Upgrading your Dodge Challenger with a Magnuson 2.4L supercharger is one of the most effective ways to unlock serious horsepower and torque. This positive-displacement blower delivers instant boost, transforming the driving experience without compromising daily drivability. Whether you're looking to dominate at the track or simply enjoy thrilling street performance, a well-installed Magnuson kit can add 150–200+ horsepower to your 5.7L, 6.1L, or 6.4L Hemi. This guide covers every phase of installation, from prep work and removal to final startup and tuning. Follow each step carefully to ensure a reliable, high-performance build.

Tools and Materials Needed

Before you begin, gather the following tools and supplies. Having everything on hand will save time and prevent unnecessary interruptions.

  • Magnuson 2.4L supercharger kit – includes blower, intake manifold, intercooler, fuel injectors, gaskets, and hardware
  • Socket set – ¼″ and ⅜″ drive, metric and SAE sizes (10mm, 13mm, 15mm, 18mm common)
  • Torque wrench – ft-lb and in-lb ranges for precise fastener tightening
  • Screwdrivers – flathead and Phillips
  • Combination wrenches – set from 8mm to 19mm
  • Gasket scraper – plastic or brass to avoid damaging surfaces
  • Shop towels and brake cleaner – for cleaning mating surfaces
  • Engine oil – 5W-20 or 0W-40 per Magnuson recommendation
  • Coolant – premixed 50/50 OAT coolant (Dodge spec)
  • Vacuum/pressure gauge – for checking boost leaks
  • Scan tool or laptop – optional but helpful for diagnostics

Preparation Steps

Proper preparation is critical for a smooth installation. Follow these steps to ready your Challenger and workspace.

  • Park the vehicle on a level, well-ventilated surface. Use wheel chocks to prevent movement.
  • Disconnect the negative battery terminal using a 10mm wrench. Isolate the cable to prevent accidental contact.
  • Allow the engine to cool completely (at least 2–3 hours after running). The intake manifold and exhaust components retain heat.
  • Remove the engine cover by unscrewing the retaining bolts or quarter-turn fasteners. Set aside.
  • Drain the coolant system via the radiator petcock and remove the coolant reservoir cap to relieve pressure. Capture coolant in a container.
  • Remove the air intake tube and filter box for access. Label all electrical connectors and vacuum lines before disconnecting.

Taking the time to organize your workspace and label components will reduce confusion during reassembly.

Removing the Stock Components

Now it's time to remove the factory parts that will be replaced. Work systematically and use penetrating oil on stubborn bolts.

Step 1: Intake Manifold and Throttle Body

  • Disconnect the throttle body electrical connector and unclip the throttle cable (if equipped).
  • Unbolt the throttle body from the intake manifold using a T25 Torx bit or 10mm socket. Set aside.
  • Remove the intake manifold bolts in a crisscross pattern to avoid warping. Lift the manifold off carefully, prying gently with a plastic tool if needed.
  • Discard the old gaskets and clean the cylinder head mating surfaces with brake cleaner and a scraper.

Step 2: Factory Supercharger (if applicable) or Components in the Way

For models with a factory supercharger (e.g., Hellcat), you will need to remove the entire assembly. For non-supercharged models, skip this step. Refer to the Magnuson kit manual for vehicle-specific instructions.

Step 3: Fuel Injectors and Fuel Rails

  • Relieve fuel system pressure by pulling the fuel pump fuse and cranking the engine briefly.
  • Disconnect the fuel supply line at the rail using a quick-disconnect tool.
  • Unbolt the fuel rail and remove the injectors. Keep them organized if reusing; otherwise, discard.
  • Install the included larger injectors that come with the Magnuson kit. Apply a light coat of engine oil to the O-rings before seating.

Step 4: Engine Harness Routing

Re-route any harness wires that may interfere with the supercharger. Typically, the MAP sensor and knock sensor connectors need repositioning. Use zip ties to secure them away from moving parts.

Installing the Magnuson Supercharger

With the engine bay cleared, you can install the blower. Work carefully to avoid damaging the intercooler bricks or gaskets.

Step 1: Install the Intercooler (if part of the kit)

  • Place the air-to-water intercooler assembly onto the intake valley of the engine. Ensure the O-rings or gaskets are properly seated.
  • Route the coolant lines and zip tie them temporarily. Do not fill coolant yet.

Step 2: Mount the Supercharger

  • Apply a thin layer of supplied sealant to the gaskets for a leak-free seal.
  • Lower the supercharger onto the mounting location, aligning with the studs or bolt holes. The unit is heavy (approx. 40–50 lbs); use a helper or engine hoist.
  • Torque the supercharger bolts in the specified sequence (refer to kit instructions). Typical torque is 18–22 ft-lb for the main fasteners, then final pass to 35–40 ft-lb.
  • Install the belt tensioner and drive belt. Rotate the engine by hand with a socket on the crankshaft bolt to verify belt alignment.

Step 3: Reinstall the Throttle Body and Intake

  • Attach the throttle body to the supercharger snout using a new gasket. Torque to 8–10 ft-lb.
  • Secure the air intake system (filter, ducting, MAF sensor). Use the provided silicone couplers and clamps.
  • Connect the PCV valve and brake booster vacuum line to the supercharger port.

Connecting Hoses and Wiring

Proper routing of coolant, vacuum, and electrical connections is vital for performance and safety.

Coolant System

  • Connect the supercharger intercooler coolant hoses to the auxiliary intercooler pump and heat exchanger. Follow the diagram provided.
  • Fill the intercooler system with a 50/50 mix of distilled water and antifreeze. Bleed air using the vent screws or by running the pump.
  • Refill the engine coolant using the radiator cap. Run the engine with the cap off to purge air.

Vacuum and PCV Lines

  • Attach the vacuum lines to the supercharger plenum ports. The Magnuson kit includes a vacuum harness – check that no lines are kinked.
  • Connect the PCV fresh air intake to the filtered side of the intake system. The dirty side (crankcase ventilation) should connect to a dedicated port on the supercharger.

Electrical Connections

  • Plug in the supercharger bypass valve solenoid (if equipped) and any boost pressure sensors.
  • Reconnect the throttle body, MAP sensor, and fuel injector harness.
  • If the kit includes an optional Boost-A-Pump or voltage controller, wire it per instructions. Use solder and heat shrink for reliability.

Final Steps and Testing

Before starting the engine, double-check every bolt, clamp, and connector. Mistakes now can lead to major problems.

Pre-Start Checks

  • Verify all supercharger bolts are torqued. Re-check after engine heat cycles.
  • Ensure the drive belt is tensioned correctly – should not deflect more than ½ inch at midpoint.
  • Reconnect the negative battery terminal.
  • Prime the fuel system by cycling the key to the ON position (without cranking) three times, waiting 5 seconds each time.

Startup Procedure

  • Start the engine and let it idle at around 1,000 RPM for the first 30 seconds. Listen for unusual noises – a slight whine from the supercharger is normal.
  • Check for coolant and fuel leaks. Inspect all hoses and fittings.
  • After 2 minutes of idle, check the radiator fan operation. The engine should reach operating temperature.
  • Do not drive the vehicle without a proper tune. The Magnuson kit requires a custom ECM calibration to adjust fuel, timing, and boost.

Test Drive

  • Once tuned, take the car for a conservative 10–15 minute drive. Avoid full throttle until you have 50 miles on the supercharger.
  • Monitor boost gauge and air/fuel ratio (if available). Boost should reach the kit’s advertised level (typically 8–10 psi).
  • After the drive, re-check fluid levels and bolt torque. Allow the engine to cool and retorque the intake manifold bolts.

Tuning and Calibration

A Magnuson supercharger installation is only as good as the tune. The increased air density demands more fuel and revised ignition timing to prevent detonation.

  • Use a reputable tuner with experience in forced-induction Hemis. Options include remote tuning via HP Tuners, DiabloSport Trinity, or a local dyno-tuner.
  • Expect the tune to include: fuel injector scaling, timing curve adjustment, boost reference fuel pressure, and torque management changes.
  • Consider upgrading the fuel system if you plan to run higher boost in the future. The stock pump may be sufficient for the base kit, but a BAP (Boost-A-Pump) or return-style system adds safety.
  • Always use premium unleaded fuel (93 octane or higher). For track use, consider a methanol injection kit for additional knock resistance.

Maintenance Tips

After installation, follow these guidelines to keep your Magnuson supercharger running strong for years.

  • Change engine oil and filter every 3,000 miles (or more frequently if tracking). Forced induction adds heat and byproducts.
  • Inspect the supercharger drive belt every 5,000 miles for cracks or glazing.
  • Check intercooler coolant level at every oil change. Air in the system reduces intercooling efficiency.
  • Keep the air filter clean – a dirty filter causes excess bypass operation and reduces power.
  • Listen for unusual bearing noise from the supercharger. Magnuson units are typically silent, but if you hear a grind or constant whine, contact support.

Conclusion

Installing a Magnuson 2.4L supercharger on your Dodge Challenger is a rewarding project that dramatically improves performance. By following this expanded guide, you’ll avoid common pitfalls and ensure a reliable, powerful build. Remember that proper tuning is non-negotiable – skip it at your engine’s peril. For additional resources, visit the official Magnuson product page, consult the Magnuson website for technical specs, or join the Challenger Talk forced induction forum for community support. A well-executed installation will reward you with blistering acceleration and the unmistakable sound of a whining Hemi.