Spanning from 1994 to 2002, this period marked Dodge’s ambitious endeavor to build upon the triumph of the 1st gen Cummins. This article meticulously navigates the specifications of the 12 Valve and 24 Valve iterations, illuminating distinctive features, performance enhancements, and towing prowess.
1994-1998 12 Valve 5.9L Cummins Specs
The formative years of the 2nd gen Cummins, spanning 1994-1998, introduced the revered “P-Pump” fuel injection pump. Noteworthy enhancements encompassed new injectors, an enlarged intercooler, and an upgraded turbocharger, all aimed at minimizing emissions while amplifying engine performance.
The 12 Valve engine exhibited impressive horsepower and torque, contingent upon transmission configurations.
Performance Specs
A pivotal upgrade manifested in the introduction of a new fuel injection system, featuring the Bosch P7100 mechanical injection pump, colloquially known as the “P-Pump.”
This injection pump played a pivotal role in enhancing fueling, with options for further augmentation. Supported by injectors designed for elevated fuel pressures, this system, coupled with piston design modifications, contributed to an augmented combustion quality.
Early Second Gen Cummins Air Induction
In response to heightened cooling demands, the 12V Cummins received a larger intercooler and a wastegated turbocharger. The initial Holset H1C turbocharger metamorphosed into the upgraded Holset HX35W or HX35 turbocharger in subsequent models, accommodating increased pressures.
Diesel Racing and Sled Pulling
Emerging as a powerhouse in diesel racing and sled pulling, the 12V Cummins demonstrated a potential to surpass 1,000 horsepower. Renowned for durability, these engines, whether for daily driving or high-performance applications, established a solid reputation.
1998.5-2002 24V Cummins Specs: Engine Changes
In 1998, the 2nd gen Cummins underwent a substantial metamorphosis, transitioning to a 24-valve configuration. The Bosch P7100 “P-Pump” gave way to a rotary electric VP44 injection pump. This period ushered in the 24V engine, featuring four valves per cylinder for enhanced performance and throttle response.
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Fuel System
The shift to an electric rotary injection pump marked a profound departure. The VP44 pump, collaborating with the ECU, governed fuel injection timing and flow. An electric lift pump was introduced to sustain consistent fuel pressure, though aftermarket options like Air Dog or Fass systems were recommended for longevity.
Air Induction
The 24 Valve 5.9L Cummins retained the turbocharger legacy of its predecessor, utilizing the Holset HX35W turbocharger to deliver reliable performance. However, trucks with automatic transmissions in 2001-2002 adopted the Holset HY35W turbocharger.
High Output 24V 5.9L Cummins
Late 2nd gen Cummins trucks offered a high-output configuration, featuring a 6-speed manual transmission. While this manual option was less advanced than contemporary automatic transmissions, it contributed to increased horsepower and torque. The NV5600 6-speed manual transmission became a popular choice for those seeking aftermarket power.
2nd Generation Cummins Specs: Engine Design
The 2nd gen 5.9L Cummins, spanning 1994 to 2002, maintained an inline 6-cylinder design with a deep skirt cast iron block and cast iron cylinder head. The engine boasted a displacement of 5.9 liters (359 cubic inches), a bore of 4.02 inches, and a stroke of 4.72 inches.
Turbocharger
Turbocharger variations included the Holset WH1C Turbo for early 1994, Holset HX35W Turbo for 1994-1998, Holset HX35W for 1998.5-2002 manuals, and Holset HY35W for 2001-2002 automatics. The high-output models in 2001-2002 featured the Holset HX35W.
Valvetrain
The 1994-1998 Cummins had an overhead valve engine with 2 valves per cylinder, while the 1998.5+ models boasted 4 valves per cylinder for a total of 24 valves.
Transmissions
Transmission options varied, with 1994-1998 trucks equipped with the 47RH 4-speed automatic or NV4500 5-speed manual. The 1998.5+ trucks featured the 47RH 4-speed automatic or NV5600 6-speed manual.
Weight and Engine Oil Capacity
The dry weight of the engine was 1150 lbs, with an engine oil capacity of 12 quarts or 11.4 liters with the filter.
12V 5.9L Cummins Horsepower & Torque
1994-1995 Auto: 160 horsepower, 400 lb-ft
1994-1995 Manual: 175 horsepower, 420 lb-ft
1996-1998 Auto: 180 horsepower, 420 lb-ft
1996-1998 Manual: 215 horsepower, 440 lb-ft
24V 5.9L Cummins Horsepower & Torque
- 1998.5-1999 Auto: 215 horsepower, 420 lb-ft;
- 2000-2002 Auto: 235 horsepower, 460 lb-ft;
- 1998.5-2002 Manual: 235 horsepower, 460 lb-ft;
- 2001-2002 High Output Models Manual: 245 horsepower, 505 lb-ft.
2nd Generation 5.9 Cummins Towing Specs
Between 1994 and 2002, substantial improvements were made in tow capacity. The maximum tow capacity varied based on the model, transmission, and drivetrain. For instance, the 2500 regular cab 4×2 could tow up to 14,100 lbs, showcasing the 2nd gen Cummins as a reliable towing companion.
Transforming your 2nd gen cummins into a powerhouse involves strategic upgrades tailored to its distinct engine variations. For the 12V models, optimizing the fuel system by upgrading injectors and fine-tuning the Bosch P7100 “P-Pump” injects a surge of power, enhancing both horsepower and torque.
Additionally, turbocharger enhancements, such as aftermarket options and compressor wheel upgrades, open avenues for personalized performance, ensuring an exhilarating driving experience.
On the 24V front, the transition from the mechanical “P-Pump” to the rotary electric VP44 injection pump marks a significant shift. Upgrading this pump, along with investing in aftermarket lift pumps like Air Dog or Fass, addresses common issues and boosts fuel supply. Tuning remains a linchpin for both 12V and 24V models, allowing enthusiasts to strike the perfect balance between power gains and engine longevity.
Conclusion
The 2nd generation 5.9L Cummins stands as a testament to the evolution of diesel trucks. From the robust 12 Valve engines to the refined 24 Valve configurations, these trucks have left an indelible mark on the automotive landscape.
Whether for daily use, high-performance endeavors, or towing capabilities, the 2nd gen Cummins remains a sought-after choice among enthusiasts. Explore the nuances of each model year, choose wisely, and experience the power and reliability of this iconic engine.
