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6.2 intercooler

Blazooki

Blazooki

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I've been thinking about adding an intercooler to my banks turbo'd 6.2

do you think it would be worth it or just a waste?

space and looks are not a consideration
 
Talk to the guys over on the 6.2-6.5 forum. I believe a few over there have done it.
 
My truck is intercooled, a modded duramax intercooler, and it did take some pretty good mods to both the cooler and the core support it works very well. However I'm running a gm8 turbo that is basically maxed out since I'm seeing 15 lbs of boost after the intercooler, was over 24 :eek1: before ic installed. The turbo that the banks kit uses doesn't work well with an intercooler. It doesn't move enough air to be beneficial. So unless you're planning on getting a better turbo I would leave it non-intercooled. If egts are an issue you could always add water-injection.
 
i have mad a few methenal /water injection kit so far and they work really well for what your wanting, more power, cool egt's, and as a side affecter your engine gets steam cleaned every time u turn the kit on plus u gain a couple mpg too. snowperformance is how i usually get my parts threw, use a stage one gas kit, part number 20001 cost about 300 dollars takes about 4 to 5 hours to install cleanly, and you'll have to make a activation switch but thats not hard, cost about 20 dollars to make one, they are very simple to make.
 
it is never a bad idea to cool charge air after the turbo. cool air is more dense, more o2 per cubic volume. loss of pressure after the addition of the CAC/ did you loose power? did you loose MPG? I bet no. I bet it makes more HP on the top end at the lower psi now, than it did before with hot intake air at 24 psi.


KirsL said:
My truck is intercooled, a modded duramax intercooler, and it did take some pretty good mods to both the cooler and the core support it works very well. However I'm running a gm8 turbo that is basically maxed out since I'm seeing 15 lbs of boost after the intercooler, was over 24 :eek1: before ic installed. The turbo that the banks kit uses doesn't work well with an intercooler. It doesn't move enough air to be beneficial. So unless you're planning on getting a better turbo I would leave it non-intercooled. If egts are an issue you could always add water-injection.
Click to expand...
 
The gm8 before I tweaked it only put out 12lbs without the CAC. Now I'm running a turbo master wastegate controller and all I actually did was put a heavy spring on it in order to get the higher boost numbers. The wastegate barely moves :eek1:, not a good thing I know but as long as I don't dump the throttle from WOT to idle it'll last for a while. While I'm pushing this turbo this far beyond its limits when at wot, under normal driving it actually sits right in the area that GM designed it for and it works great. I'm still planning on putting a better one on, but it's not a high priority right now.

You also have to remember that my engine as a whole was built for higher boost and to be beat on, and I do too, sometimes :whistle:. A stock 6.2 even with the intercooler I wouldn't push past 15lbs of boost, especially with stock head bolts. I run head studs, a wise investment on any engine.

Demon, I agree that any boosted engine should have a CAC, sometimes it's just not worth it or can't be fit.
You are also correct about the pressure loss but more dense air due to the cac too. Now my truck did actually lose some power on the top end but not because of the cac install, I swapped out a pretty aggressive cam for a stocker. I did gain better bottom end and mid range power, plus it starts WAYYYYY better. So was worth losing a bit of power. Fuel mileage might have gone up a bit, but this truck always seemed to give about 15 or so in town.
 
Your power loss on the top end is probably more to do with backpressure in your exhaust turbine housing on your turbo than anything else. It is always a sacrifice with turbos, and our motors for that matter. Much over 12-13 psi the factory 6.5 GMX series turbos start becoming horribly inefficient in terms of exhaust airflow. with the Series 8 being the least affected. If you are CAC'd then your 15 psi at that dense of a intake air temp your turbo isnt able to get rid of the exhaust fast enough. Back when I had my 1995 I welded a NPT port on the crossover pipe so I could measure exhaust pressure. Its been years now since I messed with it (Truck was stolen in 2008) but I will see if I can find my spreadsheet and post up the numbers for the different GMX series turbos and their relative pressure readings. Dont remember which forum I was on but someone had done something similar and had dyno results to go along with it.

The 6.2/6.5 Banks Non-wastegated turbos actually flow better Exhaust wise at the upper RPM's than the GMX ones however they are Pigs at building boost under lower load conditions. Hence the Tradeoff. I have a banks set up to go on my Burbalanche, I would love to use a GMX wastegated so I could play with my boost levels but Dont want to get rid of My A/C too hot where Im at for most of the year.
 
thanks for the info guys...guess ill forget the intercooler since I have the Banks turbo
 
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