Installation Instructions for: Radix - Summit Racing...

Installation Instructions for:

Radix

Intercooled Supercharger System1999 - 2002

Chevrolet Silverado & GMC Sierra TrucksSuburban 2500,Yukon XL 2500

Magnuson Products Inc3172 Bunsen Ave, Ventura, CA 93003

(805) 642-8833 phone * (805) 677-4897 faxmagnusonproducts.com * magnacharger.com

Step-by-step instructions for installing the best insupercharger systems.

Use distilled or

de-ionized water only.

89-89-60-001 Rev. F

INSTALLATION MANUALMagna ChargerRadix Intercooled Supercharger SystemGM 4.8, 5.3 & 6.0 liter engines

We encourage you to read this manual thoroughly before you begin work, for a few reasons:

A quick parts check to make certain your kit is complete (See shipper parts list in this manual). If youdiscover shipping damage or shortage, please call our office immediately.

Take a look at exactly what you are going to need in terms of tools, time, and experience.

Review our limited warranty with care.

Make sure to have 91 or higher octane fuel in the tank.

When unpacking the supercharger kit lift the supercharger assembly by the black plasticbypass actuator. This is from the factory and can be altered if used as a lifting point!

DO NOTpre-set

Tools Required

� Safety glasses

Metric wrench set

1/4” drill bit

1/4”, 3/8”, & 1/2” drive metric socket set ( standard and deep )

8mm hex (Allen) wrench

3/8” and 1/2” drive foot pound and inch pound torque wrenches

Belt tensioner wrench or 1/2” breaker bar

7/32” socket

Drill and 5/16” drill bit

Phillips and flat head screwdrivers

Fuel quick disconnect tools (included in kit)

E5 inverted Torx socket

Small or angled 3/8” drill motor

Drain pan

Compressed air

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Radix Truck & SUV InstructionsRadix...the root of power magnacharger.com

Important

Our Magna Charger kits are designed for stock engines, with stock components, in good mechanicalcondition only. Installation on worn or damaged engines is not recommended and may result in enginefailure, for which we naturally can't be responsible . Magna Charger is not responsible for the engine orconsequential damages.

Aftermarket engine re-calibration devices that modify fuel and spark curve (i.e.. programmers) are notrecommended and may cause engine damage or failure. If you have any questions, call us!

Relieve the fuel system pressure before servicing fuel system components inorder to reduce the risk of fire and personal injury. After relieving the system pressure, a small amountof fuel may be released when servicing the fuel lines or connections. In order to reduce the risk ofpersonal injury, cover the regulator and fuel line fittings with a shop towel before disconnecting. Thiswill catch any fuel that may leak out. Place the towel in an approved container when the job iscomplete, and of course, no smoking.

Magna Charger strongly recommends the following:

Clean your engine compartment before starting any engine disassembly.

Caution:

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You must have a clean fuel filter - check and replace as needed before installation.

You must have a clean air filter - this system comes with a new air filter for your convenience.

OE type / Stock spark plugs and stock plug gap is recommended.

Start with and use only 91 octane fuel or higher.

Drive belt is a Gates #K061120

Please remember to follow all safety rules that apply when working, including:

Wear eye protection at all times.

Do not work on a hot engine.

Be careful around fuel - use shop towels to catch any spills and dispose of

towels properly.

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After you finish your installation and road test your vehicle, please fill out andmail the limited warranty card, so we can add you to our files (this is importantfor your protection).

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1. Start the supercharger installation by reliving the fuel pressure Exercise extreme caution andcommon sense when working around gasoline. Extinguish all open flame or other sources ofignition and be sure to perform the following steps in an area with adequate ventilation. Personalprotection in the form of eye protection and fuel resistant gloves are strongly recommended.

3. On the right (passenger) side of theintake manifold, locate the fuel pressuretest port. CAUTION! The fuel in thesystem is under pressure! Relieve thepressure in the fuel system by depressingthe check valve with a screwdriver andcollecting the fuel with a shop towel.

2. Relieve the pressure in the fuel tank byremoving the fuel filler cap.

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4. With a 8mm wrench disconnect the(-) negative battery cable. Make sure thecable is far enough away from the batterythat it does not accidentally touch thebattery and make connection during theinstallation. (Wrap negative cable connectorwith electrical tape.)

5. With a cool engine remove theradiator cap. (Be careful not to remove thecap if the engine is still hot.)

6. Open radiator petcock and draincoolant into a clean drain pan. Save coolantfor reuse later on.

7 Remove the plastic sight shield boltusing a 10mm socket wrench.

.

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8. Lift plastic shield from top of engine.

9. Using a 8mm nut driver loosen the twolarge hose clamps holding the air cleanerduct assembly.

10. Remove the duct assembly by lifting itout. Sight shield and duct assembly will notbe reused.

11. Unplug the electrical connector to theMAF sensor.

Clamps

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12. Firmly grasp the air intake box and pullup removing it from the vehicle.

13. To prevent foam from escaping, insertthe black plastic plug supplied in the holelocated in the upper edge of the right(passenger) side wheel well.

14. Locate the can of expansion foam inyour kit. Follow the directions on the backof the can. Insert the end of the straw intothe hole and dispense the foam into thehole for 10 to 12 seconds. In the existinghole that is just to the rear of the slot thatthe coolant tank sits in, again dispense thefoam into the hole for 10 to 12 seconds.You will not need the entire can. Do notattempt to over fill the fender. (Note: donot disturb foam for 8 hours.) Noise levelswill be drastically reduced when foam hasset.

15. Remove the throttle and cruise controlcables from the throttle body assembly.Some vehicles may have a ElectronicThrottle Control (ETC) system and have nocables.

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16. Using a pair of pliers, squeeze theplastic retainers on the throttle and cruisecables, and remove from the bracket.

Coolant Hoses

17. Using a long pair of pliers, removethe coolant hoses from the bottom of thethrottle body

18. Remove the (PCV) vent hose fromthe throttle body or intake manifold onpassenger side. (Depending on year).

EGR Tube

19. Using a 10mm socket wrenchremove the 6mm bolt holding the (EGR)tube to the intake manifold. ( Some vehiclesmay not have a (EGR) system, skip steps14 and 15).

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20. Grab the (EGR) tube and pull it outof the intake manifold as shown. Make sureyou have the rubber o-ring out of themanifold.

Clips

Bolts & Clips

22. Open the large electrical harnessretainer clip, then using a 10mm socketwrench remove the bolts holding the plasticwire harness retainer to the intake manifold.

21. Remove the throttle and cruisecontrol cables from the plastic plate on topof the engine. Remove the small plasticclips from the cables.(Skip this step if yourvehicle has a fly by wire system, and hasno cables).

23. Disconnect the following electricalconnectors. (8) fuel injectors, Idle air control(IAC), Throttle position sensor (TPS),Manifold absolute pressure sensor (MAP),Evaporative emission canister purgesolenoid (EVAP),Alternator and Knock sensor,

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24. Disconnect the eight fuel injectorconnections by gently pulling up on the grayplastic release trigger on the connector andthen pulling firmly on the connector itself.

25 On late vehicles, disconnect theElectronic Throttle Control (ETC) connectorfrom the throttle body by removing the grayplastic locking tab first, then squeeze andpull free the ETC connector itself.

.

26 At the rear of the of the intake manifolddisconnect the Manifold Absolute Pressure(MAP) sensor connector by gently raisingthe gray plastic retaining clip and then pullfree the connector itself.

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Knock Sensor

27 Disconnect the engine knock sensorconnector and steel-mounting clip from theintake manifold by prying it free with a smallscrewdriver. Next gently raise the blackplastic retaining clip and then pull free theconnector from the harness.

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28 Disconnect the evaporative purgesolenoid EVAP connector by raising theblack plastic retaining clip and then pull freethe connector itself.

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29 ift the electrical harness from the topof the engine and set off to the side.

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EVAP Connector

EVAP Vent tube30. Disconnect the (EVAP) vent tubefrom the solenoid by squeezing theretainer, then release the tube from thesolenoid. Follow the same procedure on theother end of the (EVAP) vent tube andremove the tube from the vehicle.

31. Remove the positive crankcasevacuum hose (PCV) from the intakemanifold on driver side.

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35 Using a 8mm socket wrench removethe ten intake manifold bolts.

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Vacuum Hose

32. Disconnect the small vacuum hosefrom the rear passenger side of the intakemanifold, if so equipped.

33. Remove the power brake boosterhose from the booster by pulling out on thecheck valve.( Some vehicles have hydraulicassist brakes and do not have this hose).

34 With the fuel line disconnect toolsupplied, remove the fuel lines from the fuelrails. Caution! The system may be underpressure. Avoid open flame or othersources of ignition.

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36 Carefully remove the intake manifoldassembly and set aside.

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37 Using a vacuum cleaner, remove anydirt or debris from the intake port area. (Becareful not to get any dirt in the intakeports.)

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38 Cover the intake ports with tape orclean rags to keep dirt and objects fromentering the engine. (Remember, be clean.)

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39. Remove the small plastic clips fromthe knock sensor electrical harness. Theintake manifold will not clear if this step ismissed.

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40 Using a 15mm wrench, remove thesteel bracket from the rear of the driver sidecylinder head. This will not be reused.

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41. Using a 10mm socket wrench,remove the two or four coolant vent pipebolts. (Some models have a small pipe inthe front and some have a large pipe thatgoes from the front to the back).

42. Remove the vent pipe assembly.(Make sure that the o-ring gaskets did notstick to the cylinder heads, if so removethem).

43. Using a 15mm tensioner wrench orbreaker bar, remove the stock serpentinebelt from the vehicle. The belt will not bereused.

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45. Using a 10mm wrench disconnect thebattery positive terminal from the back ofthe alternator.

Bolts

44. Using a 15mm socket wrench orwrench remove the three bolts holding thefactory belt tensioner to the bracket andremove the tensioner.

46. With a 15mm socket wrench removethe two bolts holding the alternator to thealternator bracket. Remove the alternator.

Mark here

47. With a felt tip marker, make a mark 13/4” from the 90 degree corner of the airinjection tube. ( Note if your vehicle doesnot have air injection skip steps 37-43).

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48. Using a tubing cutter, hack saw orcut off wheel, cut the air injection tube inhalf on the 1 3/4” mark made in step 37.Use a file to remove any sharp edges onthe tube.

Factory hose clamp

49. Disconnect the two air injectionhoses from the other end of the tube andsave the factory hose clamp for a later step.

50. Remove the cut off air injection tubefrom the vehicle. (the tube will not be reused).

Clamp

51. Using the new supplied 90 degree5/8 molded hose cut 2” off the short endand cut 3” off the long end of the hose.Using the factory hose clamp removed instep 39, install the short end of the hose tothe air injection tube as show in the pictureabove.

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Tee

52. Install the supplied 5/8 plastic tee tothe air injection system as shown in theabove picture. No hose clamps are needed.

Cut

53. Route the modified air injection hoseassembly as show in the above picture.

54.

Cut the end off the (EGR) tube with a cutoff wheel or hack saw. Make sure not todamage the O-Ring seal.

If your vehicle does not have EGRsystem skip steps 44-45.

55. File any sharp edges from ( EGR)pipe. When finished the (EGR) pipe shouldlook like this.

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Checkclearance

56. Take the new supplied coolant ventpipe and test fit to the front of the cylinderheads. Check for clearance between thepipe and the alternator bracket as shown.

57 Use a felt tip marker and mark thealternator bracket were the coolant ventpipe hits as shown.

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58 Using a file or die grinder, removematerial from the alternator mountingbracket marked in the previous step. Onceclearance is achieved, recheck with the newvent pipe. Ensure that the vent pipe doesnot touch the alternator bracket.

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59 Using the stock bolts removed in step71 install the new coolant vent pipesupplied. Ensure that the o-ring seals areinstalled correctly. Torque the bolts with atorque wrench and 10mm socket to 106 lb-in.

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60. Using the new supplied 16” x 3/8” PCVvacuum hose, connect one end to the PCVvalve as shown and lay the other end of thehose off to the driver side, out of the way.(To be connected in a later step.)

PCV Valve

61. Install the intake manifold gasketssupplied onto the supercharger manifold.Ensure that the gaskets are fully seatedinto the reliefs in the manifold.

62 Remove the stock MAP sensor fromthe stock intake manifold by pulling back onthe two tabs and lifting the sensor out.Ensure that the orange MAP sensor seal isnot damaged, as it will be used.

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63 ut some lubricant on the MAP sensorseal and press the MAP sensor into theprovided hole in the supercharger manifoldas shown.

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64 Using a 4mm allen wrench, install theMAP sensor retaining clip with the provided6mm button head screw as shown.

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65. Make sure that the two O-rings and thescreen filter is complete as shown.

66. Using a small amount of grease or oillubricate the two O-rings on the fuelpressure regulator and push it into the newsupplied fuel manifold as shown.

67. Using a pair of C-clip pliers install thenew supplied C-clip into the fuel manifoldas shown. (Make sure that the clip seatsinto the machined grove in the manifold.)

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68 Apply a small amount of grease to thenew supplied fuel manifold O-ring and set inthe machined recessed area on the newdriver side fuel rail as shown.

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69 Install the assembled fuel manifold tothe driver side fuel rail using the two newsupplied 6mm bolts. Using a 10mm socketwrench torque the bolts to 106 lb-in. (Becareful not to pinch the O-ring.)

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71 Using a 10mm socket wrench removethe stock throttle body from the stock intakemanifold. Next using a # 5 internal Torxsocket remove the three mounting studsfrom the stock intake manifold.

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70. Using the small 5/32” hose supplied,connect one end to the small barb on thepressure regulator. Connect the remainingend of the hose to the barb at the left rear ofthe supercharger manifold.

Pressureregulatorbarb

Manifoldbarb

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72 Install the three studs removed in theprevious step into the new superchargerinlet manifold using a # 5 internal Torxsocket and wrench.

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73 Remove the EVAP solenoid from thestock manifold with a 8mm socket wrench.

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75 Mount EVAP solenoid on front of intakemanifold.

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74 Lubricate the o-ring with the suppliedgrease.

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76 Remove the one bolt directly below thealternator and factory GM idler with a 15mmsocket wrench.

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77 Here is the new tensioner supportbracket and hardware. The new bracket willlocate in the original tensioner location.Note the different fasteners and theirlocations.

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78 In the original tensioner location, installthe new tensioner support bracket. Torqueall mounting fasteners to 40 lb-ft.

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79 Install the tensioner and it’s mountingbolt on the new mounting bracket. Torquethe tensioner mounting bolt to 50 lb-ft.

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80 Install the 90mm idler and spacer onthe idler support bracket. Torque themounting bolt to 40 lb-ft.

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83 Spray silicone or some mild soap andwater solution on cylinder head surface tolubricate. This makes the intake manifoldslide around a little to help line up the holes.(Do not use anything that will damage theintake gaskets such as petroleum basedproducts, etc.)

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82 Install the short oil filler neck suppliedby inserting it into the valve cover androtating it 180 degrees clock-wise. Transferthe oil fill cap from the long neck to the newshort one.

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81. Remove the long oil filler neck from thevalve cover by rotating it 180 degreescounter clock-wise and pulling it out.

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85. Remove the 10 spilt looms that supportthe fasteners. Start all by hand.ten bolts

86 Torque all 10 bolts gradually andevenly to a torque of 89 in-lbs.

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84 Using an assistant, carefully lowermanifold assembly into place, being carefulnot to damage gaskets.

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87. Route fuel hoses to regulator.

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89 Using supplied gasket, mount throttlebody using stock nuts.

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90. Fasten throttle cable bracket and installboth cables.

91. Install both cruise control and throttlecables & PCV hose. Check for smoothcable operation.

88 Push the fuel line connector on to thefuel manifold. Ensure that the fuel line ispushed all the way on. Pull on theconnector to check that it is secure, youshould not be able to remove the connectorunless you use the removal tool.

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Small Diameter“Return”

Larger diameter “feed”

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93 Remove the wiring harness from theoriginal bracket.

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94 Route the wiring harness over the leftside fuel rail and attach it to thesupercharger manifold as shown, using theAdel clamp and bolt supplied.

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Adel Clamp

95 Plug in the electrical connectors for thefollowing components, the Fuel Injectors,Electronic Throttle Control, Map Sensor,Knock Sensor and EVAP Solenoid.

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92. If your vehicle is EGR equipped (seesteps 54 & 55), remove the 3/8” NPT plugand thread on the EGR relocation manifold.Feed the EGR tube to this manifold, re-useseal and fasten using OE hardware.

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97 Mount the nose support and torque thefasteners 15-17 ft-lbs.

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98 Reinstall the EVAP tube on the EVAPsolenoid at the front of the superchargermanifold. Route the tube under thesupercharger nose and along the inside ofthe left fuel rail to the EVAP connectionbetween the cylinder head and the firewall.

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99 Install the Radix information sticker onthe black plastic radiator cover below theGM factory-warning sticker.

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96 Attach one end of the ¼” coolant hosesupplied to the new steam vent pipe andthe other end to the barb on the bottom ofthe throttle body with the clamps supplied.Attach the original steam vent hose andclamp from the radiator to the remainingbarb on the bottom of the throttle body.

.Coolanthose

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100. Install alternator on the stock bracketand torque the fasteners to 40 ft-lb.

1 .01 Reattach the battery cable to thealternator terminal.

103. Using a screwdriver, remove the fourscrews that secure the top cover to thebase of the air box assembly.

1 .02 Using belt routing decal, install belt.Please double check your routing beforemoving to the next step. Put belt routingdiagram sticker over the GM belt routingdiagram.

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1 .05 Remove the stock air box gasket andreplace it with the new gasket supplied withthe K&N air filter.

1 .06 Install K&N air filter and reassemblethe air box assembly. Reinstall thecompleted unit on the vehicle.

Bellows Air TubeCoupler

Clamps Brass Barbs Grease

1 .07 Here is the air tube and it’scomponents.

1 .04 Remove and discard the stock paperair filter.

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1 .09 Install the brass barb into the threadedport in the bottom of the air tube with a14mm wrench. Do not over tighten!

1 .10 Using some of the O-ring greasesupplied, apply a light coating of grease onthe inside of the coupler.

1 .11 Push the bellows end of the air tubeassembly on to the air box first, and theninstall the remaining end with the coupler onto the throttle body. Tighten all clampscrews securely.

1 .08 Assemble the bellows and coupler tothe air tube. Note the position of the clampscrews. The screws must be facing up sothat you can install the assembly on thevehicle.

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1 .12 Attach the PCV hose from the right(passenger) side valve cover to the brassbarb on the bottom of the air tube. Connectthe PCV hose from step 89 to the remainingbarb next to the power brake hoseconnection on the back of the inlet manifold.Connect the power brake hose to thecontrol valve shown in step 62.

113. Remove fender to firewall bracebracket to gain access to the fuse relaypanel, on driver side.

114. Firmly grasp the relay centers coverand lift off.

115. Pull back on the two tabs holding therelay centers main cover off.

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117 Position the intercooler reservoirbracket on the engine side face of the maincover. Align the cut-away of the cover withthe edge of the bracket

.Bracket

Alignedges

116. Lift the cover off and set aside formodification.

119 Place the reservoir bracket in locationon the holes. Secure the bracket on theinside of the cover with the three nutssupplied. Tighten the nuts with a 10mmsocket wrench.

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118 Mark the location of the threemounting studs on the cover and then drill1/4” holes in these locations.

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Reservoir Inlet

Electrical Connection

Pump Outlet

1 .20 Here is the intercooler reservoir/pumpassembly. Note the hose and electricalconnections.

1 .21 Install the reservoir/pump assemblyon the two reservoir bracket studs with thesupplied nuts. Tighten the nuts securely.

1 .22 Install the intercooler pump harnessstarting at the relay center. Cover the redand black wires that lead to the intercoolercoolant pump connector with the split loomsupplied. Tuck the relay under the factoryGM wiring so that the relay center coverbase will cover it. Route the harness withthe coolant pump connector down andforward along the factory GM harness.

1 .23 In the wiring below the fuse/relaycenter, locate the gray fuel pump wire thatgoes from the relay center down the frametowards the rear of the vehicle. Use a 12volt automotive test light or voltmeter tocheck that you have the correct wire. Withthe battery temporarily connected, switchthe ignition on and your test light shouldglow for about 3 seconds and then go outwhen you have located the correct wire.Install a T-tap connector onto the gray fuelpump wire.

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125. Using a 13mm socket wrenchremove the positive terminal nut from thelug. (Caution - make sure the battery isdisconnected.)

1 .24 Connect the yellow wire from the relayinto the T-tap connector installed in the laststep.

1 .27 Using a 10mm socket wrench,remove the nut from the body ground studon the firewall as shown. Body ground stud

126. Install the positive terminal from therelay to the positive lug as shown.(This is the wire with the fuse holder in it.)

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1 .28 Locate the single black ground wirefrom the relay, strip the insulation back ¼”from the end and then firmly crimp the ringterminal on the end. Install the black wirewith its ring terminal on the body groundstud from the previous step and secure itfirmly with the original nut.

1 .29 Install the intercooler electricalconnector into the bottom of the coolantpump. Secure the wiring as necessary withthe ty-wrap straps supplied.

130. Install the wiring harness for the fuelpump in the same location as you did forthe intercooler pump wiring harness. Attachthe extra yellow wire from the intercoolerpump relay onto the male spade terminalmarked “85” on the bottom of the fuel pumprelay. Attach the ring connector from thefused power wire in the same location asyou did for the intercooler pump relay instep 126. Attach the black ground wire ringconnector in the same location as you did instep 128. Route the black and red splitloom covered wires down and along theinside of the left frame rail to the fuel filterlocation.

1 .31 Reinstall the relay center covercomplete with the reservoir and pumpinstalled.(Be careful not to pinch any wires.)

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131 Reinstall the fuse/relay cover byaligning it up and pushing down on it.

1 .32 Reinstall fender to firewall brace.

13 .3 Here is the intercooler and it’smounting components.

134. Install two of the round-headedcarriage bolts supplied into both channelson the sides of the heat exchanger. Thesquare portion of the bolt shaft must bealigned with the side of the channel.

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135. Align the bolts with the holes in thebracket.

13 .8 Remove the seven push-lockfasteners that secure the black plasticradiator cover. Do this by prying up on thecenter of the fastener with a small straightblade screwdriver.

136. Torque the mounting nuts to 18 ft-lbs.

137. Assemble the upper mountingmounting clamp with its plastic strip. Peelthe backing tape off the plastic strip andapply the strip supplied to the inside of thejaws on the mounting clamp.

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1 .39 Remove the seven fastenerscompletely.

14 .2 Pull out on the grille assembly at eachof its six corners to release the snap-infasteners.

1 .40 Remove the radiator cover.

1 .41 Remove the grille assembly by firstremoving the upper retaining bolt with a10mm socket wrench.

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14 .3 Remove the grille assembly.

146. Install the heat exchanger onto thestuds of the rubber mounts and secure itwith the nuts supplied and a 10mm socketwrench.

144. Remove the stock cross member boltsfrom the radiator brace bolt at each endwith a 13mm socket wrench.

145. Replace the cross member bolts withthe rubber mounts supplied. Tighten themounts securely by hand only.

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Remove this bolt147. Remove the bolt located below and tothe right of the hood latch with a 10mmsocket wrench.

14 .9 Here is the heat exchanger mounted.Note the hose barbs are on the right side.

14 . Install the upper mounting clamp ontothe heat exchanger core using the boltremoved in the previous step. Tighten thebolt securely

8

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1 .50 Starting at the intercooler barb on theleft side of the supercharger, attach oneend of the length of the 5/8” hose with a#10 clamp. Run the hose forward and downbeside the left side of the radiator.

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15 .1 In the rubber weather shield besidethe radiator, make a slot or hole for thehoses from the intercooler to pass.

15 .2 Continue the hose to the upper barbon the top of the heat exchanger. At thispoint cut the hose and push it on the barb.Secure it with a #10 clamp.

15 .4 From the remaining length of hose,connect one end to the inlet barb of theintercooler reservoir with a #10 clamp.

15 .3 From the remaining length of hose,attach one end to the lower barb of the heatexchanger. Route the hose through the slotin the weather shield and on to the outletbarb out the intercooler pump. Cut the hoseand secure both ends with #10 clamps.

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15 .5 Cut the remaining end of the hose tolength and connect it to the “T” connectionon the supercharger with a #10 clamp.

Reinstall the grill assembly by snapping thesix corners back in place and installing theupper retaining bolt with a 10mm socketwrench. Install the radiator cover byinserting the seven push-lock fastenersback in their holes and pressing the centerof the push-lock fasteners down to securethem.

1 .56 Locate your vehicles fuel filter,usually located on the inside of the driverside frame rail. At this time we recommendthat you replace the fuel filter.

157. Using 5/8” and 13/16” wrenches,disconnect fuel line from filter. Use rags tosoak up and fuel. (Be sure to dispose ofrags properly.) Do not lose small o-ring onfitting.

158. Using small amount of grease,lubricate o-ring threads of OE fitting.Carefully bend tube to run parallel to framerail and direct into pump discharge fitting.

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159. Using 21/64” drill carefully drillthrough bottom of frame rail. Clean upchips, deburr hole and fasten pump withsupplied hardware.

160. While supporting the pump usingback-up 7/8” wrench, tighten fuel linefittings. (Make sure adapter does not getloosened.)

161. Lubricate o-rings and threads of u-bend adapter and install on discharge sideof fuel filter. Position as in photo.

162. Wrap inlet hose & fitting around tofilter adapter, and “click” into place.

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163. Use tie wraps supplied in kit tofasten hose & wires out of harms way, andto allow smooth bends.

164. Cut the pump wiring loom installedearlier in step 170 so that the black and redwires will reach the new pump.

165. The fuel pump wiring must behooked up correctly to work, the redPositive wire goes to the “+” post on thepump and the black negative wire goes tothe “-” post on the pump. (Double checkyour installation before moving on.)*Note: Do not over-tighten the nuts and

break the studs.

166. Locate MAF cable, pull back flexloom approximately 8 inches. Separate thetan & black wires from this harness.

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167. Cut the tan & black wiresapproximately 7” from the MAF connector.

To computer

To MAFNo longerused

168. Using the new IAT harness andcrimp/shrink connectors supplied, connecteither white wire of the new harness to thetan wire and the black wire that run to thevehicles computer.

Strip about ¼” ofinsulation from the ends of the black andtan wires to the computer and the IATharness, then crimp the connectors on.Using a heat gun or blow dryer set onHIGH; shrink the insulation on theconnectors so that it contracts around thewires completely.

The wires to the MAFwill no longer be used.

You must shrink theinsulation, as crimping the connectors aloneis not enough to secure them!

170. Refill radiator and intercooler systemwith a 50/50 mixture of coolant and distilledor de-ionized water only. Let run for 5-10minutes. Bleed system at “T” and atreservoir. Check system periodically forfluid level.

1 .69 Plug the IAT harness into the IATsensor located under the superchargernose.

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171. Ensure vehicle is off and the keys areout of the ignition. Locate the interior fusepanel inside the driver door as shown.

172. Remove the 10 AMP "SEO ACCY"fuse in the top middle section of the fusebox as shown.

173. Remove the cover from the "ExteriorFuse Panel" located under the hood on thedrivers (left) side. Remove the six fuseslabeled SEO B1, SEO IGN, INFO, SEO B2,RADIO and RADIO AMP. Download theMicro tuner following the instructions thatcame with the Micro tuner.

WARNING! Before downloading the new software into your vehicles compute (PCM), make sureto turn off all power consuming accessories: heater, A/C , radio, dome light, etc. Turn off thedaytime running rights by applying the emergency brake or by turning the head lamp switchcounter-clockwise. Follow the steps below to remove all recommended fuses and any additionalpower fuses from all aftermarket add-on accessories i.e.: stereo amplifiers, DVD players, TVmonitors, MP3 players and anti-theft equipment. Keep all doors closed during programming.Never remove the programming cable during programming and always follow the instructions onthe handheld unit display. Failure of any of the above instructions can cause a "NORESPONSE" from the PCM or permanent damage to the vehicle PCM.

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174. Vehicle Programing Instructions For the Micro Tuner:

IMPORTANT! To ensure trouble-free programming of your vehicle’s computer:*Make sure the vehicle’s battery is sufficiently charged.*Turn off all accessories & close doors to prevent unnecessary drain on the battery.*Do not attempt to program your vehicle while a battery charger is connected.*Improper battery voltage will result in failure of the programming process.*Do not disconnect the cable or turn off the ignition during programming.*Apply emergency brake to disable daytime running lights.* Reconnect battery ground (-) cable.

C. Turn the ignition key to the on or runposition but do not start the vehicle.

D. To begin programming your vehicle, youmust press the YES button.

E. You only need to press the YES buttononce to start the programming cycle.The programming process only takesabout a minute.

In the event that the vehicle needs to be returned to its original calibration, follow the directionsas described above. The handheld unit will prompt you that you have already modified thevehicle’s computer. Select YES to return you vehicle’s computer back to the stock calibration.Wait for the handheld to finish, then disconnect cable as described above.

F. The handheld unit will inform you thatthe programming process hascompleted and to turn the ignition offand disconnect the cable. Only at thistime should the ignition be turned offand the cable removed.

OBD IICONNECTOR

A. Connect the supplied cable to the 9-pinconnector at the top of the handheldunit. Use the thumbscrews to securethe cable to connector.

B. Connect the other end to your OBD IIconnector located under the dash nearthe steering column. Make sure thisconnection is seated all the way in andthat it is secure. You do not want thiscable coming out of the connectorduring programming.

*DO NOT DISTURB THE CABLE OR TURNTHE IGNITION OFF DURING THIS TIME! IFTHE PROGRAMMING IS DISRUPTED YOURCOMPUTER WILL NOT START OR RUNYOUR VEHICLE!

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Fill holes

176. Start the vehicle for 5 seconds and shut off, once again check for fuel leaks and fan-supercharger belt alignment. Check radiator and intercooler reservoir.

177. Test drive vehicle for the first few miles under normal driving conditions, listen for any noises,vibrations, engine missfire or anything that does not seem normal. The supercharger does have aslight whining noise under boost conditions, which is normal. Check & bleed intercooler reservoiras needed.

178. After the initial test drive gradually work the vehicle to wide open throttle runs, listen for anyengine detonation ( Pinging ), If engine detonation is present let up on the throttle immediately.Most detonation causes are low octane gasoline still in the tank. If you have questions about yourvehicles performance, please check with your installation facility or call Magna Charger at (805)289-0044, Monday through Friday, 8am to 5pm.

Please enjoy your “Magna Charged”performance responsibly.

IN THE NEWS...IN THE NEWS...IN THE INTHE NEWS...IN THE NEWS...IN THENEWS. . . IN THE NEWS. . . IN THENEWS...IN THE NEWS....NEWS...IN THENEWS. . . IN THE NEWS. . . IN THENEWS.. . . IN THE NEWS.. . IN THENEWS. . . IN THE NEWS. . . IN THENEWS. . . IN THE NEWS. . . IN THENEWS.. . . IN THE NEWS.. . IN THENEWS. . . IN THE NEWS. . . IN THE

Ventura, CA (November 21, 2002) MagnaCharger, manufacturer of superchargers andsupercharger systems for foreign anddomestic vehicles, was presented theprestigious award at the annual SpecialtyEquipment Market Association Show (SEMA)in Las Vegas, Nevada.

Sponsored by General Motors Corporation,the 2002 SEMA Design Award for the “MostI n n o v a t i v e P r o d u c t ”

was awarded to Magna Charger andrecognized by the all-star team of judges fortheir outstanding and innovative designachievement. The criteria used by the judgesincluded innovation, technical achievement,quality and workmanship.

The award was presented for the Radix®Intercooled supercharger system, designedfor the Chevrolet, GMC and Cadillac, 4.8L,5.3L and 6.0L General Motors Trucks andSUV's including the new H2.

175. Once programing is completed,ensure the vehicle is off and the keys areout of the ignition. Install the fuses back intotheir correct locations and reinstall thecovers.

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INTERCOOLER/FUEL PUMP WIRE ROUTING DIAGRAM

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31-12-00-019 SUBASSEMBLY, HEAT EXCHANGER, RADIX TRUCK & SUV

QTY PART NUMBER ITEM DESCRIPTION

1 68-01-00-082 HEAT EXCHANGER, 1999-2002 RADIX TRUCK & SUV

1 65-12-60-008 BRACKET, HEAT EXCHANGER UPPER, 1999-2002 RADIX TRUCK & SUV

1 68-01-00-049 VIBRATION INSERT 1" X 3", 1999-2002 RADIX TRUCK & SUV

2 65-12-60-009 BRACKET, HEAT EXCHANGER BASE, 1999-2002 RADIX TRUCK & SUV

6 48-46-10-003 CLAMP, HOSE #10, 1999-2002 RADIX TRUCK & SUV

1 48-46-10-036 CLAMP, ADEL #36, 1999-2002 RADIX TRUCK & SUV

1 74-74-25-100 SCREW, SELF-TAPPING FLG HEAD, 1999-2002 RADIX TRUCK & SUV

2 68-01-00-061 RUBBER SANDWICH MOUNT, 1999-2002 RADIX TRUCK & SUV

8 77-73-06-100 NUT, FLG M6 X 1.00, 1999-2002 RADIX TRUCK & SUV

1 71-06-10-016 BOLT-HEX FLANGE M6 X 16, 1999-2002 RADIX TRUCK & SUV

4 72-08-12-016 BOLT, ROUND HEAD, SQUARE NECK, 1999-2002 RADIX TRUCK & SUV

4 77-10-08-010 NUT, FLG M8 X 1.25, 1999-2002 RADIX TRUCK & SUV

165" 82-55-00-009 HOSE 5/8" RUBBER HEATER, 1999-2002 RADIX TRUCK & SUV

1 65-12-60-001 BRACKET, COOLANT RESERVOIR, 1999-2002 RADIX TRUCK & SUV

31-12-00-015 SUBASSEMBLY, AIR INTAKE, RADIX TRUCK & SUV


2 48-46-10-024 CLAMP, #60, 1999-2002 RADIX TRUCK & SUV

1 80-59-53-010 SEAL AND CLAMP, 1999-2002 RADIX TRUCK & SUV

1 35-12-60-001 MANIFOLD, BELLOWS, 1999-2002 RADIX TRUCK & SUV

1 35-20-53-007-MA MANIFOLD, AIR INLET TUBE, 1999-2002 RADIX TRUCK & SUV

1 91-01-01-015 STICKER, MAGNA CHARGER, 1999-2002 RADIX TRUCK & SUV

1 85-05-20-053 EXPANSION FOAM SEALANT, 1999-2002 RADIX TRUCK & SUV

1 69-35-53-003 3/8" PLASTIC PLUG, 1999-2002 RADIX TRUCK & SUV

1 48-46-00-030 FITTING 1/4" NPT MALE 3/8 HOSE BARB, 1999-2002 RADIX TRUCK & SUV

31-12-00-018 SUBASSEMBLY, I/C PUMP & RESERVOIR, RADIX TRUCK & SUV


1 68-01-03-001 RESERVOIR, COOLANT, 1999-2002 RADIX TRUCK & SUV

1 68-01-03-002 RESERVOIR CAP, 1999-2002 RADIX TRUCK & SUV

1 68-14-59-002 IC PUMP, 1999-2002 RADIX TRUCK & SUV

3.25" 82-55-00-007 HOSE 3/4" COOLANT, 1999-2002 RADIX TRUCK & SUV

2 48-46-10-003 CLAMP, HOSE #10, 1999-2002 RADIX TRUCK & SUV

31-12-00-100 SUBASSEMBLY, S/C TO CYLINDER HEAD BOLTS, RADIX TRUCK & SUV



1" 82-01-04-001 WIRE LOOM, 1999-2002 RADIX TRUCK & SUV

1999-2002 RADIX TRUCK & SUV PARTS LIST

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31-12-00-013 SUBASSEMBLY, ELECTRICAL, RADIX TRUCK & SUV


1 82-55-53-005 IAT WIRE ASSY, 1999-2002 RADIX TRUCK & SUV

32" 82-55-20-002 WIRE LOOM - 3/8", 1999-2002 RADIX TRUCK & SUV

10 69-90-24-004 TIE WRAP, 1999-2002 RADIX TRUCK & SUV

1 82-55-80-001 WIRE/CONN ASSY RADIX INTERCOOLER PUMP, 1999-2002 RADIX TRUCK & SUV

1 82-55-50-115 FUSE, 15AMP, 1999-2002 RADIX TRUCK & SUV

1 82-55-60-101 16-14GA. RING TERM, 1999-2002 RADIX TRUCK & SUV

1 82-55-40-006 T-TAP FML, 1999-2002 RADIX TRUCK & SUV

31-12-00-005 SUBASSEMBLY, TENSIONER, RADIX TRUCK & SUV


1 65-03-53-001 BRACKET, LOWER STRUC, 1999-2002 RADIX TRUCK & SUV

1 56-50-53-006 TENSIONER ASSY, 1999-2002 RADIX TRUCK & SUV

1 56-50-53-004 IDLER, DAYCO, 1999-2002 RADIX TRUCK & SUV



1 69-90-57-001 SPACER, IDLER PULLEY, 1999-2002 RADIX TRUCK & SUV

1 65-12-60-002 BRACKET, UPPER STRUT, NOSE SUPPORT, 1999-2002 RADIX TRUCK & SUV




31-12-00-020 SUBASSEMBLY, HOSES & FITTINGS, RADIX TRUCK & SUV


16" 82-55-00-002 HOSE, 3/8" FUEL, 1999-2002 RADIX TRUCK & SUV

9" 82-55-00-020 HOSE, 1/4 COOLANT, 1999-2002 RADIX TRUCK & SUV


1 69-95-30-001 TUBE, OIL FILL, 1999-2002 RADIX TRUCK & SUV

1 48-46-10-022 CLAMP, ADEL #16, 1999-2002 RADIX TRUCK & SUV

2 48-46-10-019 CLAMP, HOSE 1/4" ID - 1/2" OD, 1999-2002 RADIX TRUCK & SUV

89-90-60-000 LITERATURE KIT, RADIX TRUCK & SUV


1 89-89-00-004 MAGNA CHARGER WARRANTY/REG CARD, 1999-2002 RADIX TRUCK & SUV

2 91-01-01-001 6" STICKER MAGNA CHARGER STICKER, 1999-2002 RADIX TRUCK & SUV

2 91-91-10-001 LABEL, FUEL TANK - PREMIUM FUEL ONLY, 1999-2002 RADIX TRUCK & SUV

1 91-91-60-001 LABEL, VACUUM AND BELT DIAGRAM, 1999-2002 RADIX TRUCK & SUV

1 83-91-00-013 LUBRICANT, "LUBRIPLATE", 1999-2002 RADIX TRUCK & SUV

1 80-59-57-001 GASKET, THROTTLE BODY, 1999-2002 RADIX TRUCK & SUV

81-00-57-003-MA SEAL KIT, TUB TO HEADS MACHINED, SET OF 2, RADIX TRUCK & SUV70-00-00-002 FILTER, AIR, RADIX TRUCK & SUV31-14-59-004 SUBASSEMBLY, FRONT STEAM MANIFOLD, RADIX TRUCK & SUV79-50-57-002 BELT, GM 5.7, RADIX TRUCK & SUV02-12-60-00X SUPERCHARGER ASSY, 99-05 RADIX (BOX 1)


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31-12-00-01X SUBASSEMBLY, FUEL MANIFOLD, RADIX TRUCK & SUV


1 35-15-01-201 MANIFOLD, FUEL, 1999-2002 RADIX TRUCK & SUV


1 80-62-31-112 O-RING, #112 VITON, 1999-2002 RADIX TRUCK & SUV

1 69-12-41-002 FITTING - 3/8" FUEL ADAPTER, 1999-2002 RADIX TRUCK & SUV

1 69-12-41-001 FITTING - 5/16" FUEL ADAPTER, 1999-2002 RADIX TRUCK & SUV

1 69-12-57-001 TOOL, FUEL RAIL 3/8" DISCONNECT, 1999-2002 RADIX TRUCK & SUV

1 69-00-01-006 SNAP RING-ROTOR CLIP, 1999-2002 RADIX TRUCK & SUV

15" 82-55-00-024 HOSE, 5/32" FUEL, 1999-2002 RADIX TRUCK & SUV

31-12-00-024 SUBASSEMBLY, INLINE FUEL PUMP, RADIX TRUCK & SUV


1 88-85-60-020 FUEL PUMP, INLINE, WALBRO GSL 394, 1999-2002 RADIX TRUCK & SUV


1 71-08-12-001 LOCKNUT M8 X 1.25, 1999-2002 RADIX TRUCK & SUV

12 69-90-24-004 TIE WRAP, 1999-2002 RADIX TRUCK & SUV

1 82-55-40-006 T-TAP FML, 1999-2002 RADIX TRUCK & SUV

1 82-55-40-041 CONNECTOR, BUTT, 1999-2002 RADIX TRUCK & SUV

1 82-55-60-101 16-14GA. RING, 1999-2002 RADIX TRUCK & SUV

1 82-55-80-002 WIRE/CONN ASSY RADIX FUEL PUMP, 1999-2002 RADIX TRUCK & SUV

1 82-55-50-120 FUSE, 20AMP, 1999-2002 RADIX TRUCK & SUV

31-12-00-007 SUBASSEMBLY, EARLY MODEL SUPPLEMENT, RADIX TRUCK & SUV


1 35-90-41-001 MANIFOLD, EGR, 1999-2002 RADIX TRUCK & SUV

1 48-46-00-068 FITTING, 3/8 NPT DBL.SIDED NIPPLE 3" LONG, 1999-2002 RADIX TRUCK & SUV

1 48-46-00-018 FITTING, PLASTIC 5/8" "T", 1999-2002 RADIX TRUCK & SUV

1 82-55-00-003 HOSE 5/8" COOLANT 90 DEG., 1999-2002 RADIX TRUCK & SUV

12" 82-55-00-006 WIRE, 20GA. GREEN W/BLK STRIPE, 1999-2002 RADIX TRUCK & SUV

12" 82-55-20-007 WIRE, 20GA. GREEN W/WHT STRIPE, 1999-2002 RADIX TRUCK & SUV

12" 82-55-20-008 WIRE, 20GA., LT. BLUE W/BLAK STRIPE, 1999-2002 RADIX TRUCK & SUV

12" 82-55-20-009 WIRE, 20GA., LT. BLUE W/WHT STRIPE, 1999-2002 RADIX TRUCK & SUV

12" 82-55-18-005 WIRE, 18GA., BLACK, 1999-2002 RADIX TRUCK & SUV

12" 82-55-18-006 WIRE, 18GA., DARK BLUE, 1999-2002 RADIX TRUCK & SUV

12" 82-55-18-007 WIRE, 18GA., GRAY, 1999-2002 RADIX TRUCK & SUV

1 69-99-00-022 PLUG, 1/4" NPT HEC HD., 1999-2002 RADIX TRUCK & SUV

14 82-55-40-041 CONNECTOR, BUTT 18-20 GAUGE, 1999-2002 RADIX TRUCK & SUV

18" 82-55-20-005 WIRE LOOM- 1/2", 1999-2002 RADIX TRUCK & SUV

1 65-12-60-003 BRACKET, THROTTLE, 1999-2002 RADIX TRUCK & SUV

2 68-50-57-100 STEAM COVER, 1999-2002 RADIX TRUCK & SUV


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