Magnuson Products F-150 User Manual
Installation Instructions for:
89-89-65-001 Rev C
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
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 the supercharger kit DO
NOT lift the supercharger assembly by the black plastic bypass actuator. This is pre-set from the factory and
can be altered if used as a lifting point!
Caution: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk
of fi re and personal injury. After relieving the system pressure, a small amount of fuel may be released when
servicing the fuel lines or connections. In order to reduce the risk of personal injury, cover the regulator and
fuel line fi ttings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the
towel in an approved container when the job is complete. Use only premium fuel, 91 octane or better.
Magna Charger systems are manufactured to produce about 20 RWHP per pound of boost at sea level. High
altitudes will produce different numbers.
Our Magna Charger kits are designed for engines in good mechanical condition only. Installation on high
mileage or damaged engines is not recommended and may result in engine failure, for which we are not
responsible. Magna Charger is not responsible for the engine or consequential damages.
Aftermarket engine re-calibration devices that modify fuel and spark curve (including, but not limited to
programmers) are not recommended and may cause engine damage or failure. Use of non-Magna Charger
approved programming will void all warranties. If you have any questions, call us.
Note: 2004 owners will need to replace the water pump pulley with a 2005-2006 water pump
pulley.
Ford part number # F7UZ-8509-AA
After you fi nish your installation and road test your vehicle, please fi ll out and mail in the limited warranty card,
so we can add you to our fi les (this is important for your protection).
A new fuel fi lter is recommended at the time of supercharger installation.
Autolite spark plug #HT0 is recommended
Drive belt= Gates# K061265
Air Filter= K&N# E-0945
Tools Required:
Metric wrench set
1/4” - 3/8” and 1/2” drive metric socket set (Standard & Deep)
3/8” and 1/2” drive Foot pound and inch pound torque wrenches
9/16” Spark plug socket, Snap-on #S9716KR
Phillips and fl at head screwdrivers
Fuel line quick disconnect tools (included in kit)
Small or angled 3/8 drill motor
Drain pan
Hose cutters
Hose clamp pliers
Safety glasses
Metric Allen socket set 3/8 drive
Shop vacuum cleaner
Contact information:
Magnuson Products Inc
Magna Charger Division
1990 Knoll Drive
Ventura, CA 93003
Sales/Tech support 805-289-0044
Web sites:
www.magnusonproducts.com
www.magnacharger.com
E-mail:
info@magnacharger.com
1. Start the supercharger installation by
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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.
1. Start the supercharger installation by
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removing the negative (-) battery with a 10mm
wrench.
1. Start the supercharger installation by
removing the negative (-) battery with a 10mm
wrench.
Remove Six Fas-
teners
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.
9. Remove the bolt that secures the coil to the
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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 supplied. Use an appropriate 9/16” spark plug socket
to remove and replace the plugs. Use of a standard “deep” socket will break the spark plugs.
12. Remove the standard spark plugs and replace
them with the Autolite HT0 spark plugs supplied.
Use a 9/16” spark plug socket, extention and
wrench. Torque the spark plugs to 22 ft-lbs.
Autolite HT0 Spark Plug
13. Unlock the three vehicle computer
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connections by pulling the grey release levers
forward. Remove the three connectors by pulling
them straight out.
14. Remove the four computer mounting bolts
with a 10mm socket wrench.
Unlocked
Locked
15. Remove the computer from the vehicle.
16. Here are the shipping materials supplied to
quickly ship the vehicle computer.
Mounting Bolts
17. Place the computer into the plastic packaging
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material supplied and then seal the box.
18. 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 for
shipping. Your computer will be re-programed and
quickly returned to you via UPS.
19. 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.
20. On the side of the air box remove the EVAP
hose connector by pushing down on the green
release trigger and pulling the connector free.
Release Trigger
Release Trigger
21. Remove the Mass Air Flow (MAF) connector
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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
on the air box by cutting the tape that secure it.
24. Remove the four air fi lter box bolts from the
intake manifold with a 10mm socket wrench.
Alternator Cable
25. Lift the air fi lter box off the intake manifold.
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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.
28. With the throttle body unbolted from the
intake manifold, pull up on the red release trigger
of Electronic Throttle Control (ETC) connector and
pull the connector free. Set the throttle body aside
for later installation.
Throttle Position Sensor
connection
29. Disconnect the PCV vent tube electrical
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connector.
30. Using a 8mm socket wrench, unbolt the PCV
vent tube from the intake manifold.
Vent Tube
Vent Tube
Bolts
31. Carefully withdraw the PCV vent tube from the
intake manifold.
32. Remove the Fuel Pressure Sensor connector
by pushing in on the white release trigger and
pulling the connector free.
Vent Tube
33. Remove the fuel line lock clip.
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Lock Clip
34. Use the supplied removal tool to remove the
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.
35. Squeeze the release trigger on the eight
injector connectors and then pull them free.
Tool
CAUTION! The fuel in the system is
under pressure!
Release Trigger
Fuel Line
Connector
Injector Connector
36. Remove the fuel rail assembly with the
injectors from the intake manifold by removing
the four bolts that secure the fuel rail with a 8mm
socket wrench.
37. After removing the four bolts, pull up on the
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fuel rail and wiggle it to release the injectors from
the intake manifold.
38. Disconnect the alternator cable connection
with a 10mm wrench.
Fuel Rail
39. Disconnect the alternator control connector by
squeezing the connector and pulling it free.
40. Remove the alternator bracket by removing
the three retaining bolts with a 10mm socket
wrench.
Alternator Control
Connector
41. Remove the two alternator mounting bolts
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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.
Water Pump
Pulley
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. Allow the
vehicle to cool fi rst. The cooling system is under
pressure! Relieve the pressure in the cooling system by removing the radiator reservoir cap fi rst.
Collect the coolant in a suitable drain pan.
44. Remove the upper radiator hose by
squeezing the spring clamps at each end with a
pair of pliers and the pulling the hose free. Next,
remove the two bolts that secure the thermostat
outlet with a 10mm socket wrench.
Bolt
Thermostat
Outlet
Bolt
45. Remove the thermostat outlet and O-ring seal
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from the water manifold. Next, remove the two
bolts that secure the water manifold to the cylinder
head with a 10mm socket wrench.
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
Coolant Hose
47. Remove the water manifold by removing
the two bolts on each side with a 10mm socket
wrench.
48. Remove the water manifold.
Bolt
Bolt
49. Remove the ten bolts (fi ve on each side) that
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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.
Manifold Bolts
51. Lift the manifold and pull it forward to gain
more room to work on the connections on the
rear.
52. The large wiring harness passing across the
rear of the engine is attached to the rear of the
intake manifold by nut located on the manifold
servo-motor. Remove this nut with a 10mm socket
wrench and pull the harness free. Note the location of the servo-motor electrical connection.
Manifold
Servo-Motor
Remove this Nut
Servo-Motor
Electrical Con-
nection
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