Just purchased a 2004 2500 Quadcab, @ a great price. The engine has extream blowby, runs good. Found a 2002 engine thats looks very good at a very good price, will have axcess to dornor truck during the exchange. What are some of the problems that I may encounter? I guess I should ask first is this possible?

 

The electronics could possibly turn into a nightmare just to make everything work. The injection system is totally different. The ECM on the newer truck is lightyears ahead of the older truck. Now, I'm assuming the 2002 motor is still a VP44 engine and not a super early CR....if that's the case then those are some of the problems you will incur.

 

OK how about this. Found a 2006 engine with 38k, wrecked in guys shed, will this engine plug into the 2004 truck???
BE sure and VOTE!!!

 

What is the make date and year of the 04? Need to know if you have a 305/555 engine or a 325/600 engine.

 

Yep, for sure need to know the year of the engine.....the ECM will be needed just run it!!! Keep us posted!!

 

the 04 made date is 8/03

 

Yeap, you have a SO or HO engine. Check on the valve cover(Black plastic cover) to see what HP you have. 305 is an HO and 235 is an SO. So you will need to look for an 03-04 engine or just rebuild the one you have. Injectors and pistons are different on the these early common rail trucks.

 

Actually as long as the original engines ECM's & original engine harness is kept with the new engine, it really doesn't matter if he installs a 2003-04 engine or a 2004.5 - 2007 engine in place of his 2004 engine.

The sensors are all the same and the injector bodies are identical.
The only thing to note is that the injector nozzles/tips must match the corresponding piston bowls.

Even saying that, there are many guys now running the 2003-4 injector nozzles (Bosch Motorsports) on the 2004.5 - 2007 pistons without issues.

The best engine combo using stock parts would be the 2003-04 pistons, with the 2004.5-2007 better cylinder head, with a 2006-07 ECM.
The 2003-04 pistons are a better design. The 2004.5-07 head has better valves and valve seats and the 2006-07 ECM would allow you to run EFI Live.

The 2003-04 ECM is a good second choice as it doesn't not have the 3rd injection event for better fuel economy and cleaner engine oil than the stock 2004.5-07 ECM.

 

Misinformation here.

 

I was shocked when I found out about this too.
When I installed my DDP 50HP tips 5 or more years ago, the DDP instructions were critical in making sure the nozzles were correctly matched to the piston types.
Not any more though..

http://www.cumminsforum.com/forum/3r...-05-truck.html


Starting on Page 10 of this thread:
http://www.cumminsforum.com/forum/3r...-video-10.html


I wouldn't do it but many are. It looks like it all started with the Bosch Motorsports injectors which are only available with the 2003-04 nozzles.
Installing the 2004.5-07 nozzles on the 2003-04 pistons is still not recommended though.