4BT Cummins Engine Efficiency 101

4BT Basics And Performance Options

The popularity of diesel-powered vehicles here in the U.S. has really jumped in a positive direction in recent years. More and more manufacturers are starting to offer all-new diesel powerplants in half-ton trucks, cars and midsize SUVs—the introduction of a 3.0L diesel in the new Ram 1500 trucks, an EcoDiesel in the latest Chevrolet Cruze passenger car and there’s even been talk of a 4.5L Duramax coming down the pipeline. With the big car builders starting to offer diesel upgrades from the standard gas powerplants, there must be legitimate reasoning.

Maybe it’s better highway fuel efficiency and the giant increase in torque offered by a diesel engine. In reality, it’s probably an attempt at meeting ever-increasing CAFÉ (corporate average fuel economy) numbers. Either way, these smaller V-6 and four-cylinder engines will be sticking around. But back in the day, it was Cummins that developed their own small diesel engine market with the 3.9L 4BT.

2 The 4BT engine has been used in commercial utility trucks and industrial construction equipment since the late 1980s and because of its extremely basic functionality works well as a transplant engine when space constraints restrict the use of the larger six-cylinder 5.9L Cummins. With the cylinder head off the 4BT engine, someone with 12V Cummins experience should feel right at home; the 4BT is virtually the same, just two pistons shy, of course.

4BT History

The 4BT—which stands for four-cylinder, B-series, Turbocharged—was used mostly in midsize box trucks, agricultural equipment and small industrial vehicles, and is basically a smaller version of the popular 5.9L 12V Cummins found in the 1989-98 Dodge trucks. The 4BT shares virtually all its parts with its big brother the 6BT; i.e., pistons, connecting rods, injectors and valve train design.

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Obviously, the major internal difference comes from the lack of two cylinders, which means two less journals on the crankshaft, a shorter camshaft, two less pistons in the injection pump, etc. But even these pieces are the same as the 6BT, just in an inline four-cylinder version. Because of these similarities, the 4BT Cummins has an extremely strong aftermarket, since many 5.9L 12V performance parts can be used in the smaller 3.9L engine. This, paired with the somewhat compact size of the 4BT, makes it a great candidate as a transplant engine for just about any vehicle. We’ve seen 4BTs in everything from Jeeps to old school rat rods. The simplicity of the mechanical injection system also helps make it an easy swap, as there’s little to no wiring or electronics required.

Since the engine was originally developed for industrial applications, big horsepower wasn’t a major concern and the 239-cid motor most commonly came from the factory at around 105 hp @ 2,300 rpm and 265 lb/ft of torque at 1,600 rpm. But these numbers can vary up to as much as 150 hp depending on the application it was installed in.

The 4BT engine weighs in at around 750-780 lbs, which is heavier than most of the gas engines it would be replacing in a conversion project, but much lighter than the six-cylinder 6BTversion. The inline-four also offers a fairly compact size at just 30.6 inches long and 37.7 inches tall, helping with space constraints. The engines came with a few different injection pump systems, but the P7100 is, by far, the most popular, since it’s capable of producing larger amounts of fuel and more easily modified by the aftermarket to help increase power outputs.

Performance Mods

As previously mentioned, the 4BT can easily be modified to produce higher than stock power levels when outfitted with the P7100 (P-pump). Fueling mods can be taken to the same extremes as with the 5.9L 12V Cummins; 12mm and 13mm pumps with laser-cut delivery valves, hi-rev governor springs, full-travel rack plugs along with modified injectors can all be used in the 4BT platform. Obviously, to go along with major fuel upgrades, common cylinder head and turbocharger upgrades would be required. But the aftermarket already has most of that covered as well with head studs, better valve springs, larger valves, and even performance exhaust manifolds and camshafts that are being built for the four-cylinder diesel. While these upgrades can take the 4BT to all-new levels, one thing that needs to be mentioned is that because of its lack of cylinders and nearly identical operating rpm range, each piston is going to undergo a combustion cycle much sooner than that of a 6BT Cummins, so things like camshaft profiles and pump timing become critical for maximum efficiency at higher horsepower levels.

1 The 3.9L 4BT Cummins diesel engine has become an extremely popular platform for conversion projects over the past couple years and for good reason. Sharing virtually every internal and external piece with its big brother, the 5.9L 12V Cummins found in the 1989-98 Dodge Ram pickups, and coming as regular equipment in hundreds of commercial and industrial applications, parts availability, power potential, fuel mileage and the lack of electronics make it an easy go-to engine when it’s time to squeeze a diesel platform into the frame rails of just about anything.

ACD Stroker Kit

Like any engine platform, it’s a known fact that more cubic inches generally means more power and there’s only so much a 239-cid motor will be capable of, at least safely and efficiently. With this in mind, ACD Engines of Salt Lake City, Utah, has developed what they refer to as a “Stroker Kit” that will take the 4BT to all-new performance heights.

Also known locally as “All Cummins Engines,” ACD has been a full-line Cummins dealer for more than 20 years, specializing in midrange and industrial engines. They offer virtually everything Cummins—new or remanufactured engines, new genuine Cummins parts, used engines and even salvage parts. Since they deal in nothing but Cummins, anyone looking for that hard-to-find part can most likely call ACD and find they’ll have it in stock or at least know where to get one. Through their years of experience, they’ve become extremely well versed on the 4BT platform and have the conversion process down to a fine science, inserting the small Cummins engine into Jeeps, small SUVs, pickups and even a mid-’50s ambulance.

In the search for more power, owner Robby Pederson began development of a Stroker Kit that would increase the length of stroke and add some additional cubic inches to the inline-four diesel. In the gas world, Stroker engines are nothing new, as the GM small-block 383 Stroker engines have been around for nearly 35 years. The 383 is built by using a standard GM 350-cid engine block with a modified 400-cid crankshaft, which changes how far the piston travels.

New Rods and Pistons

Not looking to do so much crankshaft work, as the factory 4BT crankshaft is a robust piece, Pederson opted for an all-new piston and connecting rod design to gain that additional stroke he was after. A factory 4BT engine runs a 4.02-inch bore with a 4.72-inch stroke; this is how we come to a 239-cubic-inch motor. The new parts from ACD will allow the overall piston bore to expand to a 4.402-inch and a much longer 5.430-inch stroke is used, which will effectively take engine output to 333 cubic inches, or 5.46-liters, almost that of the 5.9L 12V Cummins.

Knowing that the clientele for such a kit would be after extreme power levels, only the best materials were used to be sure the ACD Stroker Kit would stand up to high-boost and high-cylinder pressures. Rather than use standard-cast pistons, like the stock units, ACD went with a much stronger forged piston design that offers a different bowl design to improve the air/fuel swirl effect, helping create a more efficient burn in the combustion chamber. The piston design also has a much shorter overall height, along with the wrist pin location being moved closer to the deck; this is where most of the additional stroke comes from.

To match the new piston, connecting rods had to be developed, which were made from billet 4340, like those being used in all the high-horsepower diesel engines. The new H-beam rod design is not only stronger than a factory connecting rod, but it also has a much smaller wrist pin journal, which will only work with the ACD piston. While the pistons and rods are the true heart to the Stroker Kit, ACD has also developed a host of 4BT parts to go along with them to ensure the true peak performance can be met. Specific camshaft profiles have been designed, along with custom cylinder head work, and even 4BT-specific adjustable injection pump timing gears. The short time between injection events on the four-cylinder engine require a little different engineering of these parts than that of a six-cylinder Cummins, and ACD thinks they’ve developed the perfect pieces to help turn your run-of-the-mill 105-hp 4BT into a tire-shredding 800-hp monster.

3 The 4BT engine uses a simple two-valve per cylinder system, obviously one for intake and one for exhaust. While this design is somewhat “outdated” with the introduction of the four-valve-per-cylinder design found in the 1998.5+ 6BT engines, it’s still a sufficient and robust design, especially on the smaller cubic inch low 130-180-hp applications that most of the 4BT engines were designed for.

4&5 ACD Engines of Salt Lake City, Utah, is a strong Cummins engine and parts dealer with years of experience in both the 6BT and 4BT platforms. Through their business practices, they’ve become well known for their 4BT conversion projects and have just developed all-new engine internals to take the average run-of-the-mill industrial 130-hp four-cylinder diesel to all-new performance heights. Starting with a one-of-a-kind connecting rod and piston design, ACD will soon be offering complete Stroker Kits for anyone looking to pump up the power in their 4BT platform. Shown in the first picture is their new H-beam 4340 billet connecting rod engineered specifically for the 4BT engine. These rods not only help increase the stroke of the engine, but will provide unmatched durability to hold up to the extreme cylinder pressures from running massive power and torque through these engines. The second picture shows the new H-beam rod (top) next to a factory 4BT rod (bottom). An untrained eye may not notice much, but the design and material of the ACD connecting rods is far superior.

6 A close-up of the two connecting rods piston ends show where some of the additional piston stroke comes from. Notice how much smaller of a diameter is used to encase the piston’s wrist pin? This new connecting rod design was developed to be run exclusively with ACDs custom-forged pistons that use a tool-steel wrist pin. The combination of rod and piston raise the 4BT’s piston stroke from a factory 4.72 inches to a massive 5.430 inches. This alone will increase the engine’s cubic inches from an OEM 239 to just over 275, turning your average 3.9L 4BT into a 4.5L engine.

7&8 As mentioned before, ACD had to develop an all-new piston design for their Stroker Kits to help increase the engine’s overall stroke and work with their newly designed billet connecting rods. Knowing that customers interested in a 4BT Stroker Kit would be looking to make as much horsepower as possible, ACD decided robust forged pistons would be the best option to ensure maximum strength and durability. The combination of the forged piston and tool steel wrist pin, with special coating to reduce wear and friction, should make for a near indestructible end product. The piston bowls have also been worked over compared to a stock piston to promote a better swirl effect for a cleaner more efficient burn in the combustion chamber.

9 Sitting on the bench beside each other, the stock piston on the left looks quite a bit different than that developed by ACD Engines. The shorter skirt and much higher wrist pin location were used to once again aid in the overall piston stroke, which will allow for more displacement and performance potential. More cubic inches means more air and fuel can be drawn into the cylinders to hopefully create more power.

10 For the new forged piston design, ACD opted for complete gapless piston ring sets to limit cylinder pressure blow-by and help keep all the combustion power inside the cylinder where it belongs. This ring design is also durable, but block machining is critical, especially with the use of forged pistons. Where a stock cast piston would only need, say, .005-inch clearance between it and the cylinder wall, a forged piston will swell more under heat and stress, so piston to wall clearance needs to be increased to keep the rings from sticking and potentially ruining the piston and engine block.

11 ACD Engines has plans of installing this first monster Stroker 4BT engine into their shop’s H1 Hummer that rests on custom-built axles and 40-inch tires. The shop’s looking to prove the power potential of the little 4BT and its extreme versatility as both the perfect diesel conversion engine for an older vehicle with just mild power upgrades (like ACD’s camshaft and injection pump) to increase a stock 4BT from its underwhelming 130 hp to 200 or even 250 hp to a full-on competition 700+ hp engine like this Stroker should become. Like any engine build, it all starts with a clean, bare engine block that needs to be machined to precise cylinder and crank measurements.

12 While the 5.9L 6BT Cummins can run into block flex and main cap issues at high power levels, the shorter 4BT won’t be as susceptible to those issues. However, ACD still prefers to use a bottom-end Gorilla girdle to help tie everything together in the lower part of the engine. ARP main studs are also being used to be sure the proper clamping force is torqued onto the girdle and crankshafts main caps.

13 On the cylinder head side of things, upgrades to the ACD Engines’ 4BT are much the same as those found in performance 12V Cummins builds: hi-rev valve springs, titanium keepers, chromoly pushrods, etc… For this particular application, ACD will also be running fully ported and polished intake and exhaust ports along with larger valves to increase air volume being fed and expelled from the engine. To help those larger valves perform, ACD has spent countless hours developing different camshaft profiles that maximize lift and duration in the 4BT engines. Since the injection events are so close together with the inline-four design, the right camshaft profile is critical to how these engines perform. ACD can recommend the correct cam for any build; whether it be for power or fuel efficiency, their cams can help just about any 4BT application.

14 In high-revving and high-horsepower engine applications, the factory press-in freeze plug design is a common failure point. To prevent that, ACD Engines has the cylinder head water ports tapped to accept threaded plugs.

15 Because this engine will be running higher boost pressures, the cylinder head will be machined to use a custom fire-ringed head gasket kit and ARP head studs. Due to the swap from the factory head bolts to the stronger ARPs, like any 6BT Cummins engine, the factory rocker pedestals must be machined for clearance.

16 The Bosch P7100 injection pump has come a long way from what it was originally designed and built to do on the 1994-98 Ram trucks. Originally developed to support the mid 200-hp range, the 4BT platform with just four cylinders moves even less fuel, as it was only needed to support 130-150 hp in most applications. Using knowledge from the massive 12V performance market, those same techniques and modifications were used in the ACD injection pump. This 13mm pump uses laser-cut delivery valves, max-rack travel plug, stronger hold-downs, and a custom cam design specific to the 4BT pump to maximize fuel injection under the quicker injection events the four-cylinder engine is subject to. This particular pump is capable of moving up to 800 ccs of fuel, which should be more than enough to help move the big H1 Hummer down the street (doing long third-gear burnouts the whole way).

17&18 Again, turning to their knowledge of the 12V Cummins aftermarket, the fuel injectors for the 4BT engine were also reworked to maximize the amount of fuel that could be efficiently injected and burned in the cylinders. The dual-feed injectors and custom-honed nozzles should be more than enough to support ACD’s 800-hp goal. The custom high-flow injection lines will also be used to eliminate any restrictions between the injection pump delivery valves and the injectors.

19 Turning to their background working on the industrial side of the Cummins engine platforms, ACD will be using these OEM Cummins valve covers on this high-horsepower build, which offer dual port ventilation. While the gapless piston rings should cut down on most of the engines blow-by, the high-flow breathers in these valve covers will be much more efficient than running the factory individual cylinder covers found on most 4BT and 6BT engines.

20 Since the cylinder head intake and exhaust sides were ported and polished to maximize airflow through the head, it’s only natural that an exhaust manifold upgrade be used as well. While there are different OEM-style manifolds for the 4BT that can be used to fit different installation needs, they don’t necessarily flow what a high-horsepower build like this one would need. So ACD Engines turned to Steed Speed, which offers these custom-fabricated manifolds that can be bought with both T3 and T4 turbo flanges along with center- and top-mount exit locations. These different turbo mount locations should be more than enough to help fit a 4BT into the chassis of just about anything.

ACD will soon be installing this completely built 4BT engine into their shop vehicle, a H1 Hummer Army body sitting on the chassis from a Dodge Ram 2500. The Stroker 4BT will help push fully built axles, custom suspension and drivetrain sitting on 40-inch tires down the road. We’ll be sure to do a complete write-up on the project when it’s up and running in another issue of Diesel World.

ACD Engines understands that the complete Stroker Kit may be more than most 4BT project vehicles will need, so they have an array of 4BT-specific products that can do everything from help increase power to just improving fuel mileage and engine efficiency. They also carry a full line of custom brackets and conversion pieces that may help your conversion or transplant project go a little easier. DW

4BT Land Cruiser Conversion

The team at ACD Engines has made 4BT conversions their specialty and had this 1992 Toyota Land Cruiser up on the rack while we were shooting photos of their new 4BT Stroker Kit. The owner of the Land Cruiser wanted more pep than the factory gas engine could offer, but didn’t want to sacrifice fuel mileage, making it the perfect candidate for a mildly upgraded 3.9L Cummins.

This 1992 Toyota Land Cruiser was on the rack while we were at ACD shooting photos of their 4BT Stoker kits; it’s already been converted over to a 4BT engine platform that uses one of ACD’s custom camshafts and reworked rotary VE injection pumps, which help pump power output from 130 hp to nearly 200 hp. The power and torque increase should be enough to move the Land Cruiser up and down the freeway with ease, while offering a good, usable power band while off-road and excellent fuel mileage while on-road.

ACD Engines are experts at doing these 4BT conversions and have shoehorned the small Cummins engine into just about everything from Jeeps, mini-trucks and even a mid-’50s ambulance. Under the hood of this Land Cruiser you’ll notice that the four-cylinder diesel fits near perfect and will retain full use of the factory heat and A/C with some custom bracketry built by ACD. The addition of an intercooler in front of the radiator will also help with the turbo and engine’s efficiency.

While you may think all the magic of this conversion is found under the hood of the Land Cruiser, ACD was right in the middle of installing the new transmission and transfer case. The mildly upgraded 4BT will be backed by the NV4500 five-speed manual transmission found in the 1994-2000 Dodge Ram trucks. The transfer case is also a one-off that with use of an adaptor ring allowed for a passenger-side tail shaft exit to allow proper driveline angles be kept with the Land Cruiser’s original front and rear axles.

Knowing that major horsepower and torque would be needed and looking to keep things budget friendly, they opted for the less common and slightly cheaper VE injection pump series motor, versus the more popular and easily modified P7100 injection pump model. The VE pump working with custom ACD injectors and camshaft should bring power output up from the original 105 hp to a more user-friendly 200 hp. While this may not sound like much, the low-end torque of the 4BT backed by the NV4500 five-speed manual transmission (from the 1994-2001 Dodge Ram truck) will make for a great daily driver and off-road combination. On this particular build, ACD will also be able to retain the factory A/C and heating system, and were even able to add an intercooler system behind the grille. ACD and the vehicle’s owner are hoping this package nets a consistent 25-30 mpg.

SOURCE:
ACD Engines
877-506-8667
www.acdengines.com

FREQUENTLY ASKED QUESTIONS

What conversion and transplant products are available to assist with 4BT engine swaps?

Additionally, ACD Engines offers a variety of solutions tailored specifically for 4BT engines. These include:

Performance Enhancers: Products designed to boost power output.
Fuel Efficiency: Items aimed at improving mileage and overall engine efficiency.
Custom Brackets and Conversion Pieces: A comprehensive line of brackets and conversion parts to simplify your engine swap or transplant project.

Whether you’re looking to increase your engine’s performance or make your conversion project run smoother, ACD Engines provides the specific tools and parts to get the job done effectively.

What has driven the recent popularity of diesel-powered vehicles in the U.S.?

The popularity of diesel-powered vehicles here in the U.S. has really jumped in a positive direction in recent years. More and more manufacturers are starting to offer all-new diesel powerplants in half-ton trucks, cars, and midsize SUVs—the introduction of a 3.0L diesel in the new Ram 1500 trucks, an EcoDiesel in the latest Chevrolet Cruze passenger car, and there’s even been talk of a 4.5L Duramax coming down the pipeline. With the big car builders starting to offer diesel upgrades from the standard gas powerplants, there must be legitimate reasoning.

Maybe it’s better highway fuel efficiency and the giant increase in torque offered by a diesel engine. In reality, it’s probably an attempt at meeting ever-increasing CAFE (Corporate Average Fuel Economy) numbers. Diesel engines generally provide superior fuel efficiency compared to their gasoline counterparts, especially on highways. This efficiency can be a significant factor for drivers who log many miles. Additionally, diesel engines are known for their high torque output, which is particularly beneficial for towing and hauling heavy loads. These factors make diesel engines an attractive option for both everyday drivers and those with specific utility needs.

Either way, these smaller V-6 and four-cylinder engines will be sticking around. The combination of improved fuel economy and increased torque, along with regulatory pressures to meet stringent fuel economy standards, ensures that diesel-powered vehicles have a solid place in the market. As manufacturers continue to innovate and refine diesel technology, we can expect to see even more options and advancements in this space, making diesel a viable and popular choice for a variety of consumers.

How durable and reliable is the 3.9L Cummins engine?

The 3.9L Cummins engine is highly regarded for its durability and reliability. Stemming from the same lineage as the renowned 5.9L 12-valve Cummins, this engine has earned the trust of diesel enthusiasts worldwide.

Why It’s Durable

Robust Construction: Built with quality materials, the 3.9L Cummins is designed to withstand rigorous conditions and extended use.
Proven Design: The engine shares a lot of its foundational design with the legendary 5.9L model, which is famous for its longevity.

Reliability Factors

Consistent Performance: Known for delivering consistent power output, even after considerable mileage and tough use.
Easy Maintenance: The engine’s straightforward design facilitates easier maintenance, which helps prevent potential breakdowns.

Choosing the 3.9L Cummins means investing in an engine that promises dependable service for years to come, making it a favored choice for those prioritizing longevity in their vehicles.

What are the differences between pre-1998 and post-1998 3.9L Cummins engines?

Differences Between Pre-1998 and Post-1998 Cummins 3.9L Engines

When comparing the Cummins 3.9L engines from pre-1998 models to those manufactured after 1998, several notable differences emerge.

Valvetrain Configuration

Pre-1998 Engines: These early models sport an eight-valve configuration.
Post-1998 Engines: The later models, however, were upgraded to a 16-valve system. This change significantly impacted the engine’s overall performance and efficiency.

Performance and Power Output

Pre-1998 Performance: Engines from this era offer power ratings of about 105 horsepower (hp) with a torque capability of 265 pound-feet (lb-ft).
Post-1998 Performance: With the new 16-valve setup, base horsepower jumped to 170 hp, and torque increased impressively to 420 lb-ft. These enhancements represent a substantial improvement in performance capabilities.

These differences highlight how the technological advancements in the valvetrain contributed to enhanced power and efficiency in the post-1998 models. While power outputs may vary slightly depending on specific applications, the upgrades made in the later versions are unmistakable.

How does the weight of the 3.9L Cummins engine affect vehicle handling and suspension in conversion projects?

The Impact of the 3.9L Cummins Engine on Vehicle Handling and Suspension

When considering the 3.9L Cummins engine for a conversion project, its weight is a critical factor that influences vehicle handling and suspension dynamics. Tipping the scales at approximately 750-780 pounds, this engine is heavier than many gasoline engines it might replace. This weight differential can lead to noticeable changes in how a vehicle performs and handles.

Effects on Suspension and Axles

Increased Strain: The additional pounds can exert more pressure on the suspension system and axles, particularly in vehicles designed originally for lighter engines.
Compensation in Larger Vehicles: For full-size trucks and SUVs with inherently more robust suspension setups, the impact of the extra weight may be less pronounced. These vehicles are often better equipped to handle the stress, given their design for heavy-duty tasks.
Modification Considerations: In conversion projects involving heavily modified 4x4s, the influence of weight becomes particularly nuanced. The extent of modification can either amplify or mitigate the strain on the vehicle’s components. In this context, weight becomes a relative factor, highly dependent on the specific build and customization undertaken.

Conclusion

Overall, while the 3.9L Cummins engine offers the potential for impressive performance in conversion projects, it is essential to consider how its weight will affect the vehicle’s handling and suspension. Ensuring that the suspension system is appropriately adjusted or upgraded can help maintain optimal vehicle performance and longevity.

What are the drawbacks of the 3.9L Cummins engine compared to modern diesel engines?

When evaluating the 3.9L Cummins engine, it’s essential to understand some of the limitations that it faces, especially when stacked against contemporary diesel engines.

Outdated Design

The 3.9L Cummins comes from an earlier generation of engine designs, which might not offer the sleek engineering found in newer models. This older architecture lacks the modern touches and advancements seen in recent diesel engines, which often feature sophisticated fuel systems and superior efficiency.

Noise and Vibration Concerns

Another point to consider is the audible presence of the 3.9L Cummins. Users often note that it produces significant noise and vibration. If you prefer a quieter, more comfortable driving experience, this engine’s lack of sound dampening could be a downside.

Limited Customization and Tuning

For those passionate about tweaking for extra performance, the 3.9L Cummins might be less accommodating. Modern diesel engines often allow users to easily adjust tuning parameters to enhance performance with simple tuning kits. In contrast, increasing the power output of this engine requires more than just a plug-and-program approach—it demands a notable investment of time and money.

Significant Investment for Power Enhancements

While power enhancements are possible, they come at a cost. To boost this engine’s performance to levels comparable with newer engines, you’ll need aftermarket parts and professional labor, both of which can add up quickly. This means the cost-to-benefit ratio may not be ideal for those looking for straightforward power gains.

In conclusion, while the 3.9L Cummins engine is known for its durability, the modern user might find it lacking in refinement, noise control, and ease of tuning. Carefully consider your performance goals and resources before opting for this classic engine.

Why might fuel economy alone not justify swapping to a 3.9L Cummins engine?

Why Fuel Economy Alone May Not Justify the 3.9L Engine Swap

Swapping to a 3.9L engine might initially seem like a smart move for better fuel economy. However, it’s crucial to look deeper before making such a change.

Impact on Weight and Handling

One key consideration is the engine’s weight. Weighing about as much as one-third of a typical, compact off-roader, this hefty engine can drastically affect how your vehicle handles. Increased weight can strain the suspension and axles, potentially causing more frequent repairs and maintenance, especially in lighter vehicles.

Installation and Component Challenges

The 3.9L engine often lacks an intercooler, making installation straightforward at first. Yet, if you aim to maximize performance, adding an intercooler becomes necessary. This can demand extensive modifications under the hood, complicating the swap process.

Fuel Savings vs. Conversion Costs

Fuel savings are another factor where expectations might not align with reality. Depending on what engine you’re upgrading from, the fuel efficiency gains may be modest. Vehicles transitioning from an average of 15 miles per gallon could only see improvements up to 17 to 21 mpg. The financial benefits from improved mileage might not cover the considerable expenses of the conversion.

Consider Your Vehicle Type

For heavier trucks and larger SUVs, the weight of the new engine might be more manageable. However, in smaller 4x4s, particularly those taken off-road, handling and weight distribution become critical factors to consider.

Conclusion

While enhanced fuel economy is attractive, it’s imperative not to overlook the possible downsides of a 3.9L engine swap. Consider the entire spectrum of impacts—weight, handling, installation challenges, minimal fuel savings, and how these factors relate to your vehicle and its use—before deciding on this modification.

Are there more modern diesel engine options that might be better choices than the 3.9L Cummins?

Exploring Modern Diesel Engine Options Beyond the 3.9L Cummins

When considering whether there are more advanced diesel engines that might be preferable to the 3.9L Cummins, the answer is a resounding yes. Recent advancements in diesel technology have introduced various engines that present compelling advantages over older models.

Why Modern Diesel Engines Stand Out

Today’s diesel engines benefit from cutting-edge innovations that offer:

Superior Fuel Efficiency: Modern designs are engineered to maximize every drop of fuel, leading to significant savings.
Reduced Emissions: These engines are built to comply with strict environmental regulations, reducing their carbon footprint.
Enhanced Performance and Power: Innovations have led to engines that deliver impressive power and torque, perfect for heavy-duty tasks.

Top Modern Engine Alternatives

Consider the following popular modern diesel engines that might be better suited than the 3.9L Cummins:

Duramax Engines
- Efficiency: Designed for optimal fuel economy, providing long-term cost benefits.
- Powerful Performance: Known for robust power and torque, ideal for demanding applications.
Power Stroke Engines
- Longevity and Durability: Built with a sturdy design that promises long-lasting performance.
- Advanced Technology: Features innovative control systems to enhance operational efficiency.
EcoDiesel Engines
- Emission Standards: Meets even the most rigorous environmental benchmarks.
- Quiet Operation: Significantly quieter than predecessors, enhancing the driving experience.

Benefits of Choosing Modern Engines

Opting for these contemporary diesel engines offers several advantages over the 3.9L Cummins:

Reliability: Newer engines are often more dependable thanks to refined engineering.
Improved Performance: Enhanced speed and towing capacities can make a noticeable difference in utility and convenience.
Long-Term Cost Savings: Despite potentially higher upfront costs, the savings on fuel consumption and reduced maintenance requirements can be substantial over time.

In summary, if you’re weighing options beyond the 3.9L Cummins, modern diesel engines present a plethora of benefits that cater to efficiency, performance, and adherence to ecological standards.

What role do new connecting rods and pistons play in enhancing the 4BT engine’s performance?

The new parts will allow the overall piston bore to expand to a 4.402-inch and a much longer 5.430-inch stroke is used, which will effectively take engine output to 333 cubic inches, or 5.46-liters, almost that of the 5.9L 12V Cummins. This increase in engine displacement is a key factor in boosting performance, allowing the engine to produce more power and torque.

Knowing that the clientele for such a kit would be after extreme power levels, only the best materials were used to be sure the Stroker Kit would stand up to high-boost and high-cylinder pressures. Rather than use standard-cast pistons, like the stock units, a much stronger forged piston design was selected. This piston features a different bowl design to improve the air/fuel swirl effect, helping create a more efficient burn in the combustion chamber. The piston design also has a much shorter overall height, along with the wrist pin location being moved closer to the deck; this is where most of the additional stroke comes from.

Technical Enhancements

To match the new piston, connecting rods had to be developed, crafted from billet 4340, similar to those used in high-horsepower diesel engines. The new H-beam rod design is not only stronger than a factory connecting rod but also features a smaller wrist pin journal, compatible only with the specialized piston. These enhancements ensure the engine’s durability and performance at high power levels.

Additionally, specific camshaft profiles have been designed, along with custom cylinder head work, and even adjustable injection pump timing gears tailored for the 4BT. These adaptations are essential due to the unique timing requirements of the four-cylinder engine compared to a six-cylinder setup. Such comprehensive engineering innovations help transform a standard 105-hp 4BT into a formidable 800-hp powerhouse, ready to deliver exceptional performance.

Why is a bottom-end Gorilla girdle used?

Despite the 4BT having fewer issues with block flex than the 5.9L 6BT, a Gorilla girdle is used to reinforce the engine’s lower section, ensuring stability and strength when handling high power output.

What materials and designs are used to handle high power levels?

High-quality materials like forged pistons are employed to endure high boost and cylinder pressures. The new designs also contribute to better performance under extreme conditions.

What are the structural advantages of the new pistons?

The use of forged pistons, as opposed to standard-cast ones, enhances durability. Additionally, the redesigned bowl improves the air/fuel mixture for more efficient combustion.

How do these changes affect engine displacement?

The modifications raise the engine displacement from 239 cubic inches to 333 cubic inches, or 5.46 liters, nearing the size of the 5.9L 12V Cummins engine.

What are the specific changes in piston and stroke dimensions?

The piston bore is expanded to 4.402 inches, and the stroke is extended to 5.430 inches, which are key modifications for boosting the engine’s capacity.

What are the technical specifications of the 3.9L Cummins engine?

Technical Specifications:

Horsepower: 105hp
Torque: 265 lb-ft
Dimensions: 30.6 in long, 24.6 in wide, 37.7 in high
Weight: Nearly 800 pounds

These specifications highlight the engine’s capability despite its compactness, making it a robust option for a range of conversion projects. The engines came with a few different injection pump systems, but the P7100 is, by far, the most popular, since it’s capable of producing larger amounts of fuel and more easily modified by the aftermarket to help increase power outputs.

This combination of power and adaptability ensures the 4BT engine remains a favorite among those looking to enhance their vehicle’s performance.

What is the width of the 3.9L Cummins engine?

The width of the engine measures 24.6 inches.

How much torque does the 3.9L Cummins engine produce?

It generates 265 lb-ft of torque.

What is the horsepower of the 3.9L Cummins engine?

The engine delivers 105 horsepower.

What are the pros and cons of the 3.9L Cummins (4BT) diesel engine?

The popularity of diesel-powered vehicles here in the U.S. has really jumped in a positive direction in recent years. More and more manufacturers are starting to offer all-new diesel powerplants in half-ton trucks, cars, and midsize SUVs—the introduction of a 3.0L diesel in the new Ram 1500 trucks, an EcoDiesel in the latest Chevrolet Cruze passenger car, and there’s even been talk of a 4.5L Duramax coming down the pipeline. With the big car builders starting to offer diesel upgrades from the standard gas powerplants, there must be legitimate reasoning.

The 4BT engine has been used in commercial utility trucks and industrial construction equipment since the late 1980s and because of its extremely basic functionality works well as a transplant engine when space constraints restrict the use of the larger six-cylinder 5.9L Cummins. With the cylinder head off the 4BT engine, someone with 12V Cummins experience should feel right at home; the 4BT is virtually the same, just two pistons shy, of course.

4BT History

The 4BT—which stands for four-cylinder, B-series, Turbocharged—was used mostly in midsize box trucks, agricultural equipment, and small industrial vehicles, and is basically a smaller version of the popular 5.9L 12V Cummins found in the 1989-98 Dodge trucks. The 4BT shares virtually all its parts with its big brother the 6BT; i.e., pistons, connecting rods, injectors, and valve train design.

Compact Size and Power: Despite its relatively small dimensions (30.6 inches long, 24.6 inches wide, and 37.7 inches high), the 3.9L Cummins generates 105 hp and 265 lb-ft of torque, making it a formidable contender for various applications.
Versatility and Availability: The engine’s widespread use across delivery trucks to wood chippers makes it readily available and often inexpensive, a major advantage for those seeking affordable, reliable power.
Simplicity: Minimal electronics are required, simplifying the conversion process and making it a popular choice for enthusiasts.
Compatibility: Sharing many components with the 5.9L Cummins ensures good parts availability and reliability, further enhanced by the strong aftermarket support.
Mechanical Injection Pump: The P7100 mechanical injection pump is favored for its reliability and ease of modification, allowing for potential performance upgrades.
Fuel Economy: Offers moderate fuel savings, with real-world numbers ranging between 17-21 mpg, depending on the application.

Cons of the 3.9L Cummins (4BT) Diesel Engine

Weight: Weighing nearly 800 pounds, the engine can negatively affect handling and put additional strain on suspension and axles, especially in smaller vehicles like the Jeep Wrangler.
Non-Intercooled: Both the 4BT and 4BTA versions are non-intercooled, which could be a limitation for those seeking higher power.
Antiquated Design: The older technology results in more noise, vibration, and a lack of modern refinements.
Power Tuning Limitations: Increasing power requires significant investment and effort, unlike modern engines that can be easily tuned.

The 4BT engine weighs in at around 750-780 lbs, which is heavier than most of the gas engines it would be replacing in a conversion project, but much lighter than the six-cylinder 6BT version. The inline-four also offers a fairly compact size at just 30.6 inches long and 37.7 inches tall, helping with space constraints. The engines came with a few different injection pump systems, but the P7100 is, by far, the most popular, since it’s capable of producing larger amounts of fuel and more easily modified by the aftermarket to help increase power outputs.

Overall, the 3.9L Cummins diesel engine stands out for its mass availability, simplicity, and versatility. However, it is important to weigh these advantages against its drawbacks, particularly the added weight and lack of modern refinements. If you’re considering an engine swap, the 3.9L Cummins offers a robust and reliable option, especially for full-size applications. For smaller, more nimble vehicles, you may want to explore other alternatives.

How versatile and historically significant is the 3.9L Cummins engine?

The 3.9L 4BT Cummins diesel engine has become an extremely popular platform for conversion projects over the past couple years, and for good reason. Sharing virtually every internal and external piece with its big brother, the 5.9L 12V Cummins found in the 1989-98 Dodge Ram pickups, and coming as regular equipment in hundreds of commercial and industrial applications, parts availability, power potential, fuel mileage, and the lack of electronics make it an easy go-to engine when it’s time to squeeze a diesel platform into the frame rails of just about anything.

First hitting the market in 1983, the 3.9L Cummins, also known as the 4BT, has proven its versatility and durability over decades. It’s been utilized in everything from delivery trucks to wood chippers, highlighting its adaptability across various industries. This widespread use means the engines are not only easy to find but also affordable, making them a practical choice for enthusiasts looking for reliability without breaking the bank.

The robust design and mass availability of the 4BT offer enthusiasts and professionals alike a dependable engine option. Whether you’re looking to enhance a personal project or keep commercial operations running smoothly, this engine delivers unparalleled versatility and historical significance that make it a staple in the world of diesel conversions.

Why is the 3.9L Cummins engine considered a practical choice?

Its solid design coupled with widespread availability makes it a reliable and sensible choice for enthusiasts seeking dependable performance without exorbitant costs.

What are the economic advantages of the 3.9L Cummins engine?

The engine is both readily available and cost-effective, making it an attractive option for those looking to balance performance with budget considerations.

In what types of applications has the 3.9L Cummins engine been used?

This engine has seen a variety of uses, ranging from powering delivery trucks to operating wood chippers, showcasing its adaptability across different sectors.

When was the 3.9L Cummins engine introduced?

The 3.9L Cummins engine was introduced to the market in 1983, marking its long-standing presence in the industry.

What are the common aftermarket modifications available for the 4BT Cummins engine to increase its performance?

Performance Mods

To complement these significant fuel upgrades, common enhancements to the cylinder head and turbocharger are essential. Fortunately, the aftermarket has already addressed these needs with components like head studs, improved valve springs, larger valves, and even performance exhaust manifolds and camshafts specifically designed for four-cylinder diesels.

While these upgrades can take the 4BT to all-new levels, it’s crucial to consider the engine’s unique characteristics. Due to its fewer cylinders and nearly identical operating rpm range compared to a 6BT Cummins, each piston experiences a combustion cycle more frequently. Therefore, attention to camshaft profiles and pump timing becomes critical for achieving maximum efficiency at higher horsepower levels.

These comprehensive modifications not only boost performance but also ensure the engine maintains reliability and efficiency, making the 4BT a formidable choice for those seeking enhanced power output.

Why is it critical to focus on camshaft profiles and pump timing for the 4BT?

Given the quicker combustion cycle due to fewer cylinders, precise camshaft profiles and pump timing are crucial to maximizing efficiency and achieving higher horsepower without compromising engine performance.

How does the availability of aftermarket solutions affect the feasibility of these modifications?

The aftermarket provides comprehensive solutions, making these modifications readily achievable with a wide array of available parts tailored for performance enhancements.

What is the impact of having fewer cylinders on the 4BT compared to the 6BT?

Due to fewer cylinders, each piston in the 4BT experiences a combustion cycle more frequently, which necessitates precise camshaft profiles and pump timing to ensure efficiency at higher power levels.

What are the specific components of cylinder head and turbocharger upgrades?

Upgrades include head studs, improved valve springs, larger valves, as well as performance exhaust manifolds and camshafts, all tailored for four-cylinder diesel engines.

What specific types of fueling modifications are available?

The 4BT engine can utilize 12mm and 13mm pumps with laser-cut delivery valves, hi-rev governor springs, and full-travel rack plugs. Modified injectors are also compatible for enhanced fueling capabilities.

What types of vehicles are better suited for a 3.9L Cummins engine swap?

The 3.9L 4BT Cummins diesel engine has become an extremely popular platform for conversion projects over the past couple years and for good reason. Sharing virtually every internal and external piece with its big brother, the 5.9L 12V Cummins found in the 1989-98 Dodge Ram pickups, and coming as regular equipment in hundreds of commercial and industrial applications, parts availability, power potential, fuel mileage, and the lack of electronics make it an easy go-to engine when it’s time to squeeze a diesel platform into the frame rails of just about anything.

When considering an engine swap, it’s important to match the engine’s strengths with the vehicle’s characteristics. The 3.9L Cummins shines in full-size applications, such as trucks and larger SUVs. These vehicles can fully utilize the engine’s robust power and simplicity, making them ideal for those seeking reliability and performance in larger builds. Additionally, it’s a fantastic choice for overland-type rigs designed for long-distance travel and challenging terrain, where durability and efficiency are paramount.

However, for compact and nimble vehicles like the Jeep Wrangler, the 3.9L might not be the best fit. The engine’s weight and size could negatively impact handling and performance, so it’s wise to explore other engine options that preserve the vehicle’s agility and off-road capabilities.

In summary, the 3.9L 4BT Cummins diesel engine offers versatility across a variety of vehicle conversions, but its true potential is realized in larger vehicles. Understanding the optimal applications for this engine ensures you make the best choice for your project, whether you’re embarking on an adventurous overland build or customizing a reliable powerhouse.

What transmission options are available for the 3.9L Cummins engine?

While you may think all the magic of this conversion is found under the hood of the Land Cruiser, ACD was right in the middle of installing the new transmission and transfer case. The mildly upgraded 4BT will be backed by the NV4500 five-speed manual transmission found in the 1994-2000 Dodge Ram trucks. The transfer case is also a one-off that with use of an adaptor ring allowed for a passenger-side tail shaft exit to allow proper driveline angles be kept with the Land Cruiser’s original front and rear axles.

Transmission Versatility at its Best

The 3.9L Cummins engine doesn’t just offer power; it brings unparalleled versatility with its compatibility with a wide range of transmission options. Whether you’re eyeing a manual or an automatic setup, this engine can cater to your needs and preferences. Such adaptability makes it a prime choice for numerous applications, offering flexibility that suits both traditional and modern vehicular demands.

Manual and Automatic Options

Manual Transmissions: Like the NV4500 five-speed, these options are perfect for those who crave control and precision.
Automatic Transmissions: Ideal for a smoother ride and easier handling, especially in urban settings.

This blend of compatibility ensures that whether you’re revamping a classic or upgrading a current model, the 3.9L Cummins engine fits seamlessly, transforming your vehicle into a powerhouse of performance and adaptability.

How versatile is the engine in terms of transmission compatibility?

The engine is highly adaptable, capable of being paired with numerous transmission types to meet diverse applications and user preferences.

What types of transmission options are available for the engine?

The engine supports both manual and automatic transmissions, providing a variety of choices for users.

What are the typical fuel economy figures for vehicles with a 3.9L Cummins engine swap?

While this may not sound like much, the low-end torque of the 4BT backed by the NV4500 five-speed manual transmission (from the 1994-2001 Dodge Ram truck) will make for a great daily driver and off-road combination. On this particular build, ACD will also be able to retain the factory A/C and heating system, and were even able to add an intercooler system behind the grille. ACD and the vehicle’s owner are hoping this package nets a consistent 25-30 mpg.

However, when considering the typical fuel economy figures for vehicles with a 3.9L Cummins engine swap, it’s important to set realistic expectations. Generally, fuel economy tends to fall within the 17 to 21 miles per gallon (mpg) range. This range is based on real-world data and can vary depending on several factors:

Vehicle Weight: Heavier vehicles often consume more fuel, impacting overall efficiency.
Driving Habits: Aggressive driving can lower your mpg, while smoother driving can help maintain it.
Load and Usage: Frequently towing heavy loads or driving in stop-and-go traffic can also reduce fuel efficiency.

Understanding these variables can help in achieving optimal performance and economy from your 3.9L Cummins-powered vehicle, ensuring that whether you’re navigating city streets or tackling rugged trails, you’re getting the most out of every gallon.

Is the fuel efficiency data for the 3.9L Cummins engine swap based on practical experience?

Yes, the fuel efficiency figures are grounded in real-world experiences and data.

What elements can affect the fuel efficiency of a vehicle with a 3.9L Cummins engine swap?

The primary elements include the vehicle’s weight, driving behavior, and the nature of the load or driving conditions.

What can you typically expect for fuel efficiency when a 3.9L Cummins engine is swapped into a vehicle?

You can generally anticipate a fuel efficiency ranging from 17 to 21 miles per gallon.

What are the differences between pre-1998 and post-1998 Cummins engines in terms of valve design and power output?

3 The 4BT engine uses a simple two-valve per cylinder system, obviously one for intake and one for exhaust. While this design is somewhat “outdated” with the introduction of the four-valve-per-cylinder design found in the 1998.5+ 6BT engines, it’s still a sufficient and robust design, especially on the smaller cubic inch low 130-180-hp applications that most of the 4BT engines were designed for.

Understanding Valve Design Evolution

The shift from a two-valve to a four-valve-per-cylinder design marked a significant evolution in engine technology. This change not only improved airflow and engine efficiency but also allowed for enhanced performance in newer models. The 1998.5+ 6BT engines benefitted from this innovation, offering better power output and efficiency.

Power Output Considerations

For enthusiasts and professionals who rely on the rugged reliability of the 4BT engine, its 130-180 horsepower range remains impressive for its size. Though newer models boast higher capabilities, the 4BT’s design continues to serve well in applications where durability and simplicity are paramount.

In summary, the transition in valve technology underscores the increasing demands for performance and efficiency in engine design, while the 4BT remains a testament to enduring engineering principles.

Why is the two-valve-per-cylinder design still relevant?

Despite being seen as less modern, the two-valve-per-cylinder system is still considered effective and reliable, particularly for smaller engines with lower horsepower demands.

What is the timeline for the introduction of the four-valve-per-cylinder design?

The four-valve-per-cylinder design was introduced with the 6BT engines starting from the year 1998.5 and beyond.

What is the specific horsepower range for which the 4BT engines were designed?

The 4BT engines were designed for applications requiring horsepower in the range of 130 to 180.