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2003 To 2007 Cummins Performance Upgrades

Easy, Proven 5.9L Power—Without the Growing Pains

Text By Jason Thompson, Photography by Jason Thompson
2003 To 2007 Cummins Performance Upgrades 5 9 Cummins Engine

Nothing can ruin a perfectly good truck like the temptation of adding a cheap power upgrade. If a diesel engine gets the wrong parts, or even if the right part is installed before the vehicle (or owner) is ready—trouble is bound to follow. In this article, we walked the slippery slope of diesel performance but knew which path to take and when to stop—so we didn’t go sliding all the way to the bottom. We wanted to make sure the equipment we put on our ’06 Dodge Ram 2500 didn’t hurt anything and instead would help accomplish our goals of maintaining the proven durability of our Dodge—while increasing performance.

2003 To 2007 Cummins Performance Upgrades Ram Air Scoop Installed

Our ’06 5.9L Ram was in Florida when we did the upgrades, so we called upon Nick Dragunov and Jamie Wilson of Ultimate Diesel in Sarasota to give us a hand. The first thing they did to make working on our Dodge easier was to remove the front driver-side wheel and fenderwell. Then they took the $289 S&B cold-air intake (PN: 75-5047) from the box and checked its fit. The part shown is the optional ram-air scoop (PN: 75-5049).

  • 2003 To 2007 Cummins Performance Upgrades Stock Cummins Air Intake
    Ultimate Diesel removed the Cummins’ intake air temperature sensor (IAT) from the factory intake (so it could be used on the S&B intake) and unbolted the system so it could be removed from the 5.9L. The factory filter minder was not yet reinstalled with the S&B kit.
    2003 To 2007 Cummins Performance Upgrades Stock Cummins Air Intake
    Ultimate Diesel removed the Cummins’ intake air temperature sensor (IAT) from the factory
  • 2003 To 2007 Cummins Performance Upgrades Front Of Ram Air Scoop
    Although Florida has quite a bit of sand on its highways, this Dodge stays out of the mud, so we decided we should go with the optional S&B cold-air scoop priced at $99.
    2003 To 2007 Cummins Performance Upgrades Front Of Ram Air Scoop
    Although Florida has quite a bit of sand on its highways, this Dodge stays out of the mud,
  • 2003 To 2007 Cummins Performance Upgrades Aluminum Heater Block Delete
    The S&B billet-aluminum heater-block delete (PN: 76-1005) is located beneath the Cummins’ intake elbow and replaces the factory heater grid, which helps improve airflow. It also retails for $99.
    2003 To 2007 Cummins Performance Upgrades Aluminum Heater Block Delete
    The S&B billet-aluminum heater-block delete (PN: 76-1005) is located beneath the Cummins’
  • 2003 To 2007 Cummins Performance Upgrades S And B Intake Elbow
    The S&B intake elbow (PN: 76-1004) we first saw at SEMA last year comes with six ports for picking up a boost or temperature reading. They also serve as a place to add injectables like nitrous oxide or, in our case, a Snow Performance water-methanol injection system (PN: 49103) that retails for $866.
    2003 To 2007 Cummins Performance Upgrades S And B Intake Elbow
    The S&B intake elbow (PN: 76-1004) we first saw at SEMA last year comes with six ports for
  • 2003 To 2007 Cummins Performance Upgrades Water Methanol Injection Nozzles Installed
    We installed the two Snow Performance water-methanol injection nozzles in the S&B intake. Then we routed the red water line to the supplied pump, which we mounted to the frame. The black boost line also coming from the intake goes to the TOW-MAX controller so the water-methanol injection system knows when to inject.
    2003 To 2007 Cummins Performance Upgrades Water Methanol Injection Nozzles Installed
    We installed the two Snow Performance water-methanol injection nozzles in the S&B intake.
  • 2003 To 2007 Cummins Performance Upgrades Egt Probe Installed
    The Snow Performance water-methanol injection system also measures and reacts to exhaust gas temperature (EGT) by reading this sensor. This is the most important data point in any modified diesel, and one we would want anyway so the Snow kit fits multiple purposes. We drilled the hole in the exhaust manifold with the engine running so the shavings would be blown out, instead of falling in. Putting heavy grease on the drill bit toward the end of drilling the hole also helps to catch particles.
    2003 To 2007 Cummins Performance Upgrades Egt Probe Installed
    The Snow Performance water-methanol injection system also measures and reacts to exhaust g
  • 2003 To 2007 Cummins Performance Upgrades Tow Max Control Connector
    This electrical connector splices the EGT probe wires to the Snow TOW-MAX controller.
  • 2003 To 2007 Cummins Performance Upgrades Water Methanol Container
    This 7-gallon reservoir holds the water-methanol fluid. A 50 percent mixture of water and methanol is recommended, but to see how much is too much, check out our May ’10 article “Water-Methanol Injection: How Much is Too Much?”
    2003 To 2007 Cummins Performance Upgrades Water Methanol Container
    This 7-gallon reservoir holds the water-methanol fluid. A 50 percent mixture of water and
  • 2003 To 2007 Cummins Performance Upgrades Bully Dog Tuner
    The Bully Dog Triple Dog Gauge Tuner (or GT) was very easy to install. It plugs right into the OBD II port located under the dash, so all we had to do was add a power wire to the fuse box. We ran this wire and the wires for the Snow Performance kit at the same time.
    2003 To 2007 Cummins Performance Upgrades Bully Dog Tuner
    The Bully Dog Triple Dog Gauge Tuner (or GT) was very easy to install. It plugs right into
SOURCES
Snow Performance
1017-A East Highway 24
Woodland Park
CO  80863
866-365-2762
www.snowperformance.net
S&B Filters
787 S. Wanamaker Avenue
Ontario
CA  91761
800-358-2639
www.sbfilters.com
Bully Dog
2839 Highway 39
American Falls
ID  83211
866-285-5936
www.bullydog.com
Ultimate Diesel
941-374-0659
By Jason Thompson
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