Introduction

Installing a Mopar Performance Supercharger on your 6.2 Hellcat is one of the most effective ways to unlock massive horsepower gains while maintaining factory-level reliability. Whether you own a Dodge Charger, Challenger, or Jeep Trackhawk with the legendary Hellcat V8, this supercharger upgrade can push output well beyond 700 horsepower. This comprehensive guide provides a detailed, step-by-step approach to ensure a professional-grade installation from start to finish. With proper preparation, the right tools, and careful attention to detail, you can complete this installation in your own garage and enjoy the thrill of boosted Hellcat performance.

The Mopar Performance Supercharger kit is designed as a direct bolt-on upgrade for the 6.2L Hemi Hellcat engine. It uses the same Eaton TVS 2650 rotor pack found in the factory supercharger but with optimized internals and a larger throttle body opening. This results in improved airflow, reduced heat soak, and higher boost levels without requiring major engine modifications. Before diving into the installation, understand that this project demands mechanical aptitude, patience, and a clean workspace. If you are new to supercharger work, consider reading through the entire guide first and consulting factory service manuals for torque specs and wiring diagrams.

Tools and Materials Needed

Having the correct tools and materials on hand before you start will save time and prevent frustration. Below is a comprehensive list of everything you need for a smooth installation.

Essential Hand Tools

  • Socket set – SAE and metric sockets from 8mm to 21mm, including deep sockets for reach.
  • Torque wrench – Two types: a 3/8-inch drive for low-range fasteners (20-80 ft-lbs) and a 1/2-inch drive for high-range (80-200 ft-lbs).
  • Flathead and Phillips screwdrivers – For removing clamps, wiring connectors, and plastic covers.
  • Ratchet and extensions – A 3/8-inch ratchet with 6-inch and 12-inch extensions for tight spaces.
  • Engine hoist or transmission jack – Optional but highly recommended for safely lifting the supercharger off and on the engine.
  • Pry bar and pick set – For separating stuck hoses and gaskets.
  • Shop towels and brake cleaner – For cleaning surfaces before assembly.

Mopar Performance Supercharger Kit

The specific Mopar Performance Supercharger kit (part number 77072453AC or equivalent) includes the supercharger assembly, gaskets, O-rings, fuel injectors, belt, and fasteners. Always verify the kit contents against the inventory sheet inside the box. Do not reuse old gaskets or fasteners.

Additional Supplies

  • New gaskets and seals – Even if the kit includes them, purchase spares for the intake manifold and throttle body.
  • Coolant – Mopar OAT coolant (orange) mixed 50/50 with distilled water.
  • Supercharger oil – Use Mopar approved supercharger oil (part number 04874459AC) or equivalent synthetic ISO VG 46 oil.
  • Thread locker – Medium-strength blue Loctite for bolts subject to vibration.
  • Antiseize compound – For aluminum-to-aluminum threads to prevent galling.
  • Deweaponized data logger or scan tool – To monitor engine parameters after installation.

Preparation Steps

Proper preparation ensures safety and efficiency. Give yourself at least one full weekend for this project, and do not rush.

Workspace Setup

Choose a clean, well-lit garage with concrete flooring. Lay down cardboard or a drop cloth to catch dripping fluids. Have a fire extinguisher rated for Class B and C nearby. Ensure the vehicle is on a level surface and securely supported with jack stands if you need to work underneath. The hood should be fully open and secured with a prop rod or hydraulic struts.

Safety Precautions

Always wear safety glasses and chemical-resistant gloves when handling coolant, oil, and cleaning solvents. The engine must be completely cool before working on it—allow at least two hours after the last drive. Disconnect the negative battery terminal and isolate the cable to prevent accidental contact. The Hellcat's electrical system can retain charge in capacitors, so wait 10 minutes after disconnection before touching high-voltage components. Never work under a vehicle supported only by a floor jack; use jack stands rated for the vehicle's weight.

Vehicle Preparation

  1. Allow the engine to cool completely. Remove the engine cover by unscrewing the four retaining bolts.
  2. Disconnect the battery negative terminal and wrap it with a rag or electrical tape.
  3. Drain the cooling system by opening the radiator petcock and removing the expansion tank cap. Catch coolant in a clean container for disposal.
  4. Remove the air intake assembly (filter, tube, and mass airflow sensor). Unplug the MAF sensor and set it aside.
  5. Remove the accessory drive belt by releasing tension with the belt tensioner tool. Note the belt routing diagram on the fan shroud.
  6. Take reference photos of all wiring, hoses, and fasteners before disassembly. This will be invaluable during reassembly.

Removing the Stock Supercharger

Removing the factory supercharger requires patience. The Hellcat engine bay is tight, but following a systematic process prevents damage.

Step 1: Disconnect Electrical and Vacuum Lines

Label each connector with masking tape and a marker. Use a pick or flathead screwdriver to release locking tabs. Disconnect the supercharger bypass actuator, throttle position sensor, and any ground straps. Remove the vacuum lines that run to the brake booster and PCV system. Take a photo of the routing for reference.

Step 2: Remove the Throttle Body and Intake Ducting

Unbolt the throttle body from the supercharger snout using a 10mm socket. There are four bolts. Carefully set the throttle body aside without damaging the gasket or wiring. Remove the intake ducting that connects the air filter box to the throttle body. This may require loosening clamps with a flathead screwdriver.

Step 3: Unbolt the Stock Supercharger

The supercharger is attached to the intake manifold with eight bolts on the passenger side and eight on the driver side (total 16 bolts). Use a long 10mm socket and extension. Start by loosening all bolts in a crisscross pattern to evenly relieve stress. Remove the bolts and set them aside. Note that some bolts may be longer than others—keep them organized.

Step 4: Lift the Supercharger Off

The stock supercharger weighs approximately 65 pounds. Use a second set of hands or an engine hoist to lift it straight up. Do not pry against the intake manifold otherwise you risk cracking the composite material. Once the supercharger is free, inspect the intake manifold for any debris or old gasket remnants. Cover the open manifold intake ports with clean shop towels to prevent anything from falling in.

Installing the Mopar Performance Supercharger

With the stock unit removed, you can now install the Mopar Performance Supercharger. This section focuses on precision and cleanliness.

Cleaning the Intake Manifold Surface

Use a razor blade gasket scraper to remove all old gasket material from the intake manifold. Be careful not to gouge the aluminum surface. Wipe the surface with brake cleaner and a lint-free cloth. Repeat until no residue remains. Any leftover debris can cause vacuum leaks or damage the new supercharger seals.

Installing New Gaskets

The Mopar kit includes new intake manifold gaskets. Apply a thin bead of high-temp silicone sealant (RTV) to the corners of the gaskets as recommended by Mopar. Place the gaskets onto the intake manifold dowel pins. Ensure they are seated evenly and not twisted.

Positioning the Mopar Supercharger

With the help of an assistant or engine hoist, lower the new supercharger onto the intake manifold. Align the supercharger snout with the crank pulley. Gently wiggle the unit until it sits flush on the gaskets. Do not force it. If resistance occurs, lift and realign. Once positioned, hand-thread all 16 bolts. Then tighten them in a crisscross pattern using a torque wrench: first pass to 10 ft-lbs, second pass to 18 ft-lbs (or as specified in the kit instructions). Overtightening can crack the manifold.

Reinstalling the Throttle Body and Intake Ducting

Clean the throttle body bore and the mating surface on the supercharger snout. Install a new O-ring gasket provided in the kit. Attach the throttle body with the four bolts, torquing to 8 ft-lbs. Reconnect the intake ducting, ensuring all clamps are snug but not crushed.

Connecting the Supercharger Components

After the supercharger is mechanically installed, you must connect all ancillary systems.

Supercharger Inlet and Outlet Hoses

The Mopar kit includes reinforced silicone hoses for the intercooler circuit. Attach the inlet hose from the air filter box to the supercharger snout. Secure with worm-gear clamps. Connect the outlet hose from the supercharger to the intercooler core. Ensure the hoses are routed away from moving parts like the belt and pulleys. Tighten clamps to 5-6 inch-pounds to avoid slicing the silicone.

Intercooler Lines and Heat Exchanger

For models with a factory intercooler, the Mopar supercharger integrates directly with the existing system. However, the kit may include an upgraded heat exchanger for better cooling. If this is included, remove the factory unit and install the larger exchanger using the included brackets. Connect the coolant lines using quick-connect fittings, pressing until they click. Burp the system by filling with coolant and running the engine with the radiator cap off until no bubbles emerge.

Fuel Injector Installation

The Mopar kit contains higher-flow fuel injectors (typically 850-1000 cc/min, depending on model). Remove the fuel rail from the stock supercharger and swap the injectors. Lubricate the injector O-rings with clean engine oil before inserting them into the fuel rail. Install the new injectors into the intake manifold ports, ensuring they snap into place. Reattach the fuel rail mounting bolts to 8 ft-lbs. Replace the fuel rail crossover line if included.

Electrical Connections

Reconnect all previously removed electrical connectors: bypass actuator, throttle position sensor, MAP sensor, and ground straps. Verify each connection clicks securely. For the MAP sensor on the new supercharger, ensure the wiring harness is routed away from heat sources. If the kit includes a boost reference line for the fuel pressure regulator, connect it now.

Belt Installation

The Mopar kit includes a longer serpentine belt to accommodate the larger supercharger pulley. Route the belt according to the diagram provided. Use a belt tensioner tool to compress the tensioner and slip the belt over the last pulley. Double-check that the belt is seated on all ribs and not twisted.

Final Steps

With the supercharger fully installed, perform these final operations before starting the engine.

Fluid Refills

Refill the cooling system with the recommended Mopar OAT coolant. Fill radiator and expansion tank to the full mark. Refill the supercharger with the specified oil through the plug on the unit. The oil level should be at the bottom of the fill hole when the car is level. Do not overfill—this can cause foaming and cavitation. Check the engine oil level and top off if needed.

Battery Reconnection

Reconnect the negative battery terminal. Torque the terminal bolt to 10 ft-lbs. recheck all connections. Turn the key to the ON position without starting the engine. Listen for fuel pump prime and check for warning lights. Use a scan tool to clear any fault codes generated during disassembly.

Initial Startup Procedure

  1. Start the engine and let it idle for 15 seconds. Do not rev the engine immediately.
  2. Listen for unusual noises: tapping, squealing, or air hissing. A slight whine from the supercharger is normal.
  3. Inspect all hose connections and the throttle body for coolant or air leaks. Use a soap and water spray on boost hose connections to detect leaks—bubbles indicate a leak.
  4. Let the engine warm to operating temperature. The cooling fan should cycle on and off.
  5. Turn off the engine after 5 minutes and recheck all fluid levels. Top off coolant as needed.
  6. Inspect the supercharger oil level again—add if necessary.
  7. Test drive gently for the first 10 miles, keeping boost under 5 psi. Gradually increase to full boost over the next 50 miles. Monitor gauges for temperature and oil pressure.

Tuning Your Hellcat

Installing the Mopar Performance Supercharger is only half the equation. Without a proper tune, the engine will run lean, detonate, and potentially fail. Tuning adjusts the air-fuel ratio, ignition timing, and boost control to match the increased airflow. Never drive the vehicle aggressively without a tune.

Why Tuning is Essential

Stock Hellcat ECUs are calibrated for the factory supercharger's specifications. Adding a larger supercharger increases airflow by 20-30%, which the stock map cannot compensate for. The engine will run lean under boost, leading to high cylinder temperatures and knock. A custom tune ensures stoichiometric air-fuel ratios across the rev range and maximizes power while maintaining safety margins.

Tuning Options

  • Dyno tuning – Best results from a professional tuner with a chassis dynamometer. They can adjust parameters in real-time while monitoring wideband O2 sensors and knock response.
  • Remote tuning – Send your ECU to a reputable tuning service (like HP Tuners). They will email a calibrated file that you flash via an OBD2 cable.
  • Pre-loaded tunes – Some performance shops offer mail-order tunes tailored to the Mopar supercharger. However, dyno tuning is preferred for optimal results.

What the Tune Adjusts

  • Air-fuel ratio – Set to 11.5:1 under full boost for safety.
  • Ignition timing – Retarded slightly to prevent detonation.
  • Boost target – The Mopar supercharger typically delivers 11-12 psi; the tune must match.
  • Transmission shift points – Adjusted for the powerband.
  • Throttle response – Sharpened for immediate reaction.

Post-Tune Monitoring

After the tune is applied, monitor the following parameters with a scan tool or data logger: knock count, fuel trims, boost pressure, and coolant temperature. If knock count exceeds 3 degrees under wide-open throttle, reduce boost or have the tune refined. Regularly check supercharger oil and belt condition.

Maintenance and Reliability Considerations

A properly installed and tuned Mopar Performance Supercharger can last tens of thousands of miles without issue. However, the increased power demands more attention. Change the supercharger oil every 20,000 miles or per kit instructions. Inspect the intercooler hoses for cracking annually. Use high-octane fuel (91 or 93 AKI) at all times; lower octane can cause detonation under boost. If you hear a rattling sound from the engine, lift off the throttle immediately and consult a tuner.

Consider upgrading the fuel system if you plan to push beyond 750 hp. The Mopar kit injectors are sufficient for the advertised power, but larger pumps and injectors may be needed for higher boost. Similarly, the factory clutch or automatic transmission may need strengthening depending on usage. Join Hellcat owner forums like Hellcat.org for community tips on supporting mods.

For reference, Mopar's official installation manual provides torque specs and wiring diagrams. Always cross-reference your work with those specifications.

Conclusion

Installing a Mopar Performance Supercharger on your 6.2 Hellcat is a rewarding project that delivers dramatic performance gains. By following this guide, you ensure a safe and effective installation. The key to success lies in preparation, cleanliness, and precision at every step. From removing the stock supercharger to securing the new unit and fine-tuning with a professional calibration, each phase builds toward a reliable, high-output machine. Enjoy the sound of the whine under acceleration and the surge of power that only a Hellcat supercharger can provide. Keep your maintenance schedule strict, monitor your engine closely, and your Hellcat will reward you with years of thrilling performance.