Engine comparison 1991 non intercooled to 1992 intercooled

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Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Tue Sep 27, 2016 6:24 am

Hi All

Have a 1991 non inter cooled California project 350 truck and a 1992 250 rust bucket inter cooled doner truck. I'm trying to learn all of the differences between the two engines. My 350 has 150 k miles and the doner has 230k.

If I switch the radiator, thermostat housing, inter cooler, front end sheet metal and all of the plumbing associated with the intercooler ( I can see the plate on the intake is different and the fuel lines runs are different) will I have an equivalent engine? I want to use the lower mileage engine and sell the other one. I know for the hop ups which I'm interested in I will need the intercooler. Is the bigger cross flow radiator there because of the inter cooler blocking some of the flow or was the 1991 down draft radiator just not enough for the diesel? Is there a horse power difference between the 2 engines? I'm leaving for florida on Friday. I don't have time to switch all of the intercooler stuff but I need to know if I need to invest the time to just get the bigger radiator in. I will be towing a 8000 lb trailer in I'm assuming some 90 degree weather.
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby CumminsPower59 » Wed Sep 28, 2016 1:29 pm

Ok, first, your 91.5 you've been calling is a early 91, not a 91.5, as they are intercooled from the factory. Dodge updated the grille for the 91 model year.

If you want to use the intercooler, cross flow radiator, etc., you'll need to swap the core support, but the rest of the sheet metal will work just fine as is, including the grille. A couple more things you'll have to grab from the IC engine is the fan hub assembly, as they are different IC vs. NON-IC, and turbo, as the compressor housings and wheels are different, 50mm NON-IC vs 54mm IC.

As for the radiators, the down flow radiator is ok, my 91 has been running the same one for 25 years. If it's not leaking, save it. All of the NON-IC stuff is worth some money ;)
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Wed Sep 28, 2016 2:02 pm

Thanks for the info. I've been saying 91.5 because I have the 8 in frame. On another thread on this site they used that definition. It doesn't really mater that much any way. How every it went thru its path to me from the factory it is currently a 8 in frame non inter cooled truck. Yes I notice the bigger fan and assumed the whole assembly was different. Are the two engines different horsepower? The 92 has a know history of additive in the fuel for injector lubrication. I'm think I should at least switch them. I have a friend who has a 92 and had his freeze up and he barley made it home. Will I have to bleed them or do you think the air will work its way out?
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby CumminsPower59 » Thu Sep 29, 2016 6:31 am

Dodge Dually Nut wrote:Thanks for the info. I've been saying 91.5 because I have the 8 in frame. On another thread on this site they used that definition. It doesn't really mater that much any way. How every it went thru its path to me from the factory it is currently a 8 in frame non inter cooled truck. Yes I notice the bigger fan and assumed the whole assembly was different. Are the two engines different horsepower? The 92 has a know history of additive in the fuel for injector lubrication. I'm think I should at least switch them. I have a friend who has a 92 and had his freeze up and he barley made it home. Will I have to bleed them or do you think the air will work its way out?


They are the same horsepower rating, but there are some small differences;
1. NON-IC engines used a wider bowl piston, matches the 155degree spray angle of the injectors.
2. The injection pumps are slightly different internally, obvious difference is the KSB and the delivery valve holders on the rear of the pump.
3. The KSB on the injection pump operates opposite of each other. NON-IC KSB is advanced without 12v applied, and retards the timing to normal with 12v. IC is the opposite, normal timing without 12v, advanced timing (cold weather) with 12v applied.
4. Injectors are different. NON-IC have 9mm tips w/155 degree spray angle, 4 hole x .013"...while IC engines have 7mm tips w/145 degree spray angle and are 6 hole x .009"
5. You already pointed out the differences in the intake horn and plate, injection lines, etc., but you'll need the throttle bracket and move a few sensors around.

I've basically converted some of the stuff on my 91 over to the IC stuff, but its a mix and match deal. I have a IC pump with NON-IC DV holders, KSB is now on a switch fed from a different circuit. The injection lines are NON-IC, running the NON-IC intake plate with a 2nd gen intake horn. I had to modify the IC throttle bracket to clear the lines.
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
04 VW Jetta Wagon TDI 5speed
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Thu Sep 29, 2016 8:57 am

Should I just swap out the whole engine and not worry about the higher millage?
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Thu Sep 29, 2016 9:00 am

I'm thinking about just swaping injectors for my upcoming trip because they have a history of being taken care of. With the differences you talked about between the IC and non IC will the IC injectors work OK in a non IC engine?
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby DodgeFreak » Thu Sep 29, 2016 1:09 pm

you have to get the 7mm to 9mm adapters to run them. but would work other wise.
92 D350 Cab and Chassis. Auto stock, wiring gremlins. 330k miles
92 W250 Ext cab rotted completely out. Auto, pump maxed, 215 ppump nozzles, Denny T2 pin.
85 D350 single wheel, converted to cummins, getrag, turned up 2 turns and afc screw flush.
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Thu Sep 29, 2016 2:03 pm

Where do I get them?
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby DodgeFreak » Thu Sep 29, 2016 3:08 pm

Eric at Thehungrydiesel.com should be able to set you up, might have to email him. He is RCCUMMINS89 on here, not sure if you can pm yet or not.
92 D350 Cab and Chassis. Auto stock, wiring gremlins. 330k miles
92 W250 Ext cab rotted completely out. Auto, pump maxed, 215 ppump nozzles, Denny T2 pin.
85 D350 single wheel, converted to cummins, getrag, turned up 2 turns and afc screw flush.
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby CumminsPower59 » Fri Sep 30, 2016 10:40 am

Being so close to having to go on that long trip, I'd leave the stock injectors in and run it. Save the other stuff for later ;)
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
04 VW Jetta Wagon TDI 5speed
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Fri Oct 14, 2016 1:31 pm

I tried pulling a set out of my spare non intercooled diesel engine and the first one was stuck. So I just went for it with no spares. Got to Florida and back and the diesel didn't miss a beat!!!!!
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby Dodge Dually Nut » Tue Oct 18, 2016 6:03 am

Hey Dodge Freak

I was off line for a week + because of the trip. I got your PM and I sent one back to you with my contact info. Look forward to a phone call .I'm interested in what you got.
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Re: Engine comparison 1991 non intercooled to 1992 intercooled

Postby dpuckett » Fri Jan 06, 2017 5:30 pm

My 93 had the factory cylinder hone marks in each cylinder at 440k, has almost 500 on it now. Last 6mo I have averaged 17.5-18mpg with 1000# of tools and supplies in the back, and driving it like a rental.

I wouldnt worry about hopping up a 200k engine. Mine had almost 300k before I did anything to it.
His- 93 W250 club cab LE, auto to Getrag conversion, piston lift pump, 3.54 LSD. 400k+
Hers- 04 QC 4x4. Built auto, Triple Dog, Air Dog. Funny Round truck that aint so quiet.
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