Magnuson Products GTO LS2 User Manual
89-89-60-014 Rev B
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
Use distilled or
de-ionized water only.
INSTALLATION MANUAL
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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 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 recalibration 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.
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 GM fuel fi lter is recommended at the time of supercharger installation.
Stock spark plugs and stock plug gap is recommended
Drive belt = Gates# K061010
Air Filter = K&N# 33-2289
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
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
Websites:
www.magnusonproducts.com
www.magnacharger.com
Email:
info@magnacharger.com
1. Open the hood and remove the under hood
Latch closed
Latch open
Cover
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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.
4. There are three computer connectors, Grey, Black
and Blue. Remove the connectors by fi rst removing
the Red locking key, then pushing in on the Black
cover and pushing the Grey latch down to open it.
Latch closed
Latch open
Cover
5. The computer connectors can be removed when
Latch tail
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the latch is pushed down and the red tail of the latch is
visible on the end of the connector.
6. Remove the two T20 TORX screws that secure the
computer to its mounting bracket.
Latch tail
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.
9. Place the computer into the plastic bag supplied
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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 the strut tower brace with a 13mm socket
wrench.
12. Remove the strut tower brace and fasteners from
the vehicle, the brace can be reinstalled after the
supercharger installation.
13. Remove the two engine covers by pulling up
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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.
17. Remove the air tube completely, it will not be re-
Pull up
Squeeze here
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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.
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.
Squeeze here
Pull up
21. At the front of the intake manifold locate the
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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.
25. Remove the EVAP line at the fi rewall by squeez-
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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.
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 system by removing
the cap and depressing the check valve with a screwdriver and collecting the fuel with a shop towel.
Vacuum
accessory
hose
29. Remove the fuel line from the fuel rail by fi rst
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prying the lock clip free with a small screwdriver. Use
the supplied removal tool to remove the fuel line connector.
30. Remove the intake manifold by loosening the
ten manifold bolts with a socket wrench and a 8mm
socket.
Tool
Lock clip
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
cover.
33. Cover the intake ports with tape or clean rags to
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keep dirt and debris from entering the engine.
34. Reove the coolant vent hose from the vent pipe.
35. Remove the coolant vent pipe by removing the
attachment bolts with a 10mm socket wrench.
Coolant vent
hose
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.
37. Install the new vent pipe O-ring gaskets using the
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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.
41. Install the new tensioner assembly in place of the
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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 valley 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.
45. The gasket will be reused, the original valley
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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. Insert the six O-rings in the recesses
in the new valley cover.
48. Install the Oil Pressure Transmitter in the new val-
ley cover with a 26mm socket and torque it to 18 lb-ft.
49. Re-connect the oil pressure transmitter electrical
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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.
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