Promblems, Intercooling A Non Intercooled 1st Gen.

[doublel89]

I've got a few so I'll number them for ya'll.

1. I've heard that the 24 valve intake horns work great for a non intercooled truck. HOW the heck do you get them to clear the brake master cylinder?

2. My truck parts junkyard got me a 1st gen intercooler, sizing it up i have 1/8 of an inch between the radiator side supports and the innermost part of the cooler. I don't want to mount it so close that my hump hoses will rub through.

About the truck, it's a 91 early model year, I'm using a HX35W and turbo outlet aluminum bend unit. made the executive decision to remove all the air conditioning bs to make more room. I'd rather my engine run cool than me. Any help or input on this project would be appreciated. I've lightly searched the forums and found a few posts but not much helpfull. Thanks a ton in advance.

[PRINCETON_JAKE]

I didnt have a problem on my 92 factory innercooled truck putting on that manifold. I dont know but is the lower intake plate different? is the horn ?more centered then an innercooled truck how the horn is towards the front?

[doublel89]

i belive there is 3 or 4 bolt sets till you reach the front. i have thought about just taking off the lower manifold piece and temporaraly disconecting my heater grid, really stupid as last friday it was 20 below, they should be easy enough to lengthen though.

[lectro_static]

I believe the intake plate on a non i/c motor has the air horn back farther therefore you get the interference. I know the intake plate will bolt on but am unsure if the injector lines will be in the way or not.

[doublel89]

if i were to reverse my intake plane so that the heater grid / intake horn mounting were further foreward all would still bolt up? i'm pretty sure doing this type of job everything is in the way

[PRINCETON_JAKE]

build a custom intake, go to the parts store and buy a couple 2 1/2" or whatever mandrall bent pieces, start cutting and welding.

[lectro_static]

I dont know if it still bolts up or not I would guess it does but I would also think that you would end up hot on some cylinders, I know that my 93 they say #1 and #5&6 are hotter #1 is a bolt boss that blocks airflow #5&6 is because the air horn is more forward on the motor. M&H is making a twin ram that could solve your problems I believe.

[redneckroot]

I reversed the plate it worked out good, except you have to get a little creative with the throttle linkage bracket. I used tims cooler tubz, but there are cheaper ways to do it. I have no idea about the 24valve horn maybe this picture will help you.

[PRINCETON_JAKE]

Thats a clean motor, where did u get the blue valve cover gaskets? When I replaced mine I got black ones from orielly, all the ones we sell (auto value) are blue, and they didnt match my motor. They were both felpro, same part number, and identical boxes.

[Mark Nixon]

Just rotate the iintake plate 180 degrees and the intake horn will clear.
You'll likely have to notch the side braces on the radiator to get the Intercooler ends and boots to clear.
In truth, a 2nd gen Intercooler actually fits better in a 1st gen non-intercooled truck.
When Banks sold Intercooler conversions for them, the Intercooler pipe fittings were spaced very similar to a 2nd gens.

Mark.

[doublel89]

redneckroot and Mark. your two posts have helped me immensley. my throttle linkage is already messed up with the 24 valve intake horn as it is. and i think i may have an a$$ kissing come to jesus telephone call with the junkyard i got the 1st gen intercooler from and try to swap it for a 2nd gen one. thanks alot guys tons of help.