Whipple SUPERCHARGER WK-3500-S1-30 User manual

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 1 of 22
www.whipplesuperchargers.com
WHIPPLE SUPERCHARGER INSTALLATION MANUAL
-RMA-
2015-2023 DODGE HELLCAT, TRACKHAWK, DURANGO, REDEYE
6.2L SUPERCHARGED ENGINE
PART NUMBERS: WK-3500-S1-30, WK-3500-S2-30, WK-3500-S1-32, WK-3500-S2-32,WK-3505-S1-30,
WK-3505-S2-30, WK-3505-S1-32,WK-3505-S2-32, WK-3515-S1-30, WK-3515-S2-30, WK-3515-S1-
32,WK-3515-S2-32, WK-3600-S1-30,WK-3600-S2-30, WK-3600-S1-32, WK-3600-S2-32, WK-3700-
S1-30, WK-3700-S2-30, WK-3700-S1-32, WK-3700-S2-32
WHIPPLE SUPERCHARGERS
3292 NORTH WEBER AVE
FRESNO,CA 93722
TEL [phone]
FAX [phone]
WWW.WHIPPLESUPERCHARGERS.COM
PREMIUM FUEL ONLY (91 OCTANE OR BETTER ALWAYS) RON+MON/2
CALIFORNIA AIR RESCOURCE BOARD EXECUTIVE ORDER #D-231-88
FOR CLOSED COURSE COMPETITION USE ONLY. NOT INTENDED FOR STREET USE. THE SALE, USE, OR
INSTALLATION OF THIS PRODUCT MAY ALSO BE ILLEGAL NATIONWIDE UNDER THE FEDERAL
CLEAN AIR ACT (42 U.S.C. § 7522(A)(3))

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 2 of 22
www.whipplesuperchargers.com
INTRODUCTION
Before beginning installation, we encourage you to read this manual thoroughly before you begin any portion of the installation:
1. Please read the installation manual and verify that all items are present. If you are missing hardware or have any
questions, please contact your dealer or Whipple Superchargers before you start the installation.
2. Premium fuel (US 91 octane) is required to prevent spark-knock/detonation under certain operating conditions. Other
countries must meet US 91 octane standards, RON+MON/2. If fuel of less than 91-octane is present in the
vehicle fuel tank, the tank must be completely drained and refilled with 91 or higher octane to 1/8th of a
tank. The fuel system is returnless, therefore, initial fuel in the system will be low octane. Drain all fuel!
3. Instructions reference LH (Left Hand) and RH (Right Hand) side of vehicle. This is if you’re sitting in driver’s seat facing
forward.
COMPETITION BASED PRODUCT MAY BE USED SOLELY ON VEHICLES USED IN SANCTIONED COMPETITION
WHICH MAY NEVER BE USED UPON A PUBLIC ROAD OR HIGHWAY, UNLESS PERMITTED BY SPECIFIC
REGULATORY EXEMPTION (VISIT THE “EMISSIONS” PAGE AT HTTP://WWW.SEMASAN.COM/EMISSIONS
FOR STATE BY STATE DETAILS.
COMPETITION BASED PRODUCT IS LEGAL IN CALIFORNIA ONLY FOR RACING VEHICLES WHICH MAY
NEVER BE USED, OR REGISTERED OR LICENSED FOR USE, UPON A HIGHWAY.
IT IS THE RESPONSIBILITY OF THE INSTALLER AND/OR USER OF THIS PRODUCT TO ENSURE THAT IT IS
USED IN COMPLIANCE WITH ALL APPLICABLE LAWS AND REGULATIONS.
RECOMMENDED TOOLS AND SUPPLIES
Tools
Torque wrench (1/4”, 3/8”, ½”) Safety glasses, metric wrench set, ¼”, 3/8”, ½” assorted metric socket set, 3/8” assorted
metric allen socket set, T30 torx socket, flat head screw driver, 5/16” nut driver and drain pan (for coolant).
Tie Straps
These will be useful for securing the wiring harness away from the installation area as directed in the instruction manual.
They are inexpensive and will be very handy during installation.
Sealants
Blue Loctite™#242 or equivalent and Red Loctite™ #271 or equivalent. All bolts that need Loctite™ are marked with:
Loctite™ (#242 blue) threads, Loctite™ (#271 red) threads. Thread sealant such as pipe teflon must be used
on all pipe threads.
Chemicals and lubricants
You will need some cleaner/degreaser such as carb cleaner. Motor oil and clear automotive-type grease will be useful as a
lubricant and should be readily available during installation.
Clean Shop Towels
Use these to keep the installation area clean.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 3 of 22
www.whipplesuperchargers.com
WARNING!!
MODIFYING THE SUPERCHARGER OR THE SUPERCHARGER SYSTEM CAN RESULT IN RELIABILITY
OR FAILURES.
WELDING:
Welding onto precision components for Nitrous rails is extremely dangerous and will most likely lead to unwanted
noises and/or failures. The supercharger system is designed and manufactured to very tight tolerances, welding
on the part can cause unwanted distortion. Distortion on any part of the supercharger system can distort in
many other areas and greatly affect the life of the SC. If the product is found to have distortion due to this
modification and this created an issue, this will void the warranty.
NITROUS SPACER PLATES:
Certain spacer plates have improper oring glands, meaning the width and depth of the grooves are not specified
correctly to the 16 orings supplied. This causes severe distortion to the supercharger housing. Never run these
spacer plates with the supplied orings. It is recommended that you run two sets of Cometic/Whipple AFM
gaskets. Any plate should be validated flat with flatness checked prior. Flatness should be less than .002” per
12” in length. Ensure no bolts create interference with the supercharger housing.
MODIFIED MOTORS:
Modified motors can create another issue. Improper decking of the heads or block could create uneven surfaces
between manifold mounting flanges. Ensure flatness is less than .002” per 12” in length from front to back and
at no time are the head surfaces within .003” of each other (bank to bank).
PORTING:
Disassembling and modifying the supercharger can create multiple issues and can void warranty if the failure is
caused by the modifications. The only approved porting service is from Whipple Superchargers or Kong
Performance.
GASKETS:
Whipple has found that the only two options for gaskets are OEM stock stamped steel gaskets (with plastic
retainer removed) OR the Cometic AFM coated metal gaskets. The AFM gasket is A chemically blown;
compounded nitrile synthetic rubber bonded to an aluminum core with a temperature resistance of over 205*
F. AFM material has an 85% recovery while maintaining strong torque retention. AFM does not require sealants
or re-torquing.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 4 of 22
www.whipplesuperchargers.com
SAFETY PRECAUTIONS
CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS AND WARNINGS BEFORE PROCEEDING WITH
THE INSTALLATION!
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual
performing the kit installation. Improper installation due to the failure to correctly follow these instructions could cause
personally injury or death. Read each step of the installation manual carefully before starting the installation.
•Always wear safety glasses for eye protection.
•Place the ignition switch in the off position.
•Always apply the parking brake when working on vehicle.
•Block the front and rear tire surfaces to prevent unexpected vehicle movement.
•Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
•Do not smoke or use flammable items near or around fuel system.
•Use chemicals and cleaners only in well-ventilated areas.
•Batteries can produce explosive hydrogen gas which can cause personal injury. Do not allow flames, sparks or
flammable sources to come near the battery.
•Keep hands and any other objects away from the radiator fan blades.
•Keep yourself and your clothing away from moving parts when the engine is running.
•Do not wear loose clothing or jewelry that can be caught in rotating or moving parts.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 5 of 22
www.whipplesuperchargers.com
COMMON ABBREVIATIONS
ABBREVIATION
DESCRIPTION
DTC
Diagnostic Trouble Code
ECT
Engine Coolant Temperature
EGR
Exhaust Gas Recirculation
ETC
Electronic Throttle Control
EVAP
Evaporative emissions system
FHSCS
Flat Head Socket Cap Screw
HHFCS
Hex Head Flanged Cap Screw
IAT
Inlet Air Temperature
IC
Intercooler
ID
Internal Diameter
LB-IN
Pound-force inch
LB-FT
Pound-force foot
LH
Left Hand Side (from driver seat)
LTR
Low temp radiator
MAF
Mass Air Flow
MAP
Manifold Absolute Pressure
MY
Model Year
OBD
On Board Diagnostics
OD
Outside Diameter
PCV
Positive Crankcase Ventilation
PSI
Pound per Square Inch
RH
Right Hand Side (from driver seat)
SC
Supercharger
SHCS
Socket Head Cap Screw
TPS
Throttle Pressure Sensor
TRQ
Torque
Symbol Key
Throughout this installation guide you will see the following symbols used:
NOTE
Used to indicate tips and information to aid in installation, maintenance, or use of the supercharger.
!! CAUTION !!
Used to indicate precautions that must be taken to avoid damage to the supercharger
and associated components.
WARNING!!
Used to indicate precautions that must be taken to avoid bodily injury as well as
damage to the supercharger and associated components.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 6 of 22
www.whipplesuperchargers.com
NOTICE
Installation of Whipple Supercharger products signifies that you have read this document and have agreed to the
terms stated within.
It’s the purchaser’s responsibility to follow all installation instruction guidelines and safety procedures supplied with
the product as it’s received by the purchaser to determine the compatibility of the product with the vehicle or the
device the purchaser intends to install the product on.
Whipple Superchargers assumes no responsibility for damages occurring from accident, misuse, abuse, improper
installation, improper operation, lack of reasonable care or all previously stated reasons resulting from
incompatibility with other manufacturer’s products.
There are no warranties expressed or implied for engine failure or damage to the vehicle in any way, loss of use or
inconvenience or labor reimbursement. This includes merchantability and fitness.
 NEVER SMOKE DURING THE INSTALLATION OF THE SC, THERE WILL
BE FLAMMABLE FUMES AND LIQUID AROUND THE VEHICLE
SUPERCHARGER INSTALLATION INSTRUCTIONS
It is strongly recommended that you read through this guide before you begin installing the Whipple Supercharger.
WARNING!! Batteries normally produce explosive gases. Therefore, do not allow flames, sparks or
lighted substances to come near the battery. When charging or working near a battery, always shield your
face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in
personal injury.
WARNING!! Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin,
eyes or clothing. Also, shield your eyes when working near the battery to protect against possible splashing
of the acid solution. In case of acid contact with the skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately.
Failure to follow these instructions may result in personal injury.
1. Install the stock SIP TMAP sensor from the inlet of the supercharger to the new SC inlet. Secure using the supplied
(1x) 6mm x 14mm HHFCS. Torque to 88 in-lbs using 10mm socket.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 7 of 22
www.whipplesuperchargers.com
2. Install the post SC, post IC TMAP sensors (2x) in the back of the manifold using the supplied (2x) 6mm x 14mm
HHFCS, torque to 88 in-lbs using 10mm socket.
3. Install the Post SC, pre IC TMAP to the SC lid as shown. Secure using the supplied (1x) 6mm x 14mm HHFCS. Torque
to 88 in-lbs using 10mm socket.
4. Install the stock IC temp sensor, using light amount of thread sealant to the Whipple lid port.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 8 of 22
www.whipplesuperchargers.com
5. (Stock fuel rails) Apply grease to both orings on injectors. Reinstall factory locking clip to rail and injector to secure
to rail (*failure to do so could cause running issues). Mount stock fuel rail to supercharger using supplied (4x)
6mm x 14mm SHCS, apply light amount of Blue Loctite #243 to threads. Torque to 88 in-lbs using 5mm allen
socket.
6. (Billet fuel rails) Apply grease to both orings on injectors. Install supplied locking brackets to fuel injectors (*failure
to do so will cause running issues). Mount billet fuel rails to supercharger using supplied (4x) 6mm x 35mm
SHCS, apply light amount of Blue Loctite #243 to threads (PN# YH06-WPL83-0054 is passenger side). Torque to
88 in-lbs using 5mm allen socket. *NOTE: For stock injectors only.
7. (Billet fuel rails) Install the (2x) #2-115 Viton orings to male fitting. Apply grease to oring and slide through female
fitting. Install (1x) #3-908 Viton oring to fitting (shown with red arrow). Install fitting to the driver side fuel rail (rear).
Install the supplied fuel PSI sensor to fuel rail adapter using (1x) #2-011 oring. Reconnect fuel PSI sensor electrical
connector.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 9 of 22
www.whipplesuperchargers.com
8. (Billet fuel rails) Install the (2x) #2-115 Viton orings to male fitting. Apply grease to oring and slide through female
fitting. Install (1x) #3-908 Viton oring to fitting (shown with red arrow). Install banjo fitting to the longer fuel rail
(PN# YH06-WPL83-0054). Use light amount of grease on oring. Install fitting to the RH side rear port.
9. (Billet fuel rails) Install supplied -8 ORB plugs to front fuel rail ports, with #3-908 Viton oring. Use light amount of
grease on oring. Install supplied ½” cross over hose at the rear fittings.
10. Install the supplied -6 ORB with oring to 15.82mm fitting to RH port on SC inlet. Use light amount of grease on oring
for ease of installation.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 10 of 22
www.whipplesuperchargers.com
11. Install the supplied -6 ORB with oring to 9.89mm fitting to LH port on SC inlet. Use light amount of grease on oring
for ease of installation.
12. Install the supplied -6 ORB with oring to 3/8” barb fitting to LH top port on SC inlet. Use light amount of grease on
oring for ease of installation.
13. Make sure the supercharger is on a flat surface. Remove the oil fill plug using an 8mm allen socket.
•Fill the compressor to the MIDDLE of the sight glass (4.0 FL/OZ). Rock compressor back and forth. Then
spin compressor/rotors by the pulley so the oil fills the bearings. NEVER OVER FILL THE SUPERCHARGER!
•Apply light amount of grease to oil fill plug oring, reinstall. Torque to 140 lbs-in.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 11 of 22
www.whipplesuperchargers.com
14. Using the supplied gasket set (stock Hellcat or Cometic AFM ONLY), install supercharger assembly to engine.
Use the supplied (10x) 8mm x 30mm HHFCS bolts to locate SC in place. Lightly run bolts down hand tight DO NOT
TORQUE at this time. WARNING: DO NOT RUN PAPER GASKETS! STOCK OR WHIPPLE/COMETIC AFM
TYPE GASKETS ONLY!
15. Install the supplied (1x) 10mm x 25 SHCS bolt to front support. Lightly torque to 42 in-lbs only to slide SC
forward.
16. Using a 13mm socket, torque the supercharger assembly to cylinder heads in the following torque pattern, in the
following sequence.
•First tighten all bolts, using the sequence, to 4 ft-lbs.
•Next tighten all bolts, using the sequence, to 11 ft-lbs.
•Final pass, using the sequence, to 16 ft-lbs.
6
2
4
10
3
1
5
9
FRONT
78

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 12 of 22
www.whipplesuperchargers.com
17. Torque the 10mm x 25mm HHFCS bolt you previously installed. Use a 16mm socket wrench. Torque to 30 ft-lbs.
18. Install the supplied molded rubber oring to the supercharger oring groove.
19. Install supercharger pulley using the supplied (5x) 6mm x 14mm SHCS. Secure bolts hand tight. Install supplied SC
belt in stock routing, by releasing tension on tensioner using a 15mm socket. Torque supercharger pulley bolts to
130 in-lbs using 5mm allen socket.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 13 of 22
www.whipplesuperchargers.com
20. Install the stock EVAP hose, rubber 90deg to the 3/8” fitting you previously installed.
21. Connect the stock PCV hose to 15.82mm fitting previously installed.
22. Connect the stock bracket booster hose to the 9.89mm fitting previously installed.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 14 of 22
www.whipplesuperchargers.com
23. Apply heavy amount of grease to bypass oring. Set supercharger to lid gasket on SC. Carefully set lid in place, apply
pressure to front bypass to slide through oring (NOTE: You can see oring from inlet, ensure oring never drags or
pinches). Using the (16) 6mm x 25mm SHCS, install all hand tight. Once all hand tight. Torque as followed:
•First pass, using the sequence, 75 in-lbs.
•Second pass, using the sequence, 90 in-lbs.
•Third pass, using the sequence, 112 in-lbs.
7
4
2
3
13
15 16
8
14
6
5
1
10
9
1211
24. Connect the passenger side TMAP sensor connector (front passenger side of engine) pre-SC, inlet pressure sensor
(#1) connector 4-way (1 = blue/green, 2= blue/tan, 3 = yellow/red, 4 = purple). Route to the back of the intake
manifold for later installation at the SC inlet.
25. Install the supplied 22” MAP sensor extension to the passenger side (RH) MAP sensor connector (from front
passenger side of engine) post SC, post IC (#4) connector 4-way (1 = blue/green, 2= blue/green, 3 = yellow/red,
4 = brown/blue). Route to the back of the intake manifold and connect to the passenger side (RH) TMAP sensor.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 15 of 22
www.whipplesuperchargers.com
26. Install the supplied 18” MAP sensor harness to the post SC, pre-IC MAP sensor connector (back driver side of engine)
(#2) connector 4-way (1 =blue/green, 2 = purple/blue, 3 = yellow/red, 4 = purple/yellow). Route to the front of
engine and secure to previously installed TMAP in SC lid.
27. Lay supplied pigtail harness to LH/Driver side of supercharger. Connect the stock driver side stock TMAP sensor
connector to pigtail. Plug in 3” pigtail to (LH) back of sc (back driver side of engine) post SC, post IC (#3) connector
4-way (1 =blue/green, 2 = blue/light blue, 3 = yellow/red, 4 = brown/pink). Connect female pigtail to stock to
intermediate TMAP male connector. Connect end of pigtail to the (intermediate) TMAP sensor you previously installed
to bottom of lid (next to bypass).

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 16 of 22
www.whipplesuperchargers.com
28. Install the supplied 22” IC temp sensor extension to stock 2-way connector by cutting the stock connector off 3”
from end. Install pigtail using the supplied butt connectors, crimp together, then slide heat shrink over and shrink.
Route to front of engine and connect to previously installed temp sensor.
29. Assemble the intercooler hoses. For inlet (blue), take (2) of the #3103182 hose, face the short 90deg ends towards
each other. Secure to tee fitting using supplied pinch clamps. Assemble hose #3103184 to tee fitting, secure with
pinch clamp. For outlet (red), take (2) of the #3103182 hose, face the short 90deg ends towards each other. Secure
to tee fitting using supplied pinch clamps. Assemble hose #3103183 to tee fitting, secure with pinch clamp.
30. Install the supplied intercooler inlet ¾” ID hose (#3103184) to the factory inlet aluminum tubing, connect to factory
line using stock pinch clamp. Connect the (2) inlet hoses to the rear most fittings on each side of the supercharger
lid. Secure with the supplied black worm clamps on both inlet fittings.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 17 of 22
www.whipplesuperchargers.com
31. Install the supplied intercooler outlet ¾” ID hose (#3103183) the factory Y fitting using stock pinch clamp. Connect
the (2) outlet hoses to the forward most fittings on each side of the supercharger lid. Secure with the supplied worm
clamps on both outlet fittings.
32. (Stock throttle body) Install the stock TB adapter to the supercharger inlet using the supplied TB adapter, supplied
gasket and the (4x) 6mm x 25mm FHCS. Torque to 75 in-lbs. Install the stock throttle body oring to TB adapter,
then install the throttle body using the (4x) 6mm x 35mm HHFCS bolts. Use Blue Loctite #243 on threads, torque
to 88 in-lbs using a 10mm socket.
33. (Billet throttle body) Install supplied TB oring to TB, use light amount of grease to hold in place. Install the billet
throttle body to the SC inlet using the (4x) 6mm x 25mm SHCS bolts. Use Blue Loctite #243 on threads, torque
to 88 in-lbs using a 5mm allen socket.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 18 of 22
www.whipplesuperchargers.com
34. Reconnect the throttle body 6-way connector. Reinstall Christmas tree retainer to secure harness.
35. Install supplied rubber grommet to airbox from the inside. Install the supplied air tube, using a flat blade screwdriver
to pull grommet lip away from air tube. Once in position, push edge of grommet into position. Install air filter to end
and secure with stock clamp. Secure both ends of silicone hose couplers to air tube and throttle body. Secure airbox
to factory mount with stock bolt. Install supplied rubber airbox seal to top of airbox.
36. Couple air tube to throttle body using supplied silicone hose.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 19 of 22
www.whipplesuperchargers.com
37. Reinstall the wiper motor assembly. Reinstall the plastic wiper motor assembly shielding.
38. Reinstall the (4) factory fasteners to the cowl cross brace using a 13mm socket (2 per side). Before tightening, push
the brace back as far as possible for added supercharger clearance, 3mm clearance is required. If adequate clearance
is not found (3mm), you will need to loosen the subframe mounts and push motor forward.
39. Reinstall the (6x) push pins in the cowl cross brace.
40. Reinstall the plastic cowling to the vehicle by installing the (8) push pins you previously removed. Make sure the tabs
on each side lock in place.
41. Reinstall the cabin air filter cover to the plastic cowling.

Installation Manual: Hellcat G5 Upgrade_R16_RMA
Last Updated: September 18th, 2023
Page 20 of 22
www.whipplesuperchargers.com
42. Reinstall the cabin air filter cover to the plastic cowling. Reinstall the windshield wipers using a 15mm socket. Use
the factory (2) marks to center the wipers. Reinstall factory plastic cover.
43. Attach the negative cable to the battery and tighten using a 10mm wrench.
44. Refill the intercooler reservoir with factory purple intercooler fluid #68163848AA and distilled water (50/50). 
WARNING!! NEVER USE TAP WATER, THIS WILL CAUSE CORRISION IN THE SYSTEM.
45. Turn the Ignition key on, DO NOT START THE ENGINE (This will turn ON the fuel pump for 2 seconds) Inspect for
ANY fuel leaks, correct as required.
46. Start the vehicle or use a Tazer tool to toggle the intercooler pump to on. Fill the intercooler reservoir as needed.
Squeeze the intercooler inlet/outlet lines at the same time, while the reservoir cap is off, to help burp the system.
After 2 minutes of running, shut off and let cool, repeat at least 3 times prior to running engine with any load.
WARNING! Failure to burp properly could lead to engine damage.
47. Before driving, make SURE you have 91 [(RON+MON)/2] or higher-octane fuel in the system. NOT ½ tank of 89 and
½ tank of 91, ALL 91 or better fuel in the system.