 90 BRASS 2
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
8N106-160 WATER COOLER ASY, 07+ GM TRk 1
7A250-075 1/4-20 X .75 ShCS PLTD 8
7P500-026 1/2NPT X 3/4 BARB 90 BRASS 2
7R003-016 ADEL CLAmP, 1.0" 1
7U038-012 hoSE, 3/4 DIA 90, 4 X 12 LEGS 1
8N006-010 WATER CooLR, SETRAB SINGLE PAS 1
8N010-270 BRKT "A", hEAT EXChGR 07 GmT 1
8N010-280 BRKT "B", hEAT EXChGR 07 GmT 1
5W001-022 T-TAP CoNN,14-16 AWG 1
7F008-020 NUT, m8 X 1.25 1
7R003-027 ADEL CLAmP,1-11/16" 1
'07 NEW BODY- '11 GM 5.3L Truck
Part No. 2310100
PARTS LIST
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
ix
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P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
1
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
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 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.

'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) 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 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 PANEL
CoVER CLIPS
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Fig. 1F
Fig. 1G
FENDER LINER
FASTENERS
REmoVE
SCREWS
Fig. 1H
PULL oUT
ThEN FoRWARD
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
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
DISCoNNECT
ELECTRICAL
CoNNECToRS
oN 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 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 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: 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.
Fig. 2C
Caution: on newer body style vehicles ('07-'10), use cau-
tion 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.
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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 side
and 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 the
side 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 small
amount 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 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 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: 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 theres any doubt, replace
them with the appropriate oEm replacement parts
(Gm part number 89060413)
CRANKCASE
BREAThER hoSE
BRAKE BooSTER
hoSE
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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 VENT
TUBE
CooLANT VENT
TUBE
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 be
damaged. 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 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 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 MAP
sensor should appear as shown in Figure
3D-2.
Fig. 3C
Fig. 3D ('05-'07 Classic, '07-'08)
Fig. 3D-2 (2009 Models)
oEm mAP
Sensor
oEm mAP
Sensor
EVAP hose
Crankcase
Breather hose
Power Brake
Booster hose
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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 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.
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)
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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 the
existing 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 in
shape 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, 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
Fig. 3F
TRIm
TRIm
CENTER ShARK FIN
To 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 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 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, 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 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
Potential
Interference
Zone
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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, 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.
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 tall
under 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 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
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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 torque values are in inch-
pounds, 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 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
9 3 2 6 7
10 4
FRONT OF ENGINE
Fig. 4A
Fig. 4B
Fig. 4C
hose Clamp
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 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 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 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 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 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.
'07 NEW BODY - '10: Attach the included
throttle body adapter plate to the supercharg-
er 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. 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 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.
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 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 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 the diagram at the end of Section 7 for 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 OEM
bolts. 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: Lysholm suggests using pipe paste/sealant/tape on all
NPT threads for the cooling system.
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 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. 6D
Fig. 6E
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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.
braces and the cowl and reinstall the OEM
bolts. See Fig 6.1B
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 using
the supplied Adel clamp and -20 screw with
washer.
Fig. 6.1B
Fig. 6.1A
NOTE: Lysholm suggests using pipe paste/sealant/tape
on all NPT threads for the cooling system.
6.1 SURGE TANk AND RESERVOIR
INSTALLATION, '07 NEW BODY - '11
NOTE: See the diagram at the end of Section 7.1 for reference.
Fig. 6.1C
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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-
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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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.
braces and the cowl and reinstall the OEM
bolts. See Fig. 6.2B
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 the
reservoir using the supplied Adel clamp and
-20 screw with washer as shown in Fig.
6.2C.
Fig. 6.2B
Fig. 6.2A
NOTE: Lysholm suggests using pipe paste/sealant/tape
on all NPT threads for the cooling system.
6.2 SURGE TANk AND RESERVOIR
INSTALLATION, '07 - '10 SUV
NOTE: See the diagram at the end of Section 7.2 for reference.
Fig. 6.2C
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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 loca-
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.
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
Fig. 6.2E
Fig. 6.2D
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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
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 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.
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: 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 follow-
ing step to avoid puncturing the condenser.
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 to
remove 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 to
the 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 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.
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 still
providing adequate clearance to the EVAP
solenoid. See Fig. 7G and Fig. 7H).
Fig. 7E
Fig. 7F
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. 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
L. Connect a length of hose from the 90 fit-
ting on the side of the surge tank to the 4 X
12 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 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 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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SURGE TANK (8N056-050),
TOP VEW
1/2 NPT TO
3/4" HOSE
BARB
(7P500-078)
1/2" SOCKET HEAD CAP
SCREW (7A250-050)
SURGE TANK
MOUNTNG BRACKET
(8N010-250)
LOW TEMP
RADATOR
(8N006-020)
1" NPT HOLE
NOT USED
HOLE SHOULD
BE BLND OR
PLUGGED
90 1/2 NPT TO
3/4" HOSE
BARB
(7P500-026)
WATER
RESERVOR
(8N055-030)
3/4" HOSE UNON (7P375-075)
7U038-012
3/4 MOLDED HOSE
4X12
WATER
RESERVOR
BRACKET
(8N010-260)
WATER PUMP
CLAMP (8N010-080)
WATER PUMP
(8F001-402)
90 1/2 NPT TO 3/4"
HOSE BARB,
BOTTOM OF TANK
(7P500-026)
7U038-012
3/4 MOLDED HOSE
4X12
90 1/2 NPT TO 3/4"
HOSE BARB (7P500-026)
3/4" HOSE UNON (7P375-075)
7U038-012
3/4 MOLDED HOSE
4X12
8N101-380 CHARGE AR
COOLER (NTEGRATED
WTH SUPERCHARGER
ASSEMBLY)
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
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 this point it is recommended that you temporari-
ly place the oEm airbox into position to aid in
determining proper charge cooler hose routing.
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
M. 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 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: "Uphill" routing of the following hose sections will
aid in purging air from the cooling system at initial
startup.
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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 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 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
the surge tank.
Fig. 7.1G
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7U038-150
150
MOLDED
HOSE
8N006-010 CHARGE AR WATER HEAT EXCHANGER
90 1/2 NPT TO
3/4" HOSE
BARB
(7P500-026)
8N010-270 HEAT
EXCHANGER MOUNTNG
BRACKET
WATER
RESERVOR
(8N055-030)
WATER
RESERVOR
BRACKET
(8N010-260)
90 1/2 NPT TO
3/4" HOSE
BARB
(7P500-026)
90 1/2 NPT TO 3/4" HOSE
BARB (7P500-026)
90 1/2 NPT TO 3/4"
3/4" HOSE UNON (7P375-075)
SCREW (7A250-050)
SURGE TANK
MOUNTNG BRACKET
(8N010-250)
1/2 NPT TO
3/4" HOSE
BARB
(7P500-078)
TOP VEW
7U038-012
3/4 MOLDED HOSE
4X12
7U038-065
3/4 FORMED HOSE
SHORT
3/4" HOSE UNON (7P375-075)
8N101-380 CHARGE AR
COOLER (NTEGRATED
WTH SUPERCHARGER
ASSEMBLY)
7U038-012
3/4 MOLDED HOSE
4X12
SCREW (7A250-050)
(NSTALL THROUGH ADEL
CLAMP AND NTO WATER
TANK TO HOLD WATER
PUMP)
1" NPT HOLE
NOT USED
HOLE SHOULD
BE BLND OR
PLUGGED
WATER PUMP
(8F001-402)
WATER PUMP
CLAMP (8N010-080)
90 1/2 NPT TO 3/4"
HOSE BARB,
BOTTOM OF TANK
(7P500-026)
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 diagonal
radiator 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: 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 follow-
ing step to avoid puncturing the condenser.
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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 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 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 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: "Uphill" routing of the following hose sections will
aid in purging air from the cooling system 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 Fig
7.2G
L. Fill the charge cooler system with a 75/25
the surge tank.
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TOP VEW
3/4" HOSE
(7P038-000)
1/2 NPT TO
3/4" HOSE
BARB
(7P500-078)
SURGE TANK
MOUNTNG BRACKET
(8N010-250)
SCREW (7A250-050)
LOW TEMP
RADATOR
(8N006-020)
90 1/2 NPT TO
3/4" HOSE BARB
(7P500-026)
WATER
RESERVOR
(8N055-030)
WATER
RESERVOR
BRACKET
(8N010-260)
90 1/2 NPT TO 3/4"
HOSE BARB,
BOTTOM OF TANK
(7P500-026)
3/4" HOSE UNON
(7P375-075)
SCREW (7A250-050)
(NSTALL THROUGH ADEL
CLAMP AND NTO WATER
TANK TO HOLD WATER
PUMP)
7U038-012
3/4 MOLDED HOSE
4X12
WATER PUMP
CLAMP (8N010-080)
WATER PUMP
(8F001-402)
90 1/2 NPT TO 3/4"
3/4" HOSE UNON (7P375-075)
7U038-012
3/4 MOLDED HOSE
4X12
8N101-380 CHARGE AR
COOLER (NTEGRATED
WTH SUPERCHARGER
ASSEMBLY)
7U038-150
150 MOLDED HOSE
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 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 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 #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.
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 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 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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2011 Lysholm
43
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
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 for
more than 30 seconds without coolant flow.
Continue to check and fill the system until
the level stabilizes.
Fig. 8.1B
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45
A. Separate the OEM airbox cover from the air-
box 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 locat-
ing features on the airbox. Slide the remain-
ing #56 clamp over the open end.
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 fea-
tures on the throttle body. Slide the remain-
ing #64 clamp over the open end.
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
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 inch-
es. Separate the tan and tan w/black stripe
intake air temperature sensor wires from the
harness.
9. AIR INLET INSTALLATION
Fig. 9A
Fig. 9B
90 moLDED
hoSE
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I. 05 - 07 Classic: Cut the solid tan and black
wires approximately 2 from the MAF con-
nector (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 super-
charger 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 har-
ness to the new harness (the color of the
wires does not matter). Insulate the connec-
tions 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
Fig. 9C
Fig. 9D
IAT SENSoR
hARNESS
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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).
C. Reinstall the plastic panel covering the area
between the grille and the radiator core sup-
port. Secure with the OEM plastic expansion
plugs.
10. MISCELLANEOUS REASSEMBLY
NOTE: It will be necessary to trim away a small por-
tion of the foam bumper material to provide
clearance for the new coolant reservoir
mounted on the inside frame rail.
P/N: 4LGL020-010 v5.0, 2011-06-01
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48
Fig. 11A
SELECT
ARRoW KEYS
IMPORTANT! TO ENsuRE TROublE-fREE
PROgRAMMINg Of yOuR vEhIClEs 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 follow-
ing 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.
A. Reconnect the battery if previously dis-
connected.
B. Locate the vehicles 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 vehicles OBD2 port. Make sure this
connector is seated all the way in the
vehicles OBD2 port. Do not allow this
connector to become disconnected dur-
ing programming or damage may occur
to the vehicles ECM.
11. REFLASH COMPUTER
CANCEL
NOTEs:
All vehicles equipped with on-star that
have aftermarket stereos will experience
problems with the ability to re-program
the vehicles ECm. It is necessary to
disconnect the aftermarket stereo from
the factory wiring harness before con-
tinuing with the programming procedure.
Do not disturb the cable or turn the igni-
tion off during this time. If the program-
ming is disrupted, the computer will not
start or run your vehicle!
Fig. 11B-1 ('07 NBS - '10 Shown)
Fig. 11B-2 ('05 - '07 Classic Shown)
oBD-II
CoNNECToR
oBD-II
CoNNECToR
P/N: 4LGL020-010 v5.0, 2011-06-01
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D. The reflash tool should power up and display
PROGRAM VEHICLE at the top of the
screen. Press the SELECT button. See 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
NOTE: If you have any questions throughout this proce-
dure, please contact our service department for
further assistance.
Fig. 11D
Fig. 11E
Fig. 11F
Fig. 11G
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Fig. 11H
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
NOTE: once the programming sequence has been start-
ed 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 pro-
gramming is disrupted, permanent damage to the
vehicles computer may result!
Fig. 11I
Fig. 11J
Fig. 11K
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L. The reflash tool will then automatically pro-
ceed through the following screens during the
programming process. See Fig. 11K thru Fig.
11P
i. Unlock ECU
ii. Upload ECU
iii. Setup Device
iv. Make Adjustments
v. Calculate Checksums
vi. Unlock ECU
vii. Download tune
Fig. 11L
Fig. 11M
Fig. 11N
Fig. 11O
Fig. 11P
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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 successfu-
ly 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
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53
A. Re-install all OEM ruses that were temporari-
ly 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 sys-
tem to qualify for the 3 year limited warranty.
12. FINAL ASSEMBLY AND CHECk
P/N: 4LGL020-010 v5.0, 2011-06-01
2011 Lysholm
1650 Pacific Avenue, Channel Islands CA 93033-9901 Phone: 805 247-0226
Fax: 805 247-0669 www.lysholm.us M-F 8:00AM - 4:30PM (PST)

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