Installation Instructions for:
INTERCOOLED SUPERCHARGER SYSTEM
2009 PONTIAC G8 GXP
Step-by-step instructions for installing the best in
supercharger systems.
* PREMIUM FUEL REQUIRED *
ATTENTION!
Your MAGNA CHARGER intercooler kit
is sensitive to corrosion!
Take care of if by using 50/50
anti-freeze with de-ionized water.
89-89-60-020 Rev C
Magnuson Products Inc
1990 Knoll Drive, Ventura, CA. 93003
(805) 289-0044 * (805) 677-4897 fax
magnusonproducts.com * magnacharger.com
INSTALLATION MANUAL
Magna Charger
GM 6.2L Engine
2009 Pontiac G8 GXP
Please take a few moments to review this manual thoroughly before you begin work: Make 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 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. 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. 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 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 GM fuel filter is recommended at the time of supercharger installation
Stock spark plugs and stock plug gap is recommended
Drive belt = Gates# K060878
Tools Required:
Metric wrench set
¼” - 3/8” and ½” drive metric socket set (Standard & Deep)
3/8”and ½” drive Foot pound and inch pound torque wrenches
Phillips and flat 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
Helpful Tool: Air or electric impact wrench.
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
09 Pontiac G8 GXP
1.
On the sidewall of the trunk on the driver
side is an access panel behind which the battery
is located. Pull off this access panel to expose
the battery.
2.
Disconnect the negative battery terminal
using a 10mm wrench.
3.
Slowly remove the gas cap to release fuel
system pressure.
4.
Remove the engine cover by lifting and
put aside. This will not be reused.
07/09
Page 3
www.magnacharger.com
09 Pontiac G8 GXP
5.
Place a drain pan under the passenger
side front of the car. Using a medium Phillips
screwdriver remove the cooling system drain
plug from the bottom of the radiator on the passenger side. Facilitate the draining of coolant by
removing the radiator cap. Reinstall the drain
plug and radiator cap when draining is complete.
Coolant Drain Plug
6.
Disconnect heater hoses at the heater core
and water pump (note: heater core hard-lines
will flex). These hoses are banded together and
go back to the firewall where you will find spring
clips. Using a pair of pliers grasp the spring-clips
and pull forward beyond the barb. Then pull the
hoses free, be aware there could be fluid in the
hoses. We suggest you wrap the hose barbs
with a shop towel to catch the dribble and keep
clean. These hoses will not be reused.
7.
Use a 7mm socket to loosen the clamps
holding the air bellows to the MAF Sensor.
8.
Depress the locking tabs on the PCV Vent
tube on the passenger side hose barb and pull
the connection free.
07/09
Page 4
Hose
Barb
www.magnacharger.com
09 Pontiac G8 GXP
9.
Use the 7mm socket to loosen the clamps
holding the air intake tube to the throttle body
and remove the air intake tube. This assembly
will not be reused.
10.
Disconnect the EVAP Solenoid plug.
11.
Disconnect the MAP Sensor plug.
12.
Disconnect the eight Injector plugs on
each side of the engine.
07/09
Page 5
www.magnacharger.com
09 Pontiac G8 GXP
13.
Pull the injector wire loom free from the
stock intake manifold fuel rail mounting holes.
14.
Remove the EVAP link by squeezing the
yellow saw-tooth tabs and pull free from both
ends, put aside for later use.
15.
Remove the end of the PCV hose from
the intake manifold on the passenger side by
squeezing the locking tabs and pull free. This
will not be reused.
16.
Depress the light gray (almost white) tabs
of the EVAP tube outlet from the EVAP Solenoid
and pull free from both ends, put aside for later
use.
07/09
PCV Hose barb
EVAP Solenoid
Page 6
www.magnacharger.com
09 Pontiac G8 GXP
17.
Unplug the throttle body control by pulling
out the gray tab and pull free.
18.
Unbolt the four bolts of the throttle body
using a 10mm socket wrench and remove the
throttle body, put aside for later use.
19.
Pull the vacuum brake hose free from the
power brake booster.
20.
Pull off the retaining clip off the fuel line
hose to hardline connection, and using the fuel
line removal tool supplied, remove the fuel line to
the drivers side fuel manifold. To ease removal,
pull the fuel line forward, then insert the disconnect tool. Then push the fuel line back, removing it from the manifold. If you have or can improvise a cap we suggest you cap both the hose
and the manifold to avoid spillage.
Tool
07/09
Page 7
www.magnacharger.com
09 Pontiac G8 GXP
21.
Unbolt the intake manifold using an 8mm
socket wrench. There are five bolts on each
side.
22.
Remove the stock intake manifold and
put aside, you will be taking some parts off from
the bench.
23.
Carefully vacuum the valley cover and the
just exposed port surfaces first. Then wipe the
heads clean of oil and any debris using a solvent dampened rag. Unplug the remaining PCV
hose from the front passenger side of the valley
cover hose barb. Finally, tape over the intake
ports. It’s important to maintain a clean work environment.
Hose barb
24.
For these next few steps, you may find it
easier (and you will have more room), if you first
remove the front wheel. Pull the push pins of the
front panel fender wells out (four each side), and
pull the panels away.
07/09
Page 8
www.magnacharger.com
09 Pontiac G8 GXP
25.
For ease of work you can remove the remaining pins and completely take the fender well
liners out completely, or you can just bend the
panels out of the way as you work.
26.
As the case may be, bend the panel toward the rear of the vehicle. Then use a 10mm
socket to remove the two front end bolts on each
side of the vehicle holding the front body panel to
the upper fender section. This shows the fender
well removed completely.
27.
On the passenger side of the vehicle,
front of the fender well, unplug the connector
that splits to go to the parking lights (fog lights),
and the side marker illuminating reflector.
Connector
28.
Remove the four 13mm bolts and the four
7mm bolts on the bottom plastic splash shield,
then pull the bottom panel free by pulling aft and
away from the front of the vehicle. Set aside for
later use.
07/09
Page 9
www.magnacharger.com
09 Pontiac G8 GXP
29.
Remove the two push pins and two 10mm
bolts from the top of the front end panel connecting the front end fascia to the upper radiator support.
30.
Now, this is a little difficult, because it’s
blind. There are two plastic spring tabs under
the headlamp on each side. Accessing from below through where the plastic skid panel was located, you reach up to just below the headlight
housing on each side, as you reach up; the plastic has a forward edge bending slightly down.
Feel along these plastic flanges and you will
notice four slots on each side close together in
pairs. Between these slots are the plastic spring
tabs. This first picture shows you the tabs after
the front panel is removed.
31.
Pull down between the outer two slots on
the spring tab while slightly pushing the body
panel forward away from the vehicle. When the
outer spring tab releases, do the same for the
inside spring tab. Repeat on the other side of
the vehicle. Be sure to have a helper handy for
this step…you don’t want the front end popping
off and getting scratched when it slams to the
ground. Pull the front end body panel free from
the vehicle and put aside in a safe place where it
won’t be damaged.
32.
07/09
Locking Tabs (2-ea. side)
These are the 4-tab lock slots.
Pull off the plastic 5mph bumper guard.
Page 10
www.magnacharger.com
09 Pontiac G8 GXP
33.
box.
Unplug the MAF Sensor plug from the Air-
34.
Unclip the five spring clips that hold the
Air-box cover in place.
Spring Clip
35.
Remove the cover, put aside to reinstall
later.
Remove Cover
36.
Remove the upper Radiator hose clamps
from both ends of the hose, pull the hose off the
hose barbs and put aside for later use.
07/09
Page 11
www.magnacharger.com
09 Pontiac G8 GXP
37.
Remove the coolant overflow tube from
the hose barb just below the radiator cap, unclip
from mounts and coil up on the passenger side
of the vehicle out of the way.
38.
Reroute the secondary coolant to crossover tube out of the way. You can bend it to run
out the other side of the radiator cap.
39.
Disconnect the Fan Plug from the Fan
Shroud housing.
40.
Push down on the top of the Transmission
Heat Exchanger hoses so that they disconnect
from the mounting clips of the lower Fan Shroud
housing.
07/09
Page 12
www.magnacharger.com
09 Pontiac G8 GXP
41.
Using a medium flathead screwdriver,
push down on the top locking pins to release the
upper Fan Shroud mount.
42.
Pull the Fan Shroud assembly free from
the vehicle and put aside for later re-installation.
43.
Remove the mounting bolts from the
transmission cooler hard-line bracket at the driver side frame crossover with a 13mm socket.
44.
Remove the transmission cooler hard-line
mounting bracket bolt from the driver side frame
rail using a 10mm socket.
07/09
Page 13
www.magnacharger.com
09 Pontiac G8 GXP
45.
Using a 24mm socket and an impact hammer, remove the Main Harmonic Balancer bolt.
This will not be reused. Sometimes using a heat
gun or MAP gas torch on the surrounding pulley
material helps it to break free from the Locktite
used during initial installation. Don’t heat the
bolt itself and always use care using open flame
around engine compartments and combustible
material.
46.
Install the supplied drill guide using the
supplied bolt and tighten to 30 ft/lbs with a 24mm
socket and torque wrench.
47.
Using a small or angled 3/8” drill and the
supplied drill bit, insert the drill into the two guide
holes and drill to the second step of the drill bit.
Be sure that you drill all the way to the second
step, and use with suitable cutting oil. (Caution:
Wear safety glasses)
48.
Using compressed air, blow the drill shavings out of the holes. (Caution: Wear safety
glasses, and make sure that debris doesn’t blow
into surrounding openings…such as the thermostat housing etc.)
07/09
Page 14
www.magnacharger.com
09 Pontiac G8 GXP
49.
Insert the supplied reamer into the drill,
and using a small amount of oil, ream the holes
clean until reamer bottoms out in the holes.
(Caution: Wear safety glasses)
50.
Using a 24mm socket, remove the large
bolt and drill guide from the engine.
51.
Once again, use compressed air to blow
out the holes. (Caution: Wear safety glasses
and again be aware of surrounding openings.)
52.
Insert the two supplied hardened roll pins
into the drilled holes.
Roll Pins
07/09
Page 15
www.magnacharger.com
09 Pontiac G8 GXP
53.
The use of a small hammer and punch
may be necessary to tap the pins in. Make sure
that the pins are in far enough that they do NOT
touch the balancer bolt.
Tap in with punch
54.
Install the new supplied factory GM Harmonic Balancer bolt.
55.
Using a 24mm socket tighten the new
Harmonic Balancer bolt according to General
Motors specifications. Tighten to 50 N-m (37 ft/
lbs) then tighten an additional 140 degrees using
a torque angle meter.
56.
Using a 15mm socket on the Tensioner
Pulley bolt, spring the pulley down to remove
tension on the drive belt and remove the belt
when tension has been released.
07/09
Page 16
www.magnacharger.com
09 Pontiac G8 GXP
57.
Disconnect the oil pressure sensor connection at the rear of the valley cover.
58.
Remove the oil pressure sensor from the
valley cover using a 6-point 1-1/16” socket or
wrench, put aside for later re-installation.
59.
Remove the eleven valley cover bolts using a 13mm socket and set aside.
60.
Remove the OEM valley cover. This will
not be reused, but we will need components.
07/09
Page 17
www.magnacharger.com
09 Pontiac G8 GXP
61.
Verify the integrity of the existing valley
cover gasket, and that it is correctly positioned
on the valley surface.
62.
Remove the existing O-ring seals from
the OEM valley cover, and place in the O-ring
grooves of the new provided valley cover.
63.
Install the new valley cover using the
eleven provided Allen-countersunk bolts. torque
to 18 ft. lbs using a 5mm allen socket. Verify
your torque wrench settings.
64.
With the new valley cover in place, check
the clocking of the oil pressure sensor. Temporarily install the oil pressure sensor and torque to
15 ft lbs. If the plug locking clip is in the #1 or #2
position, no shim i sneeded. If it ends up in the
#3 position, then use the provided shim. Now
remove the oil pressure sensor.
07/09
Page 18
www.magnacharger.com
09 Pontiac G8 GXP
65.
Permanently install the clocked oil pressure sensor. IMPORTANT: Apply some Teflon
tape or paste to the threads to prevent oil leakage. See the prior step regarding shim position
requirements: The sensor must be torqued to at
least 15ft lbs, but you may have to torque your
sensor up to 24 ft lbs to reach the desired clip
position.
66.
Place a dab of some black silicone into
the recesses of the top surface of the new valley
cover to hold the six provided O-rings in place.
67.
Insert the six provided O-rings into place
on the top surface recesses of the new valley
cover.
68.
Replace the oil pressure sensor plug and
locking clip on the oil pressure sensor.
07/09
Page 19
www.magnacharger.com
09 Pontiac G8 GXP
69.
Using a medium flathead screwdriver, pry
up on the radiator release tabs. They will slide
up easily until they hit a “stop”.
70.
This stop is accessed from the front side
of the release tab, and using a small flathead
screwdriver you depress the stop allowing you
to pull the radiator mount lock free from the upper radiator mount.
Mount Lock
71.
This picture is a closeup of the locking tab
that needs to be depressed to allow the mount
lock to be removed.
Tab Stop
72.
From inside the slot where the lock tab
was removed, use the small flathead screwdriver
to lever the final locking tab inward, allowing the
upper radiator mount to be pulled up and free of
the frame.
07/09
Mount tab lock
Page 20
www.magnacharger.com
09 Pontiac G8 GXP
Upper Radiator Mount
73.
This picture shows the mount lock being removed. Repeat on other upper radiator
mount. The radiator can now be pivoted backward toward the engine block for heat exchanger
installation.
74.
Remove the rubber seal from the top of
the A/C Condenser. This will get modified and
re-installed in a later step.
75.
As an option, you can rattle-can the provided Intercooler Heat Exchanger black to minimize the visibility through the grille.
76.
Using a 10mm socket, remove the three
M6 transmission cooler bolts from the fascia
frame mounting brackets.
07/09
Page 21
www.magnacharger.com
09 Pontiac G8 GXP
77.
Apply the two ½” x 15” and the two 1” x 3”
rubber strips to the Heat Exchanger as shown.
78.
Pull back on the top of the radiator toward
the engine, slide the Heat Exchanger down in
front of the A/C Condenser, hooking the two top
brackets onto the condenser. Locate the new
Heat Exchanger so that there is 4-1/8” between
the existing AC condensor mount to the existing radiator and the new “hook” shaped mounting bracket on the passenger side of the heat
exchanger. Be sure not to pinch the small hose
coming from the windshield wiper reservoir between the heat exchanger and condenser.
79.
Next, trim the rubber seal in the two spots
as shown. This will allow the seal to re-install
around the Heat Exchanger brackets.
4-1/8”
Make the trim cuts using the
new intercooler brackets to
locate your cuts.
80.
Now re-install the modified rubber seal
onto the condenser. Refer to steps 69 thru 73
to reinstall the plastic upper radiator mounts to
secure the radiator back in place; then reinstall
the bracket locking tabs.
07/09
Page 22
www.magnacharger.com
09 Pontiac G8 GXP
81.
Cut a section of the 3/4” hose to 59” in
length. Connect one end of the hose to the top
barb of the just installed intercooler heat exchanger and clamp using the provided clamp.
Run this hose down behind the frame and temporarily out the front of the radiator cowl at the
bottom-passenger side.
82.
There are three provided transmission
cooler offset brackets. Attach one to the upper passenger side bolt hole (place a provided
washer between the bracket and frame for this
hole) where the transmission cooler was originally mounted using the provided bolt. Attach
one to the driver side bolt hole from where the
transmission cooler was originally mounted.
83.
The passenger side plastic air deflector will
need to be modified to mount the lower transmission heat exchanger offset bracket. Use dykes
or cross cutters to cut a notch for the bracket.
This will be at approximately 45 degrees from a
horizontal plane.
84.
Attach the remaining heat exchanger offset bracket to the exisiting bolt hole where the
transmission cooler was originally mounted.
07/09
Page 23
www.magnacharger.com
09 Pontiac G8 GXP
85.
Completely remove the existing transmission cooler mounting bracket from the driver side
of the transmission cooler. Using a saw or grinder modify the bracket as shown. You’re taking
off approximately 5/8” from the tab with the upper mounting hole all the way down to the bend
in the bracket.
86.
Attach the bracket back on the transmission cooler. Using the original bolts, bolt both
mounting brackets to the just installed offset
mounting brackets. Tighten all bolts using a
10mm socket being careful not to strip threads.
NOTE: Cooler lines may still require a little bending to clear the heat exchanger and any other
interference areas.
87.
Reinstall the transmission cooler hardline
on the driver side frame rail inserting the new
provided spacer between the frame and the
bracket using the provided bolt. Tighten using
10mm socket.
88.
Reinstall the transmission cooler hardline
on the crossover rail also inserting the new provided spacer between the frame and the bracket
using the provided bolt. Tighten using a 10mm
socket.
07/09
Page 24
www.magnacharger.com
09 Pontiac G8 GXP
89.
The following two steps are prep for later
procedures: The Intercooler pump plate and
bracket mount will now be located. Use the existing hole located just to the driver side of the
lower cross-member as one hole. This existing
hole is toward the center from the existing 5/8”
diameter hole located in-line with the driver-side
edge of the crank pulley. Mark the second hole
using the mounting plate as a guide. Use the
supplied self tapping screws as your drill bit, drill
and tap your hole.
90.
Open and tap the existing hole also using
the self tapping screw as shown. Set the self
tapping screws aside for later mounting of the
intercooler pump.
91.
With the radiator mounted back in its
stock location, you can now re-install the electric
fan assembly.
92.
Plug the electrical connection back into
the fan assembly.
07/09
Page 25
www.magnacharger.com
09 Pontiac G8 GXP
93.
Press the two transmission cooler lines
back into the retainer clips on the fan assembly.
94.
You can now re-connect the coolant overflow hose back to the hose barb on the radiator
neck.
95.
Now re-install the upper radiator hose and
secure in place with the stock clamps. The coolant overflows can now be relocated to the stock
locations and clips on the radiator fan shroud.
96.
Locate the ETC connector on the engine
harness. This will need to be extended with the
supplied extension harness.
07/09
Page 26
www.magnacharger.com
09 Pontiac G8 GXP
97.
This is the provided ETC connector extension harness.
98.
Plug the extension into the existing ETC
connector, route the wires adjacent to the existing wiring harness to the driver side of the engine.
99.
Disconnect the main coil connector from
the coil rail.
100.
07/09
Disconnect all plug wires from the coils.
Page 27
www.magnacharger.com
09 Pontiac G8 GXP
101. Remove five 10mm bolts from the coil
brackets on each side, and remove the coil
brackets from the engine to be modified below.
102. Remove the plastic wire loom covers from
the coil bracket assemblies. Do this procedure
on both sets of coils.
103. Trim the plastic cowl at the center of the
run as shown and described. From the center
seam, trim off 4-1/4” on the driver side. From the
center seam, trim off 3” on the passenger side.
104. The power steering reservoir mount will
need to be spaced-outward to maintain clearance with the new throttle body location. Remove the power steering reservoir by levering
out on the metal locking tab, then slide the bottle
up to remove.
07/09
Page 28
www.magnacharger.com
09 Pontiac G8 GXP
105. Remove the two stock reservoir bracket
mounting bolts using a 15mm socket.
106. Mark the bracket as shown in the picture.
On the edge closest to the passenger side bolt,
make a mark adjacent to the bolt witness mark.
The material to the outside of your mark will have
to be removed.
107. Use a grinder or suitable file to remove
the material. Your final result should look like
this. Dress the edges to avoid sharp surfaces.
108. Place the provided bolts through the holes
of the bracket, insert the provided spacers and
bolt the bracket back onto the engine. Torque
the bolts to 35-40 ft. lbs. Verify your torque
wrench settings.
07/09
Page 29
www.magnacharger.com
09 Pontiac G8 GXP
109. Remove the MAP sensor from the stock
intake manifold.
110. Use a 10mm socket wrench to unbolt the
stock Fuel Rails from the stock intake manifold.
111. Unsnap and remove the clips holding the
fuel injectors to the stock fuel rails, and remove
the injectors. Note: There will be fuel leakage
from the injectors and fuel inside the fuel rails.
Take care to have an appropriate catch pan and
shop rags handy, then dispose of the fuel collected and any rags used properly.
112. Use a 10mm socket wrench to remove the
fuel rail bolts connecting the supplied fuel rails to
the new intake manifold. You may leave the fuel
lines (front and back) attached. Lift the rails up
to allow the injectors to be installed. Use the
supplied Lubriplate Lubricant to lube the O-rings
of the stock injectors and insert the eight stock
injectors into the new manifold below the fuel
rails. Point the electrical connections outward.
07/09
Page 30
www.magnacharger.com
09 Pontiac G8 GXP
113. Lubricate the upper O-rings of the stock
injectors, align and carefully press the fuel rails
down onto the installed injectors.
114. Reinstall the fuel rail bolts and torque to
106 in lbs. Verify your torque wrench is correctly
set to inch-pounds.
115. Remove the O-ring from the stock throttle
body connector groove.
116. Install the MAP sensor on the new Supercharger assembly.
07/09
Page 31
www.magnacharger.com
09 Pontiac G8 GXP
117. Snap the supplied intake manifold gaskets
onto the new Supercharger intake manifold.
118. Install the stock O-ring for the throttle body
into the grove on the Supercharger assembly.
119. Install the Throttle Body on the supercharger using a 10mm socket wrench, torque
the bolts to 106 in.-lbs. Make sure you are using
the correct settings for your torque wrench.
120. Using the supplied Lubriplate lubricant,
lube the O-ring and insert it into the groove on
the driver side fuel rail.
07/09
Page 32
www.magnacharger.com
09 Pontiac G8 GXP
121. Install the fuel supply manifold on the fuel
rail, and torque the 106 in.-lbs. Verify your torque
wrench settings.
122. Remove the tape from the heads and lubricate with silicone spray (non petroleum base
lubricant). Get another pair of hands to help,
and carefully lift the supercharger assembly into
the engine.
123. Remove the split loom spacers from the
intake manifold bolts so that the bolts can drop
down to engage the threads on the heads.
124. After an initial hand tighten, torque the
bolts down to 106 in.-lbs. Make sure you check
your torque wrench settings. Rear passenger
side bolt is difficult with a torque wrench, you
may have to use an open-end wrench to reach
this bolt or preferably an open-end crows-foot
wrench to connect to your torque wrench. To allow more clearance in the work environment, you
may want to remove the driver-side fuel rail.
07/09
Page 33
www.magnacharger.com
09 Pontiac G8 GXP
125. Slide the power steering reservoir back
onto the relocated mounting bracket, guide the
tongue of the reservoir into the receiving angles
of the bracket.
126. Use a flat blade screwdrive to push on and
re-engage the metal locking tab of the bracket
over the lip of the reservoir bottle.
127.
tor.
Plug in the MAP sensor electrical connec-
128. Plug the fuel injector plugs to the injectors on each side of the engine. Make sure to
route and stuff the wiring to avoid moving components.
07/09
Page 34
www.magnacharger.com
09 Pontiac G8 GXP
129. Re-attach the modified coil brackets to
each side of the engine using the stock hardware. Do NOT install the second bolt back on
the passenger side at this time. Torque all remaining bolts to 106 in.-lbs. Again, verify your
torque wrench settings. Reattach the main coil
connector at this time (removed in step 106)
130.
Plug in the Throttle Body connector.
131. Attach the stock plug connectors back on
to the coils on the coil brackets.
132. Attach the fuel line to the fuel manifold
on the driver side of the supercharger. Be sure
to attach the safety clip as well. Verify that you
have a good connection. You should NOT be
able to remove the fuel line without using the fuel
line removal tool.
07/09
Page 35
www.magnacharger.com
09 Pontiac G8 GXP
133. Cut two sections of the supplied 5/8”
hose. One @ 34” and one @ 35”. You will reuse
the four stock clamps from the removed heater
hoses. The 34” hose goes to the passenger side
hose barb on the firewall, and the near hose barb
on the water pump. The 35” hose goes to the
centermost hose barb on the firewall and goes to
the front hose barb on the water pump. This is a
¾” barb. So, lubricate the end of the 5/8” hose
to facilitate installation. Slide the hose clamps
into position using pliers, or hose clamp pliers on
both the firewall and water pump ends.
34”
35”
134. Using the supplied 6 x 45mm bolts, 1”
spacer, and double hose clamp, install the clamp
with the mount hole facing down over the just installed two heater hoses. Slide the bolt through
the clamp, and put the spacer on the bottom of
the bolt. Install the bolt into the second hole of
the coil bracket on the passenger side (the one
left out in step 135). Torque bolt to 106 in.-lbs.
135. Loosely add zip ties to hold the hoses together, and add strips of split loom to prevent
chafing on the fuse box.
136. Plug in the EVAP sensor electrical connection.
07/09
Page 36
www.magnacharger.com
09 Pontiac G8 GXP
137. Use a sharp blade and split the ends of
the EVAP lines and remove the three fittings.
138. Cut a piece of the supplied 5/16” hose to
40” long and install the right angle fitting removed
in the prior step. No clamp is necessary.
139. Thread the open end of the 40” (5/16”)
hose under the front of the supercharger assembly, below the throttle body, and back along the
coil bracket. Connect the right angle end to the
EVAP solenoid as shown.
EVAP Sol.
140. Insert one of the fittings removed in step
144 into the open end of the 40” hose and attach
the fitting to the firewall connection as shown.
07/09
Page 37
www.magnacharger.com
09 Pontiac G8 GXP
141. Cut 20” of the supplied 5/16” hose and
install the remaining end (removed in step 144)
onto the EVAP Solenoid as shown.
142. The other end of this hose connects to the
supercharger hose barb as shown. Add zip tie at
the heater hoses near the oil fill cap.
Zip Tie
SC Barb
143. Cut 20” of the 3/8” hose, install on the
PCV valve barb at the rear on the driver siderear valve cover as shown.
144. Connect the other end to the front of the
supercharger barb on the driver side as shown.
07/09
Page 38
www.magnacharger.com
09 Pontiac G8 GXP
145. Cut 20” of 11/32” brake hose supplied; attach the stock check valve on one end.
146. Install check valve at the brake booster as
shown.
147. The other end of this hose connects to
the vacuum barb on the supercharger inlet as
shown.
148. Add zip ties to anchor the vacuum hoses
as shown.
07/09
Page 39
www.magnacharger.com
09 Pontiac G8 GXP
149. Cut a 16” section of the supplied 3/8”
hose. Connect one end to the hose barb on the
passenger side, front-above valve cover. The
other end will connect to the inlet tube to be installed later.
150. Near the front on the passenger side of
the supercharger are the two IAT wires exiting
the intercooler lid. Attach wire splice connectors
to these IAT plug wire ends as shown in the first
image. Route the wires from passenger side under the supercharger inlet.
151. Uncover the wire loom to the MAF connector that hooks to the air box. Cut the brown
with-white stripe, and the brown with-red stripe
about 2” from the connector. The wire ends at
the connector are abandoned and can be taped
off should you wish.
152. Crimp the wires you just cut from the MAF
connector, to the IAT sensor wires you routed
under the supercharger inlet in step 157. The
selection of the wire to connect to either terminal
is of no consequence.
07/09
Page 40
www.magnacharger.com
09 Pontiac G8 GXP
153. Heat shrink your connections to avoid
moisture contamination and ensure a good connection.
154. Re-place the split loom to the MAF plug.
Cut a piece of split loom (supplied) to cover the
new wires under the supercharger inlet (approximately 19”) to the IAT sensor wire ends.
155. Ensure that the wire loom does not contact the jack-shaft and that the wires are covered
completely.
156. This procedure is easier using a helper,
without a helper try to use your longest handle
wrench for the tensioner. Route and install the
supplied drive belt as shown in the drive belt diagram. You won’t be able to get it over all the
pulleys yet. Use a 15mm long wrench to lever
the tensioner and utilize all pulleys. With the
tensioner held compressed, push the idler firmly
toward the tensioner pulley. Tighten the idler
pulley bolt in this position. Now release the lever on the Idler tensioner allowing the belt to be
put under proper tension. It’s a good idea to go
through this process again after the vehicle is
first driven to adjust for stretching.
07/09
Page 41
www.magnacharger.com
09 Pontiac G8 GXP
157. Install the air box filter and cover, snapping the retaining clips into position.
158. Plug the MAF connector into the MAF
sensor on the air-box as shown.
159. Assemble the Intercooler Pump and
bracket mount.
160. Mount the assembly using the holes you
prepped in step 89. Be careful to not strip the
self tap screw threads…do not over tighten!
07/09
Page 42
www.magnacharger.com
09 Pontiac G8 GXP
161. To mount the intercooler reservoir you will
use the fuse box mounting bracket and need to
modify the existing accessory bracket. Remove
the nut with a 13mm socket.
162. This is the intercooler reservoir mounting
bracket. The bottom hole mounts to the bolt post
for the fuse box where you just removed the nut.
From a straight out mount it will need to rotate
approximately 30 degrees clockwise. As such
the bracket will hit the accessory bracket. Mark
the bracket as shown by scribing an estimated
notch to be removed.
163. Test your fit and adjust as necessary.
This is the modified-notched intercooler reservoir bracket, we curved the edges to eliminate
any sharp surfaces.
164. The top section of the existing accessory
bracket will rub against the reservoir bottle and
must be modified as well. From the outside forward edge, scribe a line back to the rear bend
angle. This section will need to be removed.
Use a cutting wheel, saw or suitable file to take
this section out. Make sure you also dress the
surfaces to eliminate any sharp edges.
07/09
Page 43
www.magnacharger.com
09 Pontiac G8 GXP
165. Install the Intercooler bracket mount as
shown onto the post using the nut you removed
in step 168, tighten using a 13mm socket.
166. Attach reservoir to the mounting bracket
with the three supplied bolts. Ensure that there
is no reservoir bottle to existing bracket contact.
167. At the front-bottom-passenger side of
the plastic radiator cowl, drill two 1-1/4” holes
through the plastic cowl for the heat exchanger
hoses as shown. Connect the holes by cutting
the plastic between them, clean and dress the
hole to remove sharp edges.
168. Cut a 46” section of the supplied ¾” hose
and connect one end to the lower heat exchanger barb using the provided clamp. Route the
hose through the holes, up over the lower radiator hose.
07/09
Page 44
www.magnacharger.com
09 Pontiac G8 GXP
169. Connect the free end of this hose to the
Intercooler pump discharge barb using the provided clamp..
170. In step #81 you installed a 59” section of
the supplied ¾” hose to the upper heat exchanger barb using the provided clamp. Route the
hose to follow the bottom heat exchanger hose
through the hole in the cowl and into the engine
compartment. This photo has the transmission
cooler removed for clarity.
171. Clamp the free end of this hose onto
the supercharger inlet barb using the provided
clamp.
172. Cover hoses passing through plastic cowl
with sections of the supplied split loom to avoid
chafing and wear.
07/09
Page 45
www.magnacharger.com
09 Pontiac G8 GXP
173. Cut 31” of the remaining ¾” hose and connect one end to the water pump inlet barb using
the supplied clamps.
174. Route the hose to the intercooler reservoir and connect to the hose barb as shown using the supplied worm gear clamp.
175. Cut an 8” section of the ¾” hose and connect between the intercooler reservoir and the
supercharger hose barb as shown. Clamp with
the supplied hose clamps. Make sure you use a
supplied worm gear clamp on the reservoir.
176. Use the supplied zip ties to anchor hose
bundles, and sections of split loom to protect
hoses from chafing edges.
07/09
Page 46
www.magnacharger.com
09 Pontiac G8 GXP
177.
Remove the fuse box cover.
178. Remove the HVAC ignition fuse (slot
F-37), verify the fuse by fuse name, in some instances the fuse may be in a different slot.
179. Use supplied 10amp fuse, slip the supplied fuse tap over one leg of the fuse.
180. Insert fuse with fuse tap back into slot you
removed it from, probably F-37.
07/09
Page 47
www.magnacharger.com
09 Pontiac G8 GXP
181. Insert the supplied fuse into the supplied
wire bundle.
182. Zip tie intercooler relay to wire bundle adjacent to the coolant reservoir fill cap.
183. Route the intercooler control plug wires
down along the hoses, zip tie as handy and plug
into the intercooler pump receptacle.
184. Shorten the black lead about 12” and attach the new end supplied.
07/09
Page 48
www.magnacharger.com
09 Pontiac G8 GXP
185. Use a 13mm wrench to remove the fuse
mount bracket bolt. Re-attach the bolt incorporating and grounding the black lead wire.
186. Remove the hot lead nut from the front of
the fuse box with a 13mm wrench. Add the new
hot lead wire and replace the nut.
187. Drill a 1/8” diameter hole for the new intercooler pump wire to route to the fuse-with-fusetap, probably in slot F-37. Thread the yellow wire
through the new hole, THEN attach the supplied
connector.
Drill 1/8” Hole here!
188. Plug the new yellow wire connector onto
the fuse tap installed earlier, probably in slot
F-37.
07/09
Page 49
www.magnacharger.com
09 Pontiac G8 GXP
189.
Replace the fuse box cover.
190. Remove the inlet coupling from the inlet
air tube and install it on the throat of the throttle
body.
191. Connect the air inlet tube to the air-box at
the bellows end.
192. Connect the other end of the inlet tube to
the supercharger inlet. Tighten all clamps.
07/09
Page 50
www.magnacharger.com
09 Pontiac G8 GXP
193. Connect the other end of the hose installed in step 156 to the barb on the air tube
near the throttle body.
194. Re-install the factory plastic “splash
shield” using the stock four 13mm bolts and existing mounting holes. If you removed it (step
32) replace the 5mph plastic bumper by pressing
it into place
195. Re-install the front end fascia using the
stock hardware (2-bolts, and 2-push pins) on the
top surface.
196. In front of the passenger side wheel well,
plug the lights back into the connector. This was
disconnected in step 27.
07/09
Page 51
Connector
www.magnacharger.com
09 Pontiac G8 GXP
197. Bolt the fascia to the fender with the two
connectors on each side and use the factory
push-pins to attach at all points (4-each side).
If you removed the fender well in step 25, then
reattach at this time reversing the procedure.
198. Use the four 7mm bolts to bolt the fascia
through the “splash shield”.
199. Re-attach the battery lead cables, and replace the battery cover panel access door.
200. Verify that your coolant drain is tightened
and refill the coolant reservoir, topping off as
necessary.
07/09
Page 52
www.magnacharger.com
09 Pontiac G8 GXP
201. Add the distilled water and coolant mixture (50-50) to the intercooler reservoir.
202. Attach the Vacuum Routing Diagram, Intercooler/Belt routing information and Premium
Fuel stickers on the radiator shroud.
203. Now it’s time to reprogram the tuning
for your vehicle’s computer to allow it to function correctly with your new MagnaCharger Supercharger. Follow the instructions in the supplied SuperChips tuner manual. Locate your EO
sticker and follow the instructions for placing the
sticker on the supercharger.
204. Start the vehicle for five seconds and shut
off, once again check for fuel leaks and fan-supercharger belt alignment. Check radiator and
intercooler reservoir levels.
07/09
Page 53
www.magnacharger.com
09 Pontiac G8 GXP
205. Test-drive the vehicle for the first few
miles under normal driving conditions, listen for
any noises, vibrations, engine misfire or anything
that does not seem normal. The supercharger
does have a slight whining noise under boost
conditions, which is normal.
206. Re-check the intercooler reservoir coolant level regularly over the first 1000 miles, top
level off as needed.
207. After the initial test drive, go through the
belt tensioner adjustment process (step # 163)
again. When next you start driving, gradually
work the vehicle to wide open throttle runs, listen
for any engine detonation (pinging). If engine
detonation is present let up on the throttle immediately. Most detonation causes are low octane
gasoline still in the tank.
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, 8am to 5pm (Pacific Time).
07/09
Page 54
www.magnacharger.com
09 Pontiac G8 GXP
Ventura, CA. MagnaCharger, manufacturer of superchargers and supercharger systems for foreign and domestic vehicles, was presented the prestigious award at the annual Specialty Equipment Market Association Show (SEMA in Las Vegas, Nevada.
The award was presented for the Radix Intercooled supercharger system, designed for the Chevrolet, GMC and Cadillac, 4.8L, 5.3L and 6.0L General Motors Trucks and SUV’s including the new
H2 and SSR.
Sponsored by General Motors
Corporation, the SEMA Design
Award for the “Most Innovative Product” was awarded to
Magna Charger and recognized
by the all-star team of judges for
their outstanding and innovative
design achievement. The criteria used by the judges included
innovatioin, technical achievement, quality and workmanship.
Please enjoy your “Magna Charged”
performance responsibly.
07/09
Page 55
www.magnacharger.com