Installing ProCharger’s intercooled supercharger system for the S550
By Steve Turner
Photos courtesy of Erik Radzins/ProCharger
Since the days of the original pushrod 5.0-liter engine, superchargers and Mustangs have been fast friends. One of the companies that have fostered that friendship is ProCharger. As the company that brought intercooled supercharging into the mainstream and has innovated other technologies—like self-contained and programmable-ratio superchargers—it’s no surprise that ProCharger is now offering supercharger systems for the 2015 Mustang GT
The owner of this Performance Pack-equipped, Triple Yellow 2015 Mustang GT is Joseph Rees. The owner of the garage the install was performed in is in the business of creating faux stone finishes from concrete, and business is good. Joining Joeseph’s GT in the this shot is the garage-owner’s work truck, which is a Raptor supercharged with ProCharger’s programmable-ratio i-1 supercharger. We’ll get into the details on this truck another time.
The ProCharger S550 HO kit includes everything you need to perform the install, right down to a preloaded tune on a DiabloSport handheld tuner. You can also opt for a tuner kit and leave out the tuner, but you’ll obviously need to work with someone for a custom tune to ensure it safely runs to its full potential.
“ProCharger wanted to start with a ‘clean slate’ on this system, and not just adapt something from the previous body style to work, as others have,†Erik Radzins, who handles both calibrations and social media at ProCharger, explained. “Virtually every single item changes from the previous system. About the only thing they share is the fuel injector.”
“This clean-slate approach helped the customer in many ways. For starters it created the HO System that uses the shared drive belt of the engine, and used a sized appropriate intercooler that would fit the needs of most 2015 customers,†he added. “This cuts down on costs of the system, and will still allow for big power numbers of over 700 rear-wheel horsepower to be achieved easily. We didn’t want to have to force a customer into buying a system that was overkill for what they needed. If they are looking for over 800 horsepower, they can purchase or upgrade to our Stage 2 system.â€
If the idea of installing a supercharger system on your 2015 Mustang is intimidating, there’s no need to be scared of the ProCharger for the 2015 Mustang. These are all the tools you need to install the kit. ProCharger says the installation time is about five hours, but if you have a bit of mechanical acumen, it will likely go on even quicker.
We’ve been anxious to see how the latest system mates with the new Mustang, and when Erik offered to install the HO system in a customer’s garage on a totally stock car, we jumped at the chance to share it with you. This system is based on ProCharger’s stalwart P-1SC supercharger. The SC stands for self-contained, so there’s no tapping of the oil pan to lubricate the unit. The system is a true bolt-on.
“Installation is easy! That is the only way to describe it, just look at the tools involved and its obvious that if a guy can change his own oil and spark plugs, he can install this blower kit,†Erik said. “Taking off the front bumper is the hardest part, and even that just takes a few moments.â€
Start by removing the front fascia, which is held on by numerous 5.5mm and 8mm fasteners. These are covered extensively in the ProCharger instructions, but don’t forget to pull back the fender liner to access the hidden bolt on each side that retains this top corner of the fascia. If you don’t get these you will break the clip on the fascia. You’ll also need to unplug the wiring for the foglamps before you free the fascia.
“We have the easiest kit to bolt on a car. We make crazy good power numbers with no heat soak and the system is a bargain,†he added. “Nothing is even close, price-wise.â€
Of course, with the kit installed the car was tested on ProCharger’s in-house Mustang chassis dyno. Running readily available pump gas, which isn’t the greatest mixture during the winter in Kansas City, the car put down 530 rear-wheel horsepower with nothing more than the supercharger and the preloaded tune. With that calibration, the numbers compare favorably with the 2011-2014 Coyote with a ProCharger HO system.
“The numbers on a 100-percent stock car are a tiny, tiny bit less per pound of boost (no matter what system you have) due to the changes in the exhaust, intake manifold and cams in the new Coyote motor. However with custom tuning, and exhaust changes, people are getting crazy good numbers out of the systems on just 8 psi.â€
Next you’ll want to clear some of the stock parts out of the way. Unbolt the strut-tower brace (if you car is so equipped), pop off the engine cover, take off the stock airbox, and remove the factory coolant tank. You’ll want to drain the coolant into a clean receptacle so you can replenish the new ProCharger tank as you wrap up the installation.
The HO kit is quite affordable, for a modern-car power adder, at around $5,600, and the tuner kit is a bit less for those that bring their own supporting mods to the table. If you want more power, you can obviously step up to the Stage 2 kit, which is good for 540 to 600 rear-wheel horsepower. This system offers numerous upgrades, including a dedicated eight-rib belt drive and an intercooler that is 75 percent larger.
“Power numbers from the HO system have been right in line with the system’s design. Customers are already making over 700 rear-wheel horsepower with D-1SCs and mild boost levels. Surely it won’t be long before we see someone put an F-1 on an HO system and raise that bar even higher. The Stage 2 system was really designed for those that are wanting to play in the 800 horsepower range and beyond.â€
A few of ProCharger dealers, including Blow-By Racing have recorded impressive numbers with the HO kit and custom tuning. We hope to circle back on this car, as Joseph Rees wants to upgrade his 2015 and increase the boost. In the mean time, follow along as Erik installs this system and check out the results.
The ProCharger system is complete right down to a set of larger fuel injectors. You’ll need to put a rag under the connection to soak up any fuel that leaks out before releasing the connector. Then you can unbolt the rails and remove the injectors and rails as a single assembly. Then put the rails on your workbench and swap out the injectors. With the new 52 lb/hr injectors in place, you can reverse the steps and reinstall the rails.With the factory airbox and induction hose out of the way, you have free access to the thermostat housing. The ProCharger system doesn’t require any modifications to the coolant hoses or cooling fans, but you do need to swap out the factory thermostat housing connector’s straight fitting for ProCharger’s right-angle fitting. This fitting adjusts the hose routing enough to create clearance for the supercharger.The kit requires rerouting the PCV system to mate up with the new induction.The ProCharger bracketry uses factory mounting holes on the timing cover. Just follow the detailed instructions to install the hex stand-offs and idler pulleys. Do the same with the ProCharger adjustable tensioner on the passenger side as well.Install with the stand-offs in place, you can install the ProCharger main bracket and idlers.With the bracket in place, you can install the P-1SC blower. However, you will first need to install the blower oil drain hose and fill the blower with lubricant. The blowers are shipped dry, and you’ll damage one if you run it without lube. Likewise, you will eventually need to drain the used lubricant and replace it with fresh oil. That’s where that drain hose will come in handy.With the blower bolted up and the tensioner installed, you can install the longer supplied supercharger belt. The HO kit uses a six-rib belt just like the factory FEAD, and it can be serviced without removing the supercharger or bracket.Key to any ProCharger system in the intercooler. There is ample room in the S550 to mount an intercooler, and you can see ProCharger takes advantage of this space. The sheetmetal unit bolts to the back of the factory bumper. As you can see here, you’ll need to relocate the factory mass air sensor from the inlet tube to the passenger side of the ProCharger intercooler. Use the supplied extension harness to re-connect the sensor to the factory wiring.After bolting up the blower and intercooler, you can plumb the air path from the inlet through the intercooler and out to the throttle body.It’s also time to plumb the ProCharger Proflow Surge Valve and route the vacuum line that actuates it up to the intake manifold.To pick up vacuum for the surge valve, you need to install the supplied vacuum manifold and pick up a vacuum signal at the throttle body. The small fitting feeds the surge valve.If you are regular reader, you know that ProCharger also offers this coolant tank a la carte for those that simply want to ditch the stock bubble tank. In this instance, the tank not only looks great, but it opens up room for the ample ProCharger discharge tubing.After installing the ProCharger hardware, you can reinstall the fascia. The only clue of your S550’s newfound power is that aluminum intercooler beaming behind the grille.The finished install looks nearly factory with the optional black finish on the supercharger. The engine cover goes back on unaltered, and the strut-tower brace bolts right back on.If you order the complete system with ProCharger’s preloaded tuning, you’ll receive a DiabloSport handheld tuner with that calibration onboard. It’s easy to flash the new calibration using the OBD-II port, just follow the directions and you’ll be ready to run in no time. If you opt for a tuner kit, you’ll need to have a pro create a custom tune for your car.All back together, this Triple Yellow beauty is now packing a lot more performance under its hood.In baseline form, the this manual-trans GT put down 377.83 horsepower and 349.32 lb-ft of torque on a typically conservative Mustang chassis dyno. With the addition of the ProCharger HO system, the gains takes off around 3,000 rpm and sing all the way until the factory rev limited is invoked. It put down 530.79 horsepower and 426.82 lb-ft of torque on the preloaded ProCharger tune and pump gas. That made for peak-to-peak gains of 152.96 horsepower and 77.5 lb-ft of torque at the wheels.Taking a look at the sampling of the data in chart form shows what you might expect from a centrifugal supercharger. Both the boost and power scale in accordance with rpm, which makes these cars quite tractable and easy to launch at the drag strip. Almost as impressive are the three-digit torque gains in the 6,000-rpm range. Keep in mind these solid gains were produced on a completely stock car burning pump gas. Clearly there is more to be gained with increased boost, timing, and a free-flowing exhaust.
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