Cadillac CTS-V Intercooler Radiator Kit With Temperature Controlled Auxiliary Fans 2009-2014 Model Year (6.2L LSA engine) PN: L320030709 Lingenfelter Performance Engineering 1557 Winchester Road Decatur, IN 46733 (260) 724-2552 (260) 724-8761 fax www.lingenfelter.com Revision - 1.
Parts List High Capacity Intercooler radiator for 2009-2014 CTS-V (PN:L320030709) # Description Part number 1 2 1 1 1 3 1 3 1 1 2 2 4 3 3 4 1 3 8 2 1 1 1 1 1 2 2 4 4 4 2 4 2 4 2 4 # 1 Page 1 CTS-V heat exchanger with fans 90 degree swivel push to lock 3/4” hose fitting, M22 Intercooler fan wiring harness w relays and fuse holders Temperature Based Relay Controller Coolant temperature sensor Fuse, 15 amp 3/4” x 40” heater hose with 90 degree bend 1” black b
Tools & Materials Required • • • • • • • • • • • • • • • • • Flat head screw driver 7 mm socket 10 mm socket 13 mm socket 3/8” socket 7/16” socket Ratchet 3/8” extension Universal joint socket adapter Torque wrench 7/16” wrench 3/4” wrench 1-1/16” (27mm) wrench 1-1/4” (32mm) wrench 5/32” Allen wrench Oetiker pliers (or equivalent) Hose clamp pliers • • • • • • • • • • • • • • • • Hose cutters Heat gun Wire strippers Wire crimping tool Drill 1/4” drill bit Fork tool Jack & jack stands (or vehicle hoist) D
Thank you for purchasing the Lingenfelter Performance Engineering (LPE) Cadillac CTS-V High Capacity Intercooler Radiator system. This kit is designed to improve the performance of the engine by reducing the charge air temperature at all RPM ranges and duty cycles.
1. If you have been using the vehicle, allow the vehicle to cool before beginning this installation. 2. Raise and properly support the vehicle, either on a hoist or with a jack and jack stands, using the GM specified lift locations for the vehicle. Consult your owner’s manual for details on the proper jacking/lifting points. 3. Disconnect the ground terminal from the vehicle’s battery using a 10 mm wrench. The battery is located in the trunk on the passenger side of the vehicle.
5. Open the hood and remove the six plastic retainer clips from the sight shield by turning the clips counterclockwise. Remove the sight shield 6. Using a fork tool, remove the two (2) push fasteners from each side (four total) that secure the front fascia to the vehicle. 7. Remove the two M6x1.0 screws that secure the fascia to the bumper core support using a 10mm socket TIP: It may be easier to access the screws using a universal joint socket adapter and an extension. 8.
9. Locate the flexible rubber shrouds that are on either side of the radiator. 10. Using a fork tool, remove the Christmas tree fasteners that secure each rubber shroud to the front fascia on both sides of the radiator (two per side, four total). 11. In each wheel well, an engine splash shield exists. This felt-like material shield is secured to the wheel well liner with four push pins. Remove the four (4) push pins and remove the splash shield.
13. Using a 10 mm socket and extension, remove the four bumper fascia bolts (2 per side) that secure the front fascia to the bumper beam. Access these bolts from each front wheel well. 14. Disconnect the electrical connector from each fog light. 15. The washer fluid pump is located on the passenger side of the vehicle behind the fog light area. Remove the line from the washer fluid pump that is used for the headlight washers.
17. Locate the power steering (PS) hose bracket that is found where the PS lines cross under the intercooler radiator and engine radiator on the driver side. Using hose clamp pliers to relieve the tension on the clamps, slide the hose with the attached clamps off of the metal lines and drain the fluid into a basin. Note: Power steering systems are very sensitive to dirt. Do not re-use the fluid you have removed. Dispose of the fluid properly. 18.
21. Remove the OEM power steering cooler assembly. 22. In order to make it easier to drain the fluid from the system, remove the cap from the intercooler fluid reservoir. The reservoir is located at the back of the engine on the passenger side near the firewall. 23. To drain the intercooler system of coolant, using a 3/8” square drive extension, remove the drain fitting from the passenger side of the intercooler radiator. Have a drain pan positioned to catch the fluid. Inspect the fluid.
25. Using a 10 mm socket, remove the four (4) bolts that secure the intercooler radiator to the front of the A/C condenser. 26. Remove the stock intercooler radiator from the vehicle. Be careful not to contact the A/C condenser core as this can damage the fins and affect cooling. 27. Hold the LPE CTS-V intercooler radiator (PN: XX03277-0007) up to the impact bar and center it. The mounting tabs should be resting against the OEM bracket that is welded to the bottom of the impact bar.
29. Remove the intercooler radiator and center punch the hole locations you marked in the previous step. Drill the four (4) mounting holes using the supplied #2 carbide drill bit. 30. Hold the intercooler radiator back up into place and attach it to the vehicle using the four (4) supplied 1/4-20x3/4” thread forming screws (PN: 1132408). Tighten the screws in place using a 3/8” socket and wrench. Torque to 5 lb-ft (7 Nm). 31.
33. The recommended positions for the two fittings is pointing down and back towards the engine compartment. Once the fittings are clocked properly use a 1-1/4” inch (32mm) wrench to tighten the fittings. Tighten to 30 lb-ft (40 Nm). 34. Use the image to the left as a reference for the inlet and outlet of the new intercooler radiator. OUT (COLD) IN (HOT) 35. Use the image to the left as a reference for the inlet and outlet fitting locations of the intercooler pump.
37. Take the hose you removed from the intercooler pump in the previous step. It should look like the image on the left. Remove or roll back the mesh sleeve. 38. Use a silver or white marking pen to mark the hose as shown on the left. 39. Cut the hose as marked. Now take the portion with the tight 90 degree bend on it (the side that was connected to the intercooler pump) and slide one of the 27.
41. Locate the supplied 3/4” hose with a 90 degree bend (PN: 9820). Using hose clamp pliers to release the tension on the clamp, slide one of the stock constant tension hose clamps onto the end of the hose closest to the 90 degree bend. Connect this end to the pump inlet and then use hose clamp pliers to secure the hose with the hose clamp. 42. Route the hose from the inlet of the pump over to the hose joiner (in the hose assembly you connected to the intercooler radiator outlet in an earlier step).
45. Position the shrink tube so it overlaps the end of the loom and some of the hose as well and then use a heat gun to secure the loom to the hose. Be sure not to melt the braided loom with the heat gun. Perform this step on both ends of the hose. 46. The following steps are done to allow you to re-clock the bend in the OEM hose in order for it to attach properly to the new intercooler. You are sectioning the hose and placing a hose joiner in between the two sections of the OEM hose.
49. Using hose clamp pliers, release the tension on the stock constant tension hose clamp that should already be on the hose end. Install the hose onto the lower rear (inlet) 90 degree fitting of the intercooler radiator. Once the hoses are clocked properly without any kinks or improper bends, tighten the Oetiker clamps in place with Oetiker pliers. 50. Slide the mesh sleeve over the exposed portions of the hose and joiner assembly and cut to length.
53. From the front of the vehicle, feed the end of the fan harness with the ground eyelets through the gap between the radiator and support rails on the passenger side of the vehicle. Feed the harness until the fuse holders are inside the engine compartment and the relays, fan connectors and temperature sensor connector are in front of the radiator (roughly to the yellow arrow in the image in step 52). 54.
57. Locate the two brackets (PN: XX032770009) and the supplied power steering cooler (PN: SET50-910-7612). The bolt holes on the brackets are offset, with the holes being closer to one edge. Be sure to position the brackets such that the side of the bracket with the holes closest to the edge is next to the cooler (as shown). 58. Attach the brackets to the cooler using the four (4) 1/4-20 Nylon insert lock nuts and 1/4-20x3/4” button head cap screws supplied with this kit.
61. Using a 13mm socket, loosen the top bolts, one on each brace. 62. Then loosen the bottom bolts, these are located between the impact bar and AC condenser. 63. Remove the passenger side brace above the power steering cooler by removing the upper and lower bolts with a 13mm socket. 64. Using a 1/4” bit, drill three holes in the bracket with proper spacing for the relays to mount side by side.
65. Install the three relays from the supplied wiring harness as shown using the three supplied 1/4-20x1-1/4 stainless socket head cap screws and three of the 1/4-20 Nylon insert lock nuts. 66. Re-install the brace. 67. Tighten the top bolts, while pushing up and out on the brace to allow the most room for the power steering cooler. 68. Torque the four bolts to 20 lb-ft (27 Nm). using a 13mm socket.
69. Mark the locations for the holes for mounting the power steering cooler with a scribe or marker pen. 70. Make sure your hole locations do not line up with the two weld marks in the bumper beam (examples shown here). 71. Using a punch, mark the center of the holes. Now drill out the holes using the supplied #2 carbide drill bit.
73. Remove the plastic plugs from the supplied power steering heat exchanger. Apply a light coating of oil or o-ring safe assembly lubricant to the threads of the 3/8” push to lock 90 degree fittings (PN: SET22M22PL06-90). Install the 90 degree hose end fittings into the power steering cooler as shown. 74. Slide the supplied 17mm Oetiker clamps (PN: 52545K55) over the 3/8 hoses from Step 72 and then push the hoses (PN: H1937) onto the barbed ends of the fittings.
77. Insert one end of each of the two supplied brass barbed unions (PN: LN-TT23) into the ends of the power steering hoses that are attached to the power steering cooler. 78. Slide one piece of the supplied shrink tubing over each hose section and then install one 17mm Oetiker clamp (PN: 52545K55) onto each of the hoses. Use the Oetiker pliers to secure the brass barbs into place. 79. Connect the OEM power steering hoses, from the rack and P/S pump, to the brass barbs.
81. Flip the cap open that is covering the positive terminal beside the fuse block. 82. Using a 13mm wrench undo the nut on the stud. 83. Connect the main power wires with eyelets from the fan harness, two orange and one red, to the stud. 84. Route the 6 pin TBRC connector from the fan harness around the back side of the fuse block ending in the pocket of space just to the front of the strut tower.
85. Connect the TBRC-001 relay controller to the 6 pin connector. 86. Set the activation temperatures and sensor type. Recommended temperatures are 90 degrees F for fans on low and 110 degrees F for fans on high with a 10 degree hysteresis as shown in the picture to the left. Temp 1: 0 on the x100 and 9 on the x10 Temp 2: 1 on the x100 and 1 on the x10 Hysteresis: 1 on the 16 position switch. 87.
89. Stick the other side to the recently cleaned area on the car. 90. Replace the TBRC-001 and make sure the two sides of the tape are engaged. 91. Find the fuse holders in the supplied fan harness and insert the three 15 amp fuses in the fuse holders and then install the fuse covers over them. 92. Position the fuse holders on the vertical surface of the passenger side OEM plastic cover. Using a marking pen, mark the locations for drilling the mounting holes.
93. Remove the OEM plastic cover and drill three 1/4” holes in the marked locations. 94. Re-install the OEM plastic cover and install the fuse holders using the three (3) supplied Christmas tree style push fasteners (PN MP1026). 95. On the passenger side of the vehicle near the headlight, locate the ground bolt that is behind the rubber flap as shown in the image to the left. 96.
97. Place the three ground eyelets from the fan harness over the hole, reinstall the bolt, and torque to 11 lb-ft (15 Nm). 98. LPE recommends that the LPE CTS-V Varimax intercooler pump kit (PN:L330030709) be used to maximize the effectiveness of the high capacity intercooler radiator. Steps 99 to 104 apply when using this intercooler pump upgrade kit. If you are using the stock intercooler pump, skip to step 105. 99. Strip the end of the un-terminated orange wire. 100.
101. Push the seal up till it is under the long tabs, crimp the long tabs around the seal. 102. Insert the terminal into the single pin connector and push firmly to seat it. Snap the terminal position assurance (TPA) clip down over the seal, locking it into position. 103. Route the orange wire down between the OEM wiring harness and the frame, so that it ends up underneath by the intercooler pump. 104. For the Varimax pump, connect the single pin connector to the Varimax coolant pump jumper harness.
105. If you are retaining the stock intercooler pump you will need to connect the orange wire to a switched +12v power source (for example, at the intercooler pump connector or under the fuse block). Be sure to use sealed connectors or heat shrink over the splice in order to make sure it is sealed from the environment. Do NOT use unsealed connectors. 106. The 3-pin Weatherpack connector located near the TBRC connector is for an optional timer relay control.
109. Re-connect the battery. 110. Fill the intercooler system. Run the pump to prime and get the bubbles out, being sure to keep the reservoir filled. Use a 12 volt battery jumper pack or jumper harness to the battery to power the pump. NOTE: It is very important to get all of the air out of the system. 111. Check the power steering fluid level, top off the reservoir. 112. Turn the steering wheel lock to lock 20 times and check the level again.
113. Make sure everything is clear of the engine accessory drive and of the electric fans. Start the engine and repeat step 112 with the engine running. 114. Shut off the vehicle and check the power steering system and intercooler fluid system for leaks. Check all hoses and attachment points for leaks. Note: It is recommended to do this step before re-installing the fascia and other components in case a leak is found and to make it easier to identify a leak quickly. 115.
117. Zip-tie the inlet hose to the tab that used to hold the power steering lines. 118. Zip-tie the outlet hose to the fans on the back of the intercooler. 119. Zip-tie the power steering lines to the bottom of the fans on the radiator. 120. Make sure the hoses are well secured and above the bottom of the intercooler to prevent the hoses from being snagged while driving.
121. Carefully place the facia on the car. Start the bolts accessed from the wheel well but do not tighten them at this time. 122. Connect the hose to the washer fluid pump. 123. Re-connect the fog lights. 124. Secure the rubber shrowds on either side of the radiator with the Christmas tree fasteners (two per side).
125. Install the M6x1.0 screws that secure the fascia to the bumper core support using a 10mm socket. 126. Install the two (2) push fasteners on each side of the fascia. 127. Check that the bumper is aligned with the body panels and now torque the side bolts, accessed from the wheel wells, to 18 lb-in (2 Nm). 128. Install the front fender liners, and secure with 8 push pins.
129. Install the engine splash shields and secure with four (4) push pins. 130. Install the front air deflector under the engine. 131. Install the sight shield and secure in place with the six plastic retainer clips (clockwise to tighten). 132. Install the front wheels. Have an assistant hold the brakes while you torque the lug nuts to 140 lb-ft (190 Nm). Use a star pattern to tighten.
133. Lower the car back on the ground. Test drive the vehicle and then check the vehicle again for leaks. Congratulations, the installation of your LPE High Capacity Intercooler Radiator is complete. A note about the auxiliary fan operation: If you used the settings described in this instruction manual, your intercooler fans should operate as follows: • As the fluid warms up, both fans turn on low speed at 90 degrees F intercooler fluid temperature.
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 L320030709 CTS-V intercooler radiator v1.00.
