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modifying vehicle for better MPG

U

unorthodoxneon

Expert Expediter
I'm just curious as to how many people have modified their vehicles be it a straight truck or a cargo van to get better gas mileage. Whether it be cold air intake, exhaust, underdrive pullies, lighter fans/swap to electrical fans, chips/computer, ect.

I know the way gas prices are climbing and hitting our bottom lines pretty hard the last few years i was just wondering if anyone has done anything and maybe can list what they have done and what kind of gains they have expected.

On the truck we have the exhaust leaked there was an aftermarket exhaust put on that claims to add more gas milesage. After running for a while and after checking the MPG it has slightly increased.

Also note that i'm very big into modifying vehicles as i'm 1/2 year shy of getting my automotive degrees so thats why i brough this up.
 
mrgoodtude

mrgoodtude

Not a Member
Good post Randy,
I have looked in the past at aero-foils (?) to reduce wind drag but have never installed a set. I still see them on occasion but don't think they really ever took off.
The electric fan conversion sounds like a good plan if you are running a heavy loader, wonder if there are any after market kits for big trucks?
How about an electric powered a/c in a self contained configuration or electric powered steering, both taking draw off the engine?
Mike
 
greg334

greg334

Veteran Expediter
As I am preparing to work on a few of these 'better mileage' devices for my new mission.

The best change you can make are simple starting with changing your driving habits.

The electric fan change is a good change with many vans, but I caution that investigate it carefully for diesel vans. For some reason some Diesels don't have the flow with electric fans needed to cool the engine.

Higher mileage vans, find someone who can check the Cat, especially if you have 200K on the van. The Cat may need to be replaced and some gas engines like some restrictions in the system to work properly.

I would add changing the air cleaner on regular intervals but using Amsoil and other free flowing type air filters without monitoring the silicon level in the oil can lead to a shorter engine life, especially if you drive in texas and the south west (sand).

I got a few of these fuel line add ons in the boxes and want to test them out but only one I have has been proven to actually do anything but take you money - I don't have a link to the report that indicates which one at this time so I will add this when I find out which one it is.

The turbonator, swirler and what ever you want to call it has never passed any test to increase anything. There is a guy in Australia that had a really good write up on this thing and his realy good findings, I will find that link and post it.

As for 'fooling' the ECM, there are a number of mods for that and sometimes they work and other times (like in the case of 6.5 TD I have) don't do a thing.
 
U

unorthodoxneon

Expert Expediter
There is other PCM things you can do beside the junky JET chip, i know some things like the superchips or Bullydogs work pretty good for redoing the tables of the PCM for more performance/gas mileage. Some of those are also shift kits and allow for quicker shifts (but nothing thats too harsh) to help the life of the trans.

As far as the filters go the silicone level you might experiance is from the oil itself you put on the filter. I'm sure some of it is also from particles that get past the filter. I've heard the Amsoil is one of the better filters as it traps more finer particles then K&N and such. And if you get an air intake system that has a K&N they have filter wraps that go over the filter that help reduce the sand and dirt intake and also keeps the filter cleaner longer.

Another thing that helps on the vans and such is on the piping from the filter to the manifold. Alot of time they design these to be quieter and thus causes restriction in the intake flow.

Also i think vans could also take advantage of having the rear end regeared more for highway use since from the factory they are kinda 50/50 for city/highway.

I really like using amsoil in my personal vehicle (dodge dakota) and noticed a slight increase in MPG.

As far as your post about the cat possibly being bad, if there is an issue with that i would set up to a high flow cat as that will help with gas mileage abit too.

Me i couldnt drive a van. If it was gas i'd have the engine fully worked over (head, cams, ect), have a cold air intake, headers, free flowing cat to a borla. Would be one bad expediter van. :+
 
greg334

greg334

Veteran Expediter
Randy, I left out a lot of things like ECM reprogramming.

I am looking into upgrading into a class 8 truck in the fall or winter. I hope to get another Cummins but what ever I get I am going to do a few things to it to get more miles out of a gallon of fuel.

The reprogramming of the ECM is one, I have some info on Cat's programming parameters and some mods for Cummins' ECM that couldbe done but I am inclined to look into Pittsburgh power system and see if I can use that to pull back the fuel delivery on the engine under a light to medium load. I have heard that this system has an economic setting that will increase the milleage by 8 to 10%.

The other things I have been thinking about has been the scavaging of the exhaust gases to increase the flow. One thing I did on my ISB in my 3500 was to use a turbo wrap and wrapped the exhaust from the turbo to the 'cat'.

I have a lot of info I have accumilated on Brown Gas generators a.k.a. hydrogen generator. I am doubtful that there is a big improvment in mileage with this type of enhancment but one company has marketed a system in Canada with claims of a sizable improvement and 'leases' the system to trucking companies.
 
RLENT

RLENT

Veteran Expediter
I've looked into mods for the Sprinter - there are several companies out there (Diesel Power is one) that offer a box that plugs into the fuel rail pressure sensor wiring.

It works by varying the fuel injector pulse width and it has a knob on it so that it is adjustable - so you can dial in different levels of performance increase - up to an additional 30 ponies (which ain't too bad on a 154 horse engine) At less than the max settings it can produce 3% to 5% better fuel economy apparently, depending on how you drive. Me, I like a light pedal and slow acceleration wherever possible - I'm currently averaging around 24 mpg (stock)

The Diesel Power mod is fairly transparent, in that it just plugs in - pull it and no one would ever know it had been on the vehicle.

There is also another company that will permanently modify the ECM - of course you have to pull your ECM and send it to them for them to do it. That doesn't excite me a whole lot.
 
Jack_Berry

Jack_Berry

Moderator Emeritus
gale banks makes tuner boxes that stay in the cab for dial up performance. maybe jsut for light duty diesels. bankspower.com for more information.

Jack Berry
 
OntarioVanMan

OntarioVanMan

Retired Expediter
Owner/Operator
With no modifications

I am down here in Gallatin Tn and just figured my mileage and fuel cost for the run.

Averaged 24.3 mpg at an average price of 2.65/ gallon= 28 gallons x 2.65 = 74.20
FSC is .13 cents x 681 miles = 88.53 soooo I profited $14.33 from the surcharge Sprinters do pay off!!! ....sometimes...
 
B

bryan

Veteran Expediter
Hi

Somethings you can do at little or no cost are
Wax the truck

Jack up the front of the truck and check tire pressure,see if the wheel spins freely and then have someone jam on the brakes while your spinning the tire to be sure the brakes release fully and quickly.Check wheel bearings by rocking the tire up and down by hand.Then try rocking the tire up and down with a pry bar if it moves you need new ball joints.

Clean the front of the radiator and put a screen in front of radiator to keep the bugs out.

On gas engines wrap aluminum foil around gas line this keeps the gas cool.Try to fill tank at night when it is cooler.Gas evaporates in high temps.
Have a good one.
 
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