92 intercooler on early 91

[BJMarshall]

Ok has anyone done this? It looks pretty straightforward especially since I will have both trucks side by side. Any suggestions or commets? I'm going to swap it all over this weekend. Oo.



I plan on swapping the radiator support and everything attached to it from one truck to the other. And I also am going to swap the compressor side of the turbo (4"inlet vs 3" inlet)

Is there anything else I need to look at?

Should i expect much power increase? How much lower egt's?



Thanks

 

[bgilbert]

You probly already knew this one, t-stat housing, intake horn, radiator, I think the fan and fan clutch is different, I know the shroud is different. The cool 'intercooled' decorative valve covers cover. , heck just swapped the heads, you'll have a better air flowing head, smaller injector bores, no need for the $50 injector tips adaptors for upgrade injectors.

You could have the 92 intercooler pressure checked/cleaned/sealed up etc before installing. .

 

[dpuckett]

I'd venture a power gain for sure. Lower EGT by maybe 200deg max, 75-100 at cruise. Stock nonIC injectors flow slightly more than PW injectors, or so I've read.



I'd think it'd be easier to just cut the holes you need to fit the IC through rather than mess with the core supports, etc.



I'd also just swap out the turbo. Seems like nascar mark said recently that the older H1Cs used a smaller wheel than the newer H1C. Need to swap intake hoses along with the turbos.



Fan and clutch seem to be the same between IC and nonIC, or at least Mom's looks real similar to mine. I have the thicker radiator, and the fan is awfully close to the rad.



Head flow wont be increased that much to be worth the effort. If you really MUST have the INTERCOOLED decorative plate, I have one in decent shape that I'll sell you.



Daniel

 

[BJMarshall]

Thanks for the input. I'll let you know what happens. I plan to do this on Saturday. I just called the local Dodge dealer to get a fan shroud. It doesn't look promising. Any suggestions? I am looking for one for a 92. I may just continue to use my 91 radiator and shroud and cut holes in the radiator support for the intercooler. I really wanted to use the radiator from the 92 though since it looks fairly new, and it is a crossflow.

 

[dpuckett]

Having never looked REAL close at a nonIC truck under the hood, I dont know what stock looked like, but mine has what looks like the shroud from a 92 or 93- it is identical to Mom's. It is a tight fit, but it is in there. I can post a pic as soon as she gets back in town (she has the camera). Why not use the 92 shroud when doing the rad swap?



DP

 

[bgilbert]

DP, yes they ARE different. Shrouds that is. The IC shroud is much thinner and I think the radiator sits at an angle to the engine. The nonIC shroud is much bigger, wider or something. I know this from comparing my buddies 92 vs. my 89.

 

[BJMarshall]

"Why not use the 92 shroud when doing the rad swap?"

That's what I want to do. The shroud on the 92 is broken. The shroud on the 91 is fine, but they are very different. Any ideas on where I can find one for a 92?

Also, will the vacuum pump have to be changed? The 91 has the diaphragm style where the 92 has the vane style. It looks like the Intercooler plumbing may not fit with the diaphragm there. Not sure though.

 

[BJMarshall]

Anybody?

 

[bgilbert]

If you're swapping radiators, you will want to use the shroud for the 92 or get one if possible.

I think DP did the vacuum pump swap to vane style. DP?? How much did Dodge want for the 92 shroud? Is it available? I know recently I bought a new one for my 89 and they are still available for like $20!.

 

[BJMarshall]

The dealer quoted me $20 for the 92 shroud, but they called me back today and said it was NLA from Chrysler. Anybody got one? Any other suggestions?

 

[dpuckett]

Vacuum pump swap

Bill-

Yes, I have the vane style. Cant tell you about IC piping interference-I havent got that far, and have piping from a 96 for when I get an intercooler, so it wont matter anyway- the pipe wont come near the vac pump. You shouldnt have to change the vacuum pump. If it DOES become a problem, you can have an exhaust shop do some 45deg bends on a 3" section of pipe, or whatever the right size is. Then paint it, give it that custom look



Dont know how much the shroud was- the swap was done long before I got the truck, and it got a BIG radiator- 5 gals to fill just it and engine.



I can see how the shrouds would be different between the two. Is the 92 shroud unfunctional? Or is it more of an asthetic issue? I always say if it fits, run it. If not, make something that does.



-DP

 

[BJMarshall]

It's broken and most of it is missing. I can make one. That's no problem. I just wanted it to look kinda OEM.

 

[BJMarshall]

OK I got it done. I took pictures of the whole changeover. I will get them up as soon as I can. I want to say thanks to all of the people that knew how much stuff had to be changed and didn't say anything. I may not have even done it if I had known it was going to be such a PITA, but it would have been nice to know.

On a positive note, EGT is down about 100* cruising and over 200* when pulling. The application of power is much smoother, and it seems quiter??? I think I lost a little boost, but I don't have a gauge so I am not sure. It does smoke a little more. I am going to check all of the boots this weekend. They weren't in good shape so I will probably just change them. Anybody know where to get them? Got to get an intake gasket as well. Just got silicone on it now. I didn't realize I was going to have to take it off and turn it around.