Ty1642
Member
Here is a walkthrough of my installation of the SyTy Alky Control kit. I pretty much followed the directions in the kit, but I’ll point out where I did a few things differently. One of the things I try to avoid is making permanent mods to the truck – most of the things I did differently were because of that.
The Alky Control kit is nice –Julio Don gives you everything you need and it all seems to be put together well. Here’s a photo of the kit. There are one or two extra parts in here that Julio made for me also – if you don’t see any of these things in your kit, that’s probably why.
1. HARDWARE INSTALLATION
The first thing I did was to install the new smaller overflow tank and reroute the lines from the radiator and the CAC. The instructions have this at the end, but by doing it first I could take my time with the other work and still drive the truck.
I still have the stock crossover pipe, but removed the stock airbox. I attached the overflow tank to the bracket that the airbox was attached to. This photo shows the bracket:
You can see two bolts at the top holding the bracket on. If you remove those, the bracket lifts out. Once you have it out, there is a plastic duct attached to it that routed air into the filter. The duct pops right out. I then zip-tied the bottle to the bracket.
There are two hoses included with the kit – one for the CAC vent and one for the radiator. I attached the radiator hose to the bottom fitting on the new overflow tank, and the CAC hose to the top fitting. (Julio’s kit includes a clear hose for the CAC – I had an extra black hose and used that instead.)
Once the hoses were attached, the bracket bolts right back in and the lines attach at the other ends. I tucked the lines on top of the radiator and in front of the crossover tube. They aren’t fastened down but they don’t seem to move around.
After driving the truck around for a week or so, I noticed that the bottle seemed to be slipping down from the weight of the coolant. I added a third zip-tie and tightened the other two, and it seems to have been fine since:
The next step was installing the alky nozzle in the CAC. I couldn’t come up with a better way to do this, so I bought a spare CAC to keep my original unmodded. To remove your CAC, first you need to drain the coolant using the valve on the lower heat exchanger. Remove the hose from the turbo, the upper and lower coolant lines, the overflow line, and loosen the hose clamps on the 3” hose connecting the CAC to the throttle body. There are 3 bolts under the CAC holding it to the mounting brackets – remove those and lift the CAC out. Watch for coolant still in the CAC.
The nozzle goes in the bottom of the CAC outlet, pointing up. Drill a 3/8 inch hole – I had to open it up a bit before the nozzle would fit in. When the hose between the CAC and throttle body goes on later, the hose and hose clamp will need to be cut away a bit to fit around the nozzle, so the closer the hole for the nozzle is to the CAC body, the better. (But make sure the nozzle will still seal tight against the CAC.)
The Alky Control kit includes rubber & steel washers to go on both the inside and outside of the CAC. Because the aluminum is so thick, only one set of washers will fit. I put them on the inside and put a little red loctite on the nozzle threads before installing it on the CAC. Be careful – there is a small wire mesh filter inside the nozzle tip – don’t get any loctite on it.
Put a little bit of Teflon tape on the male-male fitting and thread it into the nozzle. The fitting should point towards the rear of the truck when the CAC is installed.
While I was at it, I put aluminized heat wrap on the outside of the CAC, and bellmouthed the inlet from the turbo.
The pump goes in next. After removing the battery and unbolting the 3 bolts holding the tray, I removed the 2 screws holding the vacuum ball to the bottom of the tray. The next photo shows the area under the battery tray – the pump is going to sit on the flat shelf in front of the inner fender. The two large hoses are 3/4” heater hoses where I previously rerouted the CAC lines through the inner fender.
The pump is attached to a small metal plate with four rubber feet. The pump motor faces towards the front of the truck, with the inlet side of the pump facing the motor, and the outlet side facing the fender. The kit instructions tell you to drill holes in the flat panel in front of the inner fender, and bolt the pump to the panel. Since I didn’t want to drill any holes in the truck I installed the pump slightly differently. I found this metal plate at Home Depot in the lumber section (with the various metal brackets used to build wood decks):
The plate fits perfectly in the area where the pump is to go. At the back of the metal shelf that the pump is to install on, there are 3 holes where the inner fender is bolted to the shelf. I drilled four holes in my Home Depot plate to attach the pump, and two more holes to line up with the outer two fender attachment holes. I attached the pump to the Home Depot plate using the bolts in the Alky kit. The pump has a ground wire with a ring terminal on it – one of the bolts was run through the ring terminal so the pump was grounded to the metal plate. There are brass fittings that attach to the inlet and outlet side of the pump – I installed those now. The directions tell you to turn them hand tight, and then one more turn. The pump head is plastic, so overtightening the fittings can crack the pump. Here is the pump on the mounting plate, ready to go in the truck:
I ran 2 bolts up through the outer fender mounting holes, with big flat washers to keep them in place. I put a couple of nuts on top of the bolts, then set the mounting plate on those, and used two more nuts to tighten it down. The nuts under the plate space it up slightly from the shelf – they are needed because the heads of the four pump mounting bolts are under the plate and the shelf that the plate attaches to isn’t completely flat.
On my truck the inner fender doesn’t line up with these mounting holes. (I ‘adjusted’ the fender with a rubber mallet when I installed my PTE turbo because the wastegate actuator didn’t clear.) If your fender is straight, you should still be able to attach the pump the same way I did, but you will need to unbolt it in the future if you want to remove the inner fender.
Here is the pump bolted into the truck. It is a pretty tight fit – the pump should be installed far enough towards the front of the truck that the outlet hose will have a fairly straight shot into the inner fender.
Next the CAC went on. The 3” hose from the CAC to the throttle body needs to be notched to fit around the spray nozzle on the bottom of the CAC. Don’t cut too much away, so there aren’t vacuum / boost leaks when everything is put back together. The hose clamp also needs to be ground down to fit around the nozzle.
Once the hose and clamp are attached to the CAC, attach the longer braided steel fuel line to the nozzle, and then install the CAC back in the truck:
Attach the fuel filter from the Alky Control kit to the fuel line from the CAC. The arrow on the filter points in the direction of fuel flow. The fuel line routes around the back of the CAC, in front of the heater box, and into the inner fender. I bought some extra wire loom and covered the fuel line with it, to keep the installation stealthy:
Attach the shorter braided fuel line to the outlet side of the Alky pump, and run it into the inner fender. When tightening the fuel line to the pump, use two wrenches so that the brass fitting on the pump doesn’t get overtightened. Attach the other end of the short hose to the inlet side of the fuel filter:
The Alky Control kit is nice –Julio Don gives you everything you need and it all seems to be put together well. Here’s a photo of the kit. There are one or two extra parts in here that Julio made for me also – if you don’t see any of these things in your kit, that’s probably why.
1. HARDWARE INSTALLATION
The first thing I did was to install the new smaller overflow tank and reroute the lines from the radiator and the CAC. The instructions have this at the end, but by doing it first I could take my time with the other work and still drive the truck.
I still have the stock crossover pipe, but removed the stock airbox. I attached the overflow tank to the bracket that the airbox was attached to. This photo shows the bracket:
You can see two bolts at the top holding the bracket on. If you remove those, the bracket lifts out. Once you have it out, there is a plastic duct attached to it that routed air into the filter. The duct pops right out. I then zip-tied the bottle to the bracket.
There are two hoses included with the kit – one for the CAC vent and one for the radiator. I attached the radiator hose to the bottom fitting on the new overflow tank, and the CAC hose to the top fitting. (Julio’s kit includes a clear hose for the CAC – I had an extra black hose and used that instead.)
Once the hoses were attached, the bracket bolts right back in and the lines attach at the other ends. I tucked the lines on top of the radiator and in front of the crossover tube. They aren’t fastened down but they don’t seem to move around.
After driving the truck around for a week or so, I noticed that the bottle seemed to be slipping down from the weight of the coolant. I added a third zip-tie and tightened the other two, and it seems to have been fine since:
The next step was installing the alky nozzle in the CAC. I couldn’t come up with a better way to do this, so I bought a spare CAC to keep my original unmodded. To remove your CAC, first you need to drain the coolant using the valve on the lower heat exchanger. Remove the hose from the turbo, the upper and lower coolant lines, the overflow line, and loosen the hose clamps on the 3” hose connecting the CAC to the throttle body. There are 3 bolts under the CAC holding it to the mounting brackets – remove those and lift the CAC out. Watch for coolant still in the CAC.
The nozzle goes in the bottom of the CAC outlet, pointing up. Drill a 3/8 inch hole – I had to open it up a bit before the nozzle would fit in. When the hose between the CAC and throttle body goes on later, the hose and hose clamp will need to be cut away a bit to fit around the nozzle, so the closer the hole for the nozzle is to the CAC body, the better. (But make sure the nozzle will still seal tight against the CAC.)
The Alky Control kit includes rubber & steel washers to go on both the inside and outside of the CAC. Because the aluminum is so thick, only one set of washers will fit. I put them on the inside and put a little red loctite on the nozzle threads before installing it on the CAC. Be careful – there is a small wire mesh filter inside the nozzle tip – don’t get any loctite on it.
Put a little bit of Teflon tape on the male-male fitting and thread it into the nozzle. The fitting should point towards the rear of the truck when the CAC is installed.
While I was at it, I put aluminized heat wrap on the outside of the CAC, and bellmouthed the inlet from the turbo.
The pump goes in next. After removing the battery and unbolting the 3 bolts holding the tray, I removed the 2 screws holding the vacuum ball to the bottom of the tray. The next photo shows the area under the battery tray – the pump is going to sit on the flat shelf in front of the inner fender. The two large hoses are 3/4” heater hoses where I previously rerouted the CAC lines through the inner fender.
The pump is attached to a small metal plate with four rubber feet. The pump motor faces towards the front of the truck, with the inlet side of the pump facing the motor, and the outlet side facing the fender. The kit instructions tell you to drill holes in the flat panel in front of the inner fender, and bolt the pump to the panel. Since I didn’t want to drill any holes in the truck I installed the pump slightly differently. I found this metal plate at Home Depot in the lumber section (with the various metal brackets used to build wood decks):
The plate fits perfectly in the area where the pump is to go. At the back of the metal shelf that the pump is to install on, there are 3 holes where the inner fender is bolted to the shelf. I drilled four holes in my Home Depot plate to attach the pump, and two more holes to line up with the outer two fender attachment holes. I attached the pump to the Home Depot plate using the bolts in the Alky kit. The pump has a ground wire with a ring terminal on it – one of the bolts was run through the ring terminal so the pump was grounded to the metal plate. There are brass fittings that attach to the inlet and outlet side of the pump – I installed those now. The directions tell you to turn them hand tight, and then one more turn. The pump head is plastic, so overtightening the fittings can crack the pump. Here is the pump on the mounting plate, ready to go in the truck:
I ran 2 bolts up through the outer fender mounting holes, with big flat washers to keep them in place. I put a couple of nuts on top of the bolts, then set the mounting plate on those, and used two more nuts to tighten it down. The nuts under the plate space it up slightly from the shelf – they are needed because the heads of the four pump mounting bolts are under the plate and the shelf that the plate attaches to isn’t completely flat.
On my truck the inner fender doesn’t line up with these mounting holes. (I ‘adjusted’ the fender with a rubber mallet when I installed my PTE turbo because the wastegate actuator didn’t clear.) If your fender is straight, you should still be able to attach the pump the same way I did, but you will need to unbolt it in the future if you want to remove the inner fender.
Here is the pump bolted into the truck. It is a pretty tight fit – the pump should be installed far enough towards the front of the truck that the outlet hose will have a fairly straight shot into the inner fender.
Next the CAC went on. The 3” hose from the CAC to the throttle body needs to be notched to fit around the spray nozzle on the bottom of the CAC. Don’t cut too much away, so there aren’t vacuum / boost leaks when everything is put back together. The hose clamp also needs to be ground down to fit around the nozzle.
Once the hose and clamp are attached to the CAC, attach the longer braided steel fuel line to the nozzle, and then install the CAC back in the truck:
Attach the fuel filter from the Alky Control kit to the fuel line from the CAC. The arrow on the filter points in the direction of fuel flow. The fuel line routes around the back of the CAC, in front of the heater box, and into the inner fender. I bought some extra wire loom and covered the fuel line with it, to keep the installation stealthy:
Attach the shorter braided fuel line to the outlet side of the Alky pump, and run it into the inner fender. When tightening the fuel line to the pump, use two wrenches so that the brass fitting on the pump doesn’t get overtightened. Attach the other end of the short hose to the inlet side of the fuel filter:
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