We talk about this subject quite often and continue to learn more about the value of fuel and exhaust flow while testing trucks on our new Taylor Dyno. For instance, our ported and ceramic coated exhaust manifold flows 20% more exhaust, lowers the exhaust temperature by 125 degrees and improves the spool up time of the turbocharger.
What we have recently learned on the C-15 Caterpillar single turbo engines is coupled with our High Performance Cat Turbo the engine gains about 100 horsepower.
We are NOT adding any additional fuel just eliminating restriction and turbulence and the net gain is 3.12 horsepower per pound of turbo boost. That is an incredible gain of power just by changing two items on the engine. Keep in mind these trucks that we test already have our high flow quiet performance mufflers and most of them have the Fleet Air filters already installed. Every day we get back reports from owner-operators that install the manifold and turbocharger at the same time and they tell us they have to learn how to drive their all over again because of the power, rate of acceleration, and response and know we know why they feel such a difference, they have just gained 100 horsepower.
"During the Louisville Truck Show last month an owner-operator told me he installed the Fleet Air Filter and our Quiet Performance Muffler on his truck and gained 1/2 mile per gallon. His total investment of $518.00 was paid of the first two weeks of driving. Again it's all in the flow of air, fuel and exhaust.
Speaking of fuel flow, fuel lines need to be changed once they are about 10 years old, the rubber on the inside of the hose will swell closed thus restricting the fuel flow. The best item you can do for your engine's fuel flow is install the FASS Fuel Air Separation System. During the installation some of the fuel lines will need to be replaced so just replace them all and eliminate the chance of fuel starvation.
Diesel fuel is between 3% and 10% air and the harder the fuel pump has to work to suck the fuel out of the tank and pressurize it into the fuel pump or the injectors the more air it extracts out of the fuel. This air has to be compressed in the injector first and then the fuel second before ignition begins. This delays the timing and the ECM changes the timing every second and expects the injectors to inject the fuel it's looking for, however the air comes first and now the timing is off. The ECM could compensate for the delayed timing if all 6 injectors received the same amount of air, however they don't. Why not just eliminate the air in the fuel by installing the FASS Fuel System.
Now the fuel pump does not have to suck the fuel out of the tank, the electric motor on the FASS System does that job, plus eliminating the air and sending it back to the fuel tank and then pushes the fuel under pressure to the fuel pump. The fuel pump loves the positive pressure, the hardest part of it's job has just been eliminated, now all the fuel pump has to do is increase the pressure and push it into the injectors. Net result is the life of the fuel pump is greatly enhanced, the horsepower of the engine improves by about 30 horsepower, the fuel mileage improves by about 3/10ths , the throttle response improves, the injectors live longer, the engine runs smoother, especially the BXS Acerts, and the pull of the engine is more consistent. That is 7 improvements by installing just one item on your engine.
Please do yourself a favor, if you are bringing your truck into our shop make notes of everything that is wrong with the truck. Don't try to remember everything, makes notes, take the time to write it down, when you are standing at the counter and Gary or Pete are writing your work order, items are forgotten, so please write it down so our service department can assist you better. So many times we here once the job is completed" by the way did you see or notice that my fan or cruise control is not working all the time, or my coolant temperature fluctuates." We are now completed with the repairs you told us about, now there is more and the day is over.
Summer is coming and so it the hot weather, if your radiator is old and just getting you by, please take care of it now before it's an emergency. Something to think about in radiators, the first two rows do the majority of the cooling, the next two help some, the if your purchase a 5 or 6 row radiator, it's still only the first 4 rows that does the cooling so this is why we install 100 tubes per row on a 379 Pete. The KW has a narrower hood and so we have tubes per row. It's the amount of tubes per row, the amount of fins per inch, and dimpled tubes that make a great radiator.
Life isn't about finding yourself, it's about creating yourself! If your truck doesn't get good fuel mileage or run like a thoroughbred, how in the world can you create yourself?
Bruce C. Mallinson
Pittsburgh Power Inc.
3600 S. Noah Dr. Saxonburg, Pa. 16056
Image Source: "Pittsburgh Power Larger Turbo" Dice 1: Truckers Report: Eco Taz
Many of the articles compiled here where written by Bruce Mallinson. Attribution to other contributors is given in the specific articles.