Has anyone put an intercooler on a 97 PSD

I am thinking about doing one but wondered how much work it would be and the gain?

Thanks
Andy

 

I think Hypermax, ATS, and Banks have intercooler kits for 94-97's. $$$$

It shouldn't be too difficult to retrofit a 99+ PSD intercooler so long as there is enough room in front of the radiator??

 

I bought one off a 02 on Ebay
but have not got it yet

Just wondered how much work it was going to be to get it all figured out

 

A friend of mine adapted a '99 Superduty intercooler to his '96. The tricky part in making it work properly, was the tubing needed to be modified to have clearance in a few places. He decided to fabricate a set of pipes for his application, and now that he's seen how well it works, is selling the installation kits. He's not a sponsor of this site, so he can't solicit business here, but if anyone is interested, email me, and I can put you in contact with him. Hopefully I'm not stepping on any toes here, since I don't think this site is in competetion with him in any way. He has installed intercoolers on several other '94-'97 trucks, and it takes him all day to install one, and he's a professional mechanic, so he moves pretty quickly. When it comes time for me to get an intercooler, he's the one I'll use.
He reports an EGT drop of 200-300* while under load.

 

It's going to be a lot of work if you didn't get the rest of the system. You are going to need the CAC Y-manifold, the air tubes, clamps, boots, mounting brackets, etc. etc. and then all day to figure out how to put it together.

I have no idea who Quadzilla's source is, but if he's got an installation kit coming to market, it may be worthwhile to check it out.

 

I'm suprised it wasn't more of a drop than that. I'd imagine he picked up 40-50 HP too.

 

I have an intercooler on my '96 - it is the Banks version. Any other PSDs I buy will get an intercooler as soon as get it home. i consistantly run much cooler EGT than other '94 - '97 trucks on this board.

Theo

 

Cookie 88 said:
I don't think an intercooler, by itself, adds any power. It's my understanding that it will cool the intake air enough to allow you to keep your foot buried in the throttle longer. Can y'all enlighten me?
We've had our trucks on a dyno together, and they're set up is very similar, except he has an intercooler. Mine was consistently stronger by 10rwhp. (That was before I installed propane, and the difference is considerably more than that now.)

 

That is all it does Quad. It is like a mini-fridge for air. I run a tapered from Hypermax myself. Incredible mark up for such a simple part. On the hp gain though....40 to 50.....Hell.i would buy two of those.

 

Hey Quazilla, i emailed you the other day about your friend with the intercooler setup.Just wanted to know what all he had to do for the pipes to fit, and the y-manifold? If ya could let me know.Thanks

 

I'm sorry, I didn't get your email, but I'll tell you what I know about his system. You still need the factory Y-pipe from a Superduty, and the rest of the pipes, as far as I know, are custom. There are a bunch of silicone boots involved, and he sells the complete kit. If you've got a Superduty intercooler, he'll hook you up from there.

 

Yes Quad, i do have the 2 pipes and all the boots and intercooler. If you could have him email me. I would like to talk to him. My email is lbjozey(No Email Addresses In Posts!) Thanks for the info.

 

Thanks Quad, I'll give him a call.

 

Sorry to bring back an old thread, but I couldn't resist.

Actually, cooling the intake air will give you more power. This is because it allows more air molecules to get into the cylinders. There is an equation for gases, pv=nrt, where p is the pressure, v is the volume, n is the number of moles (molecules), r is some stupid constant, and t is the temprature of the gas. Keep in mind that this equation is only an approximation, but for the tempratures and pressures that we are talking about, it is very accurate.

Now then, to understand what this equation has to do with an intercooler, it is good to understand what happens if you start playing around with n and t.

First, the volume of gas that goes into an engine is constant, and is determined by your displacement (7.3L). The pressure is roughly constant (when you are running at constant speed), and is determined by the atmospheric pressure outside, and by the turbocharger in the case of the Powerstroke. This means the p times v is going to be roughly constant.

Now, lets look at what happens when you put an intercooler on. On the right side of the equation, t gets smaller. To make pv = nrt still hold true, n has to get bigger (p times v is roughly constant, remember). For an example, the intake gas temprature drops 250f with the addition of an intercooler, there would be an increase of the number of molecules coming in by approximatly 40-50%! This means 40-50% more oxygen molecules, which gives you more complete combustion of the fule, which gives you better fuel milage, more, power, etc... There are also some other thermodynamic advantages that come from putting cooler air into your engine, as well as some mechanical ones.