Installation Instructions for: SMALL BLOCK CHEVROLET SUPERCHARGER SYSTEM Step-by-step instructions for installing the best in supercharger systems. * PREMIUM FUEL REQUIRED * 89-89-57-008-TF Rev B Magnuson Products Inc 1990 Knoll Drive, Ventura, CA. 93003 (805) 642-8833 * (805) 677-4897 fax magnusonproducts.com
INSTALLATION MANUAL Magna Charger SMALL BLOCK CHEVROLET SYSTEM GM CHEVROLET V8, 302-400 C.I.D. Engines, Please take a few moments to review this manual thoroughly before you begin work: Μ ake 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 facility 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 fire 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 fittings 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. High performance engines require high performance fuel Use only premium fuel, 91 octane or better. TRICK FLOW by Magna Charger systems are manufactured to produce about 20 RWHP per pound of boost at sea level. High altitudes will produce different numbers. Our supercharger 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. Trick Flow/Magna Charger are not responsible for the engine or consequential damages. If you have any questions, please contact us. After you finish your installation and road test your vehicle, please fill out and mail in the limited warranty card, so we can add you to our files (this is important for your protection). A new fuel filter is recommended at the time of supercharger installation. Stock spark plugs and stock plug gap is recommended. Tools and Materials Required: Metric and inch wrench sets 3/8 drive metric and inch size socket sets (Standard & Deep) 3/8 and ½ drive Foot pound and inch pound torque wrenches Phillips and flat head screwdrivers Drain pan Hose cutters Hose clamp pliers Safety glasses Shop vacuum cleaner Top quality gasket cement RTV silicone adhesive Contact information: Magnuson Products Inc Magna Charger Division 1990 Knoll Drive. Ventura, CA 93003 Sales/Tech support 805-642-8833 Websites: www.magnusonproducts.com www.magnacharger.com Email: info@magnacharger.com
1. Start the supercharger installation by removing the negative (-) battery with a 10mm wrench. 2. Rotate the engine so that the timing mark on the crank pulley is at TDC cylinder #1. Remove the distributor cap and mark the body where the rotor arm is pointing. Note the position of the distributor body relative to the engine i.e. the vacuum advance is pointing at cylinder #7. 3. Remove the distributor, current intake system, and intake manifold gaskets (On some engines it may be necessary to remove the valve covers as well). Place a shop towel into the lifter valley to prevent any debris getting inside of your engine. Make sure the cylinder head port faces are absolutely clean of any remaining gasket material or adhesive to ensure a good seal. 4. Install the new intake manifold gaskets supplied onto the cylinder heads using a top quality gasket adhesive, we recommend Gasgacinch. Apply the adhesive to the face of the heads and to the surface of the gaskets themselves. Allow the adhesive to dry until just sticky and then place the gaskets onto the cylinder heads carefully aligning the ports and bolt holes. 03/09 Page 3 magnacharger.com
5. Apply a bead of RTV Silicone adhesive around each of the four water port openings on the manifold side of the gaskets as shown. 6. Apply a heavy bead of RTV Silicone adhesive along the front and back top surfaces of the lifter valley. Ensure that the bead of silicone contacts the gaskets on both ends. 7. The following instructions are for 1986 and earlier cylinder heads (non Vortec) 1987 and later Vortec style head please skip to step #14. Using a 10mm socket wrench to remove the 8 bolts that secure the top of the manifold to the base. There are two on each side and two in the front and back. 8. Carefully remove the supercharger and manifold top from the base. Do not lift the supercharger by the black plastic Actuator! Carefully set the supercharger aside. Do not remove the bolts that secure the supercharger to the manifold top. DO NOT REMOVE THESE BOLTS! 03/09 Page 4 magnacharger.com
9. Install the manifold into position on the engine using the new manifold to head bolts supplied. Torque the bolts to 25Ft/Lbs. in the order shown. 12 11 4 1 5 6 10 9 3 2 7 8 10. At the front of the manifold base, just behind the water outlet/thermostat location, locate where the ends of the O-ring seal cord meet. Apply a small dab of RTV silicone to seal this small gap. 11. Carefully replace the supercharger and manifold top onto the manifold base. 12. Re-install the eight bolts previously removed that secured the manifold top to the manifold base. Torque these bolts to 9Ft/Lbs. 6 2 4 7 5 8 1 3 03/09 Page 5 magnacharger.com
13. The following instructions are for 1987 and later cylinder heads (Vortec). 1986 and earlier (Non Vortec) style heads please skip to step #14. Install the supercharger and manifold into position on the engine using the new manifold to head bolts supplied. Torque the bolts to 25Ft/Lbs. in the order shown. 7 1 3 5 8 4 2 6 14. Re-install the distributor into its original location. Ensure that the rotor arm is pointing at the mark previously made. Secure the distributor with the new clamp, bolt and washer supplied. 15. 16. Remove the three bolts that secure the factory accessory drive pulley(s) to the harmonic balancer. Install the supercharger crank drive pulley on top of the accessory drive pulley as shown using the 3/8 x 3.75 bolts supplied. Tighten these bolts just finger tight or snug for now. Loop the supercharger drive belt over the pulleys and check the alignment of the pulleys. Is the supercharger and crank pulley aligned? if not, use the shims supplied to move crank drive pulley out so that the grooves in both pulleys are parallel. Place the shims between the accessory pulley and the new S/C crank drive pulley. When the pulleys are aligned, remove the S/C drive belt, and torque the three 3/8 bolts to 33Ft/Lbs. Here are the supercharger belt tensioner bracket assembly components. Note that the longest bolt will pass through the pulley and spacer, through the bracket and then thread into the square nut supplied. 03/09 Page 6 magnacharger.com
17. Here is the Tensioner assembly as viewed from the rear. Note that the Square nut must fi t into the groove provided, with its offset to the middle of the bracket as shown SQUARE NUT Rear view of bracket 18. Install the tensioner bracket assembly under the supercharger nose and secure it to the front of the manifold base with the two bolt supplied. Install the mounting bolt on the right (passenger side) by passing it through the new alternator bracket supplied fi rst. New Alternator bracket bolts 19. Tighten the two mounting bolts securely and torque them to 27Ft/Lbs. Install the supercharger drive belt over the crank, tensioner and supercharger pulleys. Slide the tensioner pulley along its slot to the right side of the engine to tension the belt. Tensioner Pulley 20. The supercharger drive belt is tensioned correctly when you can just twist the belt 90 degrees with two fi ngers. 03/09 Page 7 magnacharger.com
21. On the back of the supercharger are vacuum ports for PCV, power brake connections. The Boost port is for carburetor power valve and boost gauge etc. connections. Actuator Vacuum ports Sneeze valve Boost Port 22. 23. 24. 25. Complete the installation the same as you would a standard intake system adding the carburetion, throttle linkage, thermostat and water outlet as normal. It is Very Important to use a high quality air fi lter on a supercharger installation or supercharger damage may result! Carburetion notes: The inlet port of this supercharger is confi gured to accept most popular four-barrel carburetors. We recommend use of at least a 750 CFM carburetor with mechanical secondaries. As most carburetors are not confi gured for supercharged operation, we strongly recommend you consult your carburetor manufacturer for recommended modifi cations such as boost registered power valves etc. Ignition tuning: The ignition timing will need to be re-adjusted (retarded) before the vehicle can be driven. It will be necessary to retard the ignition timing two degrees for every pound of boost that the supercharger delivers. This supercharger will supply 5-7 psi as delivered, so if you are currently running 28 degrees total mechanical advance with out vacuum, you will need to retard your ignition timing to 10-16 degrees. A little careful experimentation will yield the best power. Detonation must be avoided! Use of an after market Boost/ Timing Controller such as the MSD Boost Timing Master 5462 is recommended for most applications. Test drive vehicle for the fi rst few miles under normal driving conditions, listen for any noises, vibrations, engine miss fi re or anything that does not seem normal. The supercharger does have a slight whining noise under boost conditions, which is normal. After the initial test drive gradually work the vehicle to wide open throttle runs, listen for any engine detonation (pinging). Use only premium fuel, 91 octane or better. If engine detonation is present let up on the throttle immediately and re-adjust your ignition timing. If you have questions about your vehicles performance, please check with your installation facility or call Magna Charger at (805) 642-8833, Monday through Friday, 8 a.m. to 3 p.m. 03/09 Page 8 magnacharger.com