 Glacier Diesel Power
Mega-Rail Fuel System
2003-07 5.9 Dodge Ram Cummins Diesel
The Mega-Rail System includes everything needed for installation of theentire fuel rail system from the larger 6.7L applications onto the 5.9LCummins. This simple bolt on package gives the 5.9L Cummins an edge inairflow and fueling like never before. Finally you can get the most fromyour modified injection pump and performance injectors!
Using our Mega-Flo Intake Manifold, Air-Boss 67 plenum and factory BoschHPCR parts we have created a package that is reliable, easy to install,and out flows any other parts combination on the market. If you'repushing the envelope on 5.9L Cummins performance the Mega-Rail kit canfuel it.
Benefits of the Mega-Rail System:
- 50% increase in fuel rail size – Perfect for modified CP-3’s
- 50% increase in fuel rail feed line size – Matched to rail size
- 50% increase in injector line size – Handles even the largest injectors
- 50% increase in crossover tube size - Removes the final restriction in the CR system
- 3000 psi higher relief valve pressure – No need for rail plugs, we leave the safety in the system
- 110% increase plenum entrance area – Over double the air entrance area at the plenum
- 20% larger intercooler piping - 3.50” Intercooler piping and intake manifold vs. 3.00” stock
- 100% Brand new Bosch fuel rail, injector lines and crossover tubes - No concerns over used or modified parts
- 100% Bolt-on installation - It doesn't get any easier than this!
The GDP Mega-Rail System is a complete package and does not requireadditional parts to be purchased. For those customers who would like tosupply their own rail, lines and crossover tubes we offer the Mega-RailInstallation Kit.
Mega-Rail System Includes:
- Mega-Flo Intake Manifold
- Air-Boss 67 Billet Plenum
- 3.50" Intercooler Pipe & Boots
- New Bosch 6.7L Fuel Rail (No Rail Pressure Sensor)
- New Bosch 6.7L Fuel Injector Lines
- New Bosch 6.7L Crossover Tubes
- CP-3 & Rail Return Line System
- Rail Pressure Sensor Extension Harness
- Dipstick Bracket
- All Required Hardware & Gaskets
Note 1: This conversion kit eliminates the factory grid heater.
Note 2: Only for single CP-3 applications.
Note 3: Currently not for use on trucks with engine mounted APPS. (Relocation bracket in the works)
Mega-Rail tips, tricks and myths
Through the course of installing the Mega-rail System we have come across a few things that you may find useful.
First is the rail pressure sensor. With minor electrical connector modification, the stock 6.7L rail pressure sensor can be used on the 5.9Ltrucks. Due to voltage mapping differences the stock 5.9L rail pressuresensor reads roughly 13% higher than the stock 6.7L sensor at the samevoltage. This can be used to your advantage if you are careful.
By using the 6.7 pressure sensor on the 5.9 you can raise rail pressureapproximately 13% without using a pressure box. For example, at WOT thisequates to 24,860 psi actual at an ECM reported 22,000 psi. At idlereported pressure would be 5000 psi with actual being 5,650 so thedifference is very small. At a reported cruise pressure of 8000 psi theactual would be 9,040 psi and this small increase is good for mileage.Since rail pressure is in essence "fooled" you will need a 6.7L railpressure gauge connected directly to the sensor to see actual railpressure readings.
Now, for the warnings and disclaimers...
Use the 6.7L rail pressure sensor at your own risk! Do not use the 6.7Lrail pressure sensor if you are running a pressure box! If your tuner ofchoice has a rail pressure adjustment setting we recommend running thetuner at the "stock" pressure setting. Most tuners increase railpressure to some degree. When combined with the 6.7L sensor railpressures can get out of hand quickly. When using the 6.7L sensor alwaysmonitor actual rail pressure with a standalone 6.7L rail pressure gaugesuch as the unit offered by ISSPRO.
Next up is the grid heater. There has been some talk of using the stock6.7L grid heaters (with the Mega-Rail kit) on the 5.9L head. The stock6.7L grid heater will NOT fit the plenum opening of the 5.9L headwithout modification to a small casting area under the plenum cover. Itcan be made to work but minor grinding will be required.
We always recommend using new parts when working on the HPCR fuelsystems. However, if you are looking to save some money, there are manysources for used 6.7L rails and injector lines. Wrecking yards and coresupply shops have good inventory levels of used 6.7L parts now and cansave you some money over buying a brand new rail and lines. Using aMega-Rail Installation kit and a used rail setup is a great way to makebig power on a budget.
Choose 6.7L or 5.9L Rail Pressure Sensor (Please read the tips section above before you choose)
You have two options below. You can use the 6.7L Rail Pressure Sensor or use your stock 5.9L Rail Pressure Sensor. If you choose the 5.9L option, no pressure sensor is included.
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