Even though I've got a lot of experience with diesels, I still have weak moments and fall "victim" to claims of better fuel mileage. I get hopeful, and somtimes my emotions tell me one thing, while my logic tells me another. Kind of like chasing girls in a bar-room after having a few too many (if you've ever fell victim to such behavior). This is not only for engine add-ons, but even for mileage claims in stock trucks. I still hear, or read, on a daily basis somebody somewhere with a Dodge Cummins truck getting 35 MPG, a Ford-IH 6.9 getting 30 MPG, a GM 6.2 getting 40 MPG, etc. &c. Funny, I've been working on of them since they came out - and have yet to see one come even close.
Around 25 years ago, I spent a lot time building and testing the magic "Pogue Vaporizer" carb. I'm lucky I didn't blow myself up.
With diesels? The stuff is endless - and I've yet to see anything that offers any real overall gains in fuel mileage. K&N is a popular one, so are many products from Banks like their Stinger exhaust systems.
Generally speaking, it's hard to beat OEM equipment for general useage. But ?? Recently, the exhaust system fell off my 92 Dodge-Cummins. So, since I had to replace anyway, I got a custom made 4" exhaust. It was a tight squeeze to fit it all in - especially by the transfer case. Gains? None - absolutely zero. Now, maybe if I'd upped the horsepower way over stock - maybe the bigger pipes would of helped a little.
In regard to air intakes in diesels - most don't get run much over 2000 RPM - so the intake-air needs are not all that much. Now, if it was a high-tech gasser turning 6000 RPM, that'd be a whole different story.
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