Cummins QSB 4.5L into YJ Wrangler
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Thread: Cummins QSB 4.5L into YJ Wrangler

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    Default Cummins QSB 4.5L into YJ Wrangler

    The motor is finally bolted between the framerails !!! ** ignore the cameras " date " stamp, this was Sept. 2010 ***






    clearance under the hood !!!!



    clearance for the A/C COMPRESSOR !!

    Last edited by Hulkgreen; 12-15-2010 at 07:35 PM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Making major progress everyday !!!

    I only have a few more things to wrap up to be able to start and drive this Bad Azz machine !!!



    Upper and Lower Radiator Hoses





    Mounted the Dodge Cummins throttle control and Stainless Steel Brakes Corp vacuum pump



    Installed the Jeep's oil pressure and water temperature sensors to work the stock guages !!





    Also, found a place to install the Air to Water Intercooler's Radiator and Fan assembly !!

    Last edited by Hulkgreen; 12-15-2010 at 07:36 PM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    cool...
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    Quote Originally Posted by cRiPpLe_rOoStEr View Post
    cool...
    Thanks ,

    Someone on this board mentioned ( after I purchased the engine ) " that this engine was bigger than a 4bt , that engine would NEVER fit within the engine bay of a JEEP " !! I am just one of those people who is determined that if I am told " you can't " ; that I must find a way !! And , I added Air Conditioning and Power Steering to this motor !!

    NOW , To that forum members credit , the QSB 4.5L is longer by 2 inches than the 4bt !!! Which did make me change from an front mount Air to Air Intercooler to an Air to Water Intercooler, but there are more than space benefits to the Air to Water Intercooler , so I did not mind !!! I also got to keep my A/C by making the change as well !!!
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Quote Originally Posted by Hulkgreen View Post
    Which did make me change from an front mount Air to Air Intercooler to an Air to Water Intercooler, but there are more than space benefits to the Air to Water Intercooler , so I did not mind !!!
    if there were just space issues the air-to-air intercooler could be mounted above the engine such in some newer japanese diesel pickups, but would need some workarounds in the engine hood... btw do you use any coolant fluid blended with the water in the intercooler?
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    I have not completed that part of the install !! When I purchased the kit, they did not mention any " additives " !! Are you referring to Ethylene Glycol for the coolant fluid ??? If not, what do you recommend ???

    The other benefits of Air to Water Intercooler are :::: very low pressure drop thru the intercooler !! and when on the trail moving slowly very little air would be moving thru the air to air intercooler; and the air to water intercooler could do a better job of cooling the charge in this instance !! This was a selling point which in theory makes sense !!

    And BTW, I will be installing the Air to Water's Intercooler above the valve cover !!
    Last edited by Hulkgreen; 10-04-2010 at 08:51 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    thats awesome!! definitely put some videos up when your done!!!!
    1989 Jeep Wrangler with 4bta zf5 np205 d30 front(posi-locked)ford 8.8 posi rear 4 inch suspension 3 inch body k&n intake 33's BFG AT pump mods

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    Awesome. Its Great when someone thows out some absolute, then Bam! not so absolute or mouthy!
    " I drank what?" - Socrates


    1986 Jeep Grand Wagonner
    4bt/47rh/Np241
    Daily Driver unless im driving my VW THING

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    Quote Originally Posted by Hulkgreen View Post
    I have not completed that part of the install !! When I purchased the kit, they did not mention any " additives " !! Are you referring to Ethylene Glycol for the coolant fluid ???
    i was referring exactly about those ethylene-glycol coolant fluids...
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    Cripple Rooster ......


    I will prolly take your advice ( unless , somebody can show evidence that it would ruin something ) but , I doubt that !!!

    Oh, and me and a buddy made a power steering bracket on his manual mill !! I will edit this post tomorrow and add a pic of just the bracket we made on the mill !!



    We designed it on a slight angle so the reservoir would not interfere with the closed hood !!!





    Sorry, I forgot to edit and post the bracket we milled !!

    Last edited by Hulkgreen; 10-07-2010 at 07:09 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Quote Originally Posted by Hulkgreen View Post
    Cripple Rooster ......


    I will prolly take your advice ( unless , somebody can show evidence that it would ruin something ) but , I doubt that !!!
    i was not exactly giving you an advice, i'm maybe even more curious than you to see the results of the ethylene glycol blend in the water... as it rises up the water vaporizing temperature about 30% and gets the freezing temperature lower maybe this can improve the air cooling during the summer and protect the intercooler from damages that can occur due to the expansion of frozen water...
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    @ cripple rooster ::::::

    OK, I thought you had some inside info you were advising on !! LOL No problem; I will call the Air to Water Intercooler people tomorrow and see what they say about that subject !!


    BTW , The Intercooler piping and silicone hoses will be here tomorrow so , I will start on that and get a drive pulley belt ordered to be here before the weekend !! Come hell or high water, I will be ready and hear this monster running by the weekend !! I will take some video and add it to flickr acct soon after !!!

    I mentioned, I have a Rough Country 2.5" lift; and that it had sagged even before I installed the engine !! My QSB 4.5L has had its weight on the springs for 1 week now and the springs have settled another 1 1/2" !! Well, after careful consideration and NOT wanting to waste money and do **** twice, I ordered a Rubicon Express Extreme Duty 4" lift that will arrive on 10-11-10 !! I had already installed a cable operated twin stick Dana 300 and I have not ordered the Tom Woods driveshafts yet, so the extra lift will not cause me any headaches !! I was gonna run the 2.5 inch lift with Gen-Right's high clearance fender kit; but, I need my inner fenders to mount all this extra stuff !! My son has a 4bt wrangler with this lift and he has no problem with the springs supporting the weight, he is running 33's with no problems and I want 35's and since I have done extensive trimming I should be OK !!!
    Last edited by Hulkgreen; 10-05-2010 at 10:00 PM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Quote Originally Posted by Hulkgreen View Post
    OK, I thought you had some inside info you were advising on !! LOL No problem; I will call the Air to Water Intercooler people tomorrow and see what they say about that subject !!
    air-to-air intercoolers are easier to find where i live, so i don't know too much about air-to-water ones...
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    Quote Originally Posted by cRiPpLe_rOoStEr View Post
    air-to-air intercoolers are easier to find where i live, so i don't know too much about air-to-water ones...

    I found a complete intercooler with barbed hose fittings, hoses, water pump, and mini radiator ( 12 inch ) with barbed hose fittings, and electric fan ( 7 inch ) !! I found this at Silicone Intakes dot com ( obviously don't leave spaces ) !!!

    This is the radiator and fan behind the windshield washer bottle !!



    I still have the air to air intercooler from a 2006 Dodge Sprinter van that I am not using that I would sell for $100 plus shipping !!
    Last edited by Hulkgreen; 10-06-2010 at 08:31 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    cool build!!! What's the HP of the 4.5lt??
    1994 Dodge Dakota Ext Cab 4x4. 4BTA 375hp and 720ft/lbs torque, 12.9 at 103mph 1/4.
    There are no stupid questions, but there are a LOT of inquisitive idiots

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    I thought the Air to Water ICs used the engine's coolant. That way you don't have to come up with a separate circulating system and radiator dedicated to the A to W IC. On the downside you would only be able to cool it down to the engine coolant's temp (mid-upper 100s) at best. Any idea what the intake air temp is on a non IC'd engine between the turbo and intake?
    Taking my toys and heading to another sandbox.

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    using the engine's coolant thru the intercooler wouldn't be too efficient due to the temperature...
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    Quote Originally Posted by khaoskustoms View Post
    cool build!!! What's the HP of the 4.5lt??
    This is the QSB 4.5L !! It ranges from 110 HP and 360 TQ up to 170 HP and 460 TQ !! I have spoken to an engineer at Cummins and they have one in R & D that is putting out 300 HP by changing the turbo and the computers parameters !!

    This engine is used in narrow vein mining Dump Trucks capable of 12 tons of payload and things like that which makes it " automotive style " throttle not just " industrial " !!!

    http://www.duxmachinery.com/dts-12.pdf
    Last edited by Hulkgreen; 10-07-2010 at 07:24 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    @ twisted 71 ::::: Cripple Rooster is correct !! I have a totally seperate liquid system for the IC ( radiator, cooling fan, and pump ) !!



    Yesterday, I figured out to reuse the original belt tensioner and purchased a smooth pulley and removed the 8 rib pulley and made a new notch in the bracket to set the tensioner to push at the correct angle !!



    Last edited by Hulkgreen; 10-07-2010 at 07:06 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    subscribed....what trucks came with the 4.5?

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    Quote Originally Posted by black06 View Post
    subscribed....what trucks came with the 4.5?

    the link in post # 18 is what the engine is intended to power !! http://www.duxmachinery.com/dts-12.pdf





    I got everything together so I could start the motor last nite, but the power gods had something else in mind !!!! The build date of the motor is 12-5-2005 and I did not purchase til March of 2010 !! March is when I registered the IN SERVICE date for warranty purposes ( Yes , the motor is covered under a 2,000 hour warranty !)

    Got some " unnerving " news today !! Seems that since no one owned the engine immediately after assembly, Cummins starts the " in-service " date 30 days after the engine's date of build; and there is a 2 year or 2000 hour warranty from that date !! So, even though I am the first registered owner and it has done nothing but sit on a shelf in a pallet; I have NO warranty !!

    After alot of phone calls to Cummins and my local distributor; it seems that the fuel " log " must have a crack in it !! Can't imagine what that is gonna cost me to replace !! I must admit for as high as I was floating to finally be ready to start the engine; this has been a quick way back down to earth !!

    ******* EDIT **************

    Removed everything to inspect it, and found NO visible cracks anywhere !! While doing this I was racking my brain........... since Macet told me that every engine gets test run before they leave the assembly line !!!! I started thinking ..... What have I done that could have caused this ???? And, I came up with ...... I tweaked the high pressure fuel line ( going from the pump to the fuel rail ) to not hit the motor mount near the pump !!! SO, I tweaked it some more and tested it, and the leak slowed down; but, I can't stop it !! I will order a NEW high pressure fuel line on monday since I will be kicking myself in the rear all weekend for causing this headache !!!
    Last edited by Hulkgreen; 11-13-2010 at 09:51 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Sure enough it was me that caused this !! I installed the new High Pressure fuel supply line from the pump to the fuel " log " rail !!! The leak is fixed so I am back on track to getting this baby to fire up !! I have to thank Cummins Mid South for getting me the part around 9:30 this morning via Fed-Ex !!

    I did receive the Rubicon Express 4" Extreme Duty springs yesterday evening ; so I will be working on changing them out during the week !! I will keep ya up to date as things progress !!
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Sorry it has been so long since I reply !! My laptop crashed and I have had knee surgery since my last post !

    I have installed the Rubicon Express 4 " lift springs and completed the water plumbing to the Air to Water Intercooler but I had to order 2 more 90's to complete the Air Piping !! I have lined the tub with a foiled bubble wrap to insulate it from noise and sound and have ordered up some interior carpet !! I have installed the Tom Woods driveshafts and thanks to the Dana 300 transfer case my rear driveshaft is 20" long now ( with out installing a t-case drop my skid plate measures 31" off the floor ) !! I will eventually run 35 inch tires but for now the 31's will have to do !!



    My 2007 JK with 3 inch lift and 33 inch tires used to fit under the hardtop holder hanging from the ceiling !



    Installed LED marker and taillights !!



    Installed Bushwacker Fender Flares !! You can kinda see the insulation I installed !!



    And here is the VIDEO I promised of initial start up !! I had to temporarily install the intercooler and I have not connected the exhaust ( the part is on order to finish it ) !! I find it very quiet considering at the beginning of the video the camera is only 12 inches away from the turbo !!

    http://www.flickr.com/photos/42246689@N06/5169660442/
    Last edited by Hulkgreen; 11-13-2010 at 10:07 AM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    what happened to your knee?
    http://formspring.me/kamikazeondrugz

    http://cripplerooster.blogspot.com/ - if you can't read in portuguese (or even spanish that is closely simillar) use the google translate

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    Old injury from 9th grade ! I hyperextended it and it caused a cyst and the cyst calcified and grew; now I am 40 and the cyst was 2.5 inches long and 1.5 inches wide so it was time to get it out of there !! It was attached to the ligaments and tendons and I could no longer bend my knee without it stabbing into the calf muscle !! I had the surgery on Nov. 4th and yesterday is the first time I have seen my knee cap since 9th grade; it had been so swollen all these years !!
    Much better now, just need to let the incision heal up !!


    Quote Originally Posted by cRiPpLe_rOoStEr View Post
    what happened to your knee?
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Uploaded more pics for ya !!

    The cable operated twin sticks and the AX-15 !! And the insulation I applied can be seen ; it is basically bubble wrap sandwiched between 2 sheets of aluminum foil !!



    And the Tom Woods Custom Driveshafts !!



    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Hangs Out With Dogs DieselSchlepper's Avatar
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    Interesting high pitched sound.
    True self-esteem comes only from what your dog thinks of you.

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    Yea !! The turbo is wide open to the atmosphere also and the camera is rather close to it !!


    Quote Originally Posted by DieselSchlepper View Post
    Interesting high pitched sound.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    Air to Water Intercooler is complete !!

    All air piping and water plumbing connected, what do ya'll think !! I am not an engineer, but it ALL fits under the hood ( barely ) !! I had to keep the engine high enough not to hit the front differential without having to cut up the hood !! I think it came out as a great compromise !!



    I borrowed the 1984 Mercedes 300 Turbo Diesel's Coolant overflow bottle for my Air to Water Intercooler's holding tank !!


    The red and white object is the Intercooler's water pump ( which is just a live bait well pump ); but it works great !! It is under the IC's radiator and fan !!
    Last edited by Hulkgreen; 11-16-2010 at 07:28 PM.
    1994 JEEP WRANGLER ...CONVERTED TO A CUMMINS 4.5L COMMON RAIL INTERCOOLED TURBO DIESEL ; NV 4500; Cable Operated twin sticked and flipped Dana 300; Tom Woods Driveshafts; and Dana 44's front and rear !! Here are some pictures of the build ..... http://www.flickr.com/photos/42246689@N06/
    Government big enough to supply everything you need is big enough to take everything you have !!!

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    We need bigger pictures.

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