Introduction

Adding a Magnuson TVS1900 supercharger to your Toyota Tundra is one of the most effective ways to unlock serious horsepower and torque. This positive-displacement supercharger delivers instant boost down low and pulls hard through the entire rev range, transforming your daily driver or tow rig into a genuine performance machine. While the installation is a substantial project, it’s within reach for a skilled DIY mechanic with the right tools and patience. This guide walks you through every critical phase: from gathering supplies to final tuning, so you can hit the road confidently with your supercharged Tundra.

What’s in the Magnuson TVS1900 Kit?

Before you begin, it helps to know exactly what comes in the box. Magnuson supplies everything needed to install the supercharger on a stock Tundra engine (typically the 5.7L 3UR-FE or 4.6L 1UR-FE). The kit includes:

  • TVS1900 supercharger unit with integrated bypass valve
  • Cast aluminum intake manifold with supercharger mount
  • High-flow air intake system with washable air filter
  • Fuel injectors (upgraded, sized for the boost level)
  • Intercooler (air-to-water or air-to-air depending on kit version)
  • Heat exchanger and pump for intercooling
  • Supercharger drive belt and tensioner
  • Throttle body adapter and gaskets
  • Hoses, clamps, and hardware
  • Installation instructions and tuning guidelines

Some variations of the kit may include a handheld tuner or a calibration device (like an SCT or HP Tuners device). Always verify the contents against the kit’s packing list before starting the job. For the most up-to-date kit details, visit the official Magnuson website.

Tools and Materials Required

Having the right tools on hand saves frustration and prevents damage. Assemble these items before you touch a bolt:

  • Socket set (metric, 8–19 mm) with extensions and ratchets
  • Torque wrench (capacity 10–150 lb-ft, preferably two: inch-pounds for small bolts, foot-pounds for large)
  • Flathead and Phillips screwdrivers
  • Combination wrenches (metric, 8–19 mm)
  • Pliers (standard, needle‑nose, and snap‑ring)
  • Hex (Allen) keys – metric set
  • Gasket scraper (plastic to avoid scratching surfaces)
  • Coolant catch pan and funnel
  • Engine oil (5W‑30 or 0W‑20 as recommended for your Tundra) – about 1 quart for priming
  • Coolant (Long‑life Toyota red or pink coolant pre‑diluted 50/50)
  • Shop towels, safety glasses, mechanic’s gloves
  • Jack and jack stands (if raising the front for access)
  • Work light and magnet (to retrieve dropped bolts)

Optional but helpful: a coolant pressure tester (to check for leaks after reassembly) and a multimeter for electrical connections.

Preparation and Safety

Preparing your Tundra correctly prevents accidents and ensures a smooth installation.

Vehicle Setup

  1. Park on level ground and engage the parking brake. Chock the rear wheels.
  2. Disconnect the negative battery terminal (use a 10 mm socket). Wrap the cable end in a rag to prevent accidental contact.
  3. Allow the engine to cool completely – the intake manifold, coolant, and exhaust headers get extremely hot. Wait at least two hours after a drive.
  4. Remove any engine covers or plastic trim that may block access. On some Tundra models the strut tower brace must come off.
  5. Relieve fuel system pressure (if swapping fuel rails or injectors) by pulling the fuel pump relay and running the engine until it stalls. Then reconnect the relay. This step is important if your kit includes upgraded injectors.

Work Area Safety

  • Ventilate the garage – gasoline vapors and coolant are hazardous.
  • Keep a fire extinguisher nearby (class A-B-C for fuel and electrical).
  • Use jack stands if you need to raise the front – never rely on a jack alone.
  • Wear eye protection when using compressed air or cleaning gasket surfaces.

Removing Stock Components

Now you’ll strip away the parts that will be replaced by the supercharger system. Work slowly and label every connector and hose.

Air Intake and Throttle Body

  1. Loosen the clamps securing the factory air intake tube. Disconnect the mass airflow (MAF) sensor electrical connector, then remove the entire intake assembly with the airbox.
  2. Unbolt the factory throttle body from the intake manifold (four bolts, typically 12 mm). Set it aside – you may reuse it with the Magnuson kit adapter, or the kit may include a larger throttle body. Keep the mounting gasket if it’s reusable.

Coolant Drain

  1. Place a catch pan under the radiator drain petcock (driver’s side bottom). Open the petcock and remove the radiator cap to speed the flow. Drain at least two gallons – enough to lower the level below the intake manifold coolant passages.
  2. You may also disconnect the lower radiator hose for faster draining, but be prepared for more coolant loss.

Intake Manifold

  1. Label and disconnect all vacuum hoses, electrical connectors, and fuel lines attached to the stock intake manifold. The Tundra’s 3UR-FE engine has a complex runner system – take plenty of photos for reference.
  2. Remove the fuel rail and injectors (if required by the kit). Unbolt the fuel rail (two 12‑mm bolts on each side), then carefully pull the injectors straight out. Cover the intake ports with clean rags to prevent debris entry.
  3. Unbolt the intake manifold – it has about eight to ten bolts (10‑mm or 12‑mm). Lift the manifold off and remove the gasket. Clean the sealing surfaces on the cylinder heads with a plastic scraper and brake cleaner. Do not scratch the aluminum.

Accessory Removal (if needed)

Depending on the kit, you may need to temporarily remove the alternator, power steering pump, or air conditioning compressor to access mounting points. Consult the Magnuson instructions for your specific kit. Typically you can pivot these components aside without disconnecting refrigerant lines, but secure them with a zip tie to avoid stressing hoses.

Installing the Magnuson TVS1900 Supercharger

With the engine bay prepped and stock parts removed, you’re ready to mount the supercharger. Follow these steps in order.

Mounting Brackets and Intercooler (if applicable)

  • If your kit includes an air‑to‑water intercooler, install the intercooler bricks and heat exchanger first. The intercooler typically bolts between the supercharger outlet and the engine intake ports. Torque the brackets to the spec in the instructions (often 18–25 lb-ft).
  • Mount the heat exchanger (the radiator for the intercooler) behind the front grille or in front of the A/C condenser. Route the hoses (supply and return) and secure them with zip ties away from moving parts.

Supercharger Unit

  1. Position the new gasket (supplied with the kit) over the mounting flange on the engine block. The gasket is usually specific to the Magnuson – do not use sealant unless instructed.
  2. With the help of a friend (the unit is heavy – about 40‑50 pounds), lower the supercharger onto the mounting points. Align the rear dowel pins and the coolant crossover passage. The unit should sit flat without force.
  3. Install the supplied bolts – typically six to eight bolts in a specific sequence. Torque in a cross‑pattern to 35–45 lb‑ft (check your kit manual). Over‑torquing can warp the housing.
  4. Reattach the throttle body to the supercharger inlet using the new gasket and the supplied bolts. Torque to 8–10 lb‑ft (over‑tightening can bend the throttle body flange).

Belt and Tensioner

  • Install the new supercharger drive belt according to the routing diagram. The Tundra’s engine has a serpentine belt that now wraps around the supercharger pulley as well. Use a long ratchet or a dedicated belt tensioner tool to pivot the spring tensioner and slip the belt over the last pulley.
  • Verify belt alignment – the belt should ride centrally on all pulleys. Rotate the engine by hand using the crankshaft bolt (24‑mm socket) to check that the belt doesn’t walk off.

Fuel System and Injectors

If your kit includes upgraded injectors, install them now.

  1. Lubricate the injector O‑rings with a small amount of engine oil or Vaseline to prevent tearing during insertion.
  2. Seat each injector into the fuel rail, then press the rail into the intake manifold (or supercharger housing, depending on design). Secure with the factory bolts – torque to 8–10 lb‑ft.
  3. Connect the fuel lines (you may need to use quick‑disconnect tools for the Tundra’s plastic lines). Listen for an audible click.

Connecting Accessories and Hoses

With the supercharger bolted in, you’ll reconnect everything that was removed – plus the new hoses and wires from the Magnuson kit.

Vacuum System

  • Use the supplied vacuum line diagram to connect all ports: bypass valve, boost gauge (if used), brake booster, and canister purge. The Magnuson kit typically includes a dedicated vacuum manifold. Use small zip ties on each connection to prevent blow‑offs.
  • Plug any unused vacuum ports with caps (included).

Coolant and Hoses

  • Refill the radiator with the specified coolant mixture (Toyota Long Life or equivalent mixed 50/50 with distilled water). Bleed air from the cooling system by running the engine with the radiator cap off until the thermostat opens and the coolant level stabilizes.
  • Connect the intercooler pump electrical leads (usually to a supplied relay harness that taps into a switched 12V source). Prime the intercooler circuit by filling it before the engine runs.

Electrical and Sensors

  • Reconnect the MAF sensor, throttle position sensor, and any engine coolant temperature sensors you disconnected. Route wiring away from the supercharger belt.
  • If your kit includes a boost‑a‑pump or fuel pump voltage controller, follow the wiring diagram carefully. These devices often require a direct battery connection and a ground.

Intake Duct and Filter

  • Attach the high‑flow intake tube from the supercharger inlet to the new air filter. Position the filter where it can draw cool air (usually behind the grille or inside the fender). Tighten all clamps – a loose clamp can cause unmetered air and a lean condition.

Final Checks Before Starting

Double‑check every connection before you turn the key. This is the most critical step to avoid damage.

Mechanical Inspection

  • Rotate the crankshaft pulley by hand (use a 24‑mm socket and breaker bar) at least one full revolution. You should feel smooth resistance – no binding or scraping. If it hits anything, stop and investigate.
  • Inspect belt tension and alignment. A misaligned belt can shred or throw off the supercharger pulley.
  • Check all bolts – especially the supercharger mounting bolts and fuel rail bolts – for proper torque.
  • Remove any rags or tools left in the engine bay.

Fluids

  • Top off engine oil (the kit requires a fresh oil change – use the oil recommended in the Magnuson instructions).
  • Fill coolant to the cold mark on the reservoir. Add more to the intercooler system (if separate).
  • Check power steering and brake fluid levels – you may have disturbed these during disassembly.

Electrical

  • Reconnect the negative battery terminal. Torque the clamp to 10‑12 lb‑ft.
  • Turn the ignition to the “on” position (without starting) and listen for fuel pump prime (2‑3 seconds). Then turn it off and on again to ensure the fuel system has pressure.
  • If your kit uses a separate hand‑held tuner, connect it to the OBD‑II port and flash the Magnuson calibration to the ECU. Follow the tuner’s instructions precisely – do not skip this step or use the factory tune with the supercharger.

Leak Test

Use a smoke machine or a pressure tester on the intake system to check for vacuum leaks. If you don’t have a smoke machine, listen for hissing after start‑up. Alternatively, spray a small amount of brake cleaner around gaskets while the engine idles – a rise in rpm indicates a leak.

Start‑Up and Break‑In Procedure

With everything verified, it’s time to start the engine.

  1. Start the engine and let it idle at around 1000‑1200 rpm (the cold calibration may raise idle). Immediately check for warning lights, unusual noises, and fluid leaks.
  2. Allow the engine to reach normal operating temperature (about 10‑15 minutes of idling). Watch the coolant temperature gauge – it should stabilize below the mid‑point.
  3. After the engine is warm, turn it off and inspect the oil for any signs of coolant mixing (milky appearance). Also check the oil level – the supercharger’s internal oil is self‑contained and should not mix with engine oil, but verify the supercharger oil level via the provided dipstick or sight glass.
  4. Perform a series of “no‑load” revs: bring the engine to 2000 rpm, then 3000 rpm, and hold each for a few seconds while listening for knock or pinging. The calibration should keep the air‑fuel ratio safe (around 11.5‑12.0:1 under boost).
  5. If everything sounds clean, take the Tundra on a gentle first drive. Avoid full throttle for at least 50 miles to let the supercharger gears bed in and the ECU learn trims. Then gradually increase boost with short pulls at 30‑50% throttle.

Break‑In and First Maintenance

Follow these guidelines for the first 500 miles after your installation:

  • Change engine oil and filter at 500 miles to flush any debris from the install.
  • Re‑torque the supercharger mounting bolts (some kits recommend checking after heat cycles).
  • Inspect the belt tension after the first 100 miles – a new belt may stretch slightly.
  • Monitor coolant and intercooler fluid levels weekly for the first month.

Performance Gains and Tuning Notes

With the Magnuson TVS1900 properly installed and calibrated, you can expect significant power increases. On a stock 5.7L Tundra, typical gains are +120 to +150 horsepower and +130 to +160 lb‑ft of torque at the wheels. The supercharger’s twin‑vortex design provides boost from just off idle, making the truck feel dramatically stronger everywhere – from merging onto highways to towing trailers.

Calibration is key. The kit’s included tune is safe for 91‑octane fuel and stock exhaust. If you add headers, a larger throttle body, or run E85 fuel, you’ll need a custom tune from a professional. For more technical details, check the Tundra supercharger forum for owner experiences and tuning advice. Also, consider reading Magnuson’s official installation blog for model‑specific tips.

Conclusion

Installing a Magnuson TVS1900 supercharger on your Tundra is a rewarding project that unlocks the engine’s true potential. By carefully following these steps – from preparation and removal to mounting, connecting, and testing – you ensure a reliable installation that will provide years of boosted performance. Take your time on every step, torque everything to spec, and never skip the calibration update. Your Tundra will respond with a surge of power that makes every drive more exhilarating. For further technical support, Magnuson’s customer service team and the online Tundra community are excellent resources. Enjoy the boost!