12v to commonrail swap pics.

[RRamsey]

Hey guy's,



I took a 225 mile trip this weekend and averaged 27. 8mpg!!! Smarty on tnt #4 w/stock timing. It hasnt so much as hiccupped since the first time I started it up. I do notice at part throttle around 25 psi the turbo surges up and down, if I give it a little throttle it goes away, very slight maybe the wastegate controller working? heres some pics as we went start to finish.

 

[RRamsey]

more pics

Here is just a couple pics of the engine speed sensor from the 12v with new bracket mounted on the c/r note the slots I had machined into the balancer. my new throttle setup tacked together, allowed me to use the apps to run the stock throttle cable in which operates a bell-crank from a p-pump mounted to a 2nd gen 24v bell-crank mount. It works perfect.

 

[Vaughn MacKenzie]

Good work RRamsey. How do you like the drivability, sound, etc. ??

27. 8 MPG, yeah right, did you ever break 55 MPH?? :-laf

Did you switch over to a 24-valve exhaust manifold or make the exhaust system work with the 3G turbo & man? Was that hard to do?

I have wondered what a commonrail could do MPG-wise in a 2nd Gen truck because the drag coefficient is considerably less than a 3rd Gen.

 

[RRamsey]

Vaughn,



It runs and drives great, sounds awesome!!. Diamond-eye sent me a down-pipe for a 03-07, I had to rotate the outlet elbow on the turbo and cut 4" out of my intermediate pipe and it fit like it was made for it. If you check around you will find that it is not on common to see a 04. 5-06 get 27+ mpg. I have a customer whose truck is bone stock except a K&N and is running a Bullydog triple dog w/crazy larry on all the time and consistantly gets 28mpg. My trip averaged 61mph over the whole trip. 35" tires w/3:54 gears. I am noticing the boost fluctuating when between 23-27psi and part throttle no load. you can hear the turbo speeding up and slowing down. Also It seems to get to 1450-1500 deg pretty easy, 3/4 throttle accelerating gets to 1400+, smarty set at #4 tnt w/stock timing, my 12v didn't get that hot that easy. What the heck would they hit if I put the smarty on level 10???

 

[Cummins Thunder]

I still would like to know more about the wiring.

How quiet is the truck compared to a third gen?

Very cool project

 

[Vaughn MacKenzie]

RRamsey you should get a video or sound file of it to post

I like the "growl" of a 3rd Gen exhaust note under load (with the right exhaust system) which is due to the manifold. Have thought of possibly putting a 3G manifold on my 2G truck for a unique sound. Of the 5 CTDs I've had the best sounding one was my '03 with an ATS manifold & Aeroturbinemuffler.

My '03 usually got about 20-22 at 68-72 mph on the highway, it was a 2wd shortbed 6-speed.

 

[Forrest Nearing]

RRamsey you should get a video or sound file of it to post



I like the "growl" of a 3rd Gen exhaust note under load (with the right exhaust system) which is due to the manifold. Have thought of possibly putting a 3G manifold on my 2G truck for a unique sound. Of the 5 CTDs I've had the best sounding one was my '03 with an ATS manifold & Aeroturbinemuffler.



My '03 usually got about 20-22 at 68-72 mph on the highway, it was a 2wd shortbed 6-speed.

Vaughn, you're crazy man... the 3rd gens sound like a an atomic goose farting after a chili cookoff!



I've got twins on my '04 so I've got a 2nd gen manifold, but I'm about to switch things up and run a single... it's keeping the 2nd gen manifold! LOL





anyhow, in response to the OP, your boost fluctuation at part throttle is most likely due to a swing in rail pressure. if you had a rail pressure gauge on the truck, I'm betting you'd see the needle dancing back and forth. It's a Smarty thing as best I can tell, though I'm sure it happens w/ other programmers.



It's one of the annoyances of owning/driving a CR vs. the deliciously simple mechanical 12v



but the clean power and broad powerband of the CR sure is nice



congrats on a nice install!

 

[grimesja]

RRamsey, That is an awesome looking rig. I have been researching installing a 12 V in my 2001 2500 4x4, has anyone done that? I get 14 -16 empty at 70 mph. I need to be getting in the 20's, my wife is screaming the gas hog needs to go. However, after seeing what you have done, I'd consider going that route. But I really want an engine that I can work on easily and not have a lot electronics going nuts.

BTW are you running Bio-Diesel?

 

[Diesel Dan]

Hey Vaughn,



What gives you the impression that a 2nd gen has a better drag coificient than a 3rd gen. I have had them side by side and the 3rd gen has less rake to the windshield therefor producing less drag. Other than that they are very similar.



RRamsey,

Nice job. Glad you got it tha way you want it

 

[AH64ID]

Very nice... mpg's are sillly high for a CR. . . Its very uncommon to even really be above 20-21 with a 04. 5+ motor. .

As far as EGT's its becuase of the stock timing. You need to run an odd number smarty, or adjust the timing with REVO. Stock these motors are 1400*+ motors, now your adding more fuel. . hence more EGT's...


What did you do for a wiring harness?

 

[Vaughn MacKenzie]

Vaughn, you're crazy man... the 3rd gens sound like a an atomic goose farting after a chili cookoff!

LMAO Forrest . . . speaking of atomic geese odds are you could find some of those in this area. Lots of geese and we're a short distance from the Hanford Nuclear Reservation :-laf

Hey Vaughn,

What gives you the impression that a 2nd gen has a better drag coificient than a 3rd gen. I have had them side by side and the 3rd gen has less rake to the windshield therefor producing less drag. Other than that they are very similar.

Hey Dan, two reasons, my '01 QC 2wd shortbed could slice through the wind noticeably easier at 80-90MPH than my '03 QC 2wd shortbed. Secondly Dodge says the drag coefficient (cd) stacks up as:

2nd Gen- 0. 422
3rd Gen- 0. 463
4th Gen- 0. 419

I think this is comparing QC shortbed 2wd trucks, but not sure.

 

[Vaughn MacKenzie]

It's one of the annoyances of owning/driving a CR vs. the deliciously simple mechanical 12v



but the clean power and broad powerband of the CR sure is nice



congrats on a nice install!

That's where the CR shines over a 12-valve. . . I too like the mechanical simplicity and reliability but the tradeoff is fixed timing and narrower useful powerband. And if you get the RPM up the 12V is thirstier, dramatically so by 2500 RPM and beyond (try comparing CR and 12V BSFC charts).

 

[Diesel Dan]

Hey Vaughn,

Since all of my trucks were lifted 4X4s w/ 35's slicing thru the wind was never an option:-laf



I am suprised at dodge's numbers on drag coefficient. You would think they would make them w/less drag/more efficient as they got newer. The 3rd gen deffinatly has a more sloped windshield and one would think it is better. I can only imagine what the drag coefficient of my first gen was. My guess is 0. 693 :-laf



best regards



DD

 

[Vaughn MacKenzie]

Hey Vaughn,
Since all of my trucks were lifted 4X4s w/ 35's slicing thru the wind was never an option:-laf

I am suprised at dodge's numbers on drag coefficient. You would think they would make them w/less drag/more efficient as they got newer. The 3rd gen deffinatly has a more sloped windshield and one would think it is better. I can only imagine what the drag coefficient of my first gen was. My guess is 0. 693 :-laf

best regards

DD

LOL Dan, you're more into the wind-rake style of transportation :-laf

I think the grille penalizes the 3G, it's considerably larger/taller. And while the windshield is more raked on the 3G the cab is taller too. An interesting comparison would be to measure a 2nd and 3rd Gen from the bottom of the front bumper to the top of the cab and see how much taller it is.

You know those old 1st Gens get good mileage, thanks to their lighter weight and injection pump with variable timing.

Vaughn

 

[RRamsey]

LMAO Forrest!!!! perfect description!!! Odly enough, mine doesnt have that goose-fart sound. It actually sounds pretty good! The exhaust tone is much louder and deeper than the 12v and doesnt cackle. Its just a simple diamond-eye 4" system. also to everyone who has asked, I built my own harness using the truck side of the C130 engine connector.

 

[Bob Wagner]

to the top to be viewed

 

[Mikey-KE7LBB]

You know those old 1st Gens get good mileage, thanks to their lighter weight and injection pump with variable timing.



Vaughn

True, but you gotta admit the 1st gens are about as aerodynamic as a parachute!! :-laf

 

[Bob Wagner]

To the top for the NW Bombers.

 

[Shadrach]

TDR member DPashko has an 03 with a twin turboed 97 12 valve in it. Works both ways. Shadrach