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Installation Instructions for:
INTERCOOLED SUPERCHARGER SYSTEM
2005-2006 PONTIAC GTO LS2
Step-by-step instructions for installing the best in
supercharger systems.
Magnuson Products Inc
1990 Knoll Drive, Ventura, CA 93003
(805) 642-8833 * (805) 677-4897 fax
magnusonproducts.com * magnacharger.com
89-89-60-014 Rev B
Use distilled or
de-ionized water only.
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INSTALLATION MANUAL Magna Charger GM 6.0 LS2 Liter Engines, 2005 and later Pontiac GTO Please take a few moments to review this manual thoroughly before you begin work, as there are special steps for both the LS1 (2004) and LS2 (2005-on) equipped vehicles: Μake 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
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1. Open the hood and remove the under hood insulation by prying out the seven plastic buttons that retain it. The insulation will not be reused. 2. Disconnecting the negative (-) and then the positive (+) battery clamps with a 13mm wrench. Next, remove the the battery anchor and the battery itself. 3. Locate the vehicles computer on the front surfase of the driver side wheel well. Latch open Latch open L Latch closed atch closed 4. There are three computer connectors, Grey, Black a
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5. The computer connectors can be removed when the latch is pushed down and the red tail of the latch is Latch tail Latch tail visible on the end of the connector. 6. Remove the two T20 TORX screws that secure the computer to its mounting bracket. 7. Remove the computer carefully from the vehicle. 8. Here are the shipping materials supplied to quick- ley return the vehicle computer to Magnuson Products Inc. Page 4 12/05 2005-2006 Pontiac GTO LS2 Supercharger Installation Instructions mag
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9. Place the computer into the plastic bag supplied and then wrap it in the bubble-pack sheet and seal the box. 10. Completely fi ll out the pre-paid shipping form supplied and then remove the adhesive label on the third page, placing it on the top of the box. Take the box to your nearest UPS offi ce to be returned to Mag- nuson Products Inc. Magnuson will then re-program the computer and quickly return it to you via UPS. 11. On top of each shock tower remove the two nuts that secure t
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13. Remove the two engine covers by pulling up fi rmly along the edges. 14. Loosen the Air Tube clamp at the Mass Air Flow meter (MAF). 15. Loosen the Air Tube clamp at the throttle body. 16. Remove the PCV tube from the air tube and from where it connects to the valve cover barb. Page 6 12/05 2005-2006 Pontiac GTO LS2 Supercharger Installation Instructions magnacharger.com
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17. Remove the air tube completely, it will not be re- used. 18. Disconnect the Electronic Throttle Control (ETC) connector on the right side. 19. Remove the PCV hose that connects the intake manifold to the engine valley cover vent. Squeeze here Squeeze here 20. Disconnect the eight fuel injector connectors by pulling up on the grey release latches and the squeezing them at the top. Remove the injector harness clips from the intake manifold. P Pull up ull up Page 7 12/05 2005-2006 Po
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21. At the front of the intake manifold locate the Manifold Absolute Pressure (MAP) sensor and disconnect the electrical connector. 22. On both sides of the engine disconnect the ignition coil pack connectors fron the coil packs by fi rst removing the blue lock key. 23. The EVAP is located at the front of the passenger (Right) cylinder head. 24. Disconnect the Evaporative Purge Solenoid (EVAP) electrical connector. Page 8 12/05 2005-2006 Pontiac GTO LS2 Supercharger Installation Instru
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25. Remove the EVAP line at the fi rewall by squeez- ing on the connector and pulling it free. 26. Remove the EVAP tube connector from the intake manifold by pushing in on the white release trigger and pulling fi rmly. 27. Remove the vacuum acessory hose and connector from the rear of the manifold. Vacuum accessory hose 28. On the left side of the intake manifold, locate the fuel pressure test port. CAUTION! The fuel in the system is under pressure! Relieve the pressure in the fuel sy
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29. Remove the fuel line from the fuel rail by fi rst Lock clip Tool prying the lock clip free with a small screwdriver. Use the supplied removal tool to remove the fuel line con- nector. 30. Remove the intake manifold by loosening the ten manifold bolts with a socket wrench and a 8mm socket. Manifold bolts 31. Remove the intake manifold, fuel system and throttle body assembly. 32. Use a shop vacuum cleaner to remove any debris or dirt from the intake port area and engine valley co
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33. Cover the intake ports with tape or clean rags to keep dirt and debris from entering the engine. Coolant vent 34. Reove the coolant vent hose from the vent pipe. hose 35. Remove the coolant vent pipe by removing the attachment bolts with a 10mm socket wrench. 36. Remove the coolant vent pipe. Ensure that the O- ring gaskets under the vent pipe blocks do not stick to the cylinder heads. If so, remove them as new gaskets are supplied. Page 11 12/05 2005-2006 Pontiac GTO LS2 Superch
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37. Install the new vent pipe O-ring gaskets using the supplied grease to hold them in place. 38. Install the new vent pipe with the supplied bolts and torque them with a torque wrench and 10mm socket to 106 in-lbs. 39. Remove the accessory serpentine belt by rotating the tensioner bolt with a 15mm wrench. Release the slack and then pull the belt off the tensioner pulley. 40. Remove the stock belt tensioner assembly by removing the two mounting bolts with a 15mm socket wrench. Pag
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41. Install the new tensioner assembly in place of the stock unit with the supplied bolts and torque them to 40 ft-lbs. 42. Remove the engine oil pressure sensor connector from the pressure sensor located at the rear of the val- ley cover. 43. Remove the engine oil pressure sensor from the valley cover with a 28mm wrench. 44. Remove the engine valley cover and gasket by re- moving the ten bolts with a ratchet and 13mm socket. Page 13 12/05 2005-2006 Pontiac GTO LS2 Supercharger Installat
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45. The gasket will be reused, the original valley cover and bolts will not. Inspect the gasket for any damage and then reinstall, note that it will only fi t cor- rectly in one position. 46. Using a small straight blade screwdriver, remove the 8 O-rings from the underside of the engine valley cover and transfer them to the grooves in the bottom of the new cover. 47. Install the new engine valley cover and fl athead bolts supplied with a 5mm Allen socket and torque the bolts to 18 lb-ft
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49. Re-connect the oil pressure transmitter electrical connector. 50. Re-install the oil pressure sensor and torque it to 15 ft-lbs. Re-attach the sensor electrical connector. 51. Remove the engine lift bracket from the rear of the right cylinder head by removing its two mounting bolts with a 15mm wrench. 52. The automatic transmission fi ll tube will need to be moved slighly outward to avoid contact with the supercharger fuel cross-over pipe. Page 15 12/05 2005-2006 Pontiac GTO LS2 S
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Move fi ll tube 53. Vehicles with automatic transmission only. Manual transmission vehicles please skip to step the next. Move the automatic transmission fi ll tube by pulling it fi rmly outward towards the fender of the vehicle. It will only be necessary to move the tube 1/ 4”- 3/8”. After installing the supercharger and mani- fold assembly, check for contact between the fi ll tube and the fuel cross-over pipe. 54. Remove the throttle body by removing the four mounting bolts with a 10mm
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57. Remove the MAF from the airbox by loosening the connector clamp. 58. Pull back the grey locking latch on the MAF electrical connector and then squeeze the connector to remove it. To connector 59. Remove the tape and split loom from the har- not used ness to about 6” below the MAF connector. Locate the Brown/Yellow and the solid Brown wires. These are the Intake Air Temperature (IAT) sensor wires on the connector. Cut these two wires approximately 2” below the connector. To compu
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61. Using the new Intake Air Tempeture (IAT) har- ness and crimp/shrink connectors supplied, connect the white 62”wires to either white wire of the new IAT harness. Strip about ¼” of insulation from the ends of the IAT harness, then crimp the connectors on. Using a heat gun or blow dryer set on HIGH; shrink the insu- lation on the connectors so that it contracts around the wires completely. You must shrink the insulation, as crimping the connectors alone is not enough to secure them!
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65. Locate the MAP connector on the harness. Re- move the black tape and split loom from the MAP connector and wires. Viewing the connector from the top or clip side note the location and colors of the three wires on the connector, Purple/White left, Green center and Black on the right. Approximately 1” be- hind the connector cut these three wires. 66. Install the new MAP harness to the Purple/White, Green and Black wires using the crimp/shrink connec- tors supplied. The new harness
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69. Install the MAP sensor in its new location using the supplied bracket and the button head Allen screw with a 4mm Allen wrench. 70. Install the fuel manifold O-ring into the recess on the fuel rail with some of the grease supplied. Next install the fuel manifold using a 4mm Allen socket and torque wrench. Torque the manifold fasteners to 106in-lbs. 71. Install the two intake manifold gaskets supplied onto the recesses in the manifold face. Ensure that the gaskets are fully seate
