D3 Performance Engineering

Chevrolet Corvette ZR1 Heat Exchanger System Install

Install:
1.) Remove front bumper.
2.) Drain OEM HX system, ten remove fa!tory eat e"!an#er, eat e"!an#er tan$, all lines
an% OEM pump usin# te fa!tory pro!e%ure.
&.) Remove OEM Inter!ooler flui% inlet manifol%.
'.) Remove OEM O(rin#s from inlet manifol% an% install onto supplie% D& )*) i# flo+ inlet
manifol%.
,.) Install D& )*) i# flo+ inlet manifol%s reusin# fa!tory fasteners an% tor-ue to
OEM spe!ifi!ations.
..) Install supplie% OEM HX entry ole blo!$ offs/ 0o+er 1teerin# !ooler mounts usin#
supplie% ar%+are, as so+n. 23mm "1.2, !ountersin$s to ol% te %u!tin#, .mm
"1.4!ountersin$s to ol% !ooler to bra!$et)
5.) Install supplie% stainless pump mountin# bra!$et to D&/ EM0 +ater pump usin# supplie%
3mm"1.2, !ounter sin$ ar%+are.

Install supplie% 3mm"1.2, stu% into trea% insert on ra%iator frame.
Install pump/bra!$et !ombination onto stu% an% ti#ten usin# lo!$ +aser an% flan#e% nut.
20ump %ire!tion so+n)

3.) Install supplie% lo+er flui% re!overy tan$ into %rivers si%e ra%iator support. 6e tan$ mounts
onto te e"istin# OEM +ater tan$ mountin# positions usin# te .mm"1.44, +asers an% lo!$
+asers provi%e%. 7eave ar%+are loose for no+.
8.) Install upper flui% re!overy tan$. 6e 9pper(mount bolts onto te e"istin# fen%er stu%
+ile te mi%(mount bra!$et bolts onto te upper bra!$et on te lo+er re!overy tan$.
1upplie% 1.,: I.D. !oupler ;oins te t+o tan$s. On!e te tan$ is bolte% into pla!e, ti#ten
te !lamps for te 1.,: I.D. !oupler.
14.) Install supplie% 2.,4:I.D. !oupler onto te lo+er flui% re!overy tan$ inlet tube an% ti#ten
one supplie% +orm !lamp to ol% it in pla!e,
On!e %one, sli%e upper fill ne!$ %o+n trou# en#ine !ompartment into te !oupler on te lo+er
flui% re!overy tan$. 0ull te tube to+ar%s te ra%iator srou% +it te lip an#in# over te
srou%, ti#ten te last !lamp 2it may be ne!essary to loosen te oter !lamp, ten reti#ten).
0osition as so+n to ave !learan!e for oo% !losure 2!learan!e +ill very ti#t). *o+ ti#ten all
ar%+are for te upper an% lo+er flui% re!overy tan$s.
11.) It is ne!essary to !ut t+o oles in te fan srou% to allo+ te ose to run from te
pump to te lo+er flui% re!over tan$. )ut oles 1.2,4: O.D. minimum ole sa+. 6e
oles +ill nee% to be rou#ly 1.44: from te front of te srou% an% 2.,4: up from te
bottom of te srou%.
12.) Install te lon# ar%line bet+een te pump an% lo+er flui% re!overy tan$. 9sin# te
supplie% 1.44: !oupler 2.44: lon# for te pump to te ar% line an% te &.44: lon# !oupler from
te ar%line to te lo+er re!overy tan$ 134 fittin#.
1&.) Install D& Heat E"!an#er onto vei!le. 6op bra!$et bolts onto front bumper support usin#
.mm"1.44 !ountersin$/flus mount rin# usin# te OEM ole lo!ate% in te !enter. 1i%e mounts
bolt to ra%iator mount usin# .mm"1.44 so!$et ea% bolts +it lo!$ +asers an% nuts.
1'.) Install 18: lon# 1.44: ose from eat e"!an#er outlet on %river si%e to upper flui% re!overy
tan$ an% ti#ten +it supplie% !lamps.

1,.) Install sort t+istin# ar%line from EM0 pump outlet port +it 2.44: lon# !oupler
off te pump. Har%line runs bet+een ra%iator an% ra%iator support en%in# bein% ra%iator.
<rom tere install &.44: lon# !oupler onto te ar%pipe an% install supplie% +ye se!tion
onto it. <rom tere atta! te supplie% 4.5,4: ID oses onto bot outlets. 6ese +ill run
to ea! ban$ of te )*) inter!ooler inlets. 6e oses +ill ave e"tra len#t to be
trimme% %epen%in# if you +ant to run all te oses up one si%e or on ea! si%e of te 1)
snout. =It +ill also be ne!essary to lo!ate te lar#e va!uum port tat !omes out near te
%rivers si%e )*) inter!ooler inlet, remove te ose off of it an% ben% it %o+n sli#tly to
ma$e room for te ose to slip over.
1..) 9sin# te lon# supplie% 1.44: ose se!tion, run tis from te HX inlet port an% run to+ar%s
te EM0 pump, ten run it trou# te ra%iator stay above te pump to+ar%s te bra$e %u!t ten
oo$in# aroun% te insi%e of te %u!t an% te ra%iator stay ten runnin# in te %ire!tion of te
ar%line outlet. 6is ose +ill be lon#er to also allo+in# trimmin# %epen%in# on ose routin# to
te super!ar#er inlets. Install supplie% +ye se!tion onto te ose an% run remainin# 4.5,4 ID
oses te same +ay as te oter set of oses. 1o you +ill ave one inlet an% one outlet ose
runnin# from ea! ban$ of !n! inlet manifol%s.
15.) >ire D&/1te+art EM0 pump into vei!le usin# supplie% manufa!turer %ia#ram.
13.) 7o!ate orn relo!ation bra!$et, ten pla!e on bumper support. Mar$, ten %rill ?: ole to
mount bra!$et. 9se supplie% .mm "1.44 !ountersin$s an% flus +aser, nut, lo!$ +aser to bolt
bra!$et to support. Ma$e sure to #rin% paint a+ay from te boltin# lo!ation so te orns !an ave
a proper #roun%. If you %o not +ant to #rin% it, a #roun% +ire !an be ma%e an% ran from a $no+n
#oo% #roun% lo!ation to te orn bra!$et.
6en use same bolts to fasten orn to bra!$et.
18.) Remove te ambient air temperature sensor out of te ra%iator %u!t an% reinstall
in ole in sub(frame. Remove front air %am atta!e% to te front bumper, it is also
re-uires to ben% %o+n te tree tabs tat te air %am use% to bolt to.
==*o+ fill system +it flui% until it !omes up to te !ap level. 6en !y!le pump to su!$ flui%
%o+n, ten refill an% !y!lin# a#ain. Do tis until te pump is fe% a stea%y stream of flui%. 6en
run te pump !ontinuously a%%in# flui% to te system as nee%e%. >it te system !ompletely
full you +ill +ant a flui% level about & in!es from te !ap.
24.) Reinstall bumper usin# te OEM pro!e%ure, use supplie% spa!ers +it flus mount +asers
an% 2.44: lon# @3 s!re+s on bottom t+o oles on te si%es of te apron mountin# lo!ations.
*ote +it te HX in te front it +ill be ar%er to #et bumper on an% +ill re-uire a little more
+or$ ten normal.
Hol% fle"ible apron up +it .mm "1.44 bolts, +asers an% nuts to bumper.