Ok guys I am in Florida and the engine in my 04.5 blew up and I bought an engine the guy thought was an 04.5 engine and turns out to be an 03 engine. I noticed the turbo was different and did some checking with the engine serial number at cummins and found out it was an 03. They are getting ready to put it in my truck right now. What should I watch out for and what needs to be changed and what differences will I notice?

Thanks alot for the immediate help and input.

Thanks,
Joe

 

Could be an SO motor. If using the 03 turbo you will not make as much boost.

 

The 03 engine is an 305hp engine. The shop will put the 04.5 325 electronic wastegate turbo on the 03 engine and we have the computer and wiring harness off both trucks. I just need to know will this work or what needs to be changed what differences there will be and stuff like that.

thanks

 

The turbo will be different on the 03 regardless of whether it's an HO or an SO. All 03s and early 04s had smaller turbos than the 04.5+.

Now, to answer your question, I have no idea if anything needs to be changed. If I was doing it, my assumption would be that it will drop right in with no modifications whatsoever and I would just drop it in and try it.

You should notice better MPGs with the 03 motor though. And if the turbo off your 04.5 is still good, I would put it on the 03 motor because I understand it's worth an additional 50hp.

 

I don't think I would run the 04.5 computer on the 03 engine because they added the 3rd injection event in 04.5 and I don't know how that would affect the 03 engine mechanically.

 

Oh yeah, the APPS will be mounted on the engine with the 03 motor whereas the 04.5 APPS is mounted in the cab by the accelerator pedal, so you will need to take that into consideration.

 

What is APPS?

If we use the 03 engine in the truck with the 03 injectors in it and the electric turbo from the 04.5. What computer do we use?

 

APPS is Accelerator Pedal Position Sensor. I would use the 03 computer but I'm not sure how you would go about controlling the 04.5 turbo. I don't know if you would even need to if the motor is stock.

 

What kinda of mileage does the 03's get? I was getting around 22-24 empty and then with the 18' trailer and a car on it I was getting 16.3-17.4 and that was with 1 cylinder going bad.

 

Take the ECU, all the sensors, harnesses, exhaust manidfold, valve cover and gasket off the 03. You can't use them on the 04.5.

You must use all the pieces that came with your truck. The 3rd event won't matter as long as you keep the injectors with engine they came in.

Your injection timing will be a bit more retarded than the 03 and the fuel delivery will be off a bit due to injector size and # of holes but it should run fine.


Nope on the engine for an auto, under the driver side battery for a manual. In-cab APPS was MY05 start.

 

The 03 engine is complete. They are putting the whole 03 engine in the 04.5 truck which come to find out the build date is 08/03 and someone told me its an 04 engine and has 305 hp and 555 tq. The electrical harness off my blown 04.5 has connected to everything that it should too on the truck.

They plan on doing the following:
put the complete 03 engine in my 04.5 truck
use an 04.5 turbo
use an 04.5 engine computer
use the 04.5 wiring harness
use the 03 injectors

From what I have been able to put together it should all work.

 

It should work just fine for ya, just like guys with 04.5+ trucks that do a cam swap, BFD on the third injection event.

 

Thanks for the input guys.

 

Well they should be done with the truck here in the next couple hours. Ended up had to go with the 03 turbo and use a boost fooler from BD. I will let you guys know how it all works out.

 

Why, the 03 turbo is no where near as good as the 04.5? Was yours bad?