3. Install Cold Air Intakes and Performance Air Filters
Upgrade the Air Intake
Improving the airflow to the engine is a surefire technique to boost a diesel vehicle’s performance. More air will reach the engine using an enhanced air flow kit, resulting in increased power.
In addition, the new airflow kit will pull air from outside the engine compartment, bringing colder air in. The amount of power produced by the engine will rise because cooler air is denser and holds more oxygen.
An enhanced air flow system can boost horsepower while also improving fuel economy.
Change or Reprogram the ECM
Engine performance is controlled by the Engine Control Module (ECM), which alters critical engine parameters such as the air-fuel mixture and maximum RPM.
You may easily change these settings by reprogramming or changing the ECM. This will allow the engine to create more horsepower and torque, which will increase performance.
ECM upgrades not only increase power, but they also help to increase diesel efficiency.
Using New Fuel Injectors
The next step is to upgrade the fuel injectors if you’ve improved the air flow to the engine and set up the ECM to produce additional power.
More fuel will reach the engine thanks to new fuel injectors, resulting in increased horsepower. Individual injector nozzles are found on most performance fuel injectors, which provide higher pressure and better atomize the fuel.
Adding extra power to diesel engines using a performance turbocharger is a wonderful way to do it.
The turbo operates by pressurizing the air intake and forcing additional air into the engine. It is possible to generate more power while improving engine efficiency by using a turbo.
In comparison to a non-turbo engine, a stock turbo boosts air flow three to four times. A performance turbo, on the other hand, can enhance airflow by five to ten times over a non-turbo engine, resulting in a bigger horsepower boost.
You’ll need to update your exhaust system if you want to increase the engine horsepower.
Unlike factory exhaust systems, which are designed to reduce noise, a performance exhaust system will have a wider diameter and fewer bends, allowing for more exhaust flow.
A broader, straighter exhaust system will help reduce exhaust gas temperature and boost the engine’s horsepower and torque.
Can you upgrade a diesel turbo?
A turbocharger is used in the majority of today’s diesel trucks. A factory-installed turbocharged diesel engine has an excellent overall baseline turbo that is also cost-effective for the OEM. This is the kind of tradeoff that occurs throughout the manufacturing process, and the aftermarket was created to allow you to choose where the compromise should be made.
Any deviation from the factory default setup has the potential to cause problems. When it comes to turbo upgrades, the risk is that you’ll end up with a turbo that’s too big for the engine, necessitating additional upgrades. Your engine may run worse rather than better after a turbo upgrade if your components aren’t properly matched.
It’s also vital to keep in mind that the turbo boost-to-fuel ratio is delicate. Too much fuel causes the engine to operate badly and smoke; too little fuel causes the engine to be power-starved and can overheat, resulting in high EGTs (Exhaust Gas Temperatures). When an engine’s intake isn’t getting enough air, similar problems emerge.
For the most part, a modest turbo boost is a wonderful approach to increase power and throttle responsiveness without jeopardizing the engine’s balance.
The Applied Performance Solution
Applied Performance Products is a newcomer to the aftermarket turbo scene, with a variety of turbos ranging from moderate to wild. On a 7.3-liter Ford Power Stroke engine, we had the opportunity to cover the installation of one of their APP-branded performance stock-replacement turbos (Part number: APP-802-011). This truck’s owner uses it primarily for work, transporting a trailer, and other general purposes. The idea was to increase power output without being trapped in a never-ending cycle of engine changes. For this diesel owner, Applied Performance had the ideal solution.
The APP turbo is larger than the factory turbo and feeds the engine additional air (boost). The most significant characteristic, though, is that this turbo isn’t so extreme that it can’t be utilized on a standard engine. This turbo, which is designed to be a “straight bolt-in” item, provides significantly more air than the factory turbo and can be your only improvement. This turbo, on the other hand, may be used with a variety of moderate improvements that are limited or impossible with the factory turbo. The benefit is that you receive greater power right now while also having room to prepare for future increases if you wish to do so.
This turbo shell is made of high-quality A-356 aluminum alloy and is both light and sturdy. It’s equipped with a billet CNC compressor wheel that’s engineered to provide maximum boost at all levels while reducing turbo lag and compressor surge. Your diesel engine will have a smooth power curve if you supply a smooth, consistent air intake flow. Faster spool-up and a boost curve that better fits engine needs are also achieved thanks to the lighter compressor wheel and improved vane design.
The internals of this turbo were also built to last by APP. A larger turbine shaft, improved step-gap oil seals, superior bearings, and greater quality control all contribute to a more consistent product than the original stock one.
Compare and Contrast with Stock
According to the specifications, the APP turbo features a 62mm inducer wheel and a 92mm exducer wheel, compared to the standard unit’s 60mm and 80mm. While the wheels are larger, the casing is only slightly larger than the stock unit, allowing it to fit into the existing space with ease. The new turbo also includes a brand-new billet aluminum adjustable wastegate actuator that is pre-set at 24 psig. The factory unit’s pressure is set to 8 psig.
What Is PSIG, Anyway?
Because the basic pressure of the air around you is roughly 14.7 psi at sea level (and somewhat lower at altitude), any absolute boost pressure readout will automatically include that amount of pressure. PSIG stands for Pounds per Square Inch Gauge, and it denotes pressure relative to atmospheric pressure by subtracting the fundamental atmospheric pressure from the value.
Other enhancements over the OEM turbo include: The turbo shaft has a greater diameter than the stock unit (22 percent at the hub and 16 percent at the journal bearings). The thrust bearing’s contact area has been expanded from 270 degrees to 360 degrees. For better sealing, a step-gap oil seal was added to the turbine side, and the turbo inlet was increased from 3 inches to 4 inches. To make installation with the larger inlet easier, APP includes a new silicone intake tube and T-bolt clamps. All intake air passes via a ported-shroud housing, which is more efficient than the stock unit. When you combine the larger turbine and compressor wheels, the more efficient housing, and the higher wastegate actuation point, you obtain superior performance.
It’s worth noting that simply replacing the turbo won’t result in significant power gains. This is due to the fact that the fuel flow remains unchanged from before. Lower EGTs will result if all you do is improve the turbo. As a general rule, the manufacturer claims a drop of 100 to 150 degrees. Lower EGTs are a positive thing since they allow you to utilise the power you’re producing without fear of engine damage caused by high exhaust gas temperatures. However, with a few little changes to the fuel flow and tune, your engine will be able to produce significantly more power. It’s only a matter of playing the correct cards, so to speak, to get higher outputs than the stock turbo.
We were given the opportunity to see the installation at R&S Automotive in Newhall, California. The modification was completed in less than a day and went without a hitch. Engine power was increased and EGTs were reduced when paired with a few basic power enhancements performed by the owner prior to the installation. With just a little more work, we’ll show you the highlights of a simple turbo modification that will result in lower EGTs and more power.
L Turbo Fitment
For the 7.3L Power Stroke, there are two turbos to choose from. One is only for cars with a circular EGR cooler from 2003 and early 2004. Later models with square EGR coolers from late 2004 to 2007 should utilize a different part number. When implemented, both will have comparable effects.
Taking Advantage Of Your New Turbo
This story’s light turbo upgrade can be completed without any more modifications. You may, however, increase the power of your truck with some more work. These upgrades are either impossible to achieve with the stock turbo or will result in even higher gains with your upgraded turbo. The owner of our 7.3L Power Stroke F-250 went above and above.
He had already fitted an MBPR 4-inch cat-back exhaust system, a Donaldson 7.3L AIS Intake, and a TS six-position switch tuner, all with Swamp’s Diesel custom programming, prior to the turbo installation (stock, high idle, fuel economy, tow, hot street, and race programs included). We were told that he was happy with the end results after the turbo installation. He did, however, install a set of Swamps Diesel Performance 7.3L injectors in search of more power. This pair of injectors was the mildest of Swamps’ injector improvements, and it was a perfect complement for the mild turbo upgrade.
Even More Power
When it comes to updating your truck, keep in mind that everything works together. We upgraded to a somewhat larger turbo in this scenario, but not a massive one. This upgrade is intended to be used with a stock injector set and tune. While you can run with just the new turbo, you can also benefit from a few enhancements and receive better overall output than you would without it.
Just keep in mind that small turbo enhancements can help other light power modifiers, but don’t get caught up in a never-ending cycle of upgrades you don’t need. A knowledgeable shop and/or supplier can guide you in the proper way, one step at a time, to achieve your goals without overstressing any of your components. A well-balanced and well-planned power boost will outperform a component mix-and-match design.
additional costs and upgrades They’ll almost certainly have the proper turbo for you, no matter what your end aim is.
Other changes were done by the truck’s owner to take advantage of the new turbo’s capabilities. Swamp’s Diesel Performance’s new, bigger injectors are one of them.
Do cold air intakes work on diesels?
Improved gas mileage is another advantage of installing a cold air intake on a diesel truck. Fuel is burned to generate power in an internal combustion engine. Your engine need the proper amount of oxygen to complete this process. If there isn’t enough oxygen, it could lead to higher fuel usage. Cold air intakes are designed to offer the best air-to-fuel ratio possible, which can result in increased horsepower and better gas mileage. Because you’re getting greater mileage out of your fuel, your fuel costs are likely to drop.
Can you add sulfur to diesel fuel?
There is more knowledge and strong science on the problem of sulfur in diesel fuel than there has ever been. Despite this, there is still a common misperception in the fuel business that diesel fuel sulfur is harmful to microorganisms and that sulfur removal is the result of the corrosion problems that are common in today’s fuel systems. Let’s have a look at some facts concerning sulfur in gasoline.
MIC has been reported since the early 1900s, and the first attempts to identify it were made in 1934. Biodeterioration and MIC have been extensively examined and studied since then. Microbiological growth (MBG) has been an issue with diesel fuel from the beginning of time. To solve the problem of MBG, Biobor JF was invented and put on the market in 1965. All of the previous fuels had a high sulfur content. Diesel fuel with ultra-low sulfur content was not introduced until 2006. MIC and biodeterioration were a severe problem before to 2006. There is no conclusive evidence that MBG or MIC are more common today. It is true that there is a greater level of awareness and research on the subject. Sulfur is required for life and is used as an energy source by microbes. The fuel business has a misconception that sulfur in historically high sulfur diesel fuel acts as a biocide or at the very least a biostatic, preventing the fuel from deteriorating. The hydrodesulfurization procedure, which was used to remove sulfur, also removed hazardous aromatic chemicals, which have been demonstrated to preserve the fuel, according to research. By eliminating polynuclear aromatic chemicals that are harmful to bacteria, the removal method made diesel fuel more vulnerable to MBG. Sulfur is not poisonous to bacteria by nature.
Around 95% of the sulfur burned in fuel is released as sulfur dioxide (SO2), a poisonous gas linked to major human health problems. A further issue is the emission of fine sulphate particles into the air, which are known to make up the bulk of particulate matter (PM), which causes asthma, heart disease, and respiratory disease. PM is also a source of pollution in the environment, as it produces acidic aerosols that eventually precipitate as acid rain, snow, and fog. Acid rain was a typical occurrence prior to the introduction of ULSD. Fuel sulfur has a significant detrimental impact that cannot be overstated. Sulfur is toxic to both humans and the environment.
Diesel engine lubricants were built with detergents to protect engines from sulfur damage before the sulfur removal effort began. Sulfur creates sulfuric acid, which is highly acidic and caustic when burned. Sulfuric acid has been shown to cause engine corrosive wear and significant damage. While sulfur is known to have a lubricity factor, the acids created during combustion have been shown to inflict substantial damage to engine components, potentially increasing maintenance costs by up to 25%. SULPHUR DOES AFFECT ENGINES.
Why would someone want to add sulfur to their fuel if it has no real benefit in today’s diesel engines? Additives or biocides that raise the sulfur level of the fuel have detrimental consequences for human life, the environment, and engine maintenance expenses. Why not choose premium options that do not include sulfur when they are available?
How can I tell whether there’s sulfur in the air? It’s possible that it’s not obvious! Sulfur is contained in biocides if the ingredients list includes the words “thio, thia, or sulfo.” Isothiazolinones, such as those found in Kathon FP 1.5 and Kathon knockoffs like FQS 1.5, fall under this category. Others, such as those manufactured with Thiocyanates, contain a lot of sulfur. Another biocide made by Buckman and sold under a variety of brand names by various businesses, such as Bell Performance’s Bellicide, E-Bio-Blast, Zoil’s or Schaeffer’s 285 Fuel Shock, contains about 14,000ppm sulfur. This diesel fuel additive does not meet government regulations for ultra-low sulfur content in engines manufactured after 2007. The prescribed dosage will significantly increase the sulfur content of your gasoline, potentially leading it to be out of specification and causing damage to your equipment.
Will a bigger turbo make more power?
Turbochargers are similar to superchargers in that they compress air. These compressors force more air into the engine than the piston could consume on its own, and this air builds up in the intake manifold, resulting in pressure.
The pressure is measured in pounds per square inch and is known as boost (PSI). Even at low pressures, a turbocharger may be able to flow more air than the engine can use, resulting in an instant gain in power.
The more turbo boost pressure there is, the more power the engine produces. Furthermore, employing a turbocharger to boost an engine increases not only its horsepower but also its torque.
Can you put a performance air filter on a diesel?
A K&N automotive air filter or diesel air intake can increase diesel performance when working, pulling, or driving in your diesel pickup truck on a daily basis.
It is possible to increase diesel performance by replacing the factory auto air filter with a K&N diesel air filter, such as the K&N diesel air filter for 2003-2009 Dodge 2500 and 3500 Cummins 5.9L diesel models.
It wasn’t long ago that the term was coined “Diesel Performance” would have been regarded as a contradiction. A diesel engine has a number of advantages over a gasoline-powered internal combustion engine, but performance was never one of them until recently. Diesel engines are well-known in the automotive industry for their fuel economy, torque output, and longevity. Diesel passenger cars are popular in Europe because a diesel engine consumes less fuel than a gasoline engine doing the same amount of work. Heavy-duty diesels, such as semi-trucks, buses, and recreational vehicles, have also taken advantage of the diesel engine’s fuel efficiency advantages, but due to the distances these vehicles travel, the ability of a diesel engine to last twice as long as a gasoline engine is a major consideration when choosing a diesel power plant.
Diesel engines have become widely regarded as a viable alternative to gasoline-powered engines thanks to recent advancements in diesel performance technology. Gone are the days when a diesel was despised because it was slow, noisy, and filthy. Direct injection and forced induction improvements have helped to dispel the myth that diesel engines are slow. The problem of diesel exhaust, or “With advancements in direct injection and electronic engine management, as well as higher-quality diesel fuels, “diesel clatter” has been addressed. Modern diesel engines have improved tailpipe emissions from diesel-powered vehicles by minimizing waste fuel. Black smoke is produced by wasted fuel in a diesel engine under load, which has been largely eradicated with contemporary computerized engine and emissions controls.
Installing a K&N diesel air intake system, such as the 77-3063KTK seen on this 2004 Chevrolet Kodiak CK4500 6.6L V8 Diesel, will boost diesel performance even further.
The K&N diesel air intake for 2010-2012 Dodge Ram 2500 and 3500 Cummins 6.7L diesel models features an enclosed air filter box to keep inlet air temperature within factory limits.
While recent breakthroughs in diesel technology have made a significant difference, they have also made it more difficult to improve diesel performance. Higher air in the cylinders allows more fuel to be burned and more horsepower and torque to be produced, which is the primary principle underlying increased diesel performance. The duty of boosting air pressure loaded into the cylinder is accomplished by forced air induction, which is provided by superchargers and turbochargers. Most diesel engines, on the other hand, come standard with forced induction.
That’s where K&N air filters comes in with a diesel air filter or diesel air intake to help you outperform the factory design. Most diesel automobiles and trucks come with restrictive disposable air filters that are housed in a constrained factory air filter box from the factory. The air is then directed through complicated factory air intake tubing, which disturbs, if not completely obstructs, airflow into a diesel engine. K&N Air Filters can increase diesel performance by increasing horsepower and torque output by removing any or all of these sites of constraint using a K&N diesel air filter or diesel air intake system.
K&N tests diesel air filters and diesel air intakes to verify that a K&N diesel filter protects the engine, improves diesel performance, and meets manufacturer standards.
K&N creates a diesel air filter with additional layers of cotton in various grades and deeper pleats for more surface area than a conventional K&N auto air filter.
The restrictive disposable diesel air filter, the constricted factory air filter box, and the complicated air intake tubing will all be removed, but it is only part of the diesel performance equation. The temperature of the air as it enters the engine is something that K&N engineers pay close attention to. Cooler air has more mass, which allows for more efficient burning. When it comes to creating power and boosting diesel performance, an engine’s capacity to run efficiently is critical. Modern diesel pickups and vehicles have engine control units (ECUs) that may change engine performance as air temperature rises, causing the engine to run more conservatively and produce less power. This means that the location of the diesel air filter and diesel air intake is critical for ensuring adequate flow, temperature, and quality of incoming air for maximum diesel performance.
K&N engineers put a lot of thought into boosting diesel performance without sacrificing engine protection when designing a diesel air filter or diesel air intake. K&N diesel air filters are often manufactured to higher standards than our basic automotive air filters. Deeper pleats and more layers of cotton in various grades are used in the conventional K&N diesel air filter to attain higher levels of filtration effectiveness. To ensure that our air filters provide high airflow without sacrificing engine protection, K&N conducts filtration efficiency testing using the internationally accepted ISO 5011 procedure.
The filtration efficiency of a diesel air filter isn’t the only consideration when it comes to engine protection. A K&N diesel air filter, like a K&N diesel intake, goes through airflow, dynamometer, and over-the-road testing to assure that our product improves diesel performance without producing drivability problems. K&N engineers must be careful to boost diesel performance without disturbing electronic engine controls since modern diesel engines are mandated by federal law to operate within such limited operating restrictions. K&N undertakes its research to ensure that a K&N diesel air filter or diesel air intake system may boost diesel performance without requiring any additional adjustments.
Since the 1990s, when diesel engines became popular in full-size pickup trucks, K&N has been dedicated to boosting diesel performance. On the Diesel Filter Performance – Air Intakes & Air Filters page, you may browse a list of K&N diesel air filter and diesel intake choices, or use the K&N product lookup tool to find a diesel air filter or diesel intake for your vehicle.
How do I get better gas mileage in my diesel?
4 TIPS FOR IMPROVING DIESEL GAS MILEAGE
- Use a synthetic diesel engine oil that is high in quality. Checking the oil level in your diesel engine on a regular basis should be part of your routine maintenance, and you should use a high-quality synthetic engine oil.