Ram 1500 Supercharger Kit Install Guide: Boost Your Truck with Procharger 2.9l

Introduction: Unlock Your Ram 1500’s Full Potential

The Ram 1500 is a versatile and capable full-size pickup, renowned for its towing capacity, comfortable ride, and powerful V8 engine options. However, even the most satisfied truck owners sometimes crave more—more horsepower, more torque, and a throttle response that pins you to the seat. Installing a supercharger kit, specifically the ProCharger 2.9L system, is one of the most effective ways to dramatically increase your Ram 1500’s performance. This forced-induction upgrade can push your HEMI® engine from respectable to exhilarating, adding 150–200+ horsepower to the wheels when properly installed and tuned.

This comprehensive guide will take you through every phase of the installation, from gathering tools and preparing your work area to final tuning and road testing. Whether you’re a seasoned DIY mechanic or a motivated enthusiast, following these detailed steps will help you complete the installation safely and correctly, ensuring many miles of boosted driving enjoyment.

Why Choose the ProCharger 2.9L Supercharger?

The ProCharger 2.9L is a self-contained, gear-driven supercharger that offers several advantages over other forced-induction systems. Unlike turbochargers, which generate boost from exhaust flow and cause lag, the ProCharger provides instant, linear power delivery from low RPMs all the way to redline. The 2.9L designation refers to the displacement of the compressor housing—a size well-matched to 5.7L and 6.4L HEMI engines in Ram 1500s. Key benefits include:

Self-contained oil system – No tapping into engine oil; the supercharger has its own dedicated oil reservoir.
Intercooler included – Air-to-air intercooler for cooler, denser charge air consistent power.
Bolt-on design – Specifically engineered for Ram 1500 applications with all necessary brackets, pulleys, and hardware in the box.
Tunability – Works with custom ECU calibrations to safely increase boost and fuel delivery.

Before you begin, it’s wise to read the entire ProCharger instruction manual that comes with your kit. This guide supplements that documentation, offering real-world tips and expanded steps for a smoother install.

Tools, Parts, and Preparation

What’s Included in the ProCharger 2.9L Kit

ProCharger 2.9L supercharger head unit with drive pulley
Self-contained oil reservoir, cooler, and lines
Supercharger mounting bracket and hardware
Intercooler and all charge piping
Drive belt (longer to accommodate supercharger pulley)
Air intake system (filter, MAF sensor adapter, tubing)
Fuel injectors (often 42 lb/hr or larger, depending on kit)
Spark plugs (colder heat range)
Installation manual and tuning device (e.g., ProCharger’s supplied handheld tuner or instructions for using DiabloSport)

Required Hand Tools and Supplies

Metric and SAE socket set with extensions (1/4”, 3/8”, and 1/2” drive)
Torque wrench capable of 0–150 ft-lbs
Set of combination wrenches (10mm–19mm)
Pick-up tool for dropped bolts
Screwdrivers (flathead and Phillips)
Trim panel removal tools (for fascia and grille removal)
Jack and jack stands (or vehicle lift)
Creeper or kneeling pad
Coolant (OEM-spec for Ram 1500)
Engine oil (SAE 5W-20 or 0W-20, depending on model year)
RTV silicone gasket maker or thread locker (as needed)
Shop rags and safety equipment (glasses, gloves)

Work Area Preparation

Choose a clean, well-lit, and well-ventilated workspace. A garage with a concrete floor is ideal. Ensure the floor is dry and free of clutter. Position your Ram 1500 so you have access to the front, both fenders, and underside. Disconnect the battery (negative terminal) to prevent any electrical shorts or accidental startup while working on the intake and electrical connectors.

Step-by-Step Installation of the ProCharger 2.9L

Step 1: Remove the Factory Air Intake System

Begin by removing the engine cover (if equipped) using a gentle pull upward. Next, loosen the clamps on the intake tube and air filter housing. Unplug the mass airflow (MAF) sensor and any other sensor connectors. Remove the entire factory intake assembly from the throttle body to the airbox. Set aside all fasteners – some may be reused for the supercharger kit.

Pro tip: Cover the throttle body opening with a clean rag to prevent debris from entering the intake manifold during the rest of the install.

Step 2: Remove the Grille and Front Fascia (for Intercooler Access)

Depending on your Ram 1500 model year, you may need to remove the front grille and upper radiator support to access the intercooler area. Typically, this involves removing a row of plastic push-pins and a few 10mm bolts along the top of the grille. Gently pull the grille straight toward you, then disconnect any fog light or sensor connectors. Set the grille assembly aside in a safe place. This step provides ample room to mount the intercooler and route piping.

Step 3: Install the Intercooler

Position the air-to-air intercooler in the lower front bumper opening. The ProCharger kit includes mounting brackets that attach to the radiator core support. Secure the intercooler with the provided bolts and rubber isolators to prevent vibration. Route the charge piping from the supercharger discharge to the intercooler, and from the intercooler to the throttle body inlet. Keep all silicone couplers and hose clamps tight but not fully torqued until final alignment.

Important: The intercooler must be positioned to allow adequate airflow. Do not block the radiator or A/C condenser fins. After installation, verify the intercooler sits level and does not contact any moving parts.

Step 4: Install the Supercharger Bracket

Using the supplied bracket, bolt it to the front of the engine block. The bracket attaches to existing bolt holes near the water pump and timing cover. Clean the thread holes and apply a small amount of medium-strength thread locker (e.g., Loctite 242) to the bolts. Torque to the specifications in the manual (typically 35–45 ft-lbs). Double-check that no wires, hoses, or sensors are pinched behind the bracket.

Step 5: Mount the Supercharger Head Unit

Lift the ProCharger 2.9L head unit (it is heavy – use two people or an engine hoist) and slide it onto the bracket. The key alignment is the drive pulley: it must align perfectly with the crankshaft and idler pulleys. Install the provided bolts and torque them incrementally in a cross pattern per the manual. Attach the supercharger oil reservoir and cooler hoses. Fill the reservoir with the supplied oil (or recommended synthetic oil) and prime the system by turning the supercharger pulley by hand several rotations – this ensures oil reaches the bearings.

Install the new longer drive belt around the crankshaft, supercharger pulley, and existing accessory pulleys (alternator, water pump, etc.). Use the belt routing diagram in the manual – typically, the belt tension is managed by a spring-loaded tensioner on the bracket. Confirm the belt is fully seated on all grooved pulleys.

Step 6: Install the Fuel Injectors and Spark Plugs

The ProCharger 2.9L kit usually includes higher-flow fuel injectors to provide enough fuel under boost. Before installing the new injectors, relieve fuel system pressure by pulling the fuel pump relay and running the engine until it stalls (or by following the manual’s safe depressurization method). Remove the fuel rail and swap the injectors, replacing the o-rings. Reinstall the fuel rail, torquing the hold-down bolts to specification (typically 7–9 ft-lbs).

Replace the spark plugs with the colder heat-range plugs provided in the kit. Gap them to the spec on the instruction sheet (often 0.035”–0.038”). Install the plugs carefully using a torque wrench – do not overtighten. Reconnect the ignition coils.

Step 7: Install the Intake System and MAF Sensor

Now install the supplied air filter and intake tube. The filter is typically a high-flow cone style that fits inside the engine bay, often with a heat shield. Reinstall the MAF sensor in the new intake tube, ensuring the orientation arrow matches the airflow direction. Tighten all clamps. Reconnect the crankcase ventilation hose to the new intake tube.

Step 8: Reassemble the Front End and Check Clearances

Reinstall the grille, fascia, and any trim panels. Ensure no piping or wiring is pinched. Check that the supercharger pulley has at least 1/4” clearance from all components. Spin the pulley manually to confirm there is no interference from the belt or brackets.

Step 9: Connect the Battery and Perform Preliminary Checks

Reconnect the negative terminal of the battery. Inspect all fluid levels: engine oil, coolant, supercharger oil. Top off if needed. Use a coolant vacuum filler if available to eliminate air pockets in the cooling system.

Step 10: Install the Tune (ECU Calibration)

The supercharger kit will not operate correctly without recalibrated engine control software. The included tuner (often a handheld DiabloSport device or ProCharger’s flash programmer) contains a base calibration for your Ram 1500. Follow the instructions to upload the tune. This step adjusts fuel maps, ignition timing, and throttle response to safely support boost. Never start the engine without the correct supercharger tune – severe engine damage can occur.

Startup, Break-In, and Test Drive

First Start

Start the engine and let it idle. Immediately check for any unusual noises, vibrations, or check engine lights. Listen for supercharger whine – some noise is normal, but grinding or squealing indicates a belt or bearing issue. Watch the oil pressure gauge and temperature. Let the engine reach operating temperature while monitoring for leaks under the hood. Inspect all coolant, oil, and supercharger oil connections. Shut the engine off and re-check fluid levels.

Break-In Procedure

ProCharger recommends a short break-in period before full-throttle operation. Drive the truck gently for the first 50–100 miles, varying engine speed and avoiding sustained high RPMs. This allows the supercharger and engine components to seat properly. After break-in, perform a visual inspection of all hardware. Re-torque clamp bolts on intake and intercooler pipes.

Test Drive and Data Logging

Take the Ram 1500 for a test drive on a safe road. Gradually increase boost levels from part-throttle to moderate accelerations. Use the handheld tuner to log key parameters: intake air temperature, coolant temperature, fuel trims, knock retard, and boost pressure. Verify the tune is adapting correctly. If you notice knock or excessively high intake temperatures, consult your tuner or ProCharger support before aggressive driving.

Post-Installation Maintenance and Tips

Supercharger oil change – change the supercharger oil every 20,000 miles or per ProCharger recommendations.
Belt inspection – check drive belt tension and condition every oil change. A slipping belt reduces boost and can damage pulleys.
Intercooler cleanliness – clean the intercooler fins with a gentle stream of water or compressed air to maintain heat transfer efficiency.
Fuel quality – always run premium octane (91+ RON) to prevent detonation under boost. Consider ethanol blends (E85) with proper tuning for more power.
Traction considerations – significant power increases may overwhelm factory tires and drivetrain components. Upgrading tires, differential, or driveshaft may be needed for high-power applications.

Troubleshooting Common Issues

Issue	Possible Cause	Solution
Low boost pressure	Belt slipping, air leak in charge piping	Re-tension belt, check all coupler clamps, boost leak test
Engine hesitation or stutter under boost	Fuel starvation, incorrect tune, spark plug gap too wide	Verify fuel pressure, reflash tune, re-gap plugs to 0.035”
Supercharger noise (whine too loud)	Improper oil level, gear wear or misalignment	Check oil level and condition, inspect pulley alignment

Performance Expectations and Final Thoughts

With a properly installed ProCharger 2.9L on a stock 5.7L HEMI, expect wheel horsepower gains of around 140–170 hp (depending on boost level and tuning). On the 6.4L HEMI, gains can exceed 200 hp. Torque numbers will similarly increase, often exceeding 500 lb-ft at the wheels. The Ram 1500’s towing ability remains, though you should verify that the transmission and cooling systems are within limits for heavy towing with increased power.

This installation is an involved but rewarding project. By taking your time, using the correct tools, and following both the ProCharger manual and this expanded guide, you can transform your truck into a formidable performer. For additional support, visit the ProCharger official website for updated instructions and parts. Also, check out enthusiast forums like RamForum.com for firsthand experiences and tuning tips from other owners. For custom tuning, reputable shops like HP Tuners offer software for advanced calibration.

Boost responsibly, enjoy the newfound power, and keep the rubber side down.