I am interested to hear from anyone who has installed an intercooler on their IDI regarding how they ran the ducts and how they modified the grill area to accommodate the intercooler. I read a web article about adapting a late model PSD intercooler to fit a non-intercooled early PSD engine, but the existing turbo ducts are quite different from the Banks Sidewinder turbo'd IDI that I am working with. I was ~supposed to get all of the PSD pipes and silicone couplers with the intercooler that I bought, but it didn't happen... I just got the 7.3L intercooler unit, so (if I can even make it work) I will be starting from scratch.

There is definitely not enough room in between my AC condenser and the grill insert so I am going to have to do something there... (oh, I am working with a 1986 bullnose truck BTW). I am kicking myself for not picking up the nice, thin billet grill I saw at the JY a while back, I just think they look "generic" and prefer my '80-'81 style factory insert. Now it looks like I might have to cut my factory grill insert back on the inside, and see if there is any way to move the radiator and AC condenser toward the engine. I found the thread where Oreocreaming posted pics of his 6.0 intercooler install on his '91, but he has the later front clip and seems like he has a lot more room. Then there's the hood latch support bar that's going to need changed. Surely I'm not the first one to do this... if anyone has already figured this out it could save me some time!

One last question... on the web article for the early PSD intercooler install, they ran a hose with a check valve to the exhaust pipe (drilled right into the hump over the rear axle) to vent the crank case so oil would not contaminate the intercooler. Is this going to be a problem with the IDI and the location of the CDR valve in the banks inlet housing? I don't think the IDI Sidewinder units were intended to be intercooled, as Banks does not make one for them. Just wondering if you folks with intercooled IDI's had to do anything different with your CDR to keep oil out of your intercoolers???

Thanks for any help you can give... I thought this was going to be a matter of tweaking a pipe or a coupling here or there to make it fit, but (as always) it is turning out to be much more complicated and involved than I thought! Hopefully it will be worth the effort.

 

have a read....
Let's Talk Intercoolers

 

I installed a '99 PSD intercooler on my 85 IDI. There is not enough room to mount the intercooler and the ac condenser with the ac condenser in its current location. I removed my AC condenser (doesn't get hot enough for long enough around here) and I couldn't get the intercooler back toward the engine far enough to install the valance. You will have to cut the hood latch support section that ties into the radiator core support leaving just the latch. I also had to shave the back of the grill down with a dremel. You will have to create larger holes in the core support/radiator mounting brackets to allow the passage of the Inet and Outlet on the intercooler. I have pics but not able to attach at this time. Shoot me a pm with your email and I will send some pics if you like. Oh I have a first gen banks turbo.

 

https://www.ford-trucks.com/forums/1...l#post10674174 For Squeaky_wheel.

 

Oh WOW!!! I really wish I had read this BEFORE I bought the PSD intercooler!!! I don't think I would have gone there... not that I am afraid of a difficult modification but I'm not likin' the downsides of intercooling. More specifically, I live in Arizona and have NO INTENTIONS of ditching my AC. I've suffered heat stroke once, and once is plenty for one lifetime. Even if I found a way to squeeze all three radiators in there, I don't want to risk overheating the engine while pulling a grade in 120* F desert heat. Whatever I'd gain, it's not worth it.

Anyone looking for a PSD intercooler?

 

Price and shipping to 83687? Haha I want one but if its for a 7.3 I can get one local for $80 the 6.0 ic is almost tripple that and I'm not sure it would fit

 

In reality overheating shouldn't be a big worry all new pickups and most older and newer semis have them as well, pretty standard equiptment for diesels.

 

Why is it that nobody is using an aftermarket version for an OBS Powerstroke?
Seems like it should be made to fit the 92-94 trucks and easily modified for the older trucks.

Jason

 

I am interested in installing an intercooler on my IDI as well. I have an ATS kit with the Garrett turbo. My biggest question is how to install the piping. Do I just turn the intake hat or what?

-Troy

 

here is one way, try searching. you might find more

https://www.ford-trucks.com/forums/1...tercooler.html

 

My supercharged car has a Water-to-Air intercooler with a small Heat Exchanger under the radiator. The supercharger is electrically clutched and kicks in "on-demand" from the ECU. Top boost is 20 PSI and and without water flowing thru the intercooler circuit, IAT's quickly reach over 195*. I've made a few modifications to the stock system (since I over boost the supercharger by 18%) and my IAT's never reach above 150* @ 170MPH.

Back to Turbo IDI trucks...

I too have been considering adding an intercooler - and with what I've experienced with water-to-air systems - this is how I would go.

Seeing how my truck does not make much boost at low RPM or when cruzing at highway speeds, I think this little gem of an intercooler (wrapped in some of my space age heat-shield) mounted over the engine in place of the black BANKS expansion tank will do the trick.




Then add a small heat exchanger under or in front the radiator





Some silicone tubing to route the air from the Turbo to the IC and from the IC to the intake manifold.

Some hose to route the water from the IC to HE. Add a small tank to add water and bleed air and small 12V pump. I found small boat pumps work well, have great lift, can handle hot water (but the water in my car's HE never gets so hot I can't touch it) and last a long time.

Might even power the pump with a relay set from a IAT temp gauge so not to run water when not needed.
<O</O
Easier to route water hoses and the entire system would cost about the same, with a much less volume and routing for the boost air.

What do you think?

 

Thanks 91dirtydiesel. That was exactly what I was looking for.

 

I think it would work fine for most of the IDI crowd. Until a guy gets to pumping boost over 20 PSI along with all the other engine and fuel delivery work. Until the air to air systems came out, big trucks used water cooled after coolers.