Unlock 100+ Horsepower: Installing a ProCharger Supercharger on Your Ram 1500

If you own a Ram 1500 with the Hemi V8 and crave more power, a ProCharger supercharger is one of the most effective bolt-on upgrades available. By forcing more air into the engine, a properly installed ProCharger system can add 100 to 150 horsepower at the wheels while maintaining daily-driver reliability. This expanded guide covers every critical step — from gathering tools to final tuning — so you can complete the installation with confidence and enjoy a significant performance increase.

Before you begin, understand that this is an intermediate-to-advanced mechanical job. Plan for a full weekend and have a shop manual or reliable online forum like RamForum.com handy for torque specs specific to your model year.

Tools and Materials Needed

ProCharger kits typically include the supercharger head unit, bracket, intercooler, intake piping, drive belt, and hardware. You will also need the following tools and supplies:

  • ProCharger supercharger kit (part number specific to your Ram 1500 engine and year)
  • Metric and SAE socket sets (3/8″ and 1/2″ drive with extensions)
  • Torque wrench (ft-lb and in-lb ranges)
  • Ratchet, breaker bar, and wobble extensions
  • Flathead and Phillips screwdrivers
  • Trim removal tools for grille and bumper covers
  • Coolant flush kit and fresh coolant (OAT or compatible)
  • Engine oil and filter for post-installation change
  • Thread locker (Loctite Blue 242 and Red 271)
  • Safety glasses, mechanic gloves, and jack stands
  • Fuel system upgrade kit (injectors + pump) if not included
  • Laptop and tuning device (e.g., HP Tuners or DiabloSport i3)

Having a helper for lifting the supercharger onto the engine bracket will save time and reduce the risk of dropping the assembly.

Safety First

Working on a modern Ram 1500 requires caution. Park on a level surface, chock the rear wheels, and disconnect the negative battery cable before starting. Allow the engine to cool completely — the exhaust manifolds and catalytic converters stay hot for hours. Keep a fire extinguisher rated for flammable liquids nearby. If you’re working with a lift, use jack stands rated for the vehicle’s weight.

Preparation Steps

1. Disconnect the Battery

Use a 10mm socket to remove the negative terminal. Wrap the cable end in a shop towel to prevent accidental contact while working.

2. Drain the Cooling System

Place a drain pan under the radiator petcock. Open the petcock and remove the radiator cap to allow proper drainage. Remove the overflow tank and set it aside. This step is necessary because the ProCharger intercooler mounts in front of the radiator, requiring removal of the fan shroud and sometimes the fan clutch.

3. Remove the Grille and Front Bumper Cover

On most Ram 1500 models, you’ll need to remove the upper grille and the plastic bumper cover to access the intercooler mounting area. Use trim tools to pop the push-pins and pry the grille free. For the bumper cover, remove the screws under the hood, inside the wheel wells, and along the lower edge. Set the cover aside carefully to avoid scratching the paint.

4. Remove the Fan Shroud and Cooling Fan

Unbolt the fan shroud and disconnect the electrical connector for the electric fan (if equipped). On some models you must also remove the mechanical fan clutch to clear the supercharger belt path. Use a fan clutch wrench or a long 32mm wrench for this step.

With the extra boost, the factory spark plugs should be replaced with a cooler heat range. ProCharger recommends NGK iridium plugs gapped to 0.035″. Use a spark plug socket and torque to spec (usually 13–15 ft-lb).

Installing the ProCharger Supercharger

1. Install the Crank Pulley (if required)

Some kits include a larger or underdrive crank pulley to help drive the supercharger at the proper speed. Remove the factory crank bolt using an impact gun and a harmonic balancer puller. Install the new pulley and torque the bolt according to the ProCharger instructions (often 210 ft-lb plus 90 degrees). Do not skip this step — a loose crank bolt can destroy the engine.

2. Mount the Supercharger Bracket

The bracket bolts to the front of the engine using the factory accessory mounting holes. Clean the threads and apply Loctite Blue to the bolts. Torque in the sequence specified in the manual (usually 37 ft-lb). Double-check that the bracket sits flat without any interference.

3. Install the Supercharger Head Unit

Lift the ProCharger head unit onto the bracket. It’s heavy — enlist a helper. Insert the four mounting bolts (typically M10 or M12) and torque to spec (typically 45–50 ft-lb). Attach the oil supply and drain lines if your kit uses a separate oil system; otherwise, the self-contained gearcase is pre-filled.

4. Route the Intake and Discharge Piping

Connect the large-diameter intake tubing from the air filter to the supercharger inlet. Then connect the discharge tube from the supercharger outlet to the intercooler. Use the supplied silicone couplers and T-bolt clamps. Tighten all clamps evenly to avoid boost leaks. Check that the piping does not rub against the radiator, hoses, or wiring.

5. Mount the Intercooler

The ProCharger intercooler mounts in front of the radiator, behind the grille. Slide it into the provided brackets and secure with bolts. Connect the intercooler outlet tube to the throttle body using the supplied adapter. You may need to modify the grille trim slightly — use a Dremel or die grinder for a clean fit.

6. Install the Drive Belt

With the supercharger and intercooler in place, install the dedicated drive belt. Route it over the crank pulley, supercharger pulley, and any idler/tensioner pulleys. Use a belt tension gauge to achieve the manufacturer’s spec (typically 110–130 lbs for a new belt). If your kit uses an automatic tensioner, ensure the belt rides in the center of each pulley.

7. Install the Boost Reference and Bypass Valve

The bypass valve (blow-off valve) vents boost when the throttle closes. Install it on the charge pipe as directed. Connect vacuum lines from the intake manifold to the bypass valve and boost gauge (if using). Use zip ties to secure lines away from heat sources.

Fuel System Upgrades

Adding 100+ HP requires more fuel. ProCharger kits often include larger fuel injectors (usually 60 lb/hr) and a higher-flow fuel pump. If yours does not, purchase an upgrade kit:

  • Fuel injectors: Replace with 60–80 lb/hr injectors. Remove the fuel rail, pull old injectors, and install new ones with fresh O-rings. Torque the rail bolts to 12 ft-lb.
  • Fuel pump: On Ram 1500s, the pump is inside the fuel tank. Drop the tank or access through the bed (depending on cab configuration). Install a DW400 or Walbro 525 pump, and re-wire with a relay kit for consistent voltage.
  • Fuel pressure regulator: Some systems require a boost-referenced regulator. Follow ProCharger’s instructions to set base pressure (usually 58 psi).

After installing the fuel components, pressure-test the system for leaks before starting the engine.

Tuning and ECU Calibration

The factory ECU cannot adjust for boost without a custom tune. You have two options:

  1. Mail-order tune: Many tuners (e.g., HP Tuners or DiabloSport) offer ProCharger-specific calibrations. You’ll send your ECU or use an in-car programmer to flash the new file.
  2. Dyno tune: For maximum power and safety, have the truck tuned on a chassis dyno by a professional. This will optimize air/fuel ratio, timing, and transmission shift points.

Do not start the engine without a tune. Running boost on factory calibration can cause immediate detonation and engine damage. Always use premium fuel (93 octane or higher).

Final Assembly and Checks

1. Reassemble Front End

Reinstall the fan shroud, cooling fan, grille, and bumper cover. Check for clearance between the supercharger piping and the fan blades. If anything touches, adjust the piping or fan shroud.

2. Refill Coolant and Oil

Fill the radiator with the recommended coolant and burp the system to remove air pockets. Change the engine oil and filter — fresh oil helps protect bearings under the new load. Use a high-quality synthetic 5W-30 (or 0W-40 for warmer climates).

3. Reconnect Battery and Check Electrical

Reattach the negative battery terminal. Verify all electrical connectors (fan, injectors, sensors) are plugged in securely. Inspect the battery terminals for corrosion and tighten.

Start-Up and Break-In

1. Check for Leaks

Perform a fuel system pressure test while the engine is off. Then start the engine and look for coolant, oil, or fuel leaks at every connection. Listen for any intake or exhaust hissing that indicates a boost leak.

2. Idle and Rev

Let the engine idle for 5–10 minutes while monitoring coolant temperature and oil pressure. Check the scanner for any check-engine codes. Gently rev the engine to 2500 RPM a few times to circulate oil through the supercharger.

3. Test Drive

Take the truck on a short test drive (5–10 miles). Avoid full-throttle runs. Gradually increase boost by accelerating from 30–50 mph. Monitor your gauges (boost, fuel pressure, wideband AFR if available). Keep logs to review with your tuner. Do not go to wide-open throttle until the tune has been validated.

Maintenance Tips for Your Supercharged Ram

  • Oil changes: Change oil every 3,000–5,000 miles using a high-zinc racing oil or a supercharger-compatible synthetic.
  • Belt inspection: Check the supercharger belt tension monthly. Replace the belt every 15,000 miles or annually.
  • Intercooler cleaning: Wash the intercooler fins with a gentle stream of water every 10,000 miles to remove bugs and debris.
  • Knock monitoring: If you hear pinging, reduce boost and get the tune revised immediately.

For detailed service intervals, refer to the ProCharger owner’s manual and your Ram’s factory maintenance schedule.

Common Challenges and Troubleshooting

Boost Leaks

If you notice power loss or a hissing sound, inspect all couplers and clamps. Soapy water sprayed on connections will reveal bubbles. Replace damaged silicone boots and retighten clamps.

Check Engine Light

Common codes after supercharger install include P0171/P0174 (lean) or P0300 (random misfire). These indicate a tune issue, fuel delivery problem, or an intake leak. Log fuel trims and consult your tuner.

Overheating

If coolant temperature rises above normal, check fan operation, coolant level, and intercooler airflow. Upgrading the radiator or adding a lower-temp thermostat may be necessary for hot climates or heavy towing.

Conclusion

Installing a ProCharger supercharger on your Ram 1500 is a rewarding project that transforms your truck into a high-performance machine. By following this step-by-step guide, using quality tools, and investing in a proper tune, you can safely achieve 100+ horsepower gains. The key is patience — take your time with each step, double-check torque specs and connections, and never rush the tuning process. Once everything is dialed in, you’ll enjoy a Ram that pulls hard from idle to redline, whether on the highway or the road course. For more information and kit specifics, visit the official ProCharger website and join the community at RamForum.com for support from fellow owners.