Installation Instructions for: INTERCOOLED SUPERCHARGER SYSTEM 2004-2005 CADILLAC CTS-V Step-by-step instructions for installing the best in supercharger systems. Magnuson Products Inc 1990 Knoll Drive, Ventura, CA. 93003 (805) 289-0044 phone * (805) 677-4897 fax magnusonproducts.com * magnacharger.com 89-89-60-015 Rev C .
INSTALLATION MANUAL Magna Charger GM 5.7 Liter Engine, 2004-2005 Cadillac CTS-V Please take a few moments to review this manual thoroughly before you begin work: 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 office 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.
1. Start the supercharger installation by removing the lower rear seat cushion by pushing in at the base and then pulling up. Remove the cushion to gain access to the two rear fuse centers located where the carpet meet the seat base. 2. Once the seat cushion has been removed pull back the carpet where it meets the seat base on the left (driver) side to expose the fuse center. Remove the fuse center cover and examine the legend printed inside the cover to locate the fuse marked “Audio”.
5. Locate the OBD II plug connection along the bottom edge of the dash to the right of the hood release lever. OBD II plug connection 6. Connect the cable supplied with the microtuner to the 9-pin connector at the top of the handheld unit. Use the thumbscrews to secure the cable to connector. Connect the other end to your OBD II plug connection. Make sure this connection is seated all the way in and that it is secure. This connection must remain secure during programming.
9. Replace the “Audio” fuse and the fuse center cover. Replace the lower rear seat cushion by pushing in at the base and then pushing down. Take care to ensure the seatbelt buckles are placed in the slots provied for them in the back edge of the seat cushion. 10. Remove the Negative battery connector from the battery. Snap the black plastic terminal off the connector and then remove the battery connector with a 8mm wrench.
13. Note: The position of the wiper arms on the windshield and then pull up firmly to remove the wiper arms. 14. Remove the rubber weather strip from the front edge of the wiper arm apron. 15. Remove the four 7mm bolts that secure the wiper apron on the right (passenger) side. 16. In the corner of the left (driver) side wiper apron, remove the bolt that secures it with a 10mm socket wrench. 10/05 Page 6 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
17. Pull the right wiper apron forward at the center, then remove the left apron completely. 18. Located on the bottom of the wiper assembly is the wiper motor electrical connector. Disconnect the connector from the motor. 19. Remove the wiper assembly retaining bolt near the center of the windsheild with a 13mm socket wrench. 20. Remove the wiper assembly complete from the vehicle. 10/05 Page 7 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
21. From the top surface of the left wiper arm lever, measure down 3/8”(10mm) and scribe a line across the lever. Using a suitable grinder or saw remove all the material above this line. Remove 3/8” 22. Install the thick spacer washer supplied over the wiper assembly mounting hole. 23. Re-install the wiper assembly into place. Note: The mounting bolt will pass through the spacer washer installed in the previous step. 24.
25. Replace the wiper aprons, mounting screws and weather strip into their original locations. 26. Replace the wiper arms into their original positions on the spindle shafts and torque the attachment nuts to 26 ft-lbs. 27. On the top of the strut towers remove the two bolts on each side that secure the strut tower brace with a 18mm socket wrench. 28. Remove the strut tower brace completely, as it cannot be reused with the supercharger.
29. Pull up firmly at the front and back of the engine cover to remove it. It will not be reused. 30. Remove the radiator mask by removing the two push rivets out along the front edge. Pull up firmly along the back edge to unclip the mask for removal. Center 31. To remove the push rivets, use a small straight blade screwdriver to pry up the center of the rivet and then the outer body. Body Remove push rivets at these locations 32.
33. Remove the eight push rivets that secure the top edge of the front fascia as shown. 34. Along the front edge of both front wheel wells remove the push rivets as shown. Lock bolts 35. Rotate the steering wheel to full lock so you can push the wheel well splash panel out of the way to gain acecess to the two fascia lock bolts on each side. As you loosen the the nuts on the lock bolts the fascia panel will drop down forming a gap between the fascia and the fender.
37. After loosening the lock bolts, pull forward on the fascia panel. The lock bolts will slide forward in their “keyhole” shaped holes and allow the fascia to detach from the vehicle. Pull forward 38. On both sides of the fascia disconnect the marker light electrical connection. 39. On both sides of the fascia disconnect the turn signal/driving light electrical connection. Remove the fascia carefully from the vehicle and set it aside. 40.
41. Remove the air tube completely, as it will not be reused. 42. On the left (drivers) side of the throttle body, disconnect the Electronic Throttle Control (ETC) connector. 43. Disconnect the Throttle Position Sensor (TPS) connector on the right (passenger) side of the throttle body. 44. Disconnect the eight injector electrical connectors. 10/05 Page 13 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
45. Disconnect the two ignition coil pack connectors. 46. Unclip the Engine Knock Sensor (Knock) connector from its location on the back of the intake manifold. Next, disconnect the Knock connector from the wiring harness connector. 47. Disconnect the Manifold Absolute Pressure (MAP) sensor connector at the rear of the intake manifold. 48. Disconnect the Positive Crankcase Ventilation (PVC) hose from the right side of the throttle body.
49. Disconnect the engine valley cover vent hose from the nipple in the intake manifold. 50. Disconnect the vacuum brake booster valve from its mounting grommet on the booster. 51. Above the drivers (right) side valve cover, disconnect the Evaporative Purge Solenoid (EVAP) electrical connector. 52. Press the white release trigger on the Evaporative emission (Evap) pipe connector to remove it from the barb on the intake manifold. Disconnect the other end of the Evap pipe from the purge solenoid.
53. Disconnect the Evap pipe from the rear of the purge solenoid. Follow the Evap pipe to the right rear of the engine and unclip it from the fuel rail. Disconnect the Evap pipe from the smaller quickrelease fitting using the supplied removal tool. Snap the tool on the pipe and push it into the quick release fitting to release the pipe. Removal tool 54. Remove the Purge solenoid and EVAP line by pulling the solenoid free from its mounting location on the left side of the intake manifold. 55.
57. Disconnect the fuel pipe from the large quickrelease fitting using the supplied removal tool. Snap the tool on the pipe and push it into the quick release fitting to release the pipe. 58. Remove the two coolant lines attached to the bottom of the throttle body. Coolant lines 59. Remove the three bolts attaching the throttle body to the intake manifold with a 10mm socket wrench. Set the throttle body and bolts aside for later installation on the supercharger assembly. 60.
61. Remove the ten intake manifold bolts with a 8mm socket wrench. Note: You may not be able to completely withdrawal all ten bolts from the manifold after unthreading them. 62. Using a shop vacuum cleaner, remove any dirt or debris from the intake port and engine valley cover area. 63. Cover the intake ports with tape or clean rags. 64. On the engine valley cover, remove the two black rubber Knock Sensor covers by gently prying them up using a small straight blade screwdriver.
65. Remove the Knock sensors by using a ratchet and a deep 22mm socket. 66. Remove the engine valley cover and gasket by removing the ten bolts with a 10mm socket wrench. 67. 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. 68. The gasket will be reused, the original valley cover will not. Inspect the gasket for any damage and then re-install. Note: It will only fit correctly in one position.
69. Install the new valley cover and ten flathead bolts supplied with a 5mm Allen socket. Torque the bolts to 18ft-lb. 70. Reinstall the knock sensors and torque them to15 ft-lb. Re-attach the electrical connectors by pushing the connector down firmly until a “click” is heard. Before re-installing the covers, apply a bead of silicone adhesive to the sides of each cover then push the covers back into place. 71.
73. 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. 74. Install the new coolant vent pipe with the supplied gaskets and bolts. Torque the bolts to 106 in-lbs with a torque wrench and 10mm socket. 75. Remove the stock belt tensioner assembly by removing the two mounting bolts with a 15mm socket wrench. 76.
77. Remove the radiator retaining bracket on each side by removing the four bolts with a 10mm socket wrench. 78. Remove the Air Conditioning (A/C) condensor from the radiator by removing the four bolts along the top and bottom radiator tanks with a 10mm socket wrench. 79. Squeeze the hose clamps with a pair of pliers and remove the upper and lower radiator hose connections. 80. Disconnect the radiator vent hose from the top tank by squeezing the hose clamp with a pair of pliers and pulling the hose off.
81. On the left side of the engine, remove the A/C pipe support tab from the fan shroud with a right angle cross-head screwdriver. 82. Disconnect the radiator fan electrical connections on each fan by squeezing the connectors and pulling them free. 83. Remove the radiator, fan and hoses complete by pulling it straight up and out carefully. 84.
85. Remove the stock balancer bolt from the end of the crankshaft with an impact gun and a 24mm socket. 86. Install the drill guide and bolt into the stock location. Note: The smaller diameter end of the guide goes towards the balancer. 87. Torque the guide bolt to 60 ft-lbs with a torque wrench and 24mm socket. 88. Using a drill and the supplied drill bit, drill Two holes in the balancer by placing the drill bit in the two holes in the guide. Take your time, as the material will cut slowly.
89. A light lubricant will help the drilling and reaming process. Drill the holes in several steps lubricating the hole and bit between each step. 90. After drilling the two holes, use the supplied reamer to correctly size the holes. Rotate the reamer clockwise only. Turning it the other direction will ruin it. 91. Use some compressed air to remove any material from the holes. 92. Remove the drill guide and bolt from the end of the crankshaft.
93. Inspect the two new holes carefully and use more compressed air to remove any residual material. Install a dowel pin into each hole. 94. Use a small hammer and a drift to tap the dowel pins in as far as they will go into the balancer. 95. Install the new balancer bolt supplied. 96. Use a torque wrench and 24mm socket to tighten the new balancer bolt to 37 ft-lbs and then rotate it an additional 140 degrees using a torque angle meter. The radiator and hoses will be replaced in a later step.
97. Locate the MAF connector and remove the tape from the wires. Approximately 3” back from the connector, cut the two Brown Inlet Air Tempeture wires. 98. Using the new IAT harness, lengths of white wire and crimps connectors supplied, install the IAT connector and extention wires to the two ends of the brown wires leading to the computer. It does not matter which white wire connects to either brown wire. The two wires from the MAF connector will no longer be used.
101. Locate the purge solinoid connector and remove the plastic tape. Cut the wires approximately 4” back from the connector. 102. Using the new lengths of color coded wire and crimps connectors supplied to extend the purge solenoid connector wires. Strip about 1/4” of insulation from the ends of all the wires, then crimp the connectors on. Using a heat gun or blow dryer set on “High” shrink the insulation on the crimp connectors so that it contracts around the wires completely.
105. Scribe a line across the upper tab on the throttle body. 106. Using a small saw or grinder carefully remove the material above the line until the throttle body looks like this. 107. Install the throttle body with the new supplied gasket onto the supercharger inlet manifold using the original three bolts and a 10mm socket wrench. 108. Torque the three throttle body bolts to 89 inlbs. 10/05 Page 29 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
109. Assemble the Evap solenoid bracket and bolts onto the fuel manifold. 110. Using some of the lubricant supplied, install the O-ring into the recess in the fuel rail. Install the fuel manifold and bracket on the fuel rail, take care not to pinch the O-ring. 111. Torque the fuel manifold bolts to 106 in-lbs with a torque wrench and 10mm socket. 112. Remove the Manifold Absolute Pressure (MAP) sensor from the stock intake manifold by tilting the sensor forward and lifting it free.
113. Apply a small amout of the grease supplied to the MAP sensor seal and install the sensor in its new location at the right rear of the supercharger manifold. 114. Install the MAP sensor in its new location using the supplied bracket and the button head Allen screw with a 4mm Allen wrench. 115. Install the new intake manifold gaskets supplied onto the recesses in the manifold face. Ensure that the gaskets are fully seated in the manifold face. 116.
117. With the help of a assistant carefully set the supercharger system in place. Take care not to damage the port gaskets. 118. Remove the split-looms that support some of the manifold to cylinder head bolts. Start all ten bolts by hand to ensure proper alignment of the manifold. 119. Using a torque wrench and 10mm socket torque the ten manifold to cylinder head bolts gradually and evenly to 89 in-lbs. 120. At the rear of the supercharger on the passenger side, plug in the MAP and new IAT connections.
121. At the firewall connect the Knock sensor connector. 122. Install the ignition coil pack connectors on both sides of the engine. 123. Install the connecors on all eight fuel injectors. 124. Install the TPS extention harness onto the harness connector. 10/05 Page 33 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
125. Install the TPS extention connector onto the throttle body connection. 126. Install the ETC connector onto the throttle body. Purge solenoid 127. Install the purge solenoid onto the new bracket and then install the EVAP electrical connector. 128. Use a adjustable wrench to rotate the PVC barb on the throttle body to the approximate “Four Oclock”position as shown. 10/05 Page 34 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
129. Install one end of a 16” length of the supplied 3/8” PCV hose onto the throttle body PCV barb. Install the remaining end of the hose on to the passenger (right) side valve cover PCV barb. 130. At the rear of the driver (left) side valve cover, remove the rubber cap covering the PCV barb. Elbow fitting 131. Assemble the new PCV outlet hose by cutting a 43” length and a 2” length of the 3/8” hose. Attach one end of each hose to the 90 degree elbow fitting. To inlet manifold barb To PCV barb 132.
Large inlet manifold barb 133. Install the plain end of the 43”PCV outlet hose on the passenger (right) side of the engine. 134. Insert the new check valve into the 11/32” brake hose supplied. 135. Install the new check valve and hose onto the brake vacuum booster. 136. On the driver (left) side of the engine connect the brake hose to the large barb on the inlet manifold. Route the brake hose along the side of the engine and behind the supercharger to the brake booster.
137. Locate the EVAP pipe removed earlier. 138. Using a sharp knife, carefully cut the plastic pipe so that the end fittings can be reused. 139. Here is the fittings removed from the pipe and the new supplied hose and clamps. 140. Secure the clamps by using a pair of side cutting pliers to crimp the loop of the clamp around the hose. Take care not to cut the loop but only tighten it. 10/05 Page 37 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
141. Here is the new EVAP hose assembled and ready for installation. Firewall EVAP connection Purge solenoid 142. Install the new EVAP hose onto the rear barb of the purge solenoid and into the firewall connector. Next, connect one end of a 12” length of 3/8” hose to the front barb of the purge solenoid. 12” length of EVAP hose 143. Install the fuel line extention into the firewall fuel line connector. 144.
145. Re-install the fuel line retaining clip. 146. Connect the remaining end of the EVAP hose from the purge solenoid to the small barb on the right side of the supercharger inlet manifold. EVAP hose 147. Install one end of a 24” length of the 1/4” coolant line onto the right side throttle body coolant barb. Secure the coolant line with a # 4 clamp supplied. New hose connector 148. Route the 24” coolant line along the front of the supercharger manifold and under the Mass Air Flow meter (MAF).
coolant vent pipe barb 149. Install one end of the 20” length of 1/4” heater hose on the coolant vent pipe barb. Secure the hose with a #4 clamp supplied. 150. Connect the remaining end of the 20” coolant hose to the left side throttle body barb using a #4 clamp supplied. S/C 151. Here is the new accessory drive belt routing diagram. ID P/S TEN W/P ALT ID CRANK 152. Using a long 15mm wrench to compress the tensioner, install the new belt using the diagram above.
153. Re-install the radiator into the vehicle. Reinstall the radiator hoses, fan electrical connections and A/C line support tab. The radiator mask will be installed in a later step. Air Bleed Passenger Side 154. This is a diagram of the complete intercooler system plumbing. Note: The routing of the hoses and their connections. Intercooler Drivers Side Heat Exchanger Coolant Tank Water Pump 155. At the lower A/C condensor attachment points, remove the two bolts on each side with a 8mm socket wrench.
157. Bolt the heat exchanger into place using the supplied Allen bolts and a 4mm Allen socket wrench. 158. Remove the the lower right A/C condensor mounting bolt with a 10mm socket wrench. Install the two reservoir brackets using the A/C mounting bolt and a new supplied bolt in the center attachment point on the radiator tank. Center attachment point Reservoir brackets A/C condensor mount 159. Here is the intercooler reservoir tank. Note: The slotted rail on the front surface.
161. Install two of the round head bolts into the slotted rail on the front of the reservoir as shown. Note: That the square portion of the bolt shaft must be aligned with the sides of the channel. 162. Mount the intercooler pump to the reservoir in this position using the supplied Adel clamps, bolts and nuts. Tighten the nuts securely with a 10mm wrench. 163. Install the two remaining round head bolts into the rails on the back of the reservoir. 164.
165. Secure the reservoir and pump assembly to the bracket uisng the supplied nuts. Tighten the nuts securely with a 12mm wrench. 166. Next to the left headlamp locate the air filter box boot. The boot will need to be removed to provide more air to the air filterbox and to allow passage of the heat exchanger lines. 167. To remove the boot, drill out the two mounting rivets at the front of the boot. 168. There are two additional retaining buttons securing the boot.
169. Cut the “J” shaped hose as shown so it forms a “U” and a right angle “L” hose. 170. Cut approximately 3” off the short leg of the large “L” hose supplied as shown. 171. Install one end of the 24” length of 3/4” hose to the left side intercooler manifold barb. Secure the hose with a #10 clamp supplied using a 8mm nutdriver. 172. Secure the remaining end of the 24” hose to the reservoir inlet barb with a #10 clamp. 10/05 Page 45 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
173. Attach the “U” shapped hose to the pump inlet barb and the reservoir outlet barb using the #10 clamps supplied. Tighten the clamps securely with a 8mm nut driver. 174. Attach the “L” shapped hose to the pump outlet barb and the heat exchanger inlet barb using two #10 clamps supplied. 175. Route the large “L” hose through the area created by removing the air box boot. Attach the short leg of the large “L” hose to the outlet barb of the heat exchanger with a #10 clamp. 176.
Rib 177. Here is the air tube assembly components. Note: The two different lengths of hose and the raised “Rib” around one end of the tube. This end of the air tube will go towards the throttle body. 178. Assemble the air tube assembly by sliding the hoses all the way onto the air tube and then place the #60 clamps in position. Note: The shorter of the two hoses will go on the end of the tube with the raised “Rib”. Do not tighten the clamps at this time.
181. Here is the intercooler pump harness and components. 182. Install the intercooler pump wiring harness at the Fuse/Relay center located at the front right corner of the engine compartment. Remove the Fuse/Relay center cover and using the legend printed inside, find the forward fuse location marked “SPARE” as shown. Spare 183. Place one leg of the supplied 15amp fuse through the Fuse-Tap as shown. 184. Install the new fuse and Fuse-Tap into the “Spare” location.
185. On the end of the yellow wire from the relay harness, strip the insulation back 1/4” and crimp on the female spade terminal. Connect the female spade terminal to the male spade of the Fuse-Tap. 186. Connect the Black ground (-) wire with the ring terminal to the forward bolt that secure the fuse/ Relay center to the chassis. Remove the bolt with a 10mm wrench and place the ring terminal on the bolt. Re-install the bolt and tighten it securely. 187.
189. Connect the Pump connector to the end of the intercooler pump. 190. Re-install the front fascia by first re-connection the four electrical connectors on the inside of the fascia. Note: The heads of the lock bolts in the top edge of the fascia, these must stand proud in order to engauge the “keyhole” slots in the bottom edge of the fenders. Lock bolt head 191. Set the front fascia in position on the vehicle. 192. Line up the lock bolt heads with the “keyhole” slots in the bottom edge of the fender.
193. Re-install all the push reivets into their original locations in the fascia and wheel wells. 194. Re-install the lower front splash panel with its push rivets. 195. Snap the radiator mask into place and secure it with the push rivets. 196. Here are the Magnavolt components and mounting hardware. 10/05 Page 51 Cadillac CTS-V Supercharger Installation Instructions magnacharger.
197. Begin the Magnavolt installation by removing the “D” shaped trunk floor cover by unscrewing the retainer located in the center. “D” cover Retainer Trunk mask panel 198. Remove the four retainer buttons that secure the trunk mask panel to the rear of the trunk by unscrewing them. There is one button on the floor and one on the wall on each side. Button locations 199. Remove the trunk mask panel from the trunk compartment. 200.
201. Locate the large branch of the wiring harness running down the wheel well. Carefully cut the tape and locate the LARGE GREY WIRE. Pull the large grey wire out of the bundle, this is where the connections will be made. Grey wire 202. Cut the large grey wire and strip the insulation back from the two ends about 1/4”. Connect BLACKwire to upper grey wire 203.
205. Here is what the finsihed connections should look like. You must shrink the insulation, as crimping the connections alone is not enough to secure them! Replace the trunk interior, “D” and mask panels with their retainers and buttons. Cable 206. The cable will follow the factory harness on the bottom of the vehicle over the top of the differential and then to the passenger side where it will follow the brake and fuel lines to the engine compartment. Cable 207.
209. Install the new strut tower brace starting on the driver side. Note: It will use the lower tower bolt not used by the previous brace. 210. Torgue the forward strut tower bolt on the passenger side first to 83 ft-lbs. using a 18mm socket and torque wrench. Next, install the new strut tower brace on the passenger side by first passing the two mounting bolts through the Magnavolt mounting bracket. Torque the remaining strut tower bolts on each side (six in total) to 83 ft-lbs. 211.
213. Release the connector closest to the front of the vehicle by squeezing the release trigger and pulling it free. 214. Remove the insulating tape below the connector and locate the solid WHITE wire. This is the Engine Speed Signal (RPM) wire. 215. Cut the white wire approximately 1-1/2” below the connector. Strip the insulation back 1/4” from both ends of the white wire and connect the ends togather with a end of the new length of white wire supplied.
217. Locate at the left rear corner of the supercharger manifold the pressure port and remove the rubber cap. Attach one end of the length of 3/16” hose supplied to the port. The other end of the hose will be routed to the Magnavolt. Pressure port Pressure hose RPM wire 218. Secure the hose and RPM wire to the harness where it pases behind the supercharger with the tie straps supplied.
Red wire from harness 221. Connect the Red (+) wire from the Magnavolt harness with the ring terminal to the main power connection on the Fuse/Relay Center. Remove the nut with a 13mm wrench and place the ring terminal on the stud. Re-install the nut and tighten it securely. Using a sharp knife, cut away at the the harness boot to allow the Red wire to pass from the inside to the engine compartment. Replace the cover to the Fuse/Relay center. Cut boot 222.
225. Reconnect the negative battery connection with a 8mm wrench. 226. Attach a short length of hose to the right intercooler manifold barb temporarily and route it to the mouth of the funnel as shown. Switch the ignition on but DO NOT START THE ENGINE! Allow the intercooler pump to circulate the coolant mixture through the system for a minimum period of at least 10 minutes. This wll purge the intercooler system of any air bubbles and ensure maximum performance.
229. In the event that the vehicle needs to be returned to its original calibration, follow the directions as described in the previous steps. The handheld unit will prompt you that you have already modified the vehicle’s computer. Select YES to return you vehicle’s computer back to the stock calibration. Wait for the handheld to finish, then disconnect cable plug as directed.
