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Whipple LT1 Installation Manual

Supercharger
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I nstallation M anual: GM LT1_A1R13E
Last Updated: February 12th, 2019
SUP ER CHARGER I N STALLATI ON M AN UAL
2014-2018 GM 5.3/ 6.2 LT1 TR UCK
2014-2019 GM 5.3/ 6.2L LT1 SUV
W HI P P LE SUP ER CHARGERS
3292 NORTH WEBER AVE
FRESNO, CA 93722
TEL 559.442.1261
FAX 559.442.4153
w w w .w hipplesuperchargers.com
A color P DF of this m anual is available, em ail
tech@w hipplesuperchargers.com
for a copy
P R EM I UM FUEL ONLY (91 OCTANE OR BETTER ALW AYS) R ON+M ON/ 2
CALI FOR NI A AI R RESCOUR CE BOAR D EXECUTI VE OR DER #D231-48
P age 1 of 36
w w w .w hipplesuperchargers.com

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Summary of Contents for Whipple LT1

  • Page 1 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 SUP ER CHARGER I N STALLATI ON M AN UAL 2014-2018 GM 5.3/ 6.2 LT1 TR UCK 2014-2019 GM 5.3/ 6.2L LT1 SUV W HI P P LE SUP ER CHARGERS...

  • Page 2: Recommended Tools And Supplies

    I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 I NTRODUCTI ON Before beginning installation, w e encourage you to read this manual thoroughly before you begin any portion of the installation: 1. A quick parts check to make certain your kit is complete (see shipper parts list in packing paperwork). If you discover shipping damage or shortage, please call our office immediately.

  • Page 3: Pre-Installation Checklist

    DO NOT remove the protective seal on the supercharger prior to installation. Foreign material entering the supercharger will automatically void all warranties. 7. Identify Supercharger Kit Components: Before beginning installation, identify all the components of your Whipple Supercharger Kit and ensure all items are present and undamaged.

  • Page 4: Common Abbreviations

    I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Symbol Key Throughout this installation guide you will see the following symbols used:  NOTE Used to indicate tips and information to aid in installation, maintenance, or use of the supercharger. CAUTION Used to indicate precautions that must be taken to avoid damage to the supercharger and associated components.
  • Page 5 7. (Complete kits only) Make sure your battery is fully charged before installing, if not, install a battery charger to maintain 14volts. Kits not using the Whipple supplied tune are not 50-state legal and are for off-road use only.  NOTE **NOTI CE: Installation of Whipple Supercharger products signifies that you have read this document and have agreed to the terms stated within.
  • Page 6 Last Updated: February 12th, 2019 I LLUSTR ATED I NSTALLATI ON GUI DE It is strongly recommended that you read through this guide before you begin installing the Whipple Supercharger.  WARNING!! Batteries normally produce explosive gases. Therefore, do not allow flames, sparks or lighted substances to come near the battery.
  • Page 7 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Disconnect the MAF sensor connector by pulling up on the red safety clip, and then squeezing the connector while pulling up. Loosen the hose clamp using an 8mm nut driver that secures the MAF housing to the stock air induction tube and the hose clamp holding the air induction tube to the throttle body.
  • Page 8 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Disconnect the factory MAP sensor electrical connector by squeezing the connector and pulling away. Using a 10mm socket, remove the MAP sensor from the intake manifold by removing the mounting bolt. Disconnect the factory EVAP solenoid quick connection from solenoid by squeezing the connector and pulling away.
  • Page 9 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Remove the (2) air duct support stands from the intake manifold using a 10mm wrench or deep-well socket. Remove the (2) fasteners located in the back securing the intake manifold cover to the intake manifold using a 10mm socket.
  • Page 10 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 The plastic cover cannot be removed due to firewall clearance, therefore you must loosen all the factory intake manifold bolts (10) using a 10mm socket. Remove the intake manifold by lifting and sliding forward. Once the intake manifold is out of the way, remove the plastic cover by removing the (4) plastic cable ties holding the wire harness to the back of the cover.
  • Page 11 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Remove the factory orings from the intake manifold (8). Install these into the new intake manifold. (5.3L) Remove the factory oring from the throttle body surface (1). Install this on the supplied throttle body adapter.
  • Page 12 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Install the supplied MAP extension harness to the MAP sensor before install manifold. Press until it clicks in place. NOTE: This extension could fit backwards, ensure that the color wires and pin locations match! (Pin 1= Gray, Pin 2=Black, Pin 3=Green).
  • Page 13 Fill to the middle of the sight glass. Tip from side to side then with the SC flat again, check oil level again, add if necessary. Whipple kits are supplied with pre-measured oil bottles, therefore, on all new installs NOTE: The W175FF compressor takes a maximum of 8 fl/oz and a minimum of 7.5 fl/oz. Failure to fill properly will result in catastrophic damage.
  • Page 14 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Carefully install the SC assembly to the engine by carrying over the intake manifold and setting down after its properly aligned. First get (16) 6mm SHCS started to ensure proper alignment. Once all (16) are hand tight, torque the first pass to 49 in/lbs and then a final pass at 89 in/lbs.
  • Page 15 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Install the supplied aluminum EVAP quick connect fitting through the supplied EVAP solenoid bracket. Follow by installing the EVAP solenoid to the bracket, securing with the factory fastener previous removed (10mm socket). Install the supplied 3/8”...
  • Page 16 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Route the EVAP solenoid hose and the 90deg quick connect fitting up to the forward quick connect fitting on drivers side SC inlet. Push until it clicks and locks in place. Install the supplied ¼”...
  • Page 17 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Install the IC filler tube to the bracket using the supplied (2) 6mm x 12mm BHCS (4mm allen socket). Connect the previously installed IC hose (5/8” to ¾” 24” L) to the rear 3/4” boss on filler neck. Secure with supplied pinch clamp.
  • Page 18 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Install the front idler plate to the engine by using the supplied 4 spacers and the idler plate. Install the 21.15mm spacer on the passenger side with the 10mm x 150mm SHCS bolt. Install the (2) 44.32mm spacers on the driver side with the (2) 8mm x 130mm SHCS.
  • Page 19 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Install the supplied grooved idler pulley to the factory tapped hole below the alternator. Use the supplied step spacer with the 10mm ID hole and the 10mm ID step washer on the front of the pulley. Use the supplied 10mm x 35mm SHCS to secure pulley to factory bracket (8mm allen socket).
  • Page 20 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Route the supplied SC belt using the following diagram. Route around the spring-loaded tensioner while it’s still loose for ease of installation. Rotate the spring-loaded tensioner back into its stock location and torque to 18 ft/lbs. using a 15mm socket. Using a ½”...
  • Page 21 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 (5.3L) Use the supplied (4) 6mm x 40mm SHCS flange bolt to secure throttle body to throttle body adapter using a 10mm socket, torque to 80 in/lbs. Loctite™ (#242 blue) threads. (6.2L) Install the supplied gaskets on both sides of the throttle body adapter.
  • Page 22 Reinstall the factory airbox lid to the factory airbox. Secure using the factory (4) fasteners and an 8mm socket. Install the supplied Whipple air inlet tube with the reducer hose to the factory MAF housing and secure with the supplied clamp. Install other end of inlet to the supplied silicone hose to the factory throttle body using supplied clamp.
  • Page 23 If necessary top off with a GM approved engine coolant. Whipple also recommends running 2 bottles of Redline Water Wetter which can be found at most  WARNING!! DO NOT USE TAP WATER OR ANY NON GM APPROVED ENGINE automotive parts stores.
  • Page 24 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Remove the factory driver side headlight by removing the (4) factory fasteners using an 10mm socket. Install the supplied intercooler electric water pump to the intercooler water reservoir using the supplied t-bolt clamp to secure the pump to the reservoir bracket.
  • Page 25 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 (Trucks only) Remove the (2) factory fasteners that secure the frame to the bumper (18mm socket) for the IC reservoir installation. (MY2016 and up truck) Unbolt bumper support bracket. (MY2016 and up truck) Install I/C tank offset brackets on top of frame to bumper mounts reinstall factory bolts using an 18mm socket, torque to 74 ft/lbs.
  • Page 26 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 (MY2016 and up truck) Install the IC reservoir by sliding up from the bottom of the bumper and resting on the I/C tank offset mounts. Secure reservoir to mounts with the (2) 10mm x 20mm SHCS and (2) 10mm flat washers, use a 10mm allen socket, torque to 74 ft/lbs.
  • Page 27 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Install the IC reservoir by sliding up from the bottom of the bumper and resting on the frame/bumper mount. Secure using the factory fasteners (2) using an 18mm socket, torque to 74 ft/lbs. Install the supplied heat exchanger rubber grommets (4) into the heat exchanger 7/8”...
  • Page 28 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Carefully set the heat exchanger behind the front grille support (do not mount yet). Remove the factory ambient air temp sensor from factory location for ease of heat exchanger installation. Remove the plastic harness support tab.
  • Page 29 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Route the hose from the IC filler neck outlet (3/4” ID x 58”) and filler neck vent line (3/8” x 58”) below the airbox, down on the inside of the forward/passenger side body mount, to the IC water reservoir. Connect both with the supplied pinch clamps.
  • Page 30 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 (Chevrolet/GMC Trucks) Use a 1 ½” hole saw and drill an access hole through the radiator sealing shroud. This should be approximately 1” up as shown an image (for hole saw center) ON GMC models. Chevrolet models should pre-install the supplied 90deg hose end and measure for proper place (must be higher on Chevrolet models/bottom right image).
  • Page 31 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 Reinstall the factory ambient air temp sensor into factory location. Reconnect plastic harness tab into factory location but from the front side. (2016 and up with air shutters) Reinstall the air shutters into factory location. Make sure the shutters have adequate clearance from the LTR and hoses.
  • Page 32 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 103. Install the fuse tap to the leg of the 15amp fuse located in location #46 (O2 Sensor B). Make sure the fuse tap is on the back most leg of the fuse (closest to the firewall). 104.
  • Page 33 113. Attach the funnel and fill with a 50/50 mixture of coolant and distilled water until the funnel is half full. Whipple recommends Zerex G-05 to match the stock color. The Whipple IC system is compatible with all common types of antifreeze, it is customer preference.
  • Page 34 I nstallation M anual: GM LT1_A1R13E Last Updated: February 12th, 2019 114. Turn the ignition to the ON position, after a brief delay, the electric pump motor will cycle. Air bubbles will begin to rise to the filler tee as the coolant level drops, continue to fill while pump is running. Once its done filling, turn the ignition key OFF, the level will drop, top off with fluid.
  • Page 35 123. DO NOT use aftermarket air filter box or duct with the supplied Whipple calibration. The Whipple calibration is designed to work with the factory air box, factory MAF and Whipple air inlet duct and nothing else. Changes to the air inlet system will require a custom calibration which Whipple does not provide and is not 50-state emissions legal.

  • Page 36: Maintenance And Service

    3. Do not operate the vehicle at large throttle opening if the MIL lamp is on steadily. This indicates an electronic engine control malfunction: reduce throttle opening and consult your vehicle dealer. 4. Check the supercharger oil level at every engine oil change. Add Whipple SC oil to the supercharger if required. Do not overfill the supercharger rear gear case.