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Installation instructions for:
INTERCOOLED SUPERCHARGER SYSTEM
2005-2007
FORD MUSTANG 4.6L 3V
Step-by-step instructions for installing the best in supercharger systems.
PREMIUM FUEL REQUIRED
ATTENTION!
Magnuson Products Inc
Your MAGNA CHARGER intercooler kit
1990 Knoll Drive, Ventura, CA. 93003
Is sensitive to corrosion!
Phone (805) 289-0044 * Fax (805) 677-4897
Take care of if by using 50/50
magnusonproducts.com * magnacharger.com
Anti-freeze with de-ionized water.
89-89-65-005 Rev F
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INSTALLATION MANUAL Magna Charger FORD 4.8 Liter 3V Engine, 2005-2007 MUSTANG 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 the super
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1. Relieve the pressure in the fuel tank by removing the cap and re-installing it. IMPORTANT! Ensure vehicle has 91 or higher-octane fuel in it prior to supercharger installation! 2. Disconnect the negative (-) battery clamp using a 7mm wrench. 3. Remove the Positive Crankcase Ventilation (PCV) line from the air tube by pressing the release trigger in the connector and pulling it free. Follow the line to its connection on the cam cover and remove the line completely from the motor
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5. Loosen the air tube clamp at the air box using a 8mm nut driver or straight blade screwdriver 6. Remove the air tube completely from the vehicle. 7. Remove the Throttle Position Switch (TPS) connector by sliding the red release latch outward and pulling the Release Latch connector free. 8. Remove the Electronic Throttle Control (ETC) connector by sliding the red release latch outward and pulling the Release Latch connector free. Page 4 9/07 2005-2007 Ford Mustang Supercharger Install
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9. Disconnect the (8) fuel injector connectors by squeezing the release trigger and pulling the connectors free. Release Trigger 10. Remove the Fuel Pressure Sensor (FPS) connector by squeezing Release Trigger the release trigger and pulling the connectors free. 11. Remove the vacuum line to the FPS. 12. Remove the (2) battery cable anchors by pulling them free from the fuel rail attachment bolts. Page 5 9/07 2005-2007 Ford Mustang Supercharger Installation Instructions magnacharger.com
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13. Remove the Evaporative Control (EVAP) line behind the throttle body by pressing Release Latch in on the white release latch and pulling the line free. 14. Remove the PCV line from the intake manifold by pressing the release trigger in the connector and pulling it free. Follow the line to its connection on the cam cover and remove the line completely from the motor. 15. Remove the fuel line lock clip from the fuel rail by gently prying it free. Fuel Line Lock Clip 16. Use the suppli
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17. Remove the (4) bolts that secure the fuel rails to the intake manifold using a deep 8mm socket wrench. 18. Remove the fuel rails complete with injectors from the intake manifold, by pulling up fi rmly on the fuel rails. 19. At the rear of the intake manifold locate the electrical connector for the manifold servo- motor. 20. Press the release trigger and pull the connector apart. Release Trigger Page 7 9/07 2005-2007 Ford Mustang Supercharger Installation Instructions magnacharger.com
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21. At the rear of the intake manifold remove the brake vacuum hose by squeezing the ears of the clamp using a pair of pliers and pulling the hose free. Brake Vacuum Hose 22. Remove the (5) bolts on each side of the intake manifold using a 10mm socket wrench. 23. Carefully lift the intake manifold free from the engine. 24. Carefully clean the cylinder head port faces and cover them with masking tape or clean shop towels. Page 8 9/07 2005-2007 Ford Mustang Supercharger Installation Instru
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25. Depress the tensioner arm by inserting the square end of a 1/2” breaker bar into the square hole on the arm. Press the bar down to relieve tension on the belt and remove the belt from the pulleys. This belt will no longer be used. 1/2” Breaker Bar 26. Remove the Alternator bracket and the (4) bolts that secure it in place using a 10mm socket wrench 27. Remove the (2) nuts that secure the alternator using a 13mm wrench. Remove Nuts 28. Lift the alternator up off its mounting studs
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29. Remove the (2) alternator-mounting studs by placing a 6mm socket wrench Remove Studs on the hex ends of the studs or “double- nutting” them and unscrewing them from the engine block. Double Nutted Stud 30. The following steps are for Intercooled vehicles only! Non-intercooled vehicles please skip to step 58. On the passenger side of the vehicle, under the nose, locate the white plastic radiator drain valve. Open the valve and collect the coolant in a drain pan for re- use late in t
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33. Remove the gray release latches from the elbow and insert them into the connector. 34. Remove the coolant manifold and the (4) bolts that secure it using a 10mm socket wrench. 35. Grasp the steel elbow on the bottom of the coolant manifold using a large set of pliers. Using a small torch or heat gun, apply heat to the bottom of the manifold were the steel elbow is inserted. Steel Elbow Torch or Heat Gun HEAT 36. Pull the elbow free from the manifold, but do not twist it, as this
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37. Allow the manifold to cool completely. Install the small 5/8” core plug supplied using a suitable drift and hammer in to the hole that the elbow was removed from. 38. Here is the core plug correctly installed in the bottom of the coolant manifold. 39. Locate the Engine Coolant Temperature (ECT) connector clipped to the steel coolant pipes in the engine valley. Disconnect it by squeezing the release trigger of the connector and pulling it apart. 40. Locate the Engine Knock Sensor (
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41. At the rear of the passenger side cylinder head, locate the bolt that secure the steel coolant pipes in place and remove it using a 13mm socket wrench. 42. Pull the coolant pipes up so you can remove the coolant hoses and clamps using a pair of pliers. 43. After removing the coolant hoses, gently lift the pipes up and back to remove them from the engine. Some additional engine coolant will be lost at this point, place a suitable drain pan under the transmission bellhousing to coll
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45. Place the coolant pipes in the soft jaws of a vice. Separate the (2) coolant pipes by cutting the connecting brackets using a hack saw. Cut Here 46. Use care when cutting, as the smaller diameter pipe will be re-used. 47. Here are the coolant pipes separated, and the smaller diameter pipe is now ready for re-installation. 48. Re-install the smaller diameter coolant pipe by fi rst carefully starting the end on the engine block nipple. Secure the coolant pipe with the bolt previously
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49. Re-install the coolant hose onto the pipe using the original clamp. 50. On to the remaining coolant hose, install Coolant Hose the 90-degree connector and the “elbow” hose supplied as shown. Secure the Spring Clamp 90-degree fi tting with the original clamp, and the elbow hose with the new spring clamp supplied. 90º Fitting “Elbow” Hose 51. Here is the 90-degree fi tting and elbow hose installed. Route the long straight section of the elbow hose forward along the side of the engine
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53. Install the hose connector supplied into the ends of the hose. Note that the barb on the connector will point rearwards, towards the engine, away from the radiator. Secure the connector in the hose with the #18 clamps supplied but leave them loose so fi nal adjustments can be done on the vehicle. 54. Here is the completed hose with the To Manifold connector installed. To Radiator 55. Re-install the water manifold. Torque the fasteners to 89 in-lbs using a 10mm socket and torque w
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57. Install the end of the elbow hose on to the barb of the new coolant hose connector with the spring clamp supplied. Position the connector and Hose Connector Barb elbow hose so that the elbow hose can be routed beside the engine. Tighten the connector hose clamps. Refi ll the radiator reservoir with the coolant Elbow Hose removed earlier. 58. Here is the new drive belt idler pulley Idler Pulley Mounts Here Bracket and mounting hardware. Pulley Bracket Bolts Spacer Idler Pulley Bol
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61. Install the idler pulley with its spacer into the remaining hole on the mounting bracket with the bolt supplied. Torque this bolt to 28 ft-lbs (38 Nm) using a 15mm socket and torque wrench. 62. Install the (2) new alternator brackets with the (4) original bolts. Torque them to 106 in-lbs (12Nm) using a 8mm and 10mm sockets and a torque wrench. Alternator Brackets 63. Remove the (3) bolts that secure the belt tensioner using a 10mm socket wrench and remove the tensioner from the fr
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65. Here is the tensioner with the stop This area must removed. Ensure that there is no be fl at and material left on the body of the tensioner smooth. where the stop previously was. Grind or fi le the body to make this area smooth and fl at with the surrounding area of the body. Removed Stop 66. Re-install the modifi ed tensioner into it original location with its bolts. Torque the (3) bolts to 22 ft-lbs (30 Nm) using a 10mm socket and torque wrench. 67. Remove the throttle body fro
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69. Install the two-throttle body-mounting studs removed in the previous step into the lower (2) holes on the supercharger inlet fl ange. Double-nut the studs, tighten them securely into the supercharger inlet fl ange and remove the nuts. Double-Nutted Stud 70. Carefully remove the throttle body gasket from the intake manifold. 71. Install the throttle body gasket into the groove in the inlet manifold fl ange. Gasket 72. Install the throttle body onto the inlet manifold with the TPS on th
