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Common Rail Conversion Information

Posted by Diesel Conversion on Oct 15th 2020

Information for Conversions using the Common Rail Cummins Engine

 

 

Possible upgrades to 2003/2004 Cummins:

 

Customers using early Commonrails (2003/2004) for their conversion may wish to utilize 2006/2007 Cummins electronics (ECM, TIPM, engine harness, & Injectors).  This allows for true drive-by-wire capability and greater engine tuning options.  An upgrade such as this can be ideal for donor engines purchased without electronics or for customers looking for power improvements.  DCS can then perform our harness service to match your engine connections to the vehicle of your choice. 

 

Engine Mounts:

1967-1997 Ford Engine Mounts

The Common Rail engine does not fit well in these trucks due to the powersteering pump being pulley driven, which protrudes down causing interference with the  power steering box on the Ford frame.  The 12v & 24V engine's power steering pumps are gear driven from the front of the geartrain and are much more conversion friendly for these frames.

1999-2007 Ford Super Duty Engine Mounts

Engine mounts for 99 - 07 trucks are designed to completely replace the Dodge Cummins engine mounts. This allows for the Cummins ECM to remain in it's factory location. The mounts also allow you to choose whether you would like to use the Vistronic clutch and manual fan or you may choose electric fans. Both mounting positions are possible with the same set of mounts.

2008-2010 Ford Engine Mounts

We build mounts designed just for the '08-'10 trucks that completely replace the Dodge Cummins mounts. This was necessary to avoid excessive overhang off the back of the driver side cross member. The mounts allow the ECM to be mounted in the stock location.

Remote Power Steering Tank Hose Adapters

We make an adapter to connect the 1999-2007 Super Duty Ford power steering suction hose to the Dodge Cummins power steering pump if it is like the pump shown in the left picture. This allows you to use the Ford power steering reservoir and keep all the return hose plumbing intact.

This adapter is also helpful when installing a Common Rail into a 1967-1997 Ford, but you will have to source a remote power steering tank yourself.

Wire Harness Services

 Some applications utilize a new conversion harness with others requiring modification of existing harnesses. Please call for details.

Common Rail Engine Driven Fan Options for 99-07 Ford Trucks 

You have three choices on fans: Aftermarket electric, non-electronic-engine driven, or the stock Dodge vistronic.

AFTERMARKET ELECTRIC

We do not recommend this option in most cases. 

DODGE VISTRONIC

This is the original equipment, engine driven radiator fan on the ’03 and newer Cummins engines is a combination viscous/electric clutch fan.

We like to use this option on 6.0 and 6.4 conversions. If you have us take care of the wiring, we pre-wire our harnesses for this option.

On 6.0 and 6.4 conversions, the 6.0 fan blades will bolt to the Dodge vistronic fan clutch which will allow you to use the factory Ford radiator side shroud.

TURBO AND EXHAUST

The common rail exhaust manifold is already conversion friendly. If you do not have one, DCS offers a high flow option. If you have a VGT turbo, you will need to purchase an aftermarket controller to retain VGT functions. Other options would be to install a 2003-2006 non VGT common rail turbo or an aftermarket turbo. DCS also offers a few options for down pipes or often times, a portion of the stock common rail downpipe can be used.

03-09 Cummins Common Rail, 5.9L/6.7L Information 

          The Cummins common rail engines are a great choice for your conversion.   They offer great power and reliability.   Engine tuning upgrades can be done electronically with several tuning service businesses existing in the US and Canada.   Full engine diagnostic capabilities are also retained.  

          There are differences in the various model years you’ll want to be aware of before sourcing an engine.   Below are some conversion related notes for your consideration.  If you are unsure if your ECM is from an automatic or manual transmission truck we can verify this if you provide us with the ESN listed on the ECM. 

2003-2004 with Manual Trans ECM:

  • Original APPS (accelerator pedal position sensor) mounted under battery.
  • ECM is compatible with DCS’s harness modification service and pedal module.
  • Key recognition security system was optional on some models which may require a re-flash of the ECM.
  • ECM and Wire harness must match.  Automatic is different than Manual transmisson wiring and ECM.

2003-2004 with Automatic Trans ECM:

  • Original APPS (accelerator pedal position sensor) mounted on engine. This is retained.
  • ECM is compatible with DCS’s harness modification service.
  • Key recognition security system was optional on some models which may require a re-flash of the ECM.
  • ECM and Wire harness must match.  Automatic is different than Manual transmission wiring and ECM.

2005:

  • Both the Automatic and Manual trans are compatible, however the Manual trans ECM has been reported to be more desirable for power & tuning.
  • Key recognition security system was enabled and will require a re-flash of the ECM.

2006-2009 5.9 & 6.7 Liter:

  • Dodge TIPM (Totally Integrated Power Module) is not required for OBD port communication (On Board Diagnostics).
  • ECM re-flash necessary to eliminate SKIM (Sentry Key Immobilizer Module) security function

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