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Nissan Patrol GU4 2006 with Cummins ISDE4.5 270HP , 830 NM Engine Conversion
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Discussion Starter #1
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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Nissan Patrol GU4 2006 with Cummins ISDE4.5 270HP , 830 NM Engine Conversion
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Discussion Starter #2 (Edited)
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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Discussion Starter #3
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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Discussion Starter #4 (Edited)
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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Discussion Starter #5
The new engine was getting ready at the factory


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Discussion Starter #6
It finally arrived Sydney on 15th December last year


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Discussion Starter #7
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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Discussion Starter #8
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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Discussion Starter #9
Front and rear diffs, plus valve body and all the seals were done


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Discussion Starter #10 (Edited)
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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Discussion Starter #11
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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Discussion Starter #12
The engine had been in and out many times till I got the engine mount measurement all right


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Discussion Starter #13
Real engine mounts made and ready to install the engine......


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Discussion Starter #14
Super strong engine mount compared to the Nissan factory ones. I used 16mm steel.....

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Well done! It will be interesting to see how the RE4 holds up.
 

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Discussion Starter #16
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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Is the Cummins a cable with throttle shaft on the pump?
 

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Discussion Starter #19
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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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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