2004 GMC Sierra Engine Upgrades Project Novakane

Part V It's as addicting as Rock Band, Facebook, and texting, combined. Horsepower-once it gets into your veins, there is no turning back. After doing several basic modifications (including Banks air intake, headers, exhaust, and programmer) to our '04 GMC Sierra, dubbed Novakane, and seeing immediate results, the desire to go faster never relinquished its stronghold. Knowing our tired 4.8L, with 150,000 miles on the odometer, wouldn't hold up much longer to the extreme abuse we were putting it through, we opted to make the most of its last days by bolting on the same parts you may be considering for your truck. Rather than pull the engine, we left it in place, and we also didn't remove the factory aluminum heads thinking the average Joe wouldn't want to pull them either. For the shade tree mechanic, all of these installs could be done in your garage and depending on your engine's history and modifications, you could expect similar horsepower increases.

Nitrous. That word either brings curiosity or a big smile to your face. There are many myths about nitrous, but the fact is, if you install it correctly on a healthy engine, it will produce more horsepower per dollar than any other mod. We bolted on a NOS drive-by-wire wet kit from Holley and were amazed at how easy each part was to install. The kit included everything we needed, looked great once installed, and performed beyond expectations.

Electric fans are finally being used on most new 1/2-ton trucks because the manufacturers realized what we've known all along, the initial cost is quickly an afterthought once more power, better cooling, and better mileage is experienced. Using an application-specific dual 15-inch fan kit from Flex-a-Lite, the 4.8L quickly responded to the easy install.

With our little V-8 making more power than ever, we didn't call it a day, rather we ordered a full complement of parts from Comp Cams and FAST. The UPS driver delivered a new Tri-Power Xtreme cam, FAST LSXRT 102mm intake manifold, billet fuel rails, also from FAST, and the necessary installation parts (valve springs, keepers, seats, locks, seals, and trunnion bearings). To make our truck run its best, we called Sean, over at SoCal Tuning, to make a couple of pulls on Superior Automotive's dyno and dial in our ECU. The end result showed a 294ci engine producing 297 hp at the tire before the nitrous, and 346 with the spray.

Helping get our LS engine get over the 300 naturally-aspirated rwhp mark, we bolted on an ASP Racing underdrive pulley set and saw the dyno read 306 rwhp. With nitrous activated, the 4.8L produced an astounding 361 lb-ft of torque and a respectable 301 lb-ft without spraying the go-juice. Gentlemen, start your engines.

Read on, as we show you how, with several vital upgrades, we made our Sierra a tire-roasting kick in the pants.

  • 2004 GMC Sierra Engine Upgrades NOS Drive By Wire Universal Wet Kit
    Horsepower per dollar, it doesn't get much better than nitrous. For our drive-by-wire throttle, we ordered a universal wet kit from NOS. This kit came with everything we needed, including a pre-fabricated fuel line with the appropriate fuel fitting for the factory Schrader valve, a two-stage window switch for full-throttle activation, and easy-to-follow instructions. Jets included could boost power output by a maximum of 150 hp. For the record, our 4.8L started out making 257 RWHP and 286 lb-ft of torque.
    2004 GMC Sierra Engine Upgrades NOS Drive By Wire Universal Wet Kit
    Horsepower per dollar, it doesn't get much better than nitrous. For our drive-by-wire thro
  • 2004 GMC Sierra Engine Upgrades Fuel And Nitrous Solenoids
    Our first step was to assemble the fuel and nitrous solenoids with flare nut wrenches. NOS included several different fittings for multiple applications and to ensure nothing leaked, each fitting was wrapped in Teflon tape.
    2004 GMC Sierra Engine Upgrades Fuel And Nitrous Solenoids
    Our first step was to assemble the fuel and nitrous solenoids with flare nut wrenches. NOS
  • 2004 GMC Sierra Engine Upgrades Schrader Valve
    Once each solenoid was ready to go, we disconnected the battery, removed the factory Schrader valve from the passenger-side fuel line fitting with a Schrader valve core tool and then installed the supplied high-pressure fuel hose.
    2004 GMC Sierra Engine Upgrades Schrader Valve
    Once each solenoid was ready to go, we disconnected the battery, removed the factory Schra
  • 2004 GMC Sierra Engine Upgrades Banks Intake Tube
    The NOS "Soft-Plume" fogger nozzle needed to be installed in the air intake tube, so off came the Banks tube and a 7/16-inch hole was drilled into a flat surface on the backside of the tube.
    2004 GMC Sierra Engine Upgrades Banks Intake Tube
    The NOS "Soft-Plume" fogger nozzle needed to be installed in the air intake tube, so off c
  • 2004 GMC Sierra Engine Upgrades Soft Plume Fogger Nozzle
    We could now install the "Soft-Plume" fogger nozzle into the nozzle adapter and secure with the supplied adapter nut. We made sure the nozzle discharge was facing towards the throttle body and the appropriate 75 hp nitrous jet (.040) was in the nitrous side of the nozzle and the matching fuel jet (.028) was in place.
    2004 GMC Sierra Engine Upgrades Soft Plume Fogger Nozzle
    We could now install the "Soft-Plume" fogger nozzle into the nozzle adapter and secure wit
  • 2004 GMC Sierra Engine Upgrades Nitrous Supply Line
    It was now time to run the nitrous supply line from the nitrous solenoid down to the cab where the bottle would be mounted. We paid close attention when routing the supply line and kept it away from the headers, any moving parts, and we used zip ties to keep it secure along the way.
    2004 GMC Sierra Engine Upgrades Nitrous Supply Line
    It was now time to run the nitrous supply line from the nitrous solenoid down to the cab w
  • 2004 GMC Sierra Engine Upgrades NOS Nitrous Tank
    We were now ready to mount the famous blue NOS nitrous tank. Rather than use the supplied bracket, we ordered a billet aluminum quick-release bracket from Pro Precision Billet. This is the best-designed kit we've come across.
    2004 GMC Sierra Engine Upgrades NOS Nitrous Tank
    We were now ready to mount the famous blue NOS nitrous tank. Rather than use the supplied
  • 2004 GMC Sierra Engine Upgrades Ergonomic Handle
    Featuring Grade 8 Allen hardware and quick-release pins for easy fill-ups, the bracket mount instantly turns into an ergonomic handle once upside down. The multiple holes allow for different bottle angles for optimum flow performance.
    2004 GMC Sierra Engine Upgrades Ergonomic Handle
    Featuring Grade 8 Allen hardware and quick-release pins for easy fill-ups, the bracket mou
  • 2004 GMC Sierra Engine Upgrades Bottle Valve
    After drilling a small hole in the floor, the nitrous supply line was run up into the cab and secured to the bottle valve.
    2004 GMC Sierra Engine Upgrades Bottle Valve
    After drilling a small hole in the floor, the nitrous supply line was run up into the cab