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a2fire2i
08-17-2006, 09:19 PM
How to Install a K&N Aircharger Cold Air Intake Kit (part number 63-1114) on a Dodge Magnum RT. This install is the same for other LX platform 5.7 or 6.1 HEMI engines.

Time: 45 minutes

Level: Beginner

Please reference the PARTS LIST
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/KN.jpg (http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/KN.jpg)

Tools Needed:
Flat Blade Screwdriver
Ratchet
10 MM Socket
13 mm Socket
10 mm Wrench
13 mm Wrench
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1380.jpg

1) Disconnect the negative battery cable and remove the engine cover by lifting up.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1357.jpg

2) Remove the air temperature sensor electrical connection. This can be done by unlocking and depressing the red tab connected to the air intake.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1358.jpg

3) Loosen the hose clamp that connects the intake to the throttle body and remove.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1359.jpg

4) Disconnect the crank case vent hose from the valve cover port.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1360.jpg

5) Remove the air box mount bolt.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1361.jpg

6) Remove the air intake box and tube from the engine compartment.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1362.jpg

7) Install the twist bracket (part V) on the core support with parts W, K, X, and L. You will use the two fender washers (part X) to sandwich the core support.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1367.jpg

8) Install the L bracket (part U)) onto the heat shield (part S) using parts T, K, and L.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1364.jpg

9) Install the two pieces of edge trim (parts Q and R) onto the heat shield, making sure to leave a gap at the bracket mounting locations.

10) Install the heat shield into the engine compartment with the bracket installed in step 7 with parts T, K and L. Also bolt the L bracket to the air box mounting location using the existing factory bolt removed in step 5.

11) Assemble the saddle tube mounting bracket (part H).

12) Install the saddle tube mounting bracket to the engine with parts M, O and P.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1370.jpg

13) Install the silicone hose (part B) onto the throttle body with a hose clamp.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1371.jpg

14) Install the grommet (part C) into the K&N intake tube.

15) Remove the air temperate sensor from the factory intake tube, and place in the grommet that was installed in step 14.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1372.jpg

16) Install the K&N intake tube (part E) to the throttle body with a hose clamp.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1373.jpg

18) Secure tube to the saddle bracket installed in step 12 with a hose clamp.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1374.jpg
a2fire2i
08-17-2006, 09:21 PM
19) Connect the K&N crankcase vent tube (part D) from the K&N tube to the crank case valve cover port.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1375.jpg

20) Install the filter adapter (part Z) into the filter charger (part AA) with hose clamps.

21) Install the silicone hose (part B) onto the filter charger with a hose clamp.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1376.jpg

22) Install the filter charger onto the K&N intake tube with a hose clamp.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1377.jpg

23) Reconnect the air temperature sensor electrical connection.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1378.jpg

24) Reinstall the engine cover.
http://i31.photobucket.com/albums/c379/a2fire2i/Magnum/KNCAIINSTALL/DSCN1379.jpg

25) Reconnect the battery cable.


The above steps came from the K&N provided installation instructions. This mod was quite an easy install. I did notice a slight whistle/hissing sound after the install coming from the filter area. This noise is normal, but check your connections just to make sure everything is snug.
Black Hemi
10-01-2006, 02:06 PM
I think the whistle is from your TBS?
pir8magnum
10-10-2006, 02:28 PM
Did you notice any benefits after the install? More responsive? Better mileage? Just curious because this is probably the first upgrade I will be performing on my Magnum.

Thanks!
stanekjp
01-30-2007, 09:02 PM
I just put in a mopar cai, and I have a whistle too... Is that really normal? To me it sounds like there might be air entering somewhere it shouldn't. Can't pinpoint it though. Sometimes it occurs softly at 2000rpms when the engine is under load like going up a hill, and other times when at full rev it sounds REAL LOUD, like a backyard style firecracker taking off kind of whistle. :pepper:

I also hear a knock/click from the intake area that gets faster underthrottle, almost like a rhythmic engine knock/ping or something flapping open and closed. Perhaps that was there before, and the new intake made it more audible.

Any thoughts?
dstyl3
01-31-2007, 12:32 PM
great write up!
06SilverSteel
01-31-2007, 12:50 PM
The whistle is normal for most CAI's.....they are more open than the stock unit filter boxes so you hear them a little more.
LX HEMI
06-08-2007, 11:38 AM
I just put in a mopar cai, and I have a whistle too... Is that really normal? To me it sounds like there might be air entering somewhere it shouldn't. Can't pinpoint it though. Sometimes it occurs softly at 2000rpms when the engine is under load like going up a hill, and other times when at full rev it sounds REAL LOUD, like a backyard style firecracker taking off kind of whistle. :pepper:

I also hear a knock/click from the intake area that gets faster underthrottle, almost like a rhythmic engine knock/ping or something flapping open and closed. Perhaps that was there before, and the new intake made it more audible.

Any thoughts?
Mine does the same thing. Being new to the club and just buying my Magnum RT about 2 months ago, it already had a K&N CAI installed, along with Magnaflow's. Makes the hissing sound when I'm on the gas and it's really loud when I stomp on it but quiets down when the rpm's get really high. Kind of intemidating to others when they hear it rev. People think there's a super charger or a turbo under there. I like it...:thumbs_u:

Even the slight knocking/clicking/flap noise I hear as well.
PUNISHER
06-09-2007, 09:23 AM
Now Add you a Fuel Saving AirTornado and Woosh you will be ready for the INDY 500!
trav_d
08-30-2009, 02:44 AM
Nice write up. Only step you forgot was to detail your engine compartment when you got you old air intake off.:rock:
draftingmonkey
11-08-2009, 12:30 AM
I installed a Volant CAI and part of the setup was a new tube from the front to the air box. The stock tube/box is a pretty hefty item as you can see. For you K&N guys it might be an idea to remove the extra weight as it is so aerodynamic.

http://i85.photobucket.com/albums/k72/draftingmonkey/maggie/Air_Tube.jpg