Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on August 25, 1992.
As of Tuesday, June 25th, 2019 this Executive Order has not been overturned or superceeded.

Approved Parts

Models
1983-1992 turbocharged Ford Motor Company heavy-duty vehicles powered by a 6.9L/7.3L Navistar International heavy-duty diesel engine.

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-175-3
  • Executive Order 175-3 / D175-3
  • ARB # D-175-3
  • Executive Order No: D-175-3
  • C.A.R.B. No. D-175-3
  • Resolution D-175-3
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-175-3 PDF

D-175-3 Document:



                                                                  Page 1 of 2)

                                    State of California
                                    AIR RESOURCES BOARD

                               EXECUTIVE ORDER D—175—3
                   Relating to Exemptions Under Section 2"156
                              of the Vehicle Code

                               HYPERMAX ENGINEERING, INC.
                               AIR—TO—AIR INTERCOOLER KIT



Pursuant to the authority vested in the Air Resources Bsard by Section 27156
of the Vehicle Code;     and

Pursuant to the authority vested in the undersigned by Section 39515 and
39516 of the Health and Safety Code and Executive Order G—45—5;

IT IS ORDERED AND RESOLVED:  That the installation of the add—on
air—to—air intercooler kit manufactured by Hypermax E   neering, Inc.
of 255 E.   Route 72,   CGilbert,    Iliinois 60136,   has been fosund not to reduce
the effectiveness of required motor vehicle pollution control devices, and
therefore is exempt from the prohibitions of Section 27156 of the Vehicle
Code for 1983—1992 turbocharged Ford Motor Company heavy—duty vehicles
powered by a 6.9L/7.3L Navistar International heavy—duty diesel engine.

This exemption shall not apply to any device,           apparatus, or mechanism
advertised, offered for sale or sold with, or installed on, a motor vehicle
prior to or concurrent with transfer to an ultimate purchaser.

This Executive Order is valid provided that installati    instructions for
this device will not recommend tuning the vehicle to specifications
different from those submitted by the device manufactursr.

Changes made to the design or operating conditions of the device, as
exempted by the Air Resources Board, that adversely affect the performance
of a vehicle‘s pollution control system shall invalidate this Executive
Order.

Marketing of this device using an identification other than that shown in
this Executive Order or marketing of this device for ar application other
than those listed in this Executive Order shall be profibited unless prior
approval is obtained from the Air Resources Board.  Exemption of a kit shall
not be construed as an exemption to sell,         offer for sals,   or advertise any
component of the product as an individual device.

This Executive Order does not constitute any opinion as to the effect that
the use of this device may have on any warranty either expressed or implied
by the vehicle manufacturer.

THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATIOH, ACCREDITATION,
APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE AIR RESOURCES BOARD OF ANY
CLAIMS OF THE APPLICANT CONCERNING ANTI—POLLUTION BENEFITS OR ANY ALLECED
BENEFITS OF THE HYPERMAX ENGINEERING, INC.‘S AIR—TO—AIR INTERCOOLER KIT.


HYPERMAX ENGINEERING, INC.                              EXECUTIVE ORDER D—175—3
AIR—TO—AIR INTERCOOLER KIT                              (Page 2 of 2)




No claim of any kind, such as "Approved by the Air Resources Board" may be
made with respect to the action taken herein in any advertising or other
oral or written communications.

Section 17500 of the Business and Professions Code makes untrue or
misleading advertising unlawful,      and Section 17534 makes violation
punishable as a misdemeanor.

Section 43644 of the Health and Safety Code provides as follows:

     "43644,  (a)  No person shall install, sell offer for sale, or
     advertise or except in an application to the state board for
     certification of a device, represent, any device as a motor vehicle
     pollution control device for use on any used motor vehicle unless that
     device has been certified by the state board.  No person shall sell,
     offer for sale, advertise, or represent any motor vehicle poilution
     control device as a certified device which, in fact, is not a certified
     device.  Any violation of this subdivision is a misdemeanor."

Any apparent violation of the conditions of this Executive Order will be
submitted to the Attorney General of California for such action as he deems
advisable.

Executed at El Monte,   California,   this   a%5~féi~    August,   1992.




                                       Mobile Source Division


                            State of California
                            AIR RESOURCES BOARD




EVALUATION OF HYPERMAX ENGINEERING, INC.‘S ADD—ON AIR—TO—AIR INTERCOOLER KIT
     FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE SECTION 27156
              IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                       CALIFORNIA CODE OF REGULATIONS




                               August 1992


                              State of California
                              AIR RESOURCES BOARD




EVALUATION OF HYPERMAX ENGINEERING, INC.‘S ADD—ON AIR—TO—AIR INTERCOOLER KIT
     FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE SECTION 27156
             IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                       CALIFORNIA CODE OF REGULATIONS




                                       by

                             Mobile Source Division
                              State of California
                              Air Resources Board
                              9528 Telstar Avenue
                            El Monte, CA 91731—2990




(This report has been reviewed by the staff of the California Air Resources
Board and approved for publication.   Approval does not signify that the
c ontents necessarily reflect the views and policies of the Air Resources
Board,   nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.)


                                    SU   ¥4




       Hypermax Engineering, Inc.   (Hypermax) of 255 E. Route 72, Gilberts,

Illinois 60136, has applied for an exemption from the prohibitions in Section

27156 of the California Vehicle Code (VC) for their add—on intercooler kit

for 1983—1987 Ford Motor Company vehicles powered by the Navistar

International 6.9L heavy—duty diesel engine and 1988~1992 model—year Ford

Motor Company vehicles powered by a 7.3L Navistar International heavy—duty

diesel engine.

       Hypermax has submitted a completed application and all the necessary

information for exemption.   Based on previous comparative tests evaluating the

exhaust emissions effects of several add—on intercooler systems and the staff‘s

evaluation of the intercooler‘s impact on exhaust emissions from turbocharged

vehicles, the staff concludes that the Hypermax‘s intercooler system will not

adversely affect exhaust emissions from vehicles for which the exemption is

requested.

       The staff recommends that Hypermax be granted an exemption as requested

and that Executive Order D—175—3 be issued.


                                   TABLE OF CONTENTS




                                                                  Page Number




SUMMARY                                                                 i

CONTENTS                                                               ii

I.        INTRODUCTION                                                  1

II.       CONCLUSION                                                    1

III.      RECOMMENDATION                                                1

Iv.       INTERCOOLER KIT DESCRIPTION                                   1

v.        DISCUSSION                                                    2

          APPENDIX A:    INSTALLATION INSTRUCTIONS AND PART NUMBERS     4




                                          i1


 EVALUATION OF HYPERMAX ENGINEERING, INC.‘S ADD—ON AIR—TO—AIR INTERCOOLER KIT
       FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE SECTION 27156
               IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                         CALIFORNIA CODR OF REGULATIONS



I.     INTRODUCTION

       Hypermax Engineering,   Inc.   (Hypermax) of 255 E. Route 72, Gilberts,

Illinois 60136, has applied for an exemption from the prohibitions in Section

27156 of the California Vehicle Code (VC) for their add—on air—to—air

intercooler kit for 1983—1987 Ford Motor Company vehicles powered by

the Navistar International 6.9L heavy—duty diesel engine and 1988—1992 model—

year Ford Motor Company vehicles powered by a 7.3L Navistar International

heavy—duty diesel engine.

11.    CONCLUSIONS

       Based on previous comparative tests evaluating the effects of several

add—on intercooler systems on exhaust emissions and the staff‘s evaluation of

the intercooler impact on exhaust emissions from turbocharged vehicles, the

staff concludes that the Hypermax‘s intercooler system will not adversely

affect exhaust emissions from vehicles for which the exemption is requested.

III.   RECOMMENDATION

       The staff recommends that Hypermax be granted an exemption for their

add—on air—to—air intercooler system as requested and that Executive Order

D—175—3 be issued.

IV.    INTERCOOLER KIT DESCRIPTION

       The purpose of the Hypermax intercooler system is to reduce the

temperature of the intake air charge into the turbocharged engine.     This

reduction in the intake charge temperature allows a greater charge density

{more mass of air flowing through the engine) to enter the combustion chamber

which means more fuel into the engine at any giyen intake manifold pressure

and, therefore, more power output of the engine.     Also, the reduction in the

intake charge temperature would result in lower combustion/exhaust temperature.


       The major components of the air—to—air intercooler system include a heat

exchanger and inter—connecting bent tubing along with the necessary nuts,

bolts, clamps, washers and brackets necessary to assemble the kit.     The

compressed air from the turbocharger enters the heat exchanger which uses

ambient air as a cooling medium.     The air—to—air heat exchanger is located in

such a way that the heated charge air flows through one section and ambient air

flows through the other section,    cooling the heated compressed charge air.     The

cooled compressed air is then passed out of the heat exchanger to the

throttle(s) for induction into the engine.     There will be a pressure drop when

the air passes through the heat exchanger which varies depending on the size of

the heat exchanger, the temperature of the cooling medium (ambient air) and the

available flow rate of the cooling medium.

       The inlet and outlet pipes of the Hypermax air—to—air intercooler kit

are made from steel tubing.     No emission control components are removed,

disconnected or relocated when the air—to—air intercooler kit is installed.

Installation instructions,    included in every kit, show how to properly install

the Hypermax intercooler kit.     Appendix A shows the installation instructions

including the part numbers.

       V.   DISCUSSION

            The Hypermax add—on air—to—air intercooler is designed for

installation on 1983—1987 Ford Motor Company vehicles powered by a 6.9L

Navistar International heavy—duty diesel engine and 1988~1992 model—year Ford

Motor Company vehicles powered by a 7.3L Navistar International heavy—duty

diesel engine.     Hypermax‘s intercooler kit is similar in design concepts and

principles as other manufacturers‘ systems that have been exempted by the Air

Resources Board.    According to the performance analysis previously submitted by

other manufacturers seeking exemption, the thermal efficiency of the

intercooler system ranges between 40 percent and 84 percent.


            Based on predicted efficiency of a heat exchanger and a review of

the intercooler kit, the staff believes that the Hypermax‘s add—on air—to—air

intercooler kit will not adversely affect a turbocharged vehicle‘s emissions or

degrade a vehicle‘s driveability.


APPENDIX A


                               HYPERMAX ENGINEERING, INC.
                              6.9/7.3L IN¥FERCOOLER PACKAGE
                  I N 8 T A L L A E L 0 KX K 8 T R V G I L 9 N &

Time will be saved if these instructions are read PRIOR to installation of
the intercooler package.

A.     ITEM            EM
      1.    Negative battery cables
      2.   <Bumper 1983=86.   Bumper/Reinforcement/Bracket Ass‘y 1987—91
      3.   Radiator grille                           .
      4.   Headlight trim (both sides) 1983—86
      5.   Stone deflector
      6.   Hood latch
      7.    Outer radiator grille support
      8.   Air filter and air cleaner mount—
      9.   Top grille cover
     10.      Intake manifold cover

B.     MOUNTING INTERCOOLER:

      1.   If the vehicle is equipped with an optional or aftermarket
           transmission oil cooler, temporarily move it out of the way and then
           relocate it after the intercooler is installed.

           Provide pass thru holes in the radiator support for the air pipes to
           and from the intercooler by referring to Fig. 1.  Use 3" hole saw.
           Cut or grind B0OTH front and rear radiator side support flanges
           so hole in support bracket is unobstructed.        Push air conditioning
           condenser as close to radiator as possible.
           Install rubber isolation mounts on outside of intercooler
           mounts.

           Install right angle intercoocler mounts on other end of rubber
           isolation mount and hand tighten. (Note:     5/16" diameter holes
           should face towards outside of vehicle.)

           Hold intercooler in place with pipe protruding THROUGH CENTER
           of 3" hole cut in radiator support bracket. Level
           intercooler and mark the (4) holes for the mounting brackets,
           keeping brackets as low as possible.     Remove intercooler/bracket
           assembly.
           Drill the (4) 1/4" diameter holes through.
           Screw 5/16" diameter self—tapping sheet metal bolts into holes to
           cut threads.


                                        Page L


                                                                    ~        042292—1


               Trial fit intercooler as needed.

         10.   For trucks with air—conditioning, remove bracket on the RIGHT
               side of the condenser and bend the condenser line back.
               Re—install the bracket UPSIDE DOWN.  (NOT APPLICABLE FOR 1987—
               1991 VEHICLES)
         11.   Re—install intercooler on truck.
         12.   Locate lower mount on left bottom of intercooler.         Mark through
               hole to locate on radiator support frame.
         13.   Remove intercooler, drill 3/8" diameter hole thru frame for lower
               mount,      (Notae: Be careful not to damage radiator.)
         14.   Grind or cut support frame for clearance of HYI—2 pipe per
     —         Fig. 1.     Also ?rind rear side of support bracket on
               radiator for pipe clearance as on above hole,.


C.         INSTALLATION    O¥ BIPES AND   INTA            R

          1.   Install intake manifolq cover with its "0" ring (apply grease
               to "0" ring).     Retain LIGHTLY with 3/8" NC x 4" bolt with "0" ring
               washer and backup washer.

          2.   Remove 3/8" boit from cutside of fuel filter mount.
               Oil dipstick tube must be bent outwards for lower pipe (HYI~3)
               clearance.  For 1985—86 trucks with mount over valve cover, remove
               and relocate it back (1 set) of valve cover holes.  Note:  For
               1987—91 vehicles, relocate to the bottom set of bolts and use
               bracket provided.
               Install lower cold pipe (HYI=3) without hose on intake cover. Check
               for clearance with fuel line heater, air conditioning equipment,
               horn,    battery cables,   etc.    If there is interference,   bend or
               cable—~tie as required.     (Note:    This is a TRIAL—FIT step.)

               Install upger hot pipe (HYI—1) noting clearance with the
               above mentioned parts.

               Install upper mount strap on the front of the fuel filter mount
               support bracket with 3/8" bolt.  Connect strap to upper hot pipe
               (HYP—1) bracket with (2) 1/4" boits, nuts, and lock washers.
               Tighten bolts and nuts after best alignment is achieved. Install
               1/4" Né boit into brackel which fholds (2) plpes LogeUer.

               Align intake cover with pipes in place.        Tighten clamps and
               3/8" bolt on cover.




                                                 Page 2


                                                                                   042292—1


     8.    Remove pipes — install hoses with clamps on pipe.     (Note:     make sure
           lower clamps are FACING UP on the outside of the pipe.  Re—install
           pipes, sliding hoses over intake cover.  Tighten upper hose clamps
           and boits.

     9.    Re—install air filter mount and air filter.


D.   INTERCOOLER
     1.    Install lower rubber isolation mount into frame with 3/8" nut
           and lock washer.

     2.    Re—install intercooler inserting 2—1/4" dia. inlet into hose
           on upper hot pipe (HYI—1).   Install u{per mount brackets with
           3/8" nuts and lock washers on rubber   isolation mount studs.
     3.    Push intercooler back against lower mount.     Shim mount with
           washers provided so as to have a minimum of 1/4" clearance at
           all points.   Install 3/8" nut with lock washer.
     4.    Install front connecting pipe (HYI—2) with hoses at both ends.
           Mark radiator support frame. Remove pipe and drill 1/4" dianeter
           hole.   CAP THE PIPE OPENING while drilling.

     5..   Screw 5/16" self—tapping sheet metal bolt into hole to cut threads.
     6.    Re—install front connector pipe (HYI—2).     Tighten ALL clanmps.

     MODIFICATION OF FRONT END COMPONENTS:

     OUTER RADIATOR GRILLE SUPPORT:  Cut—off 2—3/4" below top.        Discard lower
     piece.  Remount on radiator support frame.

     TOP GRILLE COVER: Trim as required to clear hood latch and intercooler
     brackets. 1987—91 vehicles, secondary latch handle must be cut by
     approximately 1" and bent outward 90°.

     STONE DEFLECTOR:     Cut off center tab flush.

     198%—86 — Re~install top grille cover, molding and headlight trim
     {(both sides).  Rear of grille assembly may have to be cut so it can
     be reinstalled.   The top grille cover must be trimmed around
     intercocler mounts.   The front deflector panel and lower trim strip
     are eliminated with installation of the intercooler.
     1987—91 — Additional clearance must be provided between the
     grille and radiator/cooler assemblies by spacing the grille forward
     with spacers, bolts, washers, and nylock nuts provided.        Bolt holes
     in headlamp housing (RH and LH)} must be enlarged to 11/32" where
     grille mounts.  Transfer holes to grille support.  Note:  clips on
     grille are no longer utilized.  The front deflector panel may have
     to be trimmed around the intercooler brackets and hood latch assembly.

                                        Page 3


                                                                             042292—1


F.         NAL
      .&     Install stone deflector.

     2.     Install bumper, check for clearance with intercooler.
            1983=86 vehicles, space bumper out with washers between frame and
            bumper as required.

     3.      Adjust hood Llatch per Ford Manual.

QPERATING NOTEi

O1l from the crankcase breather system may éccumulate in the intercooler
core after an extended period of time (15,000 =.20,000 miles) and cause a
REDUCTION IN TURBOCHARCER BO00ST. DO NOT CONFUSE THIS CONDETION WITH LOW
BOOST DUE TO A CONTAMINATED AIR OR FUEL FILTER.

If the intercocler is diagnosed as being oil restricted, simply flush the
interior with a petroleum solvent.      '




                                         Page 4

                                                                        042292—1


           PARTS LIST — PORD PICK—UP TRUCK ENTERCOOLER PACKAGE


LineNo.    Qt¥Y.       Desceription
 1        (1)          Assembly — intercooler
 2        (1)          Cover — intake manifold
 3         (3)         Mount =— rubber isolation
 4         {1)         Strap — upper mount (1983~88}
 5         (1)         Strap — upper mount (1989—92)
 6         {1)         Bracket — upper hénger'(right hand)
 7         (1)         Bracket = upper hanger (left hand)

 B         {(1)        Bracket — oil dipstick tube (1987—92)

 9         (5)         Hose — (2—1/4" dia. x 3—1/4" igth.)
10        (10)         Clamp — hose (2—1/4" dia.)

11         (5)         Bolt.—= self—tapping sheet metal (5/16" dia.)
12         {1)         Pipe = upper hot (HYI-l)'

           (1)         Pipe — front connector (HYI—2)

14         (1)         Pipe — lower cold (HYVI—3)
15         (2)         Nut — {1/4" NC)
16         (1)         Nut — (5/16" NC)

17         (€3)        Nut —     (3/8" NQC)

18         (3)         Washer — lock (1/4"}

19         {(1)        Washer — lock (5/16")

20        (6)          Washer — lock (3/8")
21        (3)          Washer — flat (3/8" dia.)

22        (8)          Washer — flat (5/16")       (1987—1992)

23        (3)          Bolit —   (1/4" NC x 3/4")

24        (1)          Bolt — (§/16" NC x 1")
25        {4)         Bolt =     (5/16" NC x 2")    (1987—1992}


                                      Page 5


                                                                   04229 2—1L


L    No    Oty.         Dpescription

2          {(1)         O—ring — intake cover
27         (4)          Nylock (5/16) (1987—1992)
28         (4)          Grillie Spacers (3/4" x 1")   (1987~1992)

29         (1)          Instructions — installation




HYPERMAX ENGINEERING, INC.
255 E. RT. 72
GILBBRTS, IL 60136
(708) 428—5655



                                   Page 6


                                                                    042292—1


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                       oi vahone uc uQAd   UR   MAEPNINA     laing l h e t stley   clalee
      DIESEL CONTROLLER FOR AN EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE
           SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                            CALIFORNIA CODE OF REGULATIONS


I.      INTRODUCTION

            Hypermax Engineering,               Inc.   of 255 E Route 72,           Gilberts,    Illincis

60136 has applied for an exemption from the prohibitions in Section 27156 of

the California Vehicle Code (VC) for their Diesel Controller for 1993—97

trucks equipped with a turbocharged Navistar 7.3L diesel engine.

II.      CONCLUSIONS

             Based on submitted emissions test data,                       the staff concludes that

Hypermax Engineering,        Inc.‘s Diesel Controller will not adversely affect

exhaust emissions from the vehicles for which the exemption is requested.

III.     RECOMMENDATION

            The staff recommends that Hypermax Enginsering,                           Inc.   be granted an

exemption for their Diesel Controller for installation on 1993—97 trucks

equipped with a turbocharged Navistar 7.3L diesel engine.                               The staff also

recommends that Executive Order D—175—12 be issued.

IV.    DIESEL CONTROLLER DESCRIPTION

            The Diesel Controller manufactured by Hypermax Engineering has been

specifically designed for installation on 1993—97 trucks equipped with a

turbocharged Navistar 7.3L diesel engine.

            The purpose of using Hypermax‘s Diesel Controller is to enhance the

performance of the 7.3L diesel engine during high torque and wide open

throttle conditions       (WOT).

            The new electronic control module (ECM), the Hypermax Diesel

Controller,    is a direct replacement ECM that has been modified.                              The

modifications made are designed to interface with the existing software and

hardware to improve the performance of the engine.                            The principal idea behind

the modifications is to increase the injector pulse width and allow more fuel

to be delivered to the engine during 50 percent or greater throttle position.

The manufacturer claimed that by increase the pulse width at 50 percent

throttle,   the driver would not experience any sudden surge in power that may

result if the injector pulse width is increased at or near WOT.                                 Hypermax

claims that these trucks are usually used for long haul travel and do not

exceed the 50 percent throttle position during normal driving.                               Since these

trucks are factory turbocharged and usually are equipped with manual

                                                       ~1—


transmissions, throttle position between 50 and 100 percent is rarely used,

except for high load and acceleration conditions.

v.          DISCUSSION OF THE DIESEL CONTROLLER

            A 1995 Ford F—350 equipped with a 7.3L turbocharged diesel engine

was used for the evaluation of the Diesel Controller.              Testing consisted of

one Cold 505 in the baseline configuration and one Cold 505 in the modified

configuration.     The dynamometer inertia weight and horsepower settings were

8000—1bs.    and 19.3—hp.,   respectively.       The emissions testing was conducted by

Roush Laboratories for Hypermax, data was evaluated against the vehicles‘s

baseline emission levels.       Table 1 list those results.

                                           Table 1.

                                     (gm/mile)

                   HC           co               NOx          Particulates

Baseline         0.89          4.68              7.8            0.15

Modified         0.84          4.46              7.4            0.16

            The ARB did not perform testing to confirm the emission test results

submitted by the applicant.       Emission test results submitted were below the

vehicle‘s baseline emission levels or within the allowable increases of 0.1

grams/mile or 10 percent on HC or NOx,           1.0 grams/mile or 15 percent on CO,       and

0.03 grams/mile or 15 percent on Particulates.

            In addition to their emissions evaluation Roush also performed a key

on engine off    (KOEO)   test and a key on engine running        (KOER}   test with the

vehicle in the baseline and modified configuration.              Hypermax used a new 1997

Ford F—350 truck with the 7.3L diesel engine to evaluate the affect of the

device on the vehicle‘s limited on—board diagnostic (OBD) II system.                The OBD

II system was introduced only on medium—duty diesels trucks in 1997.                No codes

were detected and the vehicle‘s monitors completed their check.                An incomplete

monitor would mean that the vehicle‘s computer had not been able to complete

its evaluation of the sensors associated with that monitor.                Therefore, based

on the test results and the OBD II checks,             the staff concludes that the

installation of the Diesel Controller will not have an adverse effect on

exhaust emissions on those applicable vehicles.

            Hypermax Engineering has submitted all the required information and

fulfilled the requirements for an exemption.
                                             —2—



Document Created: 2005-09-01 12:40:16
Document Modified: 2005-09-01 12:40:16

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