4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

[Redliner Raw]

Originally Posted by VortecZ

No, the computer would take care of that. The problem with one of those is I bet Bully Dog and other companies like them don't have a programmer to do anything extra. Of course, I would be very happy with the stock horsepower of one of those right now!

Yeah, I forgot about the whole computer thing. I guess that makes life a little easier. And I assume it'd be a common rail injection system, and all you're injection is from a pulsed solenoid?

[VortecZ]

INTERCOOLED!

Yep, I finally got the intercooler in my truck. I ended up using a '94 Dodge intercooler. I'd like to take back what I said about there being no way a D-max intercooler would fit in a non-HD truck. I did a lot of measuring and I really think it will fit with some trimming. I had a D-max, a 6.0 Powerstroke, & this Dodge intercooler all in the shop at the same time deciding which one to use. The Dodge was the obvious winner because it has the same basic size and shape of the D-max but the core is slightly shorter therefore a better fit in the shorter non-HD core support.

I used the intercooler and all of the piping from the Dodge. The cast aluminum intake elbows from those 12v motors have a big bracket on them that bolts to the front of the head. I cut that off because it would hit my a/c compressor plus it looks nicer this way. I cut a little off of one of the intake pipes and had to make a custom elbow from the 2" turbo outlet to the 3" IC pipe. I had to move the chevy computer and cut out the bracket because the outlet comes out right there. I also had to do some trimming on the bracket that connects the core support to the air-box bracket. I made new mounts for the intercooler and the radiator. The intercooler is now where the radiator is supposed to be and the radiator is set back about 3". The original radiator just barely fits between the inlet and outlet of the cooler. The factory air-box no longer fits in the truck because the radiator is in the way. This forced me to make a custom filter set-up. I also made a trim panel to cover the top of the radiator and made it look like it is part of the core support.

The engine compartment is really starting to fill up now! I think to do a 6bt, you would need a radiator and fan combo that takes up a little less room because it is getting close.


Results....
Well, I'm not impressed yet because I was expecting more power. I was also worried about the 6bt intercooler being too big for the predominantly stock 4bt. I thought it would be too much volume for my little turbo to have to pressurize. That part of it doesn’t seem bad at all. I think it spools up just as fast as it always did. I was expecting some power gains but it doesn’t really feel any more powerful though it certainly didn’t hurt it.

I'll report back in a week or two with mileage info. I have had a lot of people tell me it would help my power and my mileage if I added an intercooler. Haven’t noticed the power so I’m not getting my hopes up on the mileage. It is also supposed to help with the EGTs a little too but I don’t have gauges yet to know.

[fortplainman]

what do you think you could do to make more power? is the turbo on the 6bt bigger and could the 4bt handle it? im new to diesels so dont yell at me haha. very clean engine bay though.

[VortecZ]

The first generation 6bt used this same turbo. The newer ones are slightly bigger. The turbo is the next thing I want to upgrade. I'll either go with a single larger turbo or keep mine and add another even larger one to it.

I'm actually very pleased with the power this motor makes the way it is. I just hoped the intercooler would give it a little more and upgrading the turbo should give it a little more too. It is just one of those things that guys want more of no matter how much they have!

[fortplainman]

Originally Posted by VortecZ

The first generation 6bt used this same turbo. The newer ones are slightly bigger. The turbo is the next thing I want to upgrade. I'll either go with a single larger turbo or keep mine and add another even larger one to it.

I'm actually very pleased with the power this motor makes the way it is. I just hoped the intercooler would give it a little more and upgrading the turbo should give it a little more too. It is just one of those things that guys want more of no matter how much they have!

i have to agree that men cant get enough power. im sure you will tinker with it for a while and you will come up with more hp down the road.

[Black06]

usually you would lose a pound or so of boost with the addition of an intercooler....so now you could crank up the boost to compensate

[1LOWDIESEL]

turn the pump up a little more now. with the cooler in there it will keep your egts lower across the board, do to off set the added air you need more fuel. i would run either an HY35 or HE351 turbo. the HY is a 57mm and the HE is a 60. both would help a ton. also the IC isn't really designed to give more HP just cool the system more efficently. you would have felt more of a gain from water meth actually.

any pics of the install?

[VortecZ]

I have an HX35 already so I would like to use it but my current manifold puts the downpipe so close to the firewall, I don't think the wastegated exhaust housings will work. I'm going to have to build a header or modify a 6bt manifold to make it work. I'd prefer to run twins so I'm looking for a larger turbo.

[crossy's son]

Originally Posted by 1LOWDIESEL

turn the pump up a little more now. with the cooler in there it will keep your egts lower across the board, do to off set the added air you need more fuel. i would run either an HY35 or HE351 turbo. the HY is a 57mm and the HE is a 60. both would help a ton. also the IC isn't really designed to give more HP just cool the system more efficently. you would have felt more of a gain from water meth actually.

any pics of the install?

WORD on everything he said ^^

I was about to type it... Find a HE351 off an 05-07 5.9 cummins to put on there, its a 60/60/9 ... very efficient turbo.

I made some videos on how to tweak the VE pump, they're on my youtube channel "91CTD"

You could also buy a DennyT fuel pin- www.dennytperformance.com/products you won't believe what that will do..... It will increase power across the board.

Then a 3200 rpm gov. spring... POD injectors....muhaha

[1LOWDIESEL]

Originally Posted by VortecZ

I have an HX35 already so I would like to use it but my current manifold puts the downpipe so close to the firewall, I don't think the wastegated exhaust housings will work. I'm going to have to build a header or modify a 6bt manifold to make it work. I'd prefer to run twins so I'm looking for a larger turbo.

it looks like that manifold is off center to one side. if it is, should be able to flip the manifold around and upsidedown. then it would mount the charger forward and higher.

[Black06]

I would definately do the ISB 5.9 manifold....just chop the 1st and 6th cylinders and plate the ends

[VortecZ]

I'll certainly keep these things in mind. I don't want to hurt my milage at all so I'm ok with a turbo upgrade but a little nervous about doing anything else to the pump or injectors.

[hubob]

I have an 08 Silverado 1500 and I was wantin 2 do something like this 2 mine roughly how much did the whole build cost ya?

[VortecZ]

I paid $2700 for the truck that had the 4bt in it. I had the fuel pump rebuilt for $800. The rest of the expensive parts like the tranny, intercooler, and other various Dodge parts came from a buddy that I have not paid because we are working out a trade to do a lot of custom paint work on his truck. I've seen better deals on motors and hopefully you wouldn't need to rebuild the pump. I'm not sure what to expect to pay for the Dodge parts at a salvage yard but I suppose you could do the swap for less than $4k if you found good deals on everything.

[VortecZ]

The intercooler made the truck pick up a couple more miles per gallon.

I'm up to 32 now!

[Mark13]

Originally Posted by VortecZ

The intercooler made the truck pick up a couple more miles per gallon.

I'm up to 32 now!

Not fair. I wish my truck got that, heck I'd be happy if my s10 got that.

[Toadz]

32, nice! Would you be able to compare it to a 5.3 performance wise?

[VortecZ]

Hard to compare to a 5.3. It feels like it has way more torque and probably does but I don't think I could out run one. It has tons more low end power but runs out of rpms quickly. I used to have a rcsb with a 5.3 and this is more fun to drive.

[randeez]

badass. i really wish i hadn't started building a 355 now

[Toadz]

Originally Posted by VortecZ

Hard to compare to a 5.3. It feels like it has way more torque and probably does but I don't think I could out run one. It has tons more low end power but runs out of rpms quickly. I used to have a rcsb with a 5.3 and this is more fun to drive.

I know it'd be hard to compare to one because of the RPM difference. What is the usable RPM range?