LBZ Duramax Intercooler Upgrades for More Horsepower

Understanding LBZ Intercoolers

The Duramax LBZ engine, produced by General Motors between 2006 and 2007, features an innovative compound turbocharger system to deliver exceptional power and fuel efficiency. A key component in this forced induction system is the large air-to-air intercooler, which helps cool the heated air coming from the turbochargers before it enters the intake manifold and cylinders.

What is an Intercooler?

An intercooler is essentially a specialized heat exchanger that removes waste heat from the intake air charge, allowing more air to fit into the engine's cylinders. By cooling this pressurized air, it becomes more dense. When this cooler and denser air mixes with fuel, a bigger explosion occurs inside the cylinder, unleashing more horsepower.

The LBZ Duramax utilizes a large front-mounted air-to-air intercooler below the main grille area. Ambient airflow passes through this intercooler matrix, absorbing heat from the intake air coming from a pair of turbochargers. This allows the LBZ to make 360 horsepower and 650 ft-lbs of torque from the factory.

Intercooler Upgrade Options

One popular upgrade option for LBZ owners looking for even more power is an aftermarket top-mount intercooler kit. Companies like Mishimoto offer direct bolt-in kits that maximize intercooler size for the LBZ engine bay. Larger cores increase heat transfer capacity and further cool intake temperatures for a denser air charge.

Mishimoto uses 100% aluminum construction on their massive 31" wide x 6.5" tall x 2.5" thick LBZ intercooler. This provides significantly more cooling capacity compared to the factory unit. The aluminum composition also saves weight over an older cast iron design.

Benefits of an Upgraded Intercooler

What are some of the benefits of upgrading to a larger top-mount intercooler like the Mishimoto unit designed for the LBZ Duramax?

• Supports more horsepower - Bigger cores allow for cooler charge air temperatures, enabling the engine to handle more boost pressure and airflow safely before encountering detonation issues. This equals a significant power increase over stock.
• Improved efficiency - Cooler intake temperatures improve combustion efficiency, resulting in better fuel mileage during normal driving.
• Increased reliability - Cooler operating temperatures reduce strain on critical components like the pistons, bearings, head gasket and more compared to running hot on a smaller factory intercooler.

Mishimoto rigorously tested their Duramax LBZ intercooler design on the street and strip under intense race conditions. The all-aluminum bar-and-plate construction proved incredibly durable during harsh daily abuse. Many owners report these direct fit kits supporting well over 800+ horsepower on otherwise stock LBZ trucks.

Supporting Intercooler Components

When upgrading the LBZ intercooler system, also consider replacing old and cracked factory boost tubes with quality silicone hoses. Companies like WC Fab offer reinforced intercooler tube kits to handle increased pressures.

Their double layer LBZ intercooler pipe kit features a 4-ply silicone sleeve overtop a thick mandrel bent aluminum core pipe. This provides a super robust boost tube that improves flow while preventing blow-offs. The kit replaces the factory plastic tubes prone to cracking under higher boost.

For optimal mounting, also install new T-bolt clamps sized appropriately for the silicone sleeve diameter. Give everything a thorough check over every few months for any wear or looseness.

Conclusion

A properly engineered intercooler upgrade unleashes tremendous extra horsepower potential from the LBZ Duramax platform while increasing reliability. Companies like Mishimoto and WC Fab offer bolt-on kits that work seamlessly with the factory LBZ turbo system.

Their intercooler and piping upgrades maximize cooling capacity for thicker thermal margins on modified trucks running substantially more power compared to stock. Supporting mods like an exhaust, intake and tuning stack with an intercooler upgrade to realize the full horsepower benefits.

FAQs

What size intercooler fits the LBZ Duramax?

Most top mount intercooler upgrade kits for the LBZ Duramax feature massive cores that measure around 31 inches wide by 6.5 inches tall. Thickness ranges from 2 to 3 inches.

Should I upgrade the stock intercooler pipes?

Yes, it's a good idea to replace the factory plastic hard pipes with silicone intercooler tubes and aluminum core pipes when upgrading the LBZ intercooler. Kits from WC Fab feature 4-ply silicone sleeving over mandrel bent aluminum cores.

How much power can an intercooler add?

A larger aftermarket LBZ Duramax intercooler combined with supporting mods like an exhaust can reliably add over 100+ horsepower. Better intercooling supports more boost pressure and airflow.

Will an intercooler improve fuel economy?

Yes, a larger LBZ intercooler upgrade allows for better combustion efficiency thanks to cooler intake air temperatures. Many notice 1-3 MPG better fuel mileage around town after the install.