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Ram Charged: Installing a Procharger on a Ram 2500

Ram Charged

Jun 27, 2019
The art of superchargers has come a long way in the past several years. Gone are the days of cutting holes in the hood and strapping a potential time bomb to your long-block. Today's superchargers are pre-tuned to work with your factory configuration and come with all the necessary parts to make installation easy and performance flawless. They produce boost that's compatible with your factory pistons and other internal components, so you can realistically see 100hp gains on almost any engine throughout its natural life span. One of the companies at the forefront of making superchargers accessible to just about anyone is Procharger. The company has setups for all the popular trucks, with kits going back 20 years. It is also among the first to develop systems for new vehicles as body styles and engine configurations are updated, so you can outfit your truck as soon as you purchase it.
Recently, we chose to outfit a well-equipped '18 Ram 2500 Power Wagon with a Procharger setup. This High Output Intercooled System fits '14-and-up Dodge Ram 2500 and 3500 6.4Ls and is good for gains as high as 150 hp and 100 lb-ft of torque at the wheels. Follow along as we install the entire system, including our Power Wagon's intercooler. Then see what happens when we put it on the dyno to get you some real-world numbers. Check out procharger.com to see how you can add 100 hp to your truck.
Photo 2/32   |   The first thing we did was put our '18 Ram 2500 Power Wagon on the chassis dyno for some base numbers. It made a respectable 287 hp and 314 lb-ft of torque.
Photo 3/32   |   Let the disassembly begin! We're going to have to gloss over a few things (there are about 150 steps in the official instructions), but rest assured those directions are broken down into simple, easy-to-understand steps so someone with moderate experience can knock this kit out! The engine cover is removed first, followed by the air temperature sensor and the PCV hose.
Photo 4/32   |   Next the factory airbox was removed. First, the lid was removed, then an air line was detached so the base could come out.
Photo 5/32   |   Now the radiator shroud was removed, providing access to the bolts that hold the grille shell to the core support.
Photo 6/32   |   Soon, the grille was popped out of the way. The side and lower shrouds were the next to go.
Photo 7/32   |   Our factory ECU was removed, unlocked, and reprogramed with the Procharger tune.
Photo 8/32   |   The installation begins with the Procharger main bracket.
Photo 9/32   |   With the serpentine belt and a few bolts removed and a series of spacers and replacement bolts added, the new bracket is locked in place.
Photo 10/32   |   With the main bracket in place, the Procharger unit is checked for the best approach to set it in place and line up the holes for the bolts.
Photo 11/32   |   A few seconds later, we set the unit in place.
Photo 12/32   |   Soon, the unit was bolted into place and we were moving on.
Photo 13/32   |   Before we forgot about it, we replaced the spark plugs with a set that was one heat ranger colder than stock and gapped the plugs to .035 thousandths.
Photo 14/32   |   Moving to the fuel system, we pulled the fuel pump fuse and cranked the engine to depressurize the system, then we disconnected the wiring harness and unbolted the fuel rails. The factory injectors were then removed from the rails.
Photo 15/32   |   The new injectors are then installed using synthetic injector O-ring lube along the way.
Photo 16/32   |   Then the fuel rails are returned to position and the harness is reattached.
Photo 17/32   |   Another mod is to remove the crank pulley bolt and install a jig in its place, which enables a straight hole to be drilled through the pulley and harmonic balancer, which is then filled with a steel dowel. We reinstalled the serpentine belt, too.
Photo 18/32   |   Upper and lower mounts for the Procharger intercooler are supplied for Ram models with or without a winch, which we thought was pretty cool. We picked the appropriate parts and bolted it in place.
Photo 19/32   |   A replacement window washer tank is supplied to alleviate some clearance issues with the intercooler and plumbing. It was installed next.
Photo 20/32   |   There are a lot of pieces to plumb the intercooler, but there are clearly marked diagrams in the instructions, and only a little trimming required. We started on the intercooler side of the core support.
Photo 21/32   |   Next, we plumbed down from the throttle body.
Photo 22/32   |   It's a tight squeeze to get the inlet tube into place.
Photo 23/32   |   But once you get it situated correctly, it slides right on.
Photo 24/32   |   We snugged this one in place before fitting the rest of the plumbing in place.
Photo 25/32   |   Before we went any further, we filled the Procharger with the supplied oil.
Photo 26/32   |   The Proflow assembly was installed next—also known as a surge or bypass valve and a very important feature to the system.
Photo 27/32   |   The vacuum manifold for the Proflow valve was installed in the vacuum hose going to the EVAP canister solenoid on the passenger side of the manifold.
Photo 28/32   |   There were a couple of areas of the grille shell that required trimming before it was reinstalled.
Photo 29/32   |   At this point, the engine cover was reattached, the ECM was reinstalled with the Procharger tune, and we were headed back to the dyno.
Photo 30/32   |   After numerous safety checks and some fine tuning, we were ready to make a proper pull to see what the big Hemi could do.
Photo 31/32   |   We were pretty stoked with the results: 441 hp and 417 lb-ft of torque! That's a gain of 154 ponies and 103 lb-ft! Not bad for a day's work on an otherwise stock engine. And don't confuse these numbers with "at the crank" numbers other people throw out. This is real horsepower hitting the pavement!
Photo 32/32   |   The driveability and raw power the intercooled Procharger system provides make the Power Wagon worthy of its moniker. To see what Procharger makes for your truck, head over to procharger.com!

Sources

ProCharger
Lenexa, KS
913-338-2886
http://www.procharger.com

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