Intercooled Supercharger System 2003 - 2006 HUMMER …inst.pdf · Installation Instructions for:...

Installation Instructions for:

Radix

Intercooled Supercharger System2003 - 2006HUMMER H2

Magnuson Products Inc1990 Knoll Drive, Ventura, CA 93003

(805) 289-0044 phone * (805) 677-4897 faxmagnusonproducts.com * magnacharger.com

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

Use distilled or

de-ionized water

89-89-60-005 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). If you discovershipping 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...the root of power

2003-2006 Radix Hummer H2 & SUT Supercharger Installation Instructions 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 -

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

check and replace as needed before installation.

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 byinstalling the upgraded fuel pump. Ensurethat the fuel tank is less than 1/8” full(preferably empty) by checking the fuel levelgauge. Even though the gauge may readempty, some residual fuel will be present inthe tank. Exercise extreme caution andcommon sense when working aroundgasoline. Extinguish all open flame or othersources of ignition and be sure to performthe following steps in an area with adequateventilation. Personal protection in the formof eye protection and fuel resistant glovesare strongly recommended.

2. 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.

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

for2003 skip this section and continue to step44.

The followingsteps are for 2004 & 2005 vehicles,

4. Loosen the clamp and remove the fuelfill pipe from the tank. Disconnect the tankvent hose by squeezing the connector andpulling it apart.

Vent line

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5. Locate the EVAP cannister at the front ofthe fuel tank.

6. Disconnect the vapor lines from theEVAP cannister by squeezing and pullingthem off.

7. Remove plastic shield covering the fueltank.

8. Remove the two bolts that secure theoutside edge of the tank shield with a 13mmsocket wrench.

Vapor lines

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11 Remove the fuel tank straps byremoving the two strap bolts with a 15mmsocket wrench. Gently lower the fuel tankdown approximately 18” to gain access tothe connections on the top of the tank.

.

1 .2 Disconnect the large electricalconnector on the top of the tank by pullingback on the gray lock tab and squeezingthe end of the connector. Disconnect thetank pressure sensor connector by lifting upon it’s lock clip and pulling back on theconnector.

10 Remove the bolt along the inside edgeof the tank shield with a 13mm socketwrench.

.

9 Along the inside edge of the tank shieldlocate the attachment bracket. Remove thenut with a 10mm wrench.

.

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1 .4 The tank module is retained in the tankby a lock ring that locks into a retainingcollar on the tank. Note: the position of thelock ring in relation to the collar.

Lock Ring

Collar

15to remove the lock

ring by tapping the ring counter-clockwise.Do not use a metallic hammer and/or driftas a spark may result and ignite a fire.

CAUTION! USE A NON METALLICHAMMER OR DRIFT

.

13. Disconnect the fuel and vaporconnections on the top of the tank module.Squeeze the colored tabs on the bottom ofthe two smaller connectors together andthen push up on the tabs to release theconnectors. Push the large vaporconnector towards the tank module;squeeze the sides of it and then pull back torelease it from the tank module. Lower thetank free from the vehicle. With the aid ofan assistant, remove the fuel tank to asuitable work area.

1 .6 After rotating the lock ring counter-clockwise, remove the lock ring.

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1 .8 Pull the module out of the tankcarefully, so the fuel level float will not catchon the edge of the opening. Once the fuelmodule is removed from the tank, the whiteplastic “can” of the fuel module will stillcontain about one quart (1 liter) of fuel.Carefully tilt the module “can” so you canpour this excess fuel back into the tank.

1 .9 After removing the module from thetank, use a shop towel to cover the tankopening to prevent any debris fromentering.

17. Note: that the fuel module will only fit inone position in the tank as it is located by atab on the top flange.

20 Here is the fuel tank module assemblyas removed from the fuel tank. Prepare awell-ventilated work space away from anysource of ignition or open flame. Lay themodule assembly on clean, dry shop towelsto catch any residual fuel as youdisassemble it.

.

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21 On the underside of the module'smounting flange, unplug the electricalconnectors for the fuel pump and the fuellevel transmitter.

.

22 Locate the fuel pressure regulatormounted on the white plastic body of thefuel module. Using a straight bladescrewdriver, gently pry up on the regulatoruntil the regulator is unplugged from themodule body. The o-ring on the base of theregulator will be visible at this point.

.

Lock tab

23. Using two small screwdrivers, gentlypry out the two lock tabs that hold the pumpto filter hose connector in place. Removethe filter connector and hose from the filter.

Regulator

O-ring

24. Disassemble the module assembly byseparating the module “can” from themodule body. To do this, gently pry up onthe three retaining clips located along thetop edge of the can. It may be helpful touse three small screwdrivers as wedges tohold the edges of the can up as you pull thecan free.

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2 .5 Here is the module can separated fromthe module body. Note: that the fuel pumphas remained in the module body. Set thecan with the fuel level transmitter aside fornow for re-installation in a later step.

26. Unclip the fuel strainer from the modulebody; this will free the fuel pump.

27. Pull the fuel pump, strainer, feed lineand electrical harness free from themodule.

O-ring

28. Disconnect the electrical harness fromthe pump and remove the O-ring from theconnector as they will be reused. Thepump and attached components will not.

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29. Here are the new fuel pumpcomponents. Note: that the hose style mayvary.

Crimpclamps

Sleeve

Pump

Strainer

HoseSpade terminals

Hoseconnector

30 Assemble the fuel line by sliding acrimp-clamp over the end of the hose firstand then pushing the hose on the barbedend of the new fuel hose connector.

.

31. Use a pair of side cutting pliers tocrimp the loop of the crimp-clamp aroundthe fuel hose. Take care not to cut the loopbut only tighten it.

32 InstallSlide a crimp-clamp

over the end of the fuel hose and theninstall hose

. Crimp the loop of the crimp-clamp around the fuel line. Take care not tocut the loop but only tighten it.

. the mounting sleeve over thebody of the fuel pump.

the on the outlet nipple of thenew pump

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34. Using a heat gun or blow dryer set onHIGH; shrink the insulation on the spadeterminals so that it contracts around thewires completely. You must shrink theinsulation, as crimping the terminals aloneis not enough to secure them!

33. On one end of the pump harness, cutthe wires 1” from the plug and strip theinsulation back ¼”. Onto the stripped wireends, install the crimp/shrink spadeterminals supplied.

35. Install the pump harness on the top ofthe fuel pump. Note that the pumpterminals are marked “ ” and “ “. Install thegray wire on the “ ” terminal and the blackwire on the “ “ terminal.

:+ -

+-

36. Install the fuel strainer by placing it ona hard surface and aligning the large inletnipple on the bottom of the pump with theopening on the strainer. Note: That thestrainer should be pointing towards theoutlet nipple side of the pump.

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38. Insert the pump assembly, hose andharness first, into the body of the fuelmodule. Position the pump so that the fuelstrainer is pointing towards the fuel filter.

3 Install the O-ring from the originalconnector on the new connector.

Insert the new connector into the top of thefuel filter until it “clicks” into place.

9. fuelhose

37. Press down firmly with the pump sothat the strainer slides on until it’s collar isagainst the bottom of the pump.

40. On the inside of the can, ensure thatthe module tension spring is located in it’schannel.

Spring

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41. Slide the can back over the body of thetank module until the three clips at the topof the body snap into place. Reconnect thepump and transmitter connectors to theunderside of the module mounting flange.

42. Press the regulator down into position,ensure that it’s sealing o-ring is not visible.The tank module assembly is now ready forreinstallation into the fuel tank.

43

4

5

s

e-attach the vent line. Re-install the plasticfuel tank shield with its fasteners using a13mm socket and box wrench.

. Reinstall the tank module into the tankwith the flange tab pointing towards theword “TAB” on the tank. Coat the bottomsurface of the lock ring with some of thegrease supplied, then install the ring on theretaining collar. Apply some more greaseon the seven raised lock bumps on thesurface of the lock ring. Using the sametools you used to remove the lock ring,rotate the ring clock-wise until the lockbumps are in the same position as theywere in step 1 . With the help of anassistant, reposition the fuel tank back intothe position on your jack. Reattach the fuel,vapor and electrical connectors by pushingthem on. Raise the tank back into itsoriginal position and reinstall the fuel tankstraps with a 1 mm socket wrench, torquethese nuts to 40lb-ft. At the front tank, re-attach the vapor line to the black plasticvapor tank. Install the fuel fill pipe onto thetank and tighten the clamp securely. R

Refill thefuel tank with or higher.91 octane

This space intentionally blank

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44. 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 cableconnector with electrical tape.)

45. With a cool engine remove the radiatorcap. (Be careful not to remove the cap ifthe engine is still hot.)

46. Open radiator petcock and draincoolant into a clean drain pan. Savecoolant for reuse later on.

4 .7 Remove the plastic sight shield boltusing a 10mm socket wrench.

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48. Lift plastic shield from top of engine.

49. Using a flat blade screwdriver loosenthe two large hose clamps holding the aircleaner duct assembly.

50. Remove the duct assembly by lifting itout.

51. Remove the throttle control cablesfrom the throttle body assembly. On thesevehicles simply disconnect the electricalconnectors on the throttle body.

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Coolant Hoses

52. Using a long pair of pliers, remove thecoolant hoses from the bottom of thethrottle body.

Bolts & Clips

53. Remove the (PCV) vent hose from theintake manifold.

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

55. Disconnect the following electricalconnectors. (8) fuel injectors, Idle aircontrol (IAC), Throttle position sensor(TPS), Manifold absolute pressure sensor(MAP), Evaporative emission canisterpurge solenoid (EVAP), alternator andknock sensor.

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EVAP Vent tube

56. Lift the electrical harness from the topof the engine and set off to the side.

57. Disconnect the (EVAP) vent tube fromthe solenoid by squeezing the retainer, thenrelease the tube from the solenoid. Followthe same procedure on the other end of the(EVAP) vent tube and remove the tube fromthe vehicle. This assembly will bereinstalled.

58. Using 10mm wrench, remove & swinghood latch assembly to the drivers side forremoval and installation clearance.

59. Remove the positive crankcasevacuum hose (PCV) from the intakemanifold.

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Vacuum Hose

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

61. With the fuel line disconnect tool(included in kit), remove the fuel lines fromthe fuel rail. Be careful, the system may beunder pressure. Use shop rag under theconnections to catch any fuel spills. Stayaway from sparks and flames. (Rememberfuel is highly flammable.)

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

63. Carefully remove the intake manifoldassembly and set aside.

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

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

66. Remove the small plastic clips from theknock sensor electrical harness and setaside. The intake manifold will not clear ifthis step is missed.

67. Using a 15mm wrench, remove thesteel bracket from the rear of the driversside cylinder head.

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Bolts

68. Using a 10mm socket wrench, removethe two vent pipe bolts.

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

70. Using a 15mm tensioner wrenchremove the stock serpentine belt from thevehicle. The belt will not be reused.

71. Using a 15mm socket wrench orstandard wrench remove the three boltsholding the factory belt tensioner to thebracket and remove the tensioner. (Puttensioner and bolts aside for later use.)

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Checkclearance

Mark

72. Be sure battery has been disconnected(step 44). Using a box wrench disconnectthe battery positive terminal from the backof the alternator.

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

74. 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.

75. If contact occurs between the coolantvent pipe and the alternator bracket, use afelt tip marker and mark the bracket werethe coolant vent pipe hits as shown.

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PCV Valve

76. Using a die grinder, grind the marksmade in step 75. Once the clearance isground out, check the coolant vent pipeonce again and make sure that the ventpipe does not touch the alternator bracket.

77. Using the stock bolts removed in step68, install the new supplied front coolantvent pipe and rear block off blocks. (Latemodel vehicles already have the rearblocks installed.) Torque the bolts with atorque wrench and a 10mm socket to 106lbin. (Make sure that the O-Ring seals areinstalled correctly.)

78. Using the new supplied 16” x 3/8”(PCV) vacuum hose, connect one end tothe (PCV) valve as shown, and lay theother end of the hose off to the drivers sideout of the way. (To be connected in a laterstep.)

79. Install the intake manifold gasketssupplied onto the supercharger manifold.Ensure that the gaskets are fully seated intothe reliefs in the manifold.

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Clip

80. Remove the stock (MAP) sensor fromthe stock intake manifold, by pulling backon the two tabs and lifting the sensor out.(Make sure that the orange (MAP) sensorseal does not get damaged as it will bereused.)

81. Put some lubricant on the (MAP)sensor seal and press the (MAP) sensorinto the provided hole in the superchargermanifold as shown.

82. Using a 4mm Allen wrench, install the(MAP) sensor retaining clip with theprovided 6mm button head screw asshown.

83. This step is for vehicles only,2004 & 2005 vehicles skip to step to step87. Remove the stock fuel pressureregulator from the stock fuel rail bydisconnecting the vacuum hose, pulling offthe spring loaded clip and pulling theregulator out. (Be careful not to drop orlose any of the small O-rings on theregulator.)

2003

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O-Rings

Screen

Clip

O-Ring

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

85. 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.

86. 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 groove in the manifold.)

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

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88. Install the assembled fuel manifold tothe drivers side fuel rail using the two newsupplied 6mm bolts. (Be careful not topinch the O-ring.)

91. Using a 10mm socket wrench removethe stock throttle body from the stock intakemanifold, also using a #5 internal Torxsocket remove the three factory studs fromthe stock intake manifold.

90. vehicles only. Connect 3/16”hose from manifold top to O.E. regulatorport.

2003

8 . Using a 10mm socketwrench the bolts to 98/100 in lbs.

9 on a torque-

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92. Remove EVAP solenoid from stockmanifold, lubricate O-ring, mount on front ofnew intake manifold.

93. Remove 10mm bolt directly belowalternator and below factory idler.

A

B

94. After removing OE tensioner, reuse the2 fasteners shown in photo A in holesshown in photo B.

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95. Install new tensioner with new bracketsupport assembly, where old tensioner wasremoved.

96. Torque all fasteners to 40 ft-lbs.

97. Carefully cut out & remove cableguide/mount that was mounted on top ofintake.

98. Spray a thin coat of silicone or similarproduct to assist seating of the manifoldseals.

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A

B

C

99. Carefully remove and replace the oil fillneck with the shorter supplied assembly,and replace fill cap. In some cases, you willneed to remove the valve cover to releasethis tube. After removing fill tube, reinstallvalve cover.

100. Using an assistant, carefully lowermanifold assembly into place.

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101. Remove the flex-loom piece, allowingmanifold fastener to drop into place. Insertthe 9 remaining M6 X 100 bolts intomanifold. Start all 10 fasteners by hand.

102. Torque all ten fasteners in a criss-cross fashion to 89 in-lbs.

104. Route fuel lines around manifold forsmooth routing.

1 .03 Using supplied gasket, mount throttlebody using stock nuts and torque them to89 in-lbs.

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105. Re-attach fuel lines making sure theyare secured.

106. Re-attach injector plugs and otherrelated sensors.

107. Connect throttle body to cylinder headmanifold coolant hose.

108. Connect throttle body coolant hosefrom radiator.

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109. Route evap tube along fuel rail ondrivers side. Re-connect to fitting on backof engine, route under supercharger nose.

110. Route evap under supercharger nosedrive and connect. (Note: nose drivesupport is shown in this picture above, butis not to be installed until the next step.)

111. Attach supercharger nose drivesupport.

112. Remount alternator using OEhardware.

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113. Re-attach all electrical connections.

114. Re-attach hood latch assembly tofirewall using OE fasteners.

115. Apply the belt routing and vacuumdiagram over the existing belt route label.

116. Route belt on to all pulleys. Use15mm tensioner or breaker bar to releasetensioner. See new belt routing diagramprovided. (Drive belt is a Gates #K061120)

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117. Install/plug-in throttle control cableand check all connections for kinks orbinding.

118. Locate MAF cable, pull back flex loomapproximately 8 inches. Separate the tan &black wires from this harness.

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

To computer

To MAFNo longerused

120. 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!

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121 Plug the IAT harness into the IATsensor located under the superchargernose.

.

122 suppliedon the air filter.

. Install the clamp and bellows

123. Install the air inlet tube on the MAFand throttle body.

124. Remove the rubber cap from thecenter barb located on the back of the inletmanifold. Attach the remaining end of thehose from the PCV valve to this barb.

PCV hose connects here

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126. Check all connections, vacuumrouting, fuel hoses and wires for properplacement.

125. Route passenger side PCV hose tothe 3/8” barb located on the bottom of theair tube, shorten hose if needed for smoothrouting.

128. Firmly grasp the relay centers coverand lift off.

127. Using a 13mm socket wrench removethe four bolts holding the left side hood stopbracket to the chassis.

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130. Lift the cover off and set aside formodification.

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

.

132 Mark the location of the threemounting studs on the cover and then drill5/16” holes in these locations.

.

Bracket

Alignedges

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

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1 .34 Here is the intercooler reservoir/pumpassembly. Note: the hose and electricalconnections.

Reservoir Inlet

Electrical Connection

Pump Outlet

1 .35 Install the reservoir/pump assemblyon the two reservoir bracket studs with thesupplied nuts. Tighten the nuts securely.

1 .36 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.

133 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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1 .38 Connect the yellow wire from the relayinto the T-tap connector installed in the laststep.

139. Using a 13mm socket wrench removethe positive terminal nut from the lug.(Caution - make sure the battery isdisconnected.)

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

1 .37 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.

Note: Detailed Wiring diagram can befound in the back of this instructionmanual.

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1 .41 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.

142 This step is for 2003 vehicles only,.

Install the wiring harness for the fuel pumpin the same location as you did for theintercooler pump wiring harness. Attach theextra yellow wire from the intercooler pumprelay onto the male spade terminal marked“85” on the bottom of the fuel pump relay.Attach the ring connector from the fusedpower wire in the same location as you didfor the intercooler pump relay in step 138.Attach the black ground wire ring connectorin the same location as you did in step 140.Route the black and red split loom coveredwires down and along the inside of the leftframe rail to the fuel filter location.

2004-2005 vehicles skip to step 143.

1 .41 Using a 10mm socket wrench,remove the nut from the body ground studon the firewall as shown. Body ground stud

1 .43 Reinstall the relay center covercomplete with the reservoir and pumpinstalled. (Be careful not to pinch anywires.)

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1 .44 Reinstall the fuse/relay cover byaligning it up and pushing down on it.

145. Reinstall the left side hood stopbracket to the chassis.

1 .46 Install the intercooler electricalconnector into the bottom of the coolantpump. Secure the wiring as necessary withthe tie-wrap straps supplied.

147. Remove any brush guards or pushbars to expose original equipment grille.

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148. Open hood, and locate 6mm nuts oneither side of headlights. Remove two 6mmnuts on each side (4 total) to allow grilleremoval.

149. Pull firmly at the top and bottom of thecenter of the grille. Carefully unsnap or“pop” grille out.

150. Using supplied template, punch anddrill two 1-1/2” to 1-5/8” holes and two17/64” holes on the grille shell.

151. Here is the heat exchanger and itsmounting components. The two studmounts will be installed in the bottom twoholes of the heat exchanger. Use a 10mmwrench to install them. Peel the paper offthe adhesive side of the foam strip andapply the strip to the top of the heatexchanger.

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153. Here is a diagram of the intercoolercoolant system.

1 . From the length of hose supplied,connect one end to the driver sideintercooler fitting,

Route this hose to the heatexchanger.

54

secure it with a #10clamp.

Driver side intercooler fitting

Ton

ercooler

It

To Reservoir

Reservoir

Pump

Heat Exchanger

Intercooler

D.S.P.S.

Air Bleed

152. Carefully install the heat exchangerinto its mounting location. Secure the studmounts with the supplied nuts using a10mm wrench.

155. Pass all hoses through the radiatorbulkhead to the heat exchanger by routingthem beside the radiator on the driver side.The hoses should then pass down in frontof the radiator and out to the heatexchanger through the large rectangularhole below the front of the radiator.

Rectangularhole

Hoses pass throughbulkhead here

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15 . Connect one end of the remaininglength of hose to the air bleed fitting locatedon the pre-installed hose from thepassenger side intercooler .

8

barb Securethe hose at the fitting with a #10 clamp.

15 . Connect the hose from the driver sideheat exchanger to the outlet barb ofthe coolant pump using

7barb

enough hose sothat it will make a smooth transition to theheat exchanger without kinking. Secure thehose at the pump with a #10 clamp.

156. Route the hose from the driver sideinnercooler barb to the driver side heatexchanger barb. Use enough hose so thatit will make a smooth transition to the heatexchanger without kinking when the hood ofthe vehicle is closed. Connect a length ofthe remaining hose to the passenger sidebarb and route this hose to the outlet barbof the coolant pump.

Air bleed fitting

Pump outlet

Passenger side barb

Driver side barb

159. Attach the remaining end of the hosefrom the air bleed fitting to the inlet barb ofthe coolant reservoir. Secure the hose witha #10 clamp. Refill radiator and intercoolersystem with a 50/50 mixture of GMrecommenced coolant and distilled or de-ionized water only. Bleed the intercoolersystem at the bleed fitting. Check systemperiodically for fluid level. Replace the grilleand brush guard / pull bars if fitted.

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Drill 2 holes

1 movethe aluminum rock/skid guard. Set thisaside for reinstallation later.

61. Using a 15mm socket wrench re

162. Locate the center cross member asshown, using a 21/64 drill bit drill two holes2 ¾ inches apart from each other in the topof the cross member 1 inch out from thetorsion bar adjusting bolt as shown.

160, for 2004 & 2005 skip this

section and continue to step 175.

The following steps are for 2003vehicles only

.

Lift vehicle in the air using a automotive liftor you can also use a floor jack and jackstands. (Caution do not work under thevehicle without using safety stands, thevehicle could fall and cause serious injuryor loss of life.)

163. Drill holes by drilling straight up inbetween the cross member as shown(Caution wear safety glasses).

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165. Remove the plastic clip from the fuelfilter. Use a small pocket screwdriver orpick to aid in the removal. (Do not damagethe clip it will be reused in a future step.)

Retaining clip

166. Using the supplied clamps, 8mmbolts, and nylock nuts, fasten the fuel pumpassembly to the top of the cross member asshown with the electrical connectors facingthe passenger side of the vehicle. Installthe small plastic retaining clip removed instep 165 to the new fuel line as shown.(Make sure the connector snaps on tight.)

Plastic tabs

164. Locate the fuel filter above the crossmember on the drivers side of the vehicle.Disconnect the fuel line on the filter asshow by squeezing the two white plastictabs together and pulling the line off. Thisis the line that goes to the front of thevehicle.

(Caution fuel system could be underpressure, loosen the gas cap first and wrapa rag around the fuel line for safety.) (Wearsafety glasses.)

Inlet side

Outlet side

167. Push the inlet side pump hose on tothe fuel filter, making sure that it locks intoplace. (Pull on it to make sure it does notcome off.) Also push the outlet side hoseinto the fuel line that goes to the front of thevehicle. (Make sure you check this one toby pulling on it too.)

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170. Place the wires on the pump, installthe nuts and tighten securely. (Do not overtighten the nuts or you will break the studs.)

Black wireRed wire

1 . The fuel pump wiring must be wiredcorrectly to work, the red Positive wire goesto the “ ” post on the pump and the blacknegative wire goes to the “ ” post on thepump. (Double check your installationbefore moving on.)

69

+-

168. After running the new supplied fuelpump wires down to the fuel pump, cut thewires to length and crimp on the newsupplied wire ends to the wires. (Theterminal ends are on the fuel pump.)

Drill hole171. Set the fuel pump hose into the lip ofthe cross member, drill a small hole in thecross member just above the hose. Usingone of the supplied tie wraps, secure thehose as shown.

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174. A picture of how it should look after itis finished.

173. Using a 15mm socket wrench re-install the rock/skid plate to the chassis.

172. This is what the fuel system will looklike after it is installed. Double checkeverything and make sure that the hosesand wires will not rub on any thing. Alsomake sure that they are not close to theexhaust.

This space intentionally blank

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

177. 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.

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

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 "NO RESPONSE"from the PCM or permanent damage to the vehicle PCM.

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178. 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 directions asdescribed above. The handheld unit will prompt you that you have already modified the vehicle’scomputer. Select YES to return you vehicle’s computer back to the stock calibration. Wait for thehandheld to finish, then disconnect cable as described above.

ALDL

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 ALDLconnector 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!

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.

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Fill holes

180. 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.

181. 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.

182. 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.

179. Once programing is completed,ensure the vehicle is off and the keys areout of the ignition. Install the fuses backinto their correct locations and reinstall thecovers.

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2003 Only

INTERCOOLER/FUEL PUMP WIRE ROUTING DIAGRAM

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2004 & 2005Only

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Intercooled Supercharger System 2003 - 2006 HUMMER …inst.pdf · Installation Instructions for:...

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