Introduction: Unlocking Forced Induction on Your Charger

Adding a ProCharger Stage 2 supercharger to your Charger is one of the most effective ways to unlock substantial horsepower gains while maintaining daily drivability. Unlike turbochargers that require extensive exhaust modifications, a centrifugal supercharger like the ProCharger Stage 2 bolts onto the front of your engine and uses a belt-driven impeller to force compressed air into the intake. This results in a linear power delivery that feels natural and builds as the RPMs climb, making it an excellent choice for both street driving and track use.

The Stage 2 system from ProCharger is specifically engineered for late-model Charger R/T, Scat Pack, and Hellcat platforms (depending on the kit variant). It includes a high-efficiency intercooler, dedicated oiling system, and a calibrated fuel system upgrade to support the added airflow. This guide will walk you through the entire installation process, from preparation and tool selection through final tuning considerations. Every step is designed to help you perform the installation correctly the first time, minimizing downtime and avoiding common pitfalls.

What You Will Need: Tools, Components, and Consumables

Before you begin, gather all required items. The ProCharger Stage 2 kit is comprehensive, but you will need additional tools and supplies to complete the installation safely and professionally.

Kit Contents

  • ProCharger Stage 2 supercharger head unit (self-contained oil system or engine-fed, depending on variant)
  • Cast aluminum mounting bracket with hardware
  • Intercooler (air-to-air or air-to-water, kit-specific)
  • Piping, couplers, and T-bolt clamps for the charge air system
  • Belt drive system (tensioner, idler pulleys, and supercharger belt)
  • Fuel injectors or fuel pump booster (kit-dependent)
  • Installation manual and calibration device (if included)

Required Tools

  • Socket set: SAE and metric, ¼-inch and ⅜-inch drive
  • Torque wrench: ⅜-inch drive, capable of 15–80 ft-lbs
  • Ratchet and extensions: Short and long extensions for tight spaces
  • Flathead and Phillips screwdrivers
  • Trim panel removal tools (if removing inner fender liners or bumper cover)
  • Mechanic's wire brush and brake cleaner for preparing surfaces
  • Jack and jack stands or a lift
  • Coolant catch pan or drain pan
  • RTV silicone or thread-locker (medium strength) as specified in the manual

Safety Gear and Consumables

  • Safety glasses
  • Mechanic's gloves (cut-resistant recommended)
  • Shop rags and paper towels
  • Engine coolant (if the intercooler system requires draining)
  • Engine oil (if the supercharger requires oil fill)

Preparation: Getting the Work Area and Vehicle Ready

Proper preparation prevents mistakes and reduces frustration. Start by parking the Charger on a level concrete surface with good lighting. Disconnect the negative battery terminal and isolate it to prevent accidental contact.

Raise the front of the vehicle securely using a jack and jack stands placed under the designated lift points. You will need access to the underside of the engine bay for oil drain/feed line routing and intercooler mounting. Remove the hood if you prefer more working room, though most installers can complete the job with the hood open and supported.

Lay out the ProCharger kit components and verify that every bracket, hose, bolt, and fitting is present. Compare the hardware bag against the kit's inventory sheet. This is also the time to read the entire installation manual from start to finish—not just skim it. Understanding the sequence of operations before you begin saves time and reduces the risk of installing a component in the wrong order.

Clean the engine bay thoroughly, especially the front accessory drive area and the intake manifold surface. Debris left behind during the installation can cause issues later. Use compressed air or a shop vacuum to remove loose dirt and grit.

Step 1: Removing Stock Components

Clearing the path for the supercharger requires removing the factory air intake system, belt drive components, and sometimes the radiator fan shroud or bumper reinforcement for intercooler clearance.

Factory Air Intake Removal

  • Loosen the clamp at the throttle body and disconnect the intake tube.
  • Unclip the mass airflow sensor (MAF) harness and remove the sensor if it mounts directly to the intake tube.
  • Unbolt the air box assembly from the fender and remove it along with the filter.
  • Set aside all hardware in a labeled bag; you may reuse some bolts for the supercharger bracket.

Accessory Drive Belt and Tensioner

  • Using a belt removal tool or a long ratchet, relieve tension on the serpentine belt tensioner and slip the belt off the pulleys.
  • If the ProCharger kit relocates the alternator or idler pulleys, you will need to remove the factory tensioner assembly entirely. Refer to the manual for torque specs on the tensioner bolts—they are typically in the 35–45 ft-lb range.

Front Bumper Cover or Grille (Intercooler Clearance)

Most ProCharger Stage 2 kits include a front-mount intercooler that fits between the radiator and the bumper reinforcement. Removing the bumper cover provides direct access. Place a blanket over the paint to prevent scratches. Unbolt the cover at the fender liners, the top radiator support, and the lower splash shield. Pull the cover forward and support it or completely remove it.

Step 2: Installing the Supercharger Bracket and Drive System

The supercharger bracket replaces or supplements the factory accessory drive components. This bracket must be rigidly mounted to the engine block to handle belt loads without flexing.

  • Position the bracket over the existing mounting bosses on the passenger side of the engine block. Apply a drop of medium-strength thread-locker to each bolt as specified in the instructions.
  • Hand-start all bolts before tightening, then torque them in a crisscross pattern to the manufacturer’s specification (typically 40–55 ft-lbs for M10 bolts).
  • Install the supercharger idler pulleys and the belt tensioner onto the bracket. Torque the center bolts to spec—do not overtighten.
  • Mount the supercharger head unit onto the bracket using the supplied hardware. The head unit should slide onto locating dowels or align with slotted holes for belt alignment.
  • Rotate the supercharger pulley by hand to confirm free rotation. If there is binding, loosen the bracket bolts slightly and re-torque while supporting the supercharger weight.

Step 3: Installing the Intercooler and Charge Air Piping

The intercooler reduces the temperature of the compressed air before it enters the engine, which increases air density and prevents detonation. Proper mounting is critical for airflow and durability.

  • Position the intercooler core in the lower grille opening, using the supplied brackets to attach it to the radiator support or frame rails. Ensure there is at least ½ inch of clearance on all sides for airflow and thermal expansion.
  • Tighten the brackets securely, but do not distort the intercooler end tanks by overtightening.
  • Route the charge pipes from the supercharger outlet to the intercooler, and then from the intercooler to the throttle body. Use the supplied silicone couplers and T-bolt clamps. Do not reuse factory rubber hoses for charge air applications—they will collapse under boost pressure.
  • Orient each clamp so you can access and tighten it with a screwdriver or socket. Double-check that couplers are fully seated over the pipe beads before tightening.

Step 4: Fuel System Modifications

Adding boost increases the fuel demand significantly. The ProCharger Stage 2 kit typically includes one of the following: larger fuel injectors, a fuel pump voltage booster (BAP), or both. The exact configuration depends on your Charger's engine and fuel system type.

  • For injector upgrades: Remove the fuel rail caps, depressurize the system by pulling the fuel pump fuse and cranking the engine, then swap each injector. Reinstall the rail and torque the rail bolts to spec.
  • For a fuel pump booster: Mount the BAP module in a location protected from heat and moisture (inside the trunk near the pump access panel is common). Splice the wiring according to the kit instructions, using heat-shrink connectors for reliability.
  • Always replace the fuel filter if the kit includes one or if the factory filter has more than 30,000 miles.

Step 5: Oil Feed and Drain (For Kits Using Engine Oil)

Some ProCharger Stage 2 variants use the engine’s oil system to lubricate the supercharger, while others are self-contained. If your kit requires an oil supply from the engine, follow these steps carefully:

  • Remove the oil pressure sending unit or use a port on the oil filter housing to install the supplied oil feed fitting. Apply Teflon tape or thread sealer to the fitting’s threads.
  • Route the oil feed line from the fitting to the supercharger inlet. Keep the line away from exhaust manifolds and moving components.
  • Install the oil drain line from the supercharger to a drilled-and-tapped hole above the oil pan gasket, or use a pre-existing return port. The drain must be above the oil level in the pan and must slope downward continuously.
  • Torque all fittings to prevent leaks. Start the engine briefly and inspect for oil leaks before proceeding.

Step 6: Reinstalling Components and Reassembly

Once the supercharger, intercooler, piping, and fuel system are in place, reassemble the components you removed earlier.

  • Reinstall the bumper cover and grille, ensuring the intercooler core is visible and unobstructed by the lower valance. Trim the valance if required using a Dremel or utility knife.
  • Reinstall the inner fender liners and lower splash shields.
  • Reconnect the MAF sensor and any other electrical connectors that were unplugged.
  • Fill the cooling system if you drained it. Use the correct coolant specification for your Charger.
  • Connect the intake tube from the air filter to the supercharger inlet. Ensure the filter is securely mounted and not touching hot surfaces.

Step 7: Final Checks and Torque Verification

Before starting the engine, perform a systematic inspection. Print a checklist if needed—missing a single loose clamp can cause a boost leak or a serious mechanical issue.

  • Torque all fasteners: Bracket bolts, supercharger mounting bolts, intercooler brackets, wheel lug nuts (if removed), and suspension components.
  • Check belt tension: The belt should deflect no more than ½ inch between pulleys when pressed firmly. Adjust the tensioner if necessary.
  • Verify all hose clamps are tight: Especially the charge air couplers and radiator hoses.
  • Check clearance: Rotate the supercharger pulley by hand to ensure the belt does not rub against any bracket or hose.
  • Reconnect the battery and confirm that the terminal is tight and clean.

Step 8: Starting the Engine and Initial Run

With the battery reconnected, turn the key to the "on" position without starting the engine. Let the fuel pump prime for 3–5 seconds. This is especially important if you modified the fuel system, as air may be trapped in the lines.

Start the engine and let it idle for 30 seconds. Listen for any unusual noises: belt chirping, air leaks (hissing), or metallic contact. Check for oil leaks around the supercharger feed and drain lines. Verify that the intercooler fan (if equipped) cycles on and off normally.

Take the car for a short test drive under light throttle. Do not exceed 4,000 RPM or go into boost for the first 10 miles. This allows the supercharger lubrication to circulate fully and the fuel trims to adapt. Monitor the dashboard for check engine lights, coolant temperature, and oil pressure.

Step 9: Tuning and Calibration

The ProCharger Stage 2 system is not a "bolt-on and drive" kit. The engine management system must be recalibrated to adjust air/fuel ratio, ignition timing, and boost control. Running a supercharged engine without proper tuning risks severe engine damage from detonation.

ProCharger offers calibration devices (a handheld tuner or a preloaded PCM swap) for many vehicle models. If your kit includes one, load the provided tune file exactly as directed. If not, or if your vehicle has additional modifications (camshaft, headers, larger injectors), you must consult a professional dyno tuner. Do not rely on generic "off-the-shelf" tunes from forums or third-party sellers.

A proper dyno tune will verify that air/fuel ratio stays within 11.5–12.0:1 under full boost, and that ignition timing does not induce knock. Expect to spend 2–4 hours on the dyno for a thorough calibration. The result is a safe, reliable setup that maximizes the ProCharger's performance.

Maintenance: Keeping Your Supercharger in Top Condition

The ProCharger Stage 2 supercharger is a precision device that requires regular attention. Follow these guidelines to ensure long service life:

  • Air filter: Inspect every 5,000 miles and replace annually. Dirt ingestion will damage the impeller blades.
  • Belt inspection: Check for glazing, cracks, or fraying every oil change. The supercharger belt operates under higher load than the accessory belt.
  • Oil changes: If your supercharger uses the engine oil, change the oil at normal intervals (5,000–7,500 miles). For self-contained units, replace the supercharger oil per ProCharger's schedule (typically every 30,000 miles).
  • Charge air system: Annually inspect all couplers and clamps for looseness. Boost leaks reduce performance and can cause lean conditions.
  • Intercooler fins: Straighten bent fins with a fin comb and wash debris out gently with a low-pressure hose.

Common Pitfalls to Avoid

Experienced installers consistently see these mistakes on first-time supercharger installations. Avoid them to save time and money:

  • Skipping the thread-locker step: Vibrations will loosen critical bracket bolts over time.
  • Over-tightening T-bolt clamps: This cuts into silicone couplers and causes air leaks.
  • Neglecting to check belt alignment: A misaligned belt will shed rubber onto the pulleys and fail prematurely. Use a straightedge across the pulleys to confirm alignment.
  • Using a generic tune: Every engine responds differently to boost. Custom tuning is the only way to ensure safety and performance.
  • Ignoring the fuel system: A starving fuel pump or undersized injectors will destroy the engine. Always upgrade the fuel system as recommended by ProCharger.

Conclusion: The Right Way to Go Boost

Installing a ProCharger Stage 2 supercharger on your Charger is a rewarding project that delivers dramatic horsepower gains—typically 150–200+ wheel horsepower depending on the engine variant. By following this guide, using the proper tools, paying attention to torque specs, and investing in professional tuning, you will achieve a reliable, street-friendly power upgrade that transforms how your Charger performs.

For the latest kit-specific details and vehicle fitment information, always refer to the official ProCharger installation manual for your exact model year and engine combination. Additional resources include ProCharger's official website for technical bulletins, HP Tuners for calibration software and support, and Modern Muscle IS for community-driven installation tips and troubleshooting. Approach the work methodically, respect the engineering behind forced induction, and you will enjoy a supercharged Charger that delivers thrills every time you press the accelerator.