Chevrolet SSR 2004 Installationshandbuch

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Step-by-step instructions for installing the best in
supercharger systems.
Installation Instructions for:
Radix
INTERCOOLED SUPERCHARGER SYSTEM
2004
Chevrolet SSR Truck
Magnuson Products Inc
1990 Knoll Drive, Ventura, CA. 93003
(805) 289-0044 * (805) 677-4897 fax
magnusonproducts.com * magnacharger.com
ATTENTION!
Y
our MAGNA CHARGER intercooler kit
is sensitive to corrosion!
Take care of if by using 50/50
anti-freeze with de-ionized water.
89-89-60-010 Rev H
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Inhaltsverzeichnis

Seite 1 - Chevrolet SSR Truck

Step-by-step instructions for installing the best in supercharger systems. Installation Instru

Seite 2 - INSTALLATION MANUAL

25. Remove the nuts and washers fromeach side of the air filter apron with a 10mmsocket wrench.26. Remove the air filter apron.27. Remove the two rema

Seite 3 - Important

30. Using a long pair of pliers, remove thecoolant hoses from the bottom of thethrottle body.31. Remove the PCV vent hose from theintake manifold on p

Seite 4

34. Disconnect the eight fuel injectorconnections by gently pulling up on the grayplastic release trigger on the connector andthen pulling firmly on t

Seite 5

3.8 Disconnect the evaporative purgesolenoid EVAP connector by raising theblack plastic retaining clip and then pull freethe connector itself.EVAP Con

Seite 6

4.3 Remove the power brake hose andcheck valve .from the brake booster42 Remove the Positive CrankcaseVacuum (PCV) hose from the intakemanifold on dri

Seite 7

4.7 Using a vacuum cleaner, remove anydirt or debris from the intake port area. (Becareful not to get any dirt in the intakeports).4.6 Carefully remov

Seite 8

50 Remove the vent pipe assembly.(Make sure that the o-ring gaskets did notstick to the cylinder heads, if so removethem)..51 Using a 15mm tensioner w

Seite 9

5.4 Disconnect the positive (+) batterycable from the back of the alternator with a10mm wrench. Use a 15mm socket wrenchremove the two bolts holding t

Seite 10

5.9 Using the stock bolts removed in step72 install the new coolant vent pipesupplied. Ensure that the o-ring seals areinstalled correctly. Torque the

Seite 11

62. Remove the two knock sensors byusing a ratchet and a deep 22mm socket.63. Remove the engine valley cover andgasket by removing the ten bolts with

Seite 12

INSTALLATION MANUALMagna ChargerRadix Intercooled Supercharger SystemGM 4.8, 5.3 & 6.0 liter enginesWe encourage you to read this manual thoroughl

Seite 13

6.6 Reinstall the knock sensors and torquethm to15 lb ft. Reattach the electricalconnectors by pushing the plug down firmlyuntil a “click” is heard. B

Seite 14

71. From the hole nearest the center of theseam cover, measure over 1” and make aline across the cover.72. Cut the seam cover in two pieces witha suit

Seite 15

75. The original water pump outlet tube willneed to be replaced. Remove the outlet bycutting it off. Use a suitable hacksaw andcut it off approximatel

Seite 16

78. Here are the new components for thewater pump outlet and tensioner assembly.80. Install the two O-rings supplied into thegrooves on the new water

Seite 17

82. Install the outlet retainer and8 x 20mm bolt into the tensioner base. Donot tighten the retainer bolt yet as finalpositioning will be done in a la

Seite 18

87. Install the new intake manifold gasketssupplied onto the recesses in the manifoldface. Ensure that the gaskets are fullyseated in the manifold fac

Seite 19

90. Using a small amount of grease or oillubricate the two O-rings on the fuelpressure regulator and push it into the newsupplied fuel manifold as sho

Seite 20

94. Install the small vacuum hose from thenipple on the fuel regulator to the nipple atthe rear of the manifold.95 Using a 10mm socket wrench removeth

Seite 21

98. Remove tape from the cylinder headport faces and lubricate the surfaces withsilicone spray or soapy water. Do not useany pertroleum based products

Seite 22

102 Push the fuel line connectors on tothe fuel manifold. Ensure that the fuel lineis pushed all the way on. Pull on theconnectors to check that they

Seite 23

ImportantOur Magna Charger kits are designed for stock engines, with stock components, in good mechanicalcondition only. Installation on worn or damag

Seite 24

10 . Insert the EVAP connector supplied6inthe remaining end of the 5/16” hose andsecure it with a #4 clamp.EVAPConnector#4 clamp5/16”10 . From the rem

Seite 25

110. Install the EVAP/PCV hose on themiddle barb of the inlet manifold. Connectthe new EVAP connector to the EVAP linebehind the engine on the firewal

Seite 26

114. Insert the new vacuum check valveinto the end of the new 11/32” Vacuumhose.116. Using a 10mm socket wrench, removethe two bolts that secure the a

Seite 27

1.19 Secure the new filter cover with theoriginal fasteners and a 10mm wrench.1.A18 ssemble the air box with the newfilter cover supplied.1.20 Install

Seite 28

Lower mounting tab122. Here is the intercooler reservoir andits mounting hardware.123. Assemble the reservoir to themounting bracket using the two 6 x

Seite 29

126. Here is the intercooler heat exchangerand its mounting components.127. Install two of the round-headedcarriage bolts supplied into both channelso

Seite 30 - Purge solenoid

130. Install the cross member to thevertical brackets with the 8 x 20mm boltssupplied. Tighten securely with a 13mmwrench.8 X 20mmbolt131. Here is the

Seite 31 - Inlet barb

134. Here is the mounting bolt on the rightside of the vehicle. Note: That the heatexchanger barbs must be pointing to thisside.Mounting bolt135. To c

Seite 32

1 . Here is the intercooler pump,mounting clamp, hardware, wiring andreservoir to hose.38pump140. From underneath the vehicle on theright side locate

Seite 33

1.42 Route the hose to the top barb (inlet)on the reservoir. Secure the hose with a#10 clamp. Ensure that there are no kinksin any of the hose to rest

Seite 34 - Lower mounting tab

1. Under the right (passenger side) rearcorner of the vehicle, remove the twobattery access panel bolts with a 10mmsocket wrench.2. With a 8mm wrench

Seite 35

1.46 Cut the intercooler hose to length andsecure both ends with a #10 clamp. Attachthe new length of 1/4” heater hose to thethrottle body nipple loca

Seite 36 - 8 X 20mm

151 Use a 15mm tensioner wrench tocompress the tensioner and then install thenew drive belt using the diagram shown..152. With the drive belt installe

Seite 37

156 Remove the black tape and split loomfrom the MAF connector and wires. Pull theconnector and wires back the point wherethe coil pack connector bran

Seite 38

160 Cover the remaining MAF wires withthe 1/4” split loom and tape to the pointwhere the MAF wires meet the main branchof the harness..MAFwires158. Us

Seite 39

164 Locate the Purge solenoid connectorbranch on the main branch of the harness..NewMAFbranch163. Group the IAT branch and MAPbranches together and ro

Seite 40

165. Remove the split loom and tape fromthe wires and pull the connector and wiresback the point where the drivers coil packbranch is located. Cover t

Seite 41

169. On the passenger of the engine, plugin the ETC, A/C, Coil pack and Injector #2,#4, #6, #8 connectors.170. At the rear of the supercharger on thep

Seite 42

174. Locate the relay mounting stud on thedriver side next to the windshield washerreservoir. Remove the nut with a 10mmsocket wrench. Place the wires

Seite 43

179. Unscrew the harness connectoranchor bolt on the Fuse/Relay Center witha 7mm socket wrench. The bolt willbecome loose in the hole but cannot berem

Seite 44

183. Using a heat gun or a blow-dryer seton high, shrink the plastic covering of theconnector until the clear sealant from theinside of the connector

Seite 45

5. Here is the new fuel pump and itscomponents. Note the male and female fuellines.Connectorhole6. On the back face of the transmissioncross member, u

Seite 46

186. Remove the tape from the batterynegative ( ) cable and re-install it on to thebattery with a 8mm wrench.-185. Remove the bolt that secures thelar

Seite 47

189. Vehicle Programing Instructions For the Micro TunerIMPORTANT! To ensure trouble-free programming of your vehicle’s computer:* Make sure the vehic

Seite 48

193. Turn the ignition key to the on or runposition Tobegin programming your vehicle, you mustpress the button. Press thebutton once to start the prog

Seite 49

Fill holes196. Start the vehicle for 5 seconds andshut off, once again check for fuel leaksand fan-supercharger belt alignment.Check radiator and inte

Seite 50

INTERCOOLER/FUEL PUMP WIRE ROUTING DIAGRAM7/12Page 542003-2004 Chevy SSR Supercharger Installation Instructionsmagnacharger.com

Seite 51

MAF/IATA/CE-T/CINJ-6INJ-8R-CoilKnock SensorsTo StarterC/PO/PPurgeINJ-7INJ-5INJ-3L-CoilINJ-1Alt.ClampClampAlt.INJ-1L-CoilINJ-3INJ-5INJ-7PurgeO/PC/PTo S

Seite 52

To IntercoolerTo ReservoirReservoirPumpHeat ExchangerIntercoolerD.S.P.S.Intercooler plumbing diagram7/12Page 562003-2004 Chevy SSR Supercharger Instal

Seite 53

9. On the front surface of the fuel tank,facing the transmission cross member isthe vehicle fuel filter.10. Squeeze the blue release triggers toreleas

Seite 54

15. Here is the wiring harness for the newfuel pump. Note the different connections.16. On the pump connections, strip theinsulation back 1/4” and cri

Seite 55 - Super Charger

1 . When the engine is cool, remove theradiator reservoir cap.8Do not remove thecap if the engine is still hot or seriousinjury may result.20. Remove

Seite 56 - Intercooler plumbing diagram

21. Remove the engine cover completely,as it and the SSR badge will not be reused.23. Unplug the Mass Air Flow meter (MAF)connector by pulling out the

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