Lingenfelter High Capacity Intercooler Radiator for ZL1 Camaro and

Lingenfelter High Capacity Intercooler Radiator for
ZL1 Camaro and aftermarket supercharger
equipped Camaro SS
PN: L320061410
Revision - 1.0
Lingenfelter Performance Engineering
1557 Winchester Road
Decatur, IN 46733
(260) 724-2552
(260) 724-8761 fax
www.lingenfelter.com
Release date 14-October-2013
Parts List
LPE Camaro SS and ZL1 Camaro High Capacity Intercooler Radiator Kit (PN:L320061410)
#
Description
Part number
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1
1
1
1
3
2
4
4
2
2
2
2
6
1
1
4
2
6
7
2
2
1
1
1
Intercooler radiator and fan assembly
Dual fan radiator wiring harnessw relays and fuse holders
Temperature based relay control
Engine coolant temp sensor
15 amp fuse, ATC type
1/4” heat shrink, black
9/32” x 1 1/8” rubber grommet
5/16” x 1 1/4” stainless steel washer
M8x1.25x20 stainless steel cap screw
M8x1.25x25 stainless steel cap screw
M8 stainless steel washer
M8x1.25 stainless steel Nylock nut
Self tapping screw
5/8” hose with 90 degree bend
5/8” hose joiner
25.6mm Oetiker clamp
Constant tension stainless worm gear clamp, 14-27 mm
7.5” black Zip-Tie
4” black Zip-Tie
Self tapping screw
1” hook and loop tape
Lingenfelter decal
TBRC instructions
Instruction manual
3/4” deep socket
13 mm socket
10 mm socket
7 mm socket
3/8” drive ratchet
Pry tool or flathead screw driver
T20 Torx driver
Torque wrench/wrenches
Drill and 3/16” drill bit
AV16037
06483
L920010000
Tools & Materials Required
• Deburring tool, sandpaper, or file
• Cutting tool
• Wire strippers
• Wire Crimps
• Depinning tool
• Soldering iron
• Solder
• Heat gun or lighter
• Vehicle hoist or jack & jackstands
Optional Items
Description
High Capacity Camaro Intercooler Fluid Reservoir Kit
VariMax Intercooler Coolant Pump (Except for ZL1)
Stewart EMP high output intercooler fluid pump, 9A Stewart EMP high output intercooler fluid pump, high flow program, 25A Page 1.
XX05847-0002
XX05636-0002
TBRC-001
12608814
782-2184
98052505
9600K48
91525A230
47543
47544
47395
47215
AV12351
28471
9904
52545K74
54205K11
Part number
L300152012
TAFX410110
ST-E2512A
ST-1030002107
The Lingenfelter Performance Engineering (LPE) High Capacity Intercooler Radiator is designed to
improve the performance of the engine by reducing the charged air temperature at all RPM ranges
and duty cycles.
The system features a unique back to front double pass design to optimize heat transfer while
maintaining the same flow rate through the charge air cooling system.
This kit is designed to fit any 2010-2013 V8 Camaro that needs a liquid to air intercooler radiator,
whether it is a ZL1 Camaro or a Camaro SS using the stock ZL1, Magnuson, Edelbrock E-Force,
or Whipple superchargers or liquid to air equipped turbocharger kit equipped vehicle. Despite the
increased size, the LPE intercooler radiator has roughly the same coolant flow restriction as the stock
ZL1 intercooler radiator, making it compatible for use with the stock ZL1 intercooler fluid circulation
pump, the VariMax pump or the Bosch pump used in many of the above listed supercharger systems.
To maximize the performance of this intercooler radiator kit we recommend that vehicles equipped
with the Bosch or other similar intercooler pumps upgrade to the VariMax pump. The VariMax pump
provides the same flow as the production ZL1 pump, providing a 25% increase in flow over the Bosch
pump. Since the VariMax pump flows the same as the ZL1 pump, we do not recommend it for ZL1
applications. For applications that require an even higher flowing intercooler fluid circulation pump we
recommend the Stewart-EMP WP29 pumps (part # ST-E2512A or ST-1030002107).
WARNING: Due to the high flow rate of the Stewart EMP WP29 water pumps, changes to the
circulation system must be made in order to reduce pump inlet restriction if you want to use one of
these pumps. A custom reservoir must be made with a 1” hose going from the reservoir to the pump
inlet. The reservoir must be mounted above the pump and have as few bends as possible in the hose
from the reservoir to the inlet of the pump. Failure to perform these changes will result in significantly
reduced pump flow and potential pump failure. LPE is currently working on a reservoir design that will
allow the use of the Stewart EMP WP29 water pumps.
Page 2.
1. For the ZL1 Camaro remove the belly
pan from the underside of the vehicle by
removing the fourteen bolts using a 10 mm
socket.
2. Raise and properly support the Camaro
using a jack and jack stands, or a lift. Then
remove the front two wheels and disconnect
the ground from the battery. Please follow
the GM lifting procedure for the 5th Gen
Camaro
3. For a Camaro SS please skip to step 5.
For a ZL1 Camaro remove five screws
from the front bottom of the fender liner
as marked. Depending on the year of
production, these are either a T20 Torx head
screw or a 7mm hex head.
4. Remove the seven T20 Torx head screws
from in the wheel well from the locations
marked with a yellow arrow. Then using a
flat head screw driver remove the five plastic
retaining clips from in the wheel well from
the locations marked with a green arrow.
Remove the fender liner from the wheel
well.
Page 3.
5. For ZL1 Camaro, please skip to step 6.
On the Camaro SS remove the five screws
using a 10 mm socket and the five fasteners
using a flat head screw driver on the inner
wheel well liner, then remove the wheel well
liner.
6. Remove all six of the plastic retainer clips
from the top of the front facia marked by
yellow arrows using a flat head screwdriver.
Using a 10 mm socket, loosen the two
corner screws marked by the blue arrows.
7. Remove the bottom two screws of the front
facia using a 10 mm socket.
8. If the Camaro is equipped with fog lights,
then disconnect the two connectors for the
fog lights, one on each side.
Page 4.
9. Using a 10 mm wrench remove the 3 bolts
on each side of the car that are in the top
front area of the fender well.
10.Using a 10 mm socket, remove the bolt and
screw on the side of the facia, accessed
from the wheel well. Repeat on the other
side of the car.
11.Finish Removing the corner screws on top
of the front facia, and then carefully remove
the front facia from the car and set it in a
secure area to prevent accidental damage
from occurring.
12.Using a 13mm socket remove the six bolts
holding on the front impact bar, three each
side. Then remove the front impact bar.
Page 5.
13.For ZL1 convertibles, the front support brace
has to be removed, using a 13mm socket,
remove the four bolts holding it on.
Note: This part will not be able to be reused
with the Lingenfelter Intercooler.
14.Using a flat head screw driver, remove the
eight plastic retainer clips marked in the
picture and remove the plastic shrouds they
are holding in.
15.Un-clip the air temperature sensor from the
back of the passenger side plastic piece and
finish removing the plastic piece.
16.Remove the four bolts using a 10 mm
socket, and remove the front facia support.
Page 6.
17.For Camaro SS please skip to step 20.
Drain the intercooler by unscrewing the
plug.
Clamp the hoses off before the fittings to
minimize mess and hassle. However, if
the system is due for a flush, drain the full
system by also unscrewing the cap that
is under the plastic manifold cover on the
supercharger.
18.Undo the hose clamps on the hoses that
enter and exit the intercooler, remove the
hoses from the intercooler and plug them
with a 3/4” plug.
19.Using a 10mm socket, remove the 4 bolts
holding the intercooler to the AC condenser
and remove the intercooler from the car.
20.Install the rubber grommets
(PN:9600K48) into the intercooler radiator
(PN:XX05847-0002) by pushing it into the
hole at an angle. Make sure the grove in the
grommet is properly seated in the hole of
the brackets.
Page 7.
21.Install the supplied coolant temperature
sensor (PN:12608814) and tighten to 14 lb-ft
(20 Nm) using a 3/4” wrench or deep socket.
22.Install the supplied intercooler radiator
assembly (PN:XX05847-0002), place the
washers on the bolts and using a 6mm Allen
wrench, install the two top M8x1.25x20
stainless steel cap screw (PN:47543)
loosely. Then using a 13mm socket and
6mm Allen wrench install the two side
M8x1.25x25 stainless steel cap screws
and stainless steel Nylock (PN’s:47544
and 47214 respectively) loosely. Make sure
there is a washer between the bolt head and
rubber grommet.
23.Check the clearance to the AC condenser.
Use the provided washers to space out the
top as need. Do not tighten the bolts yet
however.
24.Connect the radiator outlet hose, bottom of
the intercooler radiator, to the top fitting of
the stock ZL1 supercharger.
Page 8.
25.Turn the 90 degree fitting on the hose
from the supercharger 90 degrees. Then
connect the given section of hose. Route
in desired location, trim the hose to length,
and connect to the elbow at the top of the
intercooler.
26.The plastic shrouds that were surrounding
the stock intercooler must now be cut to fit
the new Lingenfelter intercooler radiator.
First start with the bottom air dam.
Note: It is not recommended to just throw
the plastic away. They are there for air
control to help keep the hot engine bay air
from recirculating through the radiator.
27.Cut the driver side of the air dam to look as
shown (or use the template provided at the
end of these instructions).
28.Cut the passenger side of the scoop to look
as shown (or use the template provided at
the end of these instructions).
Page 9.
29.Next is cutting the passenger side shroud,
the one holding the air temperature sensor.
Cut the part as shown here.
Then sand the part to smooth out the edges,
and round the lower corner by the mounting
hole as shown by the arrow.
30.The cut the driver side shroud as shown.
Then sand the part to smooth out the edges,
and round the lower corner by the mounting
hole as shown by the arrow.
31.Install the bottom air dam as shown, and
push in the plastic retaining clips as marked.
32.Unwrap the wiring harness
(PN:XX05636-0002) and inspect it for
damage. Then rotate the three relays so
they are all aligned in the same direction.
Page 10.
33.Lay the harness out over the intercooler,
running the longer tail back into the engine
bay from the passenger side, and the
shorter end out over the intercooler to
the drivers side. The relays should be
positioned on the passenger side as close to
the hood latch as possible.
34.With the harness laid out, connect the two
fans to the harness.
35.Connect the intercooler coolant temperature
sensor.
36.Route the wires in a suitable manner. It
is recommended to try to keep the wires
as much out of the way of the intercooler,
such as around the intercooler, as possible,
this will help get more air flow through the
radiators.
Page 11.
37.Once the wires are routed in a suitable
position. Hold the relays up to the car and
mark the centers of the holes in the brackets
that hold the relays. Move the relays away,
and using a punch make an indent where
the hole is suppose to be.
38.Using a 3/16” drill bit, drill out the three
holes, be careful not to drill through the back
of the cross member.
39.Attach the relays using the supplied self
tapping screws.
40.Remove the fuse and relay center cover.
Page 12.
41.Run the long tail of the wiring harness, the
part that is inside the engine bay, between
the fuse block and fender.
42.Undo the power terminal using a 13mm
socket, and connect the one red and two
orange wires from the harness there. Put
the nut back on the stud and torque it to 11
lb-ft (15 Nm).
43.Neatly route the wires so the TBRC-001 is
beside the fuse block.
44.Using a 13mm wrench, undo the ground
stud to the rear of the fuse block.
Page 13.
45.Insert the three ground wires there, reinstall
the bolt and tighten to 18 lb-ft (25 Nm).
46.Set the operating temperatures on the
TBRC-001. Recommended temperatures
are 90 degrees for fans on low and 110 for
fans on high with a 10 degree hysteresis
as shown in the picture to the left. Do this
by turning the knobs for Temp 1 to 0 on the
x100 and 9 on the x10; 1 on the x100 and 1
on the x10 for Temp 2 dials; and 1 on the 16
option dial.
47.Hold the TBRC-001 up to where you would
like it mounted. A recommended location is
the metal flange just to the passenger side
of the fuse box.
48.Clean the surface well with brake clean or
equivalent and a paper towel or air hose.
Page 14.
49.Stick one side of the hook and loop tape to
the TBRC-001 and the other to the desired
location on the car that was just cleaned.
Place the TBRC-001 there so the two pieces
of tape interlock. Attach the TBRC-001 using
the supplied self tapping screws. Connect
the TBRC-001 to the fan harness.
50.Fuse and relay center removal.
Remove the fuse and relay block from its
base by undoing the three bolts on the fuse
block plate and the four tabs, two on each
side. Then, using a socket, push down on
each bolt to release the mating connectors.
51.Strip the lone orange wire and crimp on the
terminal to it.
52.Take out fuse block X3 and turn it over.
Page 15.
53.Locate pin 15, the “Charge Air Coolant
Pump B+” pin (circuit 2022). On some
vehicles this will be a tan wire and others it
will be a pink wire.
54.Mark the wire about an inch away from
where it enters the fuse block. Pull the pin
and wire out of the block, strip the coating
away from the wire close to where it was
just marked. Be careful to only cut the
insulation itself and not the wire also.
55.Strip the end of the orange wire from the
TBRC-001 harness, wrap it around the wire
from pin 15 and solder it place, being careful
not to apply too much heat to the wire.
56.Slip the supplied heat shrink over the wire at
the joined section and using a lighter or heat
gun shrink it to a tight fit. Make sure the
wire joint is sealed and covered completely.
Re-install the pin into the X3 fuse block.
57.Put the fuse plate back on the fuse block
Page 16.
and insert the three bolts and make sure
the four tabs on the perimeter are engaged.
Tighten the three bolts to 89 lb-in (10 Nm).
58.If the optional manual override switch will
not be installed, in order to maintain a water
tight seal on the connectors, place the
plug seals into the connector and close the
retainer and connect it to the harness.
59.Position the three fuse holders as follows:
the two orange wired fuses will be on the
backside of the radiator support cross
member and the one red wired fuse will be
on the outside sheet metal beside the fuse
block.
60.Mark the holes and drill them using a 3/16”
drill bit.
61.Insert the 15 amp fuses into each of the
Page 17.
three fuse holders.
62.Attach the fuse holders using the supplied
self tapping screws.
63.Clip in the air temperature sensor.
64.Install the passenger side shroud. The top
hole uses the factory plastic retainer clip
while the lower hole is now held in by the
side bolt on the intercooler.
65.Install the driver side shroud. The top is
Page 18.
held in by the factory plastic retainer clip
while the bottom is again held in by the side
bolt from the intercooler.
66.Tighten down the side bolts and top bolts of
the intercooler to 62 lb-in (7 Nm).
67.Fill the intercooler system with 50/50 Dex-
Cool according to the GM fill procedure.
Connect the battery and then run the car for
short while and check for leaks.
NOTE - if the pump sound level changes or
is erratic, you likely have air trapped in the
system and need to bleed the system and
make sure it is properly filled with coolant.
68.Install the front impact bar and tighten the
13 mm head bolts to 22 lb-ft (30 Nm)
69.Put on the front facia support and tighten the
Page 19.
four 10 mm head bolts to 89 lb-in (10 Nm).
70.Carefully place the front facia back onto the
car, loosely install the corner screws on top
of the facia.
71.Install the six bolts, three each side, on the
sides of the facia, accessed from inside the
wheel well and tighten to 62 lb-in (7 Nm).
72.Install the two 10 mm head bolts on the
bottom of the facia and tighten to 62 lb-in
(7 Nm).
73.Install the two bolts and two screws on the
Page 20.
facia, one of each on each side accessed
from inside the wheel well, and tighten the
bolt to 27 lb-in (3 Nm) and the screw to 62
lb-in (7 Nm).
74.If the vehicle is equipped with fog lights,
connect the fog lights harness to the facia.
75.Push in the six plastic retaining clips on top
of the car and tighten down the two corner
screws to 62 lb-in (7 Nm).
76.For the SS Camaro, please skip to step 79.
For the ZL1 Camaro insert the fender liner.
Start the seven screws in the wheel well to
hold it in place.
77.Install the five screws or bolts in the bottom
Page 21.
of the facia and fender liner.
78.Install the five plastic retaining clips inside
the wheel well and tighten the screws to 27
lb-in (3 Nm). Repeat on the other side.
79.For the ZL1 Camaro, please skip to step 81.
For the SS Camaro insert the fender liner
and start the five screws in the wheel well.
80.Install the plastic retaining clips and tighten
the screws to 27 lb-in (3 Nm). Repeat on the
other side.
81.For ZL1 Camaro’s, reinstall the belly pan,
Page 22.
tightening the fourteen 10mm head bolts to
7 lb-ft (9 Nm).
NOTE - if you are using jacks and
jackstands to support/lift the car you may
need to lower the vehicle first and then
install the belly pan.
82.Install the wheels. Tighten the lug nuts.
Lower the vehicle. Torque the lug nuts in a
star pattern to 122 lb-ft (165 Nm).
83.Test the fans by setting the TBRC-001 to a
lower than ambient temperature or by using
jumpers in place of the relays.
84.Installation of the Lingenfelter Camaro
SS and ZL1 Camaro intercooler radiator
is now complete.
Page 23.
For additional product installation information and technical support, contact LPE or your LPE
products distributor. You can also find technical support and usage discussions regarding
this product and many other LPE products in our Internet forums:
http://www.lingenfelter.com/LPEforumfiles
Lingenfelter Performance Engineering
1557 Winchester Road
Decatur, IN 46733
(260) 724-2552
(260) 724-8761 fax
www.lingenfelter.com
L320061410 Camaro Intercooler Radiator v1.1.indd
Page 24.
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