What a ProCharger installation involves and what to expect

Installing a ProCharger supercharger on a Dodge Challenger R/T is a significant engine modification that increases horsepower and torque by forcing more air into the combustion chamber. The job requires removing the factory intake manifold, serpentine belt system, and radiator hose routing, then mounting the ProCharger unit, its intercooler, fuel system upgrades, and custom tuning. Most installations take 20 to 40 hours of labor depending on your mechanical skill and whether you're working in a shop or your own garage.

This is not a bolt-on weekend project. You will need specialized tools, a lift or jack stands, and knowledge of engine bay layout. Many owners send their Challenger to a shop that specializes in ProCharger installations rather than attempting it themselves, because mistakes during installation can damage the engine or void warranties. If you proceed on your own, you should have prior experience with major engine work and access to the full ProCharger installation manual for your specific model year.

Key Takeaways

  • ProCharger kits for the R/T come with the supercharger unit, intercooler, fuel injectors, and engine management software, but you must purchase additional components like belts, hoses, and brackets separately.
  • Installation requires removing the intake manifold, radiator, serpentine belt system, and fuel rail, then mounting the ProCharger and routing all new plumbing and wiring through the engine bay.
  • Your fuel system must be upgraded to handle the increased fuel demand, which usually means installing larger fuel injectors and a higher-capacity fuel pump.
  • Professional tuning is essential after installation to adjust ignition timing, fuel delivery, and boost levels so the engine runs safely at its new power output.
  • The total cost including parts, labor, and tuning typically ranges from $4,000 to $8,000 depending on whether you do the work yourself and which ProCharger model you choose.

Choosing the right ProCharger kit for your R/T model year

ProCharger makes different kits for different Challenger R/T generations. The most common are kits for the 2008–2014 R/T (5.7L HEMI) and the 2015–2023 R/T (also 5.7L HEMI). You must verify which generation your Challenger is before ordering, because the mounting points, belt routing, and intercooler placement differ between years. Check your vehicle identification number (VIN) on your registration or have a dealer confirm the model year if you're unsure.

ProCharger offers both centrifugal and twin-screw supercharger designs. Centrifugal units are smaller, quieter, and less expensive but produce boost more gradually as engine RPM rises. Twin-screw units deliver boost when ready and produce more total horsepower but are louder and more costly. For an R/T, most owners choose the centrifugal ProCharger P-1SC or P-1X because they fit the engine bay without major modifications and provide a reliable 100–150 horsepower increase depending on tuning.

Tools and workspace you'll need before starting

You will need a vehicle lift or a set of jack stands rated for at least 7,000 pounds, because you must safely support the Challenger while working underneath and inside the engine bay for extended periods. A four-post lift is safest, but quality jack stands work if you also use a floor jack as a backup. Never work under a vehicle supported only by a jack.

Essential hand tools include a complete socket set (metric and standard), wrenches, screwdrivers, pliers, a torque wrench, and an engine hoist or cherry picker to remove and reinstall the intake manifold. You will also need a coolant drain pan, new coolant, fresh oil and an oil filter, gasket scraper, gasket sealant, and a fuel pressure gauge. A service manual specific to your Challenger model year is critical—it contains torque specifications, bolt locations, and the exact order in which to remove and reinstall components. ProCharger provides an installation guide, but the factory manual prevents costly mistakes.

Set aside a clean, well-lit workspace with room to lay out parts as you remove them. Take photographs or video of the engine bay before you start so you can reference the original routing of hoses, wires, and brackets.

Step-by-step removal of factory components

Begin by disconnecting the negative battery terminal to prevent electrical shorts. Drain the coolant into a pan by opening the radiator drain plug and the lower radiator hose. Remove the serpentine belt by loosening the belt tensioner bolt and sliding the belt off the pulleys. Take a photo of the belt routing diagram on the fan shroud so you remember how to reinstall it later.

Remove the air intake tube, air filter box, and any plastic covers on top of the engine. Disconnect all hoses and wires attached to the intake manifold, including the PCV hose, brake booster vacuum line, coolant bypass hoses, and fuel injector connectors. Label each connector with tape and a marker so you don't mix them up. Remove the bolts holding the intake manifold to the cylinder heads using the torque wrench in reverse order (usually starting from the center and working outward). Lift the manifold away carefully and set it aside.

Remove the radiator by disconnecting the upper and lower hoses, the transmission cooler lines (if equipped), and the fan shroud bolts. Lift the radiator out of the engine bay. Remove the factory fuel rail by disconnecting the fuel line at the fuel pressure regulator, unbolting the rail from the cylinder heads, and unplugging the fuel injector connectors. You will reinstall a new fuel rail with larger injectors as part of the ProCharger kit.

Installing the ProCharger unit and intercooler

Position the ProCharger mounting bracket on the driver's side of the engine bay according to the installation manual. The bracket bolts to the cylinder head and engine block at specific points. Use the torque wrench to tighten all bolts to the specification listed in the ProCharger manual—usually between 25 and 40 foot-pounds depending on bolt size. Bolt the ProCharger unit itself to the mounting bracket, again following the manual's torque sequence.

Install the intercooler, which cools the compressed air before it enters the engine. Most ProCharger kits for the R/T mount the intercooler in front of the radiator or to the side of the engine bay. Bolt the intercooler to its mounting location, then connect the inlet and outlet hoses from the ProCharger to the intercooler using the hose clamps and fittings provided in the kit. Tighten hose clamps firmly but do not over-tighten, as this can crack plastic fittings.

Route the serpentine belt from the crankshaft pulley around the ProCharger pulley, the alternator, the power steering pump, and the water pump, following the routing diagram in the ProCharger manual. The belt size will be different from the factory belt because the ProCharger pulley is larger. Install the new belt and adjust the tensioner so the belt deflects about half an inch when you press on it midway between two pulleys.

Fuel system and engine management upgrades

Install the new fuel injectors that come with the ProCharger kit into the fuel rail. These injectors flow more fuel per minute than the factory injectors and are necessary to support the increased air volume the supercharger provides. Bolt the new fuel rail to the cylinder heads and reconnect all fuel injector connectors, ensuring each connector clicks firmly into place.

Upgrade the fuel pump if your kit requires it. Some ProCharger kits work with the factory fuel pump, but most R/T applications benefit from a higher-capacity pump to maintain fuel pressure under boost. If your kit includes a new pump, you will need to drop the fuel tank, disconnect the factory pump assembly, and install the new one. This is a time-consuming step that many owners have a shop handle.

Connect the ProCharger engine management software to your vehicle's diagnostic port using a laptop and the tuning cable provided in the kit. The software allows you to adjust boost pressure, fuel delivery, and ignition timing. Do not attempt to drive the vehicle or start the engine until the software is installed and the initial baseline tune is loaded. Many owners send the vehicle to a ProCharger-certified tuner at this stage to may support the tune is optimized for their specific engine and fuel octane.

Reassembly, testing, and professional tuning

Reinstall the radiator, reconnect all coolant hoses, and refill the cooling system with fresh coolant. Reconnect the battery negative terminal. Start the engine and check for coolant leaks around the radiator, hoses, and intake manifold gasket. Let the engine idle for five minutes and verify that all gauges read normal. Do not rev the engine or drive the vehicle yet.

Have a ProCharger-certified tuner perform a full engine scan and custom tune. The tuner will adjust the boost curve, fuel pressure, and ignition timing based on your fuel octane (91 or 93 octane makes a difference) and driving goals. This step is not optional—a poor tune can cause engine knock, fuel system problems, or reduced reliability. Expect to pay $500 to $1,500 for professional tuning depending on your location and the tuner's experience.

After tuning, take the vehicle for a test drive at low speeds in a safe area. Listen for any unusual noises, check that the boost gauge reads correctly, and verify that the engine responds smoothly to throttle input. Return to the tuner if you notice hesitation, surging, or any warning lights on the dashboard.

Frequently Asked Questions

Will a ProCharger void my Dodge warranty?

Yes. Any engine modification, including a supercharger, voids the factory powertrain warranty. Dodge will not cover engine or transmission repairs once a ProCharger is installed. Some owners keep their vehicle stock for warranty purposes and install the supercharger after the warranty expires.

How much horsepower does a ProCharger add to an R/T?

A ProCharger typically adds 100 to 150 horsepower and 120 to 160 foot-pounds of torque to a stock 5.7L HEMI R/T, depending on boost level and tuning. Dyno testing at a professional shop will show your specific gains.

Can I install a ProCharger myself if I've never done major engine work?

It is not recommended. The installation requires precise torque specifications, proper hose routing, and knowledge of fuel system safety. A mistake can damage the engine or create a fuel leak. Most first-time installers benefit from having a shop handle the work or at least supervise key steps.

What fuel octane should I use after installing a ProCharger?

Most ProCharger tunes for the R/T are calibrated for 91 or 93 octane fuel. Using lower octane can cause engine knock and reduce performance. Check your tuner's recommendation and use that octane consistently.

How long does the ProCharger installation take at a shop?

Professional shops typically complete a ProCharger installation in 20 to 40 hours of labor, depending on whether additional fuel system work is needed and whether the shop has installed many ProChargers on R/Ts before. Ask for a labor estimate before dropping off your vehicle.