Intercooler installation
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Postmaster
Joined: Nov 2008
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From: Buckley, WA
Intercooler installation
Picked up a 99-03 7.3l psd aluminum intercooler of eBay for 150 shipped,
On my 91 7.3l I have the ats 093 turbo kit....there is no way to make the snail hat work without having pipes crossing all over the place....so I puchased one of the intakes racinndrummin makes for the idis (very good price BTW) here is a pic of that
To make the IC fit I had to cut the center core support/trim out, trim part of the grille mounts, cut/bend the bottom corners near the radiator, cut a little bit of the fan should away untill I could make it happy.
I mounted it by welding studs up top with bushings and nuts, then welded tabs on the frame down low and screwed that to lower IC mount.
For the piping I clocked the turbo, and ordered the 3" builder kit from Columbia mandrel bends. Went to silicone intakes online and got a 2"-3" 90* boot, two 3.5"-3" reducers and a 3"-3" boot.
Had to trim part of my hood to make turbo boot clear. Still need to put 2nd layer of paint on pipes, make a new coolant filter bracket, and a new intake tube.
Haven't been able to drive it yet but I will post boost/egt/mpg results when I can
On my 91 7.3l I have the ats 093 turbo kit....there is no way to make the snail hat work without having pipes crossing all over the place....so I puchased one of the intakes racinndrummin makes for the idis (very good price BTW) here is a pic of that
To make the IC fit I had to cut the center core support/trim out, trim part of the grille mounts, cut/bend the bottom corners near the radiator, cut a little bit of the fan should away untill I could make it happy.
I mounted it by welding studs up top with bushings and nuts, then welded tabs on the frame down low and screwed that to lower IC mount.
For the piping I clocked the turbo, and ordered the 3" builder kit from Columbia mandrel bends. Went to silicone intakes online and got a 2"-3" 90* boot, two 3.5"-3" reducers and a 3"-3" boot.
Had to trim part of my hood to make turbo boot clear. Still need to put 2nd layer of paint on pipes, make a new coolant filter bracket, and a new intake tube.
Haven't been able to drive it yet but I will post boost/egt/mpg results when I can
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it will be. i can tell how much difference cold air makes even without an IC on my truck. in the mornings it is nice and cool and i can hit 5psi easy with my exhaust leak and truck has more ooomph. when it gets hotter out truck looses boost and ooomph goes away as well.
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Looks good man.
And I agree with 94idi, my truck performes better in the a.m when its cool outside. When it hits 95+ degrees I cant get 10lb.s out of it and the "ooph" goes downhill
And I agree with 94idi, my truck performes better in the a.m when its cool outside. When it hits 95+ degrees I cant get 10lb.s out of it and the "ooph" goes downhill
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There is a way to clock the turbo and still use the snail and not have to cut up the hood to do it. When I get a chance I will get a couple pictures. You rotate up the turbo about 50-60 degrees use a 90 deg boot off of that, rotate snail about 90 deg counter clockwise till just before it starts to hit turbo. Install 90 deg boot off snail aiming towards drivers side valve cover behind AC if you have it. You will need to do a different air filter. By doing it this way no need to cut into hood and if cost is a factor will help to cut down some of the cost and use stock intake and snail.
I Have both my batteries on pass side and have AEM cone filter at drivers side battery location and since I have serpentine belt setup it allowed me to run the intake piping right over the AC pump easily.
I Have both my batteries on pass side and have AEM cone filter at drivers side battery location and since I have serpentine belt setup it allowed me to run the intake piping right over the AC pump easily.
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Postmaster
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From: Buckley, WA
I cut all those off the snail, twisted it with every combo and every way seemed it would create a mess piping. I'd be interested in seeing your pictures!
In western WA we don't have to worry about a.m. Cold air power....it's always cold here LOL
In western WA we don't have to worry about a.m. Cold air power....it's always cold here LOL
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Here are a couple of pictures of the routing.
<a href="http://s1252.photobucket.com/albums/hh562/anderson352000/?action=view&current=1344428258441.jpg" target="_blank"><img src="http://i1252.photobucket.com/albums/hh562/anderson352000/1344428258441.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1252.photobucket.com/albums/hh562/anderson352000/?action=view&current=1344428248233.jpg" target="_blank"><img src="http://i1252.photobucket.com/albums/hh562/anderson352000/1344428248233.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1252.photobucket.com/albums/hh562/anderson352000/?action=view&current=1344428258441.jpg" target="_blank"><img src="http://i1252.photobucket.com/albums/hh562/anderson352000/1344428258441.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1252.photobucket.com/albums/hh562/anderson352000/?action=view&current=1344428248233.jpg" target="_blank"><img src="http://i1252.photobucket.com/albums/hh562/anderson352000/1344428248233.jpg" border="0" alt="Photobucket"></a>
Last edited by xcite; Aug 8, 2012 at 07:41 AM. Reason: repair links