SuperchargersOnline.com :: HOW-TO: Install a MagnaCharger RADIX Intercooled Supercharger System

Installation Info
Installers: Randy, Jim and Dan - Cerritos GMC/Hummer Technicians and Simon - MagnaCharger Technician
Location: CERRITOS AUTO SQUARE - Cerritos, CA
Vehicle: 2003 Hummer H2 w/ 6.0L
Supercharger System: MagnaCharger RADIX Intercooled Supercharger System for 2003 Hummer H2 w/ 6.0L (Silver Stardust & Polished)
Selected Boost: 6psi

Ratings (Scale of 1-10, 10 being the best)
Packaging: 7
Installation manual: 9.5
Ease of installation: 9
Appearance of system: 10
Quality of supercharger: 10
Quality of accessories/hardware: 10
Overall value of system: 10
Performance (low-end): 10
Performance (mid-range): 10
Performance (top-end): 10
Overall Rating: 9.5

1.	Look at that beauty! Ready for the installation to begin. (Please click on images to enlarge).
2.	Verify that all kit contents are included and that you have everything needed for the installation.
3.	That's gonna be such a nice fit right on to the manifold. Check out that manifold replacement setup!
4.	BEFORE - The stock engine setup with an Air Force One Cold Air Intake System. (Passenger Side perspective)
5.	Remove the entire intake manifold and cold air kit and cover holes with colored duct tape. Die Grind Alternator Bracket to make room for the new manifold. (Driver Side perspective - in progress)
6.	A closeup of the ground bracket piece and the installed water crossover pipe. (PS)
7.	Preparation of MagnaCharger Intake. Bolt stock Throttle Body to its new home. The black knob in front is the Air Temperature Regulator.
8.	Be careful with these O-rings! Notice the tab in the bottom left. This is to ensure that the O-rings are installed properly. Later on, when you place the new intake unit on the engine block, be sure that the O-rings stay snug in their grooves. This is a crucial step to the installation process and a major reason why at least two people are required for the actual lifting and placement of this new intake unit.
9.	Preparation of Fuel Pressure Regulator Housing. (This step was not in the installation manual at the time of installation). The nozzle on the outside of the unit (larger diameter - closest to the technician) is for the Fuel Feed Line. The nozzle that is being installed into the joint of the unit (smaller diameter) is for the Fuel Return Line.
10.	Step #50 in installation manual - transplanting the Evap. solenoid (blurred in foreground). You must be sure to grind down the stock bolt that holds the Evap. solenoid in place so that it will fit in the hole on the new intake unit (focused in this shot).
11.	When placing the Fuel Pressure Regulator into its housing, be sure that the O-ring stays in place. Pesky little bugger!
12.	The engine is now ready for the new supercharger system.
13.	That's how the supercharger/intake unit looks once it's been set in its final resting place. (View from on top of the Hummer looking down the windshield at the engine).
14.	Tightening down the final bolts. (PS)
15.	When connecting the fuel lines, be sure to connect the injector wires first! (DS)
16.	Install the Nose Support Bracket before you re-install the alternator. It's easier this way. (PS)
17.	AFTER - Engine's done! (PS)
18.	Begin to drill holes in the front grill bottom lip as preparation for the installation of the Heat Exchanger - the intercooler's intercooler. (DS)
19.	The Heat Exchanger is now installed. (DS)
20.	The in-line Fuel Pump installation is a bit tricky as well. We were able to lift the vehicle and work standing underneath it. This procedure could be done with the vehicle standing stationary on the ground though. Here, we drilled two holes in an underbody beam next to the gas tank (PLEASE BE SURE TO READ INSTALLATION MANUAL VERY CAREFULLY TO ENSURE YOUR PROTECTION AND SAFETY).
21.	The Fuel Pump will sit above the beam once installed properly.
22.	'Nuff said!

Survey
We asked Randy, Jim and Dan the following general questions about the installation procedure.

Question: Please provide us with a general overview of how the installation procedure went.
Answer: The installation was fairly straightforward. The kit was complete and every little detail was thought out. Overall, the installation went well.

Question: How long did the installation take?
Answer: It took us about 5 hours. But we see these engines everyday, so it was almost second nature to us. Plus, there were 3 of us working on it. If a customer was performing it with a friend, it would probably take twice as long.

Question: What was the most difficult part of the installation?
Answer: The toughest part of the installation was setting the intake in place. Also, the H2 hood opens to the front, so it can make maneuvering around the front side of the vehicle a challenge. The supercharger, intercooler and intake piece weighs a good 65-75 pounds, so you definitely need at least two people to lift and properly place it down on the lower portion of the vehicle's intake.

Question: What was the easiest part of the installation?
Answer: Everything else.

Question: Was the installation manual easy to understand?
Answer: The installation manual was great! It came with full color photographs and detailed instructions.

Question: Did anything about the installation process surprise you?
Answers: The wiring. We thought all the wiring would take a lot longer than it actually did. Again, a benefit of the ease of installing this kit, but also of our familiarity with this engine and setup.

Question: Were any strange tools required for the installation?
Answer: None.

Question: Let's say I have installed an exhaust system and air filter on my vehicle myself without much difficulty. I am not a mechanic, but I know my way around the engine. Should I attempt this installation myself, or should I take it to a professional?
Answer: It's always better to have a professional mechanic perform an installation of this type. We have familiarity with engines and understand the type of work that installing one of these kits entails. Also, for things like "torquing specs" our technical training, and practical application of that training, allows us to perform these tasks with precision. We're an additional way to ensure that the installation is performed properly. Also, the computer wiring steps and the FMU installation could be challenging components if you aren't familiar with those aspects of the vehicle.

General comments: The difference that this kit makes is night and day compared with the stock H2! This kit puts you back in your seat and keeps you there. It's extremely smooth and efficient. Plus, it's the easiest kit we've installed and it looks great, too!