Introduction to the Magnuson TVS2650 Supercharger

The Magnuson TVS2650 supercharger represents one of the most effective bolt-on upgrades for the Dodge Charger, particularly models equipped with the 6.2L or 6.4L Hemi engines. Utilizing twin-vortex technology, this positive-displacement supercharger delivers instant throttle response and substantial increases in horsepower and torque—often exceeding 700 horsepower at the wheels with proper supporting modifications. Designed as a direct replacement for the factory intake manifold, the TVS2650 integrates an efficient air-to-water intercooler system, making it a popular choice for street-driven Chargers that see occasional track use.

Before beginning the installation, understand that this project requires mechanical aptitude, a complete tool set, and access to a reliable tuner. While the kit is engineered for a relatively straightforward installation, every step must be executed with precision to avoid leaks, belt misalignment, or poor performance. This expanded guide covers the entire process from preparation through final tuning, including critical details often omitted in basic instructions.

Tools and Materials Needed

Gathering the correct tools and supplies in advance will save significant time and frustration. In addition to the Magnuson TVS2650 supercharger kit, you will need the following:

  • Socket and ratchet set – metric and standard sizes (8mm, 10mm, 13mm, 15mm, 18mm, 21mm sockets needed for various fasteners)
  • Torque wrench – capable of measuring in foot-pounds (5–150 ft-lb range)
  • Combination wrenches – same size ranges as sockets
  • Screwdrivers – flathead and Phillips head
  • Pry bar or trim removal tools – for disconnecting fuel line clips and wiring harness brackets
  • Gasket maker or high-temp RTV silicone – specifically anaerobic or sensor-safe sealant if required by kit
  • Coolant – IAT-compatible (HOAT or OAT, depending on your Charger model year) – typically need 2 gallons
  • Engine oil and filter – fresh oil recommended before first start
  • Fuel injectors (optional but recommended) – if upgrading power beyond base kit, one step larger injectors may be needed
  • Spark plugs – colder heat range plugs (e.g., NGK 6510) gapped to 0.028″ for forced induction
  • Belt tensioner tool – 3/8″ drive ratchet or specific tool for tensioner
  • Safety goggles and mechanic gloves
  • Jack and jack stands or ramps – for access to under-vehicle components
  • Vacuum/pressure tester (optional) – for verifying intake system after installation

Preparation and Safety

Begin by parking your Charger on a level surface inside a clean, well-lit workspace. Engage the parking brake and place wheel chocks behind the rear tires. Disconnect the negative battery terminal and isolate it from the battery post to prevent accidental contact. Wait at least 10 minutes to allow the engine control modules to fully power down.

If the engine has been running recently, allow it to cool completely. The TVS2650 installation requires removing the entire intake manifold, which sits directly above hot engine components. Work on a stone-cold engine to reduce burn risk and prevent coolant sprays from a pressurized system.

Drain the engine coolant by opening the radiator drain petcock or disconnecting the lower radiator hose. Recover the coolant in a clean container for reuse if it is in good condition. Removing the intake manifold will cause coolant loss from the crossover tubes and heater hoses. Draining avoids a messy spill inside the engine valley.

Removing Stock Components

Intake System and Throttle Body

First, unclip and remove the factory air intake assembly: the air filter housing, intake tube, and mass air flow sensor (MAF). Carefully disconnect the MAF sensor electrical connector and set the assembly aside. Next, loosen the throttle body clamps and disconnect the throttle body from the intake manifold. Unplug the throttle position and idle air control connectors (if applicable). Remove the throttle body and keep its gasket if reuse is specified; otherwise use the new gasket provided in the Magnuson kit.

Fuel Injectors and Fuel Rails

Before removing the intake manifold, the fuel rails must be partially disassembled. Relieve fuel system pressure by pulling the fuel pump fuse and running the engine until it stalls. Then carefully disconnect the fuel line quick-disconnect fittings at the engine fuel rail using the correct tool (often a nylon clip release tool). Swab any spilled fuel with a shop towel. Remove the fuel rail bolts and lift the rails (injectors attached) out of the intake manifold ports. Protect the injector tips and electrical connectors with plastic caps or tape.

Intake Manifold Removal

Disconnect all vacuum lines, PCV hoses, and the brake booster line that connect to the factory intake manifold. Label each line with tape for later reattachment. Unbolt the throttle body (if not already removed) and remove the intake manifold support bracket. Then remove the intake manifold bolts in a reverse torque sequence as specified for the 6.4L Hemi (typically outer bolts first, then inner). Lift the intake manifold straight up to avoid damaging the gaskets. Be prepared for coolant to drain from the manifold crossover passages. Remove the old intake manifold gaskets and clean the mating surface of the engine block with a plastic scraper—avoid scratching the aluminum.

Installing the Magnuson TVS2650 Supercharger

Preparing the Supercharger

Inspect the new supercharger for any shipping damage. Verify the intercooler brick is seated correctly under the supercharger housing. The TVS2650 comes with a separate intercooler pump and heat exchanger that will be installed later. If your kit includes a new intake manifold gasket or RTV instructions, follow those. Some kits require applying a thin layer of high-temp RTV to the supercharger mounting flange; others use a dedicated o-ring seal. Refer to the Magnuson instruction sheet specific to your Charger model year.

Installation Steps

  • Apply sealant – If specified, apply a 2mm bead of anaerobic flange sealant to the supercharger mating surface that contacts the intake manifold. Do not over-apply as excess can block coolant passages.
  • Position the supercharger – With assistance, lower the TVS2650 onto the intake manifold studs or bolt holes. Ensure the alignment pins or dowels line up correctly. The supercharger should sit flat without forcing.
  • Tighten fasteners – Install the supplied bolts and washers. Torque in a criss-cross pattern starting from the center outward to the manufacturer’s specification (typically 18 ft-lb for M8 bolts, final angle torque specified). Use your torque wrench to avoid over-tightening.
  • Reinstall throttle body – Use the new gasket from the kit. Tighten the throttle body bolts to 10 ft-lb. Reconnect the electrical connectors to the throttle body and MAF sensor.
  • Install intercooler components – Mount the intercooler heat exchanger in the front bumper location (drilling may be required on some Chargers). Run the coolant lines from the supercharger intercooler brick to the heat exchanger and pump. Use supplied clamps. Fill the intercooler system with a mix of distilled water and coolant (or pure distilled water if racing, but use a corrosion inhibitor). Purge air by cycling the auxiliary pump.
  • Fuel system – If upgrading injectors, install them along with the factory (or aftermarket) fuel rails. Reconnect fuel lines and ensure o-ring fittings are seated. Do not pressurize the system until the intake is fully assembled.
  • Reattach accessories – Connect all vacuum lines, PCV, and brake booster. Reinstall coil packs and spark plugs if removed. Install the supercharger belt. The TVS2650 typically uses a dedicated belt routing; align the belt over the supercharger pulley (larger than stock) and the crankshaft and any auxiliary pulleys. Use a belt tensioner tool to release tension and slip the belt over all pulleys. Verify belt alignment with a straightedge—misalignment can cause premature wear.

Completing the Installation

Cooling and Fluids

Fill the engine cooling system with the recommended coolant. Using a vacuum fill tool helps eliminate air pockets. Start the engine and bring it to operating temperature, then check coolant level and add as needed. Check engine oil level and top up if necessary. If you replaced the oil, prime the lubrication system by cranking the engine with the fuel pump relay removed (about 10 seconds) to build oil pressure before actual start.

Reassemble Front End

Reinstall the factory air intake or an aftermarket cold air intake designed for the TVS2650. Many kits include a silicone coupler and adapter to connect to the supercharger inlet. Ensure all clamps are tight. Reconnect the battery negative terminal.

Final Checks and Testing

  • Leak test – Using a smoke machine or propane method, check for vacuum leaks around the supercharger gaskets, injector o-rings, and throttle body. Also check for coolant leaks at the intercooler connections and heater hoses.
  • Belt tension and alignment – With the engine off, press on the belt at the longest span; it should deflect no more than 1/2″. Look for pulley alignment; if the belt tracks to an edge, readjust or shim the supercharger.
  • Electrical connections – Verify all sensors and actuators are plugged in: throttle position, MAF, coolant temp, knock sensors, intercooler pump. Secure wiring away from moving parts.
  • Torque check – Re-torque the supercharger mounting bolts after one heat cycle to ensure they remain at spec.

Starting Your Charger for the First Time

With everything verified, start the engine. Let it idle and listen for any abnormal noises from the supercharger (a whine is normal, but grinding or knocking indicates serious issue). Watch the oil pressure gauge rise quickly; if it remains low, shut down immediately. Check for exhaust leaks at the manifold. Monitor coolant temperature and intercooler pump operation—you should hear the pump run after a few seconds. If the engine runs rough, it may be due to unmetered air leaks or incorrect spark plug gap. Recheck all connections.

Allow the engine to reach full operating temperature. Once stable, turn it off and inspect the supercharger for any fluid seepage. Check the engine oil for fuel contamination (if test starts without proper tuning, raw fuel enters oil) and change oil if necessary.

Tuning and Calibration

Installing a Magnuson TVS2650 without proper engine management calibration will result in poor drivability, potential engine damage, and no performance gain. The charger alters the volumetric efficiency and fuel requirements. Do not drive the car in boost without a custom tune. You have two primary tuning options:

  • Hand-held tuner with canned tune – Many Magnuson kits include a DiabloSport or HP Tuners device with a base map. This is suitable for initial startup and low-load driving, but not for full-throttle pulls or sustained boost.
  • Professional dyno tune – Highly recommended. A skilled tuner can adjust fuel tables, ignition timing, cam phasing, and torque management to match the exact engine condition and supporting mods. Expect 1–3 hours of tuning on a dynamometer.

Consider consulting well-known Dodge tuning specialists such as HP Tuners or DiabloSport for supported platforms. Also reference forums like DodgeCharger.com and the Magnuson official website for community tips and recommended tuners specific to your region.

Breaking In and Post-Installation Care

After tuning, drive the car conservatively for the first 500 miles. Avoid sustained high RPM or full-throttle pulls until the supercharger and intercooler system have stabilized. Check all fluid levels again after the first week. Re-torque the supercharger bolts after the first thermal cycle (engine fully cold then hot). Inspect the belt for glazing or fraying—some break-in wear is normal.

During the first oil change after installation (recommended at 500 miles or 30 hours of operation), send an oil sample to Blackstone Laboratories for analysis. This will detect any excessive bearing wear or fuel dilution, confirming the tune is safe.

Conclusion

Installing a Magnuson TVS2650 supercharger on your Charger is a challenging but highly rewarding project. When done correctly—with attention to gasket sealing, belt alignment, and professional tuning—the result is a transformed vehicle with breathtaking acceleration and street manners that remain civil for daily driving. The key is patience and precision during each step, from the initial disassembly all the way to the final calibration. By following this detailed guide and seeking expert tuning support, your Charger will deliver the power and reliability that the TVS2650 is famous for.