Vortech 2003-2004 Chevrolet SS User Manual

Download

Page 1

2001-2002, 2004, 2006 Denali,

GM 6.0L

2002-2004 Escalade SUV,

2003-2008 H2 Hummer and

2003-2004 Chevrolet SS

Supercharger System

Installation Instructions

50 State Smog Legal per CARB EO #D-213-26

ENGINEERING, LLC

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

DP/N: 4GL020-015 - v5.0 10/08/08

Page 2

FOREWORD

STOP

his manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for this vehicle. All information, illustra-

tions 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 Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0226 8:00am-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 Vortech Engineering 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 Vortech 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. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech 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 Vortech components with other modifications such as, but not limit-

ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

into another language in any form, by any means without written permission of Vortech Engineering, LLC.

Page 3

TABLE OF CONTENTS

FOREWORD ................................................................ii

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

PARTS LIST (2001-2002 Denali/2002 Escalade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

PARTS LIST (2003 Escalade/SS) ..............................................viii

PARTS LIST (2003 H2 Hummer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

PARTS LIST (2004-2007 H2 Hummer) .......................................... xii

PARTS LIST (2004 Escalade/SS Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

PARTS LIST (2004, 2006 Denali H.O.) ..........................................xv

PARTS LIST (2008 H2 Hummer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

1. COMPONENT REMOVAL .................................................1

2. COMPUTER RELOCATION (All H2 Hummers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3. SUPERCHARGER MOUNTING BRACKET ...................................4

4. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

5. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

6. OIL DRAIN LINE ........................................................7

7. OIL FEED LINE .........................................................8

8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION ('01-'02 Denali/Escalade Only) . . .9

9. BRAKE BOOSTER LINE MODIFICATION (2002 Escalade Only) . . . . . . . . . . . . . . . . 10

10. VACUUM PUMP/BRAKE LINE RELOCATION ('03-04 5.3/SS Truck,

Vehicles Equipped with adjustable pedals only) ...............................11

11.A FUEL PUMP WIRING AND INSTALLATION ('01-'03 Escalade/Denali/SS) . . . . . . . . . 12

11.B FUEL PUMP WIRING AND INSTALLATION, (2003 H2 Hummer) . . . . . . . . . . . . . . . . 14

12.A ESCALADE/DENALI INLET DUCT INSTALLATION ('01-'02 Models) ..............16

12.B ESCALADE/DENALI/SS INLET DUCT INSTALLATION ('03-'06 Models) ...........17

12.C H2 HUMMER INLET DUCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

12.D 2008 H2 HUMMER INLET DUCT INSTALLATION .............................19

13. RADITOR TUBE INSTALLATION (DENALI/ESCALADE/SS ONLY) . . . . . . . . . . . . . . . 21

14. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

15. SUPERCHARGER BYPASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

16.A ESCALADE/DENALI/SS SURGE AND RESERVOIR TANK INSTALLATION . . . . . . . . 26

16.B H2 HUMMER SURGE AND RESERVOIR TANK INSTALLATION .................27

17.A ESCALADE/DENALI/SS HEAT EXCHANGER INSTALLATION ...................28

17.B H2 HUMMER HEAT EXCHANGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

17.C 2008 H2 HUMMER GRILL INSERT REMOVEL ...............................30

18.A ESCALADE/DENALI/SS CHARGE COOLER HOSE ROUTING ..................31

18.B H2 HUMMER CHARGE COOLER HOSE ROUTING ...........................32

19. WATER PUMP WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

20. REFLASH COMPUTER (All 2004, 2006 Denali Models & 2005-2007

Models see page 36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

21. SUPERCHIPS NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

22. REFLASH COMPUTER, (2004, 2006 Denali & all 2005-2007 Model Year) .........37

23. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

iii

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 4

2001-2002, 2004, 2006 GMC Denali/

2002-2004 Cadillac Escalade/

2003-2008 H2 Hummer

2003-2004 Chevrolet SS

IMPORTANT NOTES

This kit requires ECM programming. The hand-held ECM programmer is not included in the kit box and must be ordered directly from Vortech by the installing customer (the charge for this unit has been included in the purchase price). Included in this kit is a credit tag for one hand-held programmer. The programmers are made specifically for each individual vehicle with respect to the factory ECM calibration and VIN. Simply follow the instructions on the hand-held programmer credit tag. Your ECM hand-held programmer comes with a twelve month limited warranty from the original date of purchase of your supercharger system (see the Owner’s Manual for details). Vortech Engineering is not responsible for engine or ECM damage due to an improperly installed/mishandled ECM module or ECM.

'04-'06 Models: Vehicles equipped with On-star that have aftermarket

stereos will experience problems with the ability to reprogram the vehicle’s ECM. It is necessary to disconnect the aftermarket stereo from the wiring harness before continuing with the programming procedure.

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 Vortech Engineering. 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 Vortech Engineering.

Page 5

GM 2001-2002, 2004, 2006 Denali/2002-2004

ENGINEERING, LLC

Cadillac Escalade/

2003-2008 H2 Hummer/2003-2004 SS Truck

50 State Legal Per CARB EO D-213-25* (2007-2008 Models NOT 50-State Legal.)

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® V-2® 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.

Vortech 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 Vortech Engineering. 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. Vortech 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).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech 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. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. 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 at least every 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

• 3/8" NPT Tap and Handle

• Adjustable Wrench

• Open End Wrenches: 3/8", 7/16", 1/2",

9/16"

• Center Punch and a 5/8" Tapered Punch

• Springlock 3/8" and 5/8”Fuel Fitting

Disconnect Tool

• 5 Quarts SH/CF Rated Quality En gine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16", 27/64" Drill Bits

• 3/8" Tube Bender

• 3/16" Allen Wrench

• Wire Strippers and Crimpers

• Utility Knife

• Power Steering Pulley/Puller & Installer

• Pliers

• Power steering pulley installer/puller

If your vehicl e has in excess of 10,000 miles since it s last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 6

2001-2002 Denali/2002 Escalade

Part No. 4GL218-060/068SQ

ENGINEERING, LLC

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

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 1 2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A046-140 BELT, GATES, K061140 1| 4GL011-021 MTG BRKT 1

4GL130-026 OIL FEED LINE ASY 1

7P125-026 -4 x 1/8"NPT x 90° MALE 2 7P525-067 .500" CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4" HOSE BARB 2 7U030-026 1/4" OIL FEED HOSE 3.17' 7U100-055 TIE-WRAP, 6" NYLON 2

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HOSE BARB 1 7P375-040 3/8" FEMALE ELBOW 1 7P375-041 3/8"NPT HEX NIPPLE 1 7R001-008 #8 STNLS HOSE CLAMP 2 7R003-016 ADEL CLAMP, 7/8" 1 7U030-036 1/2" OIL DRAIN HOSE 2.75' 4GL238-068 FMU ASY 8:1, w/LINES 1 7U030-046 5/32" x 12" VACUUM LINE 1 7P156-082 5/32" TEE 1

4GL101-002 FUEL SYSTEM ASY 1

7E010-075 #12 x 3/4" SHEET METAL SCREW 2 7P625-030 FTG, GM TRUCK FUEL PUMP 1 7P625-031 FTG, GM TRUCK FILTER 1 7R003-027 ADEL CLAMP, 1-11/16" 2 7U030-050 12mm FUEL HOSE 1M 7R001-008 #8 STNLS HOSE CLAMP 2 8F001-002 155 INLINE FUEL PUMP 1 7C010-050 10-24 x 1/2" SOC HD CAP, ZINC PL 1 7F010-024 10-24 NYLOCK NUT 1 7J010-001 #10 FLAT WASHER 2

8F101-320 FUEL PMP RELAY ASY, GM TRUCK 1

7U100-045 O-RING, Ø.301" 1 5W001-014 FUSE HOLDER 10GA WIRE 1 5W001-011 16-14GA EYELET Ø.25" HOLE 1 5W001-025 FEMALE SLIDE, INSULATED, MINI 1 5W001-024 MINI ATC FUSE TAP 1 5W001-015 FUSE, BLADE TYPE, 20AMP 1 5W001-017 3/8" RING TERMINAL 12GA. 1 5W001-042 12-10GA 3/16" RING TERMINAL 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-019 SOLDERLESS CONNECTOR 10-12GA 1 5W001-044 TIE-WRAP, 4" NYLON 8 7P375-050 3/8" HOSEMENDER 1

4GL112-070 AIR INTAKE ASY 1

7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7S350-300 3-1/2" x 3" SLEEVE 1 7U030-046 5/32" VACUUM LINE 1.5' 7U030-056 3/8" PCV/VAC RUBBER HOSE 2 7U034-016 1" GS HOSE 0.33' 7U035-001 Ø3-1/2" FLEX HOSE 1.16' 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 4GL010-011 BRKT, D-SIDE GM TRK AIR INLET 1 4GL010-012 BRKT, P-SIDE GM TRK AIR INLET 1

7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLTD 2 7P375-050 3/8" HOSE UNION, BRASS 1 7S350-200 3-1/2" x 2" SLEEVE 1 7U133-045 RUBBER ELBOW, Ø1" x 45° 1 4PGL012-061 INLET DUCT, MACH H.O. LS1 TRK 1 4GL012-010 DUCT, VORTECH, INLET GM TRK I 7P625-375 REDUCER, 5/8" BARB TO 3/8" BARB 1 9BR100-001 Ø1.00" BRASS ROD 2.3225" 7U033-000 Ø5/8" PCV HOSE 0.16'

4GL114-010 WATER TUBE ASY, GM TRK 1

4GL014-018 WATER TUBE, GM TRK, POLISHED 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 1 7J006-093 6mm WASHER, PLTD 1 7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2 7R003-022 ADEL CLAMP, 1-3/8" 1 7U133-125 HOSE, Ø1.25" x 90° LONG LEG 1

4PGL112-020 DISCH. ASY 1

4GL012-030 ELBOW, 3.88" - 3.0" x 90° LS1 TRK 1 7R002-044 #44 GOLDSEAL HOSE CLAMP 5 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 7R002-064 #64 GOLDSEAL HOSE CLAMP 1 7S275-200 2-3/4" x 2" SLEEVE 2 4GL012-040 DISCH TUBE “A”, 6.0 COOLER POL 1 4GL012-050 DISCH TUBE “B”, 6.0 COOLER POL 1 7S300-275 REDUCER, Ø3.00" - Ø2.75" 1 4GL114-010 ASY, WATER TUBE, 1 4GL014-010 WATER TUBE, GM TRUCK 1 7A250-050 1/4-20 x 1/2" SHCS ZINC PLTD 1 7J006-093 6mm WASHER, PLATED 1 7R002-024 #24 GOLDSEAL HOSE CLAMP 2 7R003-022 ADEL CLAMP, 1-3/8" 2 7U133-070 FILLER HOSE 1 8F060-001 FUEL INJECTORS, 8.1 8 4PGL120-020 ECM CHIP PACKAGE GM TRUCK 1 7T560-001 CUTTER, 9/16" ROTOBROACH 1 7T560-002 ARBOR, ROTOBROACH 1

8N106-050 WATR COOLR ASY 1

8N006-010 WATER COOLER 1 7P500-026 1/2"NPT.x 3/4" BARB 90° 2 4GL010-080 BRKT “A”, WATER COOLER 1 4GL010-090 BRKT “B”, WATER COOLER 1 4GL010-100 BRKT “C”, WATER COOLER 1 7A250-075 1/4-20 x 3/4" SHCS PLTD 8 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 8 7J250-001 1/4"SAE WASHER, PLTD 16

8N105-040 WATER TANK ASY, 1

7U038-000 3/4" HEATER HOSE 19 7R007-001 NYLON CLAMP 1-1/8" 12 8N055-030 TANK, LT1 AFTERCOOLER 1 7P500-026 1/2"NPT x 3/4" BARB.x 90° 2 7U100-055 TIE-WRAP, 6" NYLON 6 7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" 1 7U030-065 3/4" x 90° HOSE SHORT 1 7P375-075 3/4" HOSE BARB UNION, BRASS 1 4GL010-060 BRKT, WATER TANK, COOLER 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4 7J250-001 1/4"SAE WASHER, PLTD 4 8N056-060 SURGE TANK, PLASTIC 1 8N055-050 PLASTIC CAP, SURGE TANK 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 2 4GL010-070 BRKT, SURGE TANK, COOLER 1

8N107-050 WATER PUMP ASY, 1

8F001-402 PUMP, WATER 1 7R003-027 ADEL CLAMP, 1-11/16" 1 5W001-025 FEM SLIDE, INSULATED MINI 1 5W001-043 12-10GA x 1/4" RING TERMINAL 3

Page 7

2001-2002 Denali/2002 Escalade, cont’d

Part No. 4GL218-060/068SQ

ENGINEERING, LLC

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

7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 5W001-013 14-16AWG, SOLDERLESS 4 5W001-019 SOLDERLESS CONNECTOR 10-12 2 7U100-044 TIE-WRAP, 4" NYLON 4 5W001-022 T-TAP CONN, 14-16AWG 1 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-014 FUSE HOLDER 10GA WIRE 1 7U100-055 TIE-WRAP, 6" NYLON 6 5W001-041 12-10GA MALE SLIDE 2

8F101-320 FUEL PUMP RELAY ASY 1

8N201-078 PWR COOLER ASY. 1 8N101-118 WELDED CORE ASY. 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7P500-026 1/2"NPT 3/4" BARB x 90° 1 7U250-200 TAPE, FOAM 1/4" x 2" x 50' 1

4GL010-050 BRKT, COOLER CORE SUPPORT 1

4GL114-010 WATER TUBE ASY 1

8N201-070 POWER COOLER ASY 1

8N101-110 WELDED CORE ASY, V-10 S.D. 1 8N101-001 WELDED CORE ASY, w/ENDS ONLY 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7P500-026 1/2"NPT x 3/4" BARB, 90° BRASS 1 7U250-200 TAPE, FOAM-1/4" x 2" x 50' 1 4GL010-050 BRKT, COOLER CORE SUPPORT 1 2A017-875-13 SPACER, .875"OD x .895"LONG 1 9AL6061-0875 Ø7/8" 6061 ALUMINUM ROD 1 7C010-040 M10-1.5 x 40 HXHD CL8.8 ZN 1 7J010-002 10mm WASHER, ZINC PLTD 1 4GL238-068 FMU ASY 8:1 1

4GL238-068 FMU ASY, 8:1 5/16", GM TRK 1

4GPL110-110 '03 5.3L VACUUM PUMP RELOCATION 1

4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1 4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1 7P500-009 1/2" x 90°, HOSE BARB UNION 1 7P500-001 1/2" HOSE UNION 2 7U030-050 12mm (1/2/") FUEL HOSE 0.55m 7U030-050 12mm (1/2/") FUEL HOSE 0.48m 7U133-500 1/2" x 90°, MOLDED RUBBER HOSE 1 7A312-075 5/16-18 x 3/4" HXCS GR5 ZINC 4 7F312-017 5/16-18 NYLOCK NUT 4 7J312-000 5/16" FLAT WASHER-SAE 8

vii

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 8

2003 Escalade/SS

Part No. 4GL218-080/088SQ

ENGINEERING, LLC

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

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY, 3.33" - 6-GRV 1 2A046-113 BELT, K061130-GATES 1 7A375-224 3/8-16 x 2.25" GR5 HX 5 7J375-044 3/8"SAE WASHER, PLTD 5 7C012-050 M12-1.75 x 50mm HXHD BOLT 1 4FA016-171 DUST COVER (IDLER PULLEY) 1 4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 1 2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A046-140 BELT, GATES, K061140 1 4GL011-021 MTG BRKT 1

4GL130-026 OIL FEED LINE ASY 1

7P125-026 -4 x 1/8"NPT x 90° MALE 2 7P525-067 .500" CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4" HOSE BARB 2 7U030-026 1/4" OIL FEED HOSE 3.17' 7U100-055 TIE-WRAP, 6" NYLON 2

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HOSE BAR 1 7P375-040 3/8" FEMALE ELBOW 1 7P375-041 3/8"NPT HEX NIPPLE 1 7R001-008 #8 STNLS HOSE CLAMP 2 7R003-016 ADEL CLAMP, 7/8" 1 7U030-036 1/2" OIL DRAIN HOSE 2.75' 4GL238-068 FMU ASY 8:1, w/LINES 1 7U030-046 5/32" x 12" VACUUM LINE 1 7P156-082 5/32" TEE 1

4GL101-002 FUEL SYSTEM ASY 1

8F101-320 FUEL PMP RELAY ASY, GM TRUCK 1

7U100-045 O-RING, Ø.301" 1 5W001-014 FUSE HOLDER 10GA WIRE 1 5W001-011 16-14GA EYELET Ø.25" HOLE 1 5W001-025 FEMALE SLIDE, INSULATED, MINI 1 5W001-024 MINI ATC FUSE TAP 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-017 3/8" RING TERMINAL 12GA. 1 5W001-042 12-10GA 3/16" RING TERMINAL 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-019 SOLDERLESS CONNECTOR 10-12GA 1 5W001-044 TIE-WRAP, 4" NYLON 8 7P375-050 3/8" HOSEMENDER 1

4GL112-080 AIR INTAKE ASY, LS1 H.O. TRK 1

7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7S350-300 3-1/2" x 3" SLEEVE 1 7U030-046 5/32" VACUUM LINE 2 7U030-056 3/8" PCV/VAC RUBBER HOSE 2 7U034-016 1" GS HEATER HOSE 0.33' 7U035-001 3-1/2" FLEX HOSE 1 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 4GL010-012 BRKT, P-SIDE GM TRK AIR INLET 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLATED 2 7P375-050 3/8" HOSE UNION, BRASS 1 7S350-200 3-1/2" x 2" SLEEVE 1

7U133-045 RUBBER ELBOW, Ø1" x 45° 1 4PGL012-017 DUCT, S/C INLET, '03 ESCALADE 1 4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1 7P375-097 3/8"NPT x 3/8" BEADED HOSE BARB 1

4GL114-010 WATER TUBE ASY, GM TRK 1

4PGL112-020 DISCH. ASY 1

4GL012-030 ELBOW, 3.88" x 3.0" x 90° LS1 TRK 1 7R002-044 #44 GOLDSEAL HOSE CLAMP 5 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 7R002-064 #64 GOLDSEAL HOSE CLAMP 1 7S275-200 2-3/4" x 2" SLEEVE 2 4GL012-040 DISCH TUBE “A”, 6.0 COOLER POL 1 4GL012-050 DISCH TUBE “B”, 6.0 COOLER POL 1 7S300-275 REDUCER, Ø3.00" x Ø2.75" 1 4GL114-010 ASY, WATER TUBE, 1 4GL014-010 WATER TUBE, GM TRUCK 1 7A250-050 1/4-20 x 1/2" SHCS ZINC PLTD 1 7J006-093 6mm WASHER, PLATED 1 7R002-024 #24 GOLDSEAL HOSE CLAMP 2 7R003-022 ADEL CLAMP, 1-3/8" 2 7U133-070 FILLER HOSE 1 8F060-001 FUEL INJECTORS, 8.1 8 4PGL120-020 ECM CHIP PACKAGE GM TRUCK 1 7T560-001 CUTTER, 9/16" ROTOBROACH 1 7T560-002 ARBOR, ROTOBROACH 1

8N106-050 WATR COOLR ASY 1

8N006-010 WATER COOLER 1 7P500-026 1/2"NPT x 3/4" BARB x 90° 2 4GL010-080 BRKT “A”, WATER COOLER 1 4GL010-090 BRKT “B”, WATER COOLER 1 4GL010-100 BRKT “C”, WATER COOLER 1 7A250-075 1/4-20 x 3/4" SHCS PLTD 8 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 8 7J250-001 1/4"SAE WASHER, PLTD 16

8N105-040 WATER TANK ASY, 1

7U038-000 3/4" HEATER HOSE 19 7R007-001 NYLON CLAMP 1-1/8" 12 8N055-030 TANK, LT1 AFTERCOOLER 1 7P500-026 1/2"NPT x 3/4" BARB x 90° 2 7U100-055 TIE-WRAP, 6" NYLON 6 7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" 1 7U030-065 3/4" x 90° HOSE SHORT 1

P/N: 4GL020-015

10MAR08 GM Trk/H2(4GL..015v4.0)

08OCT08 GM Trk/H2(4GL..015v5.0)

viii

Page 9

2003 Escalade/SS, cont’d

Part No. 4GL218-080/088SQ

ENGINEERING, LLC

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

7P375-075 3/4" HOSE BARB UNION, BRASS 1 4GL010-060 BRKT, WATER TANK, COOLER 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4 7J250-001 1/4"SAE WASHER, PLTD 4 8N056-060 SURGE TANK, PLASTIC 1 8N055-050 PLASTIC CAP, SURGE TANK 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 2 4GL010-070 BRKT, SURGE TANK, COOLER 1

8N107-050 WATER PUMP ASY, 1

8F001-402 PUMP, WATER 1 7R003-027 ADEL CLAMP, 1-11/16" 1 5W001-025 FEM SLIDE, INSULATED MINI 1 5W001-043 12-10GA x 1/4" RING TERMINAL 3 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 5W001-013 14-16AWG, SOLDERLESS 4 5W001-019 SOLDERLESS CONNECTOR 10-12 2 7U100-044 TIE-WRAP, 4" NYLON 4 5W001-022 T-TAP CONN, 14-16 AWG 1 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-014 FUSE HOLDER 10GA WIRE 1 7U100-055 TIE-WRAP, 6" NYLON 6 5W001-041 12-10GA MALE SLIDE 2 8F101-320 FUEL PUMP RELAY ASY. 1 8N201-078 PWR COOLER ASY. 1 8N101-118 WELDED CORE ASY. 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7P500-026 1/2"NPT x 3/4" BARB, 90° 1 7U250-200 TAPE, FOAM 1/4" x 2" x 50' 1 4GL010-050 BRKT, COOLER CORE SUPPORT 1

4GL114-010 WATER TUBE ASY 1

8N201-070 POWER COOLER ASY 1

8N101-110 WELDED CORE ASY, V-10 S.D. 1 8N101-001 WELDED CORE ASY, w/ENDS ONLY 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 1 7U250-200 TAPE, FOAM-1/4" x 2" x 50' 1 4GL010-050 BRKT, COOLER CORE SUPPORT 1 2A017-875-13 SPACER, .875"OD x .895" LONG 1 9AL6061-0875 Ø7/8" 6061 ALUMINUM ROD 1 7C010-040 M10-1.5 x 40 HXHD CL8.8 ZN 1 7J010-002 10mm WASHER, ZINC PLTD 1

4PGL110-115 '03 5.3L VACUUM PUMP RELOCATION 1

4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1 4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1 7P500-009 1/2" x 90°, HOSE BARB UNION 1 7P500-001 1/2" HOSE UNION 2 7U030-050 12mm (1/2/") FUEL HOSE 0.55m 7U030-050 12mm (1/2/") FUEL HOSE 0.48m 7U133-500 1/2" x 90°, MOLDED RUBBER HOSE 1 7A312-075 5/16-18 x 1.00" HXCS GR5 ZINC 4 7F312-017 5/16-18 NYLOCK NUT 4 7J312-000 5/16" FLAT WASHER-SAE 8

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 10

2003 H2 Hummer

Part No. 4GL218-070/078SQ

ENGINEERING, LLC

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

8F060-005 8.1L INJECTORS 8

4809639 INSTR. MANUAL DENALI/ESCALADE/HUMMER 1

4GL011-021 MTG BRKT GM TRUCK MACH. 1

2E228-390 V2SQ S-TRIM LS1 TRK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1

4GL112-040 AIR INLET ASY, H2 HUMMER 1

4GL012-015 DUCT, INLET, HUMMER H2 TRK 1 7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7S350-300 3-1/2" x 3" SLEEVE 1 7U030-046 Ø5/32" VACUUM LINE 1 7U030-056 Ø3/8" PVC/VAC RUBBER HOSE 2 7U034-016 Ø1" GS HOSE 0.33' 7U035-001 Ø3-1/2" FLEX HOSE 0.83' 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 4PGL010-011 BRKT, D-SIDE H2 TRK AIR INLET 1 4PGL010-012 BRKT, P-SIDE H2 TRK AIR INLET 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLTD 2 7P375-050 3/8" HOSE UNION, BRASS 1 4PGL012-061 INLET DUCT, MACH H.O. LS1 TRK 1 7S350-200 3-1/2" x 2" SLEEVE 1 7U133-045 RUBBER ELBOW, Ø1" x 45° 1 7C060-050 M6-1.0 x 50mm HXHD ZINC PLTD 2 7J250-150 1/4" FENDER WASHER ZN PLTD 2 7F006-093 6mm NYLOCK NUT 2 2A017-752-02 SPACER, .750"OD x .894"LONG 2 7P625-375 REDUCER, 5/8" BARB x 3/8" BARB 1 7U033-000 5/8" PVC HOSE 0.16' 7S300-275 REDUCER, Ø3.00" x Ø2.75" 1

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HOSE BARB 1 7P375-040 3/8" FEMALE ELBOW 1 7P375-041 3/8"NPT HEX NIPPLE 1 7R001-008 #8 STAINLESS HOSE CLAMP 2 7R003-016 ADEL CLAMP, 1.0" 1 7U030-036 Ø1/2" OIL DRAIN HOSE 2.75' 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1

4PGL130-026 OIL FEED ASY 1

7U100-055 TIE-WRAP, 6" NYLON 2 7C060-050 M6 x 1.0" x 50 HXHD ZINC PLATE 2 7J006-093 6mm WASHER PLTD 2 4GL010-020 ADAPTER, ESCALADE OIL FEED 1 4GL010-030 GASKET, ESCALADE OIL ADAPTER 1 4GL010-040 GASKET, 5.3 OIL ADAPTER 1 7U250-400 OIL FEED HOSE, 40" -4 x 90° 1 7P125-005 1/8"NPT STR x -4 JIC FTG 1 7P125-004 1/8"NPT x 90° JIC FTG 2

4PGL101-001 FUEL PUMP ASY 1

7P250-047 1/4"NPT to 3/8" BARB x 90° 1 7P312-002 5/16" BARB x 1/4"NPT FEM 1 7R004-002 STEPLESS CLAMP, 17.0-70 4 7R004-001 STEPLESS CLAMP, 15.7-70 2 7U031-018 Ø5/16" EFI FUEL HSE HI-PSR 1.25' 7U032-016 Ø3/8" EFI FUEL HSE HI-PSR .167' 7U032-016 Ø3/8" EFI FUEL HSE HI-PSR .5' 7U100-044 TIE-WRAP, 4" NYLON 10 7U100-055 TIE-WRAP, 6" NYLON 10 8F001-500 PUMP, FUEL, “PRO-FLO 500” 1 7U033-010R HOSE, 5/8"ID p/STEERING RET 2

5W001-042 12-10GA x 3/16" RING TERMINAL 3 7P375-072 3/8" FEMALE FUEL FTG, STEEL 1 7P625-375 REDUCER, 5/8" BARB x 3/8" BARB 1 7P375-010 3/8" GM FUEL x 3/8" BARB FTG 1 7F012-001 M12 CAP HEX NUT, FUEL PUMP 1 7R003-028 ADEL CLAMP, 2-3/8" x .26" HOLE 2 7P312-015 FTNG, BANJO 12mm x .312" BARB 1 7R004-004 STEPLESS CLAMP, 1.0"OD HOSE 2 7E010-075 #12 x 3/4" SHT METAL SCRW, HEX 3 5W012-000 12GA STRD WIRE, RED 15' 5W001-040 12-10GA FEMALE SLIDE INSULATED 1 5W012-010 12GA WIRE, BLACK .5' 7R003-008 ADEL CLAMP, 1/2"ID 2 8F101-320 RELAY ASY, LS1 TRK 1

8N107-050 WATER PUMP ASY. 1

8F001-402 WATER PUMP 1 7R003-027 ADEL CLAMP 1-11/16" 1 5W001-025 FEMALE SLIDE MINI 1 5W001-043 12-10GA x 1/4" RING TERMINAL 3 7A250-050 1/4-20 x .50" SHCS 2 5W001-013 14-16GA BUTT-CONNECTORS 4 5W001-019 12-10GA BUTT-CONNECTORS 2 7U100-044 4" TIE-WRAPS 4 5W001-022 T-SPLICE CONNECTOR 1 7F250-021 1/4-20 NYLOCK NUT 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-014 FUSE HOLDER 10GA WIRE 1 7U100-055 TIE-WRAP, 6" NYLON 6 5W001-041 12-10GA MALE SLIDE INSULATED 2 8F101-320 WATER PUMP RELAY ASY, LS1 TRK 1

8N105-050 WATER TANK ASY 1

8N055-030 LT1 WATER TANK 1 7P500-026 90° BARBED BRASS FITTING 2 4PGL010-060 BRKT “A” 1 4PGL010-070 BRKT “B” 1 4PGL010-080 BRKT “C” 1 7A250-102 1/4-20 x 1" SHCS 1 7J250-022 1/4" WASHER 6 7F250-021 1/4-20 NYLOCK NUT 1 8N056-060 SURGE TANK 1 8N055-050 SURGE TANK CAP 1 4PGL010-090 BRKT, SURGE TANK 1 7P500-078 12"NPT x 3/4" HOSE FIT 2 7U038-020 MOLDED “S” HOSE 1 7A250-050 1/4-20 x .5" SHCS 4 7U038-000 Ø3/4" HEATER HOSE 10 7U033-000 Ø5/8" HOSE 5 7P750-625 3/4-5/8" REDUCER BARB 2 7E010-075 #12 x 3/4" SHT METAL SCRW HEX 4 7U030-065 90° MOLDED ELBOW SHORT 1 7J010-001 #10 FLAT WASHER 2 7R002-020 #20 HOSE CLAMP 2 7R007-002 NYLON CLAMPS 7/8" 4 7R007-001 NYLON CLAMPS 1-1/8" 10

8N201-078 POWER COOLER ASY 1

8N101-118 WELDED CORE ASY V-10 S.D. 1 7P500-078 1/2"NPT x 3.4" HOSE FIT 1 7P500-026 1/2"NPT x 3/4" HOSE BARB 90° 1 2A017-875-13 SPACER, CAC BRKT 1 7C010-040 10mm-1.5 x 1.5mm SCREW 1 7J010-002 10mm WASHER 1 7U250-200 COOLER FOAM 1 4GL010-050 COOLER REST BRACKET 1

Page 11

2003 H2 Hummer, con't

Part No. 4GL218-070/078SQ

ENGINEERING, LLC

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

4PGL112-028 DISCH ASY 1

4GL012-041 6.0 TUBE “A” 1 4GL012-051 6.0 TUBE “B” 1 4GL012-030 ELBOW, 3.88 x 3.0" x 90° LS1 TRK 1 7R002-044 #44 GOLDSEAL HOSE CLAMP 5 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 7R002-064 #64 GOLDSEAL HOSE CLAMP 1 7S275-200 2-3/4" x 2" SLEEVE 2 7S300-275 Ø3.00" x Ø2.75" REDUCER SLEEVE 1

8N106-075 WATER COOLER ASY 1

8N006-005 WATER COOLR, SETRAB DUAL-PASS 1 7A250-102 1/4-20 x 1" SHCS SS 4 7J250-022 1/4" WASHER SAE STAINLESS 8 7F250-021 1/4-20 NYLOCK NUT, ZINC PLT 2 8N010-140 MTG TAB, SETRAB 2-PASS COOLR 4 7P375-075 3/4" HOSE BARB UNION, BRASS 3 7U125-200 TAPE, FOAM, 1/8" x 2" x 50' 7.5" 7U038-020 HOSE, Ø3/4" “S” MOLDED RUBBER 2 7R007-001 NYLON RATCHET CLAMP, 1-1/8" 4

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 12

2004-2007 H2 Hummer

Part No. 4GL218-090/098SQ (2004 Models)

Part No. 4GL218-150/158SQ (2005-2007 Models)

ENGINEERING, LLC

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

8F060-005 8.1L INJECTORS 8

4809639 INSTR. MANUAL DENALI/ESCALADE/HUMMER 1

4GL011-021 MTG BRKT GM TRUCK MACH. 1

2E228-390 V2SQ S-TRIM LS1 TRK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1

4GL112-040 AIR INLET ASY, H2 HUMMER 1

4GL012-015 DUCT, INLET, HUMMER H2 TRK 1 7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7S350-300 3-1/2" x 3" SLEEVE 1 7U030-046 5/32" VACUUM LINE 1 7U030-056 3/8" PVC/VAC RUBBER HOSE 2 7U034-016 Ø1"GS HOSE 0.33' 7U035-001 Ø3-1/2" FLEX-HOSE 0.83' 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 4PGL010-011 BRKT, D-SIDE H2 TRK AIR INLET 1 4PGL010-012 BRKT, P-SIDE H2 TRK AIR INLET 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLTD 2 7P375-050 3/8" HOSE UNION, BRASS 1 4PGL012-061 INLET DUCT, MACH H.O. LS1 TRK 1 7S350-200 3-1/2" x 2" SLEEVE 1 7U133-045 RUBBER ELBOW, Ø1" x 45° 1 7C060-050 M6-1.0 x 50mm HXHD ZINC PLTD 2 7J250-150 1/4" FENDER WASHER ZN PLTD 2 7F006-093 6mm NYLOCK NUT 2 2A017-752-02 SPACER, .750"OD x .894"LONG 2 7P625-375 REDUCER, Ø5/8" BARB TO Ø3/8" BARB 1 7U033-000 Ø5/8" PVC HOSE 0.16' 7S300-275 REDUCER, Ø3.00" x Ø2.75" 1 7U033-000 Ø5/8" PCV HOSE .16' 7P375-113 PCV VALVE, VIPER, 3/8" x 1/2" BA 1 7U375-056 Ø3/8" PCV/VAC RUBBER HOSE .25'

4GL130-036 OIL DRAIN ASY 1

7P375-017 3/8"NPT x 1/2" BEADED HSE BRB 1 7P375-040 Ø3/8" FEMALE ELBOW 1 7P375-041 3/8"NPT HEX NIPPLE 1 7R001-008 #8 STAINLESS HOSE CLAMP 2 7R003-016 ADEL CLAMP, 1.0" 1 7U030-036 Ø1/2" OIL DRAIN HOSE 2.75' 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1

4PGL130-026 OIL FEED ASY 1

7U100-055 TIE-WRAP, 6" NYLON 2 7C060-050 M6-1.0 x 50mm HXHD ZINC PLATE 2 7J006-093 6mm WASHER PLTD 2 4GL010-020 ADAPTER, ESCALADE OIL FEED 1 4GL010-030 GASKET, ESCALADE OIL ADAPTER 1 4GL010-040 GASKET, 5.3 OIL ADAPTER 1 7U250-400 OIL FEED HOSE, 40" x -4 x 90° 1 7P125-005 1/8"NPT STR x -4 JIC FTG 1 7P125-004 1/8"NPT x 90° x JIC FTG 2

8N107-050 WATER PUMP ASY 1

8F001-402 WATER PUMP 1 7R003-027 ADEL CLAMP 1-11/16" 1 5W001-025 FEMALE SLIDE MINI 1 5W001-043 12-10GA x 1/4" RING TERMINAL 3 7A250-050 1/4-20 x .50" SHCS 2 5W001-013 14-16GA BUTT CONNECTORS 4

5W001-019 12-10GA BUTT CONNECTORS 2 7U100-044 4" TIE-WRAPS 4 5W001-022 T-SPLICE CONNECTOR 1 7F250-021 1/4-20 NYLOCK NUT 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-014 FUSE HOLDER 10GA WIRE 1 7U100-055 TIE-WRAP, 6" NYLON 6 5W001-041 12-10GA MALE SLIDE INSULATED 2 8F101-320 WATER PUMP RELAY ASY, LS1 TRK 1

8N105-050 WATER TANK ASY 1

8N055-030 LT1 WATER TANK 1 7P500-026 90° BARBED BRASS FITTING 2 4PGL010-060 BRKT “A” 1 4PGL010-070 BRKT “B” 1 4PGL010-080 BRKT “C” 1 7A250-102 1/4-20 x 1" SHCS 1 7J250-022 1/4" WASHER 6 7F250-021 1/4-20 NYLOCK NUT 1 8N056-060 SURGE TANK 1 8N055-050 SURGE TANK CAP 1 4PGL010-090 BRKT, SURGE TANK 1 7P500-078 12"NPT x 3/4" HOSE FIT 2 7U038-020 MOLDED “S” HOSE 1 7A250-050 1/4-20 x .5" SHCS 4 7U038-000 Ø3/4" HEATER HOSE 10" 7U033-000 Ø5/8" HOSE 5" 7P750-625 Ø3/4" x Ø5/8" REDUCER BARB 2 7E010-075 #12 x 3/4" SHT METAL SCRW HEX 4 7U030-065 90° MOLDED ELBOW SHORT 1 7J010-001 #10 FLAT WASHER 2 7R002-020 #20 HOSE CLAMP 2 7R007-002 NYLON CLAMPS 7/8" 4 7R007-001 NYLON CLAMPS 1-1/8" 10

8N201-078 POWER COOLER ASY 1

8N101-118 WELDED CORE ASSEMBLY V-10 S.D. 1 7P500-078 1/2"NPT x 3.4" HOSE FIT 1 7P500-026 1/2"NPT x 3/4" HOSE BARB x 90° 1 2A017-875-13 SPACER, CAC BRKT 1 7C010-040 10mm-1.5" x 1.5mm SCREW 1 7J010-002 10mm WASHER 1 7U250-200 COOLER FOAM 1 4GL010-050 COOLER REST BRACKET 1

4PGL112-028 DISCH ASY 1

4GL012-041 6.0 TUBE “A” 1 4GL012-051 6.0 TUBE “B” 1 4GL012-030 ELBOW, 3.88" - 3.0" x 90° LS1 TRK 1 7R002-044 #44 GOLDSEAL HOSE CLAMP 5 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 7R002-064 #64 GOLDSEAL HOSE CLAMP 1 7S275-200 2-3/4" x 2" SLEEVE 2 7S300-275 3.00" x 2.75" REDUCER SLEEVE 1

8N106-075 WATER COOLER ASY 1

4GL020-020 MTUNER CREDIT TAG (2004 MODEL YEAR) 1

5A003-034 DIABL0 PREDATOR (2003-2007 MODEL YEAR) 1

* It is recommended that you use the K061140 drive belt.

xii

Page 13

2004 Escalade/SS Truck

Part No. 4GL218-130/138SQ

ENGINEERING, LLC

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

4GL011-021 MOUNTING BRACKET MACH 1

4PGL130-026 OIL FEED ASY, ESCALADE 1

4GL010-020 ADAPTOR, ESCALADE OIL FEED 1 4GL130-030 GASKET, ESCALADE OIL ADAPTER 2 7C060-050 M6-1.0 x 50mm HXHD ZINC PLATE 2 7J006-093 6mm WASHER, PLATED 2 7P125-004 1/8"NPT 90° x -4 JIC FTG STL 2 7P125-005 1/8"NPT STR, x -4 JIC FTG STL 1 7U100-055 TIE-WRAP, 7.5" NYLON 2 7U250-090-400 OIL FEED HOSE, 40" x -4 x 90° 1

4GL130-036 OIL DRAIN ASY, GM TRK 1

7P375-017 3/8"NPT x 1/2" BEADED HSE BRB 1 7P375-040 3/8"NPT BRASS REM/FEM ELBOW 1 7P375-041 3/8"NPT HEX NIPPLE x 1.5" 1 7R001-008 #8 STNLS HOSE CLAMP 2 7R003-016 ADEL CLAMP, 1.0" 1 7U030-036 1/2" OIL DRAIN HOSE 2 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1

4GL112-080 AIR INT ASY, LS1 H.O. TRK 1

4GL010-011 BRKT, DRIVER’S SIDE SM TRK AIR INLET 1 4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1 4GPL012-017 DUCT, S/C INLET, '03 ESCALADE 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLATED 2 7P156-082 5/32" TEE 1 7P375-050 3/8" HOSE UNION, BRASS 1 7P375-097 3/8"NPT x 3/8" BEADED HOSE BARB 1 7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7S350-200 SLEEVE, 3-1/2" x 2", BLUE 1 7S350-300 SLEEVE, 3-1/2" x 3", BLUE 1 7S030-046 5/32" VACUUM LINE 1 7U030-056 3/8" PCV/VAC RUBBER HOSE 2 7U034-016 1" GS HEATER HOSE 0.33' 7U035-001 3-1/2" FLEX HOSE 1 7U133-045 RUBBER ELBOW, Ø1" x 45° 1 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7U030-056 Ø3/8" PCV/VAC RUBBER HOSE 0.25' 7P375-113 PCV VALVE, VIPER, 3/8" x 1/2" BA 1

4PGL112-020 DISCH ASY, LS1 H.O. TRUCK 1

4GL012-030 ELBOW, 3.88" x 3.0" x 90° GM TRUCK 1 4GL012-040 DISCH TUBE “A”, 6.0 COOLER, CAST 1 4GL012-051 DISCH TUBE “B”, 6.0 COOLER 1 7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 5 7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 2 7R002-064 #64 SAE TYPE “R” SS HOSE CLAMP 1 7S275-200 SLEEVE, Ø2.75" x 2.00"L, BLUE 2 7S300-275 REDUCER, Ø3.00" x Ø2.75" 1

4GL114-010 WATER TUBE ASY, GM TRUCK 1

4GL014-018 WATER TUBE, GM TRUCK, POLISHED 1 2A250-050 1/4-20 x .50" SHCS ZINC PLTD 1 7J006-093 6mm WASHER, PLATED 1

7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2 7R003-022 ADEL CLAMP 1-3/8" 1 7U133-125 HOSE, Ø1.25" x 90° LONG LEG 1

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1 7U100-070 KEY, 3/16" SQUARE x 7/8" LONG 1 7A040-011 PULLEY RETAINER S/C 1 7B375-110 3/8-24 x 1" GRADE-8 HXHD 1 7K375-040 3/8"AN960 FLAT WASHER PLATED 1 7A250-037 1/4-20 x .375" SHCS PLTD 6 7U100-023 DRIVE SCREW, 34 x 1/4" 2 2A046-113 BELT, K061130-GATES 1 7A375-224 3/8-16 x 2.25" GR5 HX 5 7J375-044 3/8"SAE WASHER, PLTD 5 7C012-050 M12-1.75 x 50mm HXHD BOLT 1 4F016-171 DUST COVER (IDLER PULLEY) 1 4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 1 2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A046-140 BELT, GATES K061140 1

8N201-070 PWR COOLER ASY, GMT LS1 H.O. 1

2A017-875-13 SPACER, .875"OD x .895" LONG 1 4GL010-050 BRKT, COOLER CORE SUPPORT 1 7C010-040 M10-1.5 x 40mm HXHD CL8.8 ZN 1 7J010-002 10mm WASHER, ZINC PLATED 1 7P500-026 1/2"NPT x 3/4" BARB 90° BRASS 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7U250-200 TAPE, FOAM-1/4" x 2" x 50' 12" 8N101-110 WELDED CORE ASY, V-10 S.D. 1

8N107-050 WATER PUMP ASY, GMT LS1 H.O. 1

5W001-005 3/8" PLASTIC WIRE LOOM 5' 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 4 5W001-014 FUSE HOLDER, 10GA 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-019 10-12GA BUTT CONNECTOR, INSULATED 2 5W001-022 T-TAP CONNECTOR, 14-16AWG 1 5W001-024 MINI ATC FUSE TAP 1 5W001-041 12-10GA MALE SLIDE, INSULATED 2 5W001-043 12-10GA x 1/4" RING TERMINAL 3 2A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 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 7U100-055 TIE-WRAP, 7.5" NYLON 6

8F001-402 PUMP, WATER, PIERBURG 1

8F101-320 FUEL PUMP RELAY ASY, LS1 TRK 1 5W001-010 16-14GA FEMALE SLIDE, INSULATED 2 5W001-016 RELAY, BOSCH 1 5W001-040 12-10GA FEMALE SLIDE, INSULATED 2 5W001-042 12-10GA x 3/16" RING TERMINAL 2 5W012-000 12GA, STRD WIRE, RED 9' 5W012-000 12GA, STRD WIRE, RED 1.5' 5W012-010 12GA, WIRE, BLACK 0.5' 5W014-030 14GA STRD WIRE, BLACK 0.5'

xiii

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 14

2004 Escalade/SS Truck, cont’d

Part No. 4GL218-130/138SQ

ENGINEERING, LLC

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

N105-040 WATER TANK ASY, GMT LS1 H.O. 1

4GL010-060 BRKT, WATER TANK, COOLER 1 4GL010-070 BRKT, SURGE TANK, COOLER 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4 7J250-001 1/4" WASHER, SAE PLTD 4 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7P500-026 1/2"NPT x 3/4" BARB x 90°, BRASS 3 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 3 7r007-001 NYLON RATCHET CLAMP, 1-1/8" 12 7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1 7U038-000 Ø3/4" HEATER HOSE 19' 7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1 7U100-055 TIE-WRAP, 7.5" NYLON 6 8N055-030 WATER TANK, TRIANGLE SHAPE 1 8N055-050 PLASTIC CAP, SURGE TANK 1 8N056-060 SURGE TANK, PLASTIC 1

8N106-050 WATER COOLER ASY, GMT LS1 H.O. 1

4GL010-080 BRKT “A”, WATER COOLER MOUNT 1 4GL010-090 BRKT “B”, WATER COOLER MOUNT 1 4GL010-100 BRKT “C”, WATER COOLER MOUNT 1 7A250-075 1/4-20 x 3/4" SHCS PLTD 8 7F250-021 1/4-20 NYLOCK NUT, ZINC PLATED 8 7J250-001 1/4" WASHER, SAE, PLTD 16 7P500-026 1/2"NPT x 3/4" BARB, 90° BRASS 2 8N006-010 WATER COOLER, SETRAB SINGLE PAS 1

4PGL110-110 '03 5.3L ESCALADE VACPMP RELOC 1

4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1 4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1 7A312-075 5/16-18 x 3/4" HXCS GR5 ZINC 4 7F312-017 5/16-18 NYLOCK NUT 4 7J312-000 5/16" FLAT WASHER, SAE 8 7P500-001 1/2" HOSE UNION 2 7P500-009 1/2" x 90° HOSE BARB UNION 1 7U030-050 12mm (1/2") FUEL HOSE .55m 7U030-050 12mm (1/2") FUEL HOSE .48m 7U133-500 1/2" x 90° MOLDED RUBBER HOSE 1

8F060-005 FUEL INJECTOR, GM 8.1 MARINE 8

4GL020-015 INSTALL MANUAL, H2/ESCAL/DENALI 01-0 1

xiv

Page 15

2004, 2006 Denali H.O. Kit

Part No. 4GL218-140/148SQ

ENGINEERING, LLC

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

4GL218-140SQ '04, '06 DENALI H.O. KIT SAT 1

4GL011-021 MOUNTING BRACKET - MACH 1

4PGL130-026 OIL FEED ASY, ESCALADE 1

4GL010-020 ADAPTER, ESCALADE OIL FEED 1 4GL010-030 GASKET, ESCALADE OIL ADAPTER 2 7C060-050 M6 x 1.0 x 50 HXHD ZINC PLATE 2 7J006-050 6mm WASHER, PLATED 2 7P125-004 1/8"NPT x 90° x -4 JIC FTG STL 2 7P125-005 1/8"NPT STR. x -4 JIC FTG STL 1 7U100-055 TIE-WRAP, 7.5" NYLON 2 7U250-400 OIL FEED HOSE, 40" -4 x 90° 1

4GL130-036 OIL DRAIN ASY, GM TRK 1

7P375-017 3/8"NPT x 1/2" BEADED HOSE BARB 1 7P375-040 3/8"NPT BRASS FEM/FEM ELBOW 1 7P375-041 3/8"NPT HEX NIPPLE x 1/5" 1 7R001-008 #8 STNLS HOSE CLAMP 2 7R003-016 ADEL CLAMP, 1.0" 1 7U030-036 1/2" OIL DRAIN HOSE 2.75'

4GL112-080 AIR INT ASY, '03 LS1 H.O. TRK 1

4GL010-011 BRKT, DSIDE GM TRK AIR INLET 1 4GL010-012 BRKT, PSIDE GM TRK AIR INLET 1 4GL012-010 DUCT, INLET, LONG GM SUV/TRK 1 4PGL012-017 DUCT, S/C INLET, '03 ESCALADE 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLATED 2 7P156-082 5/32" TEE 1 7P375-050 3/8" HOSE UNION, BRASS 1 7P375-097 3/8"NPT x 3/8" BEADED HOSE BARB 1 7P375-106 PCV VALVE, FORD, 3/8" HOSE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7S350-200 SLEEVE, 3-1/2" x 2", BLUE 1 5S350-300 SLEEVE, 3-1/2" x 3", BLUE 1 7U030-046 5/32" VACUUM LINE 2' 7U030-056 3/8" PCV/VAC RUBBER HOSE 2.5' 7U034-016 1" GS HEATER HOSE 0.33' 7U035-001 3-1/2" FLEX HOSE 1.16' 7U375-045 RUBBER ELBOW, Ø1" x 45° 1 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 7U030-056 3/8" PCV/VAC RUBBER HOSE 0.25' 7F375-113 PCV VALVE, VIPER, 3/8-1/2" BA 1

4PGL112-020 DISCH ASY LS1 H.O. TRUCK 1

4GL112-030 ELBOW, 3.88 x 3.0" x 90° GM TRK 1 4GL012-040 DISCH TUBE “A”, 6.0 COOLER, CAST 1 4GL012-051 DISCH TUBE “B”, 6.0 COOLER 1 7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 5 7R002-048 #48 SAE TYPE “F” SS HOSE CLAMP 2 7R002-064 #64 SAE TYPE “F” SS HOSE CLAMP 1 7S275-200 SLEEVE, Ø2.75" x 2.00"L, BLUE 2 7S300-275 REDUCER, 3.00" x 2.75" 1

4GL114-010 WATER TUBE ASY, GM TRUCK 1

7A250-050 1/4-20 x .50" SHCS ZINC PLTD 1 7J006-093 6mm WASHER, PLATED 1 7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2 7R003-022 ADEL CLAMP, 1-3/8" 1 7U133-125 HOSE, Ø1.25" x 90° LONG LEG 1 2E228-390 V2SQ S-TRIM LS1 TRUCK 1 2A036-333 S/C PULLEY 3.33" 6-GRV 1 4FH016-150 IDLER, PULLEY, 6-RIB 3" FLANGED 1 2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A046-140 BELT, 6-RIB x 114.00 EFFECT. L 1

8N201-070 PWR COOLER ASY, GMT LS1 H.O. 1

2A017-875 SPACER, .875"OD x .895"L 4GL010-050 BRKT, COOLER CORE SUPPORT 1 7C010-040 M10-1.5 x 40mm HXHD CL8.8 ZN 1 7J010-002 10mm WASHER, ZINC PLATED 1 7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7U250-200 TAPE, FOAM, 1/4" x 2" x 50' 12" 8N101-110 WELDED CORE ASY. V-10 S.D. 1 5W001-005 3/8" PLASTIC WIRE LOOM 5' 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-013 14-16GS BUTT CONN BLU INSUL 4 5W001-014 FUSE HOLDER 10GA WIRE 1 5W001-015 FUSE, BLADE TYPE, 20AMP 1 5W001-019 10-12AGA 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 2 5W001-043 12-10GA x 1/4" RING TERMINAL 3 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 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 7U100-055 TIE-WRAP, 7.5" NYLON 6 8F001-402 PUMP, WATER, PIERBURG 1 5W001-010 16-14GA FEMALE SLIDE INSULATED 2 5W001-016 RELAY, BOSCH 1 5W001-002 FUSE TAP 1

2E228-390 V2SQ S-TRIM LS1 TRUCK 1

2A036-333 S/C PULLEY 3.33" 6-GROOVE 1 2A046-140 BELT, 6-RIB x 114.00 EFFECT. L 1 2A046-113 BELT, 6-RIB x 112.89 EFFECT. L 1 4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 1 2A017-462 SPACER, IDLER SMOOTH, 6-RIB 1

8N201-070 PWR COOLER ASY, GMT LS1 H.O. 1

2A017-875-13 SPACER, .875"OD x .895"LONG 1 7C010-040 M10-1.5 x 40mm HXHD CL8 .8 ZN 1 7J010-002 10mm WASHER, ZINC PLATED 1 7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 1 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 1 7U250-200 TAPE, FOAM, 1/4" x 2" x 50' 12" 8N101-110 WELDED CORE ASY, V-10 S.D. 1

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 16

2004, 2006 Denali H.O. Kit, con't

Part No. 4GL218-140/148SQ

ENGINEERING, LLC

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

8N107-050 WATER PMP ASY, GMT LS1 H.O. 1

5W001-005 3/8" PLASTIC WIRE LOOM 5' 5W001-005 16-14GA, MALE SLIDE INSULATED 1 5W001-013 14-16GA BUTT CONN BLU INSUL 4 5W001-014 FUSE HOLDER 10GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20-AMP 1 5W001-019 10-12GA BUTT CONN INSULATED 2 5W001-022 T-TAP CONN. 14-16AWG 1 5W001-024 MINI ATC FUSE TAP 1 5W001-041 12-10GA MALE SLIDE INSULATED 2 5W001-043 12-10GA x 1/4" RING TERMINAL 3 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7F250-021 1/4-20 NYLOCK NUT, ZINC PLTD 1 7R003-027 ADEL CLAMP, 1-11/16" 1 7U100-044 TIE-WRAP, 4" NYLON 4 7U100-055 TIE-WRAP, 7.5" NYLON 6 8F001-402 WATER PUMP, PIERBURG 1 8F101-320 FUEL PUMP RELAY ASY, LS1 TRK 1 5W001-010 16-14GA FEMALE SLIDE, INSULATED 2 5W001-016 RELAY, BOSCH 1 5W001-002 FUSE TAP 1 4GL010-060 BRKT, WATER TANK, COOLER 1 4GL010-070 BRKT, SURGE TANK, COOLER 1 7A2500-050 1/4-20 x .50" SHCS ZINC PLTD 4 7J250-001 1/4" WASHER, SAE, PLTD 4 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7P500-026 1/2"NPT x 3/4" BARB 90° BRASS 3 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8" 12 7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1 7U038-000 3/4" HEATER HOSE 19' 7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1 7U100-055 TIE-WRAP, 7.5" NYLON 6 8N055-030 WATER TANK, TRIANGLE SHAPE 1 8N055-050 PLASTIC CAP, SURGE TANK 1 8N056-060 SURGE TANK, PLASTIC 1 2A017-875-08 SPACER, .875"OD x .290"LONG 2 4GL010-080 BRKT, “A”, WATER COOLER MOUNT 1 4GL010-090 BRKT “B”, WATER COOLER MOUNT 1 4GL010-100 BRKT “C”, WATER COOLER MOUNT 1 7A250-075 1/4-20 x .75" SHCS PLTD 8 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 8 7J250-001 1/4" WASHER, SAE PLTD 16 7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 2 8N006-010 WATER COOLER, SETRAB SINGLE PASS 1

008341 VORTECH CHARGE COOLER DECAL 1 4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1 4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1

7A312-075 5/16-18 x 3/4" HHCS, GR5, ZINC 4 7F312-017 5/16-18 NYLOCK NUT 4 7J312-000 5/15" FLAT WASHER, SAE 8 7P500-001 1/2" HOSE UNION 2 7P500-009 1/2" x 90° HOSE BARB UNION 1 7U030-050 12mm (1/2") FUEL HOSE .55M 7U030-050 12mm (1/2") FUEL HOSE .48M 7U133-500 1/2" x 90° MOLDED RUBBER HOSE 1

8N105-040 WATER TANK ASY, GMT LS1 H.O. 1

4GL010-060 BRKT, WATER TANK, COOLER 1 4GL010-070 BRKT, SURGE TANK, COOLER 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 4 7J250-001 1/4" WASHER, SAE PLTD 4 7P375-075 3/4" HOSE BARB UNION, BRASS 1 7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 3 7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 3 7R007-001 NYLON RATCHET CLAMP 1-1/8" 12 7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1 7U038-000 3/4" HEATER HOSE 19' 7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1 7U100-055 TIE-WRAP, 7.5" NYLON 6 8N055-030 TANK, WATER, TRIANGLE SHAPE 1 8N055-050 PLASTIC CAP, SURGE TANK 1 8N056-060 SURGE TANK, PLASTIC 1 2A017-875-08 SPACER, .875"OD x .290"L 2

8N106-050 WATER COOLR ASY, GMT LS1 H.O. 1

4GL010-080 BRKT “A”, WATER COOLER MOUNT 1 4GL010-090 BRKT “B”, WATER COOLER MOUNT 1 4GL010-100 BRKT “C”, WATER COOLER MOUNT 1 7A250-075 1/4-20 x .75" SHCS PLTD 8 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 8 7J250-001 1/4" WASHER, SAE, PLATED 16 7P500-026 1/2"NPT x 3/4" BARB x 90° BRASS 2 8N006-010 WATER COOLER, SETRAB SINGLE PASS 1 0088341 VORTECH CHARGE COOLER DECAL 1

4PGL110-110 '03 5.3"L ESCALADE VACPMP RELOC 1

4PGL010-110 BRKT, '03 BRAKE LINE RELOC 1 4PGL010-115 BRKT, '03 BRAKE VAC PUMP 1 7A312-075 5/16-18 x 3/4" HHCS, GR5, ZINC 4 7F312-017 5/16-18 NYLOCK NUT 4 7J312-000 5/16" FLAT WASHER-SAE 8 7P500-001 1/2" HOSE UNION 2 7P500-009 1/2" x 90° HOSE BARB UNION 1 7U030-050 12mm (1/2") FUEL HOSE .55M 7U030-050 12mm (1/2") FUEL HOSE .48M 7U133-500 1/2" x 90° MOLDED RUBBER HOSE 1

5A003-034 DIABLO PREDATOR, '04-'06 GM 1

8F060-005 FUEL INJECTOR, GM 8.1 MARINE 8

4GL020-015 INSTALL MANUAL H2/ENC/DEN '01-'05 1

xvi

Page 17

2008 H2 Hummer, V-3

Part No. 4GL218-330/338L

ENGINEERING, LLC

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

4GL011-021 MTG BRKT GM TRUCK MACH. 1

2F328-040 V-3 SI-TRIM LS1 TRK 1

2A036-333 S/C PULLEY 3.33" 6-GRV 1

4GL112-090 AIR INLET ASY, 2008 H2 HUMMER 1

4GL012-090 DUCT, INLET, 2008 HUMMER H2 1

7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4 7R002-052 #52 SAE TYPE “F” SS HOSE CLAMP 2 7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 4 7U030-046 5/32" VACUUM LINE 1 7U030-056 3/8" PVC/VAC RUBBER HOSE 2 7U034-016 Ø1"GS HOSE 0.33' 7U035-001 Ø3-1/2" FLEX-HOSE 0.83' 7U375-052 3/8" VACUUM CAP 1 8D001-001 STD COMPRESS BYPASS VALVE 1 4PGL010-011 BRKT, D-SIDE H2 TRK AIR INLET 1 4PGL010-012 BRKT, P-SIDE H2 TRK AIR INLET 1 7A250-050 1/4-20 x .50" SHCS ZINC PLTD 2 7J006-093 6mm WASHER, PLTD 2 7P375-050 3/8" HOSE UNION, BRASS 1 7S350-200 3-1/2" x 2" SLEEVE 1 7U133-045 RUBBER ELBOW, Ø1" x 45° 1 7C060-050 M6-1.0 x 50mm HXHD ZINC PLTD 2 7J250-150 1/4" FENDER WASHER ZN PLTD 2 7F006-093 6mm NYLOCK NUT 2 2A017-752-02 SPACER, .750"OD x .894"LONG 2 7P275-133 PCV VALVE, VIPER, 3/8"-12" BA 1 2A017-125-0280 SPACER, 1.25 od X .328id X .28 1 4FA012-013 INTAKE ELBOW, 90 DEG W/BOSSES 1 7p375-037 3/8 NPT MALE X 3/8 HSE BARB 90 1 7P750-102 3/4 NPT X 1" X 90° HSE FIT 1 7U030-056 3/8" PCV/VAC RUBBER HOSE .25'

4PGL112-028 DISCH ASY 1

8N107-050 WATER PUMP ASY 1

8F001-402 WATER PUMP 1 7R003-027 ADEL CLAMP 1-11/16" 1 5W001-025 FEMALE SLIDE MINI 1 5W001-043 12-10GA x 1/4" RING TERMINAL 3 7A250-050 1/4-20 x .50" SHCS 2 5W001-013 14-16GA BUTT CONNECTORS 4 5W001-019 12-10GA BUTT CONNECTORS 2 7U100-044 4" TIE-WRAPS 4 5W001-022 T-SPLICE CONNECTOR 1 7F250-021 1/4-20 NYLOCK NUT 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-005 3/8" PLASTIC WIRE LOOM 2 5W001-014 FUSE HOLDER 10GA WIRE 1 7U100-055 TIE-WRAP, 6" NYLON 6 5W001-041 12-10GA MALE SLIDE INSULATED 2 8F101-320 WATER PUMP RELAY ASY, LS1 TRK 1

8N105-050 WATER TANK ASY 1

8N055-030 LT1 WATER TANK 1 7P500-026 90° BARBED BRASS FITTING 2 4PGL010-060 BRKT “A” 1

4PGL010-070 BRKT “B” 1 4PGL010-080 BRKT “C” 1 7A250-102 1/4-20 x 1" SHCS 1 7J250-022 1/4" WASHER 6 7F250-021 1/4-20 NYLOCK NUT 1 8N056-060 SURGE TANK 1 8N055-050 SURGE TANK CAP 1 4PGL010-090 BRKT, SURGE TANK 1 7P500-078 12"NPT x 3/4" HOSE FIT 2 7U038-020 MOLDED “S” HOSE 1 7A250-050 1/4-20 x .5" SHCS 4 7U038-000 Ø3/4" HEATER HOSE 10" 7U033-000 Ø5/8" HOSE 5" 7P750-625 Ø3/4" x Ø5/8" REDUCER BARB 2 7E010-075 #12 x 3/4" SHT METAL SCRW HEX 4 7U030-065 90° MOLDED ELBOW SHORT 1 7J010-001 #10 FLAT WASHER 2 7R002-020 #20 HOSE CLAMP 2 7R007-002 NYLON CLAMPS 7/8" 4 7R007-001 NYLON CLAMPS 1-1/8" 10

8N201-370 CAC ASY 2008 HUMMER H2 6.2L 1

8N101-110 WELDED CORE ASSY V-10 S.D. 1 7P500-078 1/2"NPT x 3.4" HOSE FIT 1 7P500-026 1/2"NPT x 3/4" HOSE BARB x 90° 1 2A017-875-13 SPACER, CAC BRKT 1 7C010-040 10mm-1.5" x 1.5mm SCREW 1 7J010-002 10mm WASHER 1 7U250-200 COOLER FOAM 1 4GL010-110 BRKT, CAC SUPPORT 1

8N106-075 WATER COOLER ASY 1

7R007-001 NYLON RATCHET CLAMP, 1-1/8" 4

5A003-040 DIABLO PREDATOR (2003-2007 MODEL YEAR) 1

8F060-047 47 lb. DELPHI INJECTORS 8

4GL020-015 INSTR. MANUAL DENALI/ESCALADE/HUMMER 1

009035 S/C LUBE PACK 1

xvii

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 18

This page intentionally left blank

xviii

Page 19

1. COMPONENT REMOVAL

A. Escalade/Denali/SS: Drain a sufficient

amount of coolant to allow for removal of the upper radiator hose and clamps.

B. Escalade/Denali/SS: Disconnect the neg-

ative battery cable. H2 Hummer: Disconnect the positive and negative battery

C. H2 Hummer: Remove the screws securing

the battery tray, then remove the tray from the vehicle.

D. Remove all ducting between the MAF meter

and the throttle body.

E. Remove the upper fan shroud. Escalade/

Denali/SS: Remove the radiator hose.

(Exclude 2006 Model Year.)

F. Remove the accessory drive belt. (Keep in

the vehicle as a spare.)

G. Remove the two bolts securing the alternator

fusible link junction box and set aside.

H. Remove the idler from the cast bracket and

set aside for later use.

I. The plastic engine covers that extend over

the valve covers will need to be removed. The upper manifold cover section may either be removed completely or left in place and trimmed in order to clear supercharger componentry.

'08 H2: Remove the electric fan

assembly and set aside. (To provide clearance to remove the P/S pulley).

J. Remove the power steering pump pulley with

a pulley puller. Remove the three bolts securing the front of the power steering pump.

K. Remove the alternator, bushings and bolts

and set aside for later use. The alternator bushings can be removed by tapping the small end through the bracket with an appropriately sized socket.

L. Remove the alternator and power steering

pump mounting bracket by removing the three bolts securing it to the head and the bottom bolt securing it to the engine block.

M. Remove the valve cover breather hose from

the passenger’s side of the throttle body and cap off the throttle body nipple with supplied 3/8” vacuum cap. (Models with electron-

ic controlled throttle bodies only)

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 20

1. COMPONENT REMOVAL, cont’d

N. Remove the oil filler neck and cap from the

passenger’s side valve cover. Do this by twisting in a counter-clockwise motion. Reinstall the cap directly into the valve cover.

O. '03 and Earlier Models: Locate the breather

hose on the rear of the driver’s side valve cover. Pull the hose and stock PCV valve from the rubber grommet in the valve cover. Remove the stock PCV valve from the breather hose and install the supplied PCV valve in its place. Reinstall the new PCV valve with the hose attached to it into the rubber grommet in the valve cover.

Page 21

2. COMPUTER RELOCATION (H2 Hummers 2003-2007)

NOTE: 2008 H2 Hummers will not need this step.

A. Remove the plastic cover protecting the vehi-

cle ECM. Unsnap the ECM from the bracket securing it to the inner fender. Temporarily move the ECM to the side to aid in the bracket relocation.

B. Remove the two screws securing both the

battery tray bracket and the upper tab of the ECM bracket. Remove the final screw securing the botton of the ECM bracket. Remove the ECM bracket from the vehicle.

C. With a grinder, modify the plastic bracket by

removing the strengthening ribs as shown in (Fig. 2-a)

D. Using a .25" drill, enlarge the two threaded

holes where the ECM bracket was secured. (See Fig. 2-b..

RIBS TO BE REMOVED

E. Put the ECM bracket back in the vehicle plac-

ing the mounting tab underneath the original bracket. Place the battery tray mounting bracket back into its stock position. Using the supplied 6mm x 50mm screws, fender washers, 6mm nuts and two .894 spacers, secure the brackets using the original mounting holes that have been enlarged. Use the spacers between the ECM bracket and the inner fender mount to space the ECM bracket down. (See Fig. 2-b.)

F. Secure the ECM to the relocated bracket and

re-install the cover.

HOLES TO BE ENLARGED

Fig. 2-a

BATTERY BRACKET IN STOCK LOCATION

SUPPLIED SPACER

BRACKET IN RELOCATED POSITION

Fig. 2-b

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 22

3. SUPERCHARGER MOUNTING BRACKET

A. Install the original alternator bushings into the

supercharger mounting bracket with the flanged portion pointed back. (See Figs. 3-a, 3-b.)

B. Clean front of driver’s side head of debris. C. Bolt the supplied Vortech supercharger

mounting bracket to the head and block using the original mounting bolts. Make sure the mounting bracket is seated directly on a machined surface on the head and that no wires are pinched.

D. Tighten the four mounting bolts to 37 ft-lbs

(50 N-m).

E. Install the two original bolts holding the alter-

nator fusible link junction box in the supercharger mounting bracket so that it is in the stock location.

F. Attach the power steering pump to the

Vortech bracket using the original mounting hardware. Tighten the four power steering pump bolts to 37 ft-lbs (50 N-m). (One bolt is still loosely inserted in the engine block.)

G. Reinstall the power steering pump pulley.

Make sure that it is seated flush with the end of the power steering pump shaft.

H. Reinstall the alternator using the original

hardware. (See Fig. 3-c.)

I. Install the factory idler pulley at the location

shown in Fig. 5-b. Spin the idler to verify that the rotating portion does not contact the alternator bolt.

Fig. 3-a

Fig. 3-b

Fig. 3-c

Page 23

4. FUEL INJECTOR REPLACEMENT

NOTE: Complete removal of the fuel rail will aid in injector replace-

ment. Separate the fuel rail supply line from the rail using springlock disconnect tool.

A. Relieve the fuel system pressure. B. Disconnect the eight fuel injector wiring clips

and retainers from the injectors.

C. Remove the four 10mm bolts holding down

the fuel rail on the intake manifold. Lift up on the rails evenly, removing all eight injectors.

D. Using a small amount of clean motor oil, light-

ly lubricate the O-rings on both ends of the Vortech supplied fuel injectors.

E. Install the new injectors into the fuel rails with

the terminals facing outward.

F. Carefully lower the fuel rail/injector assembly

down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

G. Tighten down the fuel rail assembly with the

original bolts and attach the wiring clips to the injector terminals.

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 24

5. SUPERCHARGER INSTALLATION

SUPERCHARGER

COVER

*A. Remove the Vortech installed drain fitting

cap and attach the supplied 1/2" oil drain hose to the supercharger and tighten the clamp.

B. Loosely install the supercharger onto the

Vortech bracket. Start all five 3/8-16 x 2-1/4" supercharger mounting screws with washers.

C. Tighten the supercharger mounting

screws in a rotating pattern to 18 ft-lbs (25 N-m).

D. Install the Vortech supplied M12 x 50mm

bolt, dust cover, idler pulley and spacer onto the supercharger cover as shown in

Figs. 5-a, 5-b.

E. Install the supplied supercharger/acces-

sory drive belt per Fig. 5-b.

* Applies to "engine oil-fed" units only.

V-3 applications skip this step

Fig. 5-a

Fig. 5-b

Page 25

6. OIL DRAIN LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGER SKIP AHEAD TO STEP 8)

A. To provide an oil drain for the supercharger, it

is necessary to make a hole in the oil pan. Locate and centerpunch the hole per Fig. 6-a. Drill a 1/8” pilot hole at center location.

B. Use the supplied 9/16” rotobroach to drill the

hole in the oil pan. Take care to break through the pan gently and remove the cut out.

C. Pack the flutes of a 3/8 NPT tap with grease.

Tap the hole until the fitting can be started.

D. Thoroughly clean the threaded area. Reach

inside the oil pan and retrieve any stray chips. Apply a small amount of sealer to the new threads. Apply more sealer to the supplied 3/8” NPT hex nipple and secure in the hole. Make sure the seal is formed all around the fitting. Install the supplied 90° elbow and 3/8 NPT x 1/2” barb fitting pointing forward and slightly up.

E. Route the oil drain hose from the supercharg-

er to the barb fitting, attach and tighten the hose clamp. (See Fig. 6-a.)

IMPORTANT: Oil in the supercharger is gravity drained to the

oil pan. Trim the supplied oil drain hose as necessary so that it is continuously sloping down towards the oil pan. Avoid dips, kinks etc.

OIL DRAIN

OIL FEED HOSE

OIL FEED ADAPTER

Fig. 6-a

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 26

7. OIL FEED LINE (ENGINE OIL-FED KITS ONLY. APPLICATIONS WITH V-3 SUPERCHARGER SKIP AHEAD TO STEP 8)

A. Remove the two screws holding the small

casting or oil cooler block located directly above the oil filter.

B. Using engine oil on the threads, install

1/8"NPT to #4 90° fitting into the supplied oil feed adapter.

C. Locate the supplied gasket that matches the

factory gasket that was removed. Using the adapter, the appropriate supplied gasket and the supplied longer 6mm screws, assemble the components as shown in Fig. 6-a).

D. Install a 1/8"NPT to #4 90° fitting into the

supercharger oil feed filter. Use a small amount of engine oil on the pipe threads.

NOTE: Pipe sealant should not be used as it can clog the fil-

ter and damage the supercharger.

Install the 90° end of the stainless steel oil

feed line to the 90° fitting already installed on the supercharger. Orient the hose so that it is pointing to the rear of the vehicle. This will allow the air inlet tube to have clearance that is installed later.

E. Route the oil feed line from the supercharger

to the installed fitting. Use an adel clamp on the side of the oil pan and tie wraps to secure the oil feed and oil drain lines and protect them from kinking, abrasion and high heat areas. (See Fig. 6-a.)

F. Drain the engine oil, install a new filter and

refill the engine with fresh oil.

Page 27

STOCK RETURN LINE

(TO TANK

TO VOR ASS VALVETECH COMPRESSOR BYP

STOCK MANIFOLD

VACUUM LINE (REMOVED FROM

FUEL REGULATOR)

FUEL PRESSURE REGULATOP

ARROWS INDICATE THE DIRECTION OF FUEL FLOW

F.M.U.

1. REMOVE THIS FITTING FROM THE TOR RETURN LINEFUEL REGULA

3. ATTACH THE SUPPLIED VACUUM LINE AND TEE INTO THE FUEL REGULATOR MANIFOLD VACUUM LINE (LINE TO BYPASS VALVE WILL BE INSTALLED LATER)

2. ATTACH EACH OF THE FMU LINES TO THEIR RESPECTIVE SNAP CONNECTORS

STOCK SUPPLY LINE (FROM TANK)

8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION ('01-'02 Denali/Escalade Only)

A. Mount the supplied FMU as shown in Fig. 8-a

using the existing studs on the firewall as follows:

1. Remove the nuts securing the factory ground straps.

2. Install the FMU over the studs.

NOTE: Not all vehicles have the studs in the same location.

Drill an additional 1/4” hole in the fmu bracket as required. (See Fig. 8-a.)

3. Loosely reinstall the nuts on top of the FMU bracket.

B. Disconnect the fuel return line from the fuel

rail and connect the respective lines to their snap connectors on the end of the FMU lines. (See Fig. 8-c.)

NOTE: The fuel tank return line extends from the fuel regula-

tor to the tank. It is smaller than the fuel rail supply line.

C. Using the supplied 5/32" vacuum line and

TEE, connect the 90° fitting on top of the FMU to the manifold vacuum line connected to the fuel regulator. (See Fig. 8-c.)

Fig. 8-a

Fig. 8-b

Fig. 8-c

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 28

9. BRAKE BOOSTER LINE MODIFICATION (2002 Escalade Only)

NOTE: The purpose of Section 9 is to bend the brake booster line

and give it clearance from the supplied inlet duct.

A. Locate the brake booster hard line running

from the master cylinder down to the lower left corner of the power steering pump. Disconnect the line at the master cylinder.

B. With a 3/8" tubing bender, put a 30° bend in

the hard line. (See Fig. 9-a.)

C. Reconnect the line back to the master cylin-

der with its new bend. (See Fig. 9-b.)

D. Bleed the system as follows (The engine

should be off):

1. Raise the front wheels off the ground.

2. Turn the steering wheel full left.

3. Fill the reservoir to the “FULL COLD”

level. Maintain this level thoughout the procedure.

4. Turn the steering wheel lock to lock at least 20 times or until the bubbles stop.

Fig. 9-a

MODIFIED BRAKE BOOSTER HARD LINE MUST CLEAR INLET DUCT

Fig. 9-b

Page 29

10. VACUUM PUMP/BRAKE LINE RELOCATION ('03-04 5.3/SS Truck, Vehicles Equipped with adjustable pedals only)

A. Disconnect the electrical plug from the top of

the vacuum pump. Unbolt and remove the vacuum pump from the brake booster. Disconnect the 1/2" hose from the barbed nipple on the vacuum pump.

B. Attach the vacuum pump to the supplied

pump bracket with the supplied 5/16" hardware. (See Fig. 10-c.)

NOTE: For ease of installation, it may be easiest to

remove the driver’s side hood support and the plastic electrical center cover.

C. Unscrew the three nuts securing the small

computer style box on the driver’s side firewall. (See Fig. 10-d.)

D. Take the supplied 1/2" I.D. x 90° molded hose

and cut one end short. (See Fig. 10-c.) Slide the cut end of the molded hose on the barber end of the vacuum pump that was inserted into the grommet in the brake booster. Connect the 1/2" x 19" length of hose to the 90° molded elbow with a 1/2" hose mender. Secure the pump/bracket assembly to the three studs using the same three nuts removed in step C. Reconnect the electrical connector to the vacuum pump.

E. Route the elongated hose underneath the

master cylinder over to the grommet in the brake booster. Connect the 1/2" hose into the grommet with the supplied plastic 1/2" x 90° barbed fitting.

STOCK VACUUM

PUMP LOCATION

DROP BRACKET

INSTALLED

BRAKE LINE BRACKET

STOCK LOCATION

Fig. 10-a

BRAKE LINE BRACKET

RELOCATED

Fig. 10-b

NOTE: When relocating brake lines, be sure that the brake

lines are clear of the steering column. Tie-wrap the lines out of the way if necessary.

F. Unbolt the bracket holding the lower brake

line assembly to the brake booster/master cylinder attachment. (See Fig. 10-a.)

G. Attach the supplied drop bracket to the origi-

nal bracket securing the brake lines with the supplied 5/16" hardware. With the new bracket added, push down the brake lines and attach the new assembly to the original two studs. This will drop the brake lines making clearance for the inlet tube. (See Fig. 10-b.)

H. Using the supplied 1/2" x 22" hose and 1/2"

hose mender connect the existing hose running from the manifold to the down-turned barb on the vacuum pump. Cut hose lengths for best fit.

NOTE: It is important that the plug running to the pump is

properly connected. Failure to do so will cause the throttle not to respond.

Fig. 10-c

Fig. 10-d

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 30

11.A FUEL PUMP WIRING AND INSTALLATION ('01-'03 Escalade/Denali/SS)

IGNITION

RELAY

SIDE VIEW

FUSE TAP

MODIFICATION

BEND UP 90°

IGNITION

RELAY

MODIFIED FUSE TA P

INSTALLED MODIFIED

FUSE TAP

BOTTOM VIEW

RELAY

87A

(+)

BATTERY TERMINAL

(+) TERMINAL

ON T-REX FUEL PUMP

GROUND

A. Mount the supplied fuel pump relay on the

fire wall located to the right of the FMU bracket. (See Fig. 11.A-a.)

B. Connect the red 12-gauge wire from termi-

nal #30 to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt to the fuse box power supply terminal as shown in Fig. 11.A-b. In order to reach the terminals, the fuse box cover must be unsnapped from the base and raised for access. (See Fig. 11.A-b.)

C. Feed the yellow wire from relay terminal

#85 to the fuse box (electrical center). Route the wire to the stock fuel pump relay and connect using the supplied fuse tap. Bend the fuse tap as shown in Fig. 11.A-c.

D. Run the black wire from terminal #86 on the

fuel pump relay to ground.

E. With the long red 12-gauge wire connected

to the fuel pump relay terminal #87, route the free end down to the area near the fuel filter on the driver’s side inner frame rail under the door. Secure as necessary to avoid heat and sharp edges.

Fig. 11.A-a

YELLOW WIRE FROM VORTECH SUPPLIED

RED WIRE FROM VORTECH SUPPLIED

RELAY TERMINAL #30 ATTACHES HERE

RELAY TERMINAL #85 ATTACHES HERE

Fig. 11.A-b

VORTECH SUPPLIED

FUEL PUMP RELAY

TO MODIFIED FUSE TAP ON FACTORY FUEL PUMP RELAY

Fig. 11.A-c

Fig. 11.A-d

Page 31

11.A FUEL PUMP WIRING AND INSTALLATION ('01-'03 Escalade/Denali/SS), cont’d

VORTECH FUEL FILTER FITTING (7P625-031) (MAKE SURE THAT THE SUPPLIED O-RING IS INSTALLED AND TIGHTEN THE FITTING)

STOCK FUEL LINE:

DISCONNECT FROM FUEL FILTER AND CONNECT TO FUEL PUMP

DISCHARGE FITTING. VERIFY THA ACTORY O-RING IST THE F

INSTALLED ON THE END OF THE TUBE (BEND AS NECESSARY SO

THAT THE FUEL PUMP WILL MOUNT EASILY ON THE FRAME RAIL)

MARK AND DRILL TWO HOLES.

INSTALL THE SUPPLIED CLAMPS AND

SCREWS TO HOLD THE FUEL PUMP

SUPPLIED FUEL PUMP

SUPPLIED FUEL PUMP FITTING:

(VERIFY THAT THE COPPER WASHER

IS INSTALLED AND FITTING IS TIGHT)

VORTECH FUEL PUMP FITTING:

(7P625-030) (VERIFY THAT THE COPPER

WASHER IS INSTALLED AND FITTING IS TIGHT)

STOCK

FUEL

FILTER

STOCK FUEL LINE

FROM TANK

VORTECH SUPPLIED FUEL HOSE (ROUTE AS SMOOTHLYAS POSSIBLE, SECURE WITH ZIPTIES, ATTACH BOTH ENDS TO THE AVAILABLE BARB FITTINGS AND TIGHTEN THE CLAMPS)

F. Remove the fuel line from the outlet (front) of

the fuel filter. Remove the tube from the plastic retainer holding it so that it can be rotated freely. Some models may vary from the photo slightly. Follow the same procedure, taking care to mount the pump so that the hard line is not stressed.

G. Making sure the O-ring is seated on the

threaded end of the supplied fitting, install into the outlet (front) of the fuel filter and tighten.

H. Making sure the O-ring is seated on the tube

end of the fuel line (removed from the filter) thread the bump tube into the fitting installed on the outlet of the fuel pump and tighten.

I. Route the free end of the hose connected to

the fuel pump inlet to the fitting previously installed on the fuel filter outlet. Use the supplied hose clamp to secure the hose on the barb fitting. Try to make the bends as large as possible, so as to avoid kinking the hose. Secure the hose using the wraps and tighten all of the hose clamps.

J. Install the supplied adel clamps onto the fuel

pump and mark holes to be drilled for #12 sheet metal screws. Drill an 11/64" hole at each location. Using the supplied black 12-gauge wire with yellow ring terminal connectors, install one end under the sheet metal screw nearest the electrical terminal side of the fuel pump. Attach the other end of the ground wire to the (-) terminal of the fuel pump. Secure to the ABS module bracket as shown in Fig. 11.A-e. Tighten both adel clamps.

K. Attach the previously routed red wire to the

positive terminal of the fuel pump using the yellow ring terminal connector.

ABS MODULE BRACKET

Fig. 11.A-e

FUEL PUMP RELAY

WATER PUMP RELAY

Fig. 11.A-f

Fig. 11.A-g

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 32

11.B FUEL PUMP WIRING AND INSTALLATION, (2003 H2 Hummer)

A. Remove the hood support from the passen-

gers’ side of the vehicle. Remove the plastic cover from the power distribution center. Unsnap the plastic casing surrounding the fuses and relays. Mount the supplied fuel pump relay on the lower plastic area. Leave the hood support and plastic casing off for installation of the water pump relay. (See Fig.

11.A-f on page 11-2.)

B. Connect the red 12-gauge wire from terminal

#30 to the supplied fuse holder using the supplied butt connector. Install a yellow ring terminal on the other end of the fuse holder and bolt to the fuse box power supply terminal. (See Fig. 11.A-b.)

C. Feed the yellow wire from relay temrinal #85

to the fuse box (electrical center). Route the wire to the stock fuel pump relay and connect using the suppled fuse tap. Bend the fuse tap as shown in Fig. 11.A-c.)

D. Run the black wire from terminal #86 on the

fuel pump relay to ground.

E. With the long red 12-gauge wire connected to

the fuel pump relay terminal #87, route the free end down to the area near the fuel filter on the driver’s side inner frame rail under the door. Secure as necessary to avoid heat and sharp edges.

F. Remove the fuel line from the inlet of the fuel

filter located on the driver’s side inner frame rail directly in front of the fuel tank. Mount the pump below the fuel filter on the cross member taking care not to stress the fuel lines. (See Fig. 11.B-a.)

G. Connect the male fuel fitting supplied in the

fuel pump assembly to the female fitting removed from the inlet of the fuel filter. Connect the supplied 3/8" steel female fuel fitting to the open barb on the fuel filter. Route the lines to avoid kinking in the hose. Secure the discharge hose to the cross member with the supplied adel clamp. Secure any other hoses using tie-wraps to avoid heat or sharp areas. (See Figs. 11.B-a, 11.B-b.)

H. Attach the previously routed red wire to the

positive terminal of the fuel pump using the yellow terminal connector. Use the supplied black 12-gauge wire with yellow ring terminal to connect the negative terminal on the fuel pump to a sufficient ground.

Fig. 11.B-a

Page 33

11.B FUEL PUMP WIRING AND INSTALLATION (2003 H2 Hummer), cont’d.

5/8-3/8 REDUCER FITTING

17.0 STEPLESS CLAMPS

5/8 STEPLESS CLAMPS

ADEL CLAMPS

5/16"x16" HOSE

15.7 STEPLESS CLAMPS

3/8"x6" HOSE

15.0

STEPLESS

CLAMPS

TO FUEL RAIL

3/8"x2" HOSE

SUPPLIED FUEL FITTING 7P375-010 INSTALLED INTO FACTORY FEMALE FUEL FITTING

SUPPLIED FUEL FITTING

7P375-072 INSTALLED INTO

FACTORYFEMALE FUEL FITTING

FUEL PUMP

FUEL

FILTER

ACTORYSUPPLY LINE FROM TANK

Fig. 11.B-i

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 34

12.A ESCALADE/DENALI INLET DUCT INSTALLATION ('01-'02 Models)

A. Install the supplied 3-1/2" x 3" sleeve onto the

MAF outlet, and the 3-1/2" x 2" sleeve on the inlet of the supercharger.

B. Reinstall the upper fan shroud with the excep-

tion of the top two bolts.

C. Remove any plastic clips that are no longer

used to secure the radiator hose.

D. Slide the entry of the large plastic inlet duct

(See Fig. 12.A-d) into the sleeve installed on the MAF. Lower the inlet duct onto the top of the radiator shroud. Reinstall the factory radiator shroud bolts through the two supplied inlet duct mounting tabs and into their original bolt holes.

E. Insert the supplied 1/4-20 x 1/2" screws

through the bracket and into each side of the inlet duct using the supplied washers. Tighten the screws. (See Fig 12.A-d.)

F. Install the supplied 180° inlet duct onto the

inlet of the supercharger after the supercharger is installed. Orient the duct so that you can just slide your fingers between the duct and the master cylinder.

G. Install the supplied #52 hose clamps and

3-1/2" x 13" long flex hose between the two ducts just installed. (See Fig. 12.A-b.)

H. Use the supplied 3/8" hose from the 3/8" fit-

ting on the inlet duct to the passenger side valve cover breather hose. Secure the hose so that it cannot interfere with the throttle arm or cable. (See Fig 12.A-c.)

I. Install and tighten the hose clamps on each

connection. (See Fig. 12.A-d.)

SUPPLIED 3/8"

RUBBER CAP

Fig. 12.A-b

Fig. 12.A-c

SUPPLIED 3/8" HOSE

FACTORY

SHROUD BOLT

SUPPLIED DUCT

MOUNTING TABS

(LEFT & RIGHT)

SUPPLIED 1/4-20

HARDWARE

Fig. 12.A-d

Fig. 12.A-a

Page 35

12.B ESCALADE/DENALI/SS INLET DUCT INSTALLATION ('03-'06 Models)

A. Install the supplied 3-1/2" x 3" sleeve onto the

MAF outlet, and the 3-1/2" x 2" sleeve on the inlet of the supercharger.

B. Reinstall the upper fan shroud with the excep-

tion of the top two bolts. (Excludes '06 model

year.)

C. Remove any plastic clips that are no longer

used to secure the radiator hose.

D. Slide the entry of the large plastic inlet duct

(See Fig. 12.B-d) into the sleeve installed on the MAF. Lower the inlet duct onto the top of the radiator shroud. Reinstall the factory radiator shroud bolts through the two supplied inlet duct mounting tabs and into their original bolt holes.

E. Insert the supplied 1/4-20 x 1/2" screws

through the bracket and into each side of the inlet duct using the supplied washers. Tighten the screws. (See Fig 12.B-d.) '06 Model Year: It will be necessary to trim the fan shroud for the electric fans to gain access to the screw locations. Use the supplied 6mm hardware in place of missing factory hardware.

F. Using Fig. 12.B-b, drill a 9/16" hole in the

shown location. Use a 3/8"NPT tap and install the supplied 3/8" NPT x 3/8" hose barb.

G. Install the supplied 180° inlet duct onto the

inlet of the supercharger after the supercharger is installed. Orient the duct so that it swoops over the side of the supercharger with the end pointing at the crossover duct.

H. Install the supplied #52 hose clamps and

3-1/2" x 7" long flex hose between the two ducts just installed.

I. Use the supplied 3/8" hose from the 3/8" fit-

ting on the inlet duct to the passenger side valve cover breather hose. Secure the hose so that it cannot interfere with the throttle arm or cable. (See Fig 12.B-c.)

J. Install and tighten the hose clamps on each

connection. (See Fig. 12.B-d.)

SUPPLIED 3/8"

RUBBER CAP

NEW LOCATION

TO DRILL

Fig. 12.B-b

SUPPLIED 3/8" HOSE

Fig. 12.B-c

FACTORY

SHROUD BOLT

Fig. 12.B-a

SUPPLIED DUCT

MOUNTING TABS

(LEFT & RIGHT)

SUPPLIED 1/4-20

HARDWARE

'06 MODELS

AREA TO TRIM

USE SUPPLIED

6mm HARDWARE

Fig. 12.B-d

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 36

12.C 2003-2007 H2 HUMMER INLET DUCT INSTALLATION

SUPPLIED 1/4-20x.50 SCREW

ATTACH TO 3.5" FLEX HOSE WHICH LEADS TO CAST INLET DUCT

DRIVER'S

SIDE BRACKET

TO FACTORY AIR BOX

PASSENGER'S SIDE BRACKET

FACTORY RADIATOR SCREWS

A. Install the supplied 3-1/2" x 3" sleeve onto the

MAF outlet, and the 3-1/2" x 2" sleeve on the inlet of the supercharger.

B. Reinstall the upper fan shroud. Remove the

two screws securing the top of the radiator to the core support.

C. Slide the entry of the large plastic inlet duct

into the sleeve installed on the MAF. Lower the inlet duct onto the top of the radiator shroud.

D. Reinstall the factory radiator bolts through the

two supplied inlet duct mounting tabs and into their original bolt holes.

E. Insert the 1/4" -20 x 1/2" screws through the

brackets and onto each side of the inlet duct using the supplied washers. Tighten the screws. (See Fig 12.B-g.)

F. Install the supplied 180° inlet duct onto the

inlet of the supercharger. Orient the duct so that there is equal space between, the ECM and the master cylinder. (See Fig. 12.B-e.)

G. Install the supplied #52 hose clamps and

3-1/2" x 13" long flex hose between the 180° cast duct and the rotomold duct.

H. Using the supplied 3/8" hose mender, connect

the supplied 3/8" hose from the 3/8" fitting on the inlet duct to the passenger’s side valve cover breather hose. Secure the hose so that it cannot interfere with the throttle arm or cable. (See Fig. 12.B-c.) Using the 5/8"-to3/8" reducer, connect the 3/8" hose that comes from the valve cover breather to the 3/8" side of the reducer. With the supplied piece of 5/8" hose, connect it to the barb which in turn will connect to the 5/8" fitting on the back of the 180° inlet duct.

I. Install and tighten the hose clamps on each

connection.

180° INLET

FLEX HOSE

Fig. 12.B-e

Fig. 12.B-f

H2 HUMMER INLET

TOP VIEW

Fig. 12.B-g

Page 37

12.D 2008 H2 HUMMER INLET DUCT INSTALLATION

A. Trim fan shroud supports as seen if photos,

to clear molded inlet duct (See Fig 12.D-a).

B. Install inlet duct using factory hardware,

supplied brackets and Ø1.25” x .280” long spacers. The spacers should be positioned between the Factory rubber grommets and the supplied duct mounting brackets (See Fig 12.D-b Driver side) and Fig 12.D-c passenger side).

Fig. 12.D-a

Fig. 12.D-b

Fig. 12.D-c

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 38

12.D 2008 H2 HUMMER INLET DUCT INSTALLATION con't

C. Install the supplied 4GL012-090 alum inlet

duct to the end of the molded inlet duct using Ø3.5” x 2” sleeve and two #56 hose clamps. (See Fig 12.D-d)

D. Secure the Ø3.5” x 9” long flex hose to the

alum. inlet duct using a #52 hose clamp. (See Fig 12.D-d).

E. Install the 3/4"NPT x 1” 90° fitting and the 3/8

NPT x 3/8 barb 90° fitting in the 4FA012-013 inlet duct. (See Fig 12.D-e).

F. Secure the 4FA012-013 duct to the S/C using

a Ø3.5 x 2” sleeve and two #56 hose clamps.

G. Connect the Flex hose to the 4FA012-013

duct and secure using a #52 hose clamp.

H. Slight bending of the brake lines may be nec-

essary to clear the inlet ducts.

I. Cut the supplied 45° hose so the one leg is

approx. 2.75” long and one is approx. 1.5” long. (See Fig 12.D-f).

J. Attach the long end of the hose to the plastic

inlet duct and secure with the hose clamp that is provided. Install the compressor by pass to the open end of the hose just installed and secure with a hose clamp.

K. Using a length of hose cut from the previously

install formed hose connect the compressor bypass valve to the discharge duct coming out of the Supercharger. (See Fig 12.D-g)

L. Attach the 5/32 hose installed in an earlier

step to the inlet port of the compressor bypass..

Fig. 12.D-d

Fig. 12.D-e

Fig. 12.D-f

Fig. 12.D-g

Page 39

13. RADIATOR TUBE INSTALLATION (Denali/Escalade/SS Only)

A. Cut the supplied hose as shown in

Fig. 13-a.

B. Using the two original clamps and the two

supplied #24 hose clamps, attach the previously trimmed hose pieces to each end of the supplied radiator tube, radiator and water pump. (See Figs. 13-a, 13-b.)

C. Orient the radiator tube and hoses for best fit

and tighten all clamps.

D. Use the supplied adel clamp and 1/4-20 x

1/2" screw and washer to secure the radiator tube to the insert on the large plastic inlet duct. (See Fig. 13-b.)

E. Refill the coolant reservoir.

Fig. 13-a

ADEL CLAMP

SECURING RADIATOR

CROSS-OVER TUBE

Fig. 13-b

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 40

14. CHARGE COOLER INSTALLATION

A. Remove the screw from the front of the pas-

senger side head. Remove the stud located between the middle coil packs on the passenger side valve cover, below the white electrical connector. (See Figs. 14-a, 14-b.)

B. Install the charge air cooler support using the

fasteners supplied. (See Figs. 14-a, 14-b.) Apply adhesive foam to the top of the support bracket where the charge air cooler rests. Make sure all hoses and wires are clear from the bracket edges.

Cannot bend trans lines: Remove the

bracket holding the lines on the passenger’s side valve cover. Secure the lines underneath the wiring harness with zip-ties.

NOTE: On H2 Hummer and '04 SS, '06 Denali installations,

there will be no EGR assembly. Use the supplied 10mm x 1.5" screw, washer and .975" spacer in its place. (See Fig. 14-a.)

C. Slightly bend both the transmission and

engine oil dipsticks up and away to give clearance for the charge air cooler.

D. Install the 1/2"NPT x 3/4 90° and straight

brass fittings into the charge air cooler using thread sealant on the threads. (See Fig. 14-e.)

E. Install the S-hose and the 90° hose onto the

CAC, then set on support.

F. Attach the short 90° formed hose to the

straight barbed fitting on the charge cooler. (See Fig 14-e).

G. Set the charge air cooler on the support with

the 90° brass fitting in the upper left corner facing toward the passenger’s side. Using the 2-3/4" sleeves and #44 hose clamps, connect discharge tube “A” to the discharge of the supercharger and to the inlet of the charge air

On the H2 Hummer, use the supplied 10mm x 1.5 screw, washer and .975"

spacer in place of EGR equipment

Fig. 14-a

SECURE HOSES AWAY

FROM BRACKET

STUD TO BE REMOVED

Fig. 14-b

NOTE: It will be necessary to trim 1/2” from the 2.75” end

of the reducer sleeve for proper fit.

Page 41

14. CHARGE COOLER INSTALLATION, cont’d.

90 BRASS FITTING POINTING TOWARD SURGE TANK

VIEW FROM REAR OF COOLER

STRAIGHT BRASS FITTING

cooler.

H. Slide the 90° silicone elbow sleeve onto the

throttle body. Slide the 2-3/4" end of the reducer sleeve onto the outlet side of the cooler. Using the #48 hose clamps install discharge tube “B” from the 3" end of the 90° sleeve to the 3" end of the reducer sleeve on the cooler. Use the #64 hose clamp to secure the 90° sleeve to the throttle body. Tighten all clamps. (See Figs. 14-c, 14-d.)

Fig. 14-c

Fig. 14-d

Fig. 14-e

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 42

15. SUPERCHARGER BYPASS INSTALLATION

5/32" TEE HOSE INTO

VACUUM LINE ATTACHED

TO THE FMU

DISCHARGE

TUBESUPERCHARGER

AIR INLET

DUCT

BYPASS VALVE V

A. Connect the 4" length of Ø1" hose from the

barb on the supercharger inlet duct to the outlet of the bypass valve.

B. Cut the supplied molded hose as shown in

Fig. 15-a.

C. Using the supplied #16 hose clamps, connect

the barb on the discharge duct to the inlet of the bypass valve using the previously cut Ø1" molded hose. (See Fig. 15-b.)

D. Install and tighten hose clamps on each con-

E.1 '03 and Earlier Models: Using the supplied

NOTE: Some vehicles may require trimming of the engine

cover to clear various components. If necessary, trim the cover to clear the bypass valve hose.

nection.

Fig. 15-b

5/32" vacuum line and TEE fitting, connect the bypass valve pressure port to the manifold vacuum hose that is connected to the fuel pressure regulator. (See Fig. 8-c.)

CUT AND DISCARD

Fig. 15-a

Fig. 15-c

Page 43

15. SUPERCHARGER BYPASS INSTALLATION, cont’d.

E.2 '04-'06 Models: Locate the capped-off mani-

fold vacuum port on the passenger’s side of the intake manifold. Using a file or hacksaw, remove the tip of the capped-off section. Using the supplied 5/32" vacuum line, connect the bypass valve pressure port to the modified pressure port. (See Fig. 15-d.)

F. '04-'06 Models: Locate the hard plastic line

running to the drivers side rear of the engine. Remove the hard line from the rubber hose.

G. '04-'06 Models: Install the supplied 90° PCV

valve into the rubber hose on the engine.

H. '04-'06 Models: Cut the hard plastic line to

reach the PCV valve and connect them with the supplied length of 3/8" hose. (See Fig. 15-e.)

Fig. 15-d / ('04-'06 Models Only)

SUPPLIED 5/32" HOSE

SUPPLIED PCV VALVE

Fig. 15-e ('04-'06 Models Only)

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 44

16.A ESCALADE/DENALI/SS SURGE AND RESERVOIR TANK INSTALLATION

A. Screw two 3/4" straight brass fitting into the

plastic surge tank. (See Fig. 16.A-a.)

B. Using the supplied 1/4-20 x .50 hardware and

washers attach the surge tank mounting bracket to the surge tank.

C. Unbolt the two bolts holding the passenger’s

side hood hinge brace at the base of the windshield. Install the surge tank and bracket assembly using the stock hardware. (See Fig.

16.A-a.)

D. Remove the two screws holding the front

bumper brace in the passenger’s side fender well. (See Fig. 16.A-b.)

E. Install the reservoir bracket as shown using

the two factory screws. (See Fig. 16.A-b.)

F. Screw the 3/4" 90° brass fittings into the top

and bottom of the water reservoir.

G. Install the water pump on the reservoir using

the supplied adel clamp, 1/4-20 x .50 screws and 1/4" washers. Take the short 90° molded elbow and connect the inlet of the water pump to the bottom 90° brass fitting. (See Fig. 16.A-c.)

H. Mount the water pump/reservoir assembly to

the previously installed bracket in the fenderwell using two 1/4-20 x .50" cap screws and washers. (See Fig. 16.A-d.)

Fig. 16.A-b

Fig. 16.A-c

ESCALADE/DENALI

Fig. 16.A-a

Fig. 16.A-d

Page 45

16.B H2 HUMMER SURGE AND RESERVOIR TANK INSTALLATION

A. Screw two 3/4" straight brass fitting into the

plastic surge tank. (See Fig. 16.B-e.)

B. Using the supplied 1/4-20 x .50 hardware and

washers attach the surge tank mounting bracket to the surge tank. (See Fig. 16.B-e)

C. Unbolt the two bolts holding the passenger’s

side hood hinge brace at the base of the windshield. Remove the plastic push-pin between the two bolts.

D. Apply light pressure to drop the hood support

down and install the surge tank/bracket assembly between the hood support bracket and cowling while aligning the bracket and push-pin holes. Using the stock hardware and push-pin secure the bracket in place. (See Fig.16.B-e.)

E. Screw the 3/4" 90° brass fittings into the top

and bottom of the water reservoir.

F. Install the water pump on the reservoir using

the supplied adel clamp, 1/4-20 x .50 screws and 1/4" washers. Take the short 90° molded elbow and connect the inlet of the water pump to the bottom 90° brass fitting. (See Fig. 16.B-f.)

G. Assemble brackets “A”, “B” and “C” to the

water reservoir as shown in Fig. 16.B-f.

H. Place the water reservoir assembly under the

passenger’s side door with the short sides of the triangular tank against the frame rail and nerf bar support.

I. Holding the assembly in place, mark the three

locations where you will need to drill. Use a 1/8" drill for the two locations on the frame rail. Secure those two locations with the supplied sheet metal screws. For the third location on the nerf bar support, use a 9/32" drill and secure with the supplied 1/4-20 x 1" bolt, 1/4" nut and washer. (See Fig. 16.B-g.)

SURGE TANK BRACKET

HOOD HINGE BRACE

Fig. 16.B-e

Fig. 16.B-f

DRILL 1/8" HOLES

Fig. 16.B-g

H2 HUMMER

DRILL 9/32" HOLE

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 46

17.A ESCALADE/DENALI/SS HEAT EXCHANGER INSTALLATION

A. Remove the plastic push pins securing the

radiator core support cover to the vehicle. Remove the core support cover.

B. DENALI: Use a screw driver to unsnap the

four twist snaps securing the grill. Remove the last screw so that it is possible to unsnap the grill and remove it from the vehicle.

ESCALADE/SS: Unsnap the two top snaps

and lift the bottom tabs out of their slots. Remove the grill from the vehicle.

C. Using sealant, install two 90° brass fittings

into the inlet and outlet of the cooler. Take brackets “A”, “B” and “C” and mount them to their corresponding tabs on the heat exchanger. (See Figs. 17.A-a, 17.A-b, 17.A-c.)

D. Take the heat exchanger with all three brack-

ets mounted and place it into position. Mark the hole positions from brackets A and B and drill with a 17/64" drill. To mount bracket C, you will remove and use an existing screw in the lower passenger’s side of the hood latch support structure. Use the 1/4-20 x 3/4" hardware to secure brackets “A” and “B”. (See Figs. 17.A-d, 17.A-e.)

Fig. 17.A-b / BRACKET B - Mount To The

Upper Driver’s Side Tab.

NOTE: Temporarily place a piece of sheet metal between the

A/C condenser and the support when drilling to ensure that the condenser is not punctured.

Fig. 17.A-a / BRACKET A - Mount To Lower

Driver’s Side Tab On The Heat Exchanger.

Fig. 17.A-c

Fig. 17.A-d

Fig. 17.A-e

Page 47

17.B H2 HUMMER HEAT EXCHANGER INSTALLATION

A. Remove the two screws securing the ends of

the grill. Unsnap the middle clips and remove the grill from the vehicle. Remove the black insert (diffuser) in the grill. There are eight clips which hold it in.

B. Take four supplied cooler brackets and line

them with the supplied adhesive backed foam. Trim any extra foam.

C. Unscrew the two factory screws securing the

cross supports to the upper core support. (See Fig. 17.B-f.) Place the cooler in the brackets with the barbs facing to the passenger’s side. Grind the bottom of the stock washers flat to fit onto the cooler brackets.

D. Place the brackets on the bottom of the cool-

er and mark on the cross supports where you will need to drill. Make sure to close the hood with the brackets temporarily installed to verify clearance between the brackets and the hood supports.

NOTE: Temporaritly place a piece of sheet metal between the

core support and the A/C condenser when drilling to ensure that the condenser is not punctured. (See Figs.

17.B-f, and 17.B-g for the following steps.)

REMOVE TWO SCREWS AND INSTALL COOLER BRACKETS

Fig. 17.B-f

E. Drill two 9/32" holes at the marked locations

on the cross support.

F. Open the hood and mount the cooler to the

cross support with the supplied 1/4" hardware and brackets. Make sure that the cooler is sandwiched snuggly between the upper and lower brackets.

G. CAREFULLY and slowly close the hood.

Make sure the heat exchanger has clearance with the hood.

NOTE: Some 2005 and later vehicles may require hood sup-

port modification as shown in Fig. 17.B-h. Coat any trimmed metal edges with paint or primer to resist corrosion.

H. Reinstall the hood to its factory location.

NOTE: The clearance will be tight between the heat exchang-

er and the hood once it is installed.

Fig. 17.B-g

1/2"

6-1/8"

3/8"

Fig. 17.B-h

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 48

17.C 2008 H2 HUMMER GRILL INSERT REMOVAL

A. Remove the grill from the vehicle

using a flat bladed screw driver depress the clips retaining the grill to the vehicle (see Fig 17.B-i).

B. With the grill on a flat surface depress

the clips retaining the grill opening extensions and remove the grill extensions (Note: this will not be reused). See Fig 17.B-j

C. Reinstall the grill to the vehicle in the

reverse order of removal.

Fig. 17.B-i

Fig. 17.B-j

Page 49

18.A ESCALADE/DENALI/SS CHARGE COOLER HOSE ROUTING

FRONT OF VEHICLE

STRAIGHT/ 90° BRASS FITTINGS

CUT 1-3/4" OFF SHORT END OF HOSE

3/4" HOSEx64"

BRASS FITTINGS2x90°

WATER PUMP

MOUNTED

UPSIDE DOWN

TOP VIEW

3/4" HOSEx36.5"

3/4" HOSEx110"

WATER RESERVOIR

3/4" HOSE

x 13.5"

2 STRAIGHT

BRASS

FITTINGS

SHORT 90° MOLDED HOSE

2x90° BRASS FITTINGS

CHARGE

AIR

COOLER

SETRAB WATER COOLER

SURGE TANK

HOSE UNION

4"x12" MOLDED 90° HOSE

NOTE: When routing hoses, refer to Fig. 18.A-a.

A. Cut a 13.5" length of 3/4" hose. Run

this from the 90° fitting on the charge air cooler to the straight brass fitting on the surge tank.

NOTE: Make sure to leave the hose slightly

long to allow for engine movement.

B. Cut a 36.5" length of 3/4" hose. Run it

from the bottom fitting on the surge tank along the fender toward the front and down to the 90° brass fitting on the top of the water reservoir.

C. Take the supplied 4" x 12" 90° molded

elbow and cut 1-3/4" from the 4.0" end. Connect the trimmed end to the straight brass fitting on the charge air cooler. Route the long end toward the surge tank. Cut a 110" length of hose and connect it to the end of the installed molded elbow with the supplied 3/4" union. Route the hose along the fenderwell, down toward the water reservoir and up under the front bumper. There is

a small opening in the rubber apron between the bumper and A/C condenser. Pull the hose up and through, then connect it to the driver’s side 90° fitting.

D. Cut a 64" length of 3/4" hose. Run it

from the outlet of the water pump to the same hole in the rubber apron you pulled the previous hose through. Pull the hose up and through, then connect it to the passenger’s side 90° fitting.

E. Secure all hose ends with the supplied

nylon clamps.

F. With the key on, make sure the charge

cooler water pump is operating and that water is flowing through the surge tank. Fill the surge tank if necessary. If the water is not flowing, remove the charge cooler supply hose and lower until water flows out of the hose. If necessary, provide light suction to the hose to help prime the pump. Verify water flow. Do not let the pump run for extended periods (30 seconds or more) without water flow. Fill the charge cooler tank until the level stabilizes.

WATER PUMP HOSE ROUTING - ESCALADE/DENALI/SS

Fig. 18.A-a

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 50

18.B H2 HUMMER CHARGE COOLER HOSE ROUTING

FLOW

¯3/4"x47" HOSE

WATER RESERVOIR

90° MOLDED

ELBOW

90" HOSE

WATER PUMP MOUNTED UPSIDE DOWN

2 STRAIGHT BRASS FITTINGS

SURGE TANK

SUPPLIED S-BEND MOLDED HOSE

CUT 1-3/4" OFF SHORT END OF HOSE

¯3/4"x40" HOSE

STRAIGHT/90° BRASS FITTINGS

CHARGE

AIR

COOLER

4"x12" MOLDED 90° HOSE

2x90° BRASS

FITTINGS

NOTE: When routing hoses, refer to Fig. 18.B-b.

A. Attach one of the 3/4" formed “S” hoses

to the bottom fitting on the front heat exchanger. (See Fig. 18.B-b.) Insert a 3/4" hose mender into the open end of the hose. (See Figs. 18-d, 18-e.)

B. Cut a 90" piece of Ø3/4" hose. Connect

it to the formed hose attached to the bottom fitting of the heat exchanger and run it by the front passenger’s side of the radiator, through the plastic shrouding and into the engine compartment.

C. From the engine compartment, route

the hose along the frame rail down to the discharge of the water pump.

D. Cut a 47" piece of Ø3/4" hose. Connect

the hose to the upper fitting on the water reservoir and run the hose along the frame rail up to the botton fitting on the surge tank.

NOTE: Secure the 47" and 90" pieces of hose using

the supplied adel clamps and sheet metal screws to the frame rail keeping them clear of heat or any sharp objects. (See Fig. 18.Bc.)

Fig. 18.B-b

E. Use the supplied S-bend molded hose

to connect the remaining straight fitting on the surge tank to the 90° fitting on the charge air cooler.

F. Take the supplied 4" x 12" 90° molded

elbow and cut 1-3/4" from the 4.0" end. Connect the trimmed end to the straight brass fitting on the charge air cooler.

G. Attach one of the 3/4" formed “S” hoses

to the top fitting on the front heat exchanger. (See Figs. 18-d, 18-e.) Insert a 3/4" hose mender. (See Fig.

18.B-b.) into the open end of the hose.

TWO HOSES SECURED

TO FRAME RAIL IN

INNER FENDER

Fig. 18-c

Page 51

18.B H2 HUMMER CHARGE COOLER HOSE ROUTING, cont’d

H. Cut a 40" piece of Ø3/4" hose. Connect it to

the formed hose attached to the top fitting of the front heat exchanger and run it by the passenger’s side of the radiator and through the plastic shrouding into the engine compartment. Connect the Ø3/4" hose to the long end of the 90° molded elbow with the supplied 3/4" hose mender.

I. Secure all hose ends with the supplied nylon

clamps.

Fig. 18-d

Fig. 18-e

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 52

19. WATER PUMP WIRING

A.1 Escalade/Denali/SS: Mount the supplied

water pump relay on the fire wall located to the right of the FMU bracket. (See Fig. 19-a.)

A.2 H2 Hummer: Mount the supplied water pump

relay on the lower plastic area of the power distribution block next to the fuel pump relay. (See Fig. 11-f.)

B. Connect the red 12-gauge wire from terminal

#30 to the supplied fuse holder using the supplied butt connector. Install a ring terminal on the other end of the fuse holder. (See Fig. 19-b.)

C. Feed the yellow wire from relay terminal #85

to the fuse box (electrical center) on the driver’s side of the engine bay. Route the wire to the yellow wire from the fuel pump relay. Tap into the line using the supplied “T” splice connector. (See Fig. 19-b.) If the vehicle does not require an inline fuel pump, route the wires directly to the fuel pump relay. (See Fig. 19-c.)

FUSE BOX

POWER SUPPLY

Fig. 19-a

TAP INTO FUEL

PUMP WIRE

NOTE: Vehicles not using supplement fuel pump will tap into

the stock fuel pump relay using the supplied fuse tap. (See Fig. 19-c.)

D. Run the black wire from terminal #86 on the

fuel pump relay to ground.

E.1 Escalade/Denali/SS: With the long red

12-gauge wire connected to the water pump relay terminal #87, route the free end down along the fenderwell and under the base of the radiator over to the positive (blue/green) wire on the water pump. Secure as necessary to avoid heat and sharp edges.

E.2 H2 Hummer: With the long red 12-gauge

wire connected to the water pump relay terminal #87, route the free end down the fenderwell to the positive (blue/green) wire on the water pump. Secure as necessary to avoid heat and sharp edges.

F. Run the negative (brown) wire from the water

pump to a clean ground.

G. With the key on, make sure the charge cooler

water pump is operating and that water is flowing through the surge tank. Fill the surge tank if necessary. If the water is not flowing, remove the charge cooler supply hose and lower until water flows out of the hose. If necessary, provide light suction to the hose to help prime the pump. Verify water flow. Do not let the pump run for extended periods (30 seconds or more) without water flow. Fill the charge cooler tank until the level stabilizes.

Fig. 19-b

RED WIRE FROM VORTECH SUPPLIED

RELAY TERMINAL #30 ATTACHES HERE

YELLOW WIRE FROM VORTECH SUPPLIED

RELAY TERMINAL #85 ATTACHES HERE

Fig. 19-c

Page 53

20. REFLASH COMPUTER (KITS SUPPLIED WITH SUPERCHIPS TUNER)

MICRO TUNER VEHICLE PROGRAMMING INSTRUCTIONS

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.

• 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.

NOTE: For vehicles equipped with on-star, follow the instruc-

tions on the following page before starting.

A. Reconnect the battery. B. Connect the supplied cable to the 9-pin con-

nector at the top of the hand-held unit. If present use the thumbscrews to secure the cable to the connector.

C. Connect the other end to your ALDL connec-

tor located under the dash near the steering column. Make sure this connection is seated all the way in and that it is secure. You do not want this cable coming out of the connector during programming.

D. Turn the ignition key to the "on" or "run" posi-

tion but do not start the vehicle.

E. To begin programming your vehicle, you may

either press the “YES” button or the “A” button. If you press the “YES” button on the hand-held unit, this will download the Superchips performance program already stored in the hand-held unit. If you press “A”, you can alter some predefined options to suit your needs. These options are not perma- nently stored in the hand-held unit. When power is removed from the unit, the changes you made will be lost.

F. You only need to press the “YES” button

once to start the programming cycle. The programming process takes 1 minute and 15 seconds to complete.

NOTE: 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.

G. The hand-held unit will inform you that the

programming process has completed and to turn the ignition off and disconnect the cable. Only at this time should the ignition be turned off and the cable removed.

H. Programming is now completed. Start the

vehicle to ensure proper operation.

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 54

21. SUPERCHIPS NOTICE (APPLIES TO KITS SUPPLIED WITH SUPERCHIPS TUNER)

Regarding all GM vehicles with “ON-STAR” and Microtuner 2001. It has come to our attention that GM vehicles equipped with “ON-STAR” communications may have trouble being programmed with a Superchips Microtuner 2001. It appears the “ON-STAR” system interrupts communications between the MT2001 unit and the vehicle’s PCM...” and after cycling the ignition the vehicle can be started right back up.

Superchips is reviewing this and to temporarily correct for this situation, it is recommended that any vehicle to be programmed that has “ON-STAR” should follow these additional steps FIRST.

1. Ensure the vehicle is off and keys are out of the ignition. All model years up to 2002:

Locate “interior” fuse panel and remove QTY 2 SEO labeled fuses.

Locate “exterior” fuse panel and remove QTY 1 SEO labeled fuse.

NOTE: 2004 vehicles equipped with On-star that have aftermarket stereos will

experience problems withe 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.

2003-2004 models years: Remove the “INFO, RADIO, RADIO AMP” fuse locat-

ed on the exterior fuse panel.

2. Follow the instructions that came with the Microtuner.

Once programming is completed, ensure the vehicle is off and the keys are out of the ignition and install the fuses in the correct locations.

On GMC trucks, the interior fuse panel should be located to the left of the instrument panel/dash board. If the panel faces the door, open the door to gain full access. On GMC trucks, the exterior fuse panel should be located under the hood on the right hand side of the vehicle. It will be labeled Fuse Panel or similar.

Page 55

22. REFLASH COMPUTER, (2004, 2006 Denali & all 2005-2008 Model Year)

IMPORTANT! To ensure trouble-free programming of your vehicle’s computer:

•Allmodelyearsupto2002:

Locate “interior” fuse panel and remove Qty 2 SEO labeled fuses. Locate “exterior” fuse panel ane remove Qty 2 SEO labeled fues.

•2003-2005modelyearvehicles”

Locate “exterior” fuse panel and remove Qty 1 INFO, Qty 1 RADIO and Qty 1 RADIO AMP labeled fuses.

•Turnoffallaccessoriesandclosedoorstopreventunnecessarydrainonthebattery.

•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.

NOTE:•AllvehiclesequippedwithOn-starthathaveaftermar-

ket 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!

ESCAPE

A. Reconnect the battery. B. Locate the vehicle’s OBD2 connector lo-

cated in the lower left hand corner of the dash on the driver’s dise of the vehicle.

C. Attach the OBD2 connector from the Flash

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. You don’t want this connector to disconnect during programming or damage may occur to the vehicle’s ECM.

D. The Reash tool should power up and

display three parameters.

 •Performancetune  •Diagnostics  •Options

E. Select “performance tune” and press the

enter button in the middle of the arrow keys.

F. Read the disclaimer entirely, then select

agree and press ENTER.

G. At this point please read the screen dis-

playedonthereashtool.Ifyouhaveany

questions, either refer to the manual that

isprovidedwiththereashtoolorcontact

our service department for futther assistance.

H. Turn the ignition on (do not start the ve-

ENTER

SELECT

Fig. 22-a

hicle). Set the parking brake and press the ENTER button to continue.

I. SELECT TUNE will be displayed at the top

of the screen. Use the arrow keys to select the appropriate tune for your vehicle and press the ENTER button. You will have a choice.

J. Continue to follow the screen and when

nishedunplug thereash tool form the

vehicles OBD2 port.

ARROWKEYS

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 56

23. FINAL ASSEMBLY AND CHECK

A. Reconnect the battery. 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. The plastic engine cover that covers the

upper manifold will need to be modified in order to reinstall. Refer to Fig. 23-b to trim and reinstall.

F. Start engine and allow to idle a few minutes. G. '02 Escalade: With the engine running, check

the brake booster line. Turn the steering wheel in both directions.

Verify:

• Smooth power assist

• Noiseless operation

• Proper fluid level

• No system leaks

• No bubbles, foam or discoloration of fluid H. 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.

I. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without ALL the subassemblies completely and properly installed may cause

FAILURE OF MAJOR COMPONENTS. J. Test drive the vehicle. K. 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.

Fig. 23-a

Fig. 23-b

Page 57

23. FINAL ASSEMBLY AND CHECK, CONT'D

For internally lubricated V3 units only

Thissuperchargerhasbeenfactorypre-lledwithspecial Vortech synthetic lubricant. Oil does not need to be

addedtoabrandnewunit;howeverauidlevelcheck

should be performed. Prior to operating the supercharger on the vehicle and

after installation onto the vehicle:

Removethefactoryinstalledat-headbrassshipping

plug (not the dipstick) from the top of the supercharger case. Replace the sealed shipping plug with the supplied “vented” plug. Do not operate the supercharger

withoutit.Checkthesuperchargeruidlevel.

Fluid level checking procedure:

1. Ensure that the .06” copper sealing washer is located on the dipstick base.

2. Thread the clean dipstick into the supercharger unit it seats.

3. Once the dipstick has seated, remove the dipstick from the unit. Fluid should register in the crosshatched area on the dipstick.

4. DO NOT OVERFILL!!! Drain excess fluid the unit if it is above the maximum level on the dipstick.

Checktheuidlevelusingthedipstickatleastevery

2,500 miles.

Initialsuperchargeruidchangemustbeperformedat 2,500miles.Thesuperchargeruidmustbechanged

at least every 7,500 miles.

Draintheuid,relltheunitwith4oz.ofVortechV3 lubricatinguidandthenconrmproperoillevelusing

the dipstick. DO NOT OVERFILL!!!

WARNING: Useofanyotheruidotherthanthespe-

cial Vortech lubricant will void the warranty and may cause component failure.

08OCT08 GM Trk/H2(4GL..015v5.0)

P/N: 4GL020-015

Page 58

1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226

FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST

ENGINEERING, LLC