Sylvie Willis
With the rising cost of diesel fuel, improving fuel efficiency in heavy-duty trucks has become a priority for the trucking industry. Cummins Inc., a leading manufacturer of diesel engines, offers several tips to enhance fuel economy in Cummins diesel engines. Basic modifications such as regular maintenance, including oil and filter changes, can improve fuel efficiency. Upgrading to synthetic lubricants and optimizing airflow with a cold air intake system are also recommended. Engine upgrades, such as tuners and modern automated powertrains, can further boost fuel economy, with some upgrades claiming potential gains of up to 5 mpg. However, it's important to consider the cost-effectiveness of these upgrades, as the savings in fuel costs may not always justify the initial investment.
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What You'll Learn
Regular maintenance and oil changes
To increase the fuel economy of your Cummins diesel engine, regular maintenance and oil changes are essential. Here are some detailed steps to help you maximize your fuel efficiency:
Regular Maintenance
Maintaining your Cummins diesel engine is crucial to ensure optimal performance and fuel efficiency. Firstly, establish a regular maintenance schedule by consulting your truck's manufacturer. They can advise on the recommended service intervals and specific maintenance requirements for your vehicle. Stick to this schedule to keep your Cummins diesel in prime condition.
Oil Changes
In addition to regular maintenance, oil changes are vital. Using synthetic lubricants can increase fuel economy by up to 5%. Synthetic mixtures can be used not only in your engine but also in your transmission, transfer case, and front and rear differentials. This simple step can have a significant impact on improving your Cummins diesel's fuel efficiency.
Fuel and Air Filters
Replacing your fuel and air filters is essential for maintaining horsepower and fuel economy. Old and dirty filters can hinder the performance of your engine, so be sure to include this in your regular maintenance routine.
Airflow Optimization
To increase airflow, consider working on your fresh air intake and exhaust side. A cold air intake and a performance exhaust system can improve fuel mileage. Specifically, a 4-inch free-flowing exhaust can enhance airflow and fuel efficiency.
Efficient Driving Habits
Educating yourself and your drivers about efficient driving habits can lead to significant fuel savings. Smooth and steady acceleration is preferable to abrupt starts. Encouraging safe and efficient driving practices can help you maximize your Cummins diesel's fuel economy.
By following these steps and maintaining your Cummins diesel engine with regular maintenance, oil changes, and airflow optimizations, you can achieve better fuel efficiency and, ultimately, cost savings.
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Use synthetic lubricants
Synthetic lubricants can increase the fuel economy of your Cummins diesel engine. Replacing your regular motor oil with a synthetic mixture can increase your fuel economy by anywhere between 2% to 5%. Synthetic lubricants are better at lubricating your truck's moving parts and reducing friction between them. When your diesel parts have an easier time moving, you get better fuel mileage.
Synthetic lubricants can also be used with your transmission, transfer case, and front and rear differentials. They can help improve the performance of your engine by reducing friction and improving fuel efficiency.
It is important to choose a synthetic lubricant that meets or exceeds the original fluid requirements and specifications of your Cummins diesel engine. Valvoline's Premium Blue Engine Oils, for example, are designed to provide advanced lubricant performance in modern, emissions treatment-equipped diesel engines, including all types of Exhaust Gas Recirculation (EGR) and Diesel Particulate Filters (DPF). This product has been endorsed by Cummins and has been tested extensively in stationary and EGR on-road engines, including diesel-powered engines.
In addition to using synthetic lubricants, there are other ways to increase the fuel economy of your Cummins diesel engine. One way is to increase air density by upgrading the restrictive stock intake with a higher-flowing performance air intake, such as a cold air intake. This can lead to better fuel mileage, especially during highway driving. Another way to improve fuel economy is to ensure regular maintenance of your diesel truck, including oil changes, filter changes, and tune-ups. Replacing your fuel and air filters is crucial as old and dirty filters can impact your horsepower and fuel economy.
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Improve airflow with a cold air intake
To increase the fuel economy of a Cummins diesel engine, one of the modifications you can make is to improve airflow with a cold air intake.
The Cummins engine needs a lot of air. Diesel engines are essentially air pumps, and to maximize efficiency, they require cool, dense air to create combustion at the right time. Without proper airflow, there will be excessive fuel in the cylinders, causing heat and possibly smoke.
The factory air intake features multiple baffles to quieten the incoming air charge, so you cannot hear any sound inside the cabin. However, these baffles cause a lot of air turbulence, which slows down the incoming air charge. Nearly all aftermarket cold air intakes eliminate these baffles, immediately speeding up and smoothing out the airflow.
Upgrading with a quality cold air intake delivers more air to the engine, improving fuel economy and power. The more of the existing fuel you burn, the better the efficiency.
Combining an intake with a tuner is the best way to maximize mileage increases. You can expect to see gains of around 1mpg in city driving and up to 5mpg gains when highway driving.
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Use a tuner
A diesel tuner is a small, computerized device that plugs into your truck’s OBD2 port or connects to your wiring harness. Essentially, the tuner accesses your truck’s computer systems and allows you to run programs that fine-tune your engine and other aspects of your truck to fit your needs. Tuners come in three main types: monitor tuners, handheld tuners, and plug-and-play tuners.
Monitor tuners are more complex. They come with a monitor that you can mount in the cabin to see in real time what your engine is doing. This gives you a large degree of control over your settings. Handheld tuners go through your OBD2 port and connect to a handheld device that often resembles a smartphone. These systems often come with preprogrammed settings that you can use to customize your truck. Plug-and-play tuners are usually small devices that offer specific modules.
Tuners can increase your engine’s power, give you better fuel economy, reduce throttle delay, and give you a clear picture of what’s going on in your truck’s system. They can also help you catch problems with your truck before the check engine light comes on. These devices can alert you to issues before they become major problems. Diesel trucks often experience a certain amount of throttle delay. Tuners are a common way to solve this by increasing throttle sensitivity and making it quicker to respond to the gas pedal.
The best fuel gains are going to come from a tuner. Combining an intake with a tuner is going to be the best way to maximize mileage increases. The sweet spot of the 6.7 Cummins is 55mph to about 70mph. Live testing has shown up to 5mpg gains when highway driving with cruise control at 65mph. You are likely only going to experience around 1mpg gain driving in the city, with the best improvements coming at highway speeds.
If you’re talking about something like a 2nd gen Cummins, tuning is pretty easy and you can have a go at that yourself pretty safely. More modern engines are computer-controlled and tuning requires a computer or a purpose-built gadget of some sort. It’s important to research some tuners local to you, ask what they can offer and what it costs, and decide from there.
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Educate drivers on efficient driving habits
Educating drivers on efficient driving habits can have a significant impact on fuel economy, especially when operating heavy-duty trucks. Here are some key instructions to pass on to drivers to improve fuel efficiency:
Firstly, drivers should be encouraged to place safe performance ahead of speed. This includes increasing speed limits gradually and avoiding rapid acceleration. Diesel engines perform optimally when driven at a steady pace, and higher speeds can negatively impact fuel economy due to increased drag. Maintaining a speed of around 55-70 mph is ideal for optimising fuel efficiency, with highway driving offering better mileage than city driving.
Secondly, drivers should be made aware of the importance of airflow. Increasing airflow in and out of the engine improves fuel mileage. This can be achieved by investing in a cold air intake system and a performance exhaust. A higher-flowing air intake will increase air density, reducing the amount of fuel needed for ignition, resulting in better fuel economy.
Additionally, drivers should understand the impact of proper tire pressure. Well-maintained tires with optimal pressure can reduce drag, leading to improved fuel efficiency. It is also beneficial to streamline the truck or trailer to further decrease drag and enhance fuel mileage.
Finally, drivers should be encouraged to maintain their vehicles regularly. This includes routine maintenance such as oil changes, filter replacements, and tune-ups. Old and dirty filters can negatively affect both horsepower and fuel economy. Synthetic lubricants are also worth considering, as they have been shown to increase fuel economy by 2-5%. By following these maintenance tips, drivers can ensure their vehicles are operating at their highest level of efficiency.
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