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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.

Installation instructions can be found here

UPS Shipping Only.

Intercooling - Stage 2 Intercooler System
Customer Reviews
4.9 Based on 21 Reviews
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United States United States

Won the KR battle

Installed this about 5 months ago and no problems at all. What a relief it is to look at my aeroforce gauge and see no KR with a 3.1 pulley, lowest I want to go with stock injectors. Only issue I had was the hose running between the supercharger belt that I secured with plastic tiedown's and the heat from the engine stretched the tiedown and the hose was rubbing against the belt. I caught it in time before it wore a hole in the hose and replaced it with a steel tiedown

Kyle M.
United States United States

Stop thinking about it & just buy it

As the title of this says, stop thinking about it & just buy it. Seriously, this has to be, by far, one of the best things you can do for these motors. 6 hour install is dead on, it's very simple & easy to do, and your car will have WAAAAY more potential. If you get the billit fuel rails too, that's alot easier than it looks too. Plus, they look fantastic on either side of the blower.

Chris B.
United States United States


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
David C.
United States United States

Won the KR battle

This is my second write up..2 months after installing this intercooler everything is great only problem one hose was rubbing on the supercharger belt and had to be replaced after losing all the coolant, a metal zip tie corrected that. Everyone knows what a relief it is when looking at your aeroforce gauge and not seeing any KR. Pre-install I was running with a 3.4 pulley with some KR and not wishing to press my luck installed a 3.2 after this install and still no KR not even a hint. Bought a new beefed up long block from Summit Racing about a 2 years( their last one) and just turned 10,000 miles.. ZZP long tube headers Yella Terra 1.8 roller rocker and Gen 5 SC..Ran a 13.8 on street tires with the 3.4 pulley I feel now I'm down to the low 13's.And will get a 3.1 pulley that the lowest I want to go with stock injectors.

United States United States

Cant drive without one

Before installing this stage 2 I was constantly looking at my aeroforce gauge seeing how much KR I was getting with just a 3.4 pulley, even after installing ZZP full header setup, CAI, 1.85 yella terra roller rockers, tuned PCM and all the usual mods to fight KR. I was always getting some have no idea what a relief it is to look now and seeing 0.0 kr even with a 3.2 pulley. I don't care what you do to your L67 you will have KR. If you are serious on taking the next step beg, borrow or steal this intercooler