1990 intercooler conversion with AC

[KKunz]

I’m going to intercool my 1990. I have a intercooler off of a 1999 24v I’m just curious for the guys that have done the conversion there is not a lot of room between the grill and the AC condenser if I get a grill off of a 92 or 93 that had a stock intercooler will I have enough room to clear? Any input would be great.

 

[jdurham]

Here's what I know, mixed with what I've heard:



First, the 91. 5-93 grille will give you more room, but the headlight spacing is different, so you need a 91. 5-93 radiator core support. This is the method I am using on my 90, with ALL the front end parts off of the newer truck.



Second, I have heard of guys grinding/cutting the back off of their 90 grille to make space.



That is about all I know on the subject...

 

[Grey Wolf]

We went with the '93 core support, grill, condenser, etc. for my sons '90. It's straight forward no problems, I can't speak for the second gen intercooler install...

 

[KKunz]

I’m hoping I can just cut the grill to make room but I guess if worse comes to worse I will have to get the core support and grill off of factory intercooled truck.

 

[CSchafer]

If you get lucky you can find a banks grill for the conversion or make one. There's one in my pics.

 

[KKunz]

Other than Banks is there any other after market grills?

 

[dpuckett]

You'll also need the fascia between the bumper and grille for the 91-93 conversion.



I wasnt aware that the headlight spacing was different between the 2 models. From looking at my 90 and 92, I figured that two would interchange with just parts swapping. Learn something new every day.



Daniel

 

[AKimmel]

I used an intercooler in an 87 style frontend. I cut an inch out of the back of the grille, and had to do some major surgery on the lower valance. Its a tight fit with the 93 intercooler, if a second gen is any bigger, I don't know if it would work.

 

[dpuckett]

2nd Gen is 1/2-3/4" thicker, and maybe an inch or so higher, not to mention 10" or so wider.



DP

 

[KKunz]

I think Im in the market for a 1st gen intercooler now LoL.

 

[RSchwarzli]

If you are looking for pics of the Banks set up, I have a few in my RR gallery. As for the second gen cooler in a first gen, I have seen it done before.



Robert

 

[sdstriper]

grille and head light spacing

I was driving a sweet old 77 GMC Crew Cab until I bought my 89 D250. The old Crew needed a jump start and while the two were nose to nose I was eyeing the aftermarket grille in the GMC, looked like it would fit to me and the dimensions are very close. I am going to get a billet style grille eventually and try it, might be worth a look see for your intercooler swap...



On the head light spacing it is indeed different. My 1983 D350 gasser was totalled a few years ago and I bought a replacement 93' grille assy from MrTaillight and found out the hard way. Here's a link to an article that shows and explains how they handled it.

http://www.moparmusclemagazine.com/projectbuild/5140_1987_dodge_ram_d150_new_grille/

 

[JStokes]

I'll trade you!

I have an intercooler off a 99 PSD I was going to use in a Suburban conversion. I bought it as well as a Duramax IC. Long story short I am not going to use the PSD but I would like to play with the Dodge intercooler to see if it would fit better than the D-max IC. Do you wanna trade? I hear thet the PSD will fit the early Cummins no problem. Here is a link for sizing.





http://www.cummins-conversion.com/phpBB/viewtopic.php?t=509&highlight=intercooler