CUMMINS 3rd Gen Head On 2nd Gen VP Block
 

well with my head being cracked and the valve guides being shot Im going to do the 3rd gen head swap. I drove to Huntington, IN yesterday to pick up the new head... its off a 2006 cummins.

The only issue is the crossover tubes / fuel line nut. 3rd gen common rail motors use a crossover tube that screws into the head then the fuel line screws onto the crossover tube. The 2nd gen tubes are jammed between the injector and fuel line with the fuel line nut screwing into the head. I can either buy new fuel lines OR buy a set of custom connecting tubes.... Im going with the tubes!


DIFFERENCE between the 03-04 head and the 04.5-07 5.9L :

Here are a few pics of them side by side of the heads:

3G on left and 2G on right
Attachment 58611

3G on top and 2G on bottom
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Attachment 58613

3G on top and 2G on bottom
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Ian

very interesting Ian

while yer at it is there anything ya can do with the intake on this...........I know its a bottleneck in the system

The intake is a mess!! here are some pics... you can see the head sticks into the intake side!! I never knew this and the bottom of the intake valley cover (not sure what else to call it) is a mess as well!!! I'll take all the casting bridges out of it since Im not sure if they are for structural stability or not... I dont think so but correct me if Im wrong. I think If I can get the head to a mill I will removed the head material that sticks out into the intake side.

Ill also use some sanding disks to smooth out the intake side of the head as well as remove the casting numbers for some more flow...

As far as a modified intake Im pretty stuck with the factory since the fuel lines will be in the way to do anything like a banks dual intake (for the 12V's) I guess your best bet is to fab up a swanker intake like I did to help the flow from the intake horn and remove the heater grid in the summer.

2Gen
Attachment 58608

3Gen
Attachment 58609

bottom of intake cover
Attachment 58610

Ian.......I dont think it would be wise to remove those casting gussets ..they are there for structural integrity................however it would be cool to smooth things up for better airflow

Do you think it will crack over time? heck its bolted about every 4" just seems like a good idea to take that crud out and get the air flow as smooth as I can.

well it was designed in there for a reason .....thats all I am goin by :wacko:

hmm i kinda wish i would have gone this route now.. tell me how it goes so when i break mine again.....

will do!! I cant believe the difference between them and how open the 3rd gen head is!!

i almost pooped myself when i saw that lol

I wanna figure out how to move the fuel lines and do a homemade twin ram setup.

looks good Ian. What about milling the intake side off the head and going to a ZZ fab or custom setup?

some neat pics, is that red lint from shop towels in the 3rd gen. if you could would there be any way to fit the banks big hoss intake on it?

I think for now Im going to leave it stock as far as the intake and fabbing up anything.

The red fuzz is from the shop towels

So the injector ports are the same on 3rd gens? I have never seen 2nd gen/3rd gen sticks next to one another.

yes same injector ports but the tubes are different

I picked these up from the guy that makes the monster pumps, he came by and delivered them since he was in town today:U:..... connecting tubes for a 3rd gen head that use your stock VP lines:U:

Attachment 58477

nice! how do those go in i havent looked at the comonrails that much? same spots as teh vp44 or completly different?

Ian, what did I tell you about posting good idea's up here damit, I'm running out of money trying to keep up with you. all BS aside keep us posted, looks awesome, what did the tubes cost you?

The CR tubes screw into the head and the fuel lines screw onto the tubes.... our VP trucks the tubes just go inbetween the injector and the fuel line that screws into the head.... well with these tubes I can run my stock VP lines so it eliminates the cost of buying new lines:U:

hahah I cant let you get close so Ive got to keep doing stuff!! $240 for the tubes & O-rings. A LOT cheaper than EEP has them for... but I got em from the source so that cuts out EEP & Sheids

until you go p-pump conversion route...

Nooooo way! Im keeping the VP.... but Ill go to a Monster stage 2 :U::U:

well where is the swap atanding now? is it back together yet?

Took the head in Friday to be checked for cracks, decked, ported and polished.

Talked with Darryl today... Ive got a few things to pull off the motor yet and he will be down the 29th or April 5th to put the cam in, then hes going to take the head back with him to O-ring it then Ill put it back together :choochoo:

the head checked out good, they didnt have time to port/polish it but that turned out good in my favor since they have a guy that does this stuff on the side for them and hes 1/2 the price.... so its off to be polished up

Here are pics of the water ports that I opened up a little bit. I layed the 2nd gen gasket on the heads and traced out where the block protruded into the open gasket part with a sharpie:

3rd gen
Attachment 58432

after working it out:
Attachment 58433

2nd gen
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3rd gen
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after
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2nd gen
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If I lost my photobucket acct Im f'd!:run:

Picked up the head today from being ported and polished, it turned out great!! this sucker should flow a lot better:yeah: well worth the money if you have your head off!!

prepped and primed, Ive got one more coat of primer to shoot then its time for the paint:U: Im using VHT high temp paint. Primer is good to 1200* and the gloss black is good to 950* the clear coat is good to 1200*

Attachment 58341
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You can see the bottom of the intake valley cover once we milled the ribs off and gave it a quick buff.

Attachment 58343

I think I need to order springs soon...:stupidme:

lookin good

Lookin good Ian. What color is it gonna be? JD Green lollollollol

green....:humm: boy what are you thinking:ph: :ouch:

It will be black:U:

Well any updates this weekend Ian? I've never even seen your truck in person and a cant wait for you to get this thing back together.

hahah Thanks man!! I keep forgetting I have it from time to time... then I check my bank statements and remember where all my cash is going :argh::madd:

Final coat of paint went on today, Im still in the process of gathering information on springs, retainers & keepers, a Fluidampiner, and rocker studs... I have to order them this week as the head goes back to the motor shop to be decked and have a valve job done. I talked with Darryl this morning and its looking like Saturday he will be down to put the cam in, then after that I can get the front put back together and the new headlights put in:U:

Come to IRP the truck will be there:rocking:

I wish I could help a valve job is easy beans. I just did one this week at work. Good luck with it man.

Thanks bud!! I dont have the tools or knowledge to touch up the seats, and guides so Im letting them do it ahhah

here is pic of it over the summer
Attachment 58303

I know what you mean. Luckily we have a shop on base that has all the stuff I would need. After my new found skils out here at school I think I'll be doing alot more myself. What cam and springs did you decide on?

head is gone, being worked on, all parts are out to the polisher and Im just waiting on parts to arrive here.... but its Christmas in April so far... one of the orders came in:U:

Attachment 58173

Cool stickers but whats that metal thing :lol::lol::lol:

hahah heck I dont know... came with the sticker though!!! 2 pages of stickers WOOHOO:rock:

todays present

Attachment 58082

Still waiting on springs... and cam install

I did get a bunch of polishing stuff from Production Tool today as well... but I wasnt going to take a pic of that stuff

what color you painting the cover.

It will be orange like my twins piping and the raised parts will be polished to a shine:U:

where did u find this cover and how much it cost?

Dodge Cummins and Ford Power Stroke Diesel Truck Accessories - Geno's Garage

RED P/N: ABM_*VC24V_RED $139.02
BLACK P/N: ABM_*VC24V_BLACK $99.76
PLAIN P/N: ABM_*VC24V_PLAIN $84.36

RED:CAST ALUMINUM OEM VALVE COVER (RED) - (98.5-02, 24V) DODGE-Dodge Cummins and Ford Power Stroke Diesel Truck Accessories - Geno's Garage

You should have your injectors tomorrow:U: