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2005 Chevy 2500HD Air Compressor - Compressed Air Anywhere

How To Install An Onboard Air-Compressor System
By Trevor Reed
Photography by Trevor Reed
2005 Chevy 2500Hd Front On Lift
2005 Chevy 2500Hd Kilby Air Kit
This '05 Chevy 2500HD has... 
   
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2005 Chevy 2500Hd Kilby Air Kit
This '05 Chevy 2500HD has already been modified for off-roading and long-haul towing. The Kilby onboard air kit comes with an air tank, a compressor, a power switch, an air manifold with pressure gauge, a coalescing filter to keep lubricating oil out of the air lines, quick-connect fittings for the front and rear of the truck, air lines, and brass fittings for all connections. The kit is designed to fit a stock truck, so a few modifications were needed for this 4x4 tow rig, such as a smaller air tank than the one here to fit in the space available next to an auxiliary fuel tank.
2005 Chevy 2500Hd Disconnect Negative Battery
1. Disconnect the negative... 
   
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2005 Chevy 2500Hd Disconnect Negative Battery
1. Disconnect the negative battery terminals. Remove the serpentine belt from the engine by loosening the tensioner with a long wrench and a sleeve for maximum leverage. Don't be afraid to ask for help (it's better than explaining how you gave yourself a black eye with a wrench) because you'll need at least one buddy to assist with the install if you want it done in less than half a day.
2005 Chevy 2500Hd Remove Bolts
2. Remove the driver-side... 
   
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2005 Chevy 2500Hd Remove Bolts
2. Remove the driver-side bolts on the top of the air-conditioning compressor and temporarily mount the air-compressor bracket to check for clearances. This truck has an aftermarket engine programmer and supports a large stereo system that adds lots of wires and inline fuses to the engine bay, so many of the cables had to be rerouted.
2005 Chevy 2500Hd Install Clutch Assembly
3. Install the clutch assembly... 
   
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2005 Chevy 2500Hd Install Clutch Assembly
3. Install the clutch assembly onto the compressor and mark the keyway on the clutch housing with some paint so you can tell when the wheel is in a position where the compressor oil can be checked.
2005 Chevy 2500Hd Bolt Mounting Brackets
4. Bolt the mounting bracket... 
   
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2005 Chevy 2500Hd Bolt Mounting Brackets
4. Bolt the mounting bracket to the air compressor before installing it into the engine bay. This is one of the steps where you'll need a buddy so he can hold the compressor level while you bolt it in. This will ensure the vibration of the engine does not loosen it...
2005 Chevy 2500Hd Bolt Air Compressor
...The air compressor can... 
   
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2005 Chevy 2500Hd Bolt Air Compressor
...The air compressor can be mounted horizontally or vertically. The vertical mounting did not leave enough clearance under the stock hood in this application.
2005 Chevy 2500Hd Serpentine Belt
5. GM uses a six-rib serpentine... 
   
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2005 Chevy 2500Hd Serpentine Belt
5. GM uses a six-rib serpentine belt but doesn't use one long enough for this application, so a Ford Power Stroke eight-rib belt is relieved of two ribs. Make sure to know which engine your truck has before you order this kit. In 2005 alone, there are four different stock belt lengths for the LLY Duramax...
2005 Chevy 2500Hd Install Belt
...This version of the LLY... 
   
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2005 Chevy 2500Hd Install Belt
...This version of the LLY (single alternator with A/C and vacuum pump) requires the installation of some smaller idler pulleys in the accessory drive so the belt will fit properly.

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Jeep Grand Cherokee Research
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