FI Interchiller Install w/Aftermarket front bumper

[FULLTHROTTLERICK]

First of all, this project is definitely not for the faint of heart. I’m sure it’ll all make much more sense once we’ve run all the lines but for now it is very daunting TBH. We’ve watched all the videos 10x over and read the 25 PDFs. By the time we figure something out, my 3 kids have imploded and Im back to kid duty (Doesnt help that all 3 are sick right now either)

So far we’ve removed the factory heat exchanger (and horn), installed the chiller, the secondary condenser and the e-fan.

We’ve had to make several brackets since we dont have the 1.5” wide sheet metal under the plastic shroud to bolt to.

Glad i had some time off work! Some photos of our progress below. Yes i added reflectix to the chiller bc i had it lying around and why the F not lol.

P.S. Kirk has been very responsive and helpful

 

[FULLTHROTTLERICK]

PHASE 2

Noticed 1 clip was broken on large suction line. Kirk called and gave me options to remedy. No worries or concerns on the broken clip. Going to replace with a T-bolt clamp in same location.

All lines connected (even the one with the broken clip). Pulled vacuum. Holding for at least an hour so far at -29 hg.

Still need to do this:

Mount/secure drier and solenoid (behind grill light/bracket not making this very easy) Finish insulating lines. Extend high pressure sensor wiring. Extend/re-route horn wiring. Wire relay/etc. Add t-bolt clamp where clip broke. Try to isolate lines from chafing each other/etc. Pray the grill bolts back up over all this shit!

 

[FULLTHROTTLERICK]

PHASE 3

Made brackets for drier and solenoid. All the electrical done except horn. Fan and solenoid both work. Added high temp corrugated to most lines. System still holding vacuum for 26hrs.

SHOULD BE TURNING KEY TMRW BOYS! Still have a few loose ends to clean up but almost there. Ready to charge the system!

 

[FULLTHROTTLERICK]

Leaving open for the last phase hopefully

 

[DanZman]

Awesome write up so far. Looking forward to your results. I didn’t realize that this system was so involved. I always thought it was just the heat exchanger brick and some valves. The pricing seems more reasonable now.

 

[Crazynaclh20]

I'll be watching this one.
I've had one of these kits for a while now. Just haven't had the time to install. Shops want 6k+. One shop broke it down for me. It's not the install it's the fact that any leak will take out the entire AC system so they want to cover future costs of repair from people blaming them. It sucks shops have come to this way of doing business.

 

[ParadigmDawg]

You are a lot different than any other Attorney I know. It's probably why I like you. You're not afraid to get your hands dirty and love playing in the dirt. Most, that I know just sit around in expensive restaurants drinking .

Can't wait to see the progress.

 

[FULLTHROTTLERICK]

You are a lot different than any other Attorney I know. It's probably why I like you. You're not afraid to get your hands dirty and love playing in the dirt. Most, that I know just sit around in expensive restaurants drinking .

Can't wait to see the progress.

Haha thanks man and agreed! I know 0 others like me. Most pull into the dealership and wait to get their OEM air filter cleaned

 

[ParadigmDawg]

Haha thanks man and agreed! I know 0 others like me. Most pull into the dealership and wait to get their OEM air filter cleaned

I know man, when I think back to the days when I acted like that and had to have a new AMG every year or two, it makes me sick, I can't even stand to look at my old crowd now. We used to spend 4 nights a week in the fancy restaurants and drink way too much. Now, I would rather have a sandwich, on a tailgate, in the woods. Keep me posted on the progress and any trips you have coming up.

We are hitting Hot Springs OHV for Christmas through New Years for the Fire and Ice event. Actually, we will spend a lot of time outside of the park too just paying in the forest. My wife is taking her Jeep too.

 

[FULLTHROTTLERICK]

PHASE 2 HAS BEEN ADDED ABOVE. EXHAUSTED. FORGIVE THE DOUBLE POSTS AND MY INCH POUNDS OF MERCURY REFERENCE HAH. NITEY NITE LOL

 

[ParadigmDawg]

Holy cow, that is custom fab shop level installation. I couldn't do it.

 

[FULLTHROTTLERICK]

Holy cow, that is custom fab shop level installation. I couldn't do it.

thx man! Custom fab shop with only hand tools, a cheap vice, a drill and a sawzall lolol

 

[JKMTRX]

Man looks like a lot of work. I have two kids and can feel your pain when trying to do something like this.

Looking forward to your feedback on this! I am very interested in also getting this come summer months.

 

[ParadigmDawg]

Holy cow, that is custom fab shop level installation. I couldn't do it.

 

[FULLTHROTTLERICK]

Phase 3 added

 

[ParadigmDawg]

It somehow took you longer to install your bumpers...lol...

That is a crazy amount of detailed work. Now I see why you don't seem super impressed when I show you pictures like me successfully crimping a wite after 4 trys.

 

[HVACog]

Phase 3 added

working well?

I’m in Santa Clarita , Southern California. Always wanted to do that. It helps in the winter too I’m assuming because the engine gets hot anyways.

 

[FULLTHROTTLERICK]

It somehow took you longer to install your bumpers...lol...

That is a crazy amount of detailed work. Now I see why you don't seem super impressed when I show you pictures like me successfully crimping a wite after 4 trys.

Haha yes when you send me a pic of your flush-cut tie wrap, I am still somewhat impressed haha

The bumpers were definitely more miserable

 

[FULLTHROTTLERICK]

working well?

I’m in Santa Clarita , Southern California. Always wanted to do that. It helps in the winter too I’m assuming because the engine gets hot anyways.

Will post results once I get up and running

 

[FULLTHROTTLERICK]

Ok so we attempted to charge the system and here’s what happened:

• While truck ignition on (not running) = Got 1 full can in (approx. 320grams of R-134 give or take. We weighed the can before and after)
  • Got 2nd can hooked up and the truck only took a few grams of can #2.
  • Fired truck up and raised idle = got some more in but not much
  • Tried spraying condenser with garden hose (no change)
  • Drier sight glass is full of bubbles

• Turned switch on to activate chiller AND cabin
  • Got the rest of the 2nd can in = approx. 326grams of R-134 (total of 646 grams installed in system at this point)
  • Drier sight glass is full of bubbles

• Hooked Can #3 up and forgot to purge the air in the line (is this a huge problem necessitating a total system evac?)
  • Got a few grams in and then it wouldn’t take more so I shut the low side fill port valve.
  • Raised idle/etc and re-opened the valve and it took a few more grams.
  • Repeated this 4-5 times until the truck wouldn’t take any more refrigerant.
  • Total from Can #3 = approx. 60-65 grams
  • Drier sight glass is still full of bubbles

• Checked pressures before shutting truck off:
  • Low side = approx. 25-30
  • High side = approx. 132
  • Ambient = 76-78 degrees

• Shut truck off

• GRAND TOTAL OF REFRIGERANT INSTALLED = Approx. 710grams (way less than the 930grams in the installation instructions)
  • AC is ice cold inside truck (a bit colder than OEM)
  • OEM Hard metal suction line is condensating and about as cold as a beer can that was taken out of fridge and put outside for 1 minute.
  • IC Coolant temp is 35 degrees in chiller only
  • However, the drier sight glass is full of bubbles

Any advice on what to do? I imagine a lot more refrigerant needs to be added right??!

Hoping @217TRX or @AZDinoPwr can chime in too. Already emailed Kirk twice