how to make your non I/C Truck an I/C Truck
 

Ok guys we put a stock I/C in a truck today in the shop and figured i would take pics and post it all up

As always ~ SAFETY FIRST!!

- Disconnect the Negative cable of your battery system.
- Chock the wheels and set the parking brake.
- Have a known good fire extinguisher close by.
- Have good lighting.
- Have a clean and orderly work area.
- Always exercise good working practice with your tools.
- Use safety goggles, gloves, masks, etc where appropriate.

so first off remove the grill
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then i held up the cooler and marked the holes

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the back side before

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after cutting the holes put the cooler up where it is soupose to go and do a dry fit

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I made brackets that plated that whole thing but i forgot to take pics


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now your soupose to use a different intake manifold plate i made the stock one work

remove the crossover pipe and install the 90* intake horn

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the throtle bracket would not fit with the new horn so i modified it to fit

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with the bracket installed

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other than that is was real simple

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Final pics

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What benifit would I get with an IC in my 1st gen:humm:

cooler air means more power!

and cooler air means its denser so more will fit in the hole lol

Cooler air means denser air, so a power gain will happen. How noticeable it will be is directly related to the full power screw... You simply get more bang for the turn, with the I/C.

The largest advantage is that, when you tweak the pump, the I/C will keep those EGT's down.

Either way, it's a win-win. :choochoo:

Interesting, but why is a non-intercooled 1989 Cummins engine rated at the same horsepower as an intercooled 1993 Cummins engine is?
Both are rated at 160hp @ 2500rpms.

I am under the impression that the intercooler DOES NOT add horsepower, but helps lower EGTs, and was added in '91-1/2 for emissions reasons, not for power gain.

Mark.

I cannot answer that for sure but the injectors are different and flow different amounts of fuel. and correct the I/C was added for emissions

I'm reasonably certain that the Non-I/C engine's horsepower was also kept down due to the overall turbo size and factory tuning, which was, once again, for emissions.
Dodge (like most U.S. manufacturers) didn't want to see smoke from their diesels.
Neither did/does the E.P.A.

Mark.

If they could only see us now lol

the non-i/c trucks do have bigger injectors from the factory which will support 300hp most say. So upgrading to an injector like PODs in a non-i/c is pretty much useless. Hope i added something to this discussion :argh: and i will be intercooling mine, and water injection, just for added reliability and keep heat down and power up

IMO i would not put POD'S in nothing there junk and yes the 89-91.5 non I/C had a 9mm injector and the 91.5-93 had the 7mm the 9's flow more fuel and can support up to 300hm if it were me I would buy a set of smokems there cheep and some of the best cumnins injectors on the market


Brice

if you read that whole tag the horsepower info came off of you will see that the non-ic engines specify (irrc ic is 72 an non is 76) 4 cubic mm more fuel per shot than ic engines

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so to me that sort of proves the ic adds horsepower or they wouldnt have had to cut the fuel back to maintain the same horsepower

According to some of teh bigger names, non-I/Ced injectors in GOOD shape (thats the key) can support right up to 375-400hp with a very good tuned truck.

Alot of bone stock non-I/Ced truck put 160-170 to the wheels on dynos. I/Ced trucks wont due that. There is speculation that the I/Ced trucks left the factory with a little more HP then stated.

nice

Added to sticky! Great work!

I am wondering what differences are in the IP between IC and non-IC?

just tuned a little different from the factory, otherwise the same pump.

just to throw it out there if you flip your intake cove end for end, then you wont have your intercooler tube against the master cylinder, thats what i did, had to fab up a bit more brackets to hold the injector lines in place.

but, nice write up, better then i could have ever done :tu:

ya I went to the I/C intake housing and throttle bracket now and its too far foward due to the I/C being smashed into the front clip so the grill would still go on :lol: but it all works out

thanks

Brice, how thick of core does your IC have? I am looking to pick up a 3" core, I think it will fit, but not completely sure.

ya know I dont know let me look

Did you ever look at how thick the core is? haha. I got a 3" and either its not gonna fit in the least, or I am trying to mount my grille wrong (facepalm).

na man I forgot shoot me a pm tho I will see it in the morn and go out and do it

when i put in a 01' cummins IC in my 89 non IC, with all my mods i notice a good difference. seemed to spool up faster and run much better. plus now i have a custom billet mesh grill on now to cover it all up until i have the regular grill thinned up to fit. cant wait to see how it runns with my new HX-40 and my new smokem injectors.