Cummins Engine Information

Choosing a Cummins Engine When selecting a Cummins engine for your vehicle, it's important to understand that the primary differences among the 5.9-liter Cummins engines lie in their fuel systems. These engines are largely interchangeable when it comes to transmission mounting, provided the appropriate adapter plate is used. For states requiring emissions inspections, it's generally advisable to choose an engine that matches or exceeds the year of your donor truck. Always consult your local emissions inspector for specific regulations applicable to your project. Factors to consider include fuel efficiency, horsepower and torque, the type of fuel system (mechanical or electronic), noise levels, ease of installation, governed RPM limits, and purchase price. Some customers inquire about using Cummins Industrial engines in their conversions. Below, we'll discuss some considerations regarding these engines. Cummins Industrial engines were originally designed for school buses, dump trucks, tractors, and off-road machinery. While these engines might appear more economical upfront, converting them for automotive use can involve significant costs and effort. More details are provided below. For additional technical data or comparisons, visit: http://www.cumminsdieselspecs.com/ The 12-Valve Engine All 12-valve engines are mechanically injected and do not require any electronics from the truck to operate. Their simplicity makes them the easiest to install, maintain, and rely on. RPM Range: - 0 - 2500 RPM: Bosch VE rotary pump (most common in automotive applications) - Max Stock Torque: 400 ft/lbs @ 1600 RPM (1989-1993 models) - 0 - 2700 RPM: Non-modified P-7100 pump (1994-1998 models) - Max Stock Torque: 440 ft/lbs @ 1600 RPM - 0 - 4000 RPM: Modified inline pump The 1989-1993 engines are easy to find, affordable, and offer excellent fuel economy. They come equipped with the Bosch VE rotary injection pump, which can be adjusted for increased horsepower. Models from 1989-1991½ are non-intercooled, while those from 1991½ onward are intercooled. Upgrading to an intercooler is recommended if you plan to increase power, as it helps manage exhaust temperatures. Adding an inexpensive fuel pin can boost power by 40-60 HP. The vacuum pumps on 1993 and earlier engines are diaphragm-style and may not perform as well as later models if your truck relies on vacuum for brake assistance. Additionally, the air conditioning compressors from this era tend to be longer and use different mounting brackets compared to the 1994-1998 models. Most compressors from 1989-1993 utilized R12 refrigerant, which is costly and hard to obtain. A few 1993 compressors and brackets are similar to the more conversion-friendly 1994-1998 versions shown below. The vacuum pump and power steering mounting bracket are interchangeable. Early engines also feature a different fan support that is higher and more centered with the engine. While this works okay in 1969-1997 trucks, it doesn't fit well in newer trucks due to clearance issues with the radiator shroud. The 1994-1998 engines offer good power, torque, and fuel economy. These engines use the Bosch P7100 inline manual fuel pump, producing 160-215 HP stock. By installing a fuel plate, you can easily add 15-95 HP. These engines are particularly desirable due to their ease of upgrading. Even if you find a bargain on an earlier engine, converting it to a P7100 pump can be cost-effective if you're aiming for high torque figures. Many power upgrades can be performed on 12-valve engines without significantly impacting fuel economy or reliability. When using a Ford radiator with the upper hose connection on the passenger side, replacing the thermostat housing with our offering, which points straight up, simplifies the upper hose connection. This housing comes with a new thermostat and seals. When using a radiator with the upper hose connection on the driver's side, the "new" style thermostat housing pointing towards the driver's side is used. The 24-Valve Engine The 1998½-2002 24-valve engines are computer-controlled and provide slightly more horsepower than earlier models. We offer wiring instructions to help integrate this engine into Ford or Chevrolet vehicles. A Dodge PCM is required for OBDII diagnostics or using an aftermarket tuner that needs a data link connector. Without the PCM, diagnostic information can still be accessed at a Cummins dealership via the Cummins data link connector in the engine wiring harness, but certain performance programmers won't function. The 2001-2002 engines require an electronic speed signal input to run correctly. Trucks with a rear axle speed sensor can easily accommodate this, and it can be added to older trucks with an aftermarket speed sensor. Be aware that some of these engines have a "53 block," identifiable by the number cast onto the side of the block above the oil pan rail on the rear driver's side or front passenger side. These blocks are prone to cracking on the exterior water jacket. The thermostat housing on these trucks points toward the driver's side. If you plan to use a Ford radiator with the upper hose connection on the passenger side, purchasing our straight-up thermostat housing will simplify the upper hose connection. DCS also offers a "standalone" harness to make your Dodge Cummins 24-valve run in any chassis by simply adding power and ground. To determine which 24-valve engine you have, refer to the Cummins MAP sensor connector. The image below provides a visual guide. The Common Rail Engine RPM Range: - 0 - 3200 RPM: Max Stock Torque - 555-650 lb-ft For more detailed information on the Common Rail conversion, see our Common Rail Conversion Information article. Cummins Common Rail 2003-2009, 5.9L/6.7L - Generation 3 These engines are a great choice for conversions, offering excellent power and reliability. Engine tuning upgrades can be done electronically through various tuning services available in the US and Canada. Full engine diagnostic capabilities are retained. There are differences across model years that you should be aware of before sourcing an engine. If unsure whether your ECM is from an automatic or manual transmission truck, we can verify this if you provide the ESN listed on the ECM. Below are some conversion-related notes for your consideration. 2003-2004 with Manual Transmission ECM: - Original APPS (accelerator pedal position sensor) mounted under the battery. - Compatible with DCS's harness modification service and pedal module. - Key recognition security system was optional on some models, which may require an ECM reflash. 2003-2004 with Automatic Transmission ECM: - Original APPS mounted on the engine (retained). A pedal kit is required to operate the engine-mounted APPS. - Compatible with DCS harness modification service. - Key recognition security system was optional on some models, which may require an ECM reflash. - Must designate automatic transmission if using DCS harness modification service. Differences exist compared to the manual transmission engine. 2005: - Both automatic and manual transmissions are compatible, though the manual transmission ECM is reportedly more desirable for power and tuning. - Key recognition security system was optional on some models, which may require an ECM reflash. 2006-2009 5.9L & 6.7L: - Dodge TIPM (Totally Integrated Power Module) is not required for OBD port communication when using modern OBD scan devices. - ECM reflash necessary to eliminate SKIM (Sentry Key Immobilizer Module) security function. 2010 & Newer: Generation 4 - DCS currently does not offer technical support for these engines. Industrial Cummins Engines This information is provided to highlight the many differences between Industrial Cummins engines and Dodge Cummins engines. Converting these engines can involve substantial costs and effort. 12-Valve Industrial Engines Differences from automotive engines often include: - Injection pump - Timing cover - Turbo inlet/outlet - Throttle linkage & cable - Lower radiator hose nipple - A/C compressor bracket - Fan support & pulley - Belt tensioner bracket - Oil pan & pickup tube - Exhaust manifold - Air horn - Lower compression ratio 24-Valve Industrial Engines - Injection pump will not communicate with Dodge ECM - No electronic tuning capabilities - Much lower governed RPM is common (as low as 1900 RPM!) - Fly-by-wire TPS (throttle position sensor incorporated in the accelerator pedal) - Lower radiator hose connection, A/C pump bracket - Fan support/pulley - Thermostat housing/alternator mount - Belt tension bracket - Oil pan and pickup tube (too long sump) - Exhaust manifold - Air horn (intake) - Factory diagnostics require Cummins Insight® Possible options to make an Industrial 24-valve conversion-friendly: 1. Use a mechanical injection pump from a 1994-98 Dodge 12-valve engine known as "P-pumping" the 24-valve engine 2. Obtain ALL of the DODGE electronic engine components (VP44, ECM, PCM, TPS & throttle cable) Common Rail Industrial Engines Our adapter plates will not work with the Common Rail industrial engines due to the engine’s rear gear timing system. *Diesel Conversions® is not affiliated with Cummins, Ford, or Dodge. Our use of these trademarks is for descriptive purposes only. Diesel Conversions® Diesel Conversion Specialists www.dieselconversion.com 320.440.2900

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