Project Lead Sled - Part 2 - 2009 Dodge Ram - Magnacharger

We cannot seem to help ourselves. As much as we would like to fight the urges that are inside of us, we cannot leave well enough alone sometimes. Case in point … Project Lead Sled. Up to this point, it has received multiple exterior makeovers, suspensions, and wheels. You have, no doubt, read about nearly every one of them on these pages. Where we managed to be sensible this whole time was under the hood. The Ram’s 5.7L Hemi made us mostly happy, but with the huge 26-inch wheels and corresponding 33-inch-tall tires, the extra unsprung mass had zapped more ponies than we wanted to admit. Magnacharger assured us they could restore our Hemi’s power potential and in the process, made some real ponies. Enter the steroid known as forced induction.

Having had multiple experiences with trucks that were supercharged and turbocharged, we knew full well the attraction of a Magnacharger system. Kits nowadays are considered basic bolt-ons and can easily add more than 120 hp to the wheels with nothing but basic handtools and a decent amount of mechanical know-how. Armed with the overwhelming need to purchase new rear tires, we threw caution to the wind and headed to Magnacharger’s Ventura, California, home base to have one of the very first Hemi supercharger systems in production for the ’09-and-newer Dodge Rams.

1. Every part needed to install the TVS 2300 blower system on our Ram (PN 01-23-61-457-BL, $6,600) was included in the box. For ease of our story, only the highlights were included here. Pictured are the supercharger/intake manifold combo (complete with fuel rails and injectors), intercooler pump and reservoir, and DiabloSport Predator containing the required ECM tune. One part that should have been included in the image was the air-to-water intercooler, but you will see it shortly.
1. Every part needed to install the TVS 2300 blower system on our Ram (PN 01-23-61-457-BL,
2. It seemed backward to download the Predator program before anything else. In fact, it was most necessary to ensure the DiabloSport handheld downloaded into the ECM correctly and did not have any issues with communication or firmware. Our truck was a problem and it took a call to DiabloSport to remedy the software issue we experienced.
2. It seemed backward to download the Predator program before anything else. In fact, it w
3. Under the hood, our Ram was a bit unconventional, having had many parts moved when Ekstensive Metalworks handled the truck's suspension last month. Nonetheless, about 95 percent of the install went as instructed. After disconnecting the IAT sensor, we pulled the factory air tube, K&N filter, and plastic engine cover from the Hemi.
3. Under the hood, our Ram was a bit unconventional, having had many parts moved when Ekst

4. The control plug and charge cable were removed from the alternator and the serpentine accessory belt removed from the engine. Both of the alternator's mounting bolts were freed with a 15mm socket so the alternator could be popped free from its mounting pad.
4. The control plug and charge cable were removed from the alternator and the serpentine a
5. To gather the intake manifold from the Hemi, it was necessary to first disconnect the knock sensors, undo the EVAP and brake booster vacuum lines, disconnect the MAP sensor and eight injector plugs, and finally unplug the throttle body control harness. Ten bolts held the intake manifold in place and were spun loose with a 10mm socket so the manifold could be snatched from the engine compartment.
5. To gather the intake manifold from the Hemi, it was necessary to first disconnect the k
6. As with most new trucks, the Dodge's intake manifold does not prevent dirt and debris from getting between the intake manifold and engine during normal operation. Before moving on, the entire engine valley was vacuumed to remove as much dirt as possible.
6. As with most new trucks, the Dodge's intake manifold does not prevent dirt and debris f

7. Using a lint-free cloth, the intake ports were wiped clean with solvent to remove any leftover residue. We covered the intake ports with low-adhesive painter's tape for safety. The foam insulator sitting in the valley was also removed and tossed.
7. Using a lint-free cloth, the intake ports were wiped clean with solvent to remove any l
8. Due to our Ram's unique engine bay, it was decided that the intercooler reservoir and circulation pump should be mounted before we went too far, in case we required custom fluid hose routing. All went as planned and the normal directions applied to our application even with all the modifications.
8. Due to our Ram's unique engine bay, it was decided that the intercooler reservoir and c
9. We promised you would get a good look at the extra-large air-to-fluid intercooler for the supercharger. Both inlet and outlet hoses were clamped on and strips of adhesive-backed foam were applied to the top and bottom edges before the unit was dropped into its new home.
9. We promised you would get a good look at the extra-large air-to-fluid intercooler for t

10. The intercooler unit nestles comfortably between the core support and air conditioning condenser. A pair of rubber-lined hooks hangs the intercooler from the condenser and prevents any movement or metal contact.
10. The intercooler unit nestles comfortably between the core support and air conditioning
11. Since no customization was necessary, the hoses included in the kit for the intercooler were connected to the pump and reservoir and clamped in place.
11. Since no customization was necessary, the hoses included in the kit for the intercoole
12. Wiring the pump was quite simple with the power, ground, and ignition trigger circuits all based off factory points located in the fuse box on the driver side of the engine bay.
12. Wiring the pump was quite simple with the power, ground, and ignition trigger circuits

13. The Magnacharger reuses the factory throttle body. We dropped the unit itself from the factory intake manifold along with the original O-ring seal and installed both parts onto the supercharger's snout. The mounting bolts were tightened to 106 in-lb.
13. The Magnacharger reuses the factory throttle body. We dropped the unit itself from the
14. A limited number of preparations were necessary to ready the supercharger itself for introduction onto the 5.7-liter, such as adding intake gaskets, MAP sensor, and the previously removed IAT sensor.
14. A limited number of preparations were necessary to ready the supercharger itself for i
15. Inlet and outlet ports on the rear of the supercharger base lead to the intercooler's core. It would have been quite difficult to get the hoses on with the assembly in the truck due to the close proximity of the firewall and cowl. We placed the hoses over the ports and clamped them in place while still on the workbench.
15. Inlet and outlet ports on the rear of the supercharger base lead to the intercooler's

16. No, your eyes are not deceiving you. That is three adult men installing the supercharger assembly down into the Hemi's valley. The Magnacharger comes fully assembled and weighs quite a bit, so helping hands were a necessity to ensure everything set into place.
16. No, your eyes are not deceiving you. That is three adult men installing the supercharg
17. Coming out of the box as ready to install meant far less work for us. All 10 intake manifold bolts were slipped into place and torqued to 106 in-lb.
17. Coming out of the box as ready to install meant far less work for us. All 10 intake ma
18. Plenty of electrical plugs had to be reconnected and we ran them down one by one, including the MAP and IAT sensors, main injector harness, individual injector plugs, and throttle-body control sockets. Also, the original fuel line was popped onto the Magnacharger rail.
18. Plenty of electrical plugs had to be reconnected and we ran them down one by one, incl

19. One of the nicer amenities built into the system was this air and oil separator for the PCV system. Vacuum gets drawn through the unit and into the supercharger from the driver side valve cover. Details like this are what allow the system to be 50-state compliant.
19. One of the nicer amenities built into the system was this air and oil separator for th
20. Just like the electrical, many feet of vacuum lines ran between the supercharger, engine, and throttle body. It was imperative to hook them up according to the instructions for proper function and smog compliance.
20. Just like the electrical, many feet of vacuum lines ran between the supercharger, engi
21. The final hoses were placed onto the ports of the intercooler pump and reservoir. A 50/50 blend of coolant was filled and bled before pulling final dyno numbers.
21. The final hoses were placed onto the ports of the intercooler pump and reservoir. A 50

22. Reinstalling the alternator required the use of a supplied bolt that first ran through this pulley and bearing. The pulley is there to ensure as much belt is wrapped around the supercharger pulley as possible. That way, when the go-go pedal gets stomped to the floor, the rising amount of boost doesn't cause the belt to slip, robbing you of precious power.
22. Reinstalling the alternator required the use of a supplied bolt that first ran through
23. Look closely at the pulley with the new longer Gates serpentine belt in place. The belt wraps more than 50 percent of the pulley for greater turning power and consistent boost numbers.
23. Look closely at the pulley with the new longer Gates serpentine belt in place. The bel
24. Not having an airbox because of the custom inner fenders, we made due by placing the original air tube on the throttle body with our open-element K&N filter. A zip-tie was slipped around the clamp before it was tightened all the way so we could attempt to secure the filter from flopping around.
24. Not having an airbox because of the custom inner fenders, we made due by placing the o

25. With our completed installation, it was very obvious our engine was no longer original. Even in a wrinkle black finish, our Magnacharger looked the performance part, notwithstanding the non-factory layout of most of our engine compartment. There will be future changes coming for this engine bay to make it all better looking when the hood is opened.
25. With our completed installation, it was very obvious our engine was no longer original
26. Hemi trucks are rated at 390 hp from the factory, but at the wheels it's a different story. That is especially true with our large 26-inch wheels and tires. The dyno tells the tale and our truck only squeaked out 238.2 hp and 266.0 lb-ft of torque.
26. Hemi trucks are rated at 390 hp from the factory, but at the wheels it's a different s
27. Check out what a difference a Magnacharger and a tune did for us! Our power levels jumped to 375.9 hp and 358.3 lb-ft of torque. Doing the math, that equates to +137.7 hp and +92.3 lb-ft of torque. Those numbers represent the shot in the arm Lead Sled needed. Believe it or not, on the drive home, we got 20.4 mpg.
27. Check out what a difference a Magnacharger and a tune did for us! Our power levels jum