Project Lead Sled, Part 2: 2009 Dodge Ram - Magnacharger Photo Gallery
Project Lead Sled Receives a Dose of Tire-Churning Power with Help from Magnacharger
Harley Camilleri –
Aug 1, 2012
Photo 1/29 | 2009 Dodge Ram dyno | Project Lead Sled, Part 2: 2009 Dodge Ram - Magnacharger
Photo 2/29 | 2009 Dodge Ram dyno | Project Lead Sled, Part 2: 2009 Dodge Ram - Magnacharger
Photo 3/29 | 2009 Dodge Ram magnacharger Tvs2300 | 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.
Photo 4/29 | 2009 Dodge Ram diablosport Tune | 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.
Photo 5/29 | 2009 Dodge Ram cover Removed | 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.
Photo 6/29 | 2009 Dodge Ram alternator Removed | 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.
Photo 7/29 | 2009 Dodge Ram intake Manifold Removed | 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.
Photo 8/29 | 2009 Dodge Ram engine Valley Vacuumed | 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.
Photo 9/29 | 2009 Dodge Ram cleaned And Covered Intake Ports | 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.
Photo 10/29 | 2009 Dodge Ram intercooler Reservoir And Circulation Pump Mounted | 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.
Photo 11/29 | 2009 Dodge Ram supercharger Intercooler | 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.
Photo 12/29 | 2009 Dodge Ram supercharger Intercooler Installed | 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.
Photo 13/29 | 2009 Dodge Ram intercooler Hoses Connected | 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.
Photo 14/29 | 2009 Dodge Ram intercooler Pump Power2 05 CHRG 012 | 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.
Photo 15/29 | 2009 Dodge Ram factory Throttle Body | 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.
Photo 16/29 | 2009 Dodge Ram intake Gaskets | 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.
Photo 17/29 | 2009 Dodge Ram inlet And Outlet Ports | 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.
Photo 18/29 | 2009 Dodge Ram magnacharger Installed | 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.
Photo 19/29 | 2009 Dodge Ram intake Manifold Bolts | 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.
Photo 20/29 | 2009 Dodge Ram sensors Reconnected | 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.
Photo 21/29 | 2009 Dodge Ram air And Oil Separator | 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.
Photo 22/29 | 2009 Dodge Ram vacuum Line | 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.
Photo 23/29 | 2009 Dodge Ram intercooler Pump Hose | 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.
Photo 24/29 | 2009 Dodge Ram alternator Bolt | 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.
Photo 25/29 | 2009 Dodge Ram magnacharger Pulley | 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.
Photo 26/29 | 2009 Dodge Ram k And N Air Filter | 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.
Photo 27/29 | 2009 Dodge Ram magnacharger Installation Complete | 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.
Photo 28/29 | 2009 Dodge Ram base Dyno Results | 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.
Photo 29/29 | 2009 Dodge Ram magnacharger Dyno Results | 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.