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3800 Stage 2 Intercooler System

Intercooling - Stage 2 Intercooler System
  • 3 piece pre-sealed aluminum core
  • Dual pass front mount heat exchanges
  • Intercooler Pump
  • 2 Garlock supercharger gaskets (modified for PCV use with our revised intake manifold)
  • All hoses needed for installation
  • Installation instructions with pictures (click below link)
  • All hose clamps, fittings, RTV, and zip ties
  • Longer stainless bolts for the supercharger
  • All installation accessories

ZZPerformance is the leader in intercooler research, testing and performance. We are the only 3800 vendor with a supercharger dyno. It measures blower CFM, temperature of ambient air, air out of the blower, and air below the intercooler core. In addition we measure pressure above and below the core, water GPM into the core and temperature of the water going into the core as well as out of the core. By testing over a dozen parameters with various conditions, we are able to bring you performance unparalleled by any other manufacture. While they guess at what 'should' perform, ZZPerformance can guarantee it!

Update 12/17/19: We now include our Gen 2.5 intercooler cores in all of our Stage 2 intercooler kits. The benefits include: Straight through PCV passages, this revision no longer requires swapping the intake manifold to maintain factory PCV function.  The core itself is more efficient, 20% denser core, and the shape is optimized for the actual airflow path.  Internally it is no longer sealed by RTV, it uses o-rings with machined o-ring passages.  It is ¾ of a pound lighter than our old Stage 2 core.  It has ¾” nipples instead of 5/8” for increased water flow.  …And finally, improved machining quality. To read fully about the new cores click here.

Bring your car to the next level of performance with our intercooler. For use with all M90 powered cars. Use 3.0 pulleys or smaller with 0 KR. 300+ HP at the wheels is easily within reach with the addition of our IC. Our latest kit is the easiest to install yet with nearly a dozen improvements over our older kits. Separate system no longer ties into factory overflow, T fill ensures no air and easy priming, new gaskets eliminate PCV issues and extra work trimming.

  • Car idle, streetability and gas mileage remain unchanged
  • Works fine year round
  • Prevents detonation and chipped pistons
  • *Stock PCV function** (no breather required 5-3-06) with our revised intake manifold (must be purchased separately).
  • *Stock EGR function
  • 3/4" lines and fittings
  • New design outperform anything on the market
  • 3 piece core is bolted together and pre-sealed for easier installation

How to order:

Supercharger Generation: The '97-03 Grand Prix GTP, '04-05 Monte Carlo/Impala SS, and '97+ Regal/ Bonneville SSEi/ Park Avenue Ultra/ LSS comes from the factory with a Gen3 supercharger. The only car that comes from the factory with a Gen5 supercharger is the 04+ Grand Prix supercharged. However the Gen5 supercharger can be retrofitted to cars that came with a Gen3 supercharger, if you are going to do that, you will want to select Gen5 instead.

Fuel Rail Solution: The Series II '97-03 Grand Prix GTP, '04-05 Monte Carlo/Impala SS, and '97+ Regal/ Bonneville SSEi/ Park Avenue Ultra/ LSS comes from the factory with a Return Style Fuel System. The only car that comes from the factory with a Returnless Fuel System is the Series III '04+ Grand Prix supercharged.

6 hour install time. The most complete kit on the market with CD based installation instructions including dozens of pictures and step by step instructions.

The new ZZP heat exchangers are custom built for the W-body platform. They are bolt in with no longer require cutting of the factory hood latch.

Larger fuel injectors required for smaller than 3.1" pulley sizes.

Longer supercharger belt is required. Typical: 3.1"+ pulley needs a 685 belt, 3.0"-2.8" pulley uses 680 belt, 2.7" or smaller usually requires 675 belt

For installation of stage 2 intercoolers on 2004+ Supercharged GPs, we recommend our Alternator relocation brackets, cradle spacers and inlet turn down adapter (drive by wire only) for added hood clearance. 04+ Monte Carlos and Impalas will need the Alternator relocation brackets. Will not work with our L36 Supercharger Kit due to injector location.

Stage 2 core is made of Aluminum and weighs 8.9 lbs.

This kit DOES NOT work with our L36 supercharger kit due to injector clearance.

Instruction CD:
http://s3.amazonaws.com/zzpstorage/instructions/S2+IC/S2+IC+Install.zip


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Intercooling - Stage 2 Intercooler System
Customer Reviews
4.9 Based on 17 Reviews
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CB
07/17/2021
Chris B.
United States United States
Intercooler

Overall the intercooler itself is beautiful customer service is so so it's really hard to communicate with people to figure out how to install it but thanks to the 3800 community I was able to do it. Take your time on this do not cut any corners if you have any questions ask the community I had to order the billet fuel rails which needed a little bit of modification to the brackets to make work with the setup but overall came out nice when done. I was able to only have to purchase the turn down adapter for the throttle body. I did not need the cradle spacers or the alternator brackets but I did remove the fiberglass underlayment from under the hood. Overall this kid is excellent but it takes a long time to install but it's well worth it you will need a gallon of coolant as well. If you have an 04 Plus you will also need two self-tapping screws to mount the heat exchanger.

ZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System Review
D
04/19/2021
DCClark
United States United States
Very Happy

Just finished up the stage 2 install..with ZZP having a lot of products saying "out of stock" I thought I better get this before it is out of stock too...Install went fairly smooth the biggest problem was the belt size as others have said..the 685 will not fit on a 3.3 pulley it is simply too short had to buy another belt that measured 68.5 inches the exact same size as the 68.5 that ZZP says fit...still cant figure that out...If you have 2 belts and both say 685 you would assume they both would fit, but it didn't work out that way..

DK
03/08/2021
Daryl K.
Canada Canada
Intercooler

A well designed and fabricated system. Great packaging

JL
12/30/2020
John L.
United States United States
Beautiful

This thing looks amazing out of the box. You guys should have offered polished, bc it takes it to a different level. Amazing product

ZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System Review
JL
11/19/2020
John L.
United States United States
Awesome product

I was waiting for the restock. I got my restocked email early 2 days ago and ordered the IC and some other stuff and I got my stuff last night. Literally the next day!!!!! I was very happy with the product and FAST shipping. Not a single fin out of place on the core or heat exchanger. I've read others saying there stuff showed up bent or something and my stuff came packaged great. I'm definitely glad I opted for the billet fuel Logs!! Thanks again ZZP for great products and great service. Now gotta order more stuff for the build

ZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System ReviewZZPerformance 3800 Stage 2 Intercooler System Review