1996-00 GM Truck/SUV 5.7L

AUTOMOTIVE DIVISION
GENERAL
MOTORS
TRUCKS & SUVS
5.7 V-8
Welcome to the Magna Charger family of Eaton supercharger systems... You have made a
very important decision and we commend your choice. We're sure you'll be happy with the
ease of installation and the outright performance improvement of this bolt-on Magna Charger
kit.
Our parent company, Magnuson Products, is the exclusive aftermarket supplier for all Eaton
superchargers; therefore our products are built to O.E.M. standards for function and durability.
Your kit has been thoroughly tested and carries California Air Resources Board E.O. #D-488-1.
Installation is as simple and time sensitive as we could make it. We are as close as your
telephone, and if you have any question we encourage you to call before you start... to get
comfortable with the task ahead, during the installation process, or after your job is complete.
We appreciate the business and would like very much to hear from you regarding your
experience with the Magna Charger supercharger kit.
Sincerely,
Magna Charger
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INSTALLATION MANUAL
Magna Charger kit 10-57-001
GM 5.7 liter Vortec
1996-2000 model years
We encourage you to read this manual thoroughly before you begin work, for a few reasons:
1.
A quick parts check to make certain your kit is complete (See shipper parts list in this
manual). If you discover shipping damage or shortage, please call our office immediately.
2.
Take a look at exactly what you are going to need in terms of tools, time, and experience.
3.
Review our limited warranty with care.
You're going to need a few basic tools as follows:
3/8” drive Ratchet
Metric socket set (standard and deep)
3” and 9” extension, 3/8”
17mm open-end wrench
Flat head screwdriver
#3 Phillips screwdriver
Pliers
Electric drill
Cutting tool for rubber hose
3/8” Breaker bar
Fluid container, 2-gallon minimum capacity
A few very important items you should know:
1.
Our Magna Charger kits are designed for engines in good mechanical condition only…
installation on worn or damaged engines is not recommended and may result in engine
failure, which we naturally can't be responsible for. Magna Charger is not responsible for
engine damage or consequential damages.
2.
Aftermarket engine recalibration devices such as chips or programmers may not be
compatible and may cause engine damage or failure. If you have any questions,
call us!
3.
After you finish your installation and road test your vehicle, please fill out and mail the
limited warranty card, so we can add you to our files (this is important for your
protection).
4.
Use only premium fuel, 91 octane or better.
So… let's get started!
Any questions? Call first!
We're here 8:00 a.m. to 5:00 p.m. Pacific time
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1.
Remove the rear air chamber with the
’Vortec’ logo, by loosening the hose clamp and
removing the retaining bolt using a 10mm
socket. Remove the hose clamp from the air
chamber and set aside to be re-installed in a
later step.
2.
Plug the throttle body inlet cover with
cap PN 51-10-250. Use the hose clamp from
the air chamber, previously removed in step
#1, to secure the cap.
3.
Drill a 3/16” hole in the fan shroud in
approximately this location. Secure clamp PN
46-10-014 into this hole using the supplied nut,
washers and bolt from sub-assembly 14-57002.
4.
Disconnect the electrical connector plug
that connects to the A/C pressure sensor
(located at the top rear of the A/C compressor).
Remove the flex loom and electrical tape
around the two wires. Cut the wires about four
inches from the connector, and lengthen them
using the four connectors and pigtails (PN 5510-001, 55-10-008) supplied. Install flex loom
(PN 55-20-001) to protect the wires. Pull the
electrical plug under the upper radiator hose
and forward, then reconnect it to the A/C
pressure sensor.
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5.
Take the vehicle to a qualified air conditioning service center and have the A/C Extension
Manifold (PN 26-57-001) installed on your A/C compressor as follows:
6.
Remove refrigerant from A/C system into an appropriate holding tank.
7.
Using 15mm socket, remove the A/C
hose junction block from the A/C compressor.
8.
Install the A/C extension manifold and A/C
hose junction block, using the supplied seal
washer kits (PN 59-00-001) and bolt. Do not reuse the old seals! Route the throttle and cruise
control cables over the junction block.
9.
Remove the A/C feed hose from the
forward position in the alternator clamp
assembly, and reinstall it in the clamp (PN 46-10004) which was installed previously.
10.
Gently bend the hard line at the A/C
junction block until the A/C feed hose lies along
the radiator shroud.
11.
Gently bend the hard line at the rear
A/C junction block until the A/C return hose is
approx. 2.5” away from the firewall, to relieve
tension on the hose and provide clearance for
the supercharger. Recharge the system and
check for leaks.
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12.
Disconnect the negative (-) battery cable.
13. Drain approximately one gallon of coolant/antifreeze from the vehicle’s cooling system. The
petcock faces the rear of the vehicle and is located down low on the driver’s side of the radiator.
14. Disconnect upper heater hose assembly
from water pump, and hose at rear of
alternator. Remove bolt securing hose
assembly to alternator bracket. Remove hose
assembly.
15. Install the new heater hose from subassembly 14-57-005 using the supplied hose
clamps and hose joint coupler.
16. Remove upper radiator hose from
thermostat housing. Remove thermostat
housing using a 14mm socket on the ground
wire nut and a 13mm deep socket on the two
stud/bolts.From sub-assembly 14-57-005,
install the Magna Charger thermostat housing
(PN 26-57-002). You will find it necessary to
push downward firmly on the wiring loom
support clamp in order to make room for the
new thermostat housing. Be sure to re-install
the ground wire which attaches to the
thermostat housing bolt.
17.
Cut 4” off the end of the upper radiator
hose which goes to the engine and reinstall,
orienting the hose clamp as shown. This
will provide clearance for the supercharger.
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New Location
18.
Remove throttle body inlet cover by
removing the plastic wing nut, PCV elbow, and
loosening the hose clamp which secures it to
the air inlet assembly hose.
MAF
19.
Unplug the Throttle Position Sensor
(TPS) and Idle Air Control (IAC) plugs [both
located on the driver’s side of the throttle body]
and remove their wires out of the split loom up
to the large split loom. Add split loom PN 5520-002 to protect the wires. Route the wires
behind and under the injector wiring harness
over to the passenger side.
IAT
20. Unplug the Mass Airflow Sensor (MAF)
electrical connection. Unplug the Inlet Air
Temperature (IAT) sensor electrical connection
and remove its wires out of the loom to just
past the location of the bracket which holds the
wiring harness to the firewall. It will be
necessary to remove the bracket to pull the
wires out of the loom at that point. Install flex
loom (PN 55-20-001) on the wires. Reinstall
bracket. Remove air filter assembly and elbow
temporarily, as this will be re-installed later.
Remove the IAT sensor and rubber grommet
from the MAF hose. Plug the sensor hole in
the MAF hose with plug PN 51-57-002. Use
RTV to seal the plug.
21.
Remove the IAT holddown (PN 40-57007) and bolt (PN 71-06-012) from
supercharger assembly. Install the IAT
grommet and sensor into the hole in the side of
the supercharger plenum. Secure with
supplied holddown and bolt. (PN 40-57-007 &
71-06-012).
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22. Remove the cruise control and throttle cable
from the throttle body and cable bracket. Remove
the throttle body and cable bracket. Route the
cables along the rear of the engine.
23. Remove the power brake hose from the fitting
on the intake manifold. Cap the fitting with PN 5110-012 and use clamp 46-10-001 to secure it.
The vacuum hose will be relocated later.
CAP
24. Remove the PCV plastic hose assembly
which goes from the fitting on the intake
manifold to the driver’s side valve cover. Cap
the fitting with cap PN 51-10-038 and secure it
with clamp 46-10-002.
25. Remove the PCV valve. Install the valve in
the 3/8”x14” long hose (PN 55-00-002),secure
with clamp PN 46-10-002. Reinstall PCV valve
into the driver’s side valve cover. The other end
of the hose will be reconnected later.
26. Attach the manifold adapter plate to the
intake manifold using three countersunk
screws (PN 75-06-010) and thread sealant
provided.
27. Using a 3/8” drive breaker bar on the automatic
tensioner, rotate counter-clockwise to relieve belt
tension and remove the serpentine belt.
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Second CPS 96-97yr only
28. Remove one nut-stud on each side of the
intake manifold as indicated in the photo. Install
studs PN 76-06-100 in their place. The new
studs will not bottom out, so install each one
until it just begins to protrude through the
bottom of the intake manifold casting. Check
this by placing a fingertip underneath the hole
as the stud is being installed.
29. Unplug the canister purge solenoid (CPS)
located on passenger side of engine. Remove
the remaining nut-stud holding the solenoid, then
pull the solenoid out of the manifold, leaving the
plastic hose connected. On 1997 and earlier
year vehicles, remove the short 90-degree hose
from between the two CPS solenoids.
Passenger side
Driver’s side
Top
Bottom
30. Install CPS relocation manifold PN 40-57005 into the previous CPS location. Secure the
spacer with the supplied M6x1.0x40mm bolt.
31. Install the passenger side plenum standoff
PN 51-00-003 into the previously installed stud.
Install the solenoid onto the spacer, using bolts
PN 71-06-015.
33. Install the driver's side plenum standoff (PN
32. Install the CPS solenoid onto the manifold
51-00-002) over the stud, with the smaller
using the supplied M6x1.0x12mm bolts [PN 71diameter end into the intake manifold.
06-015]. Reconnect the CPS electrical plug onto
the solenoid. On 1996-97 year vehicles, install
the 6” piece of 1/4” hose between the two CPS
solenoids.
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34. Remove the idler pulley. Remove the front
left [as viewed from the front of the vehicle] A/C
compressor mounting bolt, replacing it with the
stud [PN 76-10-123]. Screw in the stud until it
bottoms out.
Stud
35. Apply a small bead of Gasket Eliminator
sealant [PN59-20-001] around the throttle body
mounting flange, being sure to include the IAC
air port.
Extension
36. Remove the stud extension from the throttle
body bolt. Using the stock fasteners, install the
throttle body. Install the new throttle/cruise
control cable bracket (PN 40-57-008) onto the
supercharger inlet adapter.
38. Using lubricant PN 59-30-001, lubricate
the outside of the supercharger adapter .
37. Using lubricant PN 59-30-001, lubricate the
o-ring/seal inside the throttle-body-to-MAF hose
adapter (PN 20-57-002). Remove the bolts (PN
71-05-010) and brackets (PN 40-57-006) from
the adapter. Mount the adapter onto the throttle
body with the PCV nipple facing forward.
Reinstall the brackets and bolts.
39. Using lubricant PN 59-30-001, lubricate the
supercharger adapter.
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40. Push the main wiring harness down between the Manifold Absolute Pressure (MAP) sensor,
CPS, and ignition module. Rotate power brake nipple on intake manifold toward driver’s side.
Carefully lower the supercharger assembly onto the manifold adapter plate, aligning the two mounting
tabs over the two studs with spacers on the intake manifold, and aligning the front drive support over
the stud installed previously on the A/C compressor. Make sure no components are pinched or
crushed under the plenum. Also make sure the hose clamp on the upper radiator hose is not
contacting the plenum.
41. Disconnect the A/C electrical plug to give
better access to the A/C compressor mounting
stud. Install nut PN 73-10-150 on the A/C
compressor mounting stud leave loose. Install
and tighten bolt (71-08-060) on passenger back
side of the idler bracket using a 10mm socket.
Then finish tightening the A/C compressor nut
using a 15mm wrench. Reconnect the A/C
electrical plug.
42. Install and tighten nuts (PN 73-06-100) on
the two plenum ears to secure the supercharger.
Minimum 1/4in clearance
43. Install the anti-vibration sleeve (PN 51-20001) on the throttle and cruise control cables.
44. Attach the throttle cable and cruise control
cable by routing it underneath the rear A/C
return line. Carefully bend the A/C return line
upwards to provide necessary clearance
[minimum 1/4”]. Plug in the TPS, IAC, and IAT
connectors.
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45. Note: General Motors has fitted these vehicles with either of two different types of alternators.
Follow the instruction below in accordance with the alternator the vehicle is equipped with.
Large alternator
Large alternator mount
Small alternator mount
Install the stock idler pulley on the passenger
side of the supercharger idler support bracket.
Use the upper mounting hole for the large
alternator applications. Use the lower
mounting hole for small alternator applications.
!
46. Install the serpentine belt (PN 50-57-002),
following the pattern in photo, while using a
3/8in breaker bar on the automatic belt
tensioner, rotating it counter-clockwise to
relieve tension. It is easiest to install the belt
over the water pump pulley last.
Small alternator
47. Using the supplied “T” fitting, cut and
connect the supplied vacuum hose from the
supercharger bypass actuator to the port on the
bottom of the CPS solenoid spacer, and to the
center port at the rear of the supercharger inlet
adapter. Attach the PCV hose to the driver’s
side port, and the power brake hose to the
remaining port.
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C.
Turn the ignition key to the on or run
position but do not start the vehicle.
D.
To begin programming your vehicle, you
must press the YES button.
E.
You only need to press the YES button once
to start the programming cycle. The
programming process only takes about a
minute.
*DO NOT DISTURB THE CABLE OR TURN THE
IGNITION OFF DURING THIS TIME! IF THE
PROGRAMMING IS DISRUPTED YOUR
COMPUTER WILL NOT START OR RUN YOUR
VEHICLE!
F.
The handheld unit will inform you that the
programming process has completed and
G.
Programming is now completed. Start
to turn the ignition off and disconnect the
the vehicle to ensure proper operation.
cable. Only at this time should the ignition
be turned off and the cable removed.
In the event that the vehicle needs to be returned to its original calibration, follow the directions as
described above. The handheld unit will prompt you that you have already modified the vehicle’s
computer. Select YES to return your vehicle’s computer back to the stock calibration. Wait for the
handheld to finish, then disconnect cable as described above.
53. Start vehicle and allow it to idle for a few minutes while you confirm that there are no coolant
or vacuum leaks, etc. Enjoy your new supercharger!
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48. Re-install the air filter assembly. Attach the
flexible hose to the throttle body-to-hose
adapter. Attach the crank case breather tube to
the throttle body-to-hose adapter. Reconnect
the MAF plug to the MAF sensor.
49. Install decal with Magnacharger Vacuum
Hose Routing and Accessory Belt Routing
Diagram (PN 91-57-001) under hood of
vehicle.
50. Refill coolant/antifreeze. Reconnect battery
negative (-) lead.
51. Re-adjust cruise control cable and check
operation of throttle cable to ensure that there
is no binding. Check all fittings, as well as
cable and vacuum hose routing, to ensure that
nothing is loose or may come into contact with
a spinning belt, pulley, hot manifold, etc.
54. Vehicle Programing Instructions For the Micro Tuner 2001
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.-
A.
B.
Connect the supplied cable to the 9-pin
connector at the top of the handheld
unit. Use the thumbscrews to secure
the cable to connector.
ALDL
Connect the other end to your ALDL
connector located under the dash near
the steering column. Make sure this
connection is seated all the way in and
that it is secure. You do not want this
cable coming out of the connector during
programming.
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