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  #1  
Old 08-03-2019, 05:20 PM
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Default My ZD30 GU4 Auto to Cummins 4.5 conversion

It has been a long time since I started to think to have a Cummins into my GU. Finally, I have made it happen.

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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #2  
Old 08-03-2019, 05:22 PM
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This is today, the nearly finished Cummins Commrail 4.5 with 270hp and 800nm top rpm are 3700

Tt is a 100% DIY from myself, not a mechanic, but thanks for lots of help and ideas from Patrol4x4! Really appreciated!

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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT

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  #3  
Old 08-03-2019, 05:36 PM
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it was back to last year, when i first decided to use Cummins, after carefully reviewed 6BT and ISDE4.5, i initially decided to go with 6BT which is a very simple engine, with NO electronic, and super reliable. But I decided to make a visit to the Cummins factory in China and changed my mind. The 6BT is way TOO noisy for me, sitting in the cabin, i almost cannot listen to the radio or talk to friend. the idle noise level is about 79dba. after test drive the 4.5, which has similar power and more torque at lower rpm ( vs 6bt), i decided to go the 4.5. as it is so much quieter and far more easier for a DIY job. I stayed at the factory in few weeks, and learnt all kind of engine building process which built up my confidence to get one, and also Do It Myself! the engine selected is a brand new old stock model, i had given the engineer some targeted goal for my engine: 270hp, 800nm, and max rpm3700. it took quiet sometimes to get these figures.
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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Old 08-03-2019, 05:46 PM
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The fully working zd30 at 142,000km only sold on the same week when put the ad on gumtree. If you want to do conversion, do not wait your engine to blow-up, a working zd30 can get 3000 to 4000$ back
if you take a close look at the zd30, then look at the Cummins 4.5 you will see how simple the Cummins is. it does not have many parts.
They both similar in size, the Cummins is about 350 kg ( i think about 50 to 60 kg heavier than the zd30) so I decided to use ZD30's factory engine support bracket on the Chassis.
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT

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Old 08-03-2019, 06:00 PM
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The new engine was getting ready at the factory

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Old 08-03-2019, 06:03 PM
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It finally arrived Sydney on 15th December last year

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Old 08-03-2019, 06:07 PM
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the Cummins B series engine ( 6bt, 4.5 and 6.7) are so simple in terms of design. it is the simplest engine i have ever seen. you can change the some major parts without much mechanic skills or knowledge. the 4.5's fuel pump can be replace in around 20mins, only 3 bolts hold it in place, no alignment required, the power steering pump can also be changed in similar fashion. it is just a simple design, no wonder it is so reliable.
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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Old 08-03-2019, 06:09 PM
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as the engine has very low down torque, from 1400 rpm to 1950 , you will have average 700 nm, and the peak is at 1900, which is 800nm. so i need to change my diff from 4.3 to 3.5
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Old 08-03-2019, 06:14 PM
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Front and rear diffs, plus valve body and all the seals were done

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Old 08-03-2019, 06:17 PM
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The new flexplate installed

i designed this flexplate to work with Cummins and also Nissan's factory TC. i did not change the TC, as the Engine has so much torque, i was told the auto box need certain rpm to boost pressure or the damage to the disk could happen.
i was too busy and it was also Xmas period, so i did not take many photos of the engine itself including the adaptor, and flexplate design etc. but it was a very simply job to install those items.

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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT

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Old 08-03-2019, 06:19 PM
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The hardest part was design the engine mounts and try to get the mounts working with zd30 system on the chassis, so I don't have to do the welding in the chassis. By the way, I am not a mechanic, and cannot do the welding myself.

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Old 08-03-2019, 06:25 PM
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The engine had been in and out many times till I got the engine mount measurement all right

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Old 08-03-2019, 06:32 PM
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Real engine mounts made and ready to install the engine......

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Old 08-03-2019, 06:33 PM
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Super strong engine mount compared to the Nissan factory ones. I used 16mm steel.....

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Old 08-03-2019, 06:33 PM
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Well done! It will be interesting to see how the RE4 holds up.
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Old 08-03-2019, 06:43 PM
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Quote:
Originally Posted by JFF45 View Post
Well done! It will be interesting to see how the RE4 holds up.
Thanks John, i will need your help to make the RE4 shift correctly, currently i am building a voltage modifier, ( jaycar does not sale it anymore, so i have to make one). The Cummins pedal has output voltage range from 1.1 to 4.5 ( vs ZD30's 0.5 to 4.5). so i have err code 43 ( the TPS err?). I will also need to get Brake system upgraded as well. Test drive shows the engine has so much power, and also quiet smooth.
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Old 08-03-2019, 07:27 PM
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Is the Cummins a cable with throttle shaft on the pump?
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Old 08-03-2019, 07:57 PM
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Well done mate, should be a good thing.

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Old 09-03-2019, 07:18 AM
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Quote:
Originally Posted by JFF45 View Post
Is the Cummins a cable with throttle shaft on the pump?
for the Cummins 6Bt, it is a cable linkage, for my 4.5, it a common rail engine, so all electronic control.
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Old 09-03-2019, 07:31 AM
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Ok, does Cummins specs say the TPS range is 1.1v - 4.5v or is that just what your Ecutalk is telling you?
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