ZZP 3800 Full Stack 2.25" Intercooler System

• 3 piece pre-sealed aluminum core
• Dual pass front mount heat exchanges
• Intercooler Pump
• 2 Garlock supercharger gaskets
• 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 full stack 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 (not included, found here) 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 
• Stock EGR function
• 3/4" lines and fittings
• New design outperforms 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 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.

CLICK HERE for Digital Install Instructions

CLICK HERE for Digital Install Instructions - Intercooler pump wiring. 

UPS Shipping Only.

Fitment note: Has been used in some Holden/Australian applications but we cannot confirm full fitment and functionality.