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Installation Instructions for:
INTERCOOLED SUPERCHARGER SYSTEM
2004-2006 FORD 5.4L 3V F-150 TRUCK
Step-by-step instructions for installing the best in
supercharger systems.
Magnuson Products Inc
1990 Knoll Drive, Ventura, CA 93003
(805) 289-0044 * (805) 677-4897 fax
magnusonproducts.com * magnacharger.com
89-89-65-001 Rev C
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INSTALLATION MANUAL Magna Charger FORD 5.4 Liter 3V Engine, 2004-2006 F-150 TRUCK Please take a few moments to review this manual thoroughly before you begin work: A quick parts check to make certain your kit is complete (See shipper parts list in this package). If you discover shipping damage or shortage, please call our offi ce 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. When unpacking th
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1. Start the supercharger installation by removing the negative (-) battery with a 10mm wrench. 1. Start the supercharger installation by removing the negative (-) battery with a 10mm wrench. 3. Remove the air tube with a 10mm socket wrench. 4. Remove the air tube assembly by lifting it up and pulling it towards the passenger (right) side. Page 3 05/06 2004-2006 Ford F-150 3V Supercharger Installation Instructions magnacharger.com
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Remove Six Fas- 1. Start the supercharger installation by teners removing the negative (-) battery with a 10mm wrench. 1. Start the supercharger installation by removing the negative (-) battery with a 10mm wrench. 1. Start the supercharger installation by removing the negative (-) battery with a 10mm wrench. 8. Disconnect the eight ignition coil connectors by squeezing the release trigger and pulling the connectors free. Page 4 05/06 2004-2006 Ford F-150 3V Supercharger Installat
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9. Remove the bolt that secures the coil to the cylinder head with a 7mm socket wrench. 10. Remove the eight ignition coils by carefully pulling up on them. 11. The standard spark plugs will need to be replaced with the Autolite HT0 spark plugs sup- plied. Use an appropriate 9/16” spark plug socket to remove and replace the plugs. Use of a stan- dard “deep” socket will break the spark plugs. Autolite HT0 Spark Plug 12. Remove the standard spark plugs and replace them with the Au
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13. Unlock the three vehicle computer connections by pulling the grey release levers forward. Remove the three connectors by pulling Unlocked them straight out. Locked 14. Remove the four computer mounting bolts with a 10mm socket wrench. Mounting Bolts 15. Remove the computer from the vehicle. 16. Here are the shipping materials supplied to quickly ship the vehicle computer. Page 6 05/06 2004-2006 Ford F-150 3V Supercharger Installation Instructions magnacharger.com
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17. Place the computer into the plastic packaging material supplied and then seal the box. 18. Completely fi ll out the pre-paid shipping form supplied and then remove the adhesive la- bel on the third page, placing it on the top of the box. Take the box to your nearest UPS offi ce for shipping. Your computer will be re-programed and quickly returned to you via UPS. 19. Remove the Mass Air Flow (MAF) connector Release Trigger on the top of the air fi lter box by pulling out the red
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21. Remove the Mass Air Flow (MAF) connector on the top of the air fi lter box by pulling out the red release trigger and then pulling the connector free. 22. At the rear of the intake manifold remove the PCV hose connector by pushing in on the white release trigger and pulling the connector free. Release Trigger 23. Remove the alternator cable from the anchor Alternator Cable on the air box by cutting the tape that secure it. 24. Remove the four air fi lter box bolts from the intake ma
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25. Lift the air fi lter box off the intake manifold. 26. Remove the PCV connector by pushing the green release trigger and pulling the connector free. 27. Pull up on the red release trigger of Throttle Position Sensor (TPS) connector and pull the connector free. Next remove the four throttle body bolts from the intake manifold with a 10mm socket wrench. Throttle Position Sensor connection 28. With the throttle body unbolted from the intake manifold, pull up on the red release trigge
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29. Disconnect the PCV vent tube electrical connector. Vent Tube 30. Using a 8mm socket wrench, unbolt the PCV vent tube from the intake manifold. Vent Tube Bolts 31. Carefully withdraw the PCV vent tube from the Vent Tube intake manifold. 32. Remove the Fuel Pressure Sensor connector by pushing in on the white release trigger and pulling the connector free. Page 10 05/06 2004-2006 Ford F-150 3V Supercharger Installation Instructions magnacharger.com
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Lock Clip 33. Remove the fuel line lock clip. Fuel Line Tool 34. Use the supplied removal tool to remove the Connector fuel line connector. CAUTION! The fuel in the system is under pressure! Use caution when disconnecting the fuel line. Collect any spilled fuel with a shop towel. CAUTION! The fuel in the system is under pressure! 35. Squeeze the release trigger on the eight Release Trigger injector connectors and then pull them free. Injector Connector 36. Remove the fuel rail a
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Fuel Rail 37. After removing the four bolts, pull up on the fuel rail and wiggle it to release the injectors from the intake manifold. 38. Disconnect the alternator cable connection with a 10mm wrench. 39. Disconnect the alternator control connector by Alternator Control squeezing the connector and pulling it free. Connector 40. Remove the alternator bracket by removing the three retaining bolts with a 10mm socket wrench. Page 12 05/06 2004-2006 Ford F-150 3V Supercharger Installation
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Water Pump 41. Remove the two alternator mounting bolts Pulley below the alternator with a 12mm socket wrench. Note: 2004 owners will need to replace the water pump pulley with a 2005-2006 water pump pulley at this time. Ford part # F7UZ-8509-AA. 42. Remove the alternator and set it aside. 43. On the right, lower corner of the radiator locate the drain valve. Open the drain valve only if the engine is cool. CAUTION! Do not open the drain valve if the vehicle is still hot.
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45. Remove the thermostat outlet and O-ring seal from the water manifold. Next, remove the two Bolt Bolt bolts that secure the water manifold to the cylinder head with a 10mm socket wrench. Coolant Hose 46. Remove the coolant hose from the water manifold by squeezing the spring clamp with a pair of pliers and pulling the hose free. Bolt Bolt 47. Remove the water manifold by removing the two bolts on each side with a 10mm socket wrench. 48. Remove the water manifold. Page 14 05/06 200
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Manifold Bolts 49. Remove the ten bolts (fi ve on each side) that secure the intake manifold to the cylinder heads with a 10mm socket wrench. 50. Though the intake manifold is now “loose”, it cannot be removed from the engine as there are still some connections on the back of the manifold that need to be undone. 51. Lift the manifold and pull it forward to gain more room to work on the connections on the rear. Remove this Nut 52. The large wiring harness passing across the Servo-Motor
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53. Remove the manifold servo-motor connection Release Trigger by squeezing the release trigger and pulling the connector free. 54. Disconnect the Knock Sensor connections. There will be one on each side of the manifold at the rear. Squeeze the connectors to separate them. Untangle the knock sensor wires from the servo-motor control rods. Power Brake Hose 55. On the lower driver side (left) rear corner of the intake manifold is the power brake vacuum connection. Squeeze the cla
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57. Once all connections are removed from the rear of the manifold, remove it from the engine. 58. On all 2WD and 2004 4WD vehicles remove the brake vacuum line where it meets the check valve. Remove Check Valve 59. On 2005-2006 4WD vehicles remove the “T” Fitting brake vacuum line where it meets the “T” fi tting. Remove 60. Clean the gasket surfaces and then cover them with tape or shop towels to keep debris from entering the ports. Page 17 05/06 2004-2006 Ford F-150 3V Supercharger I
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61. Remove the nut and then the hose support bracket from the front of the right cylinder head with a 13mm socket wrench. Remove Nut and Bracket 62. Remove the two nuts and the air tube bracket from the front of the left cylinder head with a 13mm socket wrench. Remove Nuts 63. Re-install the two nuts previously removed in the last step to secure the power steering fl uid reservoir. 64. Carefully remove the throttle body gasket from the intake manifold. Page 18 05/06 2004-2006 Ford F-15
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65. Carefully remove the intake manifold gasket from each side of the manifold. 66. Remove the eight standard fuel injectors from the fuel rail by carefully prying the retaining clips off the rail with a small screwdriver. With the clips removed, pull the injectors off of the rail. 67. Using some of the grease supplied, lubricate the injector O-rings and install the supplied injectors . The clips will not be re-used. 68. Using some of the grease supplied,
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60” Hose 69. Install the PCV vent tube assembly into the hole in the inlet manifold. Use the original bolts Vent Tube and tighten them to 89 in-lbs (10Nm) using a torque wrench and 8mm socket. Gasket 70. Install the throttle body gasket into the groove in the inlet manifold fl ange. 71. Using the length of hose supplied, cut a 60” length and connect one end to the passenger side intercooler barb as shown. Secure the hose with the #10 clamp supplied. 72. Clean and inspect the manifold
