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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
Page 1
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.
Page 2
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.
Page 3
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.
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.
Page 4
12.
13. Drain approximately one gallon of coolant/antifreeze from the vehicles cooling system. The
petcock faces the rear of the vehicle and is located down low on the drivers side of the radiator.
15. Install the new heater hose from subassembly 14-57-005 using the supplied hose
clamps and hose joint coupler.
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.
Page 5
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 drivers 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
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).
Page 6
CAP
Passenger side
Drivers 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.
Stud
Extension
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 drivers 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.
43. Install the anti-vibration sleeve (PN 51-20001) on the throttle and cruise control cables.
Page 10
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
Small alternator
C.
D.
E.
F.
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!
Page 13
A.
B.
ALDL
Page 12