High Performance: Performance Diesel Engines and Fuel Efficient
What makes turbo boost? Many owner-operators believe that if they install a larger turbo on their engines, that they will make more turbo boost and more horsepower. I want you to think about this: If the air can't get INTO the turbocharger or the exhaust can't get OUT of the engine effortlessly, then HOW is a larger turbocharger going to make more turbo boost? That is why we at Pittsburgh Power started designing free-flowing mufflers way back in the early 1980s. After all, you would never build a performance hot rod, streetcar, or racecar and install a stock muffler on it! What is the FIRST thing people change when they buy a new Harley Davidson motorcycle? They change the mufflers and pipes because they want the bike to sound better and run more freely. “Free” is the word; we MUST make the semi-truck run free to gain fuel mileage, performance, and longevity from the engine. So, we start with the muffler, which will allow the engine to gain 1/4 mpg or more, and yes; dual exhaust will out-perform a single stack and the exhaust gas temperature will run about 50 degrees cooler. If you don't idle the engine to stay cool or warm, then a weedburner is the most efficient exhaust system. YES, our performance mufflers are quiet during an idle, quiet while cruising along the level highway, and they have a deep throaty sound when pulling a hill.
Now let's look at the air intake system: TWO air filters mounted outside of the hood is much better for air flow than ONE air filter under the hood. Yes; the aerodynamic trucks all have the air filter under the hood, so we have to work with it, and the best thing to do is install the Fleet-Air Filter. This air filter is made of 3 layers of foam sprayed with oil over an aluminum frame. The Fleet-Air filter will greatly enhance the airflow to the turbocharger and the engine will gain another 1/4 mpg as a result.
The next change to make to the engine to enhance the air and exhaust flow is the installation of our Heavy Duty High-Performance ceramic-coated exhaust manifold. This exhaust manifold flows 20% or more exhaust than a stock manifold, will lower the exhaust gas temperatures by 125 degrees and WILL NOT LEAK at the joints. The extra exhaust flow will allow the turbo to spool up quicker and, in turn, the ECM will see the turbo boost sooner and release the fuel sooner.
Now we have quicker acceleration and the engine will live longer because the EGTs are lower and there is less soot in the oil because the exhaust manifold flows 20% more. AGAIN: An increase of 1/4 mpg in fuel savings will be realized.
Once the changes described above have been made, your truck is ready for the larger turbocharger, and YES, you will FEEL the difference in performance, gain turbo boost, decrease the EGT's even MORE, gain MORE fuel mileage, and not have to push as much on the throttle because the engine is running free! Guess what! Another 1/4 mpg in fuel savings is realized, for a total of a 1 mile-per-gallon increase in fuel savings. This means 4,000 gallons of fuel is being saved every 100,000 miles driven. That’s $16 GRAND, or $24k a year if you drive 150,000 miles!!
There are two more items to go on our journey to better fuel efficiency: If your fuel lines are 8-10 years old, replace them: The liners swell shut on the inside and will restrict the fuel pump of diesel fuel and a loss of power will result. When the engine loses power, the truck will lose fuel mileage. If you want another 1/4 mpg in fuel savings, install the FASS Fuel System, which removes the air from the fuel and gives the engine an additional 30 horsepower.
Last but not least, if your ECM or ECU is having problems, please send it to us and we will run it on our desktop simulator and advise you of any problems it may have. We will also make sure it is allowing the engine to produce the power it was designed to make. Our engineers designed this amazing piece of equipment (the D.E.S.) and as far as we know, they are the only engine simulators in existence! When bright, eager young minds are given creative freedom and encouragement, amazing things can happen. We are proud of what they have accomplished and can’t wait to see what they will learn from our new emissions testing equipment!
In closing, I want you to realize that your engine is now a cleaner-burning, more-efficient machine and the emissions are at least 30% cleaner (or more). We are installing emissions testing equipment in our engineering and dyno-testing facility and will have more results within the coming months as to how much cleaner we can make your engine. Our goal is to be able to build emissions-compliant performance diesel engines so you will never have any problems because of changes you have made to your engine pertaining to emissions. The cleaner we make the exhaust, the better the fuel mileage and the longevity of the engine will be! Wonderful things are going to happen this year for the owner-operators who bring their trucks to Pittsburgh Power!
Written by Bruce Mallinson, Pittsburgh Power Inc., 3600 S. Noah Dr., Saxonburg, Pa. 16056. Phone 724-360-408. Email: firstname.lastname@example.org