2nd gen intercooler install observations *now with pics*

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2nd gen intercooler install observations *now with pics*

Postby cmann250 » Tue Sep 18, 2012 4:36 pm

I just got done installing a 2nd gen intercooler from a '94 CTD auto in my '89 2wd auto. I've never seen a write up that shares how to fit a 2nd gen cooler in a non-IC'd auto truck. These are just observations and "by no means the authoritative how-to" as BC847 would say. I don't know if it's the best way, but it works.

-I had to grind off the flat 2nd gen mounting tabs, all the bosses for the the A/C condenser, and the brackets for the trans cooler.
-I had to dent the inner fenders so I could fit boots on the cooler.
-The only way I could get an air to fluid trans cooler to fit was to put in in the very center of the IC. I used a roughly 11" tall, 10" wide, and under 1"thick cooler. The stock trans cooler's hole through the firewall is covered by the cooler. I brought the lines up from the bottom.
-I had to sand the back of my grille significantly, but I saw no way around it.

I'll add to this as I tinker with it further.
Last edited by cmann250 on Sun Mar 17, 2013 9:15 am, edited 1 time in total.
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Re: 2nd gen intercooler install observations

Postby PToombs » Tue Sep 18, 2012 5:18 pm

I think you install them upside down, IIRC. I can't remember for sure and I'm too lazy to search for pics. I don't remember anyone saying they had to bend the fenders, but seem to sorta kinda remember the IC tubes being up high.
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Re: 2nd gen intercooler install observations

Postby cmann250 » Tue Sep 18, 2012 5:38 pm

I thought about that, but I wondered about the battery being in the way. The way it sits, about half of the driver's side outlet is under the the battery tray.
I forgot about mention that I'll be using the 2nd gen horn and as much of the 2nd gen piping as I can.

-I couldn't fit the vertical support (ties a crossmenber to that stone guard under the grille to the hood latch support) back in and it doesn't seem any worse for wear.
- KEEP the cast tabs at the top, that's what I used to mount the cooler. They are the ones that are closest to the firewall.
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Re: 2nd gen intercooler install observations

Postby RumbleFish » Tue Sep 18, 2012 6:14 pm

Dont slam the hood without removing/modifying your hood safety latch. My D350 had a nice dent in the top of the IC from this.
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Re: 2nd gen intercooler install observations

Postby Sutter1stgen » Tue Sep 18, 2012 6:52 pm

As stated above, don't slam anything shut until you know everything clears. Glad to here your intercooling it. That was the biggest improvement for my truck. It ran so hot without one.

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Re: 2nd gen intercooler install observations

Postby cmann250 » Wed Sep 19, 2012 8:11 am

RumbleFish wrote:Dont slam the hood without removing/modifying your hood safety latch. My D350 had a nice dent in the top of the IC from this.

Too late. I knocked some paint off of it, but that's it. The saftey latch disappeared this morning.
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Re: 2nd gen intercooler install observations

Postby BILTIT » Wed Sep 19, 2012 8:29 am

Derek B.
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Re: 2nd gen intercooler install observations

Postby cmann250 » Wed Sep 19, 2012 8:44 am

BILTIT wrote:A write up here:

http://www.dieseltruckresource.com/dev/ ... p?t=186908

I've read that a time or two. He practically cheated in having the later style grille and no auto trans cooler :lol:
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Re: 2nd gen intercooler install observations

Postby Hansen01 » Wed Sep 19, 2012 9:03 am

Forgot that you had an auto when you asked me a couple questions. I have one pipe coming off of my intercooler, that conects to another boot that angles at a forty five that connects to another and goes into my intake horn. My pipes and intercooler boot touches my battery box :roll:
Mine cooled about 200-250 degrees and blew my headgasket :lol:
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Re: 2nd gen intercooler install observations

Postby cmann250 » Wed Sep 19, 2012 3:33 pm

Hansen, did you install it up side down?
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Re: 2nd gen intercooler install observations

Postby PToombs » Wed Sep 19, 2012 5:16 pm

Caleb, check that 2nd gen air horn. It may be more restrictive than ours. I remember Philip posted pics of ours and 2 2nd gen ones, 1 is good, and 1 is worse. Maybe do a search and save youself some trouble.
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Re: 2nd gen intercooler install observations

Postby cmann250 » Wed Sep 19, 2012 5:34 pm

PToombs wrote:Caleb, check that 2nd gen air horn. It may be more restrictive than ours. I remember Philip posted pics of ours and 2 2nd gen ones, 1 is good, and 1 is worse. Maybe do a search and save youself some trouble.

I looked and I seriously doubt it. My cross over is incredibly choked down. I remember that he has some sort of 24v horn that's the one to have.

-I tried to fit up some pipes today. There's a shorter, bent pipe from the 2nd gen that is the prefect angle for the cold pipe. It fits under the battery box fine. It's just a few inches short. I can't decide if I want to weld in a piece and keep the beads on both ends or add another boot and have two separate pipes.
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Re: 2nd gen intercooler install observations

Postby PToombs » Wed Sep 19, 2012 5:37 pm

No brainer, weld in a piece. More pieces = more clamps= more trouble down the road. Just play with it and make sure the pipes will line up right if you stretch it.
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Re: 2nd gen intercooler install observations

Postby RCCUMMINS89 » Wed Sep 19, 2012 5:40 pm

The 2nd gen is better than the common rail one. I'm running one off of a 98 24 valve
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Re: 2nd gen intercooler install observations

Postby cmann250 » Wed Sep 19, 2012 5:53 pm

RCCUMMINS89 wrote:The 2nd gen is better than the common rail one. I'm running one off of a 98 24 valve

I just confirmed that over on CF. The 3rd gen one is worst.

I kept that 3rd point/support piece on the intake just to be different.
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