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6.5/6.2 High Performance Engine Modifications High Performance Turbocharger and Engine Related Modifications Discussion Forum - Specific To The GM 6.2 & 6.5 Diesel Engine.

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Old 11-02-2014, 08:57 PM   #1 (permalink)
bowtiebutler956
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Installing An Intercooler On My 6.5 HX40WII

After installing the HX40WII on my truck, I can easily hit 20+ psi of boost if the boost controller is set there. That got me to thinking about installing an CAC, but all the available kits cost over $900 after shipping! There is now way I could afford to go that route, but after checking prices I realized it could be done for about $300. I read a thread done by sctrailrider on his CAC install, and mine will be similar.
I decided to go with the bar & plate type CAC over the tube & fin design. Both designs have their pros, and cons, but the deciding factor for me was bar and plate design is more resistant to damage from rocks, debris, etc.. The CAC size is 31x12x3.25. I will take lots of pics, and try to show everything that it takes to get it installed in my 93 K2500. This is my first time installing a CAC, but it looks like it should be a pretty straight forward job. Hopefully.

Here are the prices, and links to the parts being used.

$60 Peninsular upper intake. I got mine from a fellow member, but here is the factory link, and we'll use their price for the sake of trying to make the price repeatable for anyone wanting to do this.
2335520 Air Intake Adaptor | Peninsular Engines
$98 Intercooler. 31x12x3.25 Bar $ Plate
Bar Plate Lightweight Aluminum Turbo 31"x12"x3 25" Fmic Front Mount Intercooler | eBay
$93 Installation kit. Should have all necessary bends needed.
DIY Custom 8 Piece Silver Pipe Intercooler 3" Piping Kit w Blue Coupler VW Euro | eBay
$15 45* silicone 2.5" to 3" silicone elbow. For coming off the turbo, and this is the only one that I believe I will need seperate of what comes in the install kit.
Silicone 45 Degree Elbow Reducer 3" to 2 5" 76mm to 64mm Turbo Silicon Blue | eBay

This brings us to $266 currently. I've already ordered the CAC, and 45* elbow, as well as the Peninsular upper. I will order the install kit in the next day or two.
I'll be working on a cold air kit as well, as it seems counterproductive to install an intercooler while sucking hot air from under the hood.
Here is a pic of the trucks current setup. ( site won't let me upload my pics as they were already used in another thread) I'll take some new pics tomorrow.

Matt

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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear

Last edited by bowtiebutler956; 11-02-2014 at 09:03 PM.
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Old 11-02-2014, 11:13 PM   #2 (permalink)
chevy410
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Cool.

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Old 11-03-2014, 05:06 PM   #3 (permalink)
bowtiebutler956
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The first piece of the puzzle arrived today from a fellow member (Thanks Paul). The Peninsular upper. Here are a couple pics of it, as well as the current setup.

Matt
Attached Images
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File Type: jpg PB030189 (1024x768).jpg (375.0 KB, 138 views)
File Type: jpg PB030190 (1024x768).jpg (404.0 KB, 134 views)
File Type: jpg PB030184 (1024x768).jpg (433.2 KB, 162 views)
File Type: jpg PB030186 (1024x768).jpg (483.8 KB, 166 views)
File Type: jpg PB030187 (1024x768).jpg (441.2 KB, 210 views)
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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear
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Old 11-03-2014, 06:06 PM   #4 (permalink)
SUPRAPULLER
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Man your engine is insanely nice!! That intake makes everything super easy.
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94 C2500 Suburban, vin F, 06' 10.5 AAM axle swap w/4.10's & disc brakes, PMD in bumper, Batt Ter mod SS, K47/snorkel delete, HX40/ATA CAC , 2.5" x-over, 4" Diamond Eye, AC delco OPS & OPS mod, FTB (drilled out IP fitting), FRC10 w/dual filters, tank sock delete, LS oil cooler lines, FD and pulley 11/14, 2k year waterpump, 2k fan, modded Hayden fan clutch, Teds injectors, Bosch GP,GS Trans/EGT/Boost gauges, TCC lock mod, aux trans cooler, Buddy's 6 gun tune, 2" lift w/285/75/16 on stock dmax wheels, 240k and counting. GONE BUT DEARLY MISSED!
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Old 11-03-2014, 07:37 PM   #5 (permalink)
TAG
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I am aware some are fussier than others, and i am anal about my truck too, but reality is, i live on a gravel road & put on about 25,000 miles a year in michigan climate. With that said, I used 2.5 inch aluminized exhaust tubing when I installed my cac 8 years ago. Still not a spec of rust on any of it. Not sure if there is a big price difference between the kits & exhaust pipe, just a heads up for those that may be curious.
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1995 K2500 ECSB 6 lug. 2006 Penninsular 18:1, Diamond Eye 4" exhaust, hx40II, Heath v2.0 chip, A/A intercooler under bumper, custom intake, 285/75/16 all terrains, 3 pod pillar guages, high idle, silverado w/ leather.
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Old 11-04-2014, 12:35 AM   #6 (permalink)
roadhog0
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Something I've thought about with this is putting a drain bolt in the bottom of the intercooler because the CDR puts oil into the air stream then that oil condenses and sits in the lowest part of the system. Might just be me over thinking, but worth a thought....
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6.2 Turbo Diesel (HX40 CKO), 6.5 Serp, 6.5 Lift Pump, intercooler (to come), more broken or missing parts than you can shake a fist at, balls.
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Old 11-04-2014, 07:44 AM   #7 (permalink)
guybb3
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Quote:
Originally Posted by roadhog0 View Post
Something I've thought about with this is putting a drain bolt in the bottom of the intercooler because the CDR puts oil into the air stream then that oil condenses and sits in the lowest part of the system. Might just be me over thinking, but worth a thought....
No, I agree. I have heard this from a lot of guys with intercoolers. Not a bad idea at all
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Old 11-04-2014, 07:46 AM   #8 (permalink)
TAG
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I had the tubes off mine a couple weeks ago doing a pitman arm. No accumulation of oil. There's a highway on ramp in town here that pretty much requires full throttle. On the occasions I use it, I'll usually see a big puff of blue smoke about 3/4 down it. Pretty sure that's the accumulation leaving the intercooler.
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1995 K2500 ECSB 6 lug. 2006 Penninsular 18:1, Diamond Eye 4" exhaust, hx40II, Heath v2.0 chip, A/A intercooler under bumper, custom intake, 285/75/16 all terrains, 3 pod pillar guages, high idle, silverado w/ leather.
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Old 11-04-2014, 08:03 AM   #9 (permalink)
bowtiebutler956
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Quote:
Originally Posted by roadhog0 View Post
Something I've thought about with this is putting a drain bolt in the bottom of the intercooler because the CDR puts oil into the air stream then that oil condenses and sits in the lowest part of the system. Might just be me over thinking, but worth a thought....
Actually, I think thats a fantastic idea, and one I will probably implement. Thanks for the idea.

Matt
__________________
93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear
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Old 11-04-2014, 08:11 AM   #10 (permalink)
bowtiebutler956
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Quote:
Originally Posted by SUPRAPULLER View Post
Man your engine is insanely nice!! That intake makes everything super easy.
Thanks, and it will be nice to have easier access to intake, and ip.

Quote:
Originally Posted by TAG View Post
I am aware some are fussier than others, and i am anal about my truck too, but reality is, i live on a gravel road & put on about 25,000 miles a year in michigan climate. With that said, I used 2.5 inch aluminized exhaust tubing when I installed my cac 8 years ago. Still not a spec of rust on any of it. Not sure if there is a big price difference between the kits & exhaust pipe, just a heads up for those that may be curious.
That sounds like a great idea. Living way down here in deep South Texas, I don't have to deal with much rust, and corrosion, so I think the kit that I posted a link too, will work well for me. Thanks

Matt

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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear
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