InterCooler?

[Jim Ross]

I am wondering if it is worthwhile to install an aftermarket intercooler (like BD sells) without making a turbo change or any other big changes, like bigger injectors.

Would the improved intercooler be worth it if it is the only change made to the engine?

I would be looking for lower EGT's and hopefully a bit of gain in the mileage.

On the exhaust side, I might add a 2 piece manifold. My muffler is gone, but my Cat is still in place.

 

[Blu-meanie]

I replaced mine with a Banks, but then I had the plastic fantastic intercooler that bothered me when pumping 30 - 35 lbs in the hills of New Mexico. It didn't improve anything that I remember, even with the fancy intake. Only my confidence.

 

[AH64ID]

I monitor intake air temps, and the OEM intercooler is pretty darn efficient. I doubt you would see any benefits at your power level.

 

[rscurtis]

I agree. Spend the money on an aftermarket turbo and manifold.

 

[Jim Ross]

You are using the stock intercooler with your Super B turbo? What boost pressures are you getting?

 

[rscurtis]

Yes. I installed the turbo for mileage, not power, although it does deliver some additional power through a reduction in drive pressure. I set the WG to open at 26 PSI, just like the stocker did. I don't think the stock fueling has the energy to exceed that. Cruising at 65 on level ground, boost is 2-3 PSI, which is less than half what it was with the 341.



BD now makes a Killer B that is supposed to be a direct bolt-on for your truck. It does not have the separate elbow or exhaust adapter that mine requires.

 

[Jim Ross]

Thanks for the info.
What kind of mileage increase did you get with the new turbo?
What did you gain in mileage with the Dynatrac hubs?

 

[rscurtis]

The hubs were worth a couple of MPG on the road, not much if any difference around town. The turbo was probably good for another 1 or 1. 5 MPG. The Rokktech crank sensor helps some also, as does the '03 engine tune. Highway cruising range is 800+ miles. Let's see you do that in a Prius- or any car for that matter.



I'm using the truck for local driving now while the Mercedes is being repainted. The overhead is sitting right at 20. 0, which would math out to about 18 MPG.

 

[Jim Ross]

Wow, 18 is way better than mine!
I'm getting a new set of injectors on Thursday and hoping they will be worth a couple of mpg. Running stock and empty, I am very lucky to see 15 mpg currently and from tests done, it appears my no. 1+6 injectors are not performing well. I'm going with stock new Bosch and I now have a 2 micron fuel filter to help protect them. If I could get 17-18 out of this truck, I would be a very happy camper.
I'll be pulling a trailer for about 500 miles next Saturday, so I should have an 'apples to apples' comparison to see how much improvement there is with the new injectors.
I'd love to have the Dynatrac hubs, but I will have to put that off until I need to rebuild the front end.

 

[rscurtis]

My last trailer towing episode was a trip into central PA to pick up a Gravely tractor in a 12' tandem axle U-haul trailer. The total weight was probably around 3000#. That trip still gave me a hand calculated 20 MPG.

 

[Jim Ross]

My last trip was from Pahrump, NV (May Madness) to Reno.
Averaged 9mpg with an 18 ft box trailer with only about 800 lbs of freight in it.
Next Saturday, I will be taking the same trailer to Idaho with only a dog and some clothes in it.
With new injectors, I'm sure hoping for a big improvement.

 

[WalterJ]

I am wondering if it is worthwhile to install an aftermarket intercooler (like BD sells) without making a turbo change or any other big changes, like bigger injectors.

Would the improved intercooler be worth it if it is the only change made to the engine?

I would be looking for lower EGT's and hopefully a bit of gain in the mileage.

On the exhaust side, I might add a 2 piece manifold. My muffler is gone, but my Cat is still in place.

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IMHO - These larger, more efficient Intercoolers are measurably effective approaching max power demands. Ask to see the manuf. performance graphs where you can see where the gains are. Good luck.

 

[Jim Ross]

I originally posted this when I owned an '07 DRW 4WD 5.9 AT. I finally sold it, I could never get more than 14-15 running unloaded downhill with the engine turned off. Towing was awful….as low as 6.5 on I-15.
I bought an early '04 SRW 3500 4WD AT. I have 4" straight pipe, BBI Stage 1's and DunRite trans upgrades and Smarty Jr set on SW1 (economy). With this set up, I get 11-12 towing, but have not run empty enough to know what it will do while "loafing". My only concern at this point is that I really have to watch my EGT's because I can hit 1200 real quick. I get virtually zero smoke with the BBI's, but I wonder if I would be able to get my EGT's lower with a custom tune (less duration/more timing) or a bigger turbo?

 

[CrewCabDiesel]

Im running a killer b with a bully dog, getting around 18 with a whipped 5.9 with lots of blow by. towing mode and above truck really preforms with the killer b, little lag but once it lites your gone or going sideways cant wait to rebuild it and see what it really can do!
Kyle