3800 Stage 2 Intercooler System

3800 Stage 2 Intercooler System
Intercooling - Stage 2 Intercooler System

3800 Stage 2 Intercooler System

24 reviews
Supercharger Generation
Fuel System
Regular price $1,129.99
  • In stock, ready to ship
  • Inventory on the way
  • 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.

Customer Reviews
4.9 Based on 24 Reviews
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Jamal E.
United States

Performance, Value, and Unbeatable Service

We received everything we needed for our build well packaged and fast shipping. I would recommend anyone looking to add power to the line of supercharged 3800's to go with ZZPerformance.

Alex S.
United States United States

Awesome product

Took me about 8 hours but could have been some faster for a more experience mechanic. Killed all my KR and the install was fairly simple. Like other have said take your time and really focus what your doing. Definitely one of the most necessary mods you can do! Thanks ZZP

United States United States

Great product

Helps keep the Temps down tremendously no doubt about it and worth every penny. Just make sure to trim your gasket. Small ball ping hammer will work great.

ZZPerformance 3800 Stage 2 Intercooler System Review
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.

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