Mercedes Mullins
Cummins diesel engines are known for their efficiency, but there are still modifications that can be made to improve fuel efficiency further. Some modifications can be made for just a few hundred dollars, and some simple changes can make a big difference. For example, ensuring that tires are inflated to the manufacturer's recommended level can improve fuel efficiency by up to 3%. Additionally, choosing the right tread patterns for tires is essential for enhancing traction and reducing wear. Aerodynamic improvements, such as fairings, side skirts, and tail extensions, can also improve fuel efficiency by reducing air resistance, which is especially beneficial for long-haul trucks.
| Characteristics | Values |
|---|---|
| Fuel additives | Hot Shot Secret’s EDT |
| Fuel | Diesel |
| Engine parts | Turbochargers, high-flow injectors, HE351 mods to the compressor and turbine |
| Engine parts suppliers | Yanmar, Cummins |
| Tire pressure | Properly inflated tires |
| Tread patterns | Deeper grooves and special siping |
| Aerodynamic improvements | Fairings, side skirts, tail extensions |
| Engine breathing | More cold dense air in, less restrictive manner to get the exhaust out |
| Engine temperature | Lower EGT |
| Tuners | Bully Dog GT, MADs Smarty Tuner |
| Exhaust | Stock turbo kit |
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What You'll Learn
Install a compound over stock turbo kit
Installing a compound over stock turbo kit can significantly enhance the performance of your Cummins diesel engine. Compound turbochargers are designed to unlock the full potential of your engine, delivering unparalleled power gains, improved efficiency, and enhanced reliability.
The key advantage of compound turbochargers lies in their ability to maximize airflow and optimize combustion. By pairing a smaller high-pressure turbo with a larger low-pressure turbo, compound turbos efficiently use exhaust gas pressures, resulting in improved fuel efficiency and reduced emissions. This setup also ensures smooth power delivery across all RPMs, providing responsive acceleration and reliable power, regardless of the driving conditions.
When upgrading to a compound turbo kit, it is essential to seek expert advice and choose reputable suppliers. Companies like BD Diesel Performance and Diesel Power Source offer compound turbo kits specifically designed for Cummins engines, ensuring compatibility and optimal performance. These kits are tailored to meet various driving needs, including towing, racing, and daily driving, with multiple stages available based on your desired goals.
Additionally, when installing a compound turbo kit, it is crucial to consider the specific combinations of components that work best for your engine. This includes selecting the right turbochargers, injectors, fuel pumps, and intake and exhaust systems. Working with experienced diesel performance experts will ensure that your engine not only performs exceptionally but also produces the right music when all the parts come together.
Upgrading to a compound turbo kit can be a significant investment, but the gains in performance, efficiency, and reliability make it well worth the cost. With the right compound turbo setup, you can expect to unlock the hidden power reserves of your Cummins diesel engine, pushing performance boundaries and enhancing your overall driving experience.
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Use a tuner
One of the ways to improve the fuel efficiency of a Cummins diesel engine is by using a tuner. Tuners can increase engine power, improve fuel economy, and reduce throttle delay. They can also help identify problems with the engine before they become major issues. Diesel tuners are generally easy to use, but it is important to read the instructions carefully before use. Tuners come in three main types: monitor tuners, handheld tuners, and plug-and-play tuners.
Monitor tuners are more complex and come with a monitor that can be mounted in the cabin to provide real-time feedback on the engine's performance. They offer a high degree of control over the engine's settings. Handheld tuners, on the other hand, connect to the OBD2 port and can be used with a handheld device similar to a smartphone. These often come with pre-programmed settings that allow for customization. Plug-and-play tuners are usually small devices that offer specific modules to improve performance, such as better fuel economy or increased towing power.
The Bully Dog GT tuner is a popular choice for diesel engines, offering multiple settings and adjustable speed and exhaust gas temperature (EGT) limiters. It can also read trouble codes and improve fuel mileage by 1-3 mpg. The TS Performance MP-8 Pro Tuner is another option that works with specific Duramax engines, increasing horsepower and torque. The PedalMonster is not a true tuner but a module that improves throttle sensitivity for Cummins engines.
It is important to note that some modifications, such as removing emissions control components, may be intended for off-road or racing applications and may not comply with local emissions regulations. Always ensure that any modifications made are legal and safe.
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Improve air density
Air density is a crucial factor in improving the fuel efficiency of Cummins diesel engines. Here are some ways to enhance air density and increase fuel economy:
Improve Air Intake
By installing an advanced air intake system, you can ensure that your engine receives an adequate airflow. This will help to avoid power loss due to insufficient airflow. Performance air filters, for instance, can increase airflow to the engine, improving combustion efficiency and resulting in better fuel mileage.
Turbochargers
Turbochargers are high-performance components that can significantly enhance fuel efficiency. They optimise the air-fuel mixture, promoting better fuel combustion. Modifications to the stock turbocharger, such as the HE351 mods to the compressor and turbine, can be made to improve efficiency. Alternatively, a completely new turbocharger can be installed, such as the Turbo Air Guide TAG-III 94-07 5.9L, which is specifically designed for Dodge Cummins engines.
Reduce Drag
Aerodynamic upgrades, such as fairings, side skirts, and tail extensions, can significantly improve fuel efficiency by reducing air resistance. This is especially beneficial for long-haul trucks, as managing air resistance can reduce fuel consumption by up to 10%. Vortex generators, vented mud flaps, drive fenders, and wheel covers are also effective methods to reduce drag and improve airflow around the vehicle.
Maintain Optimal Tire Pressure
Keeping your tires properly inflated is crucial for improving fuel efficiency. Under-inflated tires increase rolling resistance, making the engine work harder and consume more fuel. Over-inflated tires, on the other hand, can lead to uneven wear and decreased traction, negatively impacting fuel economy. Maintaining the recommended tire pressure, such as 60 psi for E Load Range tires, can improve fuel efficiency and balance performance.
Weight Distribution and Reduction
Even weight distribution across the vehicle minimises resistance and maximises fuel economy. Adhering to weight limits, using load-balancing techniques, and regularly reassessing weight distribution as loads change are essential. Additionally, removing unnecessary weight can significantly improve fuel efficiency. Every pound counts, and a lightweight vehicle is generally safer and puts less strain on the engine.
Fuel Additives
While the effectiveness of fuel additives is debated, they can help keep your intake valves, injectors, and carburetors clean, potentially improving fuel efficiency. However, it is recommended to consult a certified diesel mechanic before using fuel additives, as newer truck engines may not require them.
Driving Behaviour
Aggressive driving behaviours, such as speeding, frequent braking, and rapid acceleration, can decrease fuel efficiency. Slowing down, maintaining a moderate RPM, and driving within the ideal RPM range can optimise fuel-air mixture and combustion, leading to fuel savings.
These modifications and behavioural adjustments can help improve the air density in Cummins diesel engines, resulting in enhanced fuel efficiency.
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Use fuel additives
While fuel additives are not necessary for the proper operation of Cummins diesel engines, they can be useful in certain situations. Cummins itself recommends the use of Power Service Diesel Kleen + Cetane Boost and Diesel Fuel Supplement + Cetane Boost for their engines. The company cites the questionable cleanliness of today's diesel fuel as a reason for using these additives, noting issues such as poor lubricity, low cetane numbers, injector deposits, and low-temperature operability.
The Power Service Diesel Kleen + Cetane Boost is intended for year-round use and can help with cleaning dirty injectors, preventing injector sticking, smoothing rough-running engines, and potentially improving fuel economy. On the other hand, the Diesel Fuel Supplement + Cetane Boost is recommended for winter use when temperatures drop below 30 degrees Fahrenheit (-1 degree Celsius).
There are also other commercially available fuel additives, such as Hot Shot Secret's EDT, which claims to increase lubricity by 26% and raise Cetane levels by seven points, resulting in a more efficient-burning fuel. Independent tests have shown that adding EDT to a tank of fuel can lead to an average mileage gain of about 7.3%.
It's important to note that some users have reported no significant difference in engine performance or MPG when using fuel additives in their Cummins diesel engines. However, in extremely cold weather, anti-gel additives can be crucial to prevent issues with fuel gelling and waxing, which can lead to reduced engine performance or even stalling.
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Choose high-performance parts
When choosing high-performance parts to improve the fuel efficiency of Cummins diesels, it's important to consider the specific engine and application. Here are some key points to keep in mind:
Turbochargers
Upgrading to a performance turbocharger can significantly improve fuel efficiency in Cummins diesel engines. Turbochargers increase airflow, improve combustion, and boost engine power. When choosing a turbocharger, consider the specific model and specifications to ensure compatibility and optimal performance. Some popular options include the S400 3rd Gen Turbocharger with VGT and the HE400VG 6.7 Dodge Cummins ISX Turbo. These turbochargers are designed for faster spool times and increased power output.
High-Performance Fuel Injectors
Upgrading to high-flow fuel injectors can also improve fuel efficiency. Fuel injectors deliver fuel to the engine's combustion chambers, and high-performance injectors increase the volume of fuel delivered, resulting in more horsepower and torque. It is important to choose injectors that are compatible with your specific Cummins engine and to consider the overall engine setup, as injectors work in conjunction with other components like turbochargers and tuners.
Exhaust Systems
Installing an aftermarket high-flow exhaust system can improve fuel efficiency by reducing back pressure and enhancing exhaust flow. Cummins diesel engines benefit from efficient expulsion of exhaust gases, which not only improves performance but also reduces exhaust gas temperatures (EGTs). This type of upgrade can also give your truck a deeper, more aggressive sound.
Air Intake Systems
Upgrading to a cold air intake system is another way to improve fuel efficiency. These systems bring cooler, denser air into the engine, enhancing combustion and increasing horsepower and efficiency. The improved airflow results in better overall engine performance, especially when combined with other upgrades.
Tuners and Programmers
Tuners and programmers allow for customisation of engine performance by adjusting parameters such as fuel delivery, boost pressure, and timing. They offer flexibility, ensuring the engine is optimised for specific tasks, whether towing heavy loads or seeking maximum performance.
It is important to note that when choosing high-performance parts, selecting reputable suppliers and original equipment manufacturer (OEM) components can ensure compatibility, reliability, and adherence to quality standards.
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Frequently asked questions
Some basic modifications to improve fuel efficiency include:
- Installing a tuner, such as the Bully Dog GT or MADs Smarty Tuner.
- Upgrading the stock intake with a higher-flowing performance air intake to increase air density.
- Adding a fuel additive, such as Hot Shot Secret's EDT, to increase lubricity and raise Cetane levels.
- Ensuring proper tire pressure and choosing the right tread patterns to reduce rolling resistance and enhance traction.
Some more advanced modifications include:
- Installing high-performance engine parts, such as turbochargers and high-flow injectors, from reputable suppliers like Yanmar and Cummins.
- Making aerodynamic improvements, such as adding fairings, side skirts, and tail extensions, to reduce air resistance.
- Installing a compound over stock turbo kit for improved airflow and cooling.
When choosing modifications, it's important to consider the cost, your driving frequency, and whether your driving is primarily highway or city. For example, upgrades to improve airflow and MPG, such as a tuner or performance air intake, may be more cost-effective if you drive a lot on the highway. If you frequently tow or race, a compound turbo kit can provide extra airflow to keep EGTs low.
While modifications can improve fuel efficiency, there may be some trade-offs to consider. For example, the cost of upgrades may outweigh the improvements in fuel savings, especially for city driving. Additionally, some modifications, such as an exhaust system, may provide smaller gains in fuel economy but can still be beneficial for improving turbo efficiency and power. It's important to research and weigh the benefits and costs of each modification to determine the best options for your specific needs.
