Lower Intercooler Install

S

Static

Member
Finally got a bit of time to get my lift over to the new house and get working on the truck again. First mod I installed is the DutchTy lower intercooler upgrade. I removed the IC metal lines and ran 3/4 heater hose to the upper and installed a new pump to replace the original unit. The new pump hasn't worked from day 1 and the replacement cooked as soon as I filled the IC. I have a Johnson pump on the way that Im going to try next. I think I finally figured out why my IAT were high in my datamaster runs. The supply hose was kinked nearly completely a few inches above the pump causing low flow of water. Also noticed that the return side of the old IC was almost completely blocked off with crud. Looking to get the new pump in this week when it arrives. Hope to see way lower temps due to this mod.

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jrigby

jrigby

New member
Re: Lower Intercooler Install

Nice! what pump was giving you problems? Just curious so I don't buy one.
 
aasltmike

aasltmike

Active member
Re: Lower Intercooler Install

I had that same really bad kink in the stock line when I put my replacement IC pump in. I went with the Johnson pump and hotwired it to run continuously. I also went with 3/4 inch heater hose and deleted the crappy stock metal lines. I immediately noticed lower temps on mine, even in a coastal Georgia summer. The only PITA was burping the IC tank.
 
sy538

sy538

New member
Re: Lower Intercooler Install

aasltmike said:
...
The only PITA was burping the IC tank.
Click to expand...

If you route it so the water comes out of the pump, to lower port on lower IC and out the upper port on the lower IC (to keep air from being trapped in the lower) into the upper port on the upper IC and out the lower port on the upper IC (to try to trap the air there) back to the pump, the pump will be pulling the water out of the upper harder then its pushing it in so you can take the cap off while the pump is running. Air bubbles will go back down hill, but thats the best you can do.

Then buy
http://www.summitracing.com/parts/LIL-24610/
put some coolant in it, turn the pump on, wait 10 minutes and you are done.

I think I got it from Advanced.
 
S

Static

Member
Re: Lower Intercooler Install

jrigby said:
Nice! what pump was giving you problems? Just curious so I don't buy one.
Click to expand...

I used a pump that was linked on another thread. I got it on ebay. http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=130445561394&viewitem=&sspagename=STRK:MEWAX:IT#ht_3836wt_1134

I installed it after changing all my lines, filled it all up with fresh coolant. Turned the key on and nothing. Not even a hum. Called customer support who said it was a defective pump and promptly shipped another. Tested this one directly off the battery for less than 2 seconds to make sure I wasn't going thru all the work of installing another bad pump. Installed it, filled it and it ran for maybe 2 seconds and it fried. The first pump smells burnt and the impeller does not spin freely. I expect to find the same when I pull the second pump. Both show an open circuit with an ohm meter. Called customer support so I could arrange shipment back. Was told that they didn't want the pumps back, nor any of my business and that Im not getting any sort of refund either in a not so very nice manner. I filed a claim with ebay 4 days ago but haven't gotten any reply. I wouldn't use these pumps, IMO they are junk and manufactured in China. I hope the Johnson pump is a better pump.
 
jrigby

jrigby

New member
Re: Lower Intercooler Install

That sucks, I was hoping to use one of those for a decent stock replacement. Guess they wont be getting my business either. Hope the Johnson pump works out for ya.
 
Fighting5thSVT

Fighting5thSVT

Active member
Re: Lower Intercooler Install

I just bit it and spent the extra money for the Johnson pump when I did mine. Install was a breeze and works well. Glad I did. Good luck and keep us posted on your opinions of the new IC. I plan on ordering one next GP and have yet to hear anything negative about them. Sounds like DutchTy is the go-to guy here.
 
Slyclone

Slyclone

Well-known member
Re: Lower Intercooler Install

Are you sure that that is a intercooler?

Im reading my manual and that item your talking about is called the lower heat exchanger. im reading that water passes through it not water. its the lower one and the scoop goes on the rear.. YEA... intercooler is at the top. CAC its called charge air cooler.

Im going by the book but whatever.

I saw on Ebay some one making these for relatively cheap. I saw them offered at 80 bills.thought it was a good deal.

I now see the complete setup with pump and all. looks good.
 
S

Static

Member
Re: Lower Intercooler Install

92typhooner said:
Where did you get the lower intercooler?
Click to expand...

Dutchty ran a group purchase a while back. I highly recommend getting one next time he makes them available.

On a side note my Johnson pump came in. I installed it and filled the upper tank and burped all the air out. Pump is running just fine. Its a little loud but thats how you know its working.
 
Fighting5thSVT

Fighting5thSVT

Active member
Re: Lower Intercooler Install

Static said:
Dutchty ran a group purchase a while back. I highly recommend getting one next time he makes them available.

On a side note my Johnson pump came in. I installed it and filled the upper tank and burped all the air out. Pump is running just fine. Its a little loud but thats how you know its working.
Click to expand...

How much fluid movement do you have in the upper when you remove the cap? I know a couple of people (myself included) that can see the coolant just shaking, and some that say it overflows from bubbling when removed. I'm just wondering since I also have the Johnson pump.
Thanks
 
S

Static

Member
Re: Lower Intercooler Install

When I first got it all filled up and running I ran it with the cap off and it was surging and would push water out so I put the cap back on and ran it for a few minutes. Then I opened up the cap and filled it with more water and the surging stopped. It looked like it was circulating pretty good but anything is better than what I had before:roll:
 
Fighting5thSVT

Fighting5thSVT

Active member
Re: Lower Intercooler Install

Static said:
When I first got it all filled up and running I ran it with the cap off and it was surging and would push water out so I put the cap back on and ran it for a few minutes. Then I opened up the cap and filled it with more water and the surging stopped. It looked like it was circulating pretty good but anything is better than what I had before:roll:
Click to expand...

I wonder if the surging was pockets of air purging? Well, I will be checking mine for kinks now because you got me thinking about it. I know its moving coolant because the CAC is often times cool to the touch after driving it. Thanks for the update and info:tup:
 
dutchty

dutchty

Member
Re: Lower Intercooler Install

Nicely Installed.
Your the first I see with pics with my lower CAC:tup:
When I saw the pump I already tought that I had to post that that pump cant deliver the 30L/m they claim.
Johnson CM30P is just the best optionhttp://www.johnson-pump.com/jpmarine/products/circulation/cmco.html

 About filling the CAC up again with coolant::idea:
When the lower CAc is installed and the hoses connected to the upper, disconnect the most upper hose who should be connected to the pump.
remove your filling cap on the CAC.
Then fill it thru this hose.
When its almost full keep the hose as high as possible so the cac is also filled up a bit.
lower the hose quickly and reconnect it to the CAC.
Then fill upp the CAC.
This way most air pockets are avoided. Run the pomp after filling it up for the last few bubles.
Never fill it thru the hose on the upper side of the lower CAC, air will be trapped in and is :talkpoo:. to get the air pockets out.:tup:
Good luck for the rest of you who have to install the lower CAC.:lol:
 
S

Static

Member
Re: Lower Intercooler Install

Ok I finally got the truck started and off the lift. Made several mods and now running code$59. I think I am still having problems with intake temps tho. It was a 95 degree day. I ran it around the block and put some fresh gas in it. Ran datamaster and my intake temps were already around 158 degrees. Seems to want to go way lean when at idle when its that hot. I deleted the crossover tube and relocated the battery so the filter now resides there. I know thats hurting me. Im going to isolate the filter from the engine compartment. I also have a turbo blanket on the way. I also have the ATR upper cooler but haven't installed it yet. I pull the cap for the upper resevoir and I can see the coolant circulating. Im pretty sure no air is trapped. 50/50 mix with a bottle of water wetter. Is it possible that I have too much flow and its not staying in the lower long enuf to get cooled down? Is it also possible my stock upper is coked up like the rest of my system was and causing it to be so hot? What temps are you guys seeing normally?
 
Chest Rockwell

Chest Rockwell

Active member
Re: Lower Intercooler Install

My IAT's are in the low 100's, with a Johnson pump hardwired to run full-time. When/if the weather improves I'll be adding an additional heat exchanger (similar to the ATR cooler) to lower temps a little more. 158 seems high, wish I could say why.
 
S

Static

Member
Re: Lower Intercooler Install

Chest Rockwell said:
My IAT's are in the low 100's, with a Johnson pump hardwired to run full-time. When/if the weather improves I'll be adding an additional heat exchanger (similar to the ATR cooler) to lower temps a little more. 158 seems high, wish I could say why.
Click to expand...

Im hotwired to run full time also. When youre seeing low 100s whats the ambient temp?
 
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