Está en la página 1de 18

1

INSTRUCTIONS
FAST LSXRT 102mm Intake Manifold Part #146602 Cathedral Port Before You Begin:
Please review the packaging contents listed on page 17 to ensure you have all hardware and read the complete instructions, especially the torque specs on pages 14-15, before installation. Notes: This intake will fit many applications including GM trucks with the 4.8L, 5.3L, and 6.0L from 1999 to present with cathedral port heads. It also fits other street and race applications with cathedral port heads (LS1, LS2, LS6) where hood clearance is not an issue.

Specific application years specified are to be used as a guideline only!


GM is known to make changes in the middle of a production year. For example; 2002 GM trucks/SUVs can have a cable driven or electronic throttle body, along with other changes. Also the 2007 production year has both the Classic and New body styles, which have many differing parts also. LSXRT Requirements; 1) LSXRT Manifolds REQUIRE you to select a fuel rail mounting kit depending on which specific application you have. (See page 12) 2) 2003-2004 GM Trucks/SUV REQUIRE FAST Throttle Body Adapter Plate #146029-KIT (See page 9). 3) 1999-2002 GM Trucks/SUV REQUIRE FAST Big Mouth 102mm or 92mm Throttle Bodies (see page 8) along with GM Purge Solenoid #12582627 for use with FAST Billet Throttle Bodies (see page 10).

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
Overview of Attachment Points and Ports:

1. Optional front brake booster vacuum port Open to plenum, seal with supplied cap in not used. There is another brake booster port in the rear of the intake. 2. PCV Open to plenum, seal if not used. 3. Fuel pressure regulator vacuum Sealed, drill through if applicable. 4. Optional front MAP sensor location Sealed, drill through if applicable. There is another MAP sensor port in the rear of the intake. 5. Throttle cable bracket hold down If applicable, must use the supplied self-tapping screw & washer combo along with extra thick washer. 6. Intake Resonator Attachment If applicable must use supplied self-tapping screw & washer combo along with extra thick washer. 7. Purge Solenoid Direct Mount Sealed, drill through if applicable. 8. Fuel Rail Mounted Purge Solenoid Sealed, drill through if applicable. Not pictured: 1) Rear MAP sensor port Sealed, drill through if applicable. 2) Rear Brake booster port Open to plenum.
FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
3) Small Rear vacuum port Open to plenum. Seal if not used. 4) EGR port Passenger side of throttle body, sealed, open if applicable. Stock Manifold Disassembly: 1) Allow engine to cool, disconnect the negative battery cable and remove engine covers, if applicable. Relieve fuel pressure by depressing the Schrader valve on the fuel rail. Cover with a towel to absorb lost fuel. 2) Clean off any excess dirt and debris around the intake manifold that could become dislodged and fall into your engine during removal. 3) Disconnect fuel line from rail by using quickconnect separator tool (J37088-A). Place shop towels around connection to catch additional gasoline. Some earlier applications also have a separate return line that also needs disconnected. 4) Unplug MAF connector and remove air cleaner assembly. 5) Remove or unplug MAP sensor, depending on application it may be located in the front or the rear of the manifold. 6) Disconnect any (if applicable) PCV hoses, vacuum lines, EGR, purge solenoid, brake booster line, fuel pressure regulator. Take note of positions for reinstallation. 7) If your application uses a cable driven throttle body disconnect the Throttle Position Sensor (TPS), Idle Air Control (IAC), and Intake Air Temp sensor (IAT). 8) If your application uses an electronic throttle body, disconnect it. 9) Unplug all 8 fuel injectors. 10) Loosen all 10 intake manifold bolts (8mm hex). 11) The stock manifold is ready to be removed, carefully lift the manifold and remove. 12) Clean any remaining dirt and debris that may dislodge and enter the engine.
FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
13) Cover the open cylinder head ports with a clean, lint free, rag to prevent anything from entering your engine. 14) Remove the four (4) fuel rail mounting bolts and remove the stock fuel rail and injectors as an assembly. 15) Remove injector clips using a screwdriver to gently pry them off. 16) Remove injectors from the fuel rail, remembering the fuel rail is still full of fuel. Take precautions to contain the excess fuel that will leak out. Rubber gloves and safety glasses are required.

Required Modifications: 1) IMPORTANT: Replace 10 valley plate bolts with the button head cap screws provided. Torque to 18ft/lbs. Failure to replace these bolts could damage the FAST manifold. 2) Coolant crossover lines modification may be required, such as slight bending of outlet tube for clearance and/or replacement may be required depending on application, use GM Part #12602544 front only crossover, and (2) #12602540 plugs for most custom, non GM truck/SUV applications. 3) Remove the upper shell from the manifold. There are five (5) upper shell hold down bolts pre-installed, two (2) in the front near the throttle body and three (3) in the rear of the LSXRT.
FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
4) Due to the wide range of applications the LSXRT was designed to fit, MAP sensor locations require drilling. There is a front and a rear location provided. Both are intentionally shipped plugged. 5) Find the MAP sensor location that will work with your specific application. It will then have to be drilled all the way through to allow the MAP sensor to read manifold vacuum. 6) There are two different MAP sensors that can be used. If your MAP is a grommet style, use a 3/8 drill bit to drill through the front MAP port location. If your MAP sensor is o-ring style you must drill out the front MAP sensor location with a 15/32 drill bit. Remove all shavings left over from drilling MAP sensor. 7) A MAP sensor hold down insert and bolt has been added to the LSXRT Intake to help hold MAP sensor tightly in position. The map sensor should not be past 19 in/lb, when attaching the MAP sensor to the LSXRT Intake. 8) There are also two purge valve/solenoid locations, again these are shipped sealed and you must select the correct placement for your specific application and drill though the intake, then remove all shaving. (See page 10) 9) If your vehicle is equipped with Exhaust Gas Recirculation (EGR) cut out the round EGR mounting hole on the passenger side of the intake manifold 10) If your vehicle has a fuel pressure regulator mounted to the fuel rail and requires manifold vacuum, drill out the fuel pressure regulator vacuum port. Its labeled #3, on page 2, and is pointing upwards out of the tip of the intake manifold. Before Installation in Vehicle: 1) Before reassembly reapply a small amount of RTV in the rear seal grove to ensure a proper reseal of the manifold upon reassembly.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
2) Carefully reinstall intake upper shell on to LSXRT Intake Manifold, making sure the upper lid has seated correctly into the lower shell all the way around. There are five (5) upper shell hold down bolts, two (2) in the front near the throttle body and three (3) in the rear of the LSXRT using medium strength thread locker and in the proper sequence as pictured. Torque upper shell bolts to 7089in/lbs. These were installed prior to shipping and were removed during upper lid removal. IMPORTANT: Failure to properly align the upper shell to the lower shell could damage the FAST manifold.
3) Flip the LSXRT over, there are three

circles molded into the base for rubber bumper installation. Because the bumpers are self-adhesive it is important to pre clean the base of the manifold where the bumpers are to be installed with a cleaner, such as isopropyl alcohol, and allowed to dry. Next install the three rubber bumpers included to the bottom side of the intake by sticking them onto the clean surface.

4) Inspect LSXRT Manifold, ensuring there are not any loose nuts or bolts may fall into your engine. 5) Before reinstalling previously used injectors inspect o-rings for damage. The OEM recommends new injector o-rings after disassembly, however replacement is not necessary if seals are not worn or damaged. Lubricate ALL o-rings with clean engine oil. Including upper and lower injector o-rings and injector spacer cup o-rings if applicable. 6) Install fuel injectors into your fuel rail and mount according to your specific applications instructions. 7) OEM GM truck injectors require a lower injector o-ring swap to work with the LSXRT. These o-rings have been supplied by FAST for you in your o-ring kit! 8) Install injectors and fuel rails into LSXRT Manifold. Carefully start all injectors in pockets, and then firmly seat one side at a time. Install fuel rails to intake manifold. Attach fuel rails to manifold following the fuel rail kit instructions. IMPORTANT: Do not reuse OEM fuel rail
FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
mounting bolts! Failure to replace these bolts with the ones supplied with FAST fuel rail kits may damage the FAST manifold. 9) Install supplied intake port seals. Failure to install these seals will cause massive vacuum leaks, causing a rough idle and possibly a dangerously lean condition. 10) Install throttle cable bracket if applicable using supplied self tapping screw and washer. You must also use a supplied 2nd washer, M6 x 16.5mm O.D. x 3.5mm thick flat washer also. 11) Install supplied PCV grommet and vacuum nipple if applicable (See page 13) WARNING: Failure to use the extra supplied washer may result in puncturing through the intake manifold into the plenum!!!!

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS

Throttle Body Options 1999-2002 GM Trucks & Custom Cable Applications: 1) FAST 92mm Throttle Bodies (1999-2002 GM trucks and custom applications) Part #54092 (92mm throttle body) Part #54095 (92mm throttle body with TPS) *We also offer IAC sensors if needed, Part #307059 2) FAST 102mm Throttle Bodies (1999-2002 GM trucks and custom applications) Part #54102 (102mm throttle body) Part #54103 (102mm throttle body with TPS) *We also offer IAC sensors if needed, Part #307059 NOTE: FAST 92mm and 102mm Throttle Bodies will NOT work on any engine with electronic throttle control installed from the factory, or any custom application ECU programmed for electronic throttle. Removal of the electronic throttle body will disable the engine via the ECU. All throttle bodies require M6x 10mm use of correct bolts supplied.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

INSTRUCTIONS
Electronic Throttle Body Options 2002-2007 (Classic Body Style) GM Trucks: 1) These years of GM trucks use a three-bolt mounting 75mm electronic throttle body that requires a FAST throttle body 102mm to 75mm adapter plate. This allows for reuse of the OEM electronic throttle body 75mm throttle body with the LSXRT manifold. Part #146029KIT. Notes: A) You cannot swap on a 2007+ OEM 90mm electronic throttle body as they are NOT interchangeable. B) 2003-2004 GM trucks may require slight adjustments to the fan shroud for fitment when using throttle body adapter plate for clearance.

Electronic Throttle Body Options 2007-Present (New Body Style) GM Trucks: 1) Use OEM 90mm electronic throttle body.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

10

INSTRUCTIONS
GM Truck Vapor Purge Valve/Solenoid Options 1999-2007 (Mounted on intake manifold): Find the purge valve on your GM truck, typically located on the front of the intake manifold on 19992007 GM trucks, above the throttle body. There are two types that mount to the intake. They can also be found on attached to the fuel rail on 2007+ trucks. If your purge valve is mounted to your intake use the hole on the left with the single bolt down hole. Drill the hole out with the 15/32 drill and install your purge valve and using the supplied self-tapping screw and attach to LSXRT. *If your purge valve is mounted to your fuel rail, see page 11.

Purge solenoid style #1, GM #12582627, will bolt on with no modifications and is required for use with FAST 102mm and 92mm Throttle bodies.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

11

INSTRUCTIONS
Purge solenoid style #2, GM #1997279, requires only slight trimming of some extra material around the base of the Purge solenoid as pictured before attaching it to the manifold with the included self tapping screw. Note: This solenoid will not work with FAST cable driven 102mm or 92mm throttle bodies. You must change to style #1 solenoid; GM #12582627 that is pictured on page 10.

GM Truck Vapor Purge Valve/Solenoid Options 2007+ (Mounted on Fuel Rail): Newer 2007+ GM trucks have a square tube fuel rail with the surge solenoid mounted on the fuel rail and connected to the intake. If you have this style Purge solenoid you will need a 15/32 drill bit to drill out the hole shown below and install the extra nipple and self-tapping screws supplied.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

12

INSTRUCTIONS
Fuel Rail Options: Note: If running GM truck/SUV fuel injectors, remember to change out the lower injector o-rings with the ones supplied.
1) FAST billet fuel rail kit custom fuel systems using GM truck or FAST LS2 fuel injectors.

Includes FAST billet fuel rails, mounting brackets, and AN fittings. See instructions for mounting details. #146028-KIT

2) OEM black plastic round fuel rail mounting kit GM Trucks/SUV 1999-2007 #146030-KIT 3) OEM metal square fuel rail mounting kit GM Trucks/SUV 2007+ #146031-KIT. For metal fuel rails with that have inside fuel rail to intake manifold mounting points. Generally new body style 2007+ 4.8L & 5.3L engines 4) 4) OEM metal square fuel rail mounting kit GM Trucks/SUV 2007+ #146032-KIT. For metal fuel rails with that have outside mounting points. Generally new body style 2007+ 6.0L and 6.2L engines. Individual Runner Removal (Not Required): 1) Remove intake from engine if installed. 2) Remove the upper shell from intake, being sure to account for any loose hardware, to expose runners. 3) Using a T-20 Torx, remove the runner hold down bolt for each individual runner.
FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

13

INSTRUCTIONS
Individual Runner Reinstallation: 1) To facilitate assembly of the runner tube and to minimize potential damage to the o-ring, the customer should apply a light coating of soap-water solution to the o-rings. The soap water solution can be made with 1 tablespoon of gentle hand soap in 1 cup of warm water, which should be mixed well. 2) Install the rear most runner first and work your way to the front. 3) While holding the runner tube into the pocket of the lower manifold with light but firm force to install the runner into the pocket, the M4 screws should be torqued to 19 in/lb. tightening the screws beyond this can result in stripping of the fastener or damaging of the inserts and is not necessary. 4) Thread-locker has been provided on the fasteners. Additional thread-locker should not be necessary but can be reapplied if the thread-locker is removed through repeat installation/removal of the runners. 5) For best engine performance the runner tube o-ring should always be used. Should your o-ring require replacement, these can be ordered individually (Part #146006-1). They can also be ordered as a set of eight (Part #146006-8). Caution: Do not remove the upper lid to expose the individual runner while the intake is still on the engine. The nuts that were previously installed to hold the upper and lower together may into your engine and cause catastrophic engine failure PCV Modification: 2002-2007 GM trucks/SUVs with electronic throttle bodies require a slight modification to the PCV system. The OEM manifold has a Fresh/Makeup air on the passenger side front of the intake manifold, just behind the throttle body. If you have this you must install the supplied rubber grommet and 90 degree barbed hose fitting in your intake system between your MAF sensor and your throttle body.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

14

INSTRUCTIONS
To install, select a spot between your MAF and throttle body that your factory PCV hose will reach and that you can reach with your hand from within the intake system. 1) Use a drill bit to drill out a place to install your supplied grommet. 2) Install grommet. 3) Reach inside the intake assembly and push the 3/8 hose barb through the grommet, face the inside barb towards the MAF 4) Reconnect factory hose using supplied hose clamp.

Manifold to Engine Assembly: 1) Reconnect coolant crossover line hose. Torque crossover pipe bolts to 70-89 in/lbs 2) Place manifold in valley but do not place all the way rearward. Attach brake booster hose, push in MAP sensor by sliding in small vacuum nipple, MAP sensor bolt down insert threads are also provided with the LSXRT. Reconnect MAP sensor to harness.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

15

INSTRUCTIONS
3) Move manifold into position. DO NOT SLIDE MANIFOLD ON CYLINDER HEAD because seals could be damaged or become dislodged. Once in correct position, the bolt bosses will find counter bores in cylinder heads. 4) Add medium strength thread lock to all (10) intake bolt threads hand start all (10) fasteners. Dont forget the fuel rail stop bracket(s), if required. 5) Using two passes in the sequence shown on page13. First pass (45in/lbs), final pass (89in/lbs). Caution: Over-torquing will damage the manifold and cause improper sealing! 6) Ensure throttle body seal is installed. Next, install four (4) supplied M6 x 40mm bolts and throttle body, torque to 70-89 in/lbs. IMPORTANT: Do not reuse your OEM throttle body bolts. Failure to replace these bolts as listed in this step could damage the FAST manifold. 7) Reconnect any PCV hose on manifold previously removed, reconnect all 8 fuel injector wire connectors, finally reconnect MAF sensor and induction system. 8) Add a few drops of clean engine oil to the male end and securely reconnect fuel line to rail. 9) Reconnect the battery and check for fuel leaks before starting the engine by cycling the key a few times to build pressure in the fuel system. 10) After the engine has started, again recheck for any fuel leaks.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

16

INSTRUCTIONS
Optional Modifications: Your FAST LSXRT Manifold can be purchased in individual components:
FAST (Part #) 146201 146650 146100 146004 146203-1 146203-8 146006-1 146006-8 54092 54193 54102 54103 Lower Shell LSXRT Cathedral Port Runner Set LSXRT Upper Shell 102mm Throttle Body Seal 102mm Cylinder Head Port Seal Cylinder Head Port Seals Runner Seal Runner Seals FAST 92mm Billet Throttle Body (Non ETC) FAST 102mm Billet Throttle Body w/ TPS (Non ETC) FAST 102mm Billet Throttle Body (Non ETC) FAST 102mm Billet Throttle Body w/TPS (Non ETC) 1 Description QTY 1 8 1 1 1 8 1 8 1 1 1

The LSXRT has the capabilities for the following performance modifications: 1) The intake manifold runners can be REMOVED and ported, or simply port matched, by removing material near the port. PORTING IS NOT REQUIRED and should be done by professionals only. CAUTION: Improper porting can have severe negative impact on performance as well as permanently destroy the intake lower shell, runners, or both. 2) Nitrous boss can be tapped. 1/8 NPT max.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

17

INSTRUCTIONS
Package Contents
Hardware Included In Packet #CF007-583 2 4 1 5 10 13 10 Torx T-20x 10mm Self tapping screw (Purge valve nipple hold down) M6 x 40mm Socket Head Cap Screws (OEM Electronic Throttle Bodies) M4 x 20mm T-20 Torx head screw (MAP sensor hold down) 10mm x 20mm long, Self tapping screws (Purge valve hold down, throttle cable hold down, EGR) M6 x 110mm Socket Head Cap Screws (Bolts manifold to cylinder heads and upper shell) M6 x 16.5mm O.D. x 3.5mm Thick Flat Washer (Manifold to cylinder head bolts, throttle cable hold down) M8 x 30mm Button Head Cap Screws (Replacement OEM valley plate bolts)

Hardware Pre-Installed In LSXRT Manifold #146606 3 2 8 M6 x 16mm Socket Head Cap Screws (Rear upper shell hold down) M6 x 40mm Socket Head Cap Screws (Front upper shell hold down) M4 x 20mm T-20 Torx head screw (Runner hold down)

O-Ring Gasket Included in Package 1 1 3 2 8 8 1 1 1 Nipple (Fuel rail mounted purge valve) 102mm seal (Throttle body) Rubber bumpers (Bottom of manifold) Vacuum Plugs (Brake booster ports) Fuel Injector O-Rings (GM truck fuel injector lower o-rings) Intake Port seals (Cylinder head to manifold) 90 Degree Barbed Elbow Rubber Grommet Hose clamp

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

18

INSTRUCTIONS
Limited Warranty FAST, Inc. warrants that all of its products are free from defects in material and workmanship for a period of 1 year from the date of purchase. This limited warranty shall cover the original purchaser. FAST, Inc.s obligation under this warranty is limited to the repair or replacement of its product. To make a warranty claim, the part must be returned within 1 year of purchase to the address listed below, freight prepaid. Items covered under warranty will be returned to you freight collect. It is the responsibility of the installer to ensure that all of the components are correct before installation. We assume no liability for any errors made in tolerances, component selection, or installation. There is absolutely no warranty on the following: Any parts used in racing applications. Any product that has been physically altered, improperly installed or maintained. Any product used in improper applications, abused, or not used in conjunction with the proper parts. Damage due to excessive manifold pressure, i.e. nitrous backfires, engine misfire, etc. There are no implied warranties of merchantability or fitness for a particular purpose. There are no warranties, which extend beyond the description of the face hereof. FAST, Inc. will not be responsible for incidental and consequential damages, property damage or personal injury damages to the extent permitted by law. Where required by law, implied warranties or merchantability and fitness are limited to a term of 1 year from the date of original purchase. This warranty gives you specific legal rights and you may also have other legal rights, which vary from state to state.

FAST 3400 Democrat Rd. Memphis, TN 38118 366-1807 Phone: (901) 260-3278 Fax: (901) 375-3408 www.fuelairspark.com

Part #FAST4-164 Part #??? Revised 8/10/10 Revised ??????

También podría gustarte