6.9L Liquid to Air Intercooler Install

Oil_In_The_Gas

Registered User
Joined
Jun 26, 2017
Posts
11
Reaction score
32
Location
Sacramento, CA
I'm new to this forum but after thinking about doing this upgrade for the last couple of years I wanted to share the results. I often tow a 21ft Toy hauler that weighs somewhere around 6500 lbs loaded. Going over the Sierra mountains and the long grades I felt like the engine would heat soak and have power loss towards the tops of the grades and some extra power to hold 4th gear would be really nice.

The truck has a ATS setup and is pretty much stock besides that and the exhaust. I did a ZF5 swap a couple of years back as well. I could get to 1150+ degrees on the EGT if I wanted to, so I was hoping for a decrease in exhaust temps too.

I ordered the 600hp universal kit from Frozen Boost, ripped out the old ATS intake and also removed the radiator overflow and winsdhield washer tank to make some room. I found that the intake manifold inlet is the same as a standard 4bbl carburetor top so I made an aluminum adapter to be able to accept a 3.5" silicone hose to plumb in the intercooled air.
You must be registered for see images attach


You must be registered for see images attach


You must be registered for see images attach


I have the cad drawings and .DXF drawings for anybody that wants them.

Next I removed the grill and installed the radiator.
You must be registered for see images attach


I found I had to tilt the intercooler a bit to get it to fit, I made some steel brackets to support it, bought a bunch of 90 degree silicone bends and a couple of adapters to fit the turbo. Cut the 3"dia .060"wall aluminum tubing to length and bead rolled the ends. Assembled and disassembled many times and got things to fit half way descent.

You must be registered for see images attach


I also added a couple of cheap temp sensors to check to see if the system actually works. Overall I'm pleased with the results. I see about 30 degree drop on intake temps at freeway speeds and when pulling the hills about 50 degree drops. On sudden acceleration like getting on the freeway and such 80 degree plus drops are seen. Egt's wont pass 850 now. and boost seems to be down only 1-2psi but it could be because I'm now taking a reading at the manifold instead of the turbo.
 

Oil_In_The_Gas

Registered User
Joined
Jun 26, 2017
Posts
11
Reaction score
32
Location
Sacramento, CA
About 450ish. 300 for the kit, but I ended up not using the electric fan that comes with the kit and another 150 or so in tubing, hose, elbows and nice t-bolt clamps. Here's a pic of temp display when driving on the freeway with the trailer, a/c on, and 110 outside. And that's brake vac not boost.

You must be registered for see images attach
 

Mike_42

Kid Mechanic
Joined
Aug 24, 2016
Posts
200
Reaction score
27
Location
Canton, MS
Very nice, thanks for the right up. Ill be doing an intercooler soon after I get my BW turbo.
 

towcat

Supporting Member
Supporting Member
Joined
Jun 24, 2004
Posts
18,196
Reaction score
1,437
Location
SantaClara,Ca/Hamilton,TX
thanks for posting this. I was thinking of going water IC due to the lack of airflow on the winch bumper of the Sulaco.
 

HS108

Diesel Newb
Joined
Mar 5, 2013
Posts
783
Reaction score
77
Location
Connecticut
Looks cool!!

Maybe a dumb question, but how much would an air to air intercooler lower intake temps ?

Is there that big of an advantage to air to water


Sent from my iPhone using Tapatalk
 

IDIoit

MachinistFabricator
Supporting Member
Joined
Aug 26, 2014
Posts
13,318
Reaction score
3,879
Location
commiefornia
nice. heres how I did Asmiths's

You must be registered for see images attach


You must be registered for see images attach
 

IDIBRONCO

IDIBRONCO
Joined
Feb 5, 2010
Posts
12,235
Reaction score
10,925
Location
edmond, ks
HS108. The air to air is the most commonly used intercooler so even though I don't have any numbers for you, it does work well. I think that the biggest advantages of the air to liquid would be that when it's hot, the liquid would absorb more heat from your boosted air, quicker. I don't believe that the hot air cools as well as the liquid does.
 

Thatoneguy

Full Access Member
Joined
Jul 10, 2017
Posts
615
Reaction score
130
Location
Boerne, Texas
Hey I have the same boost gauge! But mine is on the turbo. Very nice write up and clean work too. Wish I had some CNC equipment... Someday when I grow up... Lol like that'll happen.
 

Oil_In_The_Gas

Registered User
Joined
Jun 26, 2017
Posts
11
Reaction score
32
Location
Sacramento, CA
Looks cool!!

Maybe a dumb question, but how much would an air to air intercooler lower intake temps ?

Is there that big of an advantage to air to water


Sent from my iPhone using Tapatalk

The air/air works well, but on these old slant nose trucks there is no room for the big air intercoolers unless you want to ditch the a/c condenser.
 

03wr250f

Full Access Member
Joined
Jan 13, 2014
Posts
637
Reaction score
387
Location
Hamilton/Montana
I would love the files on how you made that intake hat. That is so darn sweet! I love it!!!!!! It looks awesome man!
 
Top