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ZZP Stage 2.5 Intercooler Core

This is our latest design which has even more improvements, for example: Straight through PCV passages, this revision no longer requires swapping the intake manifold to maintain factory PCV function, reuse your stock lower intake.  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.

It is still a 2.25" core (like our last one) and will fit under most stock hoods with no modifications, but we do recommend adding our cradle spacers. It supports temperature drops of 110-160 degrees depending on blower speed and boost level.

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 manufacturer. While they guess at what 'should' perform, ZZPerformance can guarantee it!

Pricing includes longer stainless bolts to hold down the blower.

Note: Gaskets must be purchased separately, which can be found here

Gen 5 M90s have the throttle body inlet higher than on the Gen 3 M90s, please email if you have questions about clearance issues when using a Gen 5 M90.

Customer Reviews
5.0 Based on 4 Reviews
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Patrick R.
United States United States
CAC Of My Dreams

I have a short stack CAC, and it works pretty well, but I have been watching YouTube videos of Gale Banks' in the dyno booth testing a supercharged duramax engine, and I see what a CAC cooler can do to improve the intake manifold density, and the increase in horse power and torque without changing the AFR at all. I am going with it, and see how much I can derive from this principle on my 3800. Stay tuned!

John L.
United States United States

What an amazing product. I love this W to A intercooler. ZZP INTERCOOLER polished shld have been an option just saying. It was beautiful out of the box but a little elbow grease and WOW!!

ZZPerformance ZZP Stage 2.5 Intercooler Core ReviewZZPerformance ZZP Stage 2.5 Intercooler Core ReviewZZPerformance ZZP Stage 2.5 Intercooler Core ReviewZZPerformance ZZP Stage 2.5 Intercooler Core Review
Derrick M.
United States United States
Best thing yet

Haven’t stop driving my car since I got it on!!!

James H.
United States United States
New Stage 2.5 Intercooler core design is awesome

I have now installed and run the Stage 2, Stage 3 and now the Stage 2.5 in my 04GTP all with great results. Out of the three I like the Stage 2.5 the best. There are so many design improvements for performance and ease of installation. My favorite are the new O-ring seals. It also looks the best of the three, grats ZZP!