Ameer Randolph
The horsepower of a Cummins engine can be increased in a number of ways, but it is important to be aware of the limitations of the stock fuel system. The stock lift pump can support up to 800 hp, and with some modifications, it may be possible to reach 1000 hp. However, as horsepower increases, so do the demands on the engine, and the stock fuel system may not be able to keep up. To increase horsepower, modifications such as a cold air intake, ECM tuning, an intercooler, a turbo upgrade, and larger injectors can be made, with each step building on the last to safely increase horsepower.
| Characteristics | Values |
|---|---|
| Horsepower rating | 160-215 horsepower |
| Torque figures | 400-440 lb.ft |
| Maximum horsepower | 700-800 hp |
| Turbocharger | Stock mount or 2nd Gen swap |
| Horsepower gain | 50-100 hp |
| Fuel mileage | Improved |
| Airflow | Upgraded |
| Fueling | Upgraded |
| Monitoring systems | Upgraded |
| Fuel efficiency | Better at cruising speeds |
| Fuel pump | HotRod VP44 Pump |
| Horsepower gain from fuel pump | 80-100 hp |
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What You'll Learn
Cold Air Intake + 4 or 5 Exhaust: +30-50HP
If you're looking to boost the horsepower of your Cummins engine, one option is to combine a cold air intake with a 4- or 5-inch exhaust. This setup can increase horsepower by around 30 to 50. It does so by improving airflow and lowering exhaust gas temperatures (EGTs).
The stock intake horn on the driver's side of the engine can restrict airflow, so an upgrade is recommended. The Banks Monster Ram Intake and a larger boost tube are popular choices, as they can increase airflow and boost pressure while reducing air temperature. Drilling a 4-inch hole in the stock air box and adding a flex hose is another inexpensive option to improve airflow.
If you're looking for further gains, an intercooler upgrade can add another 25 to 40 horsepower. This reduces charge temperatures and adds boost.
It's important to note that the specific gains will depend on the model and specifications of your Cummins engine. The 5.9L Cummins, for example, is known for its ability to handle high horsepower with proper tuning and torque management.
Additionally, as you increase horsepower, it's crucial to consider the limitations of your stock components and make necessary upgrades to ensure the engine's reliability and longevity.
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ECM Tuning: +100-150HP
ECM tuning is a powerful tool to optimise the performance of a Cummins Heavy Duty engine. It involves modifying the settings and parameters within the ECM (electronic control module) to align with specific needs and driving conditions. The ECM is the brain of the engine, controlling functions such as fuel delivery, boost pressure, and engine timing.
Customised ECM tuning can offer improved horsepower, torque, and overall engine performance, resulting in a more capable and efficient vehicle. It can also enhance fuel efficiency, leading to better fuel economy and reduced operating costs. This is achieved by optimising fuel injection timing and improving fuel burn, which can also reduce harmful emissions.
When considering ECM tuning, it is important to consult experienced professionals as improper tuning can cause engine damage and may be illegal in some jurisdictions. The process typically involves an evaluation of the engine and driving needs, followed by the creation of a custom tuning file. This can be a more expensive and time-consuming process than off-the-shelf tuning solutions, but it provides better results tailored to the unique requirements of the driver and their vehicle.
For example, Dirty Diesel Customs offers custom tuning for the 2022-2024 6.7L Cummins engine, with tune files ranging from Stock Delete up to 150HP Race tunes. Their Level 4 tune can deliver an increase of 120HP, while their Level 5 tune can provide a boost of 150HP. These tunes are designed for standard trucks with the 68RFE or Aisin transmission.
Overall, ECM tuning is a complex but effective method to unlock the hidden potential of a Cummins engine, resulting in increased power, improved fuel efficiency, and a smoother driving experience.
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Intercooler + Banks Intake Horn: +25-40HP
The Banks Intake Horn is a component of the air intake system. While it is not the most significant piece for increasing horsepower, it can still contribute to a notable gain when combined with other upgrades.
Upgrading to an intercooler and Banks Intake Horn can result in a horsepower increase of approximately 25 to 40 HP. This modification works to reduce charge temperatures and add boost.
The stock horn has a significant boost loss at the same flow rate. By upgrading to a better-flowing horn, such as the Banks Intake Horn, you can ensure that nearly all the boost produced by the turbos reaches the valves. This results in improved airflow from the intercooler, leading to a more responsive and fuel-efficient engine.
The Banks Monster-Ram Intake System is specifically designed to improve airflow and boost without increasing backpressure at the turbine. This system includes pre-drilled ports to measure pressure, temperature, and flow, ensuring optimal performance.
While the Banks Intake Horn can provide a modest horsepower increase, it is recommended to prioritise other upgrades first, such as the exhaust, intercooler, and tune. These initial upgrades will provide more noticeable gains and improve the overall performance of your vehicle.
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Turbo Upgrade: +50-100HP
Upgrading your turbocharger is a great way to add significant horsepower to your engine. A turbo upgrade can increase horsepower by up to 100 HP on a stock fuel Cummins engine.
The right turbocharger upgrade for your Cummins engine will depend on your specific vehicle and performance goals. For example, if you're looking for a quick spool-up and improved exhaust braking, a stock-location VGT like the BD Screamer is an excellent choice. This turbocharger is well-suited for towing and can handle up to 600 HP with emissions intact.
If you're aiming for higher horsepower, you may consider a different turbo upgrade. The BD Super B Single Turbo is a popular choice for the 5.9L Dodge Cummins engine, offering a quick spool-up and increased performance in the mid and top-end ranges.
Another option is the Fleece Performance 63mm Cheetah Turbocharger, which provides lightning-quick spooling and unsurpassed drivability for the 3rd Gen 5.9L Cummins engine. This turbo upgrade can also be found for the 6.7L Cummins, providing big performance gains.
When upgrading your turbocharger, it's important to consider the overall condition of your engine and whether you plan to make additional modifications. Upgrading your turbocharger alone may require supporting mods, such as injectors, to ensure optimal performance and engine longevity.
By choosing the right turbo upgrade and supporting modifications, you can safely add significant horsepower to your stock fuel Cummins engine, improving its performance and driving experience.
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Dual CP3 + Larger Injectors: +100-150HP
Adding a second, belt-driven CP3 to the engine has long been the most effective way to support larger injectors and achieve high horsepower. Dual CP3 systems allow the workload of supplying high-pressure fuel to the rail to be shared, enabling four-digit horsepower to be reliably supported.
The Fleece Performance Engineering 6.7L Cummins Dual Pump Kit is an example of a dual CP3 system. It can be purchased with or without the company's fuel distribution block and hose and fitting kit. The pump is mounted to the front cover of the engine, making future head-related serviceability items easier. The additional CP3 is controlled through EFI Live tuning and does not require a separate CP3 controller.
Dual CP3 systems can support horsepower of over 650HP. They are also required for builds over 650HP.
In addition to dual CP3s, larger injectors can be used to command the same amount of fuel in a shorter duration, without advancing the fuel curve. This will result in a quicker drain on the rail, requiring more work from the stock CP3.
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Frequently asked questions
The amount of HP you can make on stock fuel Cummins depends on the model. For instance, the 5.9L Cummins can hold 800-1000 horsepower with proper tuning and careful torque management. The 6.7L Cummins is more powerful out of the box but has a connecting rod design that can be brittle under extreme stress.
One way to increase the HP on a Cummins engine is to upgrade the airflow and fueling systems. Another way is to monitor the engine's temperature and keep it cool, as sustained power takes a lot of cooling.
The stock 6.7 Cummins can handle around 700-800 HP. However, as you get closer to 1000 HP, you will need to take extra measures to lower your intake and exhaust temps.
The 5.9 12v P-Pump can easily go to 600 HP. Getting to 400 HP is also achievable with little air and fuel adjustments.
The Banks TwinRam Intake manifold can increase horsepower and fuel mileage by doubling the area of the stock manifold and improving air distribution.
