Instruction Manual

P/N: 4GL020-010

08OCT08 v5.0(99-07 GM Trk (4GLv5.0))

iii

TABLE OF CONTENTS

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

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

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

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

PARTS LISTS

1999 GM 4.8/5.3/6.0L Truck ................................................................................................. vi

2000-2002 GM 4.8/5.3 ..........................................................................................................vii

2001-2003 GM 6.0L Truck .................................................................................................... viii

2003 GM 4.8/5.3 Truck .........................................................................................................ix

2004-2005 GM 4.8L/5.3L Truck ............................................................................................ x

2007 GM 5.3L Truck ............................................................................................................. xi

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

2. COMPUTER RELOCATION (2003 5.3L Only) ..................................................................... 2

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

4. SUPERCHARGER INSTALLATION ..................................................................................... 4

5. OIL DRAIN LINE ...................................................................................................................5

6. OIL FEED LINE .................................................................................................................... 6

7. FUEL INJECTOR REPLACEMENT (1999 and 2003-2007 Models Only)

2000-0002 Models go to step 8 ............................................................................................ 7

8. FUEL MANAGEMENT UNIT (FMU) INSTALLATION (2000-2002 Models Only) ................. 8

8.1 FMU RECALIBRATION (2000 Models , 2002 4.8L Models Only) ........................................ 9

9. FUEL PUMP WIRING AND INSTALLATION (All 2000-2002 Models and

2003 6.0L Models Only) .......................................................................................................10

10.A INLET DUCT INSTALLATION (‘99-’03 Models) ................................................................... 12

10.B INLET DUCT INSTALLATION (2004 4.8L/5.3L Models) ......................................................13

11. RADIATOR TUBE INSTALLATION .......................................................................................14

12. DISCHARGE DUCT INSTALLATION ................................................................................... 15

13. SUPERCHARGER BYPASS VALVE INSTALLATION .......................................................... 16

14.A REFLASH COMPUTER (Superchips) ................................................................................. 17

14.B REFLASH COMPUTER (Diablo Predator) .......................................................................... 18

15. SUPERCHIPS NOTICE ........................................................................................................19

16. FINAL ASSEMBLY AND CHECK ..........................................................................................20