Intercooler on a 1993 Cummins

We are installing a 1993 12v Cummins motor into a 1994 Chevy dually. There is no room up front for the intercooler. Do any of you know of any alternative intercoolers that could be mounted somewhere besides the front of the radiator? I anticipate that the heaviest loads this truck is likely to have to pull is about 15K#, but usually considerably less. Could any of you speak from experience about what difference we might notice from running without an intercooler? Thanks.
 
(quoted from post at 21:34:22 06/15/16) We are installing a 1993 12v Cummins motor into a 1994 Chevy dually. There is no room up front for the intercooler. Do any of you know of any alternative intercoolers that could be mounted somewhere besides the front of the radiator? I anticipate that the heaviest loads this truck is likely to have to pull is about 15K#, but usually considerably less. Could any of you speak from experience about what difference we might notice from running without an intercooler? Thanks.

There are tons of aftermarket intercoolers out there. Are you running the mechanical fan? If so you could remove it and get creative on moving the radiator back, which might give enough space.
On Cumminsforum.com there is an section for these types of questions.
 
You could try to find a water to air intercooler and the correct injection lines to go with, a stand alone water to air one from a place like frozen boost or do without if you're not going crazy with the power levels
 
I put a 12V in my 93 Chevy in 2004. Used the 6.5 underbelly intercooler that mounted diagonally (still running it).
I have an intercooler that will fit in the radiator support frame, with a new frame to put it in first, in front of the radiator, larger, thicker.
Probably will sell the truck before I get that done.

Wayne
 
Yes, it still has the stock mechanical fan. At this point, considering how long this project has
taken and the fact that older model Dodge's did not have an intercooler I am inclined to run
without one.
 
(quoted from post at 15:08:49 06/17/16) Yes, it still has the stock mechanical fan. At this point, considering how long this project has
taken and the fact that older model Dodge's did not have an intercooler I am inclined to run
without one.

I'm sure you know to run a pyro gage pre-turbo not post turbo.
You'll then see if you need an intercooler. I'm thinking you will, while pulling 15,000 lbs unless its flat ground.
My 97 would easily hit 1250 on the pyro and it was stock except for a bit more fuel from a fuel plate, and 35# of boost.
 
How is a pyrometer gage going to do any good on the front side of the turbo. It is for measuring temp and will not have much in front of the turbo. A pressure or boost gage would be in front of the turbo. The pyrometer is for the exhaust temp. I would not want to run over about 1000 degrees on the exhaust temp.
 
You measure exhaust temperature in the manifold before the exhaust reaches the turbo. If you put it post turbo, meaning further down the line, its not as accurate.
Cummins engines are good up to 1250. There are many documented cases of high temps but I wouldn't suggest it.
 
Which rare if ever happens....
If your not going to run a pyro pre-turbo your just wasting your time. Your talking about as much as 300 degree variance.
 
If you are a techno nut and have lots of money to waste put your pyro pre turbo. If you are just looking to have some info if you pull the engine hard sometimes put it after. Then you don't have to worry about it creating carbon chunks or burning off the tip and having it go through your turbo. If after turbo you know it will be cooler by about 200 degrees, just don't go over 1000 deg and you will be safe.
 
I appreciate everybody's input. We decided to remove the larger Chevy radiator, and then install the smaller radiator and intercooler from an old "91 Dodge parts truck that we have in the weeds behind the shop. Hopefully there will then be adequate room for the intercooler and tubing on the "94 Chevy. Incidentally, the 12v Cummins in that "91 only has 74K original miles on it. Wish I could find an older Dodge dually body to put it in.
 
You can also get most "conversion" tips from cumminsforum. Plus, everyone there will say the same thing, pyro probe goes pre turbo. Its just common sense.
 
WayneB, where did you get this underbelly intercooler you mention here? Was it stock? I don't recall seeing any kind of an intercooler on that Chevy when we removed the 6.5 motor and tranny.

Walter
 
We are unable to find a 3 row radiator small enough to have room for the air to air intercooler pipes to pass on the sides of the radiator. So we are going to reinstall the stock Chevy radiator that came on this truck when it had the 6.5 in it. Then we will install an air to water intercooler. I tried to get on Cumminsforum but their password setup is all messed up right now. So we are just going to have to decide on the size of the intercooler and heat exchanger and how to install them.
 
The non-intercooled trucks had bigger injectors.

Is the intercooled radiator cross-flow?

Mishimoto makes a dual-cross-flow radiator for the early Cummins but it is $900 and comes with an aluminum shroud.
 
The plastic panel that mounts diagonally is removed, and the intercooler mounts up under the truck at an angle. Pipes on each side. Worked well with the 6.5L. The only problem with the Cummins is every once in a while, I would blow the pipe off the pressure side (right). I fixed the pipes and used better clamps.
Size is bigger than the early 5.9 type, but mine is over 300HP and on long pulls, my pyro would not peak but my engine would go to 220 or so. Having that engine fan pull air is a game changer.
 
A thought, if it runs warm.
Something else I've seen is moving the upper hose to the left side, then using a couple radiator hose elbows and piece of exhaust pipe to get it hooked to the t-stat housing.
 
Pyro can be pre or post turbo. It moves more and faster pre turbo. It tells you if you are hot after the turbo. The turbo robs/exchanges some heat. Now, If after the turbo at 900 and climbing start thinking about backing down, at 1000 probably back out. Pre turbo, 1250 and climbing fast keep into it to 1400. If climbing slow (cummins and mack don't climb slow, always fast) 1250 back it down to 1200 and safe there. The original cummins powers(before dodge) ran water toair coolers. These should be available and ready to install and run. Maybe not as good as an air to air, but adequate for respectable power and OOOOOHHHHHH MYYYYYY!!!!!! THEY FIT!!!! Find one and run it. Should work OK. The other thing, the turbo is prone to excessive heat in those model power plants, an upgraded turbo would drop EGT by noticeable % and also boost power/fuel mileage. Something that spools better and moves more air with less drive pressure, drive pressure is the primary restriction that causes high EGT, so inlet airis cooled to lower cylinder temps then essentially egt is lower.
 

We sell tractor parts! We have the parts you need to repair your tractor - the right parts. Our low prices and years of research make us your best choice when you need parts. Shop Online Today.

Back
Top