You have to take off the SC and intake manifold off. Take off the IC pump and you can get at bottom 2 bolts under the intake. They are a bitch! You can only turn those bolts a little at the time. You'll have to change around all the hoses that have anything to do with the intercooler (IC) system or whatever you wanna call it. So take off all the hoses as you take the car apart. I have a hoist in the shop I work at so that made it easy to get at all the hoses and stuff. So flip the 2 laminova cores (whatever ones the GM instructions say at http://www.crateenginedepot.com/store/pdfs/sidekit.pdf). Put the endplate on and put the intake and IC pump back on the car. Don't forget the bottom 2 intake bolts before the IC pump. haha

So asuming you already have the coolant bottle bolted in, and the 3/4" nipple on it pointing towards the front and towards the drivers side a bit. I ran the hose from the tank to the t-fitting down by where the SC pulley is. Make sure you tie the hose away from the belt and pulley good. Plan what stock hoses you're gonna reuse to make everthing line up right without kinks in the hoses. I started working from the dual pass endplate and out from there. You might have to cut sections out and use the straight and 90 degree 3/4" elbows to connect the hoses and lengthen them out. Watch out for the hose running from the coolant bottle to the t-fitting because it's kinda hard to run without interfering with the SC and belt. Just follow the GM instructions on the hoses. The pics I refered to which I printed are on page 5 and 6 at http://www.crateenginedepot.com/store/pdfs/sidekit.pdf. Just play around with all the hoses and make sure that you find out what one is best to use where before you start cutting them to make your connections. On page 6 where it points to the .040 orfice, thats what hooks to the top of the heat exchanger on the passenger side. you can look right in by where the hood latch it. I just used a wrench from there without taking off the plastic cover to get the pipe plug out. Thats where you screw the fitting in that takes 1/4" hose, the thread is 1/8"npt or 1/4"npt(sorry don't quite remember that one). The orfice is the part you break off the t fitting shown on page 4 of the instructions.

So basically get the two, 3/4" T-fittings( thats what I used becasue everyhing seems to fall into place better.
-5 feet of 3/4" hose
-3 feet of 1/4" hose
-bunch of clamps for both sizes
-small t-fitting to make the orfice
-some angled metal to make the brackets
-the stock Ion Redline coolant bottle
-a bunch of 90degree and straight 3/4" connectors


Once you get everthing hooked up, fill up the coolant resivor and it will go down a bit. Put on the SC, belt and everthing else. Fill the resivor back up and start the car making sure there's no leaks. Let the car warm up and keep checking for leaks. Go for a drive and check it periodicly making sure it's not too low and no leaks.

Your done!

I think I covered everthing. It's actually easier to do than it sounds, believe me. I though it was gonna be way harder to do but like I said, everything lines up pretty good.

i notice alot of extra parts, does the gm instructions have all the extra parts listed?

i was gonna buy it and have saturn put it in, is this something they can do?

keith-

Nice writeup, like you said, the most important factor when doing this is to ensure the 3/4" hose running from the resovoir to the first "t" fitting does not sit too close to the pulley as it will rub. This is especially so with the SS's. Not so much with the redlines as they have more clearence. I believe the threading for the NPT fitting is 11/16". Bill has a definite on that one as he had to re-thread the hole.

Ya the fitment of the 3/4" hose is really tight on my SS around the SC pulley. I ziptied it back just to make sure it wouldn't rub. Also found the fitting thread size is 1/8"NPT

no special gasket needed? and how's the Non-resevoir option work exactly?